49905077-Gang-Engine-13-P

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

TECHNICAL MANUAL

SERVICE AND OVERHAUL INSTRUCTIONSWITH ILLUSTRATED PARTS BREAKDOWN

DIESEL ENGINE FORSELF GENERATING NITROGEN

SERVICING CART (SGNSC)

MODEL 4LE1PW14

NSN 2815-01-470-8023

F41608-98-D-0015

PACIFIC CONSOLIDATED INDUSTRIES

3430 WEST CARRIAGE DRIVE

SANTA ANA, CALIFORNIA 92704

TELEPHONE 714-979-9200

TELEFAX 714-436-9150

DISTRIBUTION STATEMENT - Distribution authorized to U.S. Government agencies and their contractorsfor Administrative or Operational Use, 1 November 2000. Other requests for this document shall be referredto San Antonio ALC/LDEAM, 485 Quentin Roosevelt Ste 2, Kelly AFB, TX 78241-6421.

WARNING: This document contains technical data whose export is restricted by the Arms Control Act(Title 22, U.S.C., Sec 2751, et seq.) or the Export Administration Act ot 1979, as amended, Title 50, U.S.C.,App. 2401 et seq. Violations of these export laws are subject to severe criminal penalties. Disseminate inaccordance with provisions of DoD Directive 5230.25.

DESTRUCTION NOTICE - Destroy by any method that will prevent disclosure or reconstruction of thecontents.

PUBLISHED UNDER AUTHORITY OF THE SECRETARY OF THE AIR FORCE

1 NOVEMBER 2000

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

LIST OF EFFECTIVE PAGES INSERT LATEST CHANGED PAGES. DESTROY SUPERSEDED PAGES

NOTE The portion of text affected by the changes is indicated by a verticalline in the outer margins of the page. Changes to illustrations are in-dicated by shaded or screened areas, or by miniature pointing hands.

Dates of issue for original and changed pages are:

Original ... 0.... 1 November 2000

TOTAL NUMBER OF PAGES IN THIS PUBLICATION IS 4, CONSISTING OF THE FOLLOWING:

Page No. *Change No.

Title .... 0A ... .0i .... 0ii Blank ... . 0

*Zero in this column indicates an original page

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

NUMERICAL INDEX OF EFFECTIVE WORK PACKAGES

NOTEOnly those work packages and subordinate work packages assigned to this manual are listed inthis index, therefore, WP/SWP numbers may not be sequential.

WP/SWP Change TitleNumber Number

001 00 0 Alphabetically Index

002 00 0 Foreword

003 00 0 Master List of Special tools andConsumables

004 00 0 Engine Operation

004 01 0 Periodic Inspection andMaintenance

004 02 0 Engine Maintenance Schedule

004 03 0 Engine Troubleshooting

005 00 0 General repair Instructions

005 01 0 Tightening Torque Specifications

005 02 0 Engine Gaskets

005 03 0 Engine Maintenance andAdjustments

WP/SWP Change TitleNumber Number

006 00 0 Engine Disassembly, Inspectionand Repair, and Reassembly

006 01 0 Engine Disassembly Procedures

006 02 0 Engine Inspection and RepsirProcedures

006 03 0 Engine Reassembly Procedures

007 00 0 Engine Lubricating System

008 00 0 Engine Cooling System

009 00 0 Engine Fuel System

010 00 0 Engine Troubleshooting Charts

998 00 0 Illustrated Parts Breakdown

998 01 0 Maintenance Parts List withIllustrations

998 02 0 Numerical Index

V(il blank)

T.O. 38G1 -1 27-1TM1-2815-262-1 3&P

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WORK PACKAGE

LIST OF EFFECTIVE WP PAGES

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

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2 Blank .... 0

ALPHABETICAL INDEX OF EFFECTIVE WORK PACKAGES

Only those work packages and subordinate work packages assigned to this man-ual are listed in this index.

