INTRODUCTION

ENGINE BODY

3.1 Introduction Prepare the following prior to starting inspections and maintenance of the engine. (1) Fix the engine on a horizontal table. CAUTION Fix it firmly because it may fall down and injure you or damage the parts during work.

(2) Remove the cooling water hose, fuel oil pipe, wire harness, and so on connecting the engine to the forklift truck body to drain the cooling water, oil, and fuel. (3) Use detergent, air, steam, and so on to clean the engine by washing away earth, oil, dust, and so on adhered to it. When this is done, be careful not to allow foreign substances into the engine. CAUTION When using the air, steam, and so on, foreign substances may be scattered and damage your eye, and so on. Be sure to wear a protective wear such as goggles.

3-2

ENGINE BODY

CYLINDER HEAD

3.2 Cylinder Head

(1) Component Parts

1st time T = 53.9 Nm (5.5 kgf-m) <39.8 ft-lb> 2nd time T = 107.8 Nm (11 kgf-m) <79.6 ft-lb>

CAUTION At the time of disassembly, the packings, O-rings, and oil seals must be all replaced by new parts; they are not reusable. Particularly, if a head gasket packing is reused, a blow-by of the combustion gas may damage the explosion surfaces of the cylinder and cylinder head, and it is feared that you will not be able to reuse them.

3-3

CYLINDER HEAD

ENGINE BODY

(2) Disassembly and Aassembly of Cylinder Head

(3) Disassembly Procedure Disassemble in order of the numbers shown in the drawing. Remove the alternator assembly. (Note 1) Remove the fan, pulley, and V-belt. Remove the water pump assembly. Remove the fuel filter and fuel oil pipe. Remove the oil gauge assembly. Remove the fuel injection pipe. (Note 2) Remove the intake manifold assembly, Remove the exhaust manifold assembly. Remove the cylinder head cover assembly. Remove the lever shaft assembly, push rod, and valve head protector. (Note 3) Remove the cylinder head assembly and head gasket. (Note 4) Remove the fuel injection valve and fuel return oil pipe. (Note 5) Remove the glow plug and lead wires. Remove the intake/exhaust valve and valve spring. (Note 6) Remove the valve lever from the lever shaft.

3-4

ENGINE BODY

CYLINDER HEAD

(4) Assembly Procedure Assemble in the reverse order of disassembiy. (Note 1) Alternator Disassembly: Supporting the alternator, loosen the mounting bolts. Assembly: Belt tension is 10 - 15 mm (0.39 - 0.59 in) (7 - 9 mm (0.28 0.35 in) for a new belt) at finger pressure of 98 N(10 kgf) <22 lb>.

CAUTION Support the alternator firmly. Otherwise, you may have your finger caught or damage the parts. (Note 2) Fuel injection pipe Disassembly and assembly: Note combinations of the pumps A, B, C, and D marks with the cylinder numbers. A-4, B-2, C-1, D-3 Pump: Marked on the delivery section of the main body Cylinders: Numbered in order of 1, 2, 3, and 4 from the flywheel side (Note 3) Push rod Assembly: Be sure to apply oil to the contact with a valve clearance adjusting screw. (Note 4) Cylinder head Disassembly 1) Loosen the head bolts sequentially in two times. 2) Be careful not to scratch the combustion) surface. Assembly 1) Apply oil to the threads and seat surface of the head bolts and set them uniformly. 2) When tightening them, do so in two times in reverse order of disassembly. 1st-time torque T=53.9Nm (5.5kgf-m) <39.8 ft-lb> 2nd-time torque T=107.8Nm (11kgf-m) <79.6 ft-lb>

3-5

CYLINDER HEAD

ENGINE BODY

(Note 5) Fuel injection valve Disassembly: Note that the protector at the nose will remain in the cylinder head Assembly: Unless there is a gas leak, replace only the copper washer between the nozzle and protector by a new one and assemble. (Note 6) Intake/exhaust valve Disassembly: When there is a cotters burr at the shaft of the intake/exhaust valve, eliminate it with an oilstone, and so on, and then, remove the valve from the cylinder head Assembly: 1) Apply oil and assemble it, paying attention not to damage the stem seal. 2) After assembling the intake/exhaust valve, valve spring, holder, and cotter, fit in the spring by lightly hitting the head of the valve stem.

