TOYOTA Forklift Engine (11Z, 12Z, 13Z and 14Z Model) Service Repair Manual Instant Download

1
FOREWORD
This repair manual describes the description,
construction, trouble shooting, removal,
disassembly, inspection and repair, assembly and
installation of the various components of the
IZ, and model engine equipped on the To yota
Forklift Trucks.
Este manual de reparaciones abarca la desmontaje,
componentes de montacargas Toyota.
de montaje e instalacion de y equipados en
y 1
You are encouraged to become thoroughly familiar
with this manual so as to make the most of the
outstanding performance and durability features
of these vehicles mounted with the I engine
and to perform the proper servicing to maintain
them in tip-top running condition.
Le char maximo
que se familiarice completamente con este manual
para caracteristicas de rendimiento y durabilidad
sobresalientes de
estos vehiculos que montado el motor I 132
o para realizar el servicio adecuado, con el fin
de mantenerlos en condiciones de mas. Este
manual de reparaciones contiene la relativa
a modelos
This manual contains the information on the
models manufactured in the follow- ing
periods December 1990 September 1996 July
1996 For any changes thereafter, you are asked to
consult the Parts Service News. Toyota reserves
the right to make changes in specifications and
descriptions without incurring any obligation
and without previous notice.
cados en Z, 132
periodos siguientes Diciembre de 1990
Septiembre de 1996 Julio de 1996
En cuanto a cambios posteriores,
consulte Noticias de Repuestos y Servicio. Toyota
se reserva el derecho a realizar cambios
en especificaciones y en las descripciones, sin
incurrir en ninguna sin previo aviso.
TOYOTA Material Handling Company A Division of
TOYOTA INDUSTRIES CORPORATION
TOYOTA Material Handling Company A of TOYOTA
2
DE
SECTION INDEX
3
GENERALIDADES
GENERAL
Pagina 0-2
Page ENGINE EXTERIOR VIEWS ......................
. 0-2 SPECIFICATIONS .............................
... 0-6 ABBREVIATIONS ............................
.... 0-8 FOR OPERATION ...........................
0-8 STANDARD BOLT NUT TIGHTENING TORQUE 0-9
VISTAS
DEL MOTOR
................................................
0-8
........ 0-8
EL
PAR DE DE LOS Y TUERCAS ESTANDAR
0-9
4
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6
0-2
VISTAS (Motor
DEL MOTOR
ENGINE EXTERIOR VIEWS (11 engine)
I
KAL28-24.26
Engine Exterior Views
Vistas exteriores del motor 11 Z
7
I 122 Engine Exterior Views
I
motor
Vistas
8
0-4
(Motor 132)
32 engine)
132
Exterior
Vistas exteriores del motor 132
9
engine)
(Motor
I I Engine Exterior Views
del motor 142
Vistas
10
SPECIFICATIONS (11Z, 132 engine)
(Motor 1 1 Z,
Engine model
1
Diesel