Subject WP1SWP

Alphabetical Index ................ I ........... 001 00

Engine Cooling System ....................... 008 00

Engine Disassembly Procedures ...... .......... 006 01

Engine Disassembly, Inspection and Repair,and Reassembly ........... ........... 006 00

Engine Fuel System .......................... 009 00

Engine Gaskets ............................. 005 02

Engine Inspection and Repair Procedures ......... 006 02

Engine Lubricating System ....... ............. 007 00

Engine Maintenance and Adjustments .... ....... 005 03

Engine Maintenance Schedule ...... ........... 004 02

Engine Operation ............................ 004 00

Engine Reassembly Procedures ................. 006 03

Engine Troubleshooting ......... ............. 004 03

Engine Troubleshooting Charts ................. 010 00

Foreword ............................... 002 00

General Repair Instructions .................... 005 00

Illustrated Parts Breakdown ....... ............ 998 00

Snbject WP/SW`PMaintenance Parts List with Illustrations ........ 998 01

Master List of Special Tools and Consumables .... 003 00

Numerical Index ............................. 998 02

Periodic Inspection and Maintenance .... ........ 00401

Tightening Torque Specifications .... ........... 005 01

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ALPHABETICAL INDEX

SERVICE AND OVERHAUL INSTRUCTIONS

EFFECTIVITY: ISUZU DIESEL ENGINE MODEL 4LEIPW14

Change No

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WORK PACKAGE

Page No. Change No.

1-6 . 0


Total number of pages in this WP is 6Page No. Change No.

TABLE OFParagph pap

1. General Information ..................... 2

1.1 Engine Identification ..................... 2

2. Engine Factory Support .................... 4

2.1 Isuzu Engine After Sale Service .............. 4

2.2 Isuzu Genuine Parts ..................... 4

2igure

2

3

Page No. Change No

CONTENTSParagraph Eag

3. Fuel, Lubricant and Coolant ................. 4

3.1 Fuel ................... 4

3.2 Lubricant ................... 5

3.3 Coolant ................... 6

4. Notes On the Format of These Work Packages . 6

LIST OF ILLUSTRATIONSEw Figm Ew

Engine Details .2 4 Example of Major Components Order of

Location of Engine Identification.2 Disassembly and Reassembly............... 6

Recommended Oil Viscosity Grades ..... 5.....

FOREWORD



T.O. 38G1 -1 27-1TM1-2815-262-1 3&PWP 002 00

1. GENERAL INFORMATION

Figure 1 shows the shows the general arrangement of theengine.

1.1. ENGINE IDENTIFICATION

1.1.1 Location of Identification

The engine serial number is stamped on the front upperright side of the cylinder body, and the engine model iscast on the rear lower right side of cylinder body, justabove the oil filter (see Figure 2). Further, the enginemodel is also described on an ID label on the top of the cyl-inder head cover.

1.1.2 Confirmation of Engine Serial Number

IWARNING

CONDUCT CONFIRMATION OF THE ENGINESERIAL NUMBER WITH THE ENGINESTOPPED. TO AVOID INJURY, DON'T CHECKIT WHILE THE ENGINE IS STILL HOT.

It is advisable to check the engine serial number, enginemodel name, and type of machine together with the equip-ment manufacturer's name, as it is required when you con-tact the distributor for repair service or parts ordering.

Figure 2. Location of Engine Identification.

1.1.3 Engine Particulars

The following information in Table 1 applies to model4LElPW14 diesel engine.

Figure 1. Engine Details.

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WP 002 00

Table 1. Engine Leading Particulars.

Engine model name 4LEIPW14

Engine family WSZXLO2. IDNA

Engine code 21DNA

Engine type Water-cooled, 4-cycle, in-line overhead valve type

Combustion type Direct injection

No. of cylinders - bore x stroke - mm (in) 4 - 85 x 96 (3.35 x 3.78)

Engine displacement - liter (ind3 2.179 (133.0)

Number of piston rings 2 compression rings, 1 oil ring

Compression ratio 21.5 to 1

Compression pressure - kg/cm2 (psig) 31 (441) or more at 250 rpm

Firing order I -3 -4- 2

Timing drive system Gear drive

Type of combustion chamber Swirl chamber

Rated power: SAE net kW (HP)/rpm 39.0 (52.3)/3000

Fuel flow at maximum rated power (gph)_1.66

Maximum torque: SAE net Ibs-ft/rpm 104/1750

Fuel flow at maximum torque (gph)_0.993

Idling speed - rpm 850

Exhaust emission control system Engine modification

Injection pump Bosch, PFR type

Nozzle injection pressure - kg/cm 2 (psig) 135 (1920)

