Volvo EC55 Compact Excavator Service Repair Manual Instant Download

1
Service Information
Document Title Engine, description Function Group 200 Information Type Service Information Date 2015/3/29
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• Engine, description
• (YANMAR 4TNE94SM)
• The engine is a 4cycle, 4cylinder, direct
  injected, water cooled diesel engine.
• The engine produces powerful performance using
  direct injection type combustion chamber.

Figure 1 Top view, engine

1. Fuel injection nozzle
2. Gear case
3. Gear case cover
4. Starter motor
5. Exhaust manifold

1. Valve rocker cover
2. Cylinder head
3. Inlet manifold
4. Flywheel housing

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Figure 2 Flywheel side view, engine
Figure 3 Fuel injection side view, engine

1. Inlet manifold
2. Stop motor
3. Governor
4. Fuel injection pump
5. Fuel filter
6. Cooling water inlet
7. Cooling fan
8. Oil filler port

1. Fuel feed pump
2. Lubrication oil filter
3. Dipstick
4. Oil pan
5. Cooling water pump
6. Alternator
7. Cooling water outlet

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Figure 4 Fan side view , engine Engine
performance curve
Figure 5 Engine performance curve Engine
performance condition
Item
Condition
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Cooling fan f430 blower
Exhaust pressure 1000 mmAq
Air cleaner 6 inch
Radiator Installed
Alternator No charge
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Service Information
Document Title Engine, specifications Function Group 200 Information Type Service Information Date 2015/3/29
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Engine, specifications Specifications
Item Item Unit Specifications
Make Make Yanmar diesel
Model Model 4TNE94SM
Type Type Vertical, 4cylinder, water cooling, upright series, direct injection, diesel engine
Rated output Rated output PS (kW) / rpm 52 (38.2) / 2200
Maximum torque (Net) Maximum torque (Net) kgfm / rpm (lbfft / rpm) 18.5 0.5 /1600 (134 3 / 1600)
Number of cylinder Bore Stroke Number of cylinder Bore Stroke mm (in) 4 94 100 (3.7 3.9)
Total displacement Total displacement cc (cuin) 2776 (169)
Compression ratio Compression ratio 18 1
Low idle (Noload) Low idle (Noload) rpm 900 30
High idle (Noload) High idle (Noload) rpm 2450 30
Fuel consumption (rated) Fuel consumption (rated) g/PSh (g/kWh) 165 (221)
Fuel tank Capacity Liter (gal) 90 (23.4)
Fuel tank Filter 60
Firing order Firing order 1 3 4 2
Nozzle pressure Nozzle pressure kgf / cm2 (psi) 220 230 (3128 3270)
Valve clearance Inlet mm (in) 0.15 0.25 (0.006 0.010)
Valve clearance Exhaust mm (in) 0.15 0.25 (0.006 0.010)
Direction of rotation Direction of rotation Counterclockwise (viewed from flywheel)
Lubrication oil Lubrication oil SAE class CF
Oil pan capacity Maximum/Minimum Liter (gal) 9.7 (2.5) / 6.4 (1.7)
Weight of engine (dry ) Weight of engine (dry ) kg/lb 230/506
Starter motor Starter motor 12 V 2.3 kW
Alternator Alternator 12 V 40 A
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Service Information
Document Title Maintenance standards Function Group 200 Information Type Service Information Date 2015/3/29
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Maintenance standards Engine tuning Maintenance
standard, engine tuning
Inspection item Inspection item Unit Standard Limit
Gap at inlet/exhaust valve heads Gap at inlet/exhaust valve heads mm (in) 0.15 0.25 (0.006 0.010)
Vbelt tension 98N finger pressure (10 kgf/cm2) Used part mm (in) 10 15 (0.39 0.59)
Vbelt tension 98N finger pressure (10 kgf/cm2) New part mm (in) 7 9 (0.28 0.35)
Fuel injection pressure Fuel injection pressure kgf/cm2 (psi) 220 230 (3124 33266)
Fuel injection timing (FID, bTDC) Fuel injection timing (FID, bTDC) (degree) bTDC 10 12
No load rpm Maximum rpm 2450 30
No load rpm Minimum rpm 900 30
Compression at 250 rpm Compression at 250 rpm kgf/cm2 (psi) 35 1 (497 14.2)
Top clearance Top clearance mm (in) 0.737 0.869 (0.029 0.034)
Coolant capacity (engine only) Coolant capacity (engine only) Liter (gal) 4.2 (1.1)
Lubricating oil capacity (oil pan) High Liter (gal) 9.7 (2.5)
Lubricating oil capacity (oil pan) Low Liter (gal) 6.4 (1.7)
Lubricating oil pressure Maximum (in cold state) kgf/cm2 (psi) 6.0 (85)
Lubricating oil pressure At rated output kgf/cm2 (psi) 3.0 4.0 (43 57)
Lubricating oil pressure At idling kgf/cm2 (psi) 1.0 (14) or above
Oil pressure switch operating pressure Oil pressure switch operating pressure kgf/cm2 (psi) 0.5 0.1 (7 1)
Thermostat valve opening temperature Thermostat valve opening temperature C (F) 82.0 95.0 (full open) (180 203)