In-line 6 cylinders arrangement
No of cylinders and arrangement
Fuel Injection sequence Fuel Injection sequence Fuel Injection sequence Fuel Injection sequence Fuel Injection sequence 1-4-2-6-3-5
Starting system Starting system Starting system Starting system Starting system
Combustion chamber Combustion chamber type type type Direct
Valve mechanism Overhead valve
Bore stroke 960 1020 1020
78 4 021 x 4
Total displacement Total displacement cc (cub in) 4429 12671 4616 12811
Compression ratio Compression ratio Compression ratio Compression ratio Compression ratio 18 5
Compression pressure Compression pressure Compression pressure Compression pressure Compression pressure 33 14691 260
Engine horsepower Engine horsepower Engine horsepower Engine horsepower Engine horsepower 85,2200
torque torque torque torque torque 29 1600
fuel fuel at full load at full load g PS 165 112001
dimensions dimensions x width x height) mm 875 523 743 875 550 760
Engine service weight
330
325
Number of piston rings Compression 2
Number of piston rings ring 1
Cvlinder liner
Drv
Intake valve timing
Open
BTDC
Close
ABDC
Exhaust valve timing
Open
52 " BBDC
ATDC
Valve clearance
engine1
mm
Intake
0 20 0081
Exhaust
0 36 0141
speed
See the manual for each model See the repair
manual for each model
No-load maximum governed speed Positive
crankcase type
Closed
11
(Motor 122,
22,
engine)
Engine model 122
Diesel
Cycle 4
No of cylinders and arrangement 6 cylinders longitudinal arrangement
Fuel injection sequence 1-4-2-6-3-5
Starting system Self-starting
Combustion chamber type Direct injection
Valve mechanism valve drive Valve mechanism valve drive
Bore x stroke
Total displacement cc (cub-in) 4994 I3011 5204 13171
Compression Compression Compression 18 6 18 5
Compression pressure rpm 33 14691 260
Engine horsepower PS rpm 95'2200
Maximum torque Maximum torque Maximum torque 35 1600
Minimum fuel consumption at full load Minimum fuel consumption at full load Minimum fuel consumption at full load
Engine width 91 1 566 847 913 602 832
8 x 22 3 x 33 135 9 23 7 32 81
Engine service weight kg 332 327
Number of piston rings Compression ring Compression ring 2
Number of piston rings ring ring 1
Cylinder liner type Cylinder liner type Cylinder liner type
Intake valve timing Intake valve timing Open BTDC
Intake valve timing Intake valve timing Close BTDC
Exhaust valve timing Exhaust valve timing Open BTDC
Exhaust valve timing Exhaust valve timing Close ATDC
Valve clearance engine) mm Valve clearance engine) mm 0 20
Valve clearance engine) mm Valve clearance engine) mm Exhaust 0 36 I0 0141
speed speed speed See the repair manual for each model See the repair manual for each model
No-load maximum governed speed No-load maximum governed speed No-load maximum governed speed See the repair manual for each model See the repair manual for each model
Positive crankcase ventilation type Positive crankcase ventilation type Positive crankcase ventilation type Closed
12
ABBREVIATIONS
Abreviatura Abreviatura
APMI Antes muerto inferior PMI muerto muerto superior Derecha por Herrarnienta especial de Carrera Standard Par de
APMS (BTDC) Antes superior PMS (TDC) muerto muerto superior Derecha por Herrarnienta especial de Carrera Standard Par de
Despues muerto inferior H muerto muerto superior Derecha por Herrarnienta especial de Carrera Standard Par de
(ATDC) EX Despues rnuerto superior Escape rpm SST muerto muerto superior Derecha por Herrarnienta especial de Carrera Standard Par de
st muerto muerto superior Derecha por Herrarnienta especial de Carrera Standard Par de