Injection timing - BTDC 160

Governor Variable speed, mechanical type

Injection nozzles Throttle type

Valve clearance (cold) - intake and exhaust - mm (in) 0.4 (0.0157)

Intakce valve Open (BTDC) 150Valve operating Close (ABDC) 290

timingExhaust valve Open (BBDC) 400

Close (ATDC) 160

Lube oil capacity -liters (qts) About 8.5 (9)

Engine oil grade (API grade) CC or CD

Oil pump Trochoid type

Oil filter Cartridge tye

Fuel type JP-8, JP-5, DF-1, DF-2, DF-A, DL-2, Jet-A, Jet-Al

Coolant volume (engine only) - liters (qts) 2.8 (3.0)

Starter - Volts - kW 12 - 1.8

T.O. 38G1-127-1TM1-281 5-262-13&PWP 002 00

2. ENGINE FACTORY SUPPORT

211suzu Engine After Sale Service

Please feel free to contact an ISUZU dealer to obtain assis-tance for periodic inspection and maintenance.

2.2 Isuzu Genuine Parts

The ISUZU genuine parts are identical with those used inthe engine production, and, accordingly, they are warrantedby ISUZU MOTORS LIMITED.

The ISUZU genuine parts are supplied by the ISUZU dis-tributors or the authorized parts suppliers. Please designate"ISUZU Genuine Parts" when you need engine parts.

3. FUEL, LUBRICANT, AND COOLANT

3.1 Fuel

3.1.1 Fuel Selection

The following specific advantages are required for the die-sel fuel.

a. Must be free from minute dust particles.

b. Must have adequate viscosity.

c. Must have high cetane value.

d. Must have high fluidity at low temperature.

e. Must have low sulfur content.

f. Must have little residual carbon.

3.1.2 Fuel Requirements

The fuel injection pump, injector, or other parts ofthe fuel system and engine can be damaged if youuse any fuel or fuel additive, other than those spe-cifically recommended by Isuzu.

Such damage is not Isuzu's responsibility, and is notcovered by the Warranty. To help avoid fuel systemor engine damage, please heed the following:

e Some suppliers mix used engine oil with dieselfuel. Some manufacturers of large diesel enginesallow this; however, for your diesel engine, do

not use diesel fuel which has been contaminatedwith engine oil. Besides causing engine damage,such fuel can also affect emission control. Beforeusing any diesel fuel, check with the servicestation operator to see if the fuel has been mixedwith engine oil.

* Do not use any fuel additive (other than as rec-ommended under "Biocide" in this section). Atthe time this manual was printed, no other fueladditive was recommended.

Do not use home heating oil or gasoline in yourdiesel engine; either may cause engine damage.

This engine is designed to use JP-8, JP-5, DF-1, DF-2, DF-A, DL-2, Jet-A, and Jet-Al fuels. The primary fuel for thisengine's service (the Self Generating Nitrogen ServicingCart, or, SGNSC) is JP-8. However, for better fuel econ-omy, use DF-2 diesel fuel whenever possible. At tempera-tures less than 200 F, DF-2 fuel may pose operating prob-lems. At colder temperatures, use JP-8 or Jet-A fuel (ifavailable).

3.1.3 Handling of the Fuel

The fuel containing dust particles or water will cause en-gine failure. Therefore, the following precautions must beobserved. (This is for the engine as installed in theSGNSC.)

a. Take care to prevent the fuel from entry of dust parti-cles or water when filling the fuel tank.

b. When fueling is done from an oil drum directly, keepthe drum stationary over a long time so that clean fuelcan be used after the dust particles or water is com-pletely sedimented.

c. Always fully fill the fuel tank. Drain the sedimentedparticles in the fuel tank frequently by removing thetank draining plug.

