Mitsubishi 6D31 6D31T 6D31C 6D31CT Engine Workshop Manual PDF

Mitsubishi
6D31 6D31T 6D31C 6D31CT

ENGINE
GROUP INDEX
Shop Manual GENERAL ................................................ liDJ
ENGINE ................................................... 111
FOREWORD LUBRICATION ........................................ 16
11
E
This shop manual contains the specification, con FUEL AND ENGINE CONTROL ................
struction, operation, adjustment and service proce
dures of the Model 6D31, 6D31-T diesel engine for COOLING ................................................
Im
service mechanics engaged in servicing of the
Mitsubishi diesel engines.
INTAKE AND EXHAUST ..........................
Please make the most of this shop manual to perform
correct servicing and wasteless operations.
Note that some of the contents of this shop manual
ENGINE ELECTRICAL ............................. Im
are subject to change owing to improvements, etc.
that may be introduced after publication of this shop
manual.
Applicable Engine Models

6D31
6031_T
6D31-C
6D31-CT For .industna
. I use
Mitsubishi Engine Parts: www.HeavyEquipmentRestorationParts.com

Contact email: EngineParts@HeavyEquipmentRestorationParts.com
Phone: 269 673 1638
ORGANIZATION - GROUP CLASSIFICATION
1. GROUP CLASSIFICATION
This manual is organized into several groups classified according to the engine basic elements.
No. Group name Description
00 General External view, major specifications, engine outputs classified by application, engine numbers,
caution plate, general bolts and nuts tightening torque table
11 Engine Engine proper (cylinder head, valve mechanism, camshaft, piston, crankshaft, timing gear, flywheel),
specifications, service standards, special tool, troubleshooting
12 Lubrication Lubrication system (oil pump, oil filter, oil cooler), specifications, service standards, special tool,
troubleshooting
13 Fuel and engine control Fuel system (injection pump, injection nozzle, fuel filter), specifications, service standards, special tool,
troubleshooting
14 Cooling Cooling system (water pump, thermostat, radiator, cooling system cleaning procedures, fan), specifications,
service standards, special tool; troubleshooting
15 Intake and exhaust Air cleaner, turbocharger, specifications, service standards, troubleshooting
16 Engine electrical Starter, alternator, preheating system, relays, automatic stop device, specifications, service standards,
special tool, troubleshooting i;,
NOTE:
Each group starts with page 1.
'''· .
2
ORGANIZATION - GENERAL PRECAUTIONS FOR SERVICING
2. GENERAL PRECAUTIONS FOR

SERVICING
• Before starting the service procedures, check the
vehicle for total time driven, use conditions, and
user's complaints and requests to know exactly the MITSUBISHI MOTORS
engine conditions. Record information where neces
sary. GENUINE PARTS ....
To ensure you are doing correct and efficient service
jobs, observe the following precautions:
A0006A
(7) The oil seals, packings, 0-rings, and other rubber

parts, gaskets, and split pins must be replaced with a
new one whenever they are removed. For replace
ment, use Mitsubishi Genuine parts.
A0012A
(1) Before performing the service procedures given

in this manual, know the trouble spots and isolate the
possible cause to determine whether the removal or
disassembly procedure is required.
(2) Select a flat surface for the service job.
A0007A
(3) When servicing the electrical system, be sure to
disconnect the negative cable from the battery.
(8) Apply the specified grease to U-packings, oil
(4) Carefully check parts for oil leaks before cleaning.
seals, dust seals, and bearings before installation.
After cleaning, it may become difficult to spot defec
(9) When work requires an assistant or two, always
tive areas.
make sure of the safety each other. Never play with
(5) Ready and make the most of the special tools
switches and levers.
required for servicing. Use the right tools (specified
(10) Make sure that your shoes are free from grease
special tools) in the right place to prevent damages to
and oil especially when working on a heavy item.
parts and personal injury.
(11) When checking or changing lubricants, wipe off
(6) Make alignment marks and keep disassembled
grease and oil from parts immediately with a waste.
parts neatly arranged to ensure that they are reas
(12) Special care must be taken in handling sensors
sembled into the right positions.
and relays which are suspectible to shocks and heat.
• Special care must be taken for assemblies involv
(13) Use care so that hands and fingers are not
ing a number of parts, similar parts, or parts
injured by sharp edges or corners of the parts.
identical at right- and left-hand sides to ensure
(14) Wear safety goggles whenever handling a grin
correct reassembly.
der or welding machine. Wear gloves as required to
• For alignment and punching markings, select a
ensure utmost safety.
position that would not mar the appearance and
function.
• Clearly distinguish parts to be replaced from
those reused.
3
ORGANIZATION - TERMS AND UNITS, TABLE OF
CONVERSION RATE FOR FOOT-POUND UNITS INTO SI UNITS
3. TERMS AND UNITS

The following terms and units are used throughout the entire texts of this manual.
(1) Front and Rear
The terms "front" is the fan side and "rear" the flywheel side of the engine.
(2) Right and Left
The terms "right" and "left" shall be used to indicate the side as viewed from the flywheel side of the engine.
(3) Service Standard Terms
• Nominal value
Shows the nominal dimensions, dimension of an individual part, standard clearance between parts in an
assembly, or the standard performance of an assembly.
• Limit :r
Shows the value of a part at which the part is no longer serviceable from the performance as well as strength
viewpoints, requiring replacement or repair.
(4) Tightening Torque
Over- or undertightening of bolts and nuts has critical effects on performance and functions.
Tightening torque is therefore specified for some tightening points.
All tightening torque specifications may be considered as "dry" unless "wet" is specified.
yYhere no tightening torque is specified, use a torque value specified in the General Bolts and Nuts Tightening
Torque Table.
(5) Units
For length, weight, area, and volume, the SI unit (International System of Units) is used with the metric notation
jointly shown in parentheses.
Temperature is shown in centigrade (° C).
4. TABLE OF CONVERSION RATE FOR FOOT-POUND UNITS INTO SI UNITS

Unit Sign of SI unit Sign of foot-pound unit Conversion rate
Mass quantity of matter kg lb 1 kg = 2.2046 lb

g oz 1 g = 0.035274 oz
Dimension m ft. 1 m = 3.2808 ft.

mm in. 1 mm = 0.03937 in.
Capacity lit. gal. 1 lit. = 0.2642 gal. (U.S.)

1 lit. = 0.220 gal. (Imp.)
cc oz 1 cc = 0.033814 oz (U.S.)
1 cc = 0.035195 oz (Imp.)
Force N (Newton) lbf 1 N = 0.2248 lbf
Pressure kPa (kilopascal) lbf/in. 2

1 kPa = 0.145 lbf/in.2
1 kPa = 0.2953 in.Hg
Stress N/cm2 lbf/in.2 1 N/cm2 = 1.45 lbf/in.2
Moment of force N m ft. lbf 1 N m = 0.7375 ft. lbf
Output kW (kilowatt) HP 1 kW = 1.34 HP
Temperature 'C "F t'C = (1.8t'C + 32)'F
4
ORGANIZATION - READING THE ILLUSTRATION
S. READING THE ILLUSTRATION

(Ex. 1: Disassembly and Inspection)
·J:<· Protrusion from

crankcase top surface
NV 0.01 to 0.50
/
Breakage, damage
Dam"ge,
discoloration
Indicates the
service standards.
._____ 3 Carbon deposits, scratches
on outer surfaces, cracks,
discoloration
/
·):(·Connecting rod end play
NV 0.15 to 0.45
L 0.6
Indicates visual checks.
·J:<· indicates inspection to

be made before disassembly.
2
Damage on outer and inner
surfaces, corrosion. flaking
Damage on outer and inner

surfaces, corrosion, flaking
NV ... Nominal Value

L ..• Limit
t_., 2
Connecting rod cap
Connecting rod bearing
® Oil ring
7 Snap ring
3 Piston 8 Piston pin
© 1st compression ring 9 Connecting rod
® 2nd compression ring
Indicates that the disassembly

procedure is explained in the text.
A0014A
5
ORGANIZATION - READING THE ILLUSTRATION
(Ex. 2: Reassembly)
Gives instruction for jobs to

bo do,o " =•m'" �
·• '
Apply engine oil Piston projection
NV 0.48 to 0.74
Indicates a typical
\
assembly sequence
.
<Assembly sequence>
3-•��7-
\
��©--+2-+1
Indicates that the assembly

procedeure is explained in the text.
2 1 100 Nm
(10.s kgfm)
/ (wet)
Specifies the tightening torque;

(wet) means the part must be
tightened in wet state.
A0013A
(1) Illustrations (exploded views and assembly draw identical among various types of available systems
ings) show a typical service procedures if it is and units.
6
m
GENERAL
CONTENTS
1. EXTERNAL VIEW ••••.••.•••.•••..••••••••• 2 3. ENGINE NUMBERS AND

1.1 EXTERNAL VIEW CAUTION PLATE .••.........•.•......••..•
PHOTOGRAPHS ••••••••••••••.•••••••• 2 4. GENERAL BOLTS AND NUTS
2. MAJOR SPECIFICATIONS ••••••••••• 4 TIGHTENING TORQUE TABLE ......
2.1 MAJOR SPECIFICATIONS •••••••• 4
2.2 ENGINE OUTPUTS CLASSIFIED
BY APPLICATION ••.••..••.•.•.•••.••.• 4
00-1
D GENERAL - EXTERNAL VIEW
1. EXTERNAL VIEW
1.1 EXTERNAL VIEW PHOTOGRAPHS
6D31 Model
PE1025
I"'
I
PE1026
00-2
GENERAL - EXTERNAL VIEW
6031-T Model
PE1027
PE1028
00-3
D GENERAL - MAJOR SPECIFICATIONS
2. MAJOR SPECIFICATIONS
2.1 MAJOR SPECIFICATIONS
Item Specifications
Model 6031 6031-T
Combustion method Direct injection Direct injection
(with turbocharger)
No. and arrangement of cylinder 6 in-line 6 in-line
Cylinder bore x stroke mm 100 X 105 100 X 105
Total displacement cc 4948 4 948
Empty weight kg• 435 450
• Empty weight as measured according to Mitsubishi Motors Corporation standard
2.2 ENGINE OUTPUTS CLASSIFIED BY APPLICATION
6031-T
6031
Appl Medium speed High speed
Intermittent rated output kW(HP)/rpm 50(67)/1 500 65(87.1)/1 500 65(87.1)/1 500
60.5(81.1)/1 800 79(105.9)/1 800 79(105.9)/1 800
66.5(85.1)/2 000 87(116.6)/2 000 87 (116.6)/2 000
72.5(97.2)/2 200 95(127.3)/2 200 95(127.3)/2 200
80.5(107.9)/2 500 102(136.7)/2 500 105(140.8)/2 500
84.5(113.3)/2 800 111.5(149.5)/2 800
87(116.6)/3 000 114(152.8)/3 000
Continuous rated output kW(HP)/rpm 45(60.3)/1 500 59(79.1)/1 500 59(79.1)/1 500
54.5(73.1)/1 800 71(95.2)/1 800 71(95.2)/1 800
60.5(81.1)/2 000 78.5(105.2)/2 000 78.5(105.2)/2 000
66 (88.5)/2 200 86 (115.3)/2 200 86(115.3)/2 200
72.5(97.2)/2 500 93(124.7)/2 500 95.5(128)/2500.
76.5 (102.5)/2 800 101.5(136.1)/2 800
79 (105.9)/3 000 104(139.4)/3 000
NOTE:.
1. The output (SAE, gross) is corrected to
standard ambient conditions based on
SAE J1349.
2. The continuous rated output allows
10% (one hour) overload operation.
00-4
GENERAL - ENGINE NUMBERS AND CAUTION PLATE
3. ENGINE NUMBERS AND CAUTION

PLATE
(1) Engine Number VALVE CLEARANCE (COLD) ..:,.--- 1
INLET & EXHAUST 0.4mm (0.016inl I
FIRING ORDER
FUEL INJECTION TIMING □
1-5-3-6-2-4
·sTDC �2
1 Valve clearance
2 Firing order
3 Fuel injection timing
B1880B
B1879B
The engine number is stamped on the position as

illustrated.
Ex.: 6 D 3 1 - 0 0 0 0 0 1
._______ Engine number
The engine number is important in knowing the

history of the engine.
(2) Caution Plate
B1879B
The caution plate is located as illustrated. The caution

plate bears the valve clearance, fuel injection sequ
ence and timing.
00-5
GENERAL - GENERAL BOLTS AND NUTS
TIGHTENING TORQUE TABLE
4. GENERAL BOLTS AND NUTS TIGHTENING TORQUE TABLE
Unless otherwise specified, the parts and equipment of vehicle must be tightened by the following standard bolts
and nuts. Tightening torques for these bolts and nuts are shown below.
NOTE:
Threads and seat surfaces must be in dry state.
Standard bolts and nuts

Unit: N m (kgf m)
Dia. mm Pitch mm 4T (Head mark 4 or 0) 7T {Head mark 7 or 0) ST (Head mark 8 or $)
5 0.8 2.0 to 2.9 (0.2 to 0.3) 3.9 to 5.9 (0.4 to 0.6) 4.9 to 6.9 (0.5 to 0.7)
6 1.0 3.9 to 5.9 (0.4 to 0.6) 6.9 to 10.8 (0.7 to 1.1) 7.8 to 11.8 (0.8 to 1.2)
8 1.25 8.8 to 13.7 {0.9 to 1.4) 16.7 to 25.5 (1.7 to 2.6) 19.6 to 29.4 (2.0 to 3.0)
10 1.25 18.6 to 27.5 {1.9 to 2.8) 34.3 to 53.9 (3.5 to 5.5) 44.1 to 58.8 (4.5 to 6.0)
1.5 17.7 to 26.5 (1.8 to 2.7) 32.4 to 49.0 (3.3 to 5.0) 42.1 to 58.8 (4.3 to 6.0)
12 1.25 33.3 to 49.0 (3.4 to 5.0) 68.6 to 93.2 (7.0 to 9.5) 83.4 to 108 (8.5 to 11)
1.75 30.4 to 46.1 (3.1 to 4.7) 63.7 to 83.4 (6.5 to 8.5) 73.5 to 98.1 (7.5 to 10)
14 1.5 58.8 to 83.4 (6.0 to 8.5) 118 to 157 (12 to 16) 127 to 177 (13 to 18)
2.0 53.9 to 73.5 (5.5 to 7.5) 108 to 137 (11 to 14) 118 to 167 (12 to 17)
16 1.5 93.2 to 127 (9.5 to 13) 177 to 235 (18 to 24) 196 to 265 (20 to 27)
2.0 88.3 to 118 (9.0 to 12) 157 to 216 (16 to 22) 186 to 255 {19 to 26)
Flange bolts and nuts

Unit: N m {kgf m)
Dia. mm Pitch mm 4T (Head mark 4 or 0) 7T (Head mark 7 or 0) ST (Head mark 8 or $) ·
6 1.0 3.9 to 5.9 (0.4 to 0.6) 7.8 to 11.8 (0.8 to 1.2) 8.8 to 13.7 (0.9 to 1.4)
8 1.25 9.8 to 14.7 (1.0 to 1.5) 18.6 to 27.5 {1.9 to 2.8) 21.6 to 32.4 (2.2 to 3.3)
10 1.25 20.6 to 30.4 (2.1 to 3.1) 38.2 to 58.8 (3.9 to 6.0) 49.0 to 63.7 (5.0 to 6.5)
12 1.25 37.3 to 53.9 {3.8 to 5.5) 78.5 to 108 {8.0 to 11) 88.3 to 118 (9.0 to l2)
00-6
ID
ENGINE
CONTENTS
2
2
1. GENERAL .................................... 5.1.2 Cylinder Head and Valve
7
1.1 ENGINE PROPER •••••••••••••••••.••• Mechanism .......................... 17
7 Housing ............................... . 2
2. SPECIFICATIONS •••••••••••••••••••••••• 5.1.3 Flywheel and Flywheel
7 9
3. SERVICE STANDARDS ••••••••••••••••
Camshaft ............................. 32 1
3.1 SERVICE STANDARD TABLE .••• 5.1.4 Timing Gear and
9
3.2- TIGHTENING TORQUE TABLE •••
4. SPECIAL TOOL ............................ 10 5.1.5 Crankcase and Main
5. SERVICE PROCEDURES •••••••••.••• 16 Moving Parts ........ ................ 40
5.1 ENGINE PROPER ••••••••••••••••••.•• 16 5.1.6 Inspection and Adjustment
5.1.1 Measurement of Compres- of Valve Clearance ••••..•.••••••• 57
sion Pressure ••••••••••••••••••••.•• 16 6. TROUBLESHOOTING •••••.•••••••...•• 58
11-1
DI ENGINE - GENERAL
1. GENERAL (2) Valve Mechanism

1.1 ENGINE PROPER
( 1 ) Combustion Chamber
Valve cap
��'-" Valve cotter

Upper
-� retainer
Outer spring
Rocker
Rocker shaft Inner spring
Valve stem
Cylinder head seal
�1.x,;;<-1--Lower
reatiner
Exhaust
valve Valve guide
Piston Inlet valve
Cam shaft
800738
The valve mechanism is an overhead valve type.

80069A
(a) Both the inlet and exhaust valves are made of
surface-treated heat-resistant steel. The valve seat
The combustion chamber consists of the cylinder
angle is 45° in both valves.
head and toroidal pistons, hole type injection nozzles
Valve stem seal is mounted to the valve steni, which
being installed in the cylinder head.
controls the amount of lubricant on the sliding
Combustion occurs when the fuel is directly injected
surfaces between the valve and valve guide.
into the combustion chamber with the power operat
A valve guide with carbon cutter is used for the
ing the piston directly.
exhaust side.
(b) Two unevenly pitched valve springs are used, the
inner and outer with coil directions opposite to each
other.
(c) The rocker has an induction-hardened surface in
contact with the valve cap. A bushing is used in the
hole, into which the rocker shaft is fitted. Because of
them, wear resistance is improved.
(d) The rocker shaft is a hollow round rod with
sealing caps at both ends to seal it off. Its inside is an
engine oil passage.
(e) The push rod has a steel ball welded to its bottom
end and a spherical or depressed piece welded to its
top end. Both ends are carburized case-hardened.
11-2
ENGINE - GENERAL
DI
(f) The tappet is of cylindrical shape. Its mating (4) Piston and Piston Ring
surface with the camshaft is a large-diameter sphere (a) Piston
to prevent local wear.
(g) The camshaft is provided with an oil pump drive
gear, with its journals, cams, and gear induction
hardened.
(3) Crankcase and Cylinder Sleeve
80076A
The piston, made of aluminum alloy casting, has a

strut inside (no strut installed on 6D31-T) that ensures
an adequate clearance between the piston and cylin
der sleeve.
The piston pin arrangement is full-floating. The piston
Crankcase pin is offset toward the thrust side, which, together
with the effect of the strut, minimizes piston slap.
Stamped on the top surface of the piston is the piston
weight mark, plus the front mark "<l". On 6D31-T, an
ID mark "T" stamped on top and a Niresist piston ring
insert is cast in the top ring groove for increased
durability.
(b) Piston ring
80075A
(a) The crankcase is made of cast iron and built rigid

with minimum stress concentration and deformation.
(b) Four camshaft bushings are installed in the
camshaft bearings of the crankcase. To facilitate
insertion and removal of the camshaft from the front
end of the crankcase, the bushing I.D. is made smaller
Oil ring
toward the rear. Dual type with
expander spring
(c) The special cast-iron cylinder sleeve, that is highly
resistance to wear, is press-fitted into the crankcase. B0078A
There are three piston rings installed: two compres

sion rings and one oil ring. The sliding surface of each
ring is hard chrome plated.
Piston rings are shaped as illustrated.
11-3
m ENGINE - GENERAL
(5) Connecting Rod and Connecting Rod The crankshaft is a highly-rigid die forging integral
Bearing with the balance weights. The pins, journals, and rear
oil seal sliding surfaces are induction-hardened for
improved wear resistance.
<6031> <6031-T> By means of oil passages drilled through the pins and
journals, part of the main bearing lubricating oil is fed
to pins for lubrication of the connecting rod bearing.
At the front end of the crankshaft, there are a
crankshaft pulley and crankshaft gear attached with a
nut. The crankshaft pulley drives the alternator and
water pump through the V-belt and the crankshaft
gear drives the camshaft and injection pump.
A torsional damper may be installed that absorbs
torsional vibration of the crankshaft.
Connecting rod
bearing
Flywheel
Flywheel
Connecting rod cap housing
Oil seal
B0080C
The connecting rod is a die forging with an I cross

section ensuring high rigidity. A lead bronze bushing
is press-fitted into its small end, while a split-style
plain bearing is used in its big end.
An oil passage is provided obliquely through the stem
and an oil jet at the small-end to lubricate the
small-end bushing and cool the piston. The connect
ing rod small end of 6D31-T is wedge-shaped.
(6) Crankshaft and Main Bearing
(a) Crankshaft
B0082A
Crankshaft The flywheel is mounted in the rear of the crankshaft.

An oil seal is installed at front and rear of the
crankshaft.
Torsional damper
81633A
11-4
ENGINE - GENERAL
Ill
(b) Main bearing (7) Timing Gear
Crankshaft gear
z = 23
B0083B B0084A
The main bearing is a split-style plain bearing made The timing gears are housed in the timing gear case
of special alloy plated kelmet metal with a steel back. at the front of the engine. Illustration shows the gear
The upper main bearing has an internal oil groove train.
and oil hole which is aligned with the oil hole in the Each gear is a helical gear machined by a shaving
crankshaft. machine to high precision and surface-treated for
Seven pairs of main bearings are used. Split-style enhanced durability.
thrust plates are mounted with the rear pair of main A timing mark is stamped on each gear. At reassem
bearings. bly, correct meshing can be achieved by aligning
these marks.
11-5
DI ENGINE - GENERAL
The flywheel is made of cast iron. The pilot bearing of

the transmission drive pinion is installed at its center.
On its periphery, the ring gear is shrink-fitted that
meshes with the starter pinion.
The ring gear tooth crests are induction-hardened for
greater durability. At the same time, one side of the
crests is chamfered to ensure that the starter pinion
meshes easily when starter is operated.
Idler gear
800858
A bushing is press-fitted into the idler gear which

turns on the idler shaft. The oil hole drilled through
the idler shaft and gear provides an oil passage for
lubrication of bushing and gears.
An oil pipe is installed in the idler shaft that is used for
forced lubrication of the injection pump gear.
(8) Flywheel
Ring gear
B0086A
11-6
ENGINE - SPECIFICATIONS, SERVICE STANDARDS m
2. SPECIFICATIONS
Item Specifications
Engine
Model 6031 6O31-T
Type 6 in-line, 6 in-line,
4-cycle diesel engine 4-cycle diesel engine
Combustion chamber type Direct injection Direct injection
(with turbocharger)
Valve mechanism Overhead valve Overhead valve
Cylinder bore x stroke mm 100 X 105 100 X 105
Total displacement cc 4 948 4 948
Compression ratio 17.5 16.5
Firing order 1-5-3-6-2-4 1-5-3-6-2-4
Cylinder liner type Dry Ory
Piston type Trunk, slipperskirt Trunk, slipperskirt
No. of piston rings Compression ring: 2; Compression ring: 2;
Oil ring: 1 Oil ring: 1
Performance
Minimum no-load engine speed rpm Varies with specifications Varies with specifications
Maximum no-load engine speed rpm Varies with specifications Varies with specifications
3. SERVICE STANDARDS
3.1 SERVICE STANDARD TABLE
Unit:mm
Description Nominal value Correction and

(Basic diameter in [ )) Limit remarks
Compression pressure (at 200 rpm) 2.55 MPa 1.96 MPa Adjust.
(26 kgf/cm2 ) (20 kgf/cm2 ) Difference between
cylinder within
0.39 MPa (4 kgf/cm2 )
Rocker to rocker shaft clearance [19) 0.01 to 0.08 0.2 Replace bushing
Outer valve spring Free length 60.84 57.8 Replace
Installed load/installed length 240 N 205 N
(24.5 kgf)/47.25 (20.8 kgf)/47.25
Squareness - 2.5
Inner valve spring Free length 55.07 52.1 Replace
Installed load/installed length 93 N 79 N
(9.5 kgf)/40.3 (8.1 kgf)/40.3
Squareness - 2
Push rod runout - 0.4 Replace
Tappet to crankcase tappet hole clearance [28) 0.06 to 0.1O 0.2 Replace
Cylinder head bottom surface distortion 0.1 or less 0.2 Correct or replace
Height of cylinder head from top to bottom surface 94.9 to 95.1 94.6 Replace
Valve seat width 1.8 to 2.2 2.8 Correct or replace
Valve to valve Inlet )91 0.04 to 0.07 0.15 Replace
guide clearance
Exhaust (9) 0.07 to 0.10 0.2

Phone: 269 673 1638
11-7
- ENGINE - SERVICE STANDARDS
Unit: mm
Nominal value Correction and

Description (Basic diameter in I II Limit remarks
Valve stem O.D. Inlet 8.96 to 8.97 8.85 Replace

Exhaust 8.93 to 8.94 8.85
Valve sinkage Inlet 0.75 to 1.25 1.5 Replace valve seat

insert
Exhaust 0.75 to 1.25 1.5
Valve margin 1.5 1.2 Correct or replace
Valve seat angle 45• -

Flywheel Friction surface distortion 0.05 or less 0.2 Correct or replace
r
• Height to friction surface 25 24 Replace
Friction surface runout 0.1 or less 0.2 Correct or replace
(In installed state)
Timing gear backlash Between crankshaft gear and idler gear 0.11 to 0.23 0.4 Replace
Between idler gear and camshaft gear 0.12 to 0.25 0.4
Between idler gear and 0.18 to 0.31 0.4
injection pump gear
Camshaft end play 0.05 to 0.22 0.3 Replace thrust plate
Idler gear end play 0.05 to 0.25 0.35 Replace
c·amshaft journal to No.1, No.2 (54.5) 0.04 to 0.09 0.15 Replace bushing
bushing clearance
No.3 (541 0.04 to 0.09
No.4 (53) 0.04 to 0.09
Camshaft Cam lobe height 6.86 6.36 Replace.

(Difference between cam height Cam height: 46.939
and base circle diameter) Base circle dia.: 40.080
Bend 0.02 or less 0.05 Replace
Idler gear to idler shaft clearance (401 0.03 to 0.07 0.1 Replace bushing
Connecting rod end play 0.15 to 0.45 0.6 Replace
Crankshaft end play 0.10 to 0.25 0.4 Replace thrust plate
Piston projection from crankcase top surface 6D31 0.48 to 0.74 - Check parts for
clearance
6D31-T 0.43 to 0.69 -
Piston ring to piston 1st ring 6D31 0.04 to 0.10 0.2 Replace piston ring
ring groove clearance
6D31-T 0.06 to 0.12
2nd ring 6D31 0.03 to 0.06 0.15
6D31-T 0.07 to 0.10
Oil ring 0.03 to 0.06
Piston ring gap 0.3 to 0.5 1.5 Replace
Piston pin to piston pin hole clearance (34) 0.002 to 0.05 Replace
0.019
Piston pin to connecting rod small-end bushing clearance (34) 0.02 to 0.05 0.1 Replace bushing
Connecting rod bend and twist - 0.05 Correct or replace
Piston to cylinder sleeve clearance 6D31 (100) 0.04 to 0.08 - Correct to oversize or
replace
6D31-T (100) 0.10 to 0.14 -
•: Applicable for flywheel with clutch.
11-8
ENGINE - SERVICE STANDARDS
m Unit:mm

Description Limit
(Basic diameter in [ I) remarks
Crankcase top surface distortion 0.07 or less 0.2 Regrind small amount
Cylinder sleeve 1.0. 100 to 100.03 100.25 Correct to oversize or
Roundness 0.01 or less - replace
Cylindricity 0.03 or less -

Crankcase to sleeve STD 0.16 to 0.22 Less than 0.16 Replace with an oversize
interference
o.s. 0.18 to 0.20 Less than 0.18 Replace
Crankshaft Roundness of pins and journals 0.01 or less 0.03 Correct or replace
Cylindricity of pins and journals 0.006 or less 0.03
Bend 0.05 or less 0.1
Main bearing Oil clearance (78) 0.05 to 0.09 0.15 Replace
Tension when free Upper - Less than 82.5 Replace
Lower - Less than 82.27
Connecting rod Oil clearance (60) 0.05 to 0.09 0.2 Replace

bearing
Tension when free - Less than 64.27
Valve. clearance 0.4 - Adjust
3.2 TIGHTENING TORQUE TABLE

(1) Engine Proper
Thread size Tightening torque

Description Remarks
0.0. x pitch mm N m (kgf m)
Cylinder head bolt M14 x 2.0 175 (18) Wet
flywheel bolt M14 x 1.5 175 (18) Wet
flywheel housing bolt M10 x 1.5 40 (4.11
M12 x 1.75 74 (7.5)
Idler shaft bolt M10 x 1.5 44 (4.51 Wet
Crankshaft pulley nut M24 X 1.5 390 (40)
Main bearing cap bolt M14 x 2.0 175 (18) Wet
Connecting rod nut M12 x 1.25 100 (10.5) Wet

Phone: 269 673 1638
11-9
ID ENGINE - SPECIAL TOOL
4. SPECIAL TOOL
Unit: mm
Tool Name Part No. Shape Use
Compression Gauge Adaptor MH061460 Measurement of compression

pressure
M14x 1.5
80089A
Tappet Extractor MH061288 Removal of tappet
80091A
Valve Lifter 30091-08500 Removal and installation of

valve cotter
47
80092A
Rocker Bushing Puller MH061378 Removal and installation of

rocker bushing
21
80093A
Valve Guide Remover MH061066 Removal of valve guide
13
85431A
11-10
ENGINE - SPECIAL TOOL ID
Unit: mm
I
Valve Guide Installer MH061223 Installation of valve guide
18
15
B5441A
Caulking Tool Body MH061067 Installation and caulking of

valve seat insert
Caulking tool body

Caulking ring
Body
Part No. Demension A
Caulking Ring MH061275 MH061067 9

MH061069
Ring, inlet
Part No. Demension B
MH061275 47.6
Ring, exhaust
Part No. Demension B
MH061069 40.6
B0095A
Valve Lapper 30091-07500 Lapping of valve seat
B5261A
11-11
m ENGINE - SPECIAL TOOL
Unit:mm
Valve Stem Seal Installer MH061293 Installation of valve stem seal
85192A
Oil Seal and Sleeve MH061201 Installation of crankshaft
Installer auxiliary sleeve
+98.7
♦110
85461A
Cone Puller MH061101 Removal of crankshaft
taper cone
81399A
Gear Puller MH061061 Removal of pulley and gear
Max. pulled out gear 0.0. 200

85071A
Gear Puller MH061326 Removal of gears
Max. pulled out gear 0.0. 150 85072A
11-12
ENGINE - SPECIAL TOOL
ID
Unit: mm
Plug MF665002 Blind plug used for removal of
camshaft gear
M10x 1.25
B5401A
Idler Gear Bushing Puller MH061228 Removal and installation of
idler gear bushing
39.5
B5121A
Camshaft Bushing Installer MH061276 Removal and installation of
and Extractor camshaft bushing
Demensions
Part No.
B C
MH061276 58.5 54.5 58.5
58 58
57 53 57
B0099A
Piston Ring Tool MH060014 Removal and installation of

piston ring
,i,60to 120
B5091A
11-13
ID ENGINE - SPECIAL TOOL
Unit: mm
Bearing Cap Extractor MH061083 Removal of bearing caps

at front and rear ends
B0100A
MH061071 Removal of intermediate
bearing caps
B0101A
Cylinder Sleeve Installer MH061295 Installation of cylinder
sleeve
99
B0106A
Connecting Rod Bushing MH061296 Removal and installation of
Puller <6D31> connecting rod bushing
B0107A
Connecting Rod Bushing MH061891 Removal and installation of
Puller Kit <6D31-T> connecting rod bushing
B5152A
11-14
ENGINE - SPECIAL TOOL
Unit: mm
Piston Guide MH061890 Installation of piston
Piston Guide Lever MH061658
85171A
Cranking Handle MH061289 Engine cranking
80109A
Slotted Screwdriver MH060008 Adjustment of valve
clearance (on-vehicle)
80111A
11-15
m ENGINE - SERVICE PROCEDURES
S. SERVICE PROCEDURES
5.1 ENGINE PROPER