(5) Inspection and Measurement of Parts (i) Cylinder head 1) Inspection of the combustion surface and measurement of distortion. a) Distortion of the combustion surface Clean the combustion surface, apply a straight edge to two diagonal directions and four peripheral directions and use a thickness gauge to measure deformation of the combustion surface.

b) Inspection of the combustion surface When cracks are suspected, examine by a color check. 2) Wear measurement of the intake/exhaust valve seat Clean the valve seat and measure valve sinking and seat width. Depending on the circumstances, paint the valve in blue and check for a contact. a) Measurement of valve sinking

3-6

ENGINE BODY

CYLINDER HEAD

b) Measurement of seat width

(ii) Intake/exhaust valve and valve guide 1) When the intake/exhaust valve shaft is bent or greatly worn, replace it together with the valve guide. 2) Measurement of the outer diameter of the valve shaft and inner diameter of the valve guide

(iii) Valve spring 1) Replace it if it has any abnormality such as damage, corrosion. 2) Measurement of free length, inclination, and spring tension

(iv) Locker arm, shaft, spring, push rod, valve head protector, and valve clearance adjusting screw 1) Replace them if they have any abnormality such as damage, corrosion. Pay additional attention to the contact area between the locker arm and valve head protector, corrosion and damage of the spring, bent of the push rod, and contact of both ends.

3-7

CYLINDER HEAD

ENGINE BODY

(2) Measurement of the inner diameter of the locker shaft hole and outer diameter of the shaft

(6)

Correction of Valve Seat

IMPORTANT: When correcting the valve seat, check the clearance between the valve and valve guide first. If it is larger than the specified limit, replace the valve or valve guide to normalize the clearance, and then, correct the valve seat. After correcting the valve seat, wash the valve and cylinder head fully with light oil, and so on to completely eliminate grinding powder, compound, and so on. (i) When the seat is slightly rough: Perform [A] and [B] below. (ii) When the seat is considerably rough, but the seat width is normal, correct with a seat grinder or seat cutter, and then, perform [A] and [B] below.

(iii) When the seat is considerably rough and the seat width is too large, grind or cut the seat surface with a 40 seat grinder or seat cutter, finish the seat width to the reference dimension with a 150 seat grinder, perform seat correction described in (ii) above, and then, perform [A] and [B] below.

[A]: Knead the valve compound and engine oil together, and fit the valve to the seat. [B]: Fit with the engine oil alone.

3-8

ENGINE BODY

CYLINDER HEAD

(7) Replacement of Valve Guide (i) Using a drawout tool, draw out the valve guide from the cylinder head. (ii) Put liquid nitrogen or ether/alcohot plus dry ice in a container to cool a replacement valve guide, and drive in with a valve guide inserting tool. (iii)Finish to a reference inner diameter with a reamer. (iv) Check a projection amount from the cylinder head. Projection amount: 15 mm (0.59 in)

CAUTION Do not touch a cooled valve guide with a naked hand. The skin may be damaged. (8) Replacement of Valve Stem Seal (i) Whenever the intake/exhaust valve is disassembled, be sure to replace it by a new one. (ii) To reassemble it, apply grease to a stem seal, push it in with an inserting tool to install it. Only the exhaust side is painted in yellow. Be careful not to mistake the intake side for the exhaust side.

3-9

GEAR TRAIN AND CAM SHAFT

ENGINE BODY

3.3 Gear Train and Cam Shaft

(1) Component Parts

Crank pulley Fuel injection pump gear Flywheel Non-reusable part pply liquid packing Apply grease

T = 117.6 Nm(12 kgf-m) <86.8 ft-lb> T = 63.7 Nm(6.5 kgf-m) <47.0 ft-lb> T = 196 Nm(20 kgf-m) <144.7 ft-lb>

3-10

ENGINE BODY

GEAR TRAIN AND CAM SHAFT

(2) Disassembly and Assembly of Gear Train and Cam Shaft

(3) Disassembly Procedure Disassemble in order of the numbers shown in the drawing. Take the cylinder head disassembly procedural steps through Remove the fuel injection pump drive gear cover. Remove the fuel injection pump. (Note 1) Remove the crank shaft pulley. (Note 2) Remove the gear case cover. (Note 3) Remove the idle gear assembly. (Note 4) Remove the PTO drive gear. (Note 5) Remove the PTO injection pipe. Remove the starting motor. Remove the flywheel. (Note 6) Remove the cam shaft assembly. (Note 7) Remove the gear case. (Note 8) Remove the oil seal from the gear case cover. (Note 9) (4) Assembly Procedure Assemble in the reverse order of disassembly.