STD muerto muerto superior Derecha por Herrarnienta especial de Carrera Standard Par de
M P multiple T muerto muerto superior Derecha por Herrarnienta especial de Carrera Standard Par de
0 Sobretamaho U muerto muerto superior Derecha por Herrarnienta especial de Carrera Standard Par de
OPT (OPC muerto muerto superior Derecha por Herrarnienta especial de Carrera Standard Par de
Abbreviation
Meaning
Meaning
Assembly OPT option ighthand Revolutions per minute Special service tool Standard Sub-assembly Tightening torque Top dead center Undersize option ighthand Revolutions per minute Special service tool Standard Sub-assembly Tightening torque Top dead center Undersize
After bottom dead center H option ighthand Revolutions per minute Special service tool Standard Sub-assembly Tightening torque Top dead center Undersize option ighthand Revolutions per minute Special service tool Standard Sub-assembly Tightening torque Top dead center Undersize
After top dead center option ighthand Revolutions per minute Special service tool Standard Sub-assembly Tightening torque Top dead center Undersize option ighthand Revolutions per minute Special service tool Standard Sub-assembly Tightening torque Top dead center Undersize
Before bottom dead center SST option ighthand Revolutions per minute Special service tool Standard Sub-assembly Tightening torque Top dead center Undersize option ighthand Revolutions per minute Special service tool Standard Sub-assembly Tightening torque Top dead center Undersize
Before top dead center STD option ighthand Revolutions per minute Special service tool Standard Sub-assembly Tightening torque Top dead center Undersize option ighthand Revolutions per minute Special service tool Standard Sub-assembly Tightening torque Top dead center Undersize
Bottom dead center SUB-ASSY option ighthand Revolutions per minute Special service tool Standard Sub-assembly Tightening torque Top dead center Undersize option ighthand Revolutions per minute Special service tool Standard Sub-assembly Tightening torque Top dead center Undersize
Exhaust T option ighthand Revolutions per minute Special service tool Standard Sub-assembly Tightening torque Top dead center Undersize option ighthand Revolutions per minute Special service tool Standard Sub-assembly Tightening torque Top dead center Undersize
Intake TDC option ighthand Revolutions per minute Special service tool Standard Sub-assembly Tightening torque Top dead center Undersize option ighthand Revolutions per minute Special service tool Standard Sub-assembly Tightening torque Top dead center Undersize
UIS option ighthand Revolutions per minute Special service tool Standard Sub-assembly Tightening torque Top dead center Undersize option ighthand Revolutions per minute Special service tool Standard Sub-assembly Tightening torque Top dead center Undersize
UIS
EL ANTES DEL DESMONTAJE
FOR OPERATION PREPARATION BEFORE DISASSEMBLY
Prepare a Cuando desmonte un el
mecanicas, instrumentos de
y SST necesarias antes de
necessary mechanic tools, measuring tools
and before starting operation. When disassembling
a complex unit, punch or draw matching marks at
places not affecting functions to make reassembly
easy. When repairing the electrical system,
always disconnect the battery nega- tive
terminal before starting operation.
de acoplamiento en comience a
o ponga el remontaje Cuando terminal negativo de
la
que
para
el
despues de desconectar el cable
INSPECTION DURING DISASSEMBLY
DURANTE EL DESMONTAJE