3.1.4 Water in Fuel

IWARNING |

THE WATER/DIESEL FUEL MIXTURE ISFLAMMABLE AND COULD BE HOT. DO NOTTOUCH THE FUEL COMING FROM THEDRAIN VALVE AND DO NOT EXPOSE THE

4

FUEL TO OPEN FLAMES OR SPARKS. BESURE YOU DO NOT OVERFILL THE CON-TAINER. HEAT CAN CAUSE THE FUEL TOEXPAND. IF THE CONTAINER IS TOO FULL,FUEL COULD BE FORCED OUT OF THE CON-TAINER. THIS COULD LEAD TO A FIRE ANDTHE RISK OF PERSONAL INJURY AND/ORVEHICLE OR EQUIPMENT DAMAGE.

During refueling, it is possible for water (and other con-taminants) to be pumped into your fuel tank along with thediesel fuel. This can happen if a fuel supplier does not regu-larly inspect and clean its fuel tanks, or if a fuel supplier re-ceives contaminated fuel from its supplier(s).

To protect your engine from contaminated fuel, there is afuel filter system on the engine which allows you to drainexcess water.

3.1.5 Biocides

| AUIN|

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

WP 002 00

Use a diesel fuel biocide to sterilize the fuel system (followthe biocide manufacturer's instructions).

3.1.6 Smoke Suppressants

Because of extensive testing of treated fuel versus un-treated fuel, the use of a smoke suppressant additive is notrecommended because of the greater possibility of stuckrings and valve failure, resulting from excessive ash depos-its.

3.2 Lubricant

The quality of engine oil may largely affect engine per-formance, startability and engine life.

Use of unsuitable engine oil will result in piston rung, pis-ton and cylinder seizure and accelerate the sliding surfacewear causing increased oil consumption, lowered outputand, finally, engine failure. To avoid this, use the specifiedengine oil.

3.2.1 Engine Qil Selection

Fungus or bacteria can cause fuel system damage byplugging the fuel line, fuel filters, or injector. Theycan also cause fuel system corrosion.

In warm or humid weather, if there is water in the fuel, fun-gus and/or bacteria may form in diesel fuel.

The engine oil should conform to the specification listedbelow.

4LElPW14 - APL CC or CD grade, or equivalent.

ENGINE OIL VISCOSITY GRADE - AMBIENT TEMPERATURE

AmbientTemperature

-25C -2O@C -152C(-13¶F) (4¶F) (5¶F)

-0C 150C 250C 30"C(32TF) (59*F) (770F) (86WFl

Figure 3. Recommended Oil Viscosity Grades.

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

3.3.2 Oil Viscosity

Engine oil viscosity largely affects engine startability, per-formance, oil consumption, speed of engine wear and oc-currence of seizure, etc. Using lubricants whose viscosityis selected according to the atmospheric temperature is im-portant. Figure 3 shows the recommended grades of engineoil for the various ambient conditions.

NOTEUsing a mixture of different brand or quality oilswill adversely affect the original oil quality; there-fore, never mix up different brands or different typesof oils. Don't use API, CA, CB grade and refinedengine oil. Engine damage due to improper mainte-nance, or using oil of the improper quality and/orviscosity, is not covered by the warranty.

3.3COOLANT

Use a 40/60 water/ethylene (anti-freeze) mixture for thecoolant and replace it periodically.

4. NOTES ON THE FORMAT OF THESEWORKPACKAGES

These Work Packages and Subordinate Work Packages areapplicable to the 4LEIPW14 industrial diesel engines.

a. Find the applicable section by referring to the Table ofContents at the beginning of each work package orsubordinate work package.

b. Common technical data such as general maintenanceitems, service specifications, and tightening torquesare included in other work packages of this manual.

c. Each section is divided into sub-sections dealing withdisassembly, inspection and repair, and reassembly.

d. When the same servicing operation is applicable to sev-eral different units, the manual will direct you to theappropriate page.

e. For the sake of brevity, self-explanatory removal andinstallation procedures are omitted. More complexprocedures are covered in detail.

f. Each service operation section in the subordinate workpackages begin with an exploded view of the applica-ble area. As an example, Figure 4 shows the applica-ble major components to be disassembled or reassem-bled. The numbers in parentheses "( )" show the orderof disassembling or reassembling.

g. Measurement criteria are defined by the terms "stand-ard" and "limit." A measurement falling within the"standard" range indicates that the applicable part orparts are serviceable. "Limit" should be thought of asan absolute value. A measurement, which is outsidethe "limit", indicates that the applicable part or partsmust be either repaired or replaced.

h. Components and parts are listed in the singular formthroughout the subordinate work packages.

i. Directions used in these Work Packages and Subordi-nate Work Packages are as follows:

Front The cooling fan side of the en-gine viewed from the flywheel.