• FID Fuel Injection Degree
• bTDC before Top Dead Center
• Engine body
• Maintenance standard, cylinder head, unit mm
  (in)

Inspection item Inspection item Inspection item Standard Limit
Combustion surface distortion Combustion surface distortion Combustion surface distortion Maximum 0.05 (0.002) 0.15 (0.006)
Valve seat Valve sink Inlet 0.5 0.7(0.020 0.027) 1.0 (0.039)
Valve seat Valve sink Exhaust 0.6 0.8 (0.024 0.031) 1.1 (0.043)
Valve seat Seat width Intake 1.3 (0.051) 2.0 (0.079)
Valve seat Seat width Exhaust 2.2 (0.087) 3.0 (0.118)
Valve seat Seat angle (degree) Intake 120
Valve seat Seat angle (degree) Exhaust 90
Valve seat Seat correction angle (degree) Seat correction angle (degree) ?1 40, ?2 150
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Maintenance standard, inlet/exhaust valve guide,
unit mm (in)
Inspection item Inspection item Standard Limit
Inlet Valve stem outside diameter 7.965 7.980 (0.3136 0.3142) 7.915 (0.3116)
Inlet Guide inside diameter 8.015 8.030 (0.3156 0.361) 8.100 (0.3189)
Inlet Clearance 0.035 0.065 (0.0014 0.0026) 1.185 (0.0073)
Outlet Valve stem outside diameter 7.955 7.970 (0.3132 0.3138) 7.905 (0.3112)
Outlet Guide inside diameter 8.015 8.030 (0.3156 0.3161) 8.100 (0.3189)
Outlet Clearance 0.045 0.075 (0.0018 0.0029) 0.195 (0.0077)
Valve guide drivingin method Valve guide drivingin method Coldfitted
Valve guide protection from cylinder head Valve guide protection from cylinder head 14.7 15.0 (0.5789 0.591)
Replacement valve guide inside diameter after insert Replacement valve guide inside diameter after insert 8.015 8.030 (0.3156 0.3161)
Maintenance standard, valve spring, unit mm (in)
Inspection item Standard Limit
Free length 47.5 (1.87)
Inclination 1.0 (0.039)
Load for compressing uneven pitch portion by 1 mm 2.257 kgf (4.97 lb)
Maintenance standard, rocker arm and shaft, unit
mm (in)
Inspection item Standard Limit
Arm shaft hole diameter 18.50 18.52 (0.7283 0.7291) 18.57 (0.7311)
Shaft outside diameter 18.47 18.49 (0.7272 0.7279) 18.44 (0.7260)
Clearance 0.01 0.05 (0.0004 0.0020) 0.13 (0.005)
Maintenance standard, push rod, unit mm (in)
Inspection item Standard Limit
Bend 0.03 (0.0012)
Maintenance standard, cam shaft, unit mm (in)
Inspection item Inspection item Standard Limit
Side gap Side gap 0.05 0.20 (0.002 0.008) 0.30 (0.012)
Bending (1/2 the dial gauge reading) Bending (1/2 the dial gauge reading) 0.0 0.02 (0.00 0.0008) 0.05 (0.002)
Cam height Cam height 42.435 42.565 (1.6707 1.6758) 42.185 (1.6608)
Gear side Camshaft outside diameter 49.925 49.950 (1.9656 1.9665) 49.890 (1.9642)
Gear side Bushing inside diameter 49.990 50.055 (1.9681 1.9707) 50.130 (1.9736)
Gear side Clearance 0.040 0.130 (0.0016 0.0051) 0.240 (0.0094)
Intermediate Camshaft outside diameter 49.910 49.935 (1.9650 1.9659) 49.875 (1.9636)
Intermediate Block inside diameter 50.000 50.025 (1.9685 1.9695) 50.100 (1.9724)
Intermediate Clearance 0.065 0.115 (0.0026 0.0045) 0.225 (0.0089)
Flywheel Camshaft outside diameter 49.925 49.950 (1.9656 1.9665) 49.980 (1.9642)
Flywheel Block inside diameter 50.000 50.025 (1.9685 1.9695) 50.100 (1.9724)
Flywheel Clearance 0.050 0.100 (0.0020 0.0039) 0.210 (0.0083)
Maintenance standard, idle gear shaft and
bushing, unit mm (in)
Inspection item Standard Limit
Shaft outside diameter 49.950 49.975 (1.8091 1.9675) 45.900 (1.8071)
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Bushing inside diameter 46.000 46.025 (1.8110 1.8120) 46.075 (1.8140)
Clearance 0.025 0.075 (0.0010 0.0030) 0.175 (0.007)
Maintenance standard, backlash of each gear, unit
mm (in)
Inspection item Standard Limit
Crank gear, cam gear, idle gear, fuel injection pump, gear and PTO (power take-off) gear 0.08 0.14 (0.0031 0.0055) 0.16 (0.0063)
Lubricating oil pump gear 0.09 0.15 (0.0035 0.0059) 0.17 (0.0067)
Maintenance standard, cylinder block, unit mm
(in)
Inspection item Inspection item Inspection item Standard Limit