Cada vez que saque parte. el estado de defectos
de superficie de parte
la deformacon. el deteroro. la
Whenever a part removed, inspect the installation
state, deformation, damage, roughening state and
surface defects of the part.
RDENADA DE LAS PARTES DESMONTADAS Las partes
desmontadas deberan colocarse en partes que va a
volver a va a
NEAT ARRANGEMENT OF DISASSEMBLED PARTS
de
Arrange removed parts neatly and in good order.
to be reolaced.
the parts to be reused from the parts to
DE LAS PARTES DESMONTADAS
WASHING OF DISASSEMBLED PARTS
Las partes que va a volver a usar deberan
y
Thoroughly clean and wash the parts to be reused
Y necesaro. y con cuidado
INSPECTION AND MEASUREMENT
partes que va a volver a usar
required, carefully inspect and measure the parts
to be reused
MONTAJE Monte oartes que no tengan defectos en
el (valores del par de apretamento y standard)
ASSEMBLY Assemble parts correct sequence while
observing the torque and standard values).
observa
standards especificados
standards (tightening
Use partes Toyota para el recambio Use empaquetadu
ras juntas de empaquetadura y pasadores de
chaveta nuevos para el
Always use genuine Toyota parts for
replacement. Always use new gaskets and cotter
pins for reassembly,
con empaquetadura de necesarios de juntas
deslizamento y de aceite con aceite o con grasa
especificados
de contacto de
de de aceite antes
oil or grease on
sealant at necessary places on gaskets, oil on
sliding contact surfaces, specified contact
surfaces, and MP grease on oil seal before
reassembly. ADJUSTMENTS AND OPERATION CHECK
y con grasa MP bordes de juntas
DEL un multimetro para
AJUSTES Y Use medidores contadores
especificados
a
valores standard de
Use gauges and a and make adjustments to
the service standard values.
13
STANDARD BOLT NUT TIGHTENING TORQUE
DE LOS
Y TUERCAS ESTANDAR
PAR DE Nose el par de apretamento de
Standard bolt and nut tightening torques are not
indicated. Judge the standard tightening torque
as shown below.
tuercas estandar
Find out the straight type of bolt from the list
below and then find the bolt tightening torque
from the table.
Juzgue el par de apretamento estandar de la
1.
el de en a luego encuentre el par de del 2 El
par de apretamlento de a tuerca se puede DE DEL
1
2. The nut tightening torque can be judged from
the mating bolt type.
en la tabla
BOLT STRENGTH TYPE IDENTIFICATION
METHOD 1. by bolt shape 2. Identification by part
el
DE
DE LOS
Shape and class Class head bolt head Parts No.
1
segun la
2
segun el numero de la parte
Hexagon , head bolt
de cabeza hexagonal
No. de la parte
I
4 1-40625
T
Diametro
flange
bolt
,
Welded bolt
No. de la parte
4 T
Length
9 2 1 3 2 - 4 0 6 1 4
Class
No
4 T
Clase
Grooved
Diametro
6 T
14
0-10
STANDARD BOLT TIGHTENING TORQUE
PAR DE
DEL
STANDARD
Specified
Class
1
kg -cm 60
kg -cm 55
5.9
1.0 1.25
8
I 4
260 25 290 2 2 8
480 47 540 39 5 3
,
,
5
850
8 3
760
75
5 5 8 3
-
-
l o
1.5
6
' 65 I 6.4
1.25 I 2 I
i.25 330 24 32
1.25 600 43 5 9
I
I
14 16 1.5 1.5 930 1400 91 137
6 1.0 80 7.8 90 8.8
8 195 19 215 21
6 T 10 1.25 400 39 440 43
12 1.25 730 72 810 79
14 1.5 1250 123
6 110 11 120 12
8 1.25 260 25 290 28
7 T 10 12 1.25 530 970 52 95 590 1050 58 103
14 1.5 1500 147 1700 167
16 1.5 2300 226
5
1.5
I
930
91 137
67
I 4
8.8
6
I 4
730 ,
810 , 59 , 1250 90
!
-
-
6 8
8
260 530 970
28 58
38 70
43 76 123
,
95
MENTE
Y TUERCAS
1700
CON UN AGENTE DE
I 6
1.5
2300
226
EN LAS PARTES ROSCADAS)
1 No guno de (1 ) Despues de haber
en
PRECOATED BOLTS (BOLTS AND
NUTS COATED SEAL LOCK
reves
AGENT ON THREADED PARTS)