5.1.1 Measurement of Compression
Compression ring (at 200 rpm I
Pressure NV 2.55 MPa (26 kgf/cm2 )
L 1.96 MPa (20 kgf/cm2 )
Compression pressure must be measured prior to Difference between cylinders
0.39 MPa (4 kgf/cm2 ) max.
disassembly of the engine.
Measure the compression pressure at regular inter
vals and keep track of its changes. During the break-in Compression
Gauge Adapter
period or after parts have been replaced with new MH061460
ones, there is a slight increase in the pressure as the
piston rings and valve seats fit snugly in position. As
rough edges and friction between parts are gradually
reduced, the pressure comes down.
Measurement Procedure

L ... Limit
80114A
(3) Install Compression Gauge Adaptor (special tool)

on the injection nozzle mounting hole together with a
gasket and connect the compression gauge (measur 1.,
ing instrument).
85554A (4) Turn the engine with the starter and read the
compression gauge pointer value with the specified
(1) Retighten the cylinder head bolts to specified engine speed.
torque and let the engine warm up until the coolant NOTE:
temperature reaches 75° C to 85° C. 1. Keep no fuel injected.
2. Make sure that the engine speed is also
Injection nozzle
measured as compression pressure
varies with the engine speed.
3. Make measurement for all cylinders, as
wear and other conditions vary from
one cylinder to another.
80112A
(2) Remove all injection nozzles from the cylinder

head.
NOTE:
Cover the mounting holes and injection
pipes to prevent entry of dust and dirt.
11-16
ENGINE - SERVICE PROCEDURES m
5.1.2 Cylinder Head and Valve Mechanism
(1) Removal and Installation
t- 2
175N m
(18kgf m)
(Wet)
Wear, damage
4
Water leak,
oil leak,
gas leak
<Disassembly sequence>
1 Rocker cover
2 Cylinder head bolt
3 Rocker and bracket assembly
4 Push rod
5 Cylinder head assembly
6 Tappet
B1634A
Removal Procedure (a) Where the push rod is forcing up the rocker, the
rocker adjusting screw must be loosened before all
Adjusting screw cylinder head bolts are removed.
(b) Loosen the cylinder head bolts in the reverse
order of tightening.
(c) Remove the rocker and bracket assembly and
cylinder head assembly, raising them straight up
ward.
(d) When removing the cylinder head gasket, use
care to prevent scratches on the cylinder head and
crankcase.
B0117A
11-17
DI ENGINE - SERVICE PROCEDURES
Installation Procedure
(a) Install the cylinder head assembly, cylinder head
gasket and rocker and bracket assembly to align the
locating pins.
Tappet Extractor
MH061288
Tappet
B0118A
(e) Removal of the tappet 175Nm

(18kgf m)(Wet) I:
Remove the tappet, using Tappet Extractor (special
tool). B1635A
For removal, press the special tool until its 0-ring is
pressed tightly against each other and remove the (b) Tighten the cylinder head bolts in the sequence
tappet together with the special tool. shown in illustration. Tighten step by step, and as a
final step, tighten to specified torque.
(2) Disassembly
(a) Rocker and bracket assembly
Oil hole
clogging
5
1 Set bolt
2 Rocker shaft bracket
3 Rocker
4 Rocker shaft spring
5 Rocker shaft
Thread damage
Deterioration Oil hole clogging
Wear
B0120B
11-18
(b) Cylinder head assembly
Wear and damage

on both end faces
1
Carbon and Scale <Disassembly sequence> ·

Corrosion deposits, cracks,
damage, water leak 1 Push rod
2 Valve cap
® Valve cotter
4 Upper retainer
5 Outer valve spring
6 Inner valve spring
(i) Valve stem seal
8 Lower retainer
9 Inlet valve
10 Exhaust valve
@ Water director
12 Cylinder head
13 Tappet
For disassembly of parts with an encircled
number, see following items.
B0121B
Valve Lifter
30091-08500 �Valve cotter
80123A
1) To remove the valve cotter, use Valve Lifter

(special tool) and compress evenly the valve spring.
11-19
Water director
B0125B
3) Water director
Remove the water director if corroded.
B0124A
2) Whenever the valve stem seal or valve is removed,

the valve stem seal must be replaced with a new one.
(3) Inspection
Clearance
Basic diameter in I I
NV (19) 0.01 to 0.08
L 0.2
L .. Limit
NV .. Nominal Value
B0120C
11-20
EB
1) Using the rocker 1.0. and rocker shaft 0.0., calcu

late the clearance. If the limit is exceeded, replace the
bushing in the rocker. For replacement, use Rocker
Bushing Puller (special tool).
Removal Installation
Rocker Bushing Puller

MH061378
Rocker oil hole 80128A
NOTE:
1. Align the oil hole in the bushing with
that in the rocker.
2. Ensure that the bushing clinch is on the
adjusting screw end.
3. When press-fitting the bushing into
rocker, start with the chamfered side
on the rocker.
11-21
ID ENGINE - SERVICE PROCEDURES
Item NV L
Item NV L
Free length 55.07 52.1
Free length 60.84 57.8
e Installed load/
installed length
93 N (9.5 kgf)/
40.3
79 N (8.1 kgf)/
40.3
@
Installed load/ 240 N (24.5 kgf)/ 205 N (20.8 kgf)/
installed length 47.25 47.25
2
Squareness 2.5
Runout
L 0.4
Clearance
Item NV [BO) L NV L
Inlet (91 0.04 to 0.07 0.15 Distortion of 0.1 or less 0.2

bottom surface
Exhaust (91 0.07 to 0.10 0.2
Valve seat width 1.8 to 2.2 2.8
Stem outer diameter 94.9 to 95.1 94.6
Item NV L
Inlet 8.96 to 8.97 8.85
Exhaust 8.93 to 8.94
Item NV L
Valve sinkage from 0.75 to 1.25

cylinder head
bottom surface
Valve margin 1.5
Valve seat angle 45°
Clearance
Basic diameter in I I
NV (2811 0.06 to 0.10
L 0.2
BO ... Basic Diameter

L ... Limit
B0129B

Phone: 269 673 1638
11-22
ENGINE - SERVICE PROCEDURES
m
C2747A
1) Inspection of valve spring 3) Measure the push rod runout. If the limit is
Check the valve spring for squareness, free length, exceeded, replace.
and proper tension, and replace if the limit is ex
Measuring positions
ceeded.
B0132A
4) Cylinder head bottom surface distortion

If the limit is exceeded, correct with a surface grinder.
If the cylinder head height from top to bottom surface
is below the limit, replace.
c.,
B0131A
2) Tappet to crankcase clearance C3102A
If the tappet to crankcase clearance exceeds the limit,

replace the tappet. 5) Measure the valve stem 0.0. and, if the measure
ment is below the limit, replace.
11-23
000Good Defective Defective
80133A C2707A
6) Calculate the clearance with the valve guide 1.0. 8) Inspection of valve
and valve stem 0.0. If the limit is exceeded, replace Check the contacting condition of the valve seat and
�·:
'I
!,
the valve guide. valve, after inspection and replacement of the valve :;··
,.
guide. \'.'
Ji
',I,
Removal When the valve is pressed against the valve seat

Valve Guide Installer /i,
coated with red lead, make sure that the valve is not
,,
MH061223 I.
turned.
r7---
U Valve Guide Remover
MH061066
80134A
7) Replacement of valve guide

For removal of the valve guide, use the Valve Guide
Remover (special tool). C2708A
To install, use Valve Guide Installer (special tool) and
ensure that the special tool is positively seated on the 9) Correction of valve face
cylinder head. The pressing force is specified for the Grind the valve face with a valve refacer, the grinding
valve guide, which must be reached by using the dimension being limited to a minimum.
special tool.
NOTE:
1. The valve seat angle is 45°.
2. Correct to ensure that the valve margin
is up to the limit.
11-24
Cut here 0.5to 1.0

C3106A C2711A
10) Correction of valve seat 11) Replacement of valve seat

a) Grind with a valve seat cutter or valve seat grinder. The valve seat is cold fitted. Replacement procedure
b) After grinding, hold a #400 or similar sand paper is given below.
between the cutter and valve seat and regrind lightly. a) Grind the valve seat from inside to reduce the wall
NOTE: thickness. Then, remove it at normal temperature.
1. The valve seat angle is 45°.
2. Correction must be made to ensure the
valve seat width and valve sinkage are
within the limit.
c) Using a 15° or 75° cutter, correct the seat width to
the nominal value. Intake Exhaust
side side
Headl.O. Headl.O.
Sinkag e Valve
Valve seat angle +0.025 +0.025
46 39
0 0
C2737A
b) Check if there is sufficient interference between

the cylinder head and valve seat.
Valve C2710A
d) Seat the valve and valve seat. {See 12))
11-25
12) Seating of valve and valve seat

,!} Installation � Caulking
The valve and valve seat must be in even contact
Caulking Tool Body
MH061067 throughout the surfaces.
Whenever the valve or valve seat is corrected or
replaced, they must be seated.
a) Apply a thin coat of compound evenly to the
seating surface of the valve.
NOTE:
1. Make sure that there is no compound on
B0135A the stem of the valve.
2. Use intermediate mesh compound (120
c) Dip the valve seat into liquid nitrogen and let it to 150 meshes) first and then use fine
cool down. But heat the cylinder head sufficiently. mesh compound (200 meshes or more)
d) Using Caulking Tool Body and Caulking Ring for the finish.
(special tools), install the valve seat. 3. Mix the compound with a small amount
of engine oil and the compound can be
NOTE:
applied evenly.
After pressing in position the valve seat
with the chamfered side of the caulking
ring, face the ring in the opposite direction
to caulk the cylinder head.
Valve Lapper
30091-07500
Valve
�
C.>- c., c:.. c::.>
c=,
�fj_S = �
C3110A
b) Using Valve Lapper (special tool), seat the valve on

Valve sinkage valve seat.
C2714A
While turning the valve slightly at a time, strike it
against the valve seat.
e) Reface the valve seat to obtain the nominal values
c) Wash off the compound with gas oil or similar
for the seat width and valve sir,kage.
object.
d) Seat the contact surfaces with engine oil.
e) Check if they are properly seated.
C2715A
11-26
ID
(4) Reassembly
2 1 3 5
Locating pin
<Assembly sequence>
B1636A
4 2 3 sf Crowded coil down

(Blue paint side)
Apply engine oil
10
I
<Assembly sequence>
13--'> 12--+@--+ 1 a-s--+s-+0-+6--+S-�@-+ 2- 1

For assembly of parts with an encircled number, see following items. B0137B
11-27
Valve Lifter
30091-08500 � Valve cotter
groove direction
B0140B 80123A
1) Installation of water director 3) Installation of valve cotter

Install the water director with its cut facing toward the Using Valve Lifter (special tool), install the valve
sp�cified direction. cotter while compressing the valve spring.
NOTE:
When compressing the valve spring, do not
Valve Stem Seal Installer
MH061293 allow the upper retainer to be in contact
Valve
with the valve stem seal.
Apply engine oil
Valve stem seal

Lower retainer
C6621A
2) Installation of valve stem seal

Apply engine oil to the lips of the valve stem seal and
strike Valve Stem Seal Installer (special tool) until it
touches the cylinder head.
11-28
DI
5.1.3 Flywheel and Flywheel Housing
(1 ) Disassembly and Inspection
Scratches on friction
surface, stepped wear,
cracks, damage on gear,
abnormal wear
1
L .. Limit
Oil leaks NV .. Nominal Value
5
G) Flywheel
Item NV L
2 Pilot bearing
Friction surface 0.05 or less 0.2 3 Washer plate
distortion 4 Oil seal
Height to friction 25 24 5 Flywheel housing
surface
For disassembly of parts with an encircled
B1637A
Removal Procedure Inspection Procedure
C1902B C3501A
(a) Removing flywheel (a) Replacement of ring gear

Remove the flywheel by inserting flywheel mounting 1) Removal
bolts evenly into the flywheel removing holes. Using an acetyline torch or similar device, evenly heat
Remove the ring gear integral with the flywheel. the ring gear.
(b) The flywheel housing has a pointer mounted. Do By applying a protective rod, hammer the entire
not remove this pointer at the time of disassembly. periphery of the ring gear, forcing it off.
2) Installation
Heat the ring gear with piston heater (approx. 100 °C)
for three minutes.
Fit the ring gear onto the flywheel with the noncham
fered side of tooth crests toward the flywheel.
11-29
Parallelism
0.1 or less
B
Surface A
C3503A
(b) Friction surface distortion (c) Correction of friction surface

Place the flywheel on a surface plate and move a dial Correct the friction surface with a surface grinder.
indicator over the flywheel friction surface to measure Make sure that the friction surface is parallel to
the distortion. surface A within 0.1 mm.
For more accurate measurement, use a portable jack. NOTE:
If the distortion is beyond the limit, regrind the friction After correction, make sure that the height
surface. of the friction surface (dimension B) is
NOTE: within the limit.
If the ring gear develops any unusual con
dition, replace it with a new one before
taking a measurement.
(2) Reassembly
74Nm
(7,5 kgf ml
Oil seal
side
Fl
�
.,..3
3
4 Apply engine oil
to lips
'-i!l!!-t+-+1-- 2
175Nm
(18 kgf ml
(Wet)
...-------�
Friction surface runout
1 (At installed condition)
NV O. 1 or less
I.
L 0.2
<Assembly sequence>
s',--+, ,_,'J;_G)
= � � 2--1 L .. Limit
For assembly of parts with an encircled number, see following items. NV .. Nominal Value B1638A
11-30
ID
Oil
seal side
Fl
R
mJ
�'ll/o
B1639A B1640A
(a) Installing flywheel housing (c) Installation of washer plate

Measure the installed state (eccentricity) at the spigot Install the washer plate with its shear droop end
joint of the flywheel housing. If the dial gauge facing toward oil seal side.
indicates runout exceeding the specified limit, loosen
the bolts and tap the housing lightly to correct
position.
Oil Seal and Sleeve Installer

MH061201
Oil seal
!�
Flywheel
€)
175N m
(18 kgf m)
(Wet)
B1641A
Apply engine oil to (d) Installation of flywheel

crankshaft outer surfaces
B0148A
Mount the flywheel onto the crankshaft and tighten
bolts to specification.
(b) Installation of oversize oil seal Measure runout (installed position) of the flywheel. If
If an excessive amount of oil leaks from the oil seal, the dial indicator deflects over the limits, check bolts
use the auxiliary oil seal and sleeve. for looseness or mounting surface.
To install the sleeve, use Oil Seal and Sleeve Installer
(special tool). The pressed position of the sleeve is
determined where the flywheel is installed.
NOTE:
Face the white painted side of sleeve,
toward the crankcase.
11-31
5.1.4 Timing Gear and Camshaft

(1) Disassembly
Wear, damage
·*· End play 10
•l!'· Backlash NV 0.05 to 0.22
L 0.3
Item NV L
Crankshaft gear to idler gear 0.11 to 0.23 0.4 Wear,

damage 8
Idler gear to camshaft gear 0.12 to 0.25 0.4
Idler gear to injection 0.18 to 0.31 0.4

pump gear
11
Oil leak
Wear, damage
•*· End play

NV 0.05 to 0.25
L 0.35
L •• Limit
1 NV •• Nominal Value
1 Torsional damper 7 Idler gear
@ Taper cone ® Camshaft gear
@ Crankshaft pulley ® Thrust plate
4 Timing gear case @ Camshaft
® Oil seal 11 Front plate
6 Idler shaft
For disassembly of parts with an encircled number, see following items.

The part marked •*·
must be inspected before disassembly.
B1412C
11-32
ID
J
Cone Puller
MH061101
81414A 80154A
(a) Removal of taper cone (d) Measurement of backlash

To remove, use Cone Puller (special tool). Measure the backlash between gears and replace if
the limit is exceeded.
NOTE:
1. For a pair of gears, the backlash must
be measured at three points or more to
determine the condition.
2. When measuring the backlash in injec•
tion pump gears, keep the pump fixed
onto the front plate.
Crankshaft pulley
B0152B
(b) If the crankshaft pulley flange and crankshaft

pulley are hard to remove, use Gear Puller (special
tool).
80155A
(e) Measurement of end play

Measure the end play of the idler gear and camshaft
with a thickness gauge or dial indicator. If the
measurements exceed the limit, replace the idler
shaft or thrust plate.
80153A
(c) Do not remove oil seal unless abnormal condition

is evident.
11-33
Gear Puller
Camshaft gear MH061326
80157A 80158A
(f) Removal of camshaft gear 2) To remove, use Gear Puller (special tool).
1) Accessing through the holes in camshaft gear, NOTE:
loosen the thrust plate attaching bolts. Then, remove 1. Do not remove the gear unless defect is
the gear together with the camshaft. evident.
2. For removal, never attempt to tap the
gear with a hammer.
(2) Inspection
Clearance
Item NV [BDI L
No.1 and 2 journals [54.5I 0.04 to 0.09 0.15
No.3 journal [54I 0.04 to 0.09
No.4 journal [53I 0.04 to 0.09
BO .. Basic Diameter
L .. Limit
NV .. Nominal Value
Item NV L Remarks
Cam lobe height 6.86 6.36 Cam height: 46.939

(Difference between Base circle
cam height and base diameter: 40.080
Clearance circle diameter
Basic diameter in [ I
NV [401 0.03 to 0.07
L 0.1
814128
11-34
NOTE:
m
1. When installing the bushing, align the
oil hole in bushing with that in idler
gear.
2. After installation, make sure that the
bushing to idler shaft clearance is with•
in nominal value. If the clearance is
below specification, ream the bushing.
Measurement point
Cam
height
5.5 5.5 Basic circle diameter
C4101A
(c) Measure the height and base circle diameter of

each cam. If the difference between both measure
B0162A
ments is below the limit, replace.
(a) With the idler gear 1.0. and idler shaft O.D., NOTE:
calcu•ate the clearance. If the limit is exceeded, Since the taper cam is used, ensure that
replace the bushing in the idler gear. the measurement taken at the location
indicated in illustration.
Removal Installation
Idler Gear
Bushing Puller
MH061228
Idler gear bushing Idler gear oil hole B0163A
(b) Replacement of idler gear bushing

Using Idler Gear Bushing Puller (special tool), replace
the idler gear bushing. See illustration for procedure.
11-35
Make camshaft
bushing end
face flush with
crankcase end
Camshaft Bushing Installer face.
and Extractor
MH061276
80167A
L
E9 Stamped
number
80164A
0 80166A
(d) Measure the camshaft journal 0.0. and crankcase 2) Installation 1·

1.0. If the limit is exceeded, replace the bushing in the Identify bushings with a unique number stamped on
crankcase. the external surface, indicating the installation posi
tion.
Then, using Camshaft Bushing Installer and Extractor
(special tool), press-fit the bushings.
I,
Bushing No.
Stamped
(Ascending from I.D. Width
number
front of engine)
No. 1 1 54.5 41
No. 2 2 54.5 21
No. 3 3 54 21
80165A No. 4 4 53 21
(e) Replacement of camshaft bushing If the marking is illegible, determine by measuring the
1) Removal I.D. and width.
Remove the sealing cap through the camshaft hole in

the rear-end face of the crankcase. Then, using
Camshaft Bushing Installer and Extractor (special
tool), remove the camshaft bushing.
11-36
C4111A
(f) Measure the bend of camshaft. If the limit is

exceeded, replace.
NOTE:
Rotate the camshaft a turn and read the
deflection of the dial indicator pointer.
One half of the reading is the bend.
11-37
Ill ENGINE - SERVICE PROCEDURES
(3) Reassembly
44 Nm End play
(4.5 kgf m ) NV 0.05 to 0.25
(Wet) L 0.35
8 9 10
End play
NV 0.05 to 0.22
L 0.3
390Nm
(40 kgf m )
Backlas h
NV 0.12 to 0.25
0.4 Backlas h
L
NV 0.11 to 0.23
L 0.4
Apply lithium base grease
(Wheel bearing grease or
equivalent) to lips.
L .. Limit
NV .• Nominal Value
I
<Assembly sequence>
11-�®,<--+4---+3-2-1
10-@-+,_y-J 5.J
For assembly of parts with an encircled number, see foll owing items.
B1416B
11-38
m
t/ Number marking "2"
Camshaft gear
Make also sure that the idler shaft spring pin rests in
the crankcase oil groove and the "UP" mark with an
arrow on the shaft faces upward .
�
•
(d) Check gears for backlash.
/
Thrust plate
� Face oil groove
side to gear.
�
"7
Camshaft
/
B0171A
(a) Installation of camshaft gear

Timing gear case
After mounting the thrust plate, install the camshaft
Apply lithium-base grease to lips
gear with its number marking side facing outward. (Wheel bearing grease or equivalent) B0153A
(e) Apply lithium-base grease to the oil seal lips.
(b) Check the camshaft end play. Then, install the

camshaft into the crankcase.
B0173A
(c) Installation of idler gear

Install the idler gear, its side with a number marking
facing outward and its alignment mark lining up with
others.
11-39
5.1.5 Crankcase and Main Moving Parts

(1) Disassembly
•:i:·
Projection
NV 0.48 to 0.74 <6D31>
0.43 to 0.69 <6D31-T>
·:i:·
End play
NV 0.15 to 0.45 Do not remove from connecting rod
L 0.6 except for replacement
Corrosion, scale deposits,

cracks, 2
damaged thread,
oil hole clogging
·:i:·
End play
NV 0.10 to 0.25
Scratches on inner and outer 17 L 0.4
surfaces, flaking, corrosion
Scratches on inner and Scratches, cracks,

outer surfaces, corrosion, dents, seizure,
flaking oil hole clogging
Tooth surface wear
Wear
«"\ - �
Scratches on inner and outer �
surfaces, corrosion, flaking 13
So,a�hM oo ;M� aod """"I:��

·• surfaces, corrosion, flaking
� NV ..• Nominal Value
L ... Limit
1 e
1 Connecting rod cap @ Main bearing cap
@ Piston
2 Connecting rod bearing @ Thrust plate
12 Side seal
© 1st compression ring 13 Lower main bearing
2nd compression ring 14 Crankshaft
® Oil ring @ Crankshaft gear
7 Snap ring 16 Upper main bearing
Piston pin 17 Crankcase
® Connecting rod
The part marked ·:i:· must be inspected before disassembly. B0176B
11-40
Measurement points
Connecting rod
Connecting
rod bolt
B0177A B0179A
(a) Piston projection (c) Removal of piston

Incorrect piston projection adversely affects the en Withdraw the piston from the crankcase, pushing it
gine performance. If measurements are out of speci up together with the connecting rod.
fication, check parts for clearance. NOTE:
1) Hold the dial indicator on the crankcase top 1. If the piston pin is hard to remove, heat
surface to make zero adjustment. the piston with a piston heater or hot
2) Locate the piston TDC with the dial indicator. water.
3) Measure projections at three points on the piston 2. Do not remove the connecting rod bolts
top surface to obtain the average value. from the connecting rod unless defec•
tive. If the bolt is damaged, install a
new connecting rod bolt by referring to
"5.1.5, (3)(e)".
B0178A
(b) Connecting rod end play

Measure the end play of each connecting rod. If the B0180A
limit is exceeded, replace the connecting rod.
(d) Removal of piston ring
To remove the piston rings, use Piston Ring Tool
(special tool).
11-41
Gear Puller
MH061326
B0181A B0185A
(e) Crankshaft end play (g) Removal of crankshaft gear

If the end play exceeds the limit, replace the thrust To remove the crankshaft gear, use Gear Puller
plate with an oversize. (special tool).
Three oversize thrust plates are available: +0.15, NOTE:
+0.30, and +0.45 mm It is not necessary to remove the crank•
NOTE: shaft gear unless defect is evident.
The thrust plates on both ends of the
bearing cap need not be of the same size;
however, use the one of the same size for
those at the rear end of the crankcase and
in rear of the bearing cap.
1·
At front and
rear ends
Bearing Cap
Extractor
MH061083
B0182A
Intermediate
Bearing Cap Extractor
position MH061071
B0184A
(f) Removal of main bearing cap

To remove the main bearing cap, use Bearing Cap
Extractor (special tool).
11-42
ENGINE - SERVICE PROCEDURES DI
(2) Inspection
Item NV L Applicable model
Ring groove 1st 0.04 to 0.10 0.2 6D31

Clearance to ring
Basic diameter in I I clearance 0.06 to Q.12 6D31-T
NV [34) 0.002 to 0.019
L 0.05 2nd 0.03 to 0.06 0.15 6D31
0.07 to 0.10 6D31-T
Oil 0.03 to 0.06 6D31,

Clearance ring 6D31-T
Basic diameter in I ]
NV [34) 0.02 to 0.05 Ring gap 0.3 to 0.5 1.5 6D31, 6O31T
L 0.1 l�---4
Clearance
Applicable
NV [BO] model
Bend, twist
L 0.05
[100] 0.04 to 0.08 6031
(100] 0.10 to 0.14 6D31-T

Top surface distortion
NV 0.07 or less
L 0.2
Item NV L
Sleeve 1.0. 100 to 100.03 100.25
Roundness 0.01 or less Item NV L

Cylindricity 0.03 or less Roundness of pins 0.01 or less 0.03
and journals
Interference STD 0.16 to 0.22
between Cylindricity of 0.006 or less 0.03
crankcase OS 0.18 to 0.20 Less than 0.18 pins and journal
and sleeve
Item NV [BO) L Remarks
Oil clearance (78) 0.05 to 0.09 0.15 �

Free span - Less than Upper
82.5
Less than
82.27
Lower
..
Item NV [BO] L L ... Limit
Oil clearance (601 0.05 to 0.09 0.2
Free span Less than 64.27
B0186B

Phone: 269 673 1638
11-43
Crankcase A: Crankshaft direction

A: Crankshaft direction B: Direction perpendicular
Cylinder sleeve B: Direction perpendicular to crankshaft
to crankshaft , i.---=--�---1- 15
N«
I
Crankcase
J -m
60ormore
, /,>------""'1/, B01B8A B0189A
(a) Measurement of cylinder sleeve I.D. 2) Installation

Measure the cylinder sleeve I.D. at the six points After the cylinder sleeve has been removed, check the
shown in illustration. crankcase sleeve hole for damage and proper interfer
If the I.D. exceeds the limit, replace the sleeve. ence.
If the cylinder sleeve is to be used without being If defects are evident, bore the crankcase sleeve hole.
bored, correct the ring ridge wear at its top by For measurement of interference, measure the cylin
grinding with a ridge reamer. der sleeve O.D. and crankcase sleeve hole I.D. at the
positions indicated in illustration. Calculate the aver
age value of the measurements in the vertical (D1, D2,
DJ) and diametrical (A, B) directions.
If the interference exceeds the limit, bore the crank
G____[_J::n case sleeve hole to oversize.
Make round.
-0- --v-
,-..,,/
ViewX
C4406A
(b) Replacement of cylinder sleeve

1) Removal
a) With a boring machine fixed in the crankcase,
80190A
center the machine. Make sure that the machine is
centered at the bottom of the cylinder sleeve which
• When crankcase sleeve hole interference is suffi-
develops uneven wear least.
cient:
b) Bore until the wall thickness is reduced down to
approximately 0.5 mm. a) Using Cylinder Sleeve Installer (special tool) and a
c) Insert a screwdriver (machined as illustrated) be hydraulic press (sleeve installation load: 4.7 to 9 t),
tween the crankcase and cylinder sleeve. Tap the install the STD cylinder sleeve into the crankcase.
screwdriver to break and remove the sleeve. During installation, ensure that the chamfered side of
Make sure that the rounded part of the screwdriver the sleeve faces down and the sleeve top surface is
faces to the case. flush with the crankcase top surface.
b) After installing the cylinder sleeve, obtain the
nominal dimension for I.D. and finish to 3.2-S by
honing operation. 'v'vv
11-44
• When crankcase sleeve hole interference is in NOTE:
sufficient: 1. Even if only one cylinder requires bor
a) Ready an oversize cylinder sleeve with a 0.5 mm ing, make sure that all cylinders are
larger O.D. Hone the crankcase sleeve hole to 8S to bored to the same oversize.
obtain the nominal value for the interference be�en 2. Replace the piston and the piston rings
the cylinder sleeve O.D. and crankcase sleeve hole. with the corresponding oversizes.
b) Using Cylinder Sleeve Installer (special tool), in
stall the cylinder sleeve into the crankcase. After
installation, obtain the nominal value for the cylinder
sleeve I.D. and hone the surface to 3.2-S.
Measurement points
NOTE:
1. When boring the crankcase sleeve hole,
remove sleeves from all cylinders and
bore to roundness.
2. Before installing the sleeve, apply spin (
dle oil (MECHANIC #32 or equivalent) to
f C4417A
the crankcase sleeve hole.
(d) Crankcase top surface distortion

Crankcase
A: Crankshaft direction If the limit is exceeded, correct with a surface grinder.
Cylinder sleeve B: Direction perpendicular
to crankshaft
NOTE:
Crankcase must be ground only to the
extent that the piston projection does not
exceed the nominal value.
0.D. measurement position
B0188A
(c) Selection of oversize 70
0
Available oversizes (4 types):
+0.25, +0.5, +0.75, +1.00 mm
1) An oversize must be determined in consideration
of the part developing the most serious wear from all
B0191A
cylinder I.D. measurements.
2) Using a micrometer, measure the O.D. of indi
(e) Piston O.D.
vidual oversize pistons to be used.
3) Bore and hone the cylinder sleeve to obtain the Measure the piston skirt O.D. and calculate the
nominal value for the cylinder sleeve to piston clearance with the smallest cylinder sleeve I.D.
clearance. measurement [See (a)]. If the limit is exceeded,
replace the cylinder sleeve or piston.
NOTE:
If a piston is replaced, replace also the
piston ring.
11-45
Piston ring
0 c;>
Piston
Cylinder
B0192A liner B0193A
(f) Piston to piston ring clearance (g) Piston ring gap

If the limit is exceeded, replace the piston ring or Put the piston ring in the standard gauge or crankcase
piston. cylinder sleeve by pushing it with piston and measure [j:
,.,
i, ,
NOTE: the ring gap.