Cylinder bore Inner diameter 4TNE94 94.000 94.030 (3.7008 3.7020) 94.130 (3.7059)
Cylinder bore Inner diameter 4TNE98 98.000 98.030 (3.8583 3.8594) 98.130 (3.8634)
Cylinder bore Roundness Roundness 0.01 (0.0004) or less 0.03 (0.012)
Cylinder bore Cylindricity Cylindricity 0.01 (0.0004) or less 0.03 (0.012)
Maintenance standard, crank shaft, unit mm (in)
Inspection item Inspection item Inspection item Standard Limit
Bending (1/2 the dial gauge reading) Bending (1/2 the dial gauge reading) Bending (1/2 the dial gauge reading) 0.02 (0.0008)
Crank pin Pin outside diameter Pin outside diameter 57.952 57.962 (2.2816 2.2820) 57.902 (2.2796)
Crank pin Metal thickness 1.492 1.500 (0.0587 0.0591)
Crank pin Metal thickness US 0.25 1.617 1.625 (0.0637 0.0640)
Crank pin Clearance Clearance 0.038 0.074 (0.0015 0.0029) 0.150 (0.0059)
Crank journal Journal outside diameter Journal outside diameter 64.952 64.962 (2.5572 2.576) 64.902 (2.5552)
Crank journal Metal thickness 1.995 1.980 (0.0760 0.0780)
Crank journal Metal thickness US 0.25 2.125 2.130 (0.0872 0.0839)
Crank journal Clearance Clearance 0.038 0.074 (0.0015 0.0027) 0.150 (0.0059)
Maintenance standard, thrust bearing, unit mm
(in)
Inspection item Inspection item Standard Limit
Crankshaft side gap Crankshaft side gap 0.11 0.21(0.0043 0.0083)
Thrust bearing thickness Thrust bearing thickness 1.930 1.980(0.0760 0.0780) 1.850 (0.0728)
Oversize 0.25 2.055 2.105(0.0809 0.0829)
Maintenance standard, piston and ring, unit mm
(in)
Inspection item Inspection item Inspection item Standard Limit
Piston outside diameter Standard 93.945 93.955 (3.6986 3.6990) 93.900 (3.6969)
Piston outside diameter Standard Oversize 0.25 94.195 94.205 (3.7085 3.7089)
Piston outside diameter Standard Oversize 0.50 94.445 94.455 (3.7183 3.7187)
Clearance with cylinder bore Note) Measure at 22 mm above the piston bottom face in vertical direction to the piston pin. Clearance with cylinder bore Note) Measure at 22 mm above the piston bottom face in vertical direction to the piston pin. Clearance with cylinder bore Note) Measure at 22 mm above the piston bottom face in vertical direction to the piston pin. 0.050 0.080 (0.0020 0.0031) 0.120 (0.0047)
Piston pin Pin outside diameter Pin outside diameter 29.989 30.000 (1.1807 1.1811) 29.959 (1.1795)
Piston pin Hole inside diameter Hole inside diameter 30.000 30.009 (1.1811 1.1815) 30.039 (1.1826)
Piston pin Clearance Clearance 0.000 0.020 (0.000 0.0008) 0.080 (0.0031)
Top ring Ring groove width Ring groove width 2.040 2.060 (0.0803 0.0811)
Top ring Ring width Ring width 1.940 1.960 (0.0764 0.0772) 1.920 (0.0756)
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Side clearance 0.080 0.120 (0.0031 0.0047)
End clearance 0.250 0.450 (0.0098 0.0177) 0.540 (0.0213)
Second ring Ring groove width 2.080 2.095 (0.0819 0.0825) 2.195 (0.0864)
Second ring Ring width 1.970 1.990 (0.0776 0.0783) 1.950 (0.0768)
Second ring Side clearance 0.090 0.125 (0.0035 0.0049) 0.245 (0.0096)
Second ring End clearance 0.450 0.650 (0.0177 0.0256) 0.730 (0.0287)
Oil ring Ring groove width 3.015 3.030 (0.1187 0.1193) 3.130 (0.1232)
Oil ring Ring width 2.970 2.990 (0.1169 0.1177) 2.950 (0.1161)
Oil ring Side clearance 0.025 0.060 (0.0010 0.0024) 0.180 (0.0071)
Oil ring End clearance 0.250 0.450 (0.0098 0.0177) 0.550 (0.0217)
Maintenance standard, connecting rod, unit mm
(in)
Inspection item Inspection item Standard Limit
Thrust clearance Thrust clearance 93.945 93.955 (3.6986 3.6990) 93.900 (3.6969)
Small end of rod Bushing inside diameter 94.195 94.205 (3.7085 3.7089)
Small end of rod Pin outside diameter 94.445 94.455 (3.7183 3.7187)
Small end of rod Clearance 0.050 0.080 (0.0020 0.0031) 0.120 (0.0047)
Maintenance standard, tappet, unit mm (in)
Inspection item Standard Limit
Tappet stem outside diameter 11.975 11.990 (0.4715 0.4720) 11.955 (0.4707)
Tappet hole (block) inside diameter 12.000 12.018 (0.4724 0.4731) 12.038 (0.4739)