• Do not use precoated bolts as they are in the
  following cases,
• After precoated bolts are removed.
• When precoated bolts are moved
  (loosened or tightened) in tightening
• torque check, etc.
• Note
• For torque check, use the lower limit of the
  allowable range. If a bolt moves, retighten
  it according to the procedure below.
• 2. Procedure for reuse of precoated bolts
  Wash the bolt and bolt hole. (Wash the bolt hole
  also when the bolt
• Thoroughly dry the washed bolt and bolt hole by
  blowing.
• Coat the seal lock agent on the bolt threads.

(2) Cuando se han dos (aflojado o apretado) en la
con de apretamento, etc Nota Para comprobar el
par, use el del alcance se
Seal lock agent
un
a apretar de acuerdo con el
dimiento
84460
agent
2
para volver a usar
(1 Lave el el
el
(Lave cuando se
del el el
84460
)
(2) Seque
el
con
(3) Cubra con el cado roscas de
de roscas
15
ENGINE TUNE-UP
PUESTA A
DEL MOTOR
Pagina PARTES A PREPARAR ........................
................ 1-2
Page
ITEMS TO BE PREPARED
1-3
COOLANT INSPECTION
DEL
DE MOTOR
1-3
ENGINE OIL INSPECTION
INSPECCION DEL
DE LA
BATTERY ELECTROLYTE INSPECTION
1-3
1-3 DEL DE 1-3 DE ..............................
........ 1-4
1-3
AIR CLEANER INSPECTION AND CLEANING CLOGGING
WARNING INSPECTION "V" BELT INSPECTION AND
ADJUSTMENT
Y
INSPECCION DEL DE
1-4
Y AJUSTE DE LA CORREA EN "V" 1-4 DEL CALENTADOR
DE 1-5 DE LA DE 1-5
INTAKE HEATER INSPECTION
1-5
INJECTION NOZZLE INSPECTION
INJECTION TIMING INSPECTION AND ADJUSTMENT
INSPECCION Y AJUSTE DE LA
............................................. 1-6
DE
VALVE CLEARANCE INSPECTION AND ADJUSTMENT
INSPECCION Y AJUSTE DE LA HOLGURA DE LAS VALVULAS
.......................................
1 -8
COMPRESSION PRESSURE INSPECTION
1-10
INSPECCION DE LA DE ..............................
................
IDLE SPEED INSPECTION AND ADJUSTMENT NO-LOAD GOVE
RNED SPEED INSPECTION AND ADJUSTMENT
1-10
1-12
INSPECCION Y AJUSTE DE LA VELOCIDAD
.................................
1-12
DE EN 1-12
INSPECCION Y AJUSTE DE LA VELOCIDAD REGULADA
MAXIMA SIN CARGA .................... 1-12
16
PARTES A PREPARAR
ITEMS TO BE PREPARED