11 .

3-11

GEAR TRAIN AND CAM SHAFT

ENGINE BODY

(Note 1) Fuel injection pump Disassembly: Remove fuel injection pump drive gear mounting nuts. Remove the gear by a gear puller, using an M8 forcing screw. Loosen and remove fuel injection pump mounting nuts. Remember to remove the rear stay. Assembly: 1) Make sure that an O-ring is set, and adjust the fuel injection pump to a timing mark. 2) Adjust the top mark to 6 (ATDC) past the top. 3) Make sure that a plunger lift is 1 mm (0.039 in). 4) If it is not 1 mm (0.039 in), adjust a pump body setting angle. 5) Set the fuel injection pump drive gear. Tightening torque T = 63.7 Nm(6.5 kgf-m) <47.0 ft-lb>

(Note 2) Crank pulley Disassembly: Remove the crank pulley after removing pulley mounting bolts. Assembly: Apply engine oil and assemble the crank pulley, paying attention not to damage the oil seal. Tightening torque T = 117.6 Nm(12 kgf-m) (Note 3) Gear case cover Disassembly: Remember to remove two middle reinforcing bolts. Assembly: 1) Measure a backlash for each gear. 2) Apply liquid packing and set two knock pins together.

3-12

ENGINE BODY

GEAR TRAIN AND CAM SHAFT

(Note 4) Idle gear Assembly: 1) Assemble the crank gear A, fuel injection pump B, and cam gear C to the idle gears A, B, and C respectively at the same time. 2) Install the idle gear shaft with its oil hole facing upward. (Note 5) PTO drive gear Assembly: Set the inner spline side to the flywheel side. (Note 6) Flywheel Disassembly/Assembly: Set a bolt in an M8 threaded hole in the end face of the wheel and use it as a handle. Be careful not to damage the ring gear. (Note 7) Cam shaft Disassembly 1) Measure a side gap.

2) When the side gap is excessive, replace a thrust bearing. As the gear is shrink-fit, heat it to 180 to 200C to remove it. 3) Put up the engine with the mounting flange facing down. Remove a cam shaft thrust bearing mounting bolt through a cam gear hole. Paying attention not to damage the bearing bush, remove the cam shaft. Turn the cam shaft a couple of times before removing it, so that the tappet will not be caught by the cam. Assembly: After assembling the cam shaft, put back the engine horizontally and fix it onto the table.

CAUTION When putting up the engine vertically or putting it back horizontally, it may fall down and injure you. Work carefully so that it will not lose stability.

3-13

GEAR TRAIN AND CAM SHAFT

ENGINE BODY

(Note 8) Gear case Disassembly: Remember to remove oil pan mounting bolts from below. Assembly: Apply a liquid packing (No. 977770-01212) and set two knock pins together. (Note 9) Oil seal Assembly: When assembling, apply lithium grease. Inspection and Measurement of Parts (i) Cam shaft Check for a contact of the tappet with the cam surface, seizure of the bearing, wear, damage on the gear, and so on. 1) Measurement of the shaft bent

2) Measurement of Cam Height

3) Cam shaft outer diameter and bearing inner diameter

3-14

ENGINE BODY

GEAR TRAIN AND CAM SHAFT

(ii) Idle gear Measurement of the idle gear shaft outer diameter and bushing inner diameter

(iii) PTO drive gear Check both bearings for backlash and hitch, and gear shaft for any abnormality. (6) Replacement of Oil Seal 1) Remove the used oil seal. 2) Insert a new one, using an oil seal inserting tool. 3) Apply lithium grease.