Clearance 0.010 0.043 (0.0004 0.0017) 0.083 (0.0033)
Maintenance standard, trochoid pump (lubrication
oil pump), unit mm (in)
Inspection item Inspection item Standard Limit
Clearance between outer rotor and gear case Clearance between outer rotor and gear case 0.100 0.155 (0.0039 0.0061) 0.25 (0.0098)
Side clearance between outer rotor and gear case Side clearance between outer rotor and gear case 0.05 0.10 (0.0020 0.0039) 0.15 (0.0059)
Rotor shaft and gear case Shaft outer diameter 12.955 12.970 (0.5100 0.5106) 12.945 (0.5096)
Rotor shaft and gear case Bearing inside diameter 12.980 13.020 (0.5110 0.5126) 13.050 (0.5138)
Rotor shaft and gear case Clearance 0.010 0.065 (0.0004 0.0026) 0.105 (0.0041)
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Service Information
Document Title Periodic maintenance chart Function Group 200 Information Type Service Information Date 2015/3/29
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Periodic maintenance chart
CAUTION
Make a periodic inspection plan according to the
state of use. Perform periodic inspection
accurately so that inspection will not be
skipped. If periodic inspection is neglected,
failures may occur or durability may be lost.
Inspection and maintenance after 1000 hours
require expertise and skill, so consult our
dealer or distributor. Periodic maintenance chart
Part Item Daily Every month or Every 50 hours Every 3 month or Every 200 hours Every 6 month or Every 400 hours Every year or Every 1000 hours
Fuel oil system Check the fuel level and refill O (before operation) O (before operation)
Fuel oil system Drain the fuel tank sediment O
Fuel oil system Clean the fuel filter O
Fuel oil system Replace the fuel filter element O
Fuel oil system Drain the water separator if applicable O
Fuel oil system Check for fuel oil leakage O (after operation) O (after operation)
Fuel oil system Check the injection condition of fuel injection nozzle. S
Fuel oil system Check the fuel injection timing S
Fuel oil system Check the fuel injection pump S
Lube oil system Check the lube oil level in the oil pan and refill O (before operation) O (before operation)
Lube oil system Replace the lube oil O (1st time) O (2nd time and thereafter)
Lube oil system Replace lube oil filter element O (1st time) O (2nd time and thereafter)
Lube oil system Check for lube oil leakage O (after operation) O (after operation)
Cooling system Check the coolant level and refill O (before operation) O (before operation)
Cooling system Clean the cooling system O
Cooling system Replace the coolant O
Cooling system Check for coolant leakage O (after operation) O (after operation)
Cooling system Check radiator fin for clogging O (before operation) O (before operation)
Cooling system Clean the radiator fin O
Cooling system Adjust the fan belt tension O (1st time) O (2nd time and thereafter)
Cooling system Check the fan belt O (before operation) O (before operation)
Air induction Check the air cleaner element O
Air induction Replace the air cleaner element O
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system
Electric system Check the battery electrolyte level and refill O (before operation) O (before operation)
Electric system Check warning lamps O (when the engine is started) O (when the engine is started)
Engine body Adjust the inlet and exhaust valve clearance S
CAUTION
Item marked "S" should be serviced by an
authorized Volvo Construction Equipment dealer,
unless the owner has proficient mechanical
ability and the proper tools.
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Service Information
Document Title Precautions Function Group 200 Information Type Service Information Date 2015/3/29
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• Precautions
• Make preparation as follows before starting
  engine inspection and service.
• Fix the engine on a horizontal base.