1. Remove carbon and measure the clear• If the limit is exceeded, replace.
ance throughout the entire periphery of Standard 1.0.: 100 ± 0
the piston.
2. Replace piston rings as a set. Piston
EB
+
Piston pin
C4811A
Straight edge (h) Piston to piston pin clearance

C4810A
If the limit is exceeded, replace the piston pin or
piston.
For the 1st compression ring, press the ring against
the piston with a straightedge.
11-46
DI
Connecting rod Approx. 49 kN {5 tons) 0
Mandrel
�
Coller A
+
Piston pin
80194A Base C5218A
(i) Piston pin to connecting rod clearance <6031-T>

If the limit is exceeded, replace the connecting rod a) With the connecting rod bearing removed from the
bushing. connecting rod big end, secure the connecting rod to
Base (special tool).
<6031>
b) Set Mandrel and Collar A (special tools) onto the
connecting rod small end as illustrated at right and
gradually apply force with a press.
Approx. 49 kN {5 tons)
Connecting Rod Bushing Puller
MH061296
Connecting rod bushing

puller
MH061296
80195A
Chamfer
<6031-T> Connecting Rod

Bushing Puller Kit
MH061891 801968
2) Installation of bushing
<6031>
a) Insert the bushing into Connecting Rod Bushing
Puller (special tool).
b) Apply engine oil to the bushing and connecting
rod.
C5217A c) Press-fit the bushing into the connecting rod.
NOTE:
(j) Replacement of connecting rod bushing
1. Press the bushing into the chamfered
1) Removal of bushing end of the connecting rod.
Using Connecting Rod Bushing Puller or Connecting 2. Align the oil hole in the bushing with
Rod Bushing Puller Kit (special tool), remove the that in the connecting hole.
bushing. 3. After the piston pin has been inserted,
make surface that there is no exces•
sive play and it turns smoothly.
11-47
:::Q;
Approx. 49 kN (5 tons) Measurement of torsion
,.,...._..,.,,,. Oil hole
100
80197A C5207A
<6031-T> (k) Bend and twist of connecting rod

a) Set the bushing to Mandrel, Collar 8, Collar A, and Measure with Connecting Rod Aligner (special tool). If
Nut (special tools). the limit is exceeded, replace or correct with a press.
b) Apply engine oil to the connecting rod small end
NOTE:
and bushing.
1. Measure with the bushing and connect•
c) Press the special tools, to which the bushing is set,
ing rod bearing installed in the connect
into the connecting rod small end with a press.
ing rod.
d) After the bushing is pressed into position and
2. The connecting rod and connecting rod
special tools are removed, ream the bushing to obtain
cap bolts must also be tightened to
the specified bushing to piston pin clearance.
specification.
NOTE:
1. When installing the bushing, make sure
that the oil hole in bushing is aligned
with that in the connecting rod.
2. When the piston pin has been installed,
ensure that it turns smoothly with no
excessive play.
Measurement of bend
Connecting rod aligner

(I) Connecting rod bearing tension
Measure the tension of the connecting rod bearing
when free and, if the meqsurement falls short of the
limit, replace the upper and lower bearings as a set.
C5205A NOTE:
Never attempt to expand the bearings for
reuse.
11-48
DI
Measurement Measurement
directions positions
C5214A directions positions C5215A
(n) Main bearing to crankshaft clearance

If the limit is exceeded, replace the upper and lower
main bearings as a set.
directions positions C5513A
(m) Connecting rod bearing to crankshaft clearance

If the limit is exceeded, replace the upper and lower C5504A
connecting rod bearings as a set.
(o) Main bearing tension
Measure the tension of the main bearings when free.
If the measurements are below the limit, replace the
upper and lower main bearings as a set.
NOTE:
Never attempt to expand the bearings for
reuse.
80198A
11-49
Journal
35
52.5±0.1
Shore hardness Hs 75 or more 80200A
(p) Roundness and cylindricity of crankshaft (r) Correction of crankshaft to undersize

Determine roundness and cylindricity of the crank If a journal or pin is damaged or seized, grind the
shaft based on measurements of journal and pin crankshaft by using the following procedures.
O.D.s. If the limit is exceeded, grind to undersize. Replace the bearing with an undersize.
1) During grinding, use care not to change the center
distance of journal and pin.
2) Use care also not to change the width of journal
and pin._
3) Finish the fillet smooth to the specified radius.
4) Check for grinding cracks by the magnetic particle
inspection method. Make also sure that the surface
hardness (shore hardness Hs 75 or more) has not
decreased.
C5516A
Grinding Finishing
(q) Crankshaft bend

If the limit is exceeded, correct with a press or grind to
undersize.
If the bend is excessive, replace.
NOTE: Grindstone or sandpaper
Read the crankshaft center journal runout

Crankshaft
with a dial indicator. One half of the read• C5509A
ing is the bend.
5) When grinding the crankshaft with a grinder, the
grinder and crankshaft must be turned counterclock
wise as viewed from the crankshaft front end.
6) To finish the crankshaft with a grindstone or
sandpaper, turn the crankshaft clockwise.
11-50
Crankshaft Undersize Dimensions

m
Unit: mm
Journal O.D. Pin 0.D.

Out-of-
Undersize finish finish Cylindricity
roundness
dimension dimension
0.25 77.68 to 77.70 59.695 to 59.715 0.01 or less 0.006 or less
0.50 77.43 to 77.45 59.445 to 59.465
0.75 77.18 to 77.20 59.195 to 59.215
1.00 76.93 to 76.95 58.945 to 58.965

Phone: 269 673 1638
11-51
(3) Reassembly
Weight mark
stamped position
Expander spring
side
butting ends st ring open ends
-- ..
Engine front ij Lug
Weight mark
stamped
Mating mark
2nd ring open ends Oil ring open ends stamped Lug indication
mark
Piston projection
NV Applicable model
0.48 to 0.74 6D31
End play End play

12 NV 0.15 to 0.45 NV 0.10 to 0.25
L 0.6 L 0.4
Oil groove
<Assembly sequence>
L ... Limit
17-+ii -•,s. NV ... Nominal Value
7--, ,
14-•15-
_ ,@
foi--i>,-,_,,:i;---� --,_,1
3-· 9 -->· 8 ,...... 7-(6�i�(•}-2J
For assembly of parts with an encircled number, see following items. 814178
11-52
Embossed number
Main bearing cap
Oil groove side w
� w , Thrust p 1 ate
- · . attaching pin
Lower main bearing � Thrust plate
Oil groove
Lug�
>---
Apply sealant
(THREEBOND 1105D
or equivalent)
80212A 80214A
(a) Install the thrust plate and upper main bearing to (cl Installation of main bearing cap
the crankcase. 1) Fit the lower main bearing into the main bearing
NOTE: cap. At the time, make sure that the main bearing lug
1. Install the thrust plate with its side is aligned with the main bearing cap lug groove.
having no oil groove toward the crank 2) Install also the thrust plate onto the main bearing
case. cap in the rear-end position.
2. Line up the lug of main bearing with the 3) Make sure that the main bearing cap lug groove
lug· groove in crankcase. Note that the and crankcase lug groove are on the same side.
upper main bearing has an oil hole, Ensure also that the embossed numbers on main
which must not be confused with the bearing caps are in ascending order from the front of
lower. engine.
3. Apply engine oil to all sliding surfaces. NOTE:
1. Face the side of thrust plate having no
oil groove toward the main bearing cap.
- 2. Use thrust plates of the same size for
the crankcase and main bearing cap
rear end.
3. Apply sealant to the crankcase front
and rear surfaces onto which bearing
caps are mounted.
(bl Installation of crankshaft gear

When the crankshaft gear was removed, it must be
heated with a piston heater or similar device before
being reinstalled onto the crankshaft.
11-53
175 Nm (18 kgf ml (Wet)
4) Tighten the main bearing cap bolt to specification.

Then, make sure that the crankshaft turns smoothly
by hand.
Alignment mark side
5) Measure the crankshaft end play to determine if it
is within the nominal value [See 5.1.5 (1), (e)]. Weight mark
Lug side indicating

protrusion
B0217A
(el Reaseembly of piston and connecting rod

1) Assemble the piston and the connecting rod,
ensuring correct direction as illustrated.
2) Insert the piston pin to couple the piston and
connecting rod. Mount the snap ring to hold the
piston pin in position. The piston pin is a clearance fit
in the piston. If the piston pin is hard to fit, heat the
(d) Installation of side seal
piston with a piston heater or hot water.
Install the side seal with sealant applied to its end.
NOTE:
Then, apply sealant to the bearing cap.
1. The parts for an engine must be of the
NOTE: same weight mark.
When installing the side seal, ensure the 2. Apply engine oil to all sliding surface.
correct installation direction.
11-54
m
Press-fit with a press.
Max. 4.9 kN (500 kgf)
Face top groove inside. f
=
...
� Apply engine oil
DJ
Front of engine
I_)
�) L l \1
Check for scratches
I� and burrs
2nd compression �
ring ends
80220A 80221A
3) The connecting rod bolts do not normally need Direct the open ends of piston ring as shown.
removal; however, where replacement is necessary
for damaged bolt, install new bolts by using the
following procedures.
Make sure that the connecting rod bolt hole is free
from damage and burrs. Then, with engine oil applied Piston Guide
MH061890
to the connecting rod bolt, press it into position with a
press. (Pressing load: Max. 4.9 kN or 500 kgf)
80223A
(g) Installation of piston and connecting rod assem-

bly
Fit the upper connecting rod bearing into the connect
ing rod and install the piston into the crankcase with
Piston Guide (special tool).
80180A
NOTE:
(f) Installation of piston rings
1. Face the lug end mark of the connect•
ing rod toward front of engine.
To install piston rings, use Piston Ring Tool (special 2. Make sure that the piston ring ends
tool). position does not change during in•
NOTE: stallation.
A manufacturer's mark is stamped near 3. Cover the connecting rod bolt with a
the piston ring ends. Install with the mark vinyl hose so as not to damage to
up. crankshaft pins.
11-55
100 Nm 110.5 kgf ml (Wet)
Adjusting bolt B5291B B0224A
Use of Piston Guide (h) Fit the lower connecting rod bearing to the
With the Piston Guide lined up with the piston skirt, connecting rod cap and tighten the connecting rod to
set the lever in position and adjust with the adjusting specification.
bolt to match the clamp 1.0. with piston 0.0. NOTE:
On completion of adjustment, remove the Piston The lug sides of the connecting rod and
Guide from piston and apply engine oil to piston connecting rod cap must be in the same
external surfaces, Piston Guide internal surfaces, and direction.
cylinder liner internal surfaces. (i) Check the connecting rod end play [See 5. 1 .5 (1 ),
(b)].
(j) Check piston for projection [See 5. 1 .5 (1 ), (a)].
,.
B5292B
After these procedures have been completed, install

Piston Guide to the piston with .their top surfaces
flush with each other and tap piston top with a mallet
or other soft object into position so as not to damage
to the piston.
11-56
ID
5.1.6 Inspection and Adjustment of Valve
Cylinder
Clearance No.
1 2 3 4 5 6
Inspect and adjust the valve clearance when the Valve

arrange- In. Ex. In. Ex. In. Ex. In. Ex. In. Ex. In. Ex.
engine is cold by using the following procedures. ment
No.1
at TDC
on com- 0 0 0 0 0 0
pression
stroke
No.6
at TDC
on com- X X X X X X
pression
stroke
Valve clearance
(both intake and
,�
exhaust, when coldl
B0225B 0.40MM or .016 Inch
�ointer
80228A
(3) Insert the specified thickness gauge between the

rocker and valve cap to check for clearance.
Intake Valve Lash Clearance 0.40MM or .016 Inch (cold)
B1643A
Exhaust Valve Lash Clearance 0.40MM or .016 Inch (cold)
If the valve clearance is out of the nominal value,
(1) Crank the engine with Cranking Handle (special
loosen the lock nut and turn the adjusting screw to the
tool) to line up the inscribed line "1.6" position on the
extent that the thickness gauge moves slightly tight.
flywheel with the pointer of the flywheel housing
After adjustment, hold the adjusting screw in position
inspection window.
with a screwdriver, and tighten to secure the lock nut.
(2) When the piston in No. 1 cylinder is at TDC on the
Recheck the valve clearance with the thickness gauge.
compression stroke (the push rods of No.1 cylinder
not pushing up the intake and exhaust valves), check
and adjust clearances of valves marked with "O" in
the following Table. Then, with the crankshaft rotated
a turn, check and adjust clearances of the remaining
valves marked with "x".
If the No.6 cylinder piston is at TDC on the compress
ion stroke (push rods in the No.6 cylinder not pushing
up the intake and exhaust valves), similarly check and
B0229A
adjust the clearances of valves marked with "x" first;
then, turn the crankshaft a turn, check and adjust
For on-vehicle adjustment of the valve clearance, use
valves marked with "O".
Slotted Screwdriver (special tool) to turn the adjust
ing screw, which makes the job easier.
Phone: 269 673 1638 11-57
m ENGINE - TROUBLESHOOTING
6. TROUBLESHOOTING
Engine is hard to start
NO
Is right fuel used or oil viscosity adequate? Change fuel or oil
YES
NO
Is valve clearance or fuel injection timing correct? Adjust
YES
NO
Is compression pressure correct? I Check or correct below, or replace:
I
o Defective cylinder head gasket
YES o Worn valve and valve seat
o Valve spring set
o Worn or damaged piston ring
o Worn or damaged piston ring groove
o Excessive clearance between piston and
cylinder sleeve
NO
Is starting system (including preheating system) Correct or replace defective parts
in good condition? (See GROUP 16 ENGINE ELECTRICAL)
YES
Check fuel system

(See GROUP 13 FUEL AND ENGINE CONTROL)
Ii
11-58
ENGINE - TROUBLESHOOTING
m
Idling not smooth
NO
Is right fuel used or oil viscosity adequate? Change fuel or oil
YES
NO
YES
NO
Is compression pressure correct? I Check or correct below, or replace:
I
o Valve spring set
cylinder sleeve
I
YES
Is fuel filter or feed pump clogged, or air I I Correct, replace, or adjust defective parts
trapped inside?
I (See GROUP 13 FUEL AND ENGINE CONTROL)
NO
NO
I Are injection pump and nozzle intact? I
I
YES
Check governor for idling adjustment

11-59
ID ENGINE - TROUBLESHOOTING
I
Improper exhaust color
NO
Is right fuel used or oil level adequate? Change fuel, or add or reduce oil to an
adequate level
YES
NO
YES
NO
[ is compression pressure correct? I Check or correct below, or replace:
I o Defective cylinder head gasket
o Valve spring set
cylinder sleeve
NO
Is air cleaner or muffler in good condition? Correct or replace defective parts
YES
Check injection pump, timer, and nozzle

11-60
ENGINE - TROUBLESHOOTING
m
I
Engine lacks power
NO
Is correct fuel used or oil viscosity adequate? Change fuel or oil
YES
NO
YES
I Is compression pressure correct? I

I
NO
Check or correct below, or replace:
o Valve spring set
cylinder sleeve
NO
Is air cleaner or muffler in good condition? Correct or replace defective parts
YES
YES
Is fuel filter or feed pump clogged, or air Correct or replace defective parts
trapped inside? (See GROUP 13 FUEL AND ENGINE CONTROL)
NO
Check injection pump, timer, and noule

11-61
m ENGINE - TROUBLESHOOTING
Excessive oil comsumption
NO
Is fuel injecti on ti ming correct? Adjust
YES
_.,..------------------+, I
l
NO
a v e stem se a n tact? Replace valve stem seal
�1s_ v_ _1 _ _ _ _ _ _ _ _1_i_ _ _ _ _________
---,-
YES
NO
Is va lve to va lve guide clearance adequa te? Replace valve and valve guide
YES
NO
Are piston ring and ring gro o ve free fro m wear? Replace piston ring or piston
YES
Is lubrica ting system OK?

(See GROUP 12 LUBRICA TION)
YES
Is fu el system OK?
(See GROUP 13 FUEL A ND ENGINE CONTROL)
11-62
ENGINE - TROUBLESHOOTING ID
Engine develops unusual noise
Noise comes from around the

engine
•
NO
Are pipings and hoses securely Adjust installed conditions
connected?
YES
NO
Are injection pump, water pump, Check and adjust, or adjust installed
and other auxiliaries in good positions of the auxiliaries
condition, or properly installed? (See GROUP 13 FUEL AND ENGINE
CONTROL and GROUP 14 COOLING)
YES
NO
Is V-belt free from looseness or Replace V-belt, or check and adjust
damaged or is crankshaft pulley its installed position
properly installed? (See GROUP 14 COOLING)
YES
NO
Is air cleaner or muffler in good Correct or replace defective parts
condition?
YES
Check valve and valve seat for

proper contact
Noi- comes from rocker cover

and neighborhood
NO
Is valve clearance correct? Adjust
YES
NO
Is valve spring intact? Replace valve spring
YES
Check for the amount of oil from

rocker shaft
Continued on next page
11-63
ID ENGINE - TROUBLESHOOTING
Continued from previous page
Noise comes from gear case and

neighborhood
NO
Is timing gear backlash correct? Replace timing gear
YES
Check timing gear and associated

parts
Noi- comes from cylinder head

and crankca-
-
YES
Does the noise change with different
NO
Check for compression pressure;
engine coolant temperature or check and correct below, or replace:
fuel injection timings? o Defective cylinder head gasket
o Worn valve and valve seat
o Valve spring set
groove
o Excessive clearance between
piston and cylinder sleeve
i'
---+j There is a great change
I
I
Check and adjust fuel injection
timing, injection pump, noule,
and timer (See GROUP 13 FUEL
AND ENGINE CONTROL)
L-..+j There is a small change

I
Check parts for wear and damage:
check and correct below, or replace:
o Worn piston or cylinder
o Seized or broken piston and
piston ring
o Worn connecting rod small-
end bushing and piston pin
o Worn crank pin and connecting
rod big-end bearing
o Worn crankshaft journal and
main bearing
o Broken crankshaft
o Loose flywheel on crankshaft
o Excessive crankshaft end play
o Worn cam and tappet
o Excessive camshaft end play
11-64
LUBRICATION
CONTENTS
1. GENERAL .................................... 2 5. SERVICE PROCEDURES 8

2. SPECIFICATIONS ••••••••.••••••.•••••.•• 6 5.1 REMOVAL AND
3. SERVICE STANDARDS •••••••••••••••• 7 INSTALLATION ••••••••••••••••••••••••.
3.1 SERVICE STANDARD TABLE •••• 7 5.2 DISASSEMBLY, INSPECTION
3.2 TIGHTENING TORQUE AND REASSEMBLY ••••••••••••••••••
.TABLE. ...................................... 7 5.2.1 Oil Pump ............................... 10
4. SPECIAL TOOL .•..••••••••••••••••.••••.•• 8 5.2.2 Oil Cooler ..•..••..•.•..•••....••..•... 12
5.3 CLEANING OF
OIL COOLER .•••••••••••••••••••••••••.. 12
6. TROUBLESHOOTING •••••..•••••.•••.• 13
12-1
m LUBRICATION - GENERAL
1. GENERAL
The engine is lubricated by a gear-type oil pump that forces engine oil through the oil cooler and oil filter into the
engine for lubrication of various engine parts.
The illustration below shows the flow of engine oil.
Oil strainer
<6031-T>
Oil
cooler
Regulator valve Check valve
Mitsubishi Engine Parts: www.HeavyEquipmentRestorationParts.com Contact email:

EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 B1654A
12-2
LUBRICATION - GENERAL
m
(1) Oil Pump The oil pump is driven at a speed proportional to the
engine speed. Therefore, the delivery pressure of oil
pump increases at cold starting of the vehicle due to
Relief valve high oil viscosity. To avoid overloading the lubrica
tion system, the driven shaft is provided with relief
valve.
(b) Regulator valve
Regulator valve
valve 81655A
The oil pump, of a gear type, is driven by the skew

gear mounted on the camshaft.
The oil pump cover serves also as the bypass oil filter
head, requiring no oil pipe, and relief valve, regulator
pan Regulator
valve and check valve are mounted to the cover. valve
81657A
The regulator valve is mounted to the oil pump cover

and regulates. pressure of engine oil that flows
through the oil main gallery.
Skew gear
If the oil pressure of the oil main gallery exceeds
specification, the regulator valve will open to return
some of the engine oil to the oil pan.
(c) Check valve
Oil pump gear

80252A
The camshaft skew gear and oil pump gear are

lubricated by oil sprayed from the oil hole drilled in
the oil pump case.
The engine oil fed under pressure-by the oil pump is
delivered to the oil cooler.
(a) Relief valve Oil pump cover
81658A
Driven shaft
To make early lubrication of the portion to be
lubricated, at engine starting, the bypass oil filter
mounting portion is provided with the check valve.
Spring
81656A
12-3
m LUBRICATION - GENERAL
(2) Oil Cooler (b) Oil bypass alarm
From oil cooler

Cooling water
inlet
Oil bypass
alarm
B1659A oil filter B1752A
The oil cooler is an equipment for heat exchange The oil bypass alarm is so designed that when the
between the coolant and oil fed under pressure from difference in oil pressure between the engine oil
the crankcase water jacket and oil pump, respectively. before filteration and that after filteration increases
The oil cooler has a bypass valve and an oil bypass more than the specified value, the valve opens
alarm. antomatically to send engine oil before filteration to
(a) Bypass valve the inside of the engine.
In addition, the oil bypass alarm is provided with
electric contact points. When the valve opens, the
contact points close to turn on the pilot lamp,
indicating the driven that the full-flow oil filter ele
ment is clogged.
\
(3) Oil Filter
To full-flow
oil filter
B1660A
When the viscosity is high as at low temperature or l,

Full-flow
when the flow resistance is high due to clogging of filter
element, the oil bypass valve will open and let the
engine oil flow to the full-flow oil filter without
passing through the oil cooler. B1753A
The oil filter is a type incorporating both the full-flow

and bypass filters. The element is a spin-on type that
allows easy replacement.
The engine oil filtered through the full-flow filter is
delivered to the crankcase oil main gallery and the oil
circulating through the bypass filter returns through
the crankcase to the oil pan.
12-4
LUBRICATION - GENERAL
(4) Lubrication of Parts (c) Valve mechanism

The engine oil routed from the oil filter to crankcase
Engine oil sprayed
oil main gallery lubricates all engine parts as detailed
below before returning to the oil pan.
(a) Main bearing and connecting rod
bearing
Crankshaft
80259A
Ther� is an oil passage provided from the oil main

gallery to each main bearing. The oil flows through
the oil hole to lubricate the main bearing and passes
80262A
through the oil passage drilled into the crankshaft to
lubricate the connecting rod bearings.
The engine oil that has lubricated No.1 camshaft
Then, the oil passes through the oil hole in the
bushing passes through the oil hole provided at the
connecting rod to lubricate the connecting rod small
crankcase to the cylinder head.
end bushing, and sprayed to the piston from the oil jet
The engine oil then goes through the front-end rocker
to cool down the piston.
shaft bracket into the rocker shaft, lubricating each
(b) Camshaft rocker bushing. At the same time, it sprays from the
oil hole at top of rocker to lubricate the surfaces over
which the valve cap slides and valve stem. The oil
then passes through the push rod holes in the
cylinder head and crankcase to lubricate the tappets
and camshaft cams before returning to the oil pan.
81754A
Camshaft bushings are lubricated by the oil flowing

through the oil passages leading from the oil main
gallery to each bushing.
There is an oil hole provided in the journal at the front
end of engine that serves as an oil passage to
lubricate the camshaft gear and valve mechanism.
12-5
m LUBRICATION - GENERAL, SPECIFICATIONS
(d) Timing gear
Idler gear
Thrust plate
Camshaft gear
Oil pipe
B1755A
The timing gear idler gear bushing is lubricated by the

engine oil routed from the oil main gallery, part of
which spraying from the idler gear oil hole to
lubricate each gear.
The idler shaft is provided with an oil pipe for
continuous forced-lubrication of the auto timer.
The camshaft gear and thrust plate are lubricated by
the engine oil routed from No.1 camshaft bushing
through the camshaft oil hole.
2. SPECIFICATIONS
Model
6D31 6D31-T
Item
Engine oil Quality API classification API classification

class CC or better class CD or better
Capacity Oil pan Approx. 10 lit. Oil pan Approx. 10 lit.
Oil filter Approx. 1.8 lit. Oil filter Approx. 1.8 lit.
Lubrication method Pressure feed by oil pump Pressure feed by oil pump
Oil pump Type Gear pump Gear pump
Relief valve Type Ball valve Ball valve
Regulator valve Type Piston valve Piston valve
Check valve Type Ball valve Ball valve
Oil filter
Full-flow filter element Type Spin-on type filter paper Spin-on type filter paper
Bypass filter element Type Spin-on type filter paper Spin-on type filter paper
Oil cooler Type Shell-and-tube Shell-and-tube
Bypass valve Type Piston valve Piston valve
Oil bypass alarm Type Piston valve Piston valve
12-6
LUBRICATION - SERVICE STANDARDS
Unit:mm
Nominal. value Correction and

Description Limit
Oil pressure At idle 145 kPa (1.5 kgf/cm 2) 49 kPa Adjust.

(oil temperature or more (0.5 kgf/cm2)
at 70 to 90° Cl
At maximum speed 295 to 490 kPa 195 kPa Adjust.
(3 to 5 kgf/cm2) (2 kgf/cm2)
Oil pump Oil pump case to gear tooth end 0.10 to 0.19 0.2 Replace.
clearance
Difference between oil pump case 0.01 to 0.07 0.18 Replace.

depth and gear height (sinkage)
Driven gear to driven shaft clearance (20I 0.04 to 0.07 0.15 Replace.
Drive gear end play 0.03 or more
Relief valve opening pressure 880 to 1 080 kPa Replace.

(9 to 11 kgf/cm2)
Relief valve spring installed load 84N (8.6 kgfl Replace.

(Installed length: 30)
Regulator valve opening pressure 360 to 420 kPa Replace.

(3.7 to 4.3 kgf/cm2)
Check valve opening pressure 145 kPa Replace.

(1.5 kgf/cm2)
Oil cooler Bypass valve opening pressure 215 to 275 kPa Replace.
(2.2 to 2.8 kgf/cm2)
Bypass valve spring installed load 25 to 26N Replace.

(Installed length: 51) (2.6 to 2.7 kgf)
Oil bypass alarm operating pressure 145 to 175 kPa Replace.

(1.5 to 1.8 kgf/cm2)

Description Remarks
O.D. x pitch mm N m (kgf m)
Oil filter Full-flow filter element 18 to 22

(1.8 to 2.2)
Bypass filter element 12 to 20

(1.2 to 2)
Oil pump Mounting bolt MS x 1.25 20 (2)
Regulator valve M27 x 1.5 69 (7)
Cover to case mounting bolt MS x 1.25 20 (2)
Oil cooler Mounting bolt M10 x 1.5 45 (4.6)
Front and rear cover bolt MS x 1.25 13 to 21

(1.3 to 2.1)
Bypass valve M20 x i.5 15 to 20

(1.5 to 2)
Oil bypass alarm M20 x 1.5 44 to 54

(4.5 to 5.5)
12-7
-
4. SPECIAL TOOL
LUBRICATION - SPECIAL TOOL, SERVICE PROCEDURES
Unit: mm
Filter Wrench MH061509 Removal and installation of

bypass oil filter element
85222A
MH061537 Removal and installation of

full-flow oil filter element
81589A
5. SERVICE PROCEDURES
At idle
NV 145 kPa (1.5 kgf/cm2 )
or more
L 49 kPa (0.5 kgf/cm2 )
At maximum speed
NV 295 to 490 kPa
(3 to 5 kgf/cm2 )
L 195 kPa (2 kgf/cm2 )

L ... limit
80266A
With the oil pressure switch removed and pressure

gauge installed, warm up the engine until the oil
temperature reaches 70° C to 90° C.
Measure the oil pressure at idle and maximum
speeds. If the measurement is below the limit,
overhaul the lubricating system.
12-8
LUBRICATION - SERVICE PROCEDURES
5.1 REMOVAL AND INSTALLATION

(1) Oil Filter, Oil Pump, Oil Cooler
Align the relieved line

on the oil cooler with
inscribed line on the
water pipe.
1 Oil return pipe <6D31-T>
lib..��--, 2
3
4
Bypass oil filter element
Full-flow oil filter element
Oil pump
Clog, damage
18 to 22 Nm 5 Heat insulator
Clog, damage
(1.8 to 2.2 kgf ml 6 Oil cooler
12 to 20 Nm 7 Water pipe
(1.2 to 2.0 kgf ml
81757A
NOTE: (2) Oil Strainer

1. For removal and installation of the ele
ment, use Filter Wrench (special tool).
Note, however, that the bypass oil filter
element must be tightened by hand.
2. To remove the oil cooler, remove the
exhaust manifold beforehand.
3. After the element has been installed,
start the engine and check connections
for oil leaks.
4. When installing the oil cooler, align it
with the oil pump mounting.
1 Oil pan
2 Oil strainer
81758A
12-9
- LUBRICATION - SERVICE PROCEDURES
5.2 DISASSEMBLY, INSPECTION AND REASSEMBLY

5.2.1 Oil Pump
NV • . . Nominal Value
L ... Limit
Check drive gear end play
after assembly
NV 0.0or 3 more
Item NV
Cracks; clogged oil hole
Installed load 84 N 8( .6 kgf) 4
(installed length: 0
3 )
Wear, damage Clearance
Valve opening 880to 0 1 80kPa Basic diameter in I I
pressure (9 to 1 1 kgf/cm2 ) NV 2 ( 010.40to0.07
L 0.15
Wear, damage
Difference between
case depth and
gear height (sinkage)
NV 0.0to 1 0.07
L 0. 18
1
Clearance between
case and gear teeth
NV 0. 01 to0.19
L 0.2
!
Check valve
opening pressure
NV 145 kPa ( 51 . kgf/cm2)
3 (7 kgf ml
Valve opening pressure

NV 6 3 0to 420kPa
( .3 7 to 4 . kgf/cm
3 2
)
1 Oil pump cover
2 Driven gear
3 Regulator valve
4 Oil pump case assembly
5 Relief valve spring
6 Ball valve
For reassembly, reverse the order of disassembly.

NOTE:
1. The gear is shrink fitted in the shaft of the oil pump
case assembly and do not attempt to disassemble
more than the illustration.
2. Before reassembly, be sure to apply engine oil to
parts.
B 1 759A
12-10
LUBRICATION - SERVICE PROCEDURES
Inspection
B0276A
B0273A
(4) Measure the load at installed length of the valve
(1) Measure the drive and driven gears tooth end to springs. If the load is far beyond the nominal value,
oil pump case clearance. If the measurement exceeds replace parts.
the limit, replace the parts.
B0274A
(2) Measure the difference between the drive and

driven gears tooth end height and the oil pump case
depth. If the limit is exceeded, replace the parts.
B0275A
(3) Measure the play in the diametral direction of the

driven gear to check for driven gear to shaft clear
ance. If the clearance exceeds the limit, replace the
parts.
12-11
m LUBRICATION - SERVICE PROCEDURES
5.2.2 Oil Cooler
13 to 21 N m NV ... Nominal Value

Perform pressure proof test (1.3 to 2 fml_
to verify no leaks.
Water passage: 295 kPa (3 kgf/cm2 ) air pressure -i
Oil passage: 1470 kPa (15 kgf/cm2 ) air pressure
Make sure that the specified pressures
. JJ�·
are never exceeded.
Align 6 mark on the

shell outside with
notch on the
element. � Valve opening pressure
NV 145 to 175 kPa
(1.5 to 1.8 kgf/cm2 )
sequence>
Valve opening 1 Front cover
pressure
NV 215 to 275 kPa
2 Rear cover
Scale, clogged (2.2 to 2.8 kgf/cm2 1 3 Element
oil hole 4 Shell
Installed load 5 Bypass valve
(installed length: 511 15 to 20 N m
13 to 21 N m NV 25 to 26 N (1.5 to 2.0 kgfml 6 Oil bypass alarm
(1.3 to 2.1 kgfml (2.6 to 2. 7 kgfl
For assembly, reverse the order of disassembly.
B1760A
NOTE:
See 5.2.1 (4) for inspection of bypass valve
spring.
5.3 CLEANING OF OIL COOLER

(1) Check the oil path and bypass valve of the oil
cooler element for carbon deposits and sludge forma
tion. If contaminated, wash in a cleaning oil.
(2) If the element and cover are seriously scaled,
wash with referring to 5.6 "CLEANING OF COOLING
SYSTEM" in GROUP 14.
12-12
LUBRICATION - TROUBLESHOOTING
6. TROUBLESHOOTING
I
Low oil pressure
I Is oil level correct? I

I
NO
Check for oil leaks or oil trapped in the
coolant. Repair the trouble spot and add
YES oil to the required level
NO
Is oil viscosity normal? Change to oil with adequate viscosity
Troubleshoot if fuel is trapped
YES
NO
Are oil pressure switch and gauge unit Replace
operational?
YES
NO
Is oil filter element free from clogging? Replace element
YES
If oil strainer free from clogging?