Right The injection pump side of theengine.

Left

Rear

The exhaust manifold side ofthe engine.

The flywheel side of the engine.

Cylinder numbers are counted from the front of the engine.The front most cylinder is No. 1 and rear most cylinder isNo.4

The engine's direction of rotation is counterclockwise asviewed from the flywheel.

Swatr a

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

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

WP 003 00

WORK PACKAGE

MASTER LIST OF SPECIAL TOOLS AND CONSUMABLES


EFFECTIVITY: ISUZU DIESEL ENGINE MODEL 4LElPW14


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

1-4 . 0

TABLE OF CONTENTSparagrah Fg

1. Special Tools .......................... 2

2. Consumable Materials ..................... 4

LIST OF ILLUSTRATIONSfigt

1 Valve Spring Compressor ................... 3

2 Front Oil Seal Installation Tool ........ ...... 3

3 Rear Oil Seal Installation Tool ......... ...... 3

4 Drive Bar .......................... 3

5 Valve Guide Seal Installation Tool ............ 3

6 Bearing Removal Tool ..................... 3

7 Compression Gauge ....................... 3

8 Compression Gauge Adapter ......... ....... 3

9 Filter Wrench .......................... 3

10 Injection Nozzle Tester ..................... 3

11 Piston Ring Compressor .................... 3

LIST OF TABLESIAb1& Eag=

1 Master List of Special Tools ................. 2

2 Master List of Consumable Materials ......... 4

T.O. 38G1-127-1TM1-281 5-262-1 3&PWP 003 00

1. SPECIAL TOOLS

Table 1 below lists the special tools necessary to servicethe engine.

Table 1. Master List of Special Tools.

Tool Part Number CAGE Figure and Nomenclature UseCode Index No. l

1-8522-1029-0 S0226 Piston Ring Pliers Removing and installingpiston rings - SWP 006 01and SWP 006 03

5-8840-0007-0 S0226 Figure 4 Drive Bar Disassembly and re-assemblyof bushing and pins -SWP 006 01

5-8840-0015-0 S0226 Figure 6 Bearing removal tool Removing press fit bearingsfrom shafts - SWP 006 01

5-8840-2008-0 S0226 Figure 7 Compression Gauge Checking compressionpressure on the cylinders -SWP 005 03

5-8840-2009-0 S0226 Figure 8 Compression Gauge Adapter Attaching the compressiongauge to the glow plug port inthe head - SWP 005 03

5-8840-2061-0 S0226 Figure 2 Front Oil Seal Installation Installing the crankshaft frontTool oil seal - SWP 006 03

5-8840-9004 S0226 Figure 3 Rear Oil Seal Installation Tool Installing the crankshaft rearoil seal - SWP 006 03

5-8840-9007-0 S0226 Figure 5 Valve Guide Seal Installation Installing valve stem seals -Tool SWP 006 03

5-8840-9015 S0226 Figure 9 Filter Wrench Removing and installing fueland oil filter cartridges -SWP 005 03

5-8840-9016-0 S0226 Figure 10 Injection Nozzle Tester Testing the spray pattern ofthe injection nozzles -SWP 005 03

5-8840-9018-0 S0226 Figure 11 Piston Ring Compressor Installing the pistons into thecylinders - SWP 006 03

Commercial Tool Figure 1 Valve Spring Compressor Removing and installingvalve springs and valves -SWP 006 01 andSWP 006 003

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

WP 003 00

Figure 1. Valve Spring Compressor.

Figure 2. Front Oil Seal Installation Tool.

Figure 3. Rear Oil Seal Installation Tool.