WARNING

• Be sure to fix the engine securely to prevent
  injury or damage to parts due to falling during
  the work.
• Remove the cooling water hose, fuel oil pipe,
  wire harness, control wires etc. connecting the
  driven machine and engine, and drain cooling
  water, lubricating oil and fuel.
• Clean soil, oil, dust, etc. from the engine by
  washing with solvent, air, steam, etc. Carefully
  operate so as not to let any foreign matter
  enter the engine.

WARNING

• Always wear glasses or other protectors when
  using compressed air or steam to prevent any
  foreign matter from getting in the eyes.
• Any part which is found defective as a result of
  inspection or any part whose measured value does
  not satisfy the standard or limit shall be
  replaced.
• Any part predicted to dissatisfy the standard or
  limit before the next service as estimated from
  the state of use should be replaced even when
  the measured value then satisfies the standard or
  limit.

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Service Information
Document Title Special tools Function Group 200 Information Type Service Information Date 2015/3/29
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Special tools Special tools Special tools
Tool name Applicable model and tool size Illustration
Valve guide tool (for removing valve guide) l1 20 mm l2 75 mm d1 7.5 mm d2 11 mm
Valve guide tool (for inserting valve guide) l1 15 mm l2 65 mm d1 14 mm d2 20 mm
Connecting rod bushing replacer (for removal/ installation of connecting rod bushing) l1 10 mm l2 100 mm d1 30 -0.3/-0.6 mm d2 20 -0.3/-0.6 mm
Valve spring compressor (for removal/installation of valve spring) Part number 12910092630
Stem seal inserter (for inserting stem seal) l1 19 mm l2 65 mm d1 16.5 mm d2 23 mm
Filter wrench (for removal/installation of lubrication oil filter) Available on the market
Camshaft bushing tool (for removing camshaft bushing) l1 18 mm l2 70 mm d1 50 -0.3/-0.6 mm d2 53-0.3/-0.6 mm
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Flexhone (for rehoning of cylinder liner) Applicable engine model 4TNE94 Part number 12940092430 Applicable bore 83 95
Piston insertion tool (for inserting piston) Part number 95550002476 The above piston insertion tool is applicable to 60 125 (mm) diameter piston
Piston ring replacer (for removal/ installation of piston ring) Available on the market
Measuring tools Measuring tools
Instrument name Application Illustration
Dial gauge Measurements of shaft bending, strain and gap of surface
Test indicator Measurements of narrow or deep portions that cannot be measured by dial gauge.
Magnetic stand For holding the dial gauge when measuring using a dial gauge, standing angles adjustable
Micrometer For measuring the outside diameter of crankshaft, pistons, piston pins, etc.
Cylinder gauge For measuring the side diameters of cylinder liners, rod metal, etc.
Callipers For measuring outside diameters, depth, thickness, etc.
Depth micrometer For measuring of valve sink
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Square For measuring valve spring inclination and straightness of parts
Vblock For measuring shaft bend
Torque wrench For tightening nuts and screws to the specified torque
Feeler gauge For measuring gaps between ring and ring groove, and shaft joints during assembly
Cap tester For checking radiator cap relief valve and cooling system leakage
Battery/coolant tester For checking concentration of antifreeze and specific gravity of the battery electrolyte
Nozzle tester For measuring injection spray pattern of fuel injection nozzle and injection pressure
Digital thermometer For measuring temperature
Speedometer (contact type) For measuring revolution by contacting the mortise in the revolving shaft
Speedometer (photoelectric type) For measuring revolution by sensing the reflecting mark on the outer periphery of the revolving shaft 1 Revolving shaft 2 Reflection mark
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Speedometer Measuring the revolution regardless of the center or periphery of the revolving object 1 High pressure pipe
Circuit tester For measuring resistance voltage and continuity of electrical circuits
Compression gauge kit For measuring compression pressure part number TOL97190080