Are oil pump joints tight enough?
NO
�-----------------: Repair defective parts, or replace I
Is pipe free from cracks7
YES
NO
Is relief valve or regulator valve oper!ltional? Repair or replace
YES
NO
If oil pump body free from wear and damage? Replace parts
YES
NO
Are connecting-rod and main bearings free Repair defective parts, or replace
from wear?
12-13
LUBRICATION - TROUBLESHOOTING
Excessive oil comsumptlon
Check following parts for leaks:

o Oil filter
o Oil cooler
>----------------
NG
-·:
.__ _________________ I
Repair leaks
_,
o Oil pan
o Pipings
o Rocker cover
OK
NO
Are front and rear crankshaft oil seals free Repair defective parts, or replace
from leaks?
YES
NO
Are lines to cooling system free from leaks? Repair leaks of oil cooler, water jacket, etc.
YES
NG
Check engine bearings for wear, resulting in oil Correct or replace
working up, etc.
, ..
12-14
FUEL AND ENGINE
CONTROL
CONTENTS
1. GENERAL .................................... 2 5.3 FEED PUMP .............. ............... 44

2. SPECIFICATIONS ..•.•.••.••..•.••••••••• 14 5.3.1 Disassembly, Inspection
3. �ERVICE STANDARDS ...•...••••..••. 14 and Reassembly •.•............... 44
3.1 SERVICE STANDARD TABLE .••• 14 5.3.2 Test and Adjustment ••....•...•• 45
TIMER ...................................... 45
3.2 TIGHTENING TORQUE TABLE .•• 15 5.4 SCDM lYPE AUTOMATIC
4. SPECIAL TOOL •.•••••••.••.••••••••.•.••.. 16
1
5. SERVICE PROCEDURES ....•..•.•.•• 17 5.4.1 Removal ............................... 45
5.1 A lYPE INJECTION PUMP ........ 18 5.4.2 Disassembly and
5.1.1 Removal ............................... 18 Inspection ............................ 46
5.1.2 Disassembly ...•••••..••...... ...•.. 19 5.4.3 Reassembly .•••.•••••..•.••..••..... 46
5.1.3 Inspection and Correction ••• 23 5.4.4 Installation .•••.•••.•.•••••••....••.•• 48
5.1.4 Reassembly .•.••••.•.•••.•••.•••••.. 25 5.4.5 Test and Adjustment .••......... 48
5.1.5 Adjustment after 5.5 INJECTION NOZZLE ................. 48
Reassembly ......................... 29 5.5.1 Removal and Installation ..•.. 48
5.1.6 Installation .•..•••••••.••••••.•••.•••• 33 5.5.2 Disassembly •••..••••••....•.••.••.. 48
5.1.7 Bleeding the Fuel System .•••• 34 5.5.3 Cleaning and Inspection ...•.• 49
5.1.8 Inspection and Adjustment 5.5.4 Reassembly ••••••..••••••.•••••..... 50
after Installation (Fuel 5.5.5 Test and Adjustment •........... 50
Injection Timing) •••••••••.••••••.•• 35 5.6 FUEL FILTER ••.••.•••.••.••••.....••.... 51
5.2 RSV lYPE GOVERNOR ............. 37 5.6.1 Removal and Installation .•.•. 51
5.2.1 Disassembly, Inspection 5.6.2 Disassembly, Inspection
and Reassembly •••••••••••.•••.•• 37 and Reassembly ....••.•.......... 51
5.2.2 Adjustment after 6. TROUBLESHOOTING ••.......••••..•.. 52
Reassembly ......................... 40
5.2.3 Inspection and Adjustment
of No-load Minimum and
Maximum Speeds •....• •••••••••• 43
13-1
DJ FUEL AND ENGINE CONTROL - GENERAL
1. GENERAL
Fuel leak-off pipe Fuel filter
Suction pipe
fi,.
I:
[,.
::
!-
Feed pump
:r
Fuel tank
B1800A
The fuel system consists of the injection pump

assembly (injection pump proper, governor, feed
pump), auto timer, fuel filter, injection nozzle, injec
tion pipe, and other parts.
Fuel is fed from the fuel tank through suction pipe to
the feed pump of the injection pump assembly, and
then to the fuel filter, injection pump, and injection
nozzle. The excess fuel is returned from the injection
pump to fuel tank. i
[,
i[
13-2
FUEL AND ENGINE CONTROL - GENERAL
(1) A-type Injection Pump (a) Pressure feed of fuel
Delivery valve holder

Stopper
Delivery valve spring
Delivery valve
Delivery valve seat
Plunger barrel
Plunger
(a) Bottom (b) Pressurizing (c) Pressure (d) Pressure
Control rack dead start feed feed
center stroke completed
Pump housing (Suction)
82210A
Plunger spring
The plunger has an obliquely cut groove (lead) on its

side as shown. At the top of the plunger there is a hole
Tappet
which leads to the groove. The plunger barrel has
suction and discharge ports.
The fuel delivered to the injection pump is forced by
the rotation of the camshaft or reciprocating motion
of the plunger as shown above.
When the plunger is at the lowest position or bottom
80712A dead center (a), fuel flows through the suction and
discharge ports into the plunger.
The injection pump is a device which forces fuel to the Rotation of the camshaft moves the plunger up. When
injection nozzle and has a mechanism for increasing the top surface of the plunger is lined up with the
or decreasing the pressure feed quantity according to suction and discharge ports, application of pressure
the engine load and speed. to fuel begins (b).
The injection pump is constructed as shown in As the plunger moves up further (c), and the lead of
illustration above. It has one plunger and delivery the plunger meets with the suction and discharge
valve for each cylinder. ports, the high pressure fuel flows through the hole in
The plunger, pushed up by the camshaft and pushed the plunger and runs back from the lead to the suction
back by the plunger spring, moves up and down and discharge ports, and the pressure feed of fuel is
through the plunger barrel on a predetermined stroke completed (d).
to feed fuel under pressure. The plunger stroke during which the fuel is fed under
Both ends of the camshaft is supported by the taper pressure is called the effective stroke.
roller bearings and is driven by the timing gear at 1/2
engine speed.
13-3
DJ FUEL AND ENGINE CONTROL - GENERAL
(b) Injection amount control system The delivery valve, provided on the top of. the pump
housing, performs the function of discharging the
Plunger barrel pressure in the injection pump.
The fuel compressed to a high pressure by the
plunger pushes the delivery valve up and spouts out.
If the pressure feed stroke of the plunger ends, the
delivery valve is brought back to its original position
by the pressure of the delivery valve spring to block
Pinion the fuel path, thereby preventing counter flow of the
fuel.
Control sleeve
The delivery valve is brought down further until the
Plunger B2211A seat surface is held tight. During that stroke the fuel is
drawn back from above to instantly lower the residual
According to the engine load, the amount of injection pressure between the delivery valve and nozzle. The
is increased or reduced by turning the plunger a draw-back effect improves the end break of an
certain angle to change the position where the lead injection from the nozzle and prevents after-injection
meets with the suction and discharge ports on the up dripping.
stroke and increasing or reducing the effective stroke. A delivery valve stopper is provided on the top of the
The control rack is coupled to the floating lever in the delivery valve spring. The stopper limits the lift of the
governor. If the control rack is moved to right or left delivery valve and prevents valve surging during high
by operation of the accelerator pedal or governor, the speed -rotation. In addition, it reduces the dead
control sleeve in mesh with the rack is turned. Since volume between the delivery valve and nozzle, there
the bottom of the control sleeve is in mesh with the by stabilizing the injection amount.
bar of the plunger, the plunger turns with the control (d) Overflow valve
sleeve, so the effective stroke changes and the
injection amount increases or decreases. The more
the control rack is pulled toward the governor, the
less the effective stroke and the less the injection
amount.
Each plunger is in mesh with this single control rack
and simultaneously turns the same amount.
(c) Delivery valve
Retraction stroke
B0714B
When the fuel pressure in the injection pump exceeds

a set level, the steel ball in the overflow valve goes up
.
to let the fuel flow out of the injection pump and
.
.
. return to the fuel tank, thereby stabilizing the fuel
Beginning Injection Completion Completion temperature and temperature distribution in the injec
of injection . of injection of retraction
(Beginning
tion pump and maintaining the injection rate into
of retraction) B2207 A each cylinder constant.
13-4
DJ
(2) RSV Type Governor The shifter, mounted to the guide lever hung on the
supporting lever shaft of the governor cover, prevents
rotation.
Governor housing
Start spring
Supporting lever shaft
Start spring
Swivel lever Shuckle
Camshaft Floating
Governor cover lever
Floating lever
Governor spring
Idling subspring
Pressure
Ungleich spring spring
Stop· lever
Flyweight
Full load
stopper bolt
Supporting lever
81801A Return spring
The RSV type governor is a centrifugal type all-speed 81332A

governor coupled to the camshaft of the injection
pump. The governor not only controls the maximum The floating lever is mounted to the middle of the
and minimum speeds but also automatically controls guide lever by the shaft with the bottom end as the
the engine speed at any intermediate speed position. fulcrum, whereas the top of the lever is coupled
through the shackle to the control rack.
Governor sleeve The start spring, attached to the top end of the
Round nut floating lever, always pulls the control rack in the
Guide lever direction that fuel is increased.
Ball bearing
The turning shaft of the swivel lever is fitted into the
bushing of the governor cover and its center is
eccentric with respect to the mounting position of the
governor spring installed to the tension lever. The
governor spring is installed to the end of the swivel
Supporting shaft
lever. When the governor spring receives tension, the
B2658B bottom end of the tension lever touches the adjust
able full-load stopper bolt.
The governor, as shown, consists of flyweights When the angle of the adjusting lever is changed, the
mounted to the injection pump camshaft. When the angle of the swivel lever is also changed and the
flyweights turning on the flyweight supporting shaft tension of the governor spring changed. This is
open outward, the roller mounted to the end of because the turning center of the swivel lever and the
flyweight arm pushes the end of the sleeve in the mounting position of the governor spring installed to
axial direction. The governor sleeve, being made the tension lever are eccentric to each other as
integral with the shifter through a bearing, moves mentioned above.
only in the axial direction.
13-5
- FUEL AND ENGINE CONTROL - GENERAL
When the adjusting lever is moved to the start

Governor spring position (until it touches the maximum speed stop
per), the swivel lever which moves with the adjusting
lever pulls the governor spring and moves the tension
lever until it touches the full-load stopper bolt.
At that time, the flyweights are stationary, and the
start spring with weak tension pulls the floating lever
in the direction that fuel is increased.
Adjusting bolt At the same time, the shifter and governor sleeve
push the flyweight roller to the left.
D3482A As the result, the tension lever and shifter are spaced
that much apart, and the corresponding amount of
An adjusting screw is also mounted to the swivel fuel is supercharged to facilitate starting.
lever. Adjustment of the screw changes the tension of
(b) Idling control
the governor spring, thereby making it possible to
adjust the speed regulation.
An Ungleich spring is provided in the bottom portion
of the tension lever. Adjust the tension of the spring
Start spring
by adding or removing shims.
An idling sub spring adjustable from outside is Idling
provided in the middle of the governor cover. During
idling, the spring always keeps in contact with the
tension lever to maintain a constant idling speed.
The stop lever, mounted through the supporting lever
to the bottom end of the floating lever, returns the
control rack to the stop position with a slight pressure
irrespective of the adjusting lever position.
(a) Start of engine Idling
Subspring
lrll�=::il,.
Adjusting lever
Shifter
B2661A
Once the engine is started and the adjusting lever

returned to the idling P<?Sition, the tension of the
governor spring is drastically reduced.
Now the flyweights can move outward even at a low
Guide lever
speed, so the tension lever is pushed back until it
touches the idling sub spring and places the control
rack at the idling position. In this state, the centrifugal
Full:load force of the flyweight and the weak-state governor
stopper bolt spring and idling sub spring achieve balance and
maintain smooth idling.
B2660A
13-6
FUEL AND ENGINE CONTROL - GENERAL DJ
When the speed falls, the centrifugal force decreases, If the speed further increases, the centrifugal force of
the flyweights move inward, and the idling sub spring flyweight increases and pushes the tension lever to
pushes the tension lever to the left and moves the the right and also compresses the idling sub spring to
control rack in the direction that fuel is increased. pull the control rack back to the no-load maximum
If the speed falls radically, the start spring with weak speed position, thereby preventing over-speed opera
tension acts and moves the control rack in the tion of the engine.
direction that fuel is increased to maintain the idling The RSV type governor controls the entire speed
speed. range from idling to maximum speed. If load in
(c) Maximum speed control creases or decreases at a certain speed determined by
the position of the adjusting lever, the governor
automatically functions and maintains the engine
speed constant at all times.
(d) Ungleich operation
Adjusting
No-load
lever
(Idling)
When max. injection is set

at low-speed operation
Injection matched
--�----1°
\with air intake rate
A
--�10·
- - --
A''--,
When max. injection is set
at high-speed operation
Engine speed
82663A
The Ungleich device controls fuel injection in such a

way as to match the engine performance (the re
quired injection varies with engine speed).
The air intake rate of the engine falls as the engine
82662A speed increases. The injection pump, on the other
hand, increases the per-stroke injection as the speed
When the adjusting lever is moved to the full-load increases, even with the control rack at the same
position, the tension of the governor spring is in position.
creased and pulls the tension lever until it touches the Therefore, if full load is set at point A to derive
full-load stopper bolt. enough output at low speeds, the injection will reach
When the engine exceeds the specified speed, the B as the speed increases, and the engine will produce
centrifugal force of flyweights becomes larger than black smoke.
the force of the governor spring pulling the tension If full load is set at point B' to prevent black smoke, the
lever. low speed injection will come down to A', allowing
So the tension lever is moved to the right and moves combustion of more fuel.
the control rack in the direction that fuel is reduced, So the Ungleich device accomplishes the function of
thereby preventing the engine from exceeding the setting full load at point A to derive the largest
specified speed. possible torque in the low speed range, and changing
it to adjust the injection to point B' in the high speed
range.
13-7
(e) Stopping of engine
Stop
Adjusting lever
I
S!�JI.
t Without Ungleich effect

Stop
\
C: Stop lever
0 B2666A
�:�
() ,,,
., 0
er: Q.
N2 Nl N2 Nl
When the stop lever is moved to the stop position, the
Pump speed (rpm)- Engine speed (rpm)- control rack is moved to the stop position to stop the
engine regardless of the position of the adjusting
lever.
B2664A
When the engine speed is low (N2) and the centrifugal

force of flyweight smaller than the set tension of the
Ungleich spring, the shifter is moved as much as the I
Ungleich stroke to the left, so the control rack moves
in the direction (R2) that fuel is increased to increase
the torque of the engine at low speeds.
Tension lever
Control
!W!!!y ..
rack
B2665A
As the engine speed increases (N1), the centrifugal

force of flyweight increases. If it becomes larger than
the set tension of the Ungleich spring, the Ungleich
spring is slowly compressed before the start of high
speed control, and the control rack moves in the
direction that fuel is reduced. The Ungleich stroke is
completed at the position where the shifter directly
touches the tension lever (R1).
13-8
(f) Operation of torque spring
Torque spring
C
Governor
operating Torque control
C
range lever
.g
·� >----�-"-' A
�
C. Pin A
C.
A
� '------+.--�...1- _
P1
_...--1.-pz P2
Pump speed (rpm) __ Engine speed (rpm)--
stopper
82668A
82667A
In an abrupt increase of load occurs when the engine
Construction machinery engines are often subjected is running at continuous rating, the engine speed
to a large load during operation, and reduced speeds falls. So the flyweights are moved inward and the
often lead to stalls. To prevent this, a torque spring is tension lever pulled to left by the governor spring,
provided. causing the control rack to move in the direction that
When the adjusting lever is fixed in the lever set fuel is increased.
position, a sudden increase of load, if no torque At the time, the tension lever pin pushes the bottom
spring is provided, will move the control rack along of the torque control lever, and the lever moves with
the 8-D curve as the speed falls. The rotational the pin A as the fulcrum, whereas the portion B is
displacement at the time may be expressed as P,. pushed to right. As the result, the torque spring
If a torque spring is provided, the control rack moves performs the function of reducing movement of the
along 8-C, and the rotational displacement at the time tension lever.
may be expressed as P2. Therefore, large changes
occur in P2 and engine speed, and because of
increased fuel injection, the engine torque increases,
and large combustion noise warns the operator of the
increased load, enabling him to take proper action to
prevent stopping the engine.
13-9
-
(3) Feed Pump
:, Piston
Holder
Oil seal
I,'.,,'
Housing
Connector B0740A
The feed pump is driven by the camshaft of the

injection pump.
The priming pump makes it possible to manually lift
fuel when the injection pump is stationary, so it can
be used in bleeding the fuel system.
The gauze filter removes large particles of dust and
dirt contained in the fuel lifted from the fuel tank to
prevent clogging in the feed pump. Make sure the
gauze filter is cleaned in gas oil at regular intervals.
13-10
Inlet check
Piston spring
valve Pistnn
.!-l,--1-u�nroa
Tappet roller
Cam shaft
Suction stroke Pressure feed stroke Stop
83004A
The fuel is fed under pressure as described below.

When the camshaft of the injection pump forces the
push rod up, the fuel in the suction chamber is
compressed and opens the outlet check valve. Most
of the fuel forced out is drawn into the pressure
chamber above the piston. When the cam, moved
away by rotation of the camshaft, ceases to push up,
the piston is pushed back by the pressure of the
piston spring and forces out the fuel from the
pressure chamber and forces it into the fuel filter.
At the time, the outlet check valve simultaneously
closes, and the inlet check valve opens, so the fuel is
drawn into the suction chamber.
If the pressure in the pressure chamber exceeds
specification, the piston cannot be brought back by
the pressure of the piston spring and stops the pump
function. So the pressure in the fuel filter is adjusted
not to rise more than necessary.
13-11
(4) SCDM Type Automatic Timer
Timing flange
Injection pump gear
I
1:
,,
80738A
The SCDM type auto timer, of the mechanical type,

varies automatically the injection timing according to
the engine speed. Mounted on the injection pump
camshaft with a round nut, it is driven by the idler
,
gear in mesh with the injection pump gear.
The auto timer is forced-lubricated by the engine oil
being injected into its center of rotation.
.j·,
13-12
(5) Injection Nozzle

-
When not operating
Flange pin
Flyweight Timer spring
When advancing Washer

Advance angle
Spring
Flyweight at
maximum lift
rotation
Retaining nut
B0739A
80742A
There are two pins opposing to each other press
fitted into the flange, to which the injection pump The injection nozzles are of the hole type.
gear is attached. An eccentric smaller cam is installed The fuel delivered from the injection pump enters the
on the pin, and mounted on the periphery of the nozzle holder. When reaching the specified pressure
smaller cam is a larger cam. The larger cams fit into value, the fuel overcomes the spring force to push up
the two holes in the timing flange, which causes the the needle valve of the nozzle tip, spraying from the
timing flange to turn as the flange rotates, thus injection orifice at the end of the nozzle into cylinder.
driving the injection pump. The injection pressure can be adjusted by increasing
The two flyweights are installed with a given tension or decreasing the number of washers in the spring.
by the timer springs. The pins press-fitted into the
flyweights are inserted into the holes in the larger (6) Fuel Filter
cams.
With the engine running at low speed, the flyweights °
Fuel filter head
are unable to lift because of the timer spring set
tension.
When the centrifugal force of flyweights becomes
greater as the engine speed goes up, it overcomes the
timer spring set tension allowing the flyweights to lift.
This causes the larger and smaller cams to move in Fuel filter
the turning direction. element
Since the larger cams are fitted into the holes in

83502A
timing flange, the motion of the cams is imparted to
the timing flange, thus providing an advance.
The fuel filter is of the spin-on type designed for ease
of element replacement. The element is made integral
with the outer casing, the center of the casing is being
threaded.
13-13
-
2. SPECIFICATIONS
FUEL AND ENGINE CONTROL -
SPECIFICATIONS, SERVICE STANDARDS
Item Specification
<6031> <6031-T>
(Diesel kiki products) (Diesel kiki products)
Injection pump proper Type BOSCH A BOSCH A
Model NP-PES6A90 NP-PES6A90
Turning direction (As viewed from drive side) Clockwise Clockwise
Plunger Diameter 9 mm 9 mm
Lead R.H. two-step R.H. two-step
Governor Type RSV, all speed mechanical RSV, all speed mechanical
Feed pump Model NP-FP/KS-AS NP-FP/KS-AS
Auto-timer Type SCDM, mechanical SCDM, mechanical
(for high-speed type only) (for high-speed type only)
Injection nozzle Type Hole Hole
Model NP-OLLA NP-OLLA
No. of orifices 5 5
Orifice diameter 0.28 mm 0.28 mm
Orifice angle 160" 160"
Injection pressure 17.7 MPa (180 kgf/cm2 ) 17.7 MPa (180 kgf/cm2 )
Fuel filter Type Spin-on, filter paper
Unit:mm

,.
Description Limit
(Basic diameter in ( )) remarks
Injection pump Overflow valve opening pressure 155 kPa (1.6 kgf/cm2 )
proper
Control rack sliding resistance 1.5 N (0.15 kgf)
(When not rotating) or less
Camshaft end play 0.02 to 0.06 0.1 Adjust or replace.
Backlash between control rack and pinion 0.15 0.3 Replace.
Tappet roller overall clearance 0.2 Replace.
Tappet to pump hoCJsing clearance (24) 0.03 to 0.07 0.2 Replace.
Wear on lower spring seat surface in 0.2 Replace.

contact with plunger
Plunger driving face to control sleeve 0.02 to 0.08 0.12 Replace.

clearance
Control rack full stroke 21 or more
Prestroke 3.5 ± 0.05 Adjust.
Injection start interval so• ± 30• Adjust.
Tappet clearance 0.3 or more Adjust.
Governor Governor ·housing end face to shifter 19 Adjust.

distance
13-14
FUEL AND ENGINE CONTROL - SERVICE STANDARDS
DJ
Unit: mm
Description Nominal value Limit Correction and

(Basic diameter in [ ]) remarks
Feed pump Airtightness [When 195 kPa (2 kgf/cm2 ) 0 cc/min. Replace.
air pressure is applied)
Priming pump lift capacity 25 strokes or less Replace.
(No. of strokes required before lifting
when operated at 60 strokes/min.)
Delivery At 600 rpm 335 to 410 kPa Replace.
pressure (3.4 to 4.2 kgf/cm2 )
Delivery For 1 min. at 1 000 rpm 1 620 cc or more Replace.
amount
Lift When operated at 100 rpm 40 sec. or less Replace.
capacity
Auto timer Flange to washer clearance 0.02 to 0.1 Adjust.
Flyweight to cover clearance 0.05 to 0.2 Adjust.
Injection nozzle injection pressure 17.7 to 18.6 MPa Adjust.
(180 to 190 kgf/cm2 )
Description Thread size Tightening torque Remarks

Injection pump Delivery valve holder 39 to 44 (4 to 4.5)
Screw plug 54 to 74 (5.5 to 7.5)
Lock plate 4.4 to 5.9 (0.45 to 0.6)
Governor Round nut 49 to 59 (5 to 6)
Auto timer Round nut 83 to 98 (8.5 to 10)
Injection pump gear attaching bolt 7.8 to 12 (0.8 to 1.2)
Injection nozzle Nozzle bridge bolt M10 x 1.5 25 (2.5)
Retaining nut M15 x 0.5 29 to 39 (3 to 4)
Fuel filter Fuel feed hose connector bolt M14 x 1.5 34 (3.5)
Filter element M20 x 1.5 12 to 16 (1.2 to 1.6)
Air vent plug MS x 1.25 7.8 to 12 (0.8 to 1.2)

EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638
13-15
-
4. SPECIAL TOOL
FUEL AND ENGINE CONTROL - SPECIAL TOOL
Unit: mm
Socket Wrench 31391-14100 • For timing gear case bolt

used for removal and
installation of injection
pump (on-vehicle service)
• Removal and installation
of timer round nut
Width across flats 12
B0745A
Universal Extension MH061099 Adjustment of fuel injection
start timing
B5391A
Filter Wrench MH061509 Removal of fuel filter element
B5222A
Cranking Handle MH061289 For engine cranking

B0109A
13-16
Diesel Kiki Products
FUEL AND ENGINE CONTROL -
SPECIAL TOOL, SERVICE PROCEDURES
-
Special tool name Part No. Use
Injection pump Injection pump special tool set 105790-1060 Set of tools for disassembly and reassembly of injection
proper pump proper
Universal vise 105794-0020 Injection pump mounting base
Holder 157931-2500 Removal and installation of camshaft
Tappet insert 157921-0120 Removal and installation of tappet
Inserter 157931-6120
Handle 157910-1120 Removal and installation of screw plug

Seal guide 157920-5400 Protection of camshaft threads
Extractor 157921-5620 Removal and installation of plunger
Socket 157914-0500 Removal and installation of delivery valve holder
Delivery valve extractor 157920-0320 Removal of delivery valve
Cutter 157930-4120 Correction of pump housing
Extractor (inner race) 157925-4120 Replacement· of camshaft taper roller bearing
Extractor (outer race) 157925-0120 Removal of outer race
Holder 157931-4100 Retention of lower seat and tappet during prestroke measurement
Governor Socket wrench 157915-0100 Removal and installation of flyweight round nut
Extractor 157926-5110 Removal of flyweights
Timer Timer extractor 157926-6920 Removal of timer
Measurement Measuring device 105782-4080 Measurement of camshaft end play
105782-6010 Measurement of control rack position
105782-4010 Measurement of plunger prestroke
Nozzle holder wrench 157916-8220
Nozzle cleaning tool 105789-0010 Cleaning of injection nozzle
5. SERVICE PROCEDURES Scrupulous care must be exercised when disassemb

Wherever possible, test the fuel system parts before ling and reassembling critical parts.
disassembly to precisely know their conditions. Use the specified special tools for disassembly and
Select a clean site for disassembly and reassembly reassembly; never apply excessive force or handle
work, as even small dust particles on the fuel system parts carelessly.
parts can adversely affect engine performance. Before disassembly, test the system to know exactly
When disassembling the injection pump, keep work the trouble spots.
bench clean and disassembled parts neatly arranged
for each cylinder. Use special care to ensure correct
combination of plunger and plunger barrel and of
delivery valve and delivery valve seat.
13-17
- FUEL AND ENGINE CONTROL - SERVICE PROCEDURES
5.1 A TYPE INJECTION PUMP

5.1.1 Removal
,.
81802A
1 Fuel hose
2 Injection pipe
3 Leak off pipe
4 Oil pipe
5 Injection pump. stay
6 Injection pump
81803A
(1) Hold the injection pump by hand, and remove five

timer case attaching bolts.
Then, remove the injection pump, pulling it rearward.
Use of Socket Wrench (special tool) will make the
Socket Wrench
31391-14100 removal of timer case attaching bolts easier.
80752A
13-18
FUEL AND ENGINE CONTROL - SERVICE PROCEDURES
DJ
5.1.2 Disassembly
Item NV L
€� 14 -:;:-Backlash between 0.15 0.3

control rack
and pinion
-:;:•Sliding resistance 15 N(0.15 kgf) -

(at stationary) or less
22 Wear of tooth
Cracks, L ... Limit

23 damage of NV ... Nominal Value
thread
Overflow valve
opening pressure
NV 155 kPa (1.6 kgf/cm 2)
5
1
6
-:;:-End play
NV 0.02 to 0.06
L 0.1
1 Timer case 10 Plunger spring 17 Delivery valve spring
2 Cover plate 11 Upper spring seat @ Delivery valve
3 Screw plug 12 Control sleeve @ Plunger barrel
4 Center bearing 13 Control pinion 20 Control rack cover
5 Bearing cover 14 Lock plate 21 Rack guide screw
® Camshaft @ Delivery valve holder 22 Control rack
(J) Tappet 16 Stopper 23 Pump housing
@ Lower spring seat
® Plunger
Inspection items marked with -�- must be checked before disassembly. 81804A
NOTE: 2. Keep plunger, plunger barrel, and deliv•

1. Keep disassembled parts neatly ery valve in gas oil.
arranged for each cylinder.
13-19
DJ FUEL AND ENGINE CONTROL - SERVICE PROCEDURES
81805A 81807A
(1) With the auto timer and timer case removed, (3) Turn the camshaft to place the tappet at TDC.
install the injection pump to the Universal Vise Insert Holder (special tool) into the tappet, one by
(special tool) and remove following parts. one, to keep them off the camshaft.
• Feed pump
• Governor [See 5.2.1.)
• Cover plate
Measuring Device
105782-4080
80808A
(4) Install Measuring Device {special tool). to · the

camshaft and measure the end play.
(2) Measure the sliding resistance of the control rack

with spring balancer.
Turn the camshaft to check that the value is as
specified when measured at any position.
If the measurement exceeds specification, possible
causes are:
• Damage on control rack, defective teeth
• Defective pinion teeth, pinion in contact with
housing
81808A
• Excessively tightened delivery valve holder
(5) Remove the screw plug from the bottom of

injection pump with Handle (special tool).
And remove center bearing mounting screw.
13-20
-
Tappet Insert
157921-0120
808108 81810A
(6) Install Seal Guide (special tool) to the camshaft (8) With the tappet held in position with Tappet Insert
end (threads and keyway.) (special tool), insert Inserter (special tool) into cam
Remove the bearing cover by inserting a screwdriver shaft hole to remove tappet.
into notches at top and bottom of bearing cover.
If the bearing cover is . hard to remove, tap the Plunger
camshaft with a soft hammer from the governor end.
Remove camshaft center bearing at the same time.
NOTE:
Whenever the bearing cover is disassem
bled, its oil seals must be replaced with
new ones.
81351A
(9) Insert Extractor (special tool) from the bottom of

the pump and fix its end to the lower spring seat.
Then, withdraw the special tool, which removes the
lower spring seat with plunger.
Tappet Insert
NOTE:
157921-0120 When removing, ensure that the notch in
81809A the lower spring seat (for inserting the
plunger) faces up to prevent the plunger
(7) Using Tappet Insert (special tool), push the tap from dropping.
pets from under the injection pump. Remove Holders (10) Measure the backlash between the control rack
{special tool). and pinion. If the limit is exceeded, replace.

EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638
13-21
Socket
157914-0500
81811A
(11) Remove the lock plate and use Socket (special

tool) to remove the delivery valve holder. Then
remove the stopper and delivery valve spring.
1:.
i
(12) Using Delivery Valve Extractor (special tool),

remove the delivery valve.
B0765B
(13) Remove the plunger barrel.