Figure 4. Drive Bar.

Figure 5. Valve Guide Oil Seal Installion Tool.

Figure 7. Compression Gauge.

Figure 8. Compression Gauge Adapter.

Figure 9. Filter Wrench.

Figure 10. Injection Nozzle Tester.

Figure 11. Piston Ring Compressor.

Figure 6. Bearing Removal Tool.

6 �

x_}D-

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

2. CONSUMABLE MATERIALS

Table 2 below lists the consumable materials required forthe servicing of the engine.

Table 2. Master List of Consumable Materials.

Nomenclature Specificationl CAGE Use ReferencePart No. Code

Gasket sealant TB1207C S0226 Sealing engine gaskets SWP 005 02, paragraph 2;SWP 006 03, paragraphs4.1.5, 4.1.10, 4.1.12, 4.1.17,4.1.21, 5.3.3, 5.3.4, 5.3.7,5.3.11; WP 008 00,paragraphs 2.1.1, 2.2.3

Locking compound Loctite No. 601 08028 Securing bushings to the WP 009 00, paragraph 2.1governor control lever

Molybdenum disulfide MIL-G-21164 81349 Lubricating bolt threadss SWP 005 01, paragraph 3grease

Sealant BELCO bond No. 4 Water pump impeller seal WP 008 00, paragraph 2.2.2

Teflon pipe thread sealing MIL-T-27730A 81349 Sealing pipe threads SWP 005 02, paragraph 2tape

Thread locking compound Loctite No. 262 08028 Locking bolt and nut SWP 005 01, paragraphsthreads 4.2, 4.3; WP 008 00,

paragraph 2.2.3

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

WP 004 00

WORK PACKAGE


Total number of pages in this WP is 10Change No. Page No. Change No. Page No.

1-10 . 0

TABLE OF CONTENTSPngc Paragraph

Foreword .................. 2

Safety Summary ......... ......... 2

Engine Operation ............. ...... 4

Engine Exhaust Gas Caution ................ 4

Pre-operational Check .................. 4

Engine Oil Level ................... 4

Fan Belt Check .................. 5

Coolant Level Check .................. 5

Battery Cable Connection ................... 5

Engine Starting ........ .......... 5

Pre-starting Preparations .................. 5

Pre-heating Procedures ................... 5

Engine Starting ........ .......... 6

Check and Operation After the Engine Start-up. . 6

Warming-up Operation ................... 6

4.2 Check After the Engine Start-up ....... ...... 6

5. Care in the Engine Operation ......... ...... 7

5.1 Engine Oil Pressure ....................... 7

5.2 Coolant Temperature ...................... 7

6. Engine Stopping ........................ 8

7. Operation and Care For New Engine ......... 9

8. Engine Care For Over-cooling ........ ...... 9

9. Starting the Engine After Long Periods ofNon-use ................... 9

10. Engine Care In Cold Season ................ 9

10.1 Fuel ................... 9

10.2

10.3

10.4

10.5

Coolant...............................

Engine Oil ..............................

Battery .................................

Engine Starting ..........................

9

9

9

9

ENGINE OPERATION



Page No.

Paragrap

Change No

1.

1.1

2.

2.1

2.2

2.3

2.4

3.

3.1

3.2

3.3

4.

4.1

T.O. 38G1-127-1TM1-2815-262-1 3&PWP 004 00

FOREWORD

This Work Package (WP) provides information on startingand operating the diesel engine on the SGNSC. It also pro-

vides information on general care of the engine to maxi-mize trouble-free service life.

SAFETY SUMMARY

ROTATING MACHINERYThere are two areas where rotating components present ahazard. One is at the rear of the engine where the coolingwater pump and feed air compressor are driven by a beltand pulley drive off the engine output shaft. The other is atthe front of the engine where the cooling fan is driven by abelt drive off the engine front crankshaft pulley. The unitshould always be operated with the enclosure in place andsecured down on the unit chassis. If there is any reason tooperate the unit with the enclosure lifted or removed, spe-cial precautions must be observed, such as placing a barrierin front of the rotating parts to prevent coming in contactwith them, or other such positive means.