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Service Information
Document Title Tightening torque Function Group 200 Information Type Service Information Date 2015/3/29
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Tightening torque Tightening torque, unit kgfm
(lbfft)
Item Item Nominal size Tighten torque
Cylinder head Thermostat case M8 2.3 2.9 (16.6 20.9)
Cylinder head Intake manifold M8 2.3 2.9 (16.6 20.9)
Cylinder head Exhaust manifold M8 2.3 2.9 (16.6 20.9)
Cylinder head Rocker cover M8 2.3 2.9 (16.6 20.9)
Cylinder head Valve arm support M10 4.5 5.5 (32.5 39.7)
Cylinder head Fuel injection nozzle M6 0.7 0.9 (5.1 6.5)
Cylinder head Engine hoisting hook M8 2.3 2.9 (16.6 20.9)
Cylinder block L Cylinder head M11 10.5 11.5 (75.8 83.0)
Cylinder block Gear case M8 2.3 2.9 (16.6 20.9)
Cylinder block Idle gear shaft M8 2.3 2.9 (16.6 20.9)
Cylinder block Camshaft thrust bearing M8 2.3 2.9 (16.6 20.9)
Cylinder block Oil pan M8 2.3 2.9 (16.6 20.9)
Cylinder block Mounting flange M10 M8 4.5 5.5 (32.5 39.7) 2.3 2.9 (16.6 20.9)
Cylinder block L Bearing cap M11 11.0 12.0 (79.4 86.6)
Cylinder block Lubricating oil suction pipe M8 2.3 2.9 (16.6 20.9)
Cylinder block Power take-off lubrication pipe M8 1.3 1.7 (9.4 12.3)
Cylinder block Fuel injection pump inlet pipe M8 1.3 1.7 (9.4 12.3)
Cylinder block Fuel injection pump rear stay M8 1.3 1.7 (9.4 12.3)
Gear case Cooling water pump M8 1.8 2.3 (13.0 16.6)
Gear case Alternator M10 4.5 5.5 (32.5 39.7)
Gear case Gear case cover M8 1.8 2.3 (13.0 16.6)
Gear case Fuel injection pump M10 3.5 4.5 (25.3 32.5)
Gear case Oil pan M8 1.8 2.3 (13.0 16.6)
Gear case Lubricating oil pump assembly M8 1.8 2.3 (13.0 16.6)
Gear case Fuel injection pump drive gear cover M8 1.8 2.3 (13.0 16.6)
Gear case Power take-off lubrication pipe M8 1.3 1.7 (9.4 12.3)
Crankshaft L Flywheel M14 19 21 (137 152)
Crankshaft L Crankshaft pully M14 11 13 (79.4 93.9)
Connecting rod L Rod screw M10 5.5 6.0 (39.7 43.3)
Mounting flange Starting motor M12 8.0 10.0 (57.8 72.2)
Main bearing cap Lubricating oil suction pipe stay M8 2.3 2.9 (16.6 20.9)
Intake manifold Fuel filter M10 3.5 4.5 (25.3 32.5)
Cooling water pump Cooling fan M8 1.8 2.3 (13.0 16.6)
Fuel injection pump Fuel injection pipe M12 2.0 2.5 (14.4 18.1)
Fuel injection pump Delivery valve holder 6.0 7.0 (43.3 50.5)
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Fuel injection nozzle Drive gear M14 8.5 9.5 (61.4 68.6)
Fuel injection nozzle Fuel pipe (inlet) M14 2.0 2.5 (14.4 18.1)
Fuel injection nozzle Fuel pipe (return) M14 2.0 2.5 (14.4 18.1)
Fuel injection nozzle Feed pump M6 0.8 0.96 (5.8 6.9)
Fuel injection nozzle Inlet pipe M10 1.0 1.3 (7.2 9.4)
Fuel injection nozzle Rear stay M10 4.5 5.5 (32.5 39.7)
Fuel injection nozzle Fuel injection pipe M12 2.0 2.5 (14.4 18.1)
Fuel injection nozzle Nozzle holder 4.0 4.5 (28.9 32.5)
Fuel feed pump Fuel pipe (inlet) M14 2.0 2.5 (14.4 18.1)
Fuel feed pump Fuel pipe (outlet) M14 2.0 2.5 (14.4 18.1)
Fuel feed pump Priming pump M16 4.0 4.5 (28.9 32.5)
Fuel feed pump Plug M26 8.0 9.0 (57.8 65.0)
Fuel filter Fuel pipe 2.5 3.5 (18.1 25.3)
Fuel filter Fuel return pipe M14 4.0 4.5 (28.9 32.5)
Alternator Bracket M8 2.3 2.9 (16.6 20.9)
NOTE! Marked Reinforced type screw, L
Lubrication oil applied tightening torque.
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Service Information
Document Title Troubleshooting chart Function Group 200 Information Type Service Information Date 2015/3/29
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Troubleshooting chart The following table
summarizes the general trouble symptoms and their
causes. If any trouble symptom occurs, take
corrective action before it develops into a
serious problem so as not to shorten the engine
service life.
Figure 1 Engine troubleshooting chart (1)
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Figure 2 Engine troubleshooting chart (2)
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Service Information
Document Title Adjusting operation Function Group 210 Information Type Service Information Date 2015/3/29
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• Adjusting operation
• Perform adjusting operation as follows after the
  maintenance job
• Supply the fuel oil, lubricating oil and coolant.