SST 09240-32880-7 1 For injection timing Tool, plunger stroke adjustment SST 09240-32880-7 1 For injection timing Tool, plunger stroke adjustment
Measuring instruments and tools Measuring instruments and tools
tester For checking current in each
Belt tension gauge For V belt tension measurement
Straightedge For V bet tension measurement
tester For injection nozzle
SST SST SST
SST 09240 32880 7i Para el ajuste de a de la bornba de in
de de
Prooaaor de c Prooaaor de c Para cornprobar a de corriente de parte
a tension ia correa a tension ia correa Para la tension de la correa en V
de trazar de trazar Para la de la correa en V
Para la de la de
de esfera de esfera Para el de la holgura de la
Calibrador de espesor - Calibrador de espesor - Para el de la holgura de la
Llave de torsion (1 0 100 kgcm Llave de torsion (1 0 100 kgcm Para la de la cubierta de a culata
Cornpresornetro Cornpresornetro Para a de la compresion
I
gauge
For valve clearance adjustment
For valve clearance adjustment
Torque wrench (10 - 100
For head cover installation
gauge
For compression measurement
La SST 09240-32880-71 se puede preparar
maquinando parcialmente la SST 09275-76002-71
5401 (No de la parte de Toyotai dimensones de
rndquinado son del de la
09275-
SST 09240-32880-71 can be prepared by partial
part No The machining are as shown below. SST
Maching Drawing
of SST 09275-76002-71
central del del
del
de la SST
Maching Drawing
17
INSPECCION DEL RANTE Vea la 4
COOLANT INSPECTION See Section 4
Standard The coolant level in the radiator
reserve tank shall be between the FULL and LOW
lines. The LLC concentration shall be 30 (50
in frigid zone) or more, and the coolant shall
not be contaminated with oil, etc.
El nivel del serva del radiador
del estar entre
de
"FULL" (Ileno) "LOW" La del LLC
ser del 30
(50 en zonas frias) o mas, y el
con aceite, etc.
no estar INSPECCION DEL MOTOR Standard El
nivel de aceite cas "F" "L" del
the Coolant
Inspecting the Coolant
ENGINE OIL INSPECTION Standard The oil level
shall be between F and L on the dipstick. The
oil shall not be heavily con- taminated, and the
viscosity shall be proper. Neither coolant nor
light oil shall exist in the engine oil.
DE
estar entre de El aceite
contaminado su ser adecuada. No deberan
no estar
mezclarse el aceite de motor con aceite ligero
ni refrigerante Engine
INSPECCION DEL ELECTRO- DE LA
BATTERY ELECTROLYTE INSPECTION Standard The
electrolyte level shall be between
Standard El nivel del marca de nivel superior
estar entre la y la de nivel
UPPER LEVEL and LOWER LEVEL. The shall be 1.28 (at
inferior La especifica ser de (a 20C).
Caution If the battery fluid is insufficient,
add distill- ed water.
Precaucion Si el fluido de la agua destilada.
es insuficiente,
KA L33-2
Battery Electrolyte Level
Battery Electrolyte Level
DEL
INSPECCION Y DE
AIR CLEANER INSPECTION AND CLEANING 1. Air
cleaner element inspection and cleaning
de
Check the cleaner element for damage, and Use
compressed to clean the cleaner element.
de are
) Compruebe el por esta (2) Use filtro de
o
para
el
Caution The air pressure shall be 7 or less.
(99 psi)
La presion de psi) o
ser de 7 kg/cm2 (99
Air Cleaner Element
Cleaner Element
18
DE LA CAJA DEL
Air cleaner case cleaning
DE
Clean the inner and outer surface of the
with cloth.
as superfic es interior con un trapo
1
exterior de
CLOGGING WARNING SYSTEM INSPECTION 1 Inspection
on vehicle Check the air cleaner warning lamp on
DEL
DE
AIR CLEANER
AIR CLEANER
DE 1 nspeccion en el
de se
Compruebe que la panel el nterrupto de la
de cuando coloca en
the Instrument panel comes on when the key
set to ON, and that when the engine starts
goes off
Warning Lamp
LAOS5151
Warning Lamp
LAOS5151
I
que se aoaga cuando se pone en el motor
I I
inspection Check current conduction when a
negative pressure applied to the vacuum switch.
2.
2 nspeccion individual Compruebe la cuando
se una rruotor de vacio
de a corriente negativa
Standard 132 655 rnm Aq or more 122, 142 762
mrn Aq or more
Estandar 112, 132 655 mm Aq o mas 122, 142
762 mm Aq o mas
I
Inspecting the Vacuum
the Vacuum
"V" BELT INSPECTION AND ADJUSTMENT
1. " V" belt inspection Check that the belt
correctly installed. If squealing or slipping
exists, check the belt surface in contact with
the pulley for wear, damage and scratches, and
the pulley for surface defects. Apply SST (belt
tension gauge) to the center of the belt between
the and water pump, and measure the " V" belt
tension SST 0921 -71 0921 6-00020) Standard "V"
belt tension
Y AJUSTE DE LA CORREA EN "V" 1 Inspeccon de a
correa en "V" Compruebe que la correa esta mente
hay o pruebe la de la correa en con-
(2)
Inspecting the Belt Tension
tacto con la polea por s nay desgaste.
the Belt
KAL29-4
o rayaduras. la defectos en su Aplique la SST
tiene
de tension de
correas) de la correa entre el alternador la
bornba de agua. y rnida a de la correa en
0921 0921 Tension standard de la correa en "V".
inspection
Correa en " V" nueva kg. Correa en " V" nueva kg. Z, 132 Z, 132 38 - 62 (84 -
Correa en " V" nueva kg. Correa en " V" nueva kg. 142 142
Para la general kg. 1 132 20- 40 20- 40
Para la general kg. 142 142 33 - 57 33 - 57
Gauge
1669
Tension Gauge
19
When a tension gauge not available, push the
center of the belt between the alternator and
water pump with a force of 10 kg and
measure the flexure.
(4) Cuando no haya un empuje el a correa
entre el alternador la bornba de agua con una
fuerza de 10 kg (22 lb) y a
Pressure 10
pressure
standard de la correa en
Standard " V" belt flexure
Para la
general con 10 kg
For general inspection 8 - 13
(pushed with kg) (in) (0.31 0.51)
8 - 13
de la correa en "V" (1) Afloje el de ajuste
A y el de
2
" V" belt adjustment
Loosen bolt A and fixing bolt B.
668
Inspecting the
Belt Flexure
Inspecting the
Belt Flexure
de 300 - 400 mm (1 2 - 16") de
(2)
la correa una palanca