HOT SURFACESThe diesel engine surfaces and exhaust system have ex-tremely hot surfaces. Do not touch them during operationor within 30 minutes of stopping the engine.

WARNING AND CAUTION STATEMENTSThe following warning and caution statements appear inthis Work Package:

I WARNING

DO NOT BREATHE EXHAUST GAS BECAUSEIT CONTAINS CARBON MONOXIDE, WHICH,BY ITSELF, HAS NO COLOR OR ODOR.CARBON MONOXIDE IS A DANGEROUSGAS. IT CAN CAUSE UNCONSCIOUSNESSAND CAN BE LETHAL.

WARNING

IWARNING

IN ADDING OIL, TAKE CARE NOT TO SPILLIT. IF YOU SPILL OIL ON THE ENGINE OREQUIPMENT, WIPE IT UP COMPLETELY, ORTHIS COULD LEAD TO A FIRE AND THE RISKOF PERSONAL INJURY AND/OR EQUIPMENTDAMAGE.

IWARNING

DO NOT REMOVE THE RADIATOR CAPWHEN THE ENGINE IS HOT.

WARNIG

DO NOT TOUCH THE RED (HOT) CONTROLRESISTANCE COIL OR ALLOW COMBUSTI-BLE MATERIALS ON IT. THIS COULD LEADTO A FIRE.

IWARNING

IF THE ENGINE COOLANT TEMPERATUREGAUGE (TIl) SHOWS AN OVERHEAT CONDI-TION OR YOU HAVE OTHER REASON TOSUSPECT THE ENGINE MAY BE OVERHEAT-ING, CONTINUED OPERATION OF THE EN-GINE MAY RESULT IN A FIRE AND THE RISKOF PERSONAL INJURY.

TO AVOID INJURY CONDUCT THE INSPEC-TIONS BEFORE START-UP AND WITH THEENGINE STOPPED.

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

WP 004 00

SAFETY SUMMARY (continued)

IWARNING I

DO NOT OPEN THE ENGINE ACCESS COVERIF YOU SEE OR HEAR STEAM OR ENGINECOOLANT ESCAPING FROM THE ENGINECOMPARTMENT. WAIT UNTIL NO STEAMOR ENGINE COOLANT CAN BE SEEN ORHEARD BEFORE OPENING THE ENGINECOVER. DO NOT REMOVE THE RADIATORCAP WHEN THE ENGINE IS HOT.

S|IANNG |

DO NOT SPILL ANTIFREEZE OR ENGINECOOLANT ON THE EXHAUST SYSTEM ORHOT ENGINE PARTS. UNDER SOME CONDI-TIONS THE ETHYLENE GLYCOL IN THE EN-GINE COOLANT IS COMBUSTIBLE.

| ATON|

Do not use starting "aids" in the air intake system.Such aids can cause immediate engine damage.

T.O. 38G1-127-1TMI-2815-262-1 3&PWP 004 00

2. PRE-OPERATIONAL CHECK

All operational instructions pertain to the engine as in-stalled in the Self Generating Nitrogen Servicing Cart(SGNSC).

1.1 Engine Exhaust Gas Caution

|WAR

| WARNING |

TO AVOID INJURY CONDUCT THE INSPEC-TIONS BEFORE START-UP AND WITH THEENGINE STOPPED.

2.1 Enalne Oil Level

DO NOT BREATHE EXHAUST GAS BECAUSEIT CONTAINS CARBON MONOXIDE, WHICH,BY ITSELF, HAS NO COLOR OR ODOR.CARBON MONOXIDE IS A DANGEROUSGAS. IT CAN CAUSE UNCONSCIOUSNESSAND CAN BE LETHAL.

If at any time you think exhaust fumes are leaking, havethe cause determined and corrected as soon as possible. Ifyou must operate the engine under these conditions, oper-ate with caution.

Protect against carbon monoxide concentration around thecontrol panel of the system. The best way is to keep the en-gine exhaust system properly maintained. We recommendthat the exhaust system be inspected by a competent techni-cian:

* Each time the vehicle has an oil change.

* Whenever a change is noticed in the sound of theexhaust system.