NOTE:
Keep the plunger and plunger barrel in
original combination and leave them im•
mersed in gas oil.
13-22
5.1.3
Inspection and Correction

-
Correct flaw in pump housing
with special tool Cutter
(157930-4120) or replace.
A1rt1ghteness
Clearance between plunger

driving face and control
sleeve
NV 0.02 to 0.08
L 0.12
Clearance between tappet

and housing
BO 24
Wear of plunger NV 0.03 to 0.07
contacting surface L 0.2
L 0.2
Combined clearance between

tappet (roller) and housing BO ... Basic Diameter
L 0.2 NV ... Nominal Value
L ... Limit
B0815A
(1) Plunger and Plunger Barrel

After cleaning in gas oil, check to see if the plunger
falls smoothly in the plunger barrel by its own weight.
For inspection, use the following procedure:
• Tilt the plunger barrel about 60°.
• Pull the plunger out by about 20 mm, and let it go.
• Make the check several times by turning the
plunger.
If the plunger does not fall by gravity, replace.
O1584A
(2) Delivery Valve (with Ungleich Cut)
After cleaning the valve and valve seat of the delivery
valve in gas oil, check for wear.
13-23
Dial gauge
Roller
Roller bushing
80768A O1586A
(3) Tappet (5) Replacement of Taper Roller Bearing

Set a dial indicator to the tappet roller and move roller Inner Race
up and down with a rod to check for overall clearance. To remove the inner race, use Extractor (special tool)
If the overall clearance exceeds the limit, replace as a and remove the roller and inner race from the
tappet assembly. camshart.
At installation, press-fit the ring, shim, and bearing, in !.
that order.
NOTE:
Install shims of almost the same thickness
on both ends of camshaft.
Measure the clearance between the tappet and pump

housing and, if the limit is exceeded, replace parts.
Outer Race
To remove the outer race, use Extractor (special tool).
For installation, use a press.
(4) Lower Spring Seat

Check the lower spring seat surface in contact with
the plunger for wear and, if the limit is exceeded,
replace.
13-24
111
5.1.4 Reassembly
39 to 44 Nm
(4 to 4.5 kgf ml 4.4 to 5.9 Nm
(0.45 0.6 kgf m)
15 L ... Limit
1; NV ... Nominal Value
� �
16�""'
17�
------------ � Align locating groove
� of plunger barrel with
�18 � knock pin on housing
21
"----
Item NV L
Sliding resis- 1.5 N -

tance (at (0.15 kgf)
stationary) or less
Pinion backlash 0.15 0.3
End play
NV 0.02 to 0.06
L 0.1 6
5
1
54 to 74 Nm
(5.5 to 7.5 kgf ml
<Assembly sequence>
23-+@-+@-� 18-+ 17-+ 16

-+@-+ 14-y 11-+ 1D-+(D--+@
@-o-1 �@1'
-+4-+5---+3-+20-+2-+ 1
For reassembly of parts with an encircled number, see following items.
B1804B
13-25
(3) Place the injection pump horizontally, and set the

control rack so that its marking lines are positioned at
Control rack
the same distance away from the housing end faces.
Mate the control pinion with control sleeve and put
the pinion in mesh with the control rack teeth.
NOTE:
1. Make sure that the joint of control
pinion and notch in control sleeve face
toward you.
2. Move the control rack each time the
81813A
pinion is in mesh to ensure that the
control pinion joint evens out at right
(1) Mount the control rack and rack guide screw.
and left. (This is done to ensure an
NOTE: entire rack stroke of 21 mm).
Check to see if the rack moves smoothly.
Check also if the rack does not turn.
Locating notch
81815A
81590A (4) Fit Extractor (special tool) into the lower sp_ring
seat, and install the plunger into the lower spring
(2) At installation of the plunger barrel into the seat.
housing align the notch in the plunger barrel with the Insert the plunger into the plunger barrel with care
housing knock pin. not to allow the plunger end to hit the pump housing
NOTE: and plunger spring.
Do not tap the plunger barrel, but push into NOTE:
position with a finger. 1. After the plunger has been installed,
turn the lower spring seat to face its
Marking line notch downward. This prevents the
lower spring sea\ from coming off posi
tion.
2. Make sure that plunger flange side with
a part number marking faces upward.
81814A
13-26
DJ
Tappet Insert
157921-0120 Socket
157914-0500
81810A 81816A
(5) Clamp the tappet with Inserter {special tool) and (7) Using Socket {special tool), install the delivery
with the tappet guide aligned with the housing valve holder.
groove, install it into the pump housing.
Tappet Insert
157921-0120 80782A
81809A
(8) Install the camshaft with the marking line at the

(6) Using Tappet Insert {special tool), push the tappet end of its thread facing toward the drive end.
to TDC, insert Holder {special tool) and remove Install the center bearing.
Tappet Insert {special tool).
At this time, make sure that the part number marking
on the plunger flange is positioned on the cover plate
side.
For each cylinder, check the control rack for sliding
condition each time Holder {special tool) is installed.
13-27
Measuring Device
105782-4080
80808A B1806A
(10) With Tappet Insert (special tool) removed, mea I ,•

sure the sliding resistance of the control rack. (At
Bearing stationary)
Turn the camshaft to check that the value is within the
�'�
Shims
specified range when measured at any position.
Adjust ring
80783A
(9) Temporarily mount the bearing cover to measure

the camshaft end play with Measuring Device (special
tool). If the limit is exceeded, adjust with shims or
replace bearing. B1817A
NOTE:
Use shims of almost equal thickness for (11) Apply sealant to screw plug and install it with
the governor and timer end. Handle (special tool).
(12) Install th.e governor.
Shim Thickness (mm) (13) Install the following parts after adjusting the
Timer end Q1Q Q1� Q1, Q1� Q1L
injection pump:
0.30, 0.50, 1.00
• Control rack cover
Governor end Q1Q Q1� Q1' Q1� Q1L
0.30, 0.50, 0.70, 1.00, 1.40
• Cover plate
• Timer case
• Feed pump
After installing the bearing cover in position, measure
• Auto timer [See 5.4.4.)
again end play to ensure that it is up to specification.
13-28
DJ
5.1.5 Adjustment after Reassembly
For fuel injection rate adjusting standard, see Service
Information published separately.
Control rack full stroke

NV 21 or more
B1818A
NOTE: (1) Control Rack "0" Position Setting

Feed oil to the injection pump cam cham Install Measuring Device (special tool) on the injection
ber. pump.
Temporarily set the adjusting lever to maintain the
injection pump speed at 500 to 600 rpm. Further
Measuring Device
105782-6010
increase the speed to pull the control rack; at the
same time, push the control rack fully.
With this position of control rack regarded as "0", set
"0" on the Measuring Device scale to the position.
NOTE:
If zero position is set by the adjusting lever
operation without running the injection
pump, the governor linkage could be dam
O3423A
aged. Do not use the adjusting lever to set
the zero position.
13-29
D3424A D3426B
(2) Control Rack Stroke Check (c) With No. 1 cylinder plunger at BOC, send fuel to
Move the control rack to check its stroke is more than injection pump under high pressure with the high
the specified value. pressure pump of the pump tester and install Nozzle
Ensure also that the start spring and idling spring Holder Wrench (special tool) to test nozzle to let the
move the control rack smoothly in the direction to fuel flow out from overflow pipe.
increase the amount of fuel injected. NOTE:
The fuel pressure must be over the deliv•
ery valve opening pressure.
!''
D3425C
Static injection starts

(3) Prestroke Check D3427A
(a) Remove the overflow valve and apply plug.

(b) With the control rack withdrawn and fixed in the (d) Slowly turn the tester coupling until the fuel stops
full injection position, install Me.asuring Device (spe flowing out of the test nozzle overflow pipe (static
cial tool). injection starts).
NOTE:
Measurement must be made with the cam•
shaft turned in the normal rotating direc
tion (clockwise as viewed from the drive
end).
13-30
FUEL AND ENGINE CONTROL - SERVICE PROCEDURES DJ
Prestroke Angle scale
(Bottom dead center)

D3428A B0823B
(e) Read the prestroke of plunger on the indicator, (5) Measurement of Injection Start Interval
from BOC until fuel stops flowing. With the static injection start of No. 1 cylinder used as
If the prestroke is out of the nominal value, adjust as a basis, read the injection start interval of each
follows. [See (4).) cylinder according to the injection sequence using an
angle scale of the tester.
Holder
157931-4100 If the interval is out of specification, adjust as in
prestroke adjustment.
NOTE:
Injection �equence
1- s- 3---+ 6- 2- 4
Measuring
Device
B1819A 105782-4010
(4) Adjustment of Prestroke

With the tappet at TDC, insert Holder (special tool)
between the lower spring seat and tappet.
Turn camshaft, and you have a clearance between the
lower spring seat and tappet. Increase or decrease B0790B
shim thickness to fill the clearance, to adjust the
prestroke. (6) Tappet Clearance Measurement
A greater shim thickness makes prestroke smaller.
Install Measuring Device (special tool) and turn the
A smaller shim thickness makes prestroke greater.
camshaft to bring the tappet to TDC.
Push up the tappet and measure the lift for the
plunger flange top to come into contact with the
plunger barrel.
If the tappet clearance is out of specification, adjust
within the allowable range of injection start intervals.
If the range does not permit correction, readjust with
No. 1 cylinder prestroke at the maximum nominal
value.
13-31
(8) Adaptation to Engine

Decrease - Increase
After the governor has been adjusted, measure the
J-·� '= fuel injection rate adaptable to the engine.
© @
(9) Inspection of Fuel and Oil Leaks
• Fuel leaks from delivery valve attaching position
and other parts
• Oil leaks from oil seals and other parts
(10)Inspection of Parts
03472B
Check parts for unusual noise and bearings for
excessive heat.
(7l Fuel Injection Rate Adjustment
Install the overflow valve and hose.
Measure the fuel injection rate and uneven ratio at the
specified rack position and speed.
If the injection rate is out of specification, adjust as
follows.
(a) Loosen pinion clamp screw.
(bl With the control rack held in position, turn the
control sleeve with the adjusting rod.
(cl Tighten pinion clamp screw.
NOTE:
1. Use special care to make the adjust•
ment. Improper or failure of adjustment
greatly influences engine performance.
2. The fuel injection rate varies with noz•
zle and pipe used. Observe measuring
requirements strictly.
3. Uneven ratio
Uneven ratio ( +)
Max. fuel injec• Average fuel
tion rate in - injection rate
each cylinder in each cylinder
=-------------x100
Average fuel injection
rate in each cylinder
Uneven ratio (-)
Min. fuel injec• Average fuel
tion rate in injection rate
each cylinder in each cylinder
-------------x100
Average fuel injection
rate in each cylinder
13-32
m
5.1.6 Installation
1
81802A
G) Injection pump
2 Injection pump stay
3 Oil pipe
4 Leak off pipe
5 Injection pipe
6 Fuel hose
81803A
802258 81643A
(1) Set the piston of the engine No.1 cylinder at the

top dead center on compression stroke. For this
purpose, use Cranking Handle (special tool) to crank
the engine until the engraved line "1.6" position on
the flywheel is lined up with the pointer.
13-33
At this time, if the intake and exhaust valves of the (4) Make sure that the alignment mark of the injection
No.1 cylinder are not pushed up by the push rod, the pump gear is aligned with that of the timer case.
No.1 cylinder is at the top dead center on compress Then, push in the injection pump. At the time, the
ion stroke. If the intake and exhaust valves are pushed alignment mark on the gear moves to the end of that
up by the push rod, turn the crankshaft through 360 on the timer case.
degrees. 5.1. 7 Bleeding the Fuel System
Here is the procedure for bleeding the fuel system.
Air plug
I .
Marking
B0791B
B1820A
(2) Line up the marking on the timer case with the
notch in the injection pump gear.
(1) Turn the injection pump priming pump counterc
lockwise until it comes loose.
(2) Loosen the air plug of the fuel filter.
(3) Move the priming pump up and down by hand to
feed fuel until air bubble does not come out from the
air plug.
(4) When no air bubble comes out in fuel, keep the
priming pump down and turn it clockwise until i� fits
into position. Then, tighten the air plug.
NOTE:
Guide hole B0793A 1. The air plug must be tightened after the
priming pump is secured into position.
(3) Insert the guide bar on the timer case into the 2. Sop up fuel spilt around.
guide hole in front plate. Using this as a guide, push (5) Actuate the starter to discharge air from the
until the injection pump gear is about to be in mesh injection pump.
with the idler gear. NOTE:
Do not operate the starter for more than 15
seconds.
B0794A
13-34
DJ
5.1.8 Inspection and Adjustment after In
stallation (Fuel Injection Timing)
807988
807968
(5) Crank the engine even more slowly as the fuel is
about to stop flowing out from the injection pipe.
(1) Remove the injection pipe, delivery valve, deliv Stop cranking as soon as no more fuel comes out
ery valve spring, and stopper from No. 1 cylinder of from the pipe.
the injection pump. Keep the delivery valve holder (6) Check that the inscribed line on the flywheel and
attached. the pointer indicate the position about 1 degree
before the fuel injection timing.
NOTE:
Keep disassembled parts in gas oil to NOTE:
prevent contamination by dust and dirt. 1. The injection timing is advanced by
about 1 degree from specified timing as
the delivery spring's valve opening
pressure does not work.
2. The injection timing is indicated at the
caution plate on the rocker cover.
If the timing is out of specification, adjust as follows.
To retard
807978
To advance
(2) Install a spare injection pipe to No. 1 cylinder.
Face the other end of the pipe downward for easier
observation of fuel flow out condition.
(3) Crank the engine to bring the piston in No. 1
cylinder 30° before top dead center. 813498
(4) While operating the priming pump to let fuel run

out from the injection pipe, slowly crank the engine in (7) Loosen the injection pump attaching nut with
the direction of normal rotation. Universal Extension (special tool).
NOTE: (8) To advance the fuel injection timing, move the
Make sure that the stop lever on the injection pump toward the crankcase side.
governor is not pulled toward the STOP To retard the timing, move the injection pump away
position. from the crankcase.
13-35
(9) With the injection pump attaching nut tightened,

measure the injection start timing again.
39 to 44 Nm
(4 to 4.5 kgf m)
4.4 to 5.9 Nm
(0.45 to 0.6 kgf m)
B0802B
(10) After the adjustment has been made, install the

delivery valve, delivery valve spring, and stopper and
tighten the delivery valve holder to specification.
Then, install the injection pipe.
(11) For inspection at dusty locations, proceed as
follows.
(a) Remove only the injection pipe and keep a small
amount of fuel remaining at the top of delivery valve
holder.
(b) Crank the engine to bring the piston in No. 1
cylinder to a position about BTDC 30° on the com
pression stroke. Further crank the engine slowly, and
the fuel on top of the delivery valve will begin to
move.
(c) This is the fuel injection start timing.
NOTE:
If the fuel injection timing is radically
different from the specification and the
deviation is beyond the adjustable range
of the injection pump, the engine timing
gear and injection pump gear are not prob
ably in proper mesh. In this case, remove
the injection pump and reinstall it accord
ing to 5.1.6.
13-36
FUEL AND ENGINE CONTROL - SERVICE PROCEDURES DI
5.2 RSV TYPE GOVERNOR
5.2.1 Disassembly, Inspection and Reassembly
= 5
23
0� 14 13
-L�
29
1 Idling subspring adapter 11 Adjusting lever 21 Lever bushing
2 Torque spring adapter 12 Supporting lever shaft 22 Oil seal
3 Stopper @ Guide lever assembly @ Swivel lever
© Governor cover assembly 14 Shackle 24 Stop lever
(8 to 28) @ Governor sleeve 25 Return spring
® Start spring @ Governor spring 26 Supporting lever
® Round nut 17 Tension lever 27 Support pin
0 Flyweight 18 Ungleich spring adapter 28 Torque control lever
@ Cap nut, Lock nut 19 Snap ring 29 Governor housing
9 Full load stopper bolt 20 Collar
10 Cover
For disassembly and reassembly of parts with an encircled number, see following items.
For reassembly, reverse the order of disassembly. B1821A
NOTE: Disassembly Procedure

1. Do not disassemble the shackle and
governor sleeve from the guide lever,
unless replacement is necessary.
2. Do not remove the governor housing
unless removal is necessitated for cor•
rection of oil leaks, parts replacement,
etc.
Before removing the housing, use Tap•
pet Insert (special tool) to separate the
camshaft from the tappet.
B1353A
(1) Remove the governor cover assembly from the

governor housing.
Open the governor cover slightly to the front and slide
downward the shackle latch connected to the control
rack to disconnect it from the control rack.
13-37
Governor
cover
B1354A B1356A
(2) Remove the start spring using long-nose pliers. (5) Removal of Swivel Lever
Remove the snap ring from the lever bushing and tap
lightly the swivel lever shaft from the adjusting lever
mounting side to remove the bushing from both
ends. Then, remove the swivel lever.
NOTE:
Do not remove the swivel lever from the
governor cover unless such removal is
necessary for parts replacement or for
Socket Wrench correcting unsmooth motion.
157915-0100
02050A
(3) Remove the round nut using Socket Wrench or Governor

Round Nut Wrench (special tools). sleeve
Shifter
B1357A
(6) Replacement of Governor Sleeve or Guide lever

(a) Using a press, remove the bearing in the governor
sleeve and remove the guide lever assembly shifter
from the bearing.
(4) Screw in Extractor (special tool) to the flyweight
and extract it.
13-38
81358A 81360A
(b) Press-fit the bearing to the governor sleeve. (2) When mounting the governor spring to the swivel
Press-fit the guide lever assembly shifter to the lever, position the spring so that its end faces the
bearing. shackle.
(c) Make sure that the sleeve turns smoothly.
NOTE:
1. Do not replace the shim as its thickness
has been established.
2. During removal and installation take
care not to damage the chromium
plated surface of the shifter.
Reassembly Procedure
81359A
(1) If shims have to be replaced, assemble the

associated parts correctly and select the thickness of
shims that gives correct housing end to shifter
dimension.
Shim Thickness: 6 types
0.2, 0.3, 0.4, 0.5, 1.0, 1.5 mm
NOTE:
Measure the assembled dimension with•
out lifting the flyweight.
13-39
-
5.2.2
Adjustment after Reassembly

For governor performance curve, see Service In
formation published separately.
Adjustment of speed
reg�lation
Adjustment of
maximum speed Adjustment of
stopper idling subspring
B1361B
NOTE: f'
1. Supply engine oil to the injection pump

cam chamber.
2. Loosen the adjusting lever stopper bolt.
3. Remove the idling subspring.
4. Do not allow the Ungleich spring and
torque spring to work.
Ungleich
a
Ra1------..�/ b c j
B1362B
Rct------+---a,�--...
t
Rg
(2) Mount the angle scale plate for the adjusting lever
_g Ret--t-'..---;-+--t---t--\ fixing device.
c: Ri
.'ing
0
� Ng Ni Nh Na Nb Ne Nd Ne
cc Pump speed (rpm) -
03474A
Adjust the relationship between the pump speed and

the rack position to the specified governor perform
ance curve as follows.
(1) "O" Position Setting of Control Rack
See 5.1.5 (1).
13-40
DJ
Change the Ungleich spring assembly so that the rack
is positioned at Ra when the speed is Na.
813638 Stopper bolt
(3) Adjustment of Intermediate Speed Control 813648

This adjustment sets the control rack position point C
(maximum injection) when the injection pump is at (5) Adjustment of Low Speed Control
full load. (a) Adjustment of stopper bolt
With the injection pump at Ne rpm, set the adjusting
While rotating the pump at Ni, tilt the adjusting lever
lever to its tilted position where the governor spring
and adjust the stopper bolt to bring the control rack to
in the governor is tensioned fairly strongly and hold
the Ri position.
the lever at that position temporarily.
Then, adjust the full load stopper to bring the control
rack to the Re position.
Turning the full load stopper clockwise as viewed
from the rear of the governor moves the rack in the
direction that fuel is increased and turning in coun
terclockwise moves the rack in the direction that fuel
is decreased.
Tension lever
813658
Ungleich
spring Lock nut
(b) Adjustment of idling sub spring
Adjust the idling sub spring so that the rack is
Shim plate positioned at Rh when the pump is running at a speed
Adapter screw of Nh.
Then, decrease the pump speed and check that the
03477A rack is positioned at Rg at the pump speed of Ng.
(4) Adjustment of Ungleich

Set the adjusting lever at the maximum speed
stopper position.
Adjust the adapter screw so that the rack position
changes from Ra to Re when the speed is changed
from Na to Nb. The change in the rack position from
Ra to Re is called the Ungleich stroke.
Tightening the adapter screw increases the Ungleich
stroke and loosening the screw decreases the Un
gleich stroke.
13-41
m FUEL AND ENGINE CONTROL - SERVICE PROCEDURES
(b) Adjustment of speed variation rate

Increase the pump speed from Nd and check to see
that when the speed reaches Ne, the rack position is
pulled back to Re.
If it is out of specification, adjust the amount the
Stopper bolt
adjusting screw of the swivel lever is turned down.
Tightening the screw will improve the speed variation
rate.
Loosening it will worsen the speed variation rate.
81366B Speed variation rate
Ne - Nd
x 100 (%)
(6) Adjustment of High Speed Control = Nd
(a) Adjustment of maximum speed stopper NOTE: ii
l;
Tilt the adjusting lever and set the maximum control 1. If the variation rate is poor, the engine ';:
speed of the governor. will exceed the specified maximum 1,
Tilt the adjusting lever and adjust the maximum speed at no load and will enter a hazar i:
speed stopper so that the control rack is moved from dous condition. I,
the Re position when the pump speed increased 2. The maximum extent to which the ad• !,
slowly from Ne reaches Nd. justing screw can be loosened is 20

notches (5 rotations) from the fully
tightened position. Loosening it any
further can be dangerous.
3. If the adjusting screw is adjusted, the
tension of the governor spring · will
change and the high speed control start
point will change. Make sure that the
maximum speed stopper of lteni (a) is
readjusted.
813678
81368B
Adjusting bolt
(7) Stop Lever Operation Check

D3482A With the injection pump at full load, move the stop
lever fully to the stop side and check that this moves
the rack to the O mm position.
13-42
5.2.3 Inspection and Adjustment of No•

-
load Minimum and Maximum
Speeds
Start engine and warm up sufficiently. After the
temperature of coolant exceeds 60 ° C, perform the
following inspection and checks.
Full-load
position , Idling position
B1369A
Full-load
set bolt
(8) Adjustment for Adaptation to Engine
Upon completion of the governor adjustment, mea
sure the total injection amount with the lever set at
the same angle as in the high speed control in
accordance with the adjustment standard and adjust Adjusting lever Stop lever
as necessary. B1371B
(1) Minimum Speed

(a) Make sure that the adjusting lever is in contact
Lock with wire
with the idling set bolt.
(b) In this state, measure the minimum speed to
•X· ensure that it is within the specification.
Lock with wire (c) If the measurement is out of the specification, use
the set bolt for adjustment.
(2) Maximum Speed
Lock with wire
(a) Operate the adjusting lever to the position where
B1370B
it touches the full load set bolt.
(b) In this state, measure· the maximum speed to
(9) Locking
ensure that it is within the specification.
After all adjustments have been made, lock the (c) If the measurement is out of the specification,
governor as follows. adjust with full load set bolt.
NOTE: NOTE:
Locking of the sections marked with ·>":<· Ensure that the engine does not stall or
must be done after adjustment of no-load hunting does not occur even when the
minimum and maximum speeds. adjusting lever is abruptly returned from
the full load to idling position. If any un•
usual condition is present, adjust within
the specification range.
13-43
5.3 FEED PUMP

5.3.1 Disassembly, Inspection and Reassembly
.-j
�
�
3-e
�
s
4 Deterioration
�
�
fl
--I r
i
Deterioration 4
Seat wear 5 ii
1 Priming pump
2 Eye bolt
Cracks. thread damage 14 3 Valve support
13 Wear
4 Spring
5 Check valve
6 Eye bolt
7 Gauze filter
8 Plug
'f2t 9 Spring
u- I I
Dirt, clogging 10 Piston
11 Push rod
�·
7 Clean or replace
12 Snap ring
13 Tappet
14 Housing
8 9 10 11 For reassembly, reverse the order of disassembly.
80978A
NOTE:
Know the trouble spots thoroughly by mak•
ing tests before disassembly.
13-44
5.3.2 Test and Adjustment
Airtightness
No leaks from push
rod sliding surface
Air-
pressure : - ::-�-
Lift capacity 195kPa �
Conditions (2kgf/cm 2 ) Feed pump
No. of strokes required
before lifting when operated
Delivery pressure at 60strokes per minute.
Condition 600rpm NV 25 strokes or less
NV 335to410kPa
(3.4 to4.2kgf/cm 2 )
Delivery
Condition
For 1min . at 1 000rpm
NV 1 620cc or more
Lift capacity
Conditions
Time required before lilting
when operated at 100rpm.
NV 40 sec. or less
Test conditions
Fuel pipe
1.0. 8
Length 2 000
Cam lift 6
Height from oil level 1 000
Test oil JIS No. 2light oil
B0979A
5.4 SCDM TYPE AUTOMATIC TIMER

5.4.1 Removal
Socket Wrench
31391-14100
Timer Extractor
157926-6920 B0995A
(2) Using Timer Extractor (special tool), remove the

B0994A
auto timer from the injection pump.
(1) Using Socket Wrench (special tool), loosen the

round nut.
13-45
5.4.2 Disassembly and Inspection
1 1 Injection pump gear
2 Snap ring
3 Shim
4 Flange
5 Smaller cam
6 Larger cam
7 Snap ring
8 Shim
3
9 Cover
10 Flyweight assembly
11 Snap ring
4 12 Outer spring seat
Wear of pin
13 Shim
14 Spring
15 Inner spring seat
16 Pilot pin
17 Flyweight
7 8 9 18 Timing flange
80996A
5.4.3 Reassembly
10
Clearance
NV 0.02 to 0.1
18 NV ... Nominal Value
<Assembly sequence>
1
-�
11-1 � 1 S-1�13--+12-11__J
-®-+��@---.2-1-W--:@-7
Clearance
NV 0.05 to 0.2
For reassembly of parts with an encircled number, see following items.
B0996B
13-46
Timing
(3) Put the timing flange and flange closely tied
-
Flyweight
pin flange together and ensure that the clearance between the
flange and shim is up to specification. If the clearance
is out of specification, replace shim.
Shim Thickness
0.10, 0.12, 0.14, 0.16, 0.18, 0.9, 1.1, 1.3, 1.5, 1.7 mm
Smaller
cam
Cover
Keyway Shim
81652A
(1) After the flyweight assembly has been installed to

the timing flange, position the flyweight pins as
shown, with reference to the keyway in the timing
flange, and install the larger and smaller cams.
Clearance between
cover and shim
809988
Alignment mark
(ldentation) Flange
(4) Vary shim to obtain the specified clearance be
tween the cover and shim.
Shim Thickness
0.10, 0.12, 0.14, 0.16, 0.18, 0.9, 1.1, 1.3, 1.5, 1.7 mm
NOTE:
When measuring the clearance, closely
Timing
contact the cover and flyweight.
flange 80997A
After adjustment, install snap ring.
(2) Install the flange, aligning it with the hole in the

smaller cam and ensuring that its alignment mark
(identation) is positioned on the same side as the
timing flange keyway.
Timing flange
Alignment mark
"indentation"
Shim Alignment mark "0"
7.8to 12 Nm
(0.8to 1.2 kgf ml
81653A
(5) After the timer characteristic adjustments have

Clearance between been completed (see next items), install the gear with
flange and shim
its alignment mark "0" lined up with the timing flange
80998A
keyway or alignment mark on the flange.
Then tighten six bolts diagonally to the specified
torque.
13-47
DJ FUEL ANO ENGINE CONTROL - SERVICE PROCEDURES
5.4.4 Installation 5.5 INJECTION NOZZLE

5.5.1 Removal and Installation
I Replace: 3 ]�2
25Nm
\ 'iJf
•:·•�ml
83to98Nm �
____,,, f
i�Bridge
la
(8.5 to 10 kgf ml 2 Injection nozzle
B1001A 3 Nozzle tip gasket
" 81004A
Mount the auto timer onto the camshaft, aligning it
with the camshaft key. Using Socket Wrench (special NOTE:
tool), tighten the round nut to specification. Cover pipes, injection nozzle, and injection
5.4.5 Test and Adjustment pump to prevent entry of dust and dirt. If
the injection nozzle is removed, provide
adequate means to prevent entry of dust
into the cylinder.
5.5.2 Disassembly
1 Retaining nut ,.,1.\
Nozzle
3 Needle valve
TI mer spring
4 Packing
81002A 8 5 Pressure pin
6 Spring
7 Shim
Whenever the auto timer has been disassem,bled, its 8 Nozzle holder
advance angle must be measured and adjusted with ..,____ 6 Deterioration,
cracks
the manufacturer's measuring device.
-5 Wear
To adjust the advance characteristics of the auto
timer, add or reduce the adjusting shims or replace
�4
the spring.
� 3 Wear, damage
LJ ------------- 2
To reduce the advance angle, increase the shim
thickness. Carbon deposits
Shim Thickness 0--1

0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1.0 mm
B1008A
NOTE:
Make sure that the combination of the
nozzle and needle valve is not changed.
13-48
FUEL AND ENGINE CONTROL - SERVICE PROCEDURES ID
5.5.3 Cleaning and Inspection (b) Insert, while turning, a cleaning needle into the
( 1 ) Cleaning injection orifice of the nozzle to remove carbon.
Use first a smaller cleaning needle than orifice
diameter and then finish with following:
Nozzle Cleaning Tool
105789-0010 Orifice diameter: 0.28 mm
(c) To remove burnt and hardened carbon, use FUSO
Carbon Remover.
(2) Inspection
D7002A
After cleaning the nozzle with gas oil, remove carbon

deposits with Nozzle Cleaning Tool (special tool).
Proceed as follows.
D7005A
Clean and immerse the nozzle in gas oil, slide the

needle valve, and ensure that it moves smoothly.
Next, pull up the needle valve vertically about 1/3 of
its entire stroke and check if it falls under its own
weight. If it does not fall, replace the nozzle.
(a) Remove the needle valve from the nozzle and

clean the needle valve with the needle valve cleaning
wood piece.
13-49
-
5.5.4
Reassembly (a) Install a nozzle tester to the nozzle.

(b) Operate the nozzle tester to inject several times.
This allows the tester to be bled of air.
(c) Operate the nozzle tester at the specified speed.
Then, vary shims to obtain the specified injection
pressure.
Shim Thickness
0.95 to 1.25 mm in 0.05 increments
A 0.05 mm variation in shim thickness varies the
injection pressure by 490 kPa (5 kgf/cm2 ).
(d) With a correct shim selected, recheck the injection
pressure.
NOTE:
Never let yourself exposed directly to the
29 to39N m
atomized fuel injected from the nozzle.
{3to4kgfmt
(2) Spray Condition
<Assembly sequence>
1 2 3 4 5 6
B1010A
Good Good Poor Poor Poor Poor
)
NOTE:
1. Never touch the sliding surfaces of the
1
needle valve by hand.
2. When replacing the nozzle tip with a
1�
new one, remove the seal peel (synthe
tic resin film) and move the needle
valve in nozzle in a clean gas oil to
I ,
t B1013A
completely remove the anti-rust oil.