• Tension the belt by applying a 300
• 400 mm (12 16 in) long lever to the alternator,
  and tighten adjusting bolt A.
• Tighten fixing bolt B.

alternador y el de ajuste A

1. el de
2. Compruebe la tension de la correa (tension

(4) Check the belt tension or flexure).
o
DEL DOR DE Desconecte cables
INTAKE HEATER INSPECTION
1. Disconnect the cables from the intake
heater.
calentador de
2. Check of the intake heater.
2
Compruebe la
calentador de
Check continuity between terminal
Adjusting the Fan Belt Tension
Adjusting the Fan Belt Tension
and -
of the intake heater
(1) Compruebe la y el
terminal calentador de
INJECTION NOZZLE INSPECTION
1
nozzle pressure (1) Remove the injection
nozzle. Install the nozzle to the nozzle tester.
Operate the tester quickly to cause injection a
few times to remove the carbon at the injection
holes. (3) Slowly lower the tester lever to
increase the pressure and read the pressure im-
mediately before the indication drops
suddenly. Standard injection pressure spring
type)
DE LA
DE 1

• de la boquilla de inyeccion
• Saque a boquilla de
• la

de
de la
en el
de
Accione rapidarnente la palanca del dor para
que haya inyeccion veces
Inspecting the
Heater
de sacar el carbon que haya en de inyeccion
con el
(3) Baje lentamente la palanca del para aumentar
la presion y lea la presion inrnediatarnente
antes de que descienda repentinamente la de
inyeccion standard 180 kg/cm2 (2560 de 1 12Z de
2 180 5 kg/cm2 7650 490 de 1 kglcm2 9610
70 psi) 490 kPal
180 5 kgicrn2 12560 7650 122 type) 200 kgicrn2
12840
psi) kPal
70 psi) 490 kPal
180 5 kgicm 2 12560 7650 5 (3270
L Injection Pressure
142 230
70 490 kPal
Injection Pressure
180 5 (17650 490 142 230 5 kglcrn2 (22560 490
20
1-6
Y AJUSTE DE LA REGULACION DE DE LA REGULACION DE
INJECTION TIMING INSPEC- TION AND
ADJUSTMENT INJECTION TIMING INSPECTION
Place the No 1 cylinder at the TDC. Align the
crank pulley TDC notch mark with the timing
pointer
Coloque el No 1 en el PMS
(1 ) Alinee a marca de la con a
PMS de la de
o
KA
the TDC
the TDC
(2) Saque ae a
de de
Remove the fuel pump
No. 1 on
en el
No 1
KAL29.13
the fuel pipe No. 1
the fuel
ei que de bomba oe
Remove the bolt Injection
the rear end of the
en el extremo
Removing the Bolt
Removing the Bolt
Set the SST and dial gauge to the bolt hole SST
09240-32880-71
la
de esfera en
el SST
71
Caution Apply the tip end of the dial gauge to a
flat surface. Prevent foreign matter or dust
entrance during operation.
Aplique el extremo de la punta del de esfera a
una superficie Evite que entren materias o polvo
durante esta operacion.
the
Timing
Inspecting the Injection Timing
21
While observing the dial gauge, rotate the
crankshaft in the reverse direction
(5)
el calibrador de esfera. en n -
gire el arbol del versa superior a 25' a
by a crank angle over from the TDC of
cylinder No. 1. When the dial gauge pointer
deflection stops, set the dial gauge to Slowly
rotate the crankshaft in the forward direction
until cylinder No. 1 comes to the TDC. Read the
dial gauge indication there the reading within
the standard, the setting normal. not, adjustment
necessary.
un
del
de el
No 1 Cuando se
la
caibrador de esfera. a cero el arbol
a
(6) Gire
en
hasta que el el PMS caibrador de esfera
de
No 1 Lea la
la lectura esta dentro de a standard, el es
normal no, es
Rotating the Crankshaft in Reverse Direction
the Crankshaft in Reverse Direction
1
tar
I
112, 122 1.56 - 1.62 rnm
Standard
(0.06 14 - 0.0638 in)
Standard
112,122
(0,0614 - 0,0638")
(0.0535 - 0.0559 in)
132 1.36 1.42 rnm
132 1.36 - rnrn.
(0,0535 - 0,0559")
(0.0654 - 0.0677 in) adjustment
142 1.66 1.72 rnm
142 -
(0,0654 - 0,0677")
2. I
Check alignment of the degree of offset
2
de a de on
between mark on the gear case and mark (A) on
the injection pump body. (To use as in
making (2) Loosen the joints of piping with the
injection pump Fuel inlet pipe pipe 3 Overflow
pipe
a plazamiento entre de (A) cuerpo (Para
de
marca (B)
Match Marks
KAL31 - 14
Checking Match Marks
KAL31 - 14
y la
a oomba de
el
)
de as con la bornba de inyeccion rigda de
adrnision de bustible rigda de nyeccion de rebose
(2)
Loosening the
Loosening the Piping
KAL30 - 6
Loosen injection pump set nut and the bracket
underneath.
la tuerca de de la bornba de nyeccion soporte
inferior
(3)
the Set Nut
Loosening the Set Nut
22
Move the pump body for adjustment the measured
value in step 6 of in- jection timing
inspection below the lower limit, move the pump
direction A the measured value in step 6 of in-
jection timing inspection exceeds the upper
limit move the pump in
cuerpo de a nomba para el
ajuste
el valor en la nspeccion de la
6 de la de n -
yeccion esta por debajo
ferior, A el valor nspeccion de la
bomba en la
de a de superior, B
en la
el mueva la bomba en (5) Apriete la tuerca de
Tighten the injection pump set nut and the
bracket underneath, and inspect the injection
timing again. Tighten the loosened pipe joints.
de a bomba
Adjusting the Injection
the Injection
de y el soporte inferior. e
de nyeccon de tuberias
core de nuevo a
After the timing inspection and adjustment,
remove the SST and dial gauge and install the
bolt at the rear end of the pump.
(6)
que se nabian (7) Despues de la
del de a
de nyeccon quite la SST el de esfera
e el en el extremo trasero de la bomba
T 100 160 kg-cm (7.23 11.6 15.7 Caution Use
a new copper washer. Carefully prevent dust
and foreign matter entrance.
T 1.6 kgm. Ib-pie)
Precauciones o Use una arandela
de nueva. 3 cuidadosamente que entre el polvo o
materlas
VALVE CLEARANCE INSPECTION AND ADJUSTMENT
Y AJUSTE DE LA HOLGURA DE LAS VALVULAS

• Warm up the engine.
• Standard coolant temperature 75
• lntake removal
• Ventilation hose