CAUTION

• Check the levels of the lubricating oil and
  coolant again after test running (for about 5
  minutes) and add as required.
• Start the engine, and carry out idling at a low
  revolution (from 700 to 900 rpm) for a few
  minutes.
• Run in the engine for about five minutes at the
  rated revolution (noload). Check for coolant,
  fuel or oil leaks and existence of abnormal
  vibration or noise. Also check the oil pressure,
  coolant temperature and exhaust gas color.
• Adjust the noload minimum and maximum
  revolutions according to the specifications.
• Long storage
• Observe the following instructions when the
  engine is to be stored for a long period without
  operation
• Always drain cooling water in a cold season or
  before a long storage. (This is unnecessary when
  antifreeze is used.)

CAUTION

• Negligence of water draining will cause the water
  remaining inside the engine to freeze and
  expanded, damaging the engine cooling system
  components.
• Coolant draining procedure
• Remove the radiator cap.
• Loosen the draining cock under the radiator to
  drain coolant.
• Loosen the drain cock on the side of the engine
  block to drain coolant.
• After draining coolant, tighten the radiator cap
  and drain plug and cocks.
• Remove all mud, dust, oil deposits and thoroughly
  clean the engine and attached components.
• Perform the nearest periodic inspection before
  the storage.
• Drain or fill the fuel oil fully to prevent
  condensation in the fuel tank.
• Disconnect the battery cable from the battery
  negative terminal.
• Cover the silencer, air cleaner and electric
  parts with PVC cover to prevent water and dust
  from depositing or entrance.
• Select a wellventilated location without
  moisture and dust for storage.
• Perform battery recharging once a month during
  storage to compensate for selfdischarge.

23
Service Information
Document Title Compression pressure inspection Function Group 210 Information Type Service Information Date 2015/3/29
Profile Profile Profile Profile

• Compression pressure inspection
• Compression pressure drop is one of major causes
  of increasing blowby gas (lubricating oil
  contamination or increased lubricating oil
  consumption as a resultant phenomenon) or
  starting failure. The compression pressure is
  affected by the following factors
• Degree of clearance between piston and cylinder
• Degree of clearance at intake/exhaust valve seat
• Gas leak from nozzle gasket or cylinder head
  gasket
• In other words, the pressure drops due to
  increased parts wear and reduced durability
  resulting from long use of the engine. A
  pressure drop may also be caused by scratched
  cylinder or piston by dust entrance from the
  dirty air cleaner element or worn or broken
  piston ring. Measure the compression pressure to
  diagnose presence of any abnormality in the
  engine.
• Compression pressure measurement method
• After warming up the engine remove the fuel
  injection nozzle from the cylinder to be
  measured.
• Before installing the compression gauge, cut off
  the fuel supply by the adjusting lever and check
  if fuel comes out while rotating the flywheel
  manually.
• Install the compression gage and compression gage
  adapter at the cylinder to be measured.