5.5.5 Test and Adjustment When adjusting the pressure with a nozzle tester,
check also for clogged injection orifices, spray condi
(1) Injection Pressure
tion, and fuel leaks from the orifices. Replace the
nozzle if defective.
Good
Injection pressure
{Lever operating 1 Evenly sprayed from ·five injection orifices
frequency Once/second)
NV 17.7 to 18.6 MPa 2 Even and symmetrical
(180 to 1 90 kgf/cm 2 )
Poor
NV .
. Nominal Value 3 Asymmetrical
4 Branched
5 Thin
6 Irregular
B1012A

Phone: 269 673 1638
13-50
FUEL AND ENGINE CONTROL SERVICE PROCEDURES DI
(3) Fuel Tightness Test To remove the element, use Filter Wrench (special
tool).
NOTE:
1. For installation, tighten the element by
Test pressure
15.7 to 16.7 MPa hands.
( 160 to 170 kgf/cm2 ) 2. After installation, run the engine and
check for fuel leaks.
5.6.2 Disassembly, Inspection and Reas
sembly
810128 1 Fuel filter head

2 Element
�1
a��
Mount a nozzle, that has been adjusted to start Cracks and thread damage
injection at the specified pressure, to the nozzle tester
and slowly increase the pressure to the test pressure.
/:,";'1 " ,.,
g �'-'�=:::\ Appl_y thin coat
Keeping this condition, check for fuel leaks from the tj) of 011 when
installed
bottom of the nozzle. The nozzle is in good condition
2 Clogging, breakage
if there is no leak. 12 to 16 Nm
5.6 FUEL FILTER (1.2 to 1.6 kgf m)
D7303C
1 Fuel feed hose

2 Fuel filter
34 Nm
.S\
(3.5 kgfm)--t::,
81822A
Filter Wrench
MH061509 D73048
13-51
-
6. TROUBLESHOOTING
FUEL AND ENGINE CONTROL - TROUBLESHOOTING
Idling is not smooth
NO
Is idling speed set at normal level? Adjust the idling stopper bolt
YES
NO
Is fuel system free from air trapped inside? Isolate the cause of trouble and repair
YES
NO
Is fuel system free from water trapped inside? Remove water from the fuel tank, fuel filter,
etc.
YES
NO
Are fuel filter element and gauze filter free Replace fuel filter element or clean gauze
from clogging? filter
YES
YES
Is injection pump adjusting lever clamping nut Tighten to specified torque
left loose or lost?
NO
NO
Is injection pump injection timing correct? Readjust injection timing
YES
N0
Remove nozzle and make following checks: Adjust injection start pressure if incorrect
Is injection start pressure of nozzle correct? If spray condition is poor. clean and recheck
Is spray condition good? the condition; replace nozzle tip if necessary
(If excessive amount of carbon is deposited
around nozzle hole, clean before inspection)
YES
With injection pump removed, make following

check on the pump tester:
1-----------------
NO
➔·1: Isolate the cause of rack binding and repair
I
Does the control rack move smoothly when pulled by
the load control lever?
YES
13-52
Continued fro
1
previous page
-
NO
Are the fuel injection rates even between Isolate the cause of trouble and repair
cylinders when measured?
YES
NO
Is injection interval between cylinders correct? Isolate the cause of trouble and repair
YES
NO
Are idling spring and damper spring set Readjust the idling spring and damper spring
properly as checked in the governor test?
YES
NO
Is feed pump deliver rate up to specification? Repair or replace feed pump
13-53
- FUEL AND ENGINE CONTROL - TROUBLESHOOTING
Engine is hard to start
NO
Is the amount of fuel sufficient? Add fuel
YES
I NO
I
Is fuel system free from air? Bleed fuel system using priming pump.
(Engine would not start even after bleeding) Check the following and make necessary
corrections.
YES o Loose piping connectors
o Aspiration of air at feed pump
NO ··•·
YES
NO
Is fuel system free from water trapped inside? Drain water from the injection pump, fuel
filter, fuel tank, and other parts
YES
NO
Is injection pump piping free from fuel leak Repair or replace
due to cracks or loose connector?
YES !·'
NO
YES
NO
Remove nozzle and make following checks: Adjust the injection start pressure if incorrect
Is injection start pressure of nozzle correct? If spray condition is poor. clean and recheck the
Is spray condition good? condition; replace nozzle tip if necessary
(If excessive amount of carbon is depos.ited
YES
NO
With the injection pump removed, make
following check on the pump tester:
�----------------...!: Isolate the cause of trouble and repair
I
Does the rack move smoothly when pulled by the
load control lever?
YES
13-54

-
NO
Are the fuel injection rates even between Isolate the cause of trouble and repair
YES
NO
YES
NO
Are idling spring and damper spring Readjust the idling spring and damper spring
set properly as checked in the governor test?
YES
NO
Is feed pump deliver rate up to specification? Repair or replace feed pump
13-55
DJ FUEL AND ENGINE CONTROL - TROUBLESHOOTING
Loss of power output
I NO
I
Is fuel system free from air? Bleed fuel system using priming pump.
(Engine would not start even after bleeding) Check the following and make necessary
corrections.
YES o Loose piping connectors
o Aspiration of air at feed pump
NO
YES
NO
Is fuel system free from water trapped inside? Drain water from the injection pump, fuel
filter, fuel tank, and other parts
YES
NO
Is the injection pump overflow valve spring Replace
free from set and breakage?
YES
NO
Is injection pump piping free from fuel leak Repair or replace
due to cracks or loose connector?
YES
NO
YES
NO
Is injection start pressure of nozzle correct? If spray condition is poor, clean and recheck
Is spray condition good? the condition; replace noule tip if necessary
YES
NO
With injection pump removed, make the
following check on the pump tester:
Does the rack move smoothly when pulled by the
1-------------------➔1: Isolate the cause of binding rack and repair
I
load control lever?
YES
NO
Are fuel injection rates between cylinders even? Isolate the cause of trouble and repair
YES
NO
YES
NO
Is automatic timer advance correct? 1-------------------➔>I Isolate the cause of trouble and repair.
13-56
Excessive amount of black smoke in exhaust

gas
NO
Is full load stopper on governor control lever tight? f------------------->1 Adjust full load stopper bolt
YES
NO
YES
NO
Is injection start pressure of nozzle correct? If spray condition is poor, clean and recheck
Is spray condition good? the condition; replace nozzle tip if necessary
YES
NO
With injection pump removed, make following .: Isolate the cause of trouble and readjust fuel
check on the pump tester: I injection rate
Does fuel injection rate of injection pump
exceed specification?
YES
NO
Are the fuel injection rate between cylinders even? Isolate the cause of trouble and repair
YES
NO
YES
NO
Is automatic timer advance correct? Isolate the cause of trouble and repair
13-57
- FUEL AND ENGINE CONTROL - TROUBLESHOOTING
There is knocking noise from around the

injection pump
NO
Is injection pump coupling tight? Align timing marks and retighten bolt
YES
NO
Is injection pump piping free from cracks and Repair or replace
loose connector?
YES
NO
Is the injection pump free from unusual noise Worn parts around tappet:
when the engine runs at low speed? disassemble injection pump and replace
defective parts
There is knocking noise from engine
NO
Is fuel of adequate quality used? Change fuel to the one of specified quality
YES
NO
YES
1------------------+1: : Isolate the cause of trouble and repair I

NO
With injection pump removed, make following
check on the pump tester:
Are fuel injection rates even between
YES
NO
YES
__,1-----------------➔,1
NO
is automatic timer advance correct? Isolate the coiuse of trouble and repair
._ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ______
13-58
Speed shifting from high to

idle is not smooth
Is linkage to governor adjusting 1----------------------------�1

NO
I Rep
air portion causing binding
I
lever free from binding?
YES
Is adjusting lever return spring i---------------

NO
-------------:: Replace return spring
free from set and breakage?
YES
NO
Does adjusting lever move smoothly
when governor adjusting lever
linkage is disconnected?
YES
NO
With the injection pump removed, mak-----------� Isolate the cause of binding rack
following check on the pump tester: and repair
Does the rack move smoothly in
moving the rack?
YES
Isolate the cause of binding in

governor linkage and repair
I
NO
I
I
Is control pinion set screw Adjust injection pump injection
installed correctly? rate and retighten control
pinion set screw
YES
i With injection pump removed, make

following check on pump tester
I
I
Measure the governor idling
characteristics and, if they are
out of specification, adjust
13-59
'1·
!
ID
COOLING
CONTENTS
1. GENERAL .................................... 2 5.3 THERMOSTAT •••.•.•••••••••••••••••••• 8

2. SPECIFICATIONS •••••••••••••••••••••••• 4 5.3.1 Removal and Installation •.••• 8
3. SERVICE STANDARDS ................ 4 5.3.2 Inspection ............................ 9
3.1 SERVICE STANDARD TABLE .... 4 5.4 RADIATOR ................................ 9
3.2 TIGHTENING TORQUE 5.4.1 Inspection ............................ 9
TABLE ...................................... 5 5.5 INSPECTION AND ADJUSTMENT
4. SPECIAL TOOL ............................ 5 OF V-BELT TENSION .•••.•••••••••• 10
5. SERVICE PROCEDURES ••••••••••••• 6 5.6 CLEANING OF COOLING
5.1 COOLING FAN ••••••••••••••••••••••••• 6 SYSTEM ................................... 101
5.1.1 Removal and Installation ••.•. 6 5. 7 GAS LEAK TEST •••••••••••••••..•••••.• 12
5.2 WATER PUMP .......................... 6 5.8 BLEEDING THE COOLING
5.2.1 Removal and Installation ••••• 6 SYSTEM ................................... 12
5.2.2 Disassembly and 6. TROUBLESHOOTING •••••.•••••••••••• 13
Inspection ............................ 6
5.2.3 Reassembly ••.••••••••.•.••••••••••• 8
14-1
m COOLING - GENERAL
1. GENERAL (2) Thermostat
The engine is cooled by forced circulation of coolant

At low
by the water pump. The illustration below shows the To radiator -
coolant flow.
Radiator
Thermostat
Bypass pipe
To water pump l 81720A
The thermostat is bottom bypass type that stops

supply of coolant to the bypass side when the path to
Radiator drain cock Crankcase drain cock
B1797A the radiator becomes full open.
The thermostat pellet, of wax pellet type, contains a
(1) Water Pump special wax which changes from a solid to liquid state
and vice versa, depending on heat, and consequent
change in its volume causes the valve to open or
close, thereby changing the quantity of coolant which
flows into the radiator and water pump (bypass side)
to control the coolant temperature.
To crank
case
B1290A
Water pressure
Of a centrifugal type, the water pump is driven by the
V-belt from the crankshaft pulley.
A unit seal is installed between the impeller and water
pump that prevents leakage of coolant. There is a 80292A
drain hole provided at the bottom of the water pump
case, which ensures that coolant, should it leak from A jiggle valve is provided in the air purge hole of the
the unit seal, does not enter bearings. thermostat to quickly increase the coolant tempera
The water pump is mounted on the timing gear case ture.
provided with a suction pipe and swirl chamber. The jiggle valve is in down position by its own weight
Pressed into the one end of water pump shaft is the when the engine is stationary. When pouring in
impeller with combination-type blades which feeds coolant, the air in the system is forced into the
coolant under pressure into the engine. radiator through the clearance between the air purge
hole and jiggle valve.
When the engine is started, coolant circulates and the
jiggle valve is forced upward by the hydraulic press
ure. As a result, the valve closes the air purge hole,
preventing outflow of coolant through the air purge
hole.
14-2
COOLING - GENERAL
m
(3) Radiator The pressure cap regulates the pressure in the
cooling system. When the pressure builds up exceed
ing the predetermined level, the pressure valve
compresses the pressure spring relieving the ex
Pressure cap
cessive pressure to the atmosphere.
As the coolant temperature falls forming a vacuum in
the radiator, the vent valve opens to admit air into the
radiator, thus preventing the radiator from being
deformed by the vacuum.
When the pressure release lever is raised, the press
ure valve opens, so the pressure in the cooling
system can be reduced.
<Model with hydraulic
oil cooler>
Radiator
Oil cooler
81798A
The radiator cooling capacity varies depending on

applications (installation in an enclosed generator
room of a building, operation in stationary state, etc.).
Considerations are, therefore, paid to the fan dia-
meter, radiator capacity and other factors. Some units
for construction plants are equipped with a oil cooler
to cool hydraulic oil.
Pressure
release
lever
B1716B
14-3
m COOLING - SPECIFICATIONS, SERVICE STANDARDS
2. SPECIFICATIONS
Model
6D31, 6D31-T
Item
Cooling method Water-cooling, forced circulation

Coolant capacity 11.5 lit. (Engine proper)
Water pump Type Centrifugal type
Drive V-belt
V-belt Type xq'ty Low edge plain A type x 2
Thermostat Type/valve opening temperature Wax-pellet, bottom bypass (with jiggle valve)n6.5°C
Fan Type Polypropylene, pusher
*Polypropylene, suction
Radiator Type Tube-and-corrugated-fin
Cap Type Pressure type
*: Option
Unit: mm

Description Limit
Water pump Interference between pump shaft [25] 0.04 to 0.06 Reassembly up to twice Replace
and flange
Interference between pump shaft [13] 0.03 to 0.06

and impeller
Pump case to impeller installed 20.8 to 21.7 Replace

dimension
Thermostat Valve opening temperature 74.5 to 78.5°C Replace

°
Valve lift/temperature 1O or more/90 C Replace
Radiator Pressure cap Positive 39 to 59 kPa Replace

opening pressure (0.4 to 0.6 kgf/cm2)
Negative 4.9 kPa (0.05 kgf/cm2)

or less
Radiator check pressure 98 kPa (1.0 kgf/cm2) Replace
V-belt deflection (between alternator and water pump) 10 to 15 Replace
14-4
COOLING - SERVICE STANDARDS, SPECIAL TOOL m
Description Thread size Tightening torque Remarks

0.D. x pitch mm N m (kgf m)
Cooling fan attaching bolt MS x 1.25 20 (2)
M10 x 1.5 44 (4.5)
Water pump flange attaching nut M22 x 1.5 155 (16)
4. SPECIAL TOOL
Unit: mm
Tool name Part No. Shape Use
Water Pump Impeller Puller MH061417 Removal of

pump impeller
Q 85251A
14-5
ID COOLING SERVICE PROCEDURES
5. SERVICE PROCEDURES 5.2 WATER PUMP

5.1 COOLING FAN 5.2.1 Removal and Installation
5.1 .1 Removal and Installation
80399A
MS
r
20 Nm
Mitsubishi Engine Parts:
www.HeavyEquipmentRestorationParts.com
Contact email:
(2 kgf m)
M10 EngineParts@HeavyEquipmentRestorationParts.com
44 Nm
(4.5 kgf m) Phone: 269 673 1638
1 Cooling fan
2 Spacer
3 Water pump pulley
4 V-belt
B1799A
2 Corrosion,
Damage, damage
wear
CD Flange
4 Bend
® Impeller
@ Unit seal
Rotating © Water pump shaft
condition
® Ball bearing
6 Spacer
7 Washer plate
8 Water pump case
1
Interference
NV IBDJ Remarks
[131 0.03 to 0.06 Reassembly is permissible

BO ... Basic Diameter up to two times
NV ... Nominal value Interference
NV IBDI Remarks For disassembly of parts with an encircled

Reassembly is permissible
[251 0.04 to 0.06
up to two times
81299A
14-6
COOLING - SERVICE PROCEDURES
ID
Water Pump Impeller Puller
MH061417
B1625A B1626A
(a) Using gear puller, remove the flange. When the unit seals alone are to be replaced, tap two
holes in the impeller to MS and, using Water Pump
Impeller Puller (special tool), remove the impeller.
Impeller
Water pump
shaft
80403A
(b) After removing the snap ring, withdraw the water B0411C
pump shaft together with the ball bearing by using a
press and remove the impeller. Heating the water (d) Using a gear puller or press, remove the ball
pump case to approximately 80° C helps make the job bearings.
easier.
O0031A
80404A
(e) When the impeller and flange are removed from

(c) Check the unit seals installed in the impeller and the water pump shaft, it may result in insufficient
water pump case for damage and wear. If defects are interference. If the interference is below the specifica
evident, or when water leaks during operation, re tion even reassembly is two times or less, they must
place the unit seals with new ones. be replaced with new ones.
NOTE:
Whenever the unit seal is removed, it must
be replaced with a new one.
14-7
m COOLING - SERVICE PROCEDURES
5.2.3 Reassembly
Apply grease
(Mitsubishi wheel
bearing grease or
1
�/\
5
2
4
Align shaft
and impeller
ends flush.
155 Nm (16 kgf m) \,·
Pack 60 g of grease. 20.8 to 21.7

(Mitsubishi wheel <Assembly sequence>
bearing grease or Apply sealant to the
equivalent). outer circumference
of unit seal
(THREEBOND 1102
or equivalent). B1300A
NOTE: 5.3 THERMOSTAT

1. After reassembly, install the water 5.3.1 Removal and Installation
pump onto the timing gear case and
make sure that the impeller is not in 1.
contact with the timing gear case.
2. Reassembly of the flange and impeller
into the water pump shaft is allowed up
o
to two times. �
s, <h, project:.
of thermostat to th
�
recess of case
� Apply engine oil to

4 prevent damage
�
1 Thermostat cover
2 Thermostat
3 Thermostat case
4 Bypass pipe B0414B
14-8
COOLING - SERVICE PROCEDURES ID
5.3.2 Inspection 5.4 RADIATOR
5.4.1 Inspection
Stiring rod Valve opening temperature

,,,,,,,,.,--- NV 74.5 to 78.5° C
Thermometer - Remarks
Valve fully closed at
normal temperature
Container
/
00402A
(1) Using a copper wire or similar device, remove

Valve lift/temperature dirt, mud, and bugs from the front of radiator core
NV 10 or more/90°C with care to prevent damage to tubings.
Inspection pressure
98 kPa (1.0 kgf/cm 2 )
80416A
Agitate water in the container with the stirrer to

obtain uniform temperature. For the inspection, use
the following procedures.
(1) Slowly heat water to the thermostat valve open
ing temperature. D0409B
Keep this condition for about five minutes and make

sure that the valve is open. (2) Connect a hose to one of the radiator ports, cap
(2) Raise the water temperature up to 95°C. the other port, and immerse the radiator into water.
Keep the condition for five minutes and measure the Using a radiator cap tester, force the compressed air
lift of pellet. under the specified inspection pressure from the hose
(3) Lower temperature down to 65°C or below and end to check for leaks.
ensure that the valve is fully closed. If there is a leak, resolder the point of leakage or
If the thermostat is found defective in any of the replace the radiator.
above items, replace it with a new one.
NOTE:
Support the thermostat so that the heat
will not directly transfer to it.
14-9
ID COOLING - SERVICE PROCEDURES
Radiator
cap tester
pressure
39 to 59 kPa
(0.4 to 0.6 kgf/cm 2 )
Radiator
cap D0420A 813118
(3) Inspection of Radiator Cap (2) Adjustment of Fan Belt

Check the spring tension and sealing condition of the To adjust the fan belt tension, slightly back off the
pressure valve and vent valve. If defective, reprace. alternator attaching nut and adjusting bolt and move
Check the pressure valve opening pressure, using a the alternator.
radiator cap tester. 5.6 CLEANING OF COOLING SYSTEM
5.5 INSPECTION AND ADJUSTMENT OF
V-BELT TENSION
['
80429A
,.
813108 If the radiator is used for a long time, rust, scale, mud, j,
l
etc. are deposited inside, resulting in overheat. Clean
(1) Adjust the belt tension to obtain the specified belt the cooling system with city water by using the b·
deflection when the center of each belt is pressed following procedures.
with a force of approximately 98 N (10 kgf). The city water to be used should have the following
NOTE: properties.
1. A slack belt can be a cause of overheat• Required properties of city water
ing and undercharge.
2. An excessively tight belt may result in Total hardness 300 ppm or less
damaged bearings and belts. Sulfates� 100 ppm or less
Chloride c1- 100 ppm or less

Total dissolved solids 500 ppm or less
PH 6 to 8
14-10
COOLING - SERVICE PROCEDURES
m
NOTE: (a) Discharge coolant from the radiator and crank
1. Use a cleaning solution if the radiator is case.
seriously obstructed or coolant is (b) Ready a mixture of Fuse Radiator Cleaner
seriously contaminated. (Radipet-7 or equivalent: 5 to 10%) and cooling water.
2. When the cooling system is cleaned or Pour the specified amount of mixture into the
washed with water, make sure that the radiator.
coolant temperature is maintained at
90° C; the coolant temperature below
the valve opening temperature closes
the thermostat resulting in poor
coolant circulation.
(1) Washing with Water (Every six months
at coolant change or before and after
the use of antifreeze)
B0428A
(c) Run the engine to raise the solution temperature

to around 90° C. Let the engine run at idle for another
30 minutes, then remove the solution.
B0426A
(a) Discharge coolant from the radiator, and crank

case.
(b) After draining the system, fill it with tap water
(preferably hot water) and, with the water tempera
ture kept at around 90° C, run the engine at idle for
about 10 minutes. Then, discharge water. B0426A
Continue flushing until the drained water runs clear.

(d) After discharging the solution, fill the system with
(2) Washing with Cleaning Solution
tap water (preferably hot water) and, with the water
(Radipet-7 or equivalent) (When
temperature kept at around 90° C, run the engine at
radiator clogging or coolant contamina
idle for about 10 minutes. Then, drain water.
tion are serious)
Continue flushing until the drained water runs clear.
B0427A
14-11
ID COOLING SERVICE PROCEDURES
(3) Antirust and Antifreeze 5. 7 GAS LEAK TEST

Air or exhaust gas leaked into the coolant promotes
corrosion and rust formation. Perform the following
check and, if defects are found, take remedial action.
(1) Inspection
B1310A
(a) After cleaning, add Fuso Radiator Antirust

(Radipet-98 or equivalent) at a ratio of 5% to the
coolant quantity to prevent corrosion in summer.
Remove the pressure cap from the radiator, and run

the engine to raise the coolant temperature up to
around 90° C.
If bubbles continue forming in the coolant under the
condition, it indicates that air or exhaust gas has
leaked into the coolant.
(2)Causes ,:
(a) If air is trapped in coolant, check cylinder head

81322A bolts, water pump mounting bolts, and hose and its
connections for looseness. Check also hoses· for
(b) In winter, add the Fuso Antifreeze or equivalent at damage.
a ratio of 30 to 60% to prevent freezing. (bl If the exhaust gas has leaked into coolant, check
NOTE: the cylinder head gasket or nozzle tube end stake for
1. Make sure that the antirust is added in damage. Check also cylinder head for cracks.
summer and the antifreeze in winter at
the specified ratios. s.a BLEEDING THE COOLING SYSTEM
2. The antifreeze or antirust added (1) With the pressure cap removed from the radiator,
coolant used for a season (about six let the engine run at idle with coolant temperature of
months) must not be reused. about 90° C to bleed the system completely.
3. Use the antifreeze at a proper mixing (2) After the system has t5een bled of air, add coolant
ratio of 30 to 60% suitable for the to radiator as required.
atmospheric temperature. If the mixing
ratio is less than 30%, the antirust
effect will fall. If the ratio exceeds 60%,
the antifreeze effect will fall, and en•
gine overheating will result.
14-12
COOLING - TROUBLESHOOTING
Ill
6. TROUBLESHOOTING
I Overheating
Is fan belt tight enough 7 1----------------

-11 Adjust belt tension. Also check belt for
NO
'----------- _ __________, damages; if defects are evident, replace
V ES
I
Is coolant level correct? 1---------------- -11 Add coolant. If water leak is suspected,
NO
go to "Rapid coolant loss•
'6!
Is radiator fin clear of obstruction?
NO
Clean radiator core and correct core
bend as required
YES
Is coolant free from contamination and rust? Flush cooling system

NO
YES
Is thermostat operational? Replace thermostat

NO
YES
Is water pump impeller intact 7 Replace impeller

NO
YES
Check engine for possible cause of overheating
14-13
ID COOLING - TROUBLESHOOTING
Rapid coolant loss
NO
Is radiator hose free from water leak?
YES
NO
Are hose clamps tight? Retighten clamps
YES
NO
Are hoses free from decay Replace hoses
and cracks?
NO
Is radiator core free from water leak? Repair or replace radiator
YES
NO
i-------------------------- •1
I
Is water pump free from water leak? ➔ Replace gasket or unit seal
YES
NO
Is radiator pressure valve free
from water leak?
YES
NO
Is pressure valve set pressure Replace pressure cap
correct?
Check engine for possible water

leaks
14-14
INTAKE AND EXHAUST
CONTENTS
1. GENERAL ••.• ••.•...•...•••••.•....•.•...•••. 2 4.2 DISASSEMBLY, INSPECTION

2. SPECIFICATIONS .•...••....••••.•••.••.. 5 AND REASSEMBLY •.••...•.•.•••.... 7
3. SERVICE STANDARDS ••.••..•..•••..• 5 4.2.1 Air Cleaner .••.•..••.•. .•..........•... 7
3.1 SERVICE STANDARD TABLE .•.• 5 4.2.2 Turbocharger ••..••••••.............. 9
3.2 TIGHTENING TORQUE 5. TROUBLESHOOTING •.•............... 21
· TABLE .•.•.••••••••.••..•..•.......•••...•.• 5
4. SERVICE PROCEDURES ....•.••••••• 6
4.1 REMOVAL ANO INSTALLA-
TION ...•••••••..•••••••..•.••........•..•..• 6
15-1
-
1. GENERAL
INTAKE AND EXHAUST - GENERAL
(2) Dust Indicator

(1) Air Cleaner
Reset button
<Single element type>

Indicator body
Signal
Transparent
section
B06058
80618A
The dust indicator is directly mounted near the outlet
of the air cleaner.
<Double element type> The dust indicator operates on the negative pressure
Air
of the air drawn into the engine performing the
function of indicating the time to clean or replace the I,
element.
If dust is collected in the element, the suction
resistance increases. When the negative pressure
reaches 7.47 kPa (762 mmH20), the signal is pulled
down against the spring pressure, and the transpa
To engine
rent portion of the body changes to red, indicating the
80608A time to clean or replace the element.
After the element has been cleaned or replaced,
The air cleaner uses a filter paper type element. depress the reset button on the top, and the signal
Because of plastic coating and heat treatment, the will return to its original position.
element is highly resistant to water and oil. Even if it
is contaminated, its functions can be regained by Warning lamp
Starter switch
cleaning. Electrical
J.
The intake air is given a spin by the element vanes for dust indicator �
Battery
centrifugal separation of large particles of dust and
dirt. Small particles of dust and dirt are filtered out by
the filter paper element so that a clean air is drawn
into the engine.
The standard air cleaner is a single element type, and
the double element type can be effective for operation
safety under unusual conditions with a lot of dust and 81824A
dirt.
In the electric dust indicator, its electric contact points
close at a negative pressure of 6.23 kPa (635 mm H20)
to turn on the warning lamp, indicating to the driver
the time to clean or replace the element.
15-2
(3) Turbocharger
-
Turbine housing
Turbocharger
Over-boost
valve Compressor
wheel
Compressor
cover
Actuator B1206A
B1825A
The turbocharger can be divided into two basic
The TD06 turbocharger installed on the 6O31-T en sections: the turbine wheel that is driven by the
gine is manufactured by Mitsubishi Heavy Industries. exhaust gases and the compressor wheel which
The turbocharger utilizes the energy of the engine forces intake air into cylinders.
exhaust gas to feed more air into the engine, thereby The turbine wheel shaft is supported by separate type
offering advantages such as boosted engine power bearings and a thrust bearing is mounted on the
output, thrifter fuel consumption, and reduced engine compressor end.
noise. Some models have a waste gate mechanism
(actuator) to control the boost pressure.
Turbine wheel
Compressor
wheel
B1826A
The exhaust gases discharged from the cylinder of

the engine are led through the exhaust manifold into
the turbocharger and are accelerated in the turbine
housing and are blown against the turbine wheel.
Accordingly, the turbine is made to rotate at a speed
of scores of thousands of revolutions a minute, and
turns the compressor wheel mounted on the same
shaft as the turbine wheel. By rotation of the com
pressor wheel, a larger amount of air .than without
supercharging is forced into the cylinder of the
engine, so a correspondingly larger amount of fuel
can be burnt. This increases the effective pressure
during combustion (the pressure forcing the piston
down) and thus increases the output.
15-3
- Before activated
(b) Function of over-boost valve

(boost pressure below a set level) The over-boost valve functions when the boost
pressure abnormally increases due to a waste gate
valve malfunction.
If the boost pressure inside the air inlet pipe exceeds a
air
predetermined level, the over-boost valve is forced to
1 Waste gate
valve
open by the pressure to release it in atmosphere. This
protects the engine from undue boost pressure.
When the over-boost valve is opened, a hiss is heard.
In such an event, it is necessary to check and repair
B1207A
the turbocharger promptly.
When activated
(boost pressure above a set level)
Exhaust gas B1208A

80435A
(a) Waste gate mechanism

(c) Lubrication of turbocharger
The waste gate mechanism relieves part of exhaust
gases with the engine at high rpm range, allowing it The turbocharger is lubricated as follows.
to bypass the turbine wheel. This controls the boost From the oil main galiery in the rear of engine, engine
pressure at an optimum level and prevents the oil is introduced through the oil pipe to the turboc_
_ har
turbocharger overrun as well as pressure buildup ger bearing housing.
inside the exhaust manifold. The engine oil passes through the oil hole in the
The boost pressure is introduced from the compress bearing housing to lubricate bearing and is returned
or cover through rubber hose to the chamber A of through the outlet at the bottom of the bearing
actuator. housing to the crankcase and to the oil pan.
The boost pressure over a predetermined level being The piston rings mounted at both ends of the turbine
applied to the chamber A overcomes the spring force wheel shaft function as an oil seal.
to open the waste gate valve, which decreases the
j
volume of exhaust gas blown against the turbine
wheel. This, in turn, reduces the speeds of turbine and
compressor wheel to lower the boost pressure.
To en ine
;
!�
. .
Air inl
�
. t
.!Ii$ 0 0
pipe ..
:;-u... Over-boost
valve
'[]'
Intake��-+
a,r�r
Turbocharger f
Exhaust gas
B1209A
15-4
INTAKE AND EXHAUST -
SPECIFICATIONS, SERVICE STANDARDS
2. SPECIFICATIONS
el
6031 6O31-T
Item
Air cleaner
Element Type Cyclone type paper element Cyclone type paper element
Supercharger
(manufactured by Mitsubishi
Type - Turbocharger
Model Mitsubishi TD06
Heavy Industries)
Unit: mm

Description Limit
(Basic diameter in [ )) remarks
Suction resistance when Mechanical type 7.47 ± 0.57 kPa Replace

dust indicator operates (762 ± 58 mmH 0)
2
Electric type 6.23 ± 0.57 kPa
(635 ± 58 mmH 0)
2
Turbopharger 1.0. of bearing inserting portion of [15.6] 15.686 Replace
bearing housing
Shaft and turbine wheel Bearing journal [9.01 8.994 Replace

diameter
Shaft bend 0.015 Replace
Bearing 0.0. 15.574 Replace
1.0. 9.04
Length 9.34
Piston ring open end clearance 0.05 to 0.15 Replace insert
Clearance between shaft and turbine wheel and 0.42 to 1.10 Check
turbine housing
End play of shaft and turbine wheel 0.057 to 0.103 Check
Clearance between turbine wheel and turbine 0.37 to 0.85 Check

back plate

Description Remarks
Attaching nut M10 x 1.25 34 to 44 (3.5 to 4.5)
Turbocharger Compressor wheel attaching lock nut - 9.8 to 11 (1.0 to 1.1) Apply MOLYKOTE
to threads
Coupling - 3.9 to 4.9 (0.4 to 0.5)
Inlet manifold attaching bolt MS x 1.25 16 to 24 (1.6 to 2.4)
Exhaust manifold I Attaching nut M10 x 1.25 32 to 50 (3.3 to 5.1)
15-5
- INTAKE AND EXHAUST - SERVICE PROCEDURES
4.1 REMOVAL AND INSTALLATION
8 I•·· .
3
:?n�--Direct arrow
mark downward
Cracks, damage
16 to 24 Nm
(1.6 to 2.4 kgf m)
Face this side to the

cylinder head
(The side with bead)
1 Earth plate 6 Oil pipe

Air inlet pipe 7 Oil return pipe
Air heater 8 Turbocharger
Inlet manifold 9 Exhaust manifold
5 Rubber hose
NOTE:
For inspection of air heater, see "GROUP 16".
Contact email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 B1827A
15-6
INTAKE AND EXHAUST - SERVICE PROCEDURES
4.2 DISASSEMBLY, INSPECTION AND REASSEMBLY

-
4.2.1 Air Cleaner
(1) Disassembly and Reassembly
<Single element type>
Deterioration, Assembly direction

damage indicating mark
Deterioration, 1
damage
Deformation,
damage 5
6
1 Clamp
2 Dust cup
3 Buffle
4 Wing nut
4
5 Element
6 Air cleaner body
7 Dust indicator
81828A
<Double element type>

Assembly
direction
indicating mark
Deterioration,
damage
1 Clamp
2 Dust cup
3 Buffle
4 Wing nut
3 5 Outer element
1 Deterioration, 6 Wing nut
damage 7 Inner element
8 Air cleaner body
9 Dust indicator
8
Deformation, To reassemble, reverse the order of disassembly.
damage NOTE:
Do not remove the inner element when cleaning the outer
element. 814298
15-7
(2) Inspection and Cleaning
Window (red signal)

Operating resistance
NV Remarks
7.47 ± 0.57 kPa Mechanical type
(762 ± 58 mmH 20)
6.23 ± 0.57 kPa Electric type
(635 ± 58 mmH20)
C7210B
C7207A
(b) Inspection of dust indicator
Start the engine and close the inlet port of air cleaner
gradually to increase negative pressure. If the red
signal is displayed at the dust indicator, or warning
lamp lights for the electric type, the dust indicator is
normal.
C7208A
(a) Cleaning of element

If the dust on the element is dry, blow a compressed
air of lower than 7 kg/cm2 (685 kPa) pressure from
inside the element along the folds.
When there is moist dust on the element, clean using
element cleaner.
NOTE: l
1. Avoid striking the element or blow com
pressed air from outside.
2. Do not clean the inner element.
3. When the element has to be dried up in
a short time, an electric fan may be
used, but compressed air or fire must
not be used.
Check the element after cleaning. If there are dam
ages on the element, replace the element.
An element which has been washed four times must
be replaced irrespective of the specified intervals.
For periodic cleaning and replacement of the element,
see Owner's Handbook.
15-8
4.2.2 Turbocharger
-
(1) Disassembly
0- 21
6 2· /
15 1
12 14 �1
\.J
�-.•
19
B0449A
4
<Turbocharger with waste gate mechanism>
22
81829A
1 Hose ® Compressor wheel 16 Thrust ring
2 Actuator @ Snap ring @ Shaft and turbine wheel
3 Lever @ Insert 18 Piston ring
© Coupling assembly 12 Oil deflector 19 Turbine back plate
® Turbine housing 13 Piston ring 20 Bearing
® Snap ring 14 Thrust sleeve 21 Snap ring
0 Compressor cover 15 Thrust bearing @ Bearing housing
8 Lock nut
NOTE:
For models with waste gate mechanism, do not remove the
waste gate valve inside the turbine housing.
15-9
m INTAKE AND EXHAUST - SERVICE PROCEDURES
(a) Be sure to make alignment marks on the com

pressor cover, bearing housing, and turbine housing,
as their positional relationship is extremely critical at
reassembly.
80452A
(d) Using a plastic hammer, tap the compressor

cover on its periphery and remove.
Turbine housing 80450A NOTE:
Be careful not to hit the compressor wheel
(b) Remove the coupling assembly to remove turbine against compressor cover as its blades
housing. are easy to bend.
NOTE:
The turbine wheel blades are easy to bend.
Use care not to drop them or hit them Bearing
against other objects. housing
80453A
(e) Removal of Compressor Wheel

Compressor
cover 1) Fit the bearing housing into the turbine housing
80451A which is clamped in a vise.
Hold the bolt on shaft and turbine wheel and remove
(c) Remove the snap ring. the lock nut that attaches the compressor wheel.
NOTE:
Retain the snap ring by hand to prevent it
from springing out when slipping off the
snap ring pliers.
15-10
Compressor
wheel
80454A
2) With the turbine wheel held by one hand, lightly (g) Removal of Insert, Oil Deflector, and Other Parts
turn the compressor wheel to remove it. Using two screwdrivers, carefully remove the insert
from the bearing housing. Then, remove parts shown
in illustration.
Turbine housing
80455A
(f) Remove the snap ring. 80457A