el motor Temperatura standard
1
75 - 85C
refrigerante.
2 Remocion de flexible de
de
Removing the Ventilation Hole
Removing the Ventilation Hole
lntake pipe Set bolt (engine hanger 2 Set bolt
and set nut (intake heater
rigda de de motor)
(2)
colgador
v calentador de rigda de
de sujecion
3 lntake pipe
Removing the Intake
the Intake
KAL28-13
23
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3
de a
de la culata de
3. Cylinder head cover removal
dros (1 ) con (2) Arandelas de de a culata c
Bolts washers Seal washers head cover
the Cylinder Head Cover
KA L27-30
the Cylinder Head Cover
KAL27 - 30
de la holgura de la valvula
Valve clearance inspection
el avance para
en de No 1 en el PMS
3
4. Rotate the crankshaft in the forward to
set cylinder No. 1 at the TDC
5
la valvula de most-adas en
la
5. Measure the valve clearance for each of the
valves shown in the figure.
Holgura standard de la valvula. 0.20 mm. (0,008")
(motor 0.36 mm. (0.01 4") (motor
Standard valve clearance IN 0.20 mm (0.008 in)
(hot EX 0.36 mm (0.014 in)
engine)
the Valve Clearance
Inspecting the Valve Clearance
KAL28 - 5
el avance para
en la No 6 en
6. Rotate the crankshaft the forward to set
cylinder No 6 at the TDC.
7
a
de
restantes
7. Measure the valve clearance of the ing
valves.
Inspecting the Valve Clearance
the Valve Clearance
KAL28 - 5
Ajuste de la holgura de la valvula
Valve clearance adjustment
8
la tuerca de y el de para Use un de
espesor motor para el ajuste de la holgura
8. Loosen the lock nut and turn the screw for
adjustment. Use an engine feeler gauge for
clearance measurement.
Holgura standard de la valvula
Standard valve clearance IN 0.20 mm (0.008 in)
(hot EX 0.36 (0.014 in) (hot engine) 9. Tighten
the lock nut, and inspect the valve clearance
again.
IN EX
mm. (0.008") (motor caliente) mm. (0,014") (motor
caliente)
9
a tuerca de e de nuevo la holgura de la valvula
Adjusting the Valve Clearance
Adjusting the Valve Clearance
KAL28-4
25
10 lnstalacion de a de la culata de dros (1 )
Cuberta de la culata de (2) Arandelas de
10. Cylinder head cover installation Cylinder
head cover Seal washers
50 90 kg-cm (3.6 - 6.5
(3) Bolts with washers
- 8 8
(3) con arandelas
T 50 - 90 kgm. - 6.5 - 8.8 N
KAL27-22
KAL27-22
Installing the Cylinder Head Cover
Installing the Cylinder Head Cover
de la rigda de de flexible de

• lntake pipe
• lntake
• Set bolt and set nut Ventilation hose

rigida de
(1 ) (2) (3)
y tuerca de
KAL28-13
Installing the lntake Pipe
the Intake Pipe
DE LA
COMPRESSION PRESSURE INSPECTION
DE
el motor Temperatura standard del
refrigerante 75 85C Hemocion de la de (1
) flexible de
Warm up the engine. Standard coolant temperature
75 2. intake removal (1 Ventilation hose
1
2
Removing the
Hose
Removing the
Hose
(2) lntake pipe I Set bolt and set nut lntake
pipe
rigda de de rigda de
(2)
y tuerca de
KAL28-13
Removing the
Pipe
the lntake
26
3 Rernocon de la a rigida de
rigida de
y de
de as boquillas
de
4 Rernocon de todos y de las boquillas (1 )
Tuercas de
(2) de boquillas boquillas de la compresion
5.
Ponga en las materias comenzar la
el motor para que salgan de cilindros antes
de de la compresion.
measurement.
KAL27-5
Removing the Nozzle Leakage
Removing the Nozzle Leakage
(1 )
el accesorio del cornpresometro
el
de la e Juego de SST 09992-76002-71
(2) Ponga en rnarcha el motor y de
compresion Standard 33 (469 Limite 20 (284
la
rprn
rpm
Removing the Nozzle and Nozzle Holder
Removing the Nozzle and Nozzle Holder
rprn
Nota Use una mantener la
totalmente cargada para del motor superior a
rprn especificadas.
(3)
y (2) para
anteriores cilindros
todos
Limite de diferencia entre 2 (28
cilindros rprn rprn de cualquier
(4) la presion de cilindro es inferior de
preson entre
limite o la diferencia cilindros es superior
from the nozzle hole and repeat steps to above.
Measuring the Compression Pressure
Measuring the Compression Pressure
limite, por el
un poco de aceite de motor de la boquilla
If the raises the pres- sure, the piston rings
and bore may have been worn. If the pressure
is still low after the oil addition, valve
seizure, valve contact defect or pressure
leakage from the gasket may be the
cause. Caution See page 3 - 19 for the
nozzle holder and nozzle installation method.
anteriores a (3)
echar aceite aurnenta la presion. del piston y el
calibre cilindro pueden estar desgastados
a preson es todavia de haber
despues la causa
puede ser agarrotamiento valvula, de
de la de la por la
valvula o escape de junta de empaquetadura
la pagina 3 - 19 en cuanto de instalacion de
la boquilla
de
27
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28
https//www.ebooklibonline.com Hello dear
friend! Thank you very much for reading. Enter
the link into your browser. The full manual is
available for immediate download. https//www.eb
ooklibonline.com