Figure 1 Measuring the compression
pressure 1. Compression gauge
CAUTION

• Do not forget to install a gasket at the tip end
  of the adapter.
• Install the compression gage and compression gage
  adapter at the cylinder to be measured.
• Crank the engine by the starting motor until the
  compression gage reading is stabilized.
• Standard compression pressure
• Standard 35 1 kgf/cm2 (497 14.2 psi)
• Limit 27 kgf/cm2 (383.4 psi)
• Difference among cylinders 2 3 kgf/cm2 (28.4
  42.6 psi)
• Engine speed and compression pressure

24

• Figure 2
• Engine speed and compression pressure
• P Compression pressure
• N Engine speed
• Check items
• When the measured compression pressure is below
  the limit value, inspect each part by referring
  to the table below.
• Compression pressure check items

Item Cause Corrective action
Air cleaner element Clogged element Broken element Defect at element seal portion Clean the element Replace the element
Valve clearance Excessive or no clearance Adjust the valve clearance
Valve timing Incorrect valve clearance Adjust the valve clearance
Cylinder head gasket Gas leak from gasket Replace gasket Retighten the cylinder head screws to the specified torque
Inlet/exhaust valve Valve seat Gas leak due to worn valve seat or foreign matter Sticking valve Lap the valve seat Replace the inlet/exhaust valve
Piston Piston ring Cylinder Gas leak due to scoring or wear Perform honing or boring/honing and use an oversized part
25
Service Information
Document Title Cylinder head, disassembly/assembly Function Group 2111 Information Type Service Information Date 2015/3/29
Profile Profile Profile Profile

• Cylinder head, disassembly/assembly
• Disassemble in the order of the numbers shown in
  the illustration. (service point)
• Remove the alternator assembly. (service point 1)
• Remove the fan, pulley and Vbelt.
• Remove the thermostat case. (service point 2)
• Remove the fuel filter and fuel oil piping.
  (service point 3)
• Remove the oil level gauge assembly.
• Remove the oil filter. (service point 4)
• Remove the fuel injection pipes. (service point
  5)
• Remove the intake manifold assembly.
• Remove the exhaust manifold assembly.
• Remove the rocker cover.
• Remove the rocker shaft assembly, push rods and
  valve caps. (service point 6)
• Remove the cylinder head assembly and head
  gasket. (service point 7)
• Remove the fuel injection valves and fuel return
  pipe. (service point 8)
• Remove the intake/exhaust valves, stem seals and
  valve springs. (service point 9)
• Remove the rocker arms from the rocker shaft.

CAUTION

• Do not tilt the alternator toward the cylinder
  block in a haste since it may damage the
  alternator or pinch a finger.
• Reassemble
• The belt deflection shall be between 10 15 mm
  (7 9 mm for a new belt).

• Figure 1 Vbelt tension
• Cooling water pump
• Crankshaft pulley
• Alternator

26

• Replace the belt with a new one if cracked, worn
  or damaged.
• Carefully prevent the belt from being smeared
  with oil or grease.

• Figure 2
• Tension adjustment
• Adjuster
• Alternator
• Adjust the Vbelt tension by inserting a bar
• Point 2
• Reassemble
• Check the thermostat function.
• Point 3
• Reassemble
• Replace the fuel filter element with a new one.
• Disassemble

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• Loosen the cylinder head screws in two steps in
  the illustrated order.

• Figure 3
• Head screw disassembly order
• 1. Fan side
• Place the cylinder head assembly on card board to
  prevent any damage to the combustion face.
• Reassemble
• Replace the head gasket with a new one.
• Uniformly install the head screws manually after
  applying oil on the threads and seat portions.

• Figure 4
• Head screw tightening order
• 1. Fan side
• They shall be tightened in two steps in the
  reverse of the order for disassembly. Tightening
  torque
• First step 5 6 kgfm (36.1 43.3 lbfft)
• Second step 10.5 11.5 kgfm (75.8 83.0
  lbfft)
• Point 8
• Disassemble
• Carefully remove the fuel injection valve so as
  not to leave the tip end protector from being
  left inside the cylinder.
• Reassemble
• Replace the fuel injection valve protector with a
  new one.

• Figure 5
• Valve spring compressor
• Keep each removed inlet/exhaust valve after
  attaching a tag showing the corresponding
  cylinder number.
• If cotter burr is seen at the shaft of each
  inlet/exhaust valve stem, remove it with an oil
  stone and extract the valve from the cylinder
  head.
• Reassemble

29
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