NOTE:
Retain the snap ring by hand to prevent it (h) Removal of Shaft and Turbine Wheel, and Bearing
from springing out when slipping off the 1) Hold the shaft of shaft and turbine wheel by one
snap ring pliers. hand and the bearing housing by the other hand, and
carefully withdraw from the turbine housing.
Turbine back plate
� �\1•
Bearing
'"""'b,oa w>�I
"�""�
M�
Bearing housing 80469A
2) Remove the parts shown in illustration from the

bearing housing.
15-11
m INTAKE AND EXHAUST - SERVICE PROCEDURES
(2) Cleaning and Inspection
End gap when new Bearing

piston ring is installed
NV 0.05 to 0.15 1.0. Length
9.04 9.34
Blade bend, damage,
marks of interference
on back surface,
corrosion
Wear
Interference
with compressor
wheel
l'
,·
Clean
Journal 0.0.
BO 9.0
L 8.994
Shaft bend
L 0.015
Blade bend, damage,

marks of interference
on back surface,
corrosion, damage
of ring groove

NV ... Norminal Value
L ... Limit
804498
15-12
(a) Cleaning
INTAKE AND EXHAUST - SERVICE PROCEDURES -
Turbocharger manufacturers use a blasting equip
ment for cleaning parts at their workshop. As an
alternative, effective method for overhaul at the
dealer's workshop, use the following procedures.
NOTE:
When a commercially-available neutral de•
tergent is used for cleaning, make sure
that it does not contain corrosive compo
nent. 80460A
1) Before cleaning, visually check the condition of
parts. Check for burns, wear, and other defects which 3) Blow compressed air against the entire internal
could not be identified after washing. and external surfaces.
80459A 80461A
2) Immerse disassembled parts in a nonflammable 4) Using a plastic scraper or bristle brush, remove
solvent (Daido Kagaku Kogyo's Dai Cleaner T-30 or deposits from the surfaces.
equivalent) to clean oily contamination. Then, dip parts in the nonflammable solvent and blow
compressed air to them again.
NOTE:
Use care to prevent damage to parts.
15-13
B0462A C8971A
5) Apply clean engine oil to all sliding surfaces. 2) Bearing

Measure 0.D., 1.0., and length of the bearing.
(b) Inspection If the measurement exceeds the limit, replace the I,
bearing.
B0463A
B0465A
1) Bearing housing
Measure the I.D. of bearing hole. 3) Shaft arid turbine wheel
If the measurement exceeds the limit, replace the
a) Measure O.D. of the shaft and turbine wheel
bearing housing.
journal.
If the measurement exceeds the limit, replace the
shaft and turbine wheel.
Replace the piston ring with a new one.
15-14
INTAKE AND EXHAUST - SERVICE PROCEDURES -
80466A
b) Measurement of shaft bend

Set a dial indicator just beside the threads on the shaft
to measure bend.
If the deflection of dial indicator exceeds the limit,
replace the shaft and turbine wheel.
If the shaft journal gets rough, hold the shaft between
centers of a lathe, and polish the surface with a sand
paper #400 and engine oil at a spindle speed of 300 to
600 rpm.
NOTE:
Do not attempt to correct, but replace, a
bent shaft.
80467A
4) Insert
Measure the piston ring gap.
Fit a new piston ring into the bore of the insert and
measure the ring gap.
If the ring gap is out of the specification, replace the
insert.
15-15
Bl INTAKE AND EXHAUST - SERVICE PROCEDURES
(3) Reassembly
Pay attention to the Apply grease Apply engine oil

installation direction
Turbine wheel to
turbine housing clearance
NV 0.42 to 1.10
Axial play
NV 0.057 to 0.103
Turbine wheel to
Hf--f,7
u __ turbine back plate
c_ clearance •:I
NV 0.37 to 0.85
3.9 to 4.9 Nm
4 (0.4 to 0.5 kgf ml
Apply MOLYKOTE or equivalent to threads I:"
9.8 to 11 Nm 14
(1.0 to 1.1 kgf ml 8
I
Apply MOL YKOTE
16
or equivalent 80468A
Apply engine oil
to threads
!
11,.
<Assembly sequence> <Turbocharger with waste gate mechanism>
For reassembly of parts with an encircled number,

see following items.
NOTE:
With the overhauled turbocharger mounted on the engine, 2
crank the engine with starter to allow the engine oil to
circulate through the turbocharger. 81829A
15-16
Turbine back plate

-
Apply engine oil
to both surfaces
Bearing Thrust bearing
I I
Piston ring
Apply engine oil
Bearing housing 80469A 80470A
(a) Installation of shaft and turbine wheel, and bear (b) Installation of thrust ring
ing Before installation, apply engine oil to the surfaces of
NOTE: thrust ring and thrust bearing.
1. Apply engine oil to the piston ring and
do not expand the ends when mounting
it onto the shaft and turbine wheel.
2. Do not apply excessive force to the
shaft and turbine wheel during installa• Apply grease
tion.
B0471A
(c) Installation of 0-ring

Turbine housing Install 0-ring with grease applied to it.
80457B
After assembly, temporarily install the bearing hous

ing to the turbine housing and temporarily secure
with the coupling assembly.
15-17
(e) Installation of snap ring

Oil deflector Install the snap ring to the bearing housing with its
Piston ring
taper up.
Insert
NOTE:
1. Ensure the correct installation direc•
tion.
2. To fit the snap ring into position, tap its
Thrust sleeve
ends with a screwdriver and hammer
into the groove in bearing housing.
B0472A 3. Special care must be exercised, when
tapping the snap ring into position, to
(d) Assembly of insert subassembly prevent damage to the bearing housing
by the screwdriver.
NOTE:
1. When mounting piston ring to the thrust
sleeve, ensure that the ring is not ex
panded and ring ends are not twisted.
2. Apply MOL YKOTE or equivalent to the
piston ring that has been mounted to Shaft and turbine wheel
the thrust sleeve. Install the thrust

sleeve to the insert with care to prevent
damage to the piston ring.
Install the subassembly into the bearing housing.
B0474A 1···
(f) Measurement of turbine wheel to turbine housing

clearance
Snap ring Set the dial gauge to the shaft and turbine wheel end.
Move the shaft and turbine wheel in the axial
direction to measure the ·clearance.
If the measurement is not within specification, dis
assemble and locate the cause of trouble.
B0455B
B0473A
15-18
Apply MOL YKOTE to the

threaded section of
lock nut
Compressor wheel
Compressor
B0453B 80476A
(g) Installation of compressor wheel (i) Measurement of turbine back plate to turbine
With the compressor wheel installed in position, wheel back surface
apply MOLYKOTE to lock nut threads and tighten to With the turbine housing removed from the bearing
specification. housing and compressor cover installed, make the
following measurement.
Using thickness gauges, measure the clearance be
tween the turbine back plate and turbine wheel back
surface.
If the clearance is not within specification, disassem
ble and locate the cause of trouble.
NOTE:
Compressor
wheel Use two thickness gauges. Make the
measurement at the end of the blade.
80475A
Compressor cover
(h) Measurement of play in shaft and turbine wheel in
axial direction
Set the dial indicator at the end of shaft and turbine
wheel.
Move the compressor wheel in the axial direction to
measure the play.
If the play is not within specification, disassemble and
locate the cause of trouble. 80477A
(j) Installation of compressor cover

Install the compressor cover, ensuring the correct
installation direction.
Apply grease to 0-ring when mounting.
15-19
Compressor
cover
80451A
(k) Installation of snap ring

Install the snap ring to the compressor with its taper !
up. Use the snap ring pliers for installation.
Bearing housing
Turbine housing
80478A
(I) Installation of turbine housing

Install the turbine housing to the bearing housing,
ensuring correct installation direction.
Coupling assembly
Apply MOLYKOTE
to the threaded
section
80450A
(m) Installation of coupling assembly

Apply MOLYKOTE or equivalent to threads in cou
pling assembly and tighten to specification.
15-20
INTAKE AND EXHAUST - TROUBLESHOOTING
5. TROUBLESHOOTING
Loss of power
1
Intake system
NO
Is air cleaner free from obstruction? Clean, wash, or replace element
YES
NO
Are intake system connections free Tighten clamps
from air leaks?
Exhaust system
NO
Are muffler and exhaust pipe free R epair or replace
from deformation?
Is no carbon deposited?
YES
NO
---------
......1s_ sys
_ _ te_ m
_ _fre_ e_ _ fro
_ _ m_ g_a_s _1e_a_k?_ ___ _;
_ -ll..__R_ ep_ a_ ir_ _ o_r _re_p_1a_c_e________...,
Turbocharger <6031-T>
NO
Are compressor cover and intake pipe f-----------�'L.----------------'
Tighten clamps
connections free from air leaks?
YES
NO
Are compressor inside, compressor Clean
cover, compressor wheel, etc.
contamination?
YES l
NO
Does turbine wheel turn smoothly Carbon deposits:
when turned by hand? Disassemble and clean turbocharger
15-21
Unusual noise and vibration
Intake system
NO
Are clamping bolts and nuts of Tighten
the intake system tight enough?
Exhaust system
NO
Are clamping bolts and nuts of Tighten
the exhaust system tight enough?
YES
NO
Are muffler and exhaust pipe free Repair or replace
from damages?
I
Turbocharger <6D31-T>
I Are bearing and rotating parts intact?

NO
:i-------------+t Make the following checks:
o Engine oil for deterioration
YES o Oil filter element for clogging
o Foreign objects trapped in oil
supply pipe
o Damaged bearing due to repeti
tive sharp acceleration/
decceleration
NO
Do rotating parts turn smoothly? o Defective bearing
Is shaft and turbine wheel free from o Damaged compressor wheel or
bend? turbine wheel due to foreign
objects trapped inside
YES
NO
I
Is turbocharger free from foreign
objects trapped? I Check the intake and exhaust pipes
carefully for chips of compressor
or turbine wheels
15-22
Oil leak into intake and exhaust

pipes; white exhaust smoke
l
Turbocharger <6D31-T>
NO
Is oil discharge pipe from Disassemble and clean
turbocharger free from clogging?
YES
NO
Are piston ring and ring groove free Replace piston ring or thrust
from excessive wear? sleeve
YES
I
NO
Is air cleaner free from clogging .I Clean. wash, or replace element
resulting in oil leaking into intake I
pipe?
YES
I
NO
Are bearing and piston ring free from .I Replace
defects, resulting in oil leaking I
into intake and exhaust pipes?
15-23
m
ENGINE ELECTRICAL
CONTENTS
1. GENERAL .................................... 2 4.2 STARTER RELAY ....................... 24

1.1 STARTER ................................. 4 4.3 ALTERNATOR ........................... 24
1.2 ALTERNATOR 4.3.1 Removal and Installation •.... 24
<IDLE-SPEED EFFICIENT 4.3.2 Disassembly and
TYPE> ..................................... 6 Inspection •••...•.••••••...•..•.•..••. 25
1.3 SAFETY RELAY ••••••••••••••••••••••••• 8 4.3.3 Reassembly •.••••••••.....•...•..••. 27
1.4 PREHEATER ............................. 9 4.3.4 Tests ...... .............................. 28
1.5 AUTOMATIC STOP DEVICE •••••• 9 4.4 SAFETY RELAY ......................... 31
2. SPECIFICATIONS •••.•.•••••••.•••••••••• 13 4.5 PREHEATER ••••.••••••.•.•••.••.••.••... 32
3. SERVICE STANDARDS •••••••••••••••• 14 4.5.1 Intake Air Heater •••..•..••.•..•••.• 32
!! I
3.1 SERVICE STANDARD TABLE •••• 14 4.5.2 Heater Relay •••.•.••.••••••.•......•. 33
3.2 TIGHTENING TORQUE TABLE ••• 16
4. SERVICE PROCEDURES ••••••••••••• 17 :::.1 A'::u':,��::��-��•-��---::::::
4.1 STARTER ................................. 17 4.6.2 Run On Type ••....••.••.•••••..•..••. 35
4.1.1 Removal and Installation ••••• 17 5. TROUBLESHOOTING •••••.•..••••.••.. 37
4.1.2 Disassembly •••••••••••••••••••••••• 17
4.1.3 Inspection and Correction ••• 18
4.1.4 Reassembly ••••••••••••••.•••••••••• 22
4.1.5 Adjustment and Test
after Reassembly ••••••••••••••••• 23
16-1
-
1. GENERAL
ENGINE ELECTRICAL - GENERAL
<24 V type>
Alternator
Air heater
indicator
Oil Oil bypass Tachometer Tachometer

bypass unit
alarm
alarm lamp
15
Battery
sI-=-
switch
Battery
s.i
Oil pressure
gauge
Code symbol
Oil pressure 0.85 0.85 mm2 or more
unit _5_ 5 mm2 or more
,.1.§._ 15 mm2 or more
..§Q__ 60 mm2 or more
Thermometer unit
B1440B
16-2
m
<12 V type>
Alternator
Starter relay :Starter
"' "'
- "! Air heater
Charge lamp Heater relay indicator
Tachometer
Tachometer unit
Oil bypass Oil bypass
alarm alarm lamp Air heater
15
60
1 Battery
switch
0.85
-=- Battery
f61
0.85
0.85
Oil pressure
gauge Thermometer
Oil pressure
unit Code symbol
0.85 0.85 mm2 or more
� 1.25 mm2 or more
...1L 15 mm2 or more
..§ll__ 60 mm2 or more
(j) Key position

@ Terminal
B1864A
16-3
-
1.1 STARTER
(2) Overrunning Clutch
Outer race Spring
81865A 80031A
The starter is either an overhang type in which the A roller-type overrunning clutch is used.
pinion sliding surfaces are not exposed to the outside Rollers are housed in the wedge-shaped grooves
or a front nose type in which they are exposed to the formed by the outer and inner races (sleeve) and
outside. pressed by springs.
Major components include: the motor that develops a When the starter is started, the roller is pressed
high torque required to get the engine started; towards the narrower side of the groove, functioning
overrunning clutch that transmits torque and pre as a key to transmit rotation of the outer race to the
vents the starter from overrunning; magnetic switch pinion. No torque is transmitted, however, from the
that brings the pinion into mesh with the ring gear, pinion (as it is turned by the engine), as the roller
while turning on/off the load current to the motor; compresses the spring moving toward the wider side
and, the reduction gear which boosts the armature of groove and releasing the key action.
torque.
( 1) Reduction Gear
Overrunning clutch
800308
The end of the armature is a gear which is in mesh

with the reduction gear.
The armature rotation, thus reduced in speed or
increased in torque, is transmitted to the pinion.
16-4
(3) Operation
-
Starter switch
Starter switch
I
Ring gear
Ring gear
81446A
81445A
When the pinion comes into complete mesh with the
While the starter switch is ON, current flows from the ring gear, the contact P1 closes and the large current
terminal "SW" of the starter relay to the terminal "L H
of the battery directly flows to the motor section to
and closes the contact P2. turn the pinion powerfully.
When the contact P2 closes, current from the battery In this condition, no current flows to the pull-in coil.
flows from the terminal "S" of the magnetic switch to The plunger is retained by the holding coil alone.
the pull-in coil (P) and holding coil (H). Furthermore,
the current that has decreased flows from the termin
al "M" to the motor section.
The plunger, attracted by the magnetic flux of the
pull-in coil and holding coil, closes the contact P1 and
simultaneously pushes out the pinion turning slowly
on weak current.
16-5
- ENGINE ELECTRICAL - GENERAL
The alternator with a built-in IC regulator (abbrevtated

to the built-in alternator) is used.
The alternator consists of the IC regulator and brush
Starter switch
holder accommodated in the rear bracket.
Alternator
r--------<u�,,.-0-1Starter
switch
rI:
I
Ring gear
.L Battery
IC regulator
B1447A
Power transistor
-----------..../IE
When the starter switch is placed to OFF, current to
the holding coil (H) is interrupted. The plunger is
returned to its original position by the return spring B1449B
and the contact P1 opens so that current to the motor
section is interrupted. Features of the Built-in Alternator
The moment the starter switch is opened, the battery
(1) For better voltage buildup especially at idle
current flows from the terminal "B" to the pull-in coil
speeds, the alternator is provided with the R terminal
(P) and holding coil (H). Since the coils are wound in
independent from the L terminal (charge lamp circuit)
opposite direction to each other, the magnetic fluxes
as the initial excitation circuit.
cancel each other so that the return spring can move
(2) The three diodes (diode trio) built into the alterna
the plunger back to its original position.
tor apply the field current directly to the field coil,
eliminating voltage drop caused by the starter switch
1.2 ALTERNATOR
and wiring.
<IDLE-SPEED EFFICIENT TYPE>
(3) The P terminal is for detecting the safety relay
frequency.
B4008A
16-6
ENGINE ELECTRICAL - GENERAL m
Operation As the engine starts with the alternator generating
power, the base current is supplied by the alternator
itself.
The field current also flows from the diode trio to
energize the rotor.
At the time the charge lamp goes off, since the output
voltage from the 8 terminal becomes the same as that
from the L terminal.
----·77
814508
When the starter switch is turned ON, base current

flows from the battery to power transistor to turn it
ON, allowing the current to flow through the field coil
to turn on the charge lamp.
814528
As the voltage developed by the alternator builds up,

the zener diode Dz conducts providing base current
for the transistor Tr, to turn it ON.
As a result, the base current of the power transistor is
shorted to Tri, which turns OFF the power transistor.
This means that there is no field current flow,
dropping the voltage generated by the alternator.
When the zener diode Dz is shut off with a voltage
drop, the base current flows to the power transistor to
turn it ON. As a result, the field current again starts
flowing, increasing the generated voltage.
These IC regulator operations repeat to regulate the
alternator voltage.
814518
16-7
-
1.3 SAFETY RELAY
B1453A
The alternator rpm is detected and when it exceeds

I:'
I!'
,i
the reference level, the safety relay prevents the
starter from operating even if its switch is accidentally
turned on during engine revolution.
Operation
Alternator
Starter switch
I
Battery
switch
P1 i
-L
Battery
�tarter
' ��lay
To starter
B1454A
(1) When the starter switch is set to ON, current flow (3) When the pulse frequency at terminal "P" ex
from the starter relay to terminal "S" and to terminal ceeds the specified value, continuity between termin
"E" of the safety relay, closing contact P1. The charge als "S" and "E" is lost. Then, the starter does not
lamp also illuminates if provided. operate even if the starter switch is set to ON while
(2) As the starter runs and the engine starts running, the engine is running.
pulses of frequency 1/10th of the alternator speed
appear at terminal "P" of the alternator. The charge
lamp goes out.
16-8
m
1.4 PREHEATER
(1) Intake Air Heater
Starter switch
OFF
HEAT
ON
START
Battery
switch
Air heater
indicator
B4508B
The intake air heater which is electric type heats

intake air in the inlet manifold to facilitate engine
startup in. cold weather.
Set the starter switch to HEAT to energize the intake
air heater mounted on the inlet manifold. The heater
becomes red heated and its temperature reaches
800°C or higher. Then, the air heater indicator comes
on to indicates heat state to the driver.
The heater relay has a fuse to prevent overcurrent
from flowing to the intake air heater circuit.
1.5 AUTOMATIC STOP DEVICE

If the coolant temperature rises or the oil pressure
falls while the engine is running, this device operates
the stop lever of the injection pump governor to cut
fuel supply and automatically stops the engine.
16-9
m ENGINE ELECTRICAL - GENERAL
(1) Run Off Type
Ir---====��------------ ··7
Solenoid relay
Ra
Battery switch
--------�•I---
• ---1--
i·
B4926A
(a) Start circuit 3) The engine starts, and a voltage of 24V or more is
1) Current flows from the solenoid relay (8) to the RY applied from the terminal "L" of the alternator
coil and applies the voltage to the collectors of TR4 through VR1 to ZD1 (Zener voltage 24V), and charge
and TRs but RY does not operate, as there is no input begins with the time constant (Oil pressure timer)
to the base. determined by VR1 and c,.(At this point the engine
2) Current also flows from the oil pressure switch to oil pressure increases beyond the specified value and
the solenoid relay (W) to R4 to Rs and applies the the engine enters the operating state.) The charge
voltage to the base of TRJ. When the voltage is voltage passes through R2. If it becomes higher than
applied to the base of TRJ, current flow from Rs to C the level of the emitter of TR,, current flows from R4
and E of TRJ to the ground, and RY does not operate, to C and E of TR, and biases TR2. TR2 passes current
as there is no input to TR4 and TRs of the stop circuit. from R4 to C and E of TR2 and to the ground, and the
circuit from Rs to base of TRJ is caused to be OFF. (Oil
pressure switch circuit opened)
16-10
4) In the condition of the above item (c), the oil 2) Solenoid relay @ -+RY coil-+C and E of TR4 and TRs-+
pressure rises as the engine speed increases, and the Ra--+Ground
contact of the oil pressure switch is opened and no
3) Thus RY contacts close, the solenoid operates, and
voltage applied from R4 to TR1. In this condition, the
the engine stops. When the engine stops, the alterna
alternator voltage is applied up to the base of TR1
tor voltage goes out. At the same time, the stop timer
while the engine is running.
made up of C2 and VR7 h·olds the solenoid.
(b) Automatic stop circuit
When the thermo switch and oil pressure switch (c) Pushbutton stop
detect an abnormal condition, the circuit operates as To stop the engine during operation, operate the stop
follows: switch, and the stop operation is performed as at the
1) Solenoid relay @) &-+D1TC2:-+Ground time of an automatic stop. (The engine stops regard
[ L...+vR7-+Base of TR-
Base of TRs-+Ra--+Ground
less of whether the alternator voltage is available.)
R.,-+C and E of TR1-+Base of TR2:-+Ground
_ L-+c and E of TR2:-------
(2) Run On Type <24 V Type>
Solenoid relay
RY
Stop
switch
Battery switch
.--Jl\-.JT\.-"'°n.o--j 'it-_i_
VR1
Battery .,. C
----
� -- ---+
Starter switch
B4927A
(a) Start circuit Stater switch S -+Solenoid relay Resistor Ro-+Ground

Diode D�RY holding coil H
1) When the battery switch is turned ON: 1 -+Ground
Solenoid relay @ -+RY pull-in coil P_,.-+TR1 collector Diode D1-+Capacitor C

4TR2 collector
When the capacitor C is charged, voltage is applied
RY contacts do not operate with no input to the base from VR1 to the base of TR1 actuating TR1.
of TR1 and TR2. As voltage is applied to TR1 collector, TR1 emitter, and
2) When the starter switch is placed in the START to TR2 base, a current flows from TR2 collector to TR2
position: emitter, resistor TR2, and ground, causing the RY
pull-in coil P to close the RY contacts.
16-11
-
3) When the RY contacts turn ON:
(b) Automatic stop circuit

Current flows from solenoid relay @ to RY, solenoid When the thermo switch and oil pressure switch
relay@, and the solenoid, activating the solenoid and detect an abnormal condition, each switch turns OFF
starting the engine. and the RY contacts open, deactivating the solenoid
4) As the engine starts and starter switch is placed in and stopping the engine.
the ON position, voltage to the solenoid relay® is cut (c) Pushbutton stop
off; however, TR1 and TR2 stay ON for approximately
To stop the engine during operation, operate the stop
another 30 seconds by the discharge current of the
switch, and the stop operation is performed just as
capacitor C. During capacitor C's discharging, the oil
when the automatic stop is performed.
pressure builds up as the engine speed increases,
causing the oil pressure switch to turn ON.
This causes the current to flow from the starter switch
Q to oil pressure switch, thermo switch, solenoid
relay®, RY holding coil H, and to ground, keeping the
RY contacts in ON state.
(3) Run On Type <12V Type>
Solenoid relay
_ _ __ ---i
I
Oil pressure
switch Thermo switch
Stop
switch
OJ
Starter switch
84928A
(a) Start circuit Stater· switch S -solenoid relay ® Resistor R�Ground

t
Diode o,-capacitor C
1) When the battery switch is turned ON:
Solenoid relay @ -coil C TR1 collector When the capacitor C is charged, voltage is applied
tTR2-collector from VR1 to the base of TR1 activating TR1.
TR3 collector As voltage is applied to TR1 collector, TR1 emitter, and
TR2 base, current flows from TR2 collector to TR2
RY contacts do not operate with no input to the base
emitter, resistor Ra, and to ground, causing the coil C
of TR1, TR2 and TR3.
to close the RY contacts.
2) When the starter·switch is placed in the START
position:
16-12
ENGINE ELECTRICAL - GENERAL, SPECIFICATIONS m
3) When the RY contacts turn ON: And current flows from TR3 collector to TR3 emitter,
Current flows from the solenoid relay @ to RY, resistor R4, and ground, keeping the RY contacts in
solenoid relay @, and the solenoid, activating the ON state.
solenoid and starting the engine. (b) Automatic stop circuit
4) As the engine starts and starter switch is placed in When the thermo switch and oil pressure switch
the ON position, voltage to the solenoid relay@ is cut detect an abnormal condition, each switch turns OFF
off; however, T1 and TR2 stay ON for approximately and the RY contacts open, deactivating the solenoid
another 30 seconds by the discharge current of the and stopping the engine.
capacitor C. During capacitor C's discharging, the oil
pressure builds up as the engine speed increases,
(c) Pushbutton stop
causing the oil pressure switch to turn ON. To stop the engine during operation, operate the stop
This cause a voltage to develop at: switch, and the stop operation is performed just as
when the automatic stop is performed.
Stater switch 0 -Oil pressure switc�Thermo switc�
Solenoid relay ®TResistor R1-Ground
·
4Resistor R-TR3 base
2. SPECIFICATIONS
<D�>
Item Specification
Voltage-polarity <Standard> <Option>
24V-0 earth 12 V-0 earth
(Mitsubishi Electric Corp. products)
Starter <Standard> <Option>
Type Overhang electromagnetic push-in Front nose electromagnetic push-in
type reduction starter type reduction starter
Model M2TT8371
(Output) (24V-5 kW) (12V-3 kW)
Reduction mechanism Single external spur gear Single internal spur gear
Starter relay
Model U1T07075
Alternator <Standard> <Option>
Type Alternator with built-in IC regulator Alternator with built-in IC regulator
(Idle-speed efficient type) (Idle-speed efficient type)
Model A2T72988 A5TT0383
(Output) (24V-30 A) (24V-25 A)
Safety relay
Model R8T30172 R8T30171
Intake air heater <Standard> <Option>
Type Electric heating type Electric heating type
Capacity 22V-2.86 kW 11V-1.41kW
Heater relay
Fuse capacity 164 A 164 A
Automatic stop device
Stop solenoid (Nippondenso Co., Ltd. products)
Type Electromagnetic type
Solenoid relay (Nikko Denki products)
<Run off type> <Run on type>
Model 0-25000-5592 <24V type> 0-25000-6720 <24 V type>
0-25000-6361 <12V type> 0-25000-6990 <12 V type>
Oil pressure switch
Type Diaphragm, built-in electric contact
Thermo switch
Type Wax type, built-in electric contact
16-13
-
ENGINE ELECTRICAL - SERVICE STANDARDS

Unit: mm
Description (Basic diameter in ( )) Limit remarks
Starter Commutator 0.0. 24V type 32 31.4 Replace

12V type 38.7 38.1
Commutator runout on periphery 0.05 or more Correct or replace
Mica depth of grooves between segment 0.2 or less Correct
Brush length 24V type 18 11 Replace
12V type 17 11
Brush spring tension 24V type 25 to34 N 20 N (2 kgf) Replace
(2.55 to3.45 kgf) \.
12V type 25 to 34 N 18 N 1( .8 kgf)
2( .55 to3.45 kgfJ
Pinion shaft thrust gap 0.1 to0.5 Adjust with washer
Pinion gap 0.5 to2.0 Adjust with packing
No-load Voltage 24V type 23V Check
characteristics
12V type 11 V
Current 24V type 65 A or less
12V type 180 A or less
Speed 24V type 4 250 rpm or more
12V type 3 200 rpm or more 1;·
Magnet switch operating 24V type 16V or less Check
voltage
12V type 8V or less
Starter relay coil resistance 24V type 9.6 n Check
12V type 30
Alternator A5T- Slip ring 0.0. 32.8 to33.2 32.4 Replace
70383
Brush spring tension 3 to4.2 N 2.1 N Replace
(0.31 to0.43 kgfJ (0.21 kgf)
1.
Brush length 18.5 7 Replace
Field coil resistance (20°C) Approx. 10 n Replace
Load characteristics Terminal 27V Check
(When cold) voltage
Current 14 A or more
Rotating 1 500 rpm
speed
Load characteristics Terminal 27V
(When cold) voltage
Current 22A or more
Rotating 2 500 rpm
speed
IC regulator regulated voltage range 28 to29V
5( 000 rpm, 5 A or less)
16-14
ENGINE ELECTRICAL - SERVICE STANDARDS m
Unit: mm

Description Limit
(Basic diameter in [ II remarks
Alternator A2T- Slip ring O.D. 40.8 to 41.2 40.4 Replace

72988
Brush spring tension 3.1 to 4.3 N 2 N (0.2 kgf) Replace
(0.32 to 0.44 kgf)
Brush length 23 8 Replace

°
Field coil resistance (20 C) Approx. 9 n Replace
Load characteristics Terminal 27 V Check

(When cold) voltage
Current 17A or more
Rotating 1 500 rpm

speed
Load characteristics Terminal 27 V

(When cold) voltage
Current 26 A or more
Rotating 2 500 rpm

speed
IC regulator regulated voltage range 28 to 29V

(5 000 rpm, 5 A or less)
TI me• required for air heater indicator and 24 V type 20 to 30 seconds Check
glow plug indicator to become red hot
12 V type 40 to 60 seconds
Auto- Run 24 V Stop solenoid actuating voltage 17 V or less Replace

matic off type (Stroke: 27, load: 39 N or 4 kgf)
stop type
device Solenoid Delay time at starting 13 to 23 Replace
relay (after 28.5 V applied seconds
to terminal "B" and
28.5 V to terminal "A")
Delay time at stopping 25 to 35

(after 24 V applied to seconds
terminal "B" and no
voltage to terminal "A")
Thermo switch 30098-39300 93 to 97°c Replace

actuating
temperature 30098-39400 96 to 100"C
Oil pressure switch actuating 69 to 98 kPa Replace

pressure (0.7 to 1.0 kgf/cm2)
or less
Oil prssure switch Rated 24 V Replace

relay voltage
Coil 190 to 280 n

resistance
Min. operating 16 V or less

voltage
12 V Stop solenoid actuating voltage 12 V or less Replace

type (Stroke: 27, load: 9.8 N or 1 kgf)
Solenoid Delay time at starting 13 to 23 Replace

relay (after 14 V applied seconds
to terminal "B" and
14 V to terminal "A")
Delay time at stopping 25 to 35

(after 12 V applied to seconds
terminal "B" and no
voltage to terminal "A·)
16-15
m ENGINE E;LECTRICAL - SERVICE STANDARDS
Unit: mm

Description Limit
(Basic diameter in I I) remarks
Auto- Run 12 V Thermoswitch 30098-39300 93 to 91•c Replace

matic off type actuating
°
stop type temperature 30098-39400 96 to 100 c
device
or less
Oil pressure switch Rated 12 V Replace

relay voltage
Coil 55 to 100 n Replace

resistance
Min. operating 8 V or less

voltage
Run 24 V Stop solenoid actuating voltage 24 V or less Replace

on type (Stroke: 27, load 9.8 N or 1 kgf)
type
Solenoid relay delay time 26 to 34 seconds Replace
°
Thermoswitch actuat- ME049147 94 to 98 C Replace
ing temperature
°
ME048169 96 to 100 C

or less
12 V Stop solenoid actuating voltage 12 V or less Replace

type (Stroke: 27, load: 9.8 N or 1 kgf)
Solenoid relay delay time 26 to 34 seconds Replace
Thermoswitch actual• ME049147 94 to 98°C Replace

ing temperature
°
ME048169 96 to 100 c

or less

Part to be tightened Remarks
Alternator nut M12 x 1.25 91 (9.3)
Alternator adjusting bolt M12 X 1.25 82 (8.4)
Alternator pulley nut A5n0383 M17 X 1.5 83 to 105 (8.5 to 11)
A2TT2988 M20 x 1.5 130 to 160 (13.5 to 16.5)