3-15

CYLINDER BLOCK

ENGINE BODY

3.4 Cylinder Block

(1) Component Parts

Rod bolt T = 53.9 Nm(5.5 kgf-m) <39.8 ft.-lb> Metal cap T = 112.7 Nm(11.5 kgf-m) <83.2 ft-lb> Non-reusable Part Apply liquid packing Apply grease

3-16

ENGINE BODY

CYLINDER BLOCK

(2) Disassembly and Assembly of Cylinder Block

(3) Disassembly Procedure Disassemble in order of the numbers shown in the drawing. Take the cylinder head disassembly procedural steps through 11 . Take the gear train disassembly procedural steps through 12. . Remove the oil pan. (Note 1) Remove the lubricant suction pipe. Remove the piston W/rod. (Note 2) Remove the flywheel housing. (Note 3) Remove the metal cap. (Note 4) Remove the crank shaft. (Note 5) Remove the tappet. Remove the piston pin and ring. (Note 6) Remove the oil filter assembly. (Note 7) Remove the oil seal from the flywheel housing. (Note 8) (4) Assembly Procedure Assemble in the reverse order of disassembly.

3-17

CYLINDER BLOCK

ENGINE BODY

(Note 1) Oil pan Disassembly: The liquid packing has been applied to its mounting surface to the block. Be careful not to cause a damage or distortion on the adhering surface. Assembly: Apply the liquid packing (code No. YM977770-01212) and assernble. (Note 2) Piston W/rod Disassembly: 1) Measure the side gap of the rod. Standard mm (in) 2) 3) 4) 0.10-0.20 (0.004-0.008)

Eliminate the carbon deposit accumulated on the cylinder carefully not to damage the interior of the cylinder. Set the piston to BDC and remove the rod cap. Next, set the piston to TDC and push out the rod larger end, using the wooden handle of a hammer. Care should be taken so that the rod larger end will not be caught by the cylinder block. Set the rod cap and metal and assemble them.

Assembly: 1) Apply oil elaborately to the slideways of the piston, rod, and ring. 2) Incorporate into the block, using a piston inserting tool, and install the metal cap. Tightening torque T = 53.9 Nm (5.5 kgf-m) <39.8 ft-lb> (Note 3) Flywheel housing Disassembly: Paying attention not to damage, put the engine on the stable table with its explosion surface facing down, and remove the flywheel housing. Assembly: Apply the liquid packing (code No. YM977770-01212) and set two knock pins together. After assembling, put up the engine with the flywheel housing facing down. CAUTION When putting up the engine, it may fall down and injure you. Pay attention to its stability.

3-18

ENGINE BODY

CYLINDER BLOCK

(Note 4) Journal metal cap Disassembly 1) Prior to removing the journal metal cap, measure the side gap of the crank shaft. Standard 0.11-0.21 mm (0.004-0.008 in) 2) When the side gap is beyond the above-mentioned limits, apply a thrust metal oversize.

3) Remove the metal cap, metal cap-side metal, and thrust metal. Put the thrust metal in such a manner that you can tell its position and direction. Assembly 1) When assembling the thrust metal, its slotted side shoulld be outside to the cap. 2) Note that the upper metal (block side) has an oil hole and the lower metal (cap side) does not. 3) Install the metal cap with its wheel, arrow mark facing the flywheel. Metal cap bolt tightening torque T = 112.7 Nm(11.5kgf-m)<83.2 ft-lb>

(Note 5) Crank shaft Disassembly 1) Remove the crank shaft. 2) Remove the upper metal (block side) and assemble it to the metal cap. CAUTION The crank shaft is heavy. When installing it, be careful not to damage the metal or injure your fingers.

3-19

CYLINDER BLOCK

ENGINE BODY

(Note 6) Piston pin and ring Disassembly: 1) Remove the rings with a piston ring tool. 2) Remove a circlip and push out the piston pin to remove it. Assembly: 1) Install the rings to the piston with their makers mark facing up. Shift ring splits by about 120 from each other. 2) When assembling the piston pin to the rod and piston, the marking on the rod larger end and the size marking on the crest of the piston should be on the opposite sides, respectively. 3) Assemble to the block in such a manner that the marking at the rod larger end will face the fuel injection pump. (The embossed marking on the rod body faces the flywheel)

(Note 7) Oil filter Assembly: Close fully with hand, and then, tighten additionally by 3/4 turn with a filter wrench. (Note 8) Oil seal: Assembly: Apply lithium grease at the time of assembly. (5) Inspection and Measurement of Parts (i) Cylinder block 1) Eliminate dirt, rust, adhesive agent, and so on. The oil hole should be cleaned thoroughly so that it will not be blocked. When any cracks are suspected, make a color check to judge.