Contact email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638
16-16
ENGINE ELECTRICAL - SERVICE PROCEDURES
Whenever removing electrical parts from the vehicle,
be sure to place the starter switch (battery switch) in
OFF position and disconnect the negative battery
cable.
4.1 STARTER
B1866A
Remove the starter from the flywheel housing.
4.1.2 Disassembly
<24 V type>
1 2
15
Bearing rotating
condition, wear of
sleeve
l
Wear
13
9 10 \ 12 17 Damage, wear
11 4
Damage, wear of gear 5 Brush powder deposit,
Installation condition uneven wear, brush
of pole and field coil movement in the holder
1 Starter relay @ Pinion stopper
2 Magnetic switch 11 Pinion
3 Rear bracket 12 Spring
4 Brush holder 13 Gear
5 r>
Yoke 14 Pinion shaft
6 Armaturei 15 Lever assembly
7 Cover 16 Packing
8 Center bracket 17 Front bracket
9 Ring
NOTE:
1. Do not remove the bearings on both ends of the
armature unless defective.
2. Note the installed direction of the lever to avoid wrong
reassembly. B1867A
16-17
- ENGINE ELECTRICAL - SERVICE PROCEDURES
(1) Removal of Pinion Stopper
Pinion shaft Apply a tubular tool to the pinion stopper and tap it
with a hammer until the pinion stopper comes off
position to the clutch side.
Remove the ring and the pinion stopper.
NOTE:
If the pinion stopper cannot be removed,
deburr the groove in the pinion shaft.
Pinion
Pinion stopper
B1460A
4.1.3 Inspection and Correction
Short-circuit test
Coil ground test
Applicable
Item NV L
model
Coil open-circuit Commutator 0.0. 32 31.4 24 V type

test, contact weld
12 V type
inspection contact failure ----- -38.
- 7- -38.1
1- -4 1--
Runout of 0.05 24 V type,
commutator 0.0. or more 12 V type
Mica depth 0.2 24 V type,

between segments or less 12 V type
Coil ground test,

open-circuit test
, ..
Applicable
NV L
Brush length model
25 to 34 N 20 N (2 kgf) 24 V type
Applicable
NV L (2.55 to
model
3.45 kgf) 18 N (1.8 kgf) 12 V type
18 24 V type
11
17 12 V type

L ... Limit
B1867B
16-18
( 1 ) Armature
ENGINE ELECTRICAL - SERVICE PROCEDURES -
D7507A
D7505A
(c) Inspection of commutator
(a) Coil short circuit test 1) Measure the runout of commutator with a dial
Place the armature on a growler tester. Hold a piece of gauge.
iron in parallel with the armature and slowly turn If the runout exceeds the limit, correct, ensuring that
armature by hand. If the iron piece is attracted or the 0.0. limit is not exceeded.
vibrates, it means there is a short circuit. Replace the If the commutator surface is rough developing ridge
arm�ture. wear, correct with sandpaper (No. 300 to 500).
D7506A
(b) Coil earth test 2) Measure the commutator 0.0. If the measurement
exceeds the limit, replace the armature.
Check for continuity across the commutator and shaft
(or core). If there is a continuity, indicating that the
coil is earthed, replace the armature.
16-19
Sogm
Bad
Mica depth
D7509A D7511A
3) Measure the mica depth of groove between seg (bl Coil earth test
ments. If it does not reach the limit, correct. Check to ensure that there is no continuity between
(2) Field Coil the yoke and brush ( + ).
If there is continuity indicating that the coil is earthed,
check for poor insulation. If repair is impossible,
replace the yoke assembly.
(3) Brush and Brush Holder
Brush
D7510A
(a) Coil open circuit test

Check to ensure that there is continuity between the
terminal lead and brush ( + ). D7512A
If there is no continuity, indicating an open circuit,

replace the yoke assembly. (a) Brush wear ,,1
Measure the brush length and, if the measurement is

less than the limit, replace the brush.
If the brush is unevenly worn or develops rough
surfaces, correct with sandpaper (No. 300 to 500).
NOTE:
Correct the brush contact surface to a
curve of the commutator.
16-20
m
u
Check to ensure that the pinion shaft turns smoothly
when truned in the drive direction (clockwise) and
locks when turned in the opposite direction (counterc
lockwise).
If the pinion shaft does not properly rotate, replace
the overrunning clutch.
(5) Magnetic Switch
B terminal
07513A
(b) Brush spring tension

Measure the installed load of the brush spring. Using
a new brush, read the load at the moment the spring
leaves the brush.
If the spring tension is below the limit, replace the
spring. B1868A
Perform the following continuity tests and, if any

faulty condition is evident, replace the magnetic
switch.
(a) Coil open circuit test
Check to ensure that there is a continuity across S and
M terminals, and S terminal and ground.
(b) Fused contact check
Check to ensure that there is no continuity across B
and M terminals.
(c) Loose contact test
(c) Brush holder insulation test Check to ensure that voltage drop across contacts is
Check to ensure that there is no continuity between small.
the ( +) brush holder and (-) holder plate. If a large voltage drop involves, it means that the
If there is continuity, replace the brush holder. contacts are defective.
(4) Overrunning Clutch
07545A
16-21
-
4.1.4 Reassembly
<24 V type>
Recommended grease 2 16
MULTEMP PS-2
(KYODO YUSHI) or equivalent
Apply grease
12
3 9
10
11.
Pinion gap
NV 0.5 to 2.0
Apply grease to lever contacting surface

14
Pack with grease
Apply grease Pinion shaft thrust gap
<Assembly sequence> NV 0.1 to 0.5
I ,1-1�1s-14-1�,2-@-10-�8--+7-
-�S-4-�2-1
For neassembly of parts with an encircled number, see following items.
NV .. Nominal Value
NOTE:
1. Ensure correct installation direction for the lever
assembly.
2. Be sure to align mating marks on the yoke and the
center bracket. 81869A
(1) To install the pinion, pass the pinion shaft through

front bracket. Then, with the spring, pinion, and
pinion stopper mounted and the ring fixed to the
pinion shaft groove, pull the pinion or pinion stopper
toward ring to fix in position.
81465A
16-22
Pinion
Adjusting washer
Pinion shaft
Snap ring
Pinion gap
Center bracket
O7550A 80054A
(2) Adjustment of Pinion Shaft Thrust Gap Then, push the sleeve lightly back and measure the
Measure the thrust gap with the following procedure backward travel (movement), which is the pinion gap.
and, ifthe measurement is out of specification, adjust Adjust by varying the number of packings in the
by using adjusting washers. magnetic switch to obtain the nominal value for the
gap. To reduce the pinion gap, use a greater number
(a) With pinion removed
of packings.
Mount the gear onto the pinion shaft and pass the
(2) Test
shaft through the center bracket. Then, secure the
pinion shaft with a washer and snap ring.
Now, move the pinion shaft in the axial direction to
measure the thrust gap.
(b) With pinion mounted
Ammeter
Temporarily secure the pinion shaft and gear be
tween the front and center brackets with attaching Battery T
24V or 12v:
bolts. Then, adjust the thrust gap by moving the
pinion shaft in the axial direction.
4.1.5 Adjustment and Test after Reas• 81870A

sembly
(1 ) Adjustment of Pinion Gap Set up a circuit as shown to check for no-load
characteristics.
Model 24 V type 12 V type

No-load Voltage 23 V 11 V
character-
istics Current 65 A 180 A
or less or less
Rotating 4 250 rpm 3 200 rpm

speed or more or more
Magnetic switch operating 16 V or less 8 V or less
voltage
NOTE:
B1466B
1. Use wires as thick as possible and
tighten all terminals securely.
When the reassembled starter is wired as shown, the
2. The reduction gear built into the starter
pinion comes out rotating. When the M terminal is produces high rotating sound at no
disconnected, the pinion stops rotating, being held in load.
the out position.
16-23
m ENGINE ELECTRICAL - SERVICE PROCEDURES
3. If the starter is operated for a long 4.3 ALTERNATOR

period, the battery will run down result• 4.3.1 Removal and Installation
ing in reduced rotating speed. Do not
operate the starter for more than 10 to
15 seconds at one time.
4.2 STARTER RELAY
S terminal
B terminal
SW terminal Coil resistance

NV 9.6 !l (24 V type)
L terminal 3 n (12 v type)
B1871A
91 Nm
(9.3 kgf ml
B
B1872A
L_ _j
: L
D8002A
(1) Check for continuity between the SW and L

terminals and check to ensure that the coil resistance
is up to specification.
(2) Check to ensure that when the battery voltage
(24 V or 12 V) is applied across the SW and L
terminals, there is continuity between the 8 and S
terminals.
16-24
ENGINE ELECTRICAL - SERVICE PROCEDURES m
Ground test
Applicable
Item NV L
model
Slip ring O.D. 32.8 to 33.2 32.4 A5T70383
40.8 to 41.2 40.4 A2T72988
Field coil !Approx. 10 n - A5T70383

resistance
(20 'C) Approx. 9 n - A2T72988
Rotating condition
Short test
Open test
Applicable
Item NV L
model
5 3 to 4.2 N 2.1 N
Brush spring A5T70383
(0.31 to 0.43 k fl (0.21 k f)
Open circuit tension
3.1 to 4.3 N 2N
test A2T72988
(0.32 to 0.44 k fl (0.2 k f)
Ground test Brush length 18.5 7 A5T70383 NV ... Nominal Value
L ... Limit
23 8 A2T72988
1 Connector assembly <A2TI2988> ® Rear bracket assembly
2 Front bracket assembly 7 Regulator assembly
3 Pulley and fan 8 Rectifier assembly
4 Rotor 9 Rear bracket
5 Stator
NOTE:
Use care not to lose the spring installed in the outer
periphery of the bearing on the rear end. B1873A
16-25
m
(1) Stator
D8060A
08058A
(b) Measure the resistance across slip rings. Replace
(a) Check that there is continuity across stator leads. the rotor if the resistance is not within the specifica
If there is no continuity indicating a broken wire, tion.
replace the stator.
(b) Check that there is no continuity across the stator
leads and core.
If there is, replace the stator as it is earthed.
(2) Rotor
D8061A
(c) If the slip ring has rough surface or is une"'.enly

worn, correct with sandpaper or lathe.
Correction must be made within the limit of slip ring
O.D.
08059A
(3) Brush
(a) Check that there is no continuity between the slip
ring and core.
If there is, replace the rotor.
..
::r
ii"
:::,
CQ
�
�::r
.,
.,�
:::,
:::,
Wear limit line D8062A
(a) Replace the brush if it is worn beyond the limit.
16-26
(4) Diode
Brush spring
Pigtail 08063A
(bl When a brush has been replaced with a new one,

push it in to measure the brush spring pressure. For each diode, check the resistance across diode
If the spring pressure is lower than the limit, replace leads and heat sink.
the brush spring. Make the check in two modes, by connecting the
(cl Replacement of brush and brush spring positive ( + l lead of multimeter to the diode and the
The brush and brush spring can be removed by negative (-l lead to the diode.
unsoldering the pigtail. The diode is open if the resistance is infinite in both
cases.
It is shorted if the resistance is almost O in both cases.
Replace the rectifier if the diode is open or shorted.
For the diode trio, check resistance across leads.
4.3.3 Reassembly
<A5TT0383>
·X•
·7
I
'
<Assembly sequence>
6 (�S-7H� 1
@-2-�
For neassembly of parts with an encircled number,
see following items. 1
The parts marked •:i:· are included in the rear
bracket assembly 6. <A2TT2988>
D8065C
16-27
- ENGINE ELECTRICAL - SERVICE PROCEDURES
4.3.4 Tests
(1) Handling Precautions
When servicing the alternator, observe the following
precautions.
When installing the lock :;pring into the eccentric

groove in the outer periphery of the rear bearing,
ensure that the maximum protrusion rests in the
deepest parts. D8072B
Pull-up pin
(a) If the polarity of the battery is reversed when
connections are made, a large current flows from the
battery to alternator, damaging the diode and IC
regulator.
08067A
NOTE:
1. When installing a new bearing, make
sure that the groove on its outer
periphery is positioned on the spring D8073B
end�
2. Push the brush into the brush holder (b) Do not disconnect the battery terminal connec
and secure with the brush pull-up pin. tions while the engine is running, or a surge voltage
After reassembly, be sure to remove develops deteriorating the diode and regulator.
the pin.
16-28
I /
/
D8074A D8077B
(c) Do not use a megger or other high-voltage (f) When quick-charging the battery with a quick
multi-meter, or damaged diode and regulator will charger, be sure to disconnect terminal connections
result. in advance. Otherwise, a damaged diode and regula
tor will result.
(2) Performance Test (On Test Bench)
Ammeter
Switch Switch
+ K, Kz
V Voltmeter
I
T
I
D8075B Battery ..1... Load resistance
(variable resistor)
(d) When a steam cleaner is used, take adequate D8068A

measures to prevent direct exposure of the alternator
to the steam. With the load resistance set at maximum (meaning
that there is almost no load current flowing), close
switches K1 and K2.
While gradually increasing the alternator speed to
reduce the load resistance, measure the current value
with the specified terminal voltage and speed.
If the measurement is below the specification, check
alternator parts.
Load Characteristics
Model A5TT0383 (25 A) A2TT2988 (30 Al

D8076B Terminal voltage 27 V 27 V
Current 14 A or more 17 A or more
(e) Operating the alternator with its Band L terminals
Rotating speed 1 500 rpm 1 500 rpm
shorted results in the damaged diode trio.
Terminal voltage 27 V 27 V
Current 22 A or more 26 A or more
Rotating speed 2 500 rpm 2 500 rpm
16-29
m ENGINE ELECTRICAL SERVICE PROCEDURES
(3) Performance Test (On-vehicle) Use a fully-charged battery. Turn on the switch and
gradually increase the alternator speed up to 5 000
rpm. Check that the current value at this speed is 5 A
Ammeter
or less.
The regulator is in good condition if the regulated
I
voltage under this condition is within specification.
Switch
If not, replace the regulator assembly as the regulated
voltage is not readjustable.
T
1 Battery
(5) IC Regulator Regulated Voltage Test
(On-vehicle)
D8069A
(a) Provide a switch between the battery and alterna

tor B terminal. With the switch turned off, connect an
?. Switch
ammeter (60 A class) and voltmeter. �

: Ammeter
(b) Turn on the switch and make sure that the
voltmeter indicates the battery voltage.
(c) Start up the engine and immediately turn on all I Battery
lamp switches. Then, increase the engine speed and

read the maximum current value when the alternator D8071A
speed reaches 5 000 rpm.
(d) If the current reading is 70% or more of the (a) Connect a voltmeter and ammeter and provide a
nominal output, the alternator may be regarded as in
t
switch.
good condition. (b) The regulator is in good condition if the voltmeter
NOTE: registers O when the switch turns ON. If the voltmeter
The on-vehicle test is an easier way of pointer deflects, the alternator or wiring is defective.
inspection; the test bench inspection is (c) With the ammeter terminal shorted to prevent
necessary for more accurate results. flow of the starter current through it, start the engine.
(4) IC Regulator Regulated Voltage Test

(d) Increase the engine speed to around 2 000 rpm
i
and read the regulated voltage value if the charge
I
(On Test Bench) current is 5 A or less. . .
If the charge current is 5 A or more, continue charging
1:.
for a while or replace it with a fully-charged battery.
n
Ammeter
1
Or, a 1/4 (25 W) resistor may be connected in series
to the battery to limit the charge current.
(e) The regulator is in good condition if the regulator
Switch
voltage is within specification.
I
If not, replace the regulator assembly as the regulator
Battery voltage is not readjustable.
D8070A
IC regulator regulated voltage

28to29V Measured across terminals "L • and
<24 V type> "E" at 5 000rpm, load 5 A or less
16-30
4.4 SAFETY RELAY
Inspection
NV ... N ominalValue
B1453B
Measure voltage at each terminal in the sequence

shown below to identify faulty parts.
(1) On-vehicle Test
Engine Voltage at Voltage at Voltage at terminal

Sequence
operation terminal •p• terminal •s• "R" or "L"
1 Starter switch ON •1V or less Terminal "R"

• (+) diode shorted if close to • Approx. 24V
battery voltage • If OV, wiring is faulty
Terminal "L• (with charge lamp)
• Approx. 24V
Terminal "L• (without charge lamp)
• Approx. 3V or less
• If OV, wiring or alternator is faulty
2 During cranking • Approx. 1V or less

• If close to battery voltage,
safety relay is faulty
(cranking impossible)
3 Idling (600 rpm or • Approx. 13 to 16V • A bulb connected between

higher) battery and terminal •s•
not to come on
• If bulb comes on despite
normal terminal •p• voltage
(shown to left), replace
safety relay and test again
(2) Off-vehicle Test

The resistance valve between terminals "R" and "L"
shall be within specified range.
16-31
4.5 PREHEATER (2) Inspection

4.5.1 Intake Air Heater
(1) Removal and Installation
Starter switch
Air intake pipe
,I'''
B4508B
Perform the following inspection and check the

81874A
function of each part or the wiring if necessary.
(a) Time required before indicator becomes red-hot:
NOTE:
Standard time
When installing, direct the arrow mark
20 to 30 seconds <24 V type>
embossed on the air heater toward the
40 to 60 seconds <12 V type>
inlet manifold.
(b) Check each terminal of the air heater for loose
ness and the heater element for damage and contact
with other parts.
16-32
4.5.2 Heater Relay
Energize the stop solenoid and check to see that the

-
Inspection stop lever comes to the ON position. Using an
ammeter, check to see that when the solenoid is held,
only the holding coil is energized.
(2) Solenoid Relay
Terminal voltage Stop solenoid

Oil pressure timer measurement relay
DC28.5V <24V type> �----'-----,
DC14V <12V type>
Stop timer measurement E
DC24V <24V type> B C ST W A
DC12V <12V type> ......,__,.,......,....--,.,......,....,.
SW@
SW terminal
O8901A ---t:�o-------11"'---J
SW©
ef SW@
L Terminal
voltage
DC28.5V
(a) Check to ensure that there is continuity between Solenoid or <24V type>
coil load DC14V
the terminals "B" and "S" when 2.3 A exciting current 30A ± 3A <12V type>
<24 V> is applied between terminal SW in the figure SW@
SW@
and body earth. ON
Oil pressure 18 ± 5"
(bl �heck also the heater relay fuse and replace with timer
new one if it has been burnt out. SW@ ---
When replacing fuses, be sure to use a fuse of 30 ± 5"
Stop tim�r
specified capacity.
Test schedule
4.6 AUTOMATIC STOP DEVICE Description of symbols

SW © : Snap switch A
4.6.1 Run Off Type SW@ : Snap switch B
SW © : Push 11witch C O9558A
(1) Stop Solenoid
Make connections as shown above and perform the
Governor following checks.
Stroke: approx. 27
ON
7\.-
(Engine (a) Oil pressure timer
stopped)
Set the snap switch A to ON. Operate a stop watch as
1 soon as the snap switch B is set to ON, and measure

the time required before the solenoid is operated.
Stop
solenoid (bl Stop timer
Stop lever Set the snap switch B to OFF 5 seconds after the
solenoid has been operated. At the same time, using
Before attraction After attraction
P.C
a stop watch, measure the time required before the
P.C
,
11 ,
solenoid is reset.
11 The snap switch B is set to OFF 5 seconds after
operation of the solenoid because if the solenoid is
--e:j
hem Nominal Value 7E:C:l
Remarks
operated, it takes 5 seconds before the alternator
Operating vohage 17 V or less 24V type
Stroke: 27 voltage disappears.
load: 39 N (4 kgf)
12 V or less 12V type
Stroke: 27
Load: 9.8 N ( 1 kg!)
Current Pull-in 20A or less 24V type
coil
25A or less 12V type
Holding 5A or less 24 and 12V type
coil B1943A
16-33
m
(c) Manual stop timer
(4) Oil Pressure Switch

When the push switch C (stop switch) is set to ON, the
solenoid will be operated. Operate a stop watch as Engine oil
Testing oil pressure gauge
soon as the stop switch C is set to OFF, and measure pressure gauge
the time required before the solenoid is reset.
After the tests of the above items (a) and (b), allow 5
minutes before making retests. It takes 5 minutes
before the capacitor c,
which is an element of the Crankcase
t-->c.)'------11___....j--; oil pressure
time constant of the oil pressure timer finishes outlet port
discharging.
Cock B
(3) Thermo Switch
O9560A
f·
Item NV Remarks
Operating 93 to 97 °C 30098-39300
temperature
96 to 100 °C 30098-39400 Operating pressre
NV 69 to 98 kPa
ON-OFF 7 °C 30098-39300 (0.7 to 1.0 kgf cm2 ) or less
difference 30098-39400
NY ... Nominal Value

Tern perature-sensing
portion 09559A
O9561A
The thermo switch won't operate if the temperature
sensing portion is not in contact with coolant. If the Connect the pipes as shown above, close the cocks A
coolant level is low or if there is only steam, the and B, and"start the engine. After the oil pressure has
thermo switch won't operate completely. risen, fully open the cock A to lead the oil pressu�e to
Immerse the temperature-sensing portion in water, the oil pressure switch. Then close the cock A to shut
heat the water, and check the thermo switch operat off the oil passage to the engine and hold the oil
ing temperature with a mercury thermometer. pressure directly in the oil reservoir.
Slowly open the cock B to lower the oil pressure and
check the oil pressure switch operating oil pressure
with the test oil pressure gauge.
16-34
(5) Oil Pressure Switch Relay 4.6.2 Run On Type

-
(1) Stop Solenoid
Item NV Remarks Stroke: 27

Rated voltage 24V 24V type
12V 12V type
0 Coil resistance 1so to 2so

55 to 100 !l
n 24V type
12V type
Minimum 16V 24V type Stop
operating solenoid
voltage BV 12V type
Engine
stopped Before attraction After attraction
P.C P.C
\I• II •
H.C H.C
Item �
Nominal Value
�
Remarks
Operating voltage 24V or less 24V type

Stroke: 27
load: 9.8 N (1 kgf)
12V or less 12V type

Stroke: 27
load: 9.8 N (1 kgf)
Current Pull-in 31A or less 24V type

coil
NV ... Nominal Value 25A or less 12V type
D9562A Holding 1A or less 24V type

coil
SA or less 12V type
B1944A
(a) Check to ensure that there is continuity between
the terminals ® and @. Energize the stop solenoid and check to see that the
(b) Check to ensure that there is no continuity stop lever comes to the stop position. Using an
between the terminals G) and @. ammeter, check to see that when the solenoid is held,
(c) Check to ensure that there is continuity between only the holding coil is energized.
the terminals© and® and that the coil resistance has
a nominal value.
(d) Check to ensure that when the battery voltage is
applied across the terminals © and @, there is
continuity between the terminals G) and @ and no
continuity between the terminals ® and @.

Phone: 269 673 1638
16-35
(2) Solenoid Relay (4) Oil Pressure Switch
Engine oil
Testing oil pressure gauge
E o-------,
pressure gauge
B C H S
SW1 SW3 SW2

-./co---+---'1'--...........---'
Terminal voltage
Crankcase
24V <24V type> Solenoid or coil load
12V <12V type> 30A ± 3A j--'<.)L.------<L___.....J--j oil pressure
outlet port
Delay time
NV 26 to 34 sec. NV ... Nominal Value
09564A 09560A
Wire as shown at right and check the following. I,' !:,'

(a) Relay operation and delay time
1) Check if the solenoid is energized when switches
Operating pressure
SW1 and SW2 are turned ON. NV 79 to 118 kPa
2) Using a stopwatch, measure the time required for (0.8 to 1.2 kgf/cm2 ) or less
the solenoid to return after switch SW2 is turned OFF.

(b) Relay holding NV ... Nominal Value
1) Turn ON switches SW1 and SW2 and, after the

solenoid is activated,turn ON the switch SW3.
09565A
2) Turn OFF the switch SW2 and make sure that the
solenoid remains activated for more than 34 seconds.
3) After verifying 2) above, turn OFF the switch SW3 Connect the pipes as shown above, close the cocks A
to ensure that the solenoid returns. and B, and start the·engine. After the oil pressure has
risen, fully open the cock A to lead the oil pressure to
(3) Thermo Switch the oil pressure switch. Then close the cock A to shut
off the oil passage to the engine and hold the oil
pressure directly in the oil reservoir.
Item NV Remarks Slowly open the cock B to lower the oil pressure and
Operating 94 to 98 •c ME049147 check the oil pressure switch operating oil pressure
temperature
96 to ME048169
with the test oil pressure gauge.
100 ·c
ON-OFF 1 ·c ME049147
difference ME048169

Temperature-sensing
portion
09559B
The thermo switch won't operate if the temperature

sensing portion is not in contact with coolant. If the
coolant level is low or if there is only steam, the
thermo switch won't operate completely.
Immerse the temperature-sensing portion in water,
heat the water, and check the thermo switch operat
ing temperature with a mercury thermometer.
16-36
5. TROUBLESHOOTING
ENGINE ELECTRICAL - TROUBLESHOOTING
m
Starter turns but engine d-•
not start
NO
Does flywheel speed increase?
YES
Does starter speed increase?
YES
NO
Are magnetic switch main contacts Repair or replace magnetic
intact? switch
YES
Repair or replace defective

starter parts
NO
If overrunning clutch free from Repair or replace defective
slipping? starter parts
NO
Is starter or surrounding parts
developing no unusual noise or
vibration?
YES
NO
Is starter pinion free from wear Repair or replace pinion
and damage? and allied parts
YES
Repair or replace defective

starter parts
•
Check fuel system and other parts
on the engine side for defects
16-37
DI ENGINE ELECTRICAL - TROUBLESHOOTING
Starter does not tum when the

starter switch is placed in "START"
position
j Does pinion develop meshing sound? 1----------,

1
NO
YES
NO
Is voltage across starter S terminal
normal when the starter switch is
in "START" position?
YES
NO
Is voltage across SW terminal Replace starter switch or
of starter relay normal? repair wiring
'i
YES
NO
Is there continuity between S and B Replace starter relay
terminals of the starter relay?
Is starter in operation?
\,'
NO
Is there continuity between S and M Replace magnetic switch
terminals of the magnetic switch?
YES
Defective starter.
Is wiring between M terminal
>-----:
NO
Repair or replace
I
and ground free from breaks?
NO
Is starter free from chattering?
YES
NO
Are magnetic switch main contacts Replace magnetic switch
free from fusion or damage?
YES
Repair or replace starter
NO
Is magnetic switch holding coil Replace magnetic switch
free from breaks?
16-38
m
Battary overdlscharges.
1. Starter rpm too low.
2. Charge wamlng lamp comes on.
NO
Is fan belt free from looseness Adjust belt tension or replace
or damage?
YES
YES
Is wiring between alternator and Repair or replace
battery not intact?
Are there any broken fuse or poor
connection 7
NO
High
With engine speed increased up to
1 000 to 1 200 rpm, measure the B
terminal voltage
No change from
. battery voltage
With an ammeter (60 A or higher) connected to the output terminal of alternator, turn ON all electrical
equipments. Start the engine and rev it up to 2 300 rpm or more, and measure the maximum value
indicated by the ammeter. (Make this check quickly with an assistant.)
l
70 % or less of rating
I 70 % or more of rating
YES YES
Alternator is in fair condition:

Check battery and electrical
equipment for unusual conditions
Continued on next page Repair or replace alternator
16-39
- ENGINE ELECTRICAL - TROUBLESHOOTING
! H.19 h
Measure the B terminal voltage of IC
regulator when F terminal is ground-
ed. (Watch for sudden voltage rise;
Slowly rev up while checking
voltages.)
Voltage not
increasing
NO
Does charge warning lamp come on Replace IC regulator
with engine stationary?
YES
Repair or replace diode trio
High (Near battery voltage)

Measure L terminal voltage with Positive diode is shorted:
engine stationary Repair or replace
Low ( 1 V or less)
NO
Does charge warning lamp come on Brush failure to contact or broken
with engine stationary? field coil: Repair or replace
YES
NO
Is L terminal or positive brush Repair or replace
. free from grounding?
16-40
Battery overcharging
1. Battery needs water frequently
2. Battery temperature la high
l
Does B terminal voltage remain
NO
unchanged while gradually
revolving up?
YES
NO
Is negative brush free from Grounded negative brush does not
grounding with starter switch allow the IC regulator to operate:
in "OFF"? Repair
YES
Replace defective IC regulator
�---------------,1 NO
Is F terminal voltage at high engine 1---------------------------i IC regulator is defective
rpm higher than that at idle? or negative brush is grounded:
�--------,-------�
YES
1 Replace IC regulator or repair
grounded point
High
Check for regulated voltage Excessively high regulated
Measure L terminal voltage with voltage: Replace IC regulator
engine at high rpm
Low
Alternator is in good condition:

Check battery for unusual
conditions
16-41
Phone: 269 673 1638
,,
p,
:!,,
I':,
,,
//
;:·

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Mitsubishi 6D31 6D31T 6D31C 6D31CT Engine Workshop Manual PDF

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Mitsubishi

6D31 6D31T 6D31C 6D31CT

Applicable Engine Models

Mitsubishi Engine Parts: www.HeavyEquipmentRestorationParts.com

No. Group name Description

2. GENERAL PRECAUTIONS FOR

(7) The oil seals, packings, 0-rings, and other rubber

(1) Before performing the service procedures given

3. TERMS AND UNITS

4. TABLE OF CONVERSION RATE FOR FOOT-POUND UNITS INTO SI UNITS

Mass quantity of matter kg lb 1 kg = 2.2046 lb

Dimension m ft. 1 m = 3.2808 ft.

Capacity lit. gal. 1 lit. = 0.2642 gal. (U.S.)

Force N (Newton) lbf 1 N = 0.2248 lbf

Pressure kPa (kilopascal) lbf/in. 2

Stress N/cm2 lbf/in.2 1 N/cm2 = 1.45 lbf/in.2

Moment of force N m ft. lbf 1 N m = 0.7375 ft. lbf

Output kW (kilowatt) HP 1 kW = 1.34 HP

Temperature 'C "F t'C = (1.8t'C + 32)'F

S. READING THE ILLUSTRATION

·J:<· Protrusion from

·J:<· indicates inspection to

Damage on outer and inner

NV ... Nominal Value

Indicates that the disassembly

Gives instruction for jobs to

Indicates that the assembly

Specifies the tightening torque;

NV ... Nominal Value

1. EXTERNAL VIEW ••••.••.•••.•••..••••••••• 2 3. ENGINE NUMBERS AND

2.2 ENGINE OUTPUTS CLASSIFIED BY APPLICATION

3. ENGINE NUMBERS AND CAUTION

The engine number is stamped on the position as

._______ Engine number

The engine number is important in knowing the

The caution plate is located as illustrated. The caution

4. GENERAL BOLTS AND NUTS TIGHTENING TORQUE TABLE

Standard bolts and nuts

Dia. mm Pitch mm 4T (Head mark 4 or 0) 7T {Head mark 7 or 0) ST (Head mark 8 or $)

Flange bolts and nuts

Dia. mm Pitch mm 4T (Head mark 4 or 0) 7T (Head mark 7 or 0) ST (Head mark 8 or $) ·

1. GENERAL (2) Valve Mechanism

���'-" Valve cotter

Piston Inlet valve

The valve mechanism is an overhead valve type.

The piston, made of aluminum alloy casting, has a

(a) The crankcase is made of cast iron and built rigid

There are three piston rings installed: two compres­

The connecting rod is a die forging with an I cross

Crankshaft The flywheel is mounted in the rear of the crankshaft.

The flywheel is made of cast iron. The pilot bearing of

A bushing is press-fitted into the idler gear which

Description Nominal value Correction and

Mitsubishi Engine Parts: www.HeavyEquipmentRestorationParts.com

Nominal value Correction and

Valve stem O.D. Inlet 8.96 to 8.97 8.85 Replace

Valve sinkage Inlet 0.75 to 1.25 1.5 Replace valve seat

Valve margin 1.5 1.2 Correct or replace

Valve seat angle 45• -

Camshaft Cam lobe height 6.86 6.36 Replace.

Nominal value Correction and

Cylinder sleeve 1.0. 100 to 100.03 100.25 Correct to oversize or

Roundness 0.01 or less - replace

��'-" Valve cotter

There are three piston rings installed: two compres

1) Using the rocker 1.0. and rocker shaft 0.0., calcu