3-20

ENGINE BODY

CYLINDER BLOCK

2) Measurement of the cylinder inner diameter and distortion amount

Use a cylinder gauge to measure the inner diameter of each cylinder. Measure at the crest, position 20 mm (0.29 in) from the lower end, and three central dimensions, a, b, and c. Roundness: Difference between the maximum and minimum dimensions of a, b, and c Cylindricity: Difference in the respective dimensions, a, b, and c, in the directions, A and B. 3) When the dimension exceeds the abovementioned limits or the cylinder is damaged, repair it by boring or honing, and use an oversize piston as required.

[Note] Measure the dimensions at a, b, and c in both A- and B-directions.

3-21

CYLINDER BLOCK

ENGINE BODY

(iii) Crank shaft The crank gear has been shrink-fit. When it is necessary to remove it, heat it to 180 to 200 C. 1) Check for cracks by a color check, or with a magnetic defectoscope depending on the case. 2) Measurement of bent 1/2 of reading of the dial gauge Limit: 02 mm (0.0008 in) or less

3) Measurement of the journal

When the oil clearance exceeds its limits, apply an undersize metal.

3-22

ENGINE BODY

CYLINDER BLOCK

4) Measurement of the crank pin

When the oil clearance exceeds the limits, use an undersize metal.

IMPORTANT 1) When thickness of the journal metal and crank pin metal is normal and the oil clearance is excessive, or when local eccentric wear is recognized, regrind the crank shaft and use an oversize metal. 2) When the back of the metal is rusty or coarse, apply blue color or minium, assemble with a specified torque and check for a contact. It is normal if there is a contact of 3/4 or more. If there is not a sufficient contact, a metal interference is not enough. Replace the metal.

(iii) Thrust metal

When the side cap exceeds the limits, use an oversize metal.

(iv) Piston 1) Eliminate the deposit on the exposition surface, outer circumference, and ring slots, not damaging the piston. If the ring slots or snap ring slots have burr, deburr them. If cracks are suspected, make a color check to examine.

3-23

CYLINDER BLOCK

ENGINE BODY

2) Measurement of the piston large diameter Measure at a position about 20 mm (0.8 in) from the lower end in the right-angled direction of the piston pin.

When the clearance from the cylinder exceeds the limit, use an oversize piston.

3) Measurement of the piston pin hole

(v) Piston rings

3-24

ENGINE BODY

CYLINDER BLOCK

Except the top ring, when measuring the ring groove width, measure the ring width and put the ring in its groove. Use a thickness gauge to measure the clearance between the groove and ring. Add the measured value to the ring width and assume the sum to be the groove width. To measure the clearance of the slit, push the ring into the cylinder by the head of the piston and measure it with the thickness gauge. Push it in as far as about 20 mm (0.8 in) from the lower end of the cylinder. (vi) Connecting rod 1) Care should be taken when the piston bushing, crank pin metal, or both rod larger and smaller ends have an extreme local contact. 2) Measurement of the piston pin

When the oil clearance exceeds its limit and you need to replace the bushing, use a replacement part, No. 12990023910. (vii) Tappet 1) Pay attention to a contact with the cam and push rod. If it has burr, eliminate it. 2) Measurement of the outer diameter

3-25

CYLINDER BLOCK

ENGINE BODY

(6) Honing 1) When satisfactory repair cannot be done only by honing, judging from the conditions of local eccentric wear, damage, and so on, perform boring first. 2) Prepare a flexible hone (code No. 129400-92430), electric drill, and honing liquid (mixed liquid of the engine oil and light oil). 3) Apply the honing liquid to the flexible hone. Running the electric drill at 300 to 1,200 rpm, insert it into the cylinder bore and move up and down the flexible hone to hone the cylinder bore at 30 to 40. IMPORTANT 1) Do not run the drill at a higher rpm because it will lead to a breakage. 2) Do not put in/out the flexible hone in its stopping state. 3) The cylinder will be damaged. Each grinding allowance should be about 1/1,000 mm (1/25,000 in).

(7) Replacement of Cam Shaft Bushing and Connecting Rod Bushing Replace them by using their respective special purpose tools. (8) Replacement of Oil Seal 1) Draw out the used oil seal. 2) Use an oil seal inserting tool to set a new oil seal. 3) Apply lithium grease.

3-26