* Whenever the exhaust system, underbody or cabis damaged or becomes corroded.

See Maintenance Schedule, SWP 004 02, for parts requir-ing inspection.

To allow proper operation of your vehicle's ventilation sys-tem, keep the air inlet and outlet ducts clear of snow,leaves or other obstructions at all times.

Do not run the engine in confined areas (such as garages ornext to a building) any more than needed to move the vehi-cle or the equipment.

Keep the exhaust tailpipe area clear of snow and other ma-terial to help reduce the buildup of exhaust gasses underthe vehicle or the equipment. This is particularly importantwhen parked in blizzard conditions.

a. Place the engine on a level surface.

b. Remove the dipstick from the crankcase, wipe it withcloth. Insert if fully and take it out gently again.

c. Check the oil level by the level marks on the dipstick.The oil level must be between the "Max" level markand the "Min" level mark as illustrated.

|IWARNING I

IN ADDING OIL, TAKE CARE NOT TO SPILLIT. IF YOU SPILL OIL ON THE ENGINE OREQUIPMENT, WIPE IT UP COMPLETELY, ORTHIS COULD LEAD TO A FIRE AND THE RISKOF PERSONAL INJURY AND/OR EQUIPMENTDAMAGE.

d. Take care not to add too much engine oil.

f. Drain oil to the max oil level if oil level is above themax level mark.

g. Add oil to the max oil level if oil level is below themin level mark.

h. Also check the sample oil on the dipstick for foulingand degrees of viscosity.

NOTEOil level check must be made after the engine hasbeen stopped for ten or twenty minutes. When theoil level check is necessary while the engine isrunning, stop the engine and keep it stationary ten ortwenty minutes until the oil thoroughly flows downto the crankcase.

e. Oil is poured either through the oil filler at the front ofthe cylinder head cover or through the oil filler on theright side of the timing gear case.

1. ENGINE OPERATION

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

WP 004 00

A certain period of time is required before the engine oilcompletely flows down from the oil filler to the crankcase.Check the oil level ten or twenty minutes after oil replen-ishment.

NOTE

If the engine oil is splashed on the fan drive belt, itcauses belt slippage or slackness; therefore, takecare to avoid it.

2.2 Fan Belt Check

Check the fan belt for tension and abnormalities.

a. When the belt is depressed about 10 mm (0.39 in) withthe thumb with about 10 kg (22 lb) pressure midwaybetween the fan pulley and alternator pulley, the belttension is correct (see Figure 1).

b. When the belt tension is too high, it will result in alter-nator failure. Contrarily, a loose belt will cause beltslippage which may result in a damaged belt and ab-normal noise.

c. Check the belts. Replace them if any damage is found.

2.3 Coolant Level Check

||WARIGi

Figure 1. Checking Belt Tension.

c. Never reverse (+) and (-) terminals when reconnectingcables after disconnection. Even a short period of re-verse connection will damage the electrical parts.

e. When handling such metallic articles as a tool near thebatteries, be sure not to contact the (+) terminal. Asthe vehicle body is (-), it may cause a hazard.

f. When disconnecting the terminals, start with the (-) ter-minal. When connecting them, connect the (-) termi-nal last.

3. ENGINE STARTING


a. The coolant level must be 1/2 inch below the radiatorfiller neck. Check and see that the level is correct.

b. When the coolant level is lower than the low point, re-plenish the radiator by the filler port.

c. Use a 40/60 ratio of water/ethylene glycol (anti-freeze)for the coolant.

d. After the replenishment of the coolant, install the radia-tor cap. Make sure the cap is securely installed.

2.4 Battery Cable Connectlon

a. Check the battery cable connections for looseness orcorrosion. The loosened cable connection will resultin hard engine starting or insufficient battery charge.

b. The battery cables must be tightened securely.

3.1 Pre-starting Preparation

a. Make sure that all hydraulic control levers etc. on theequipment are in the nuetral or off position. (Refer tothe SGNSC operating instruction manual, T.O.35D29-7-6-InTMI-3655-234-12.)

b. Set the main circuit breaker to the ON position.

c. Switch ON the ignition switch.

d. Make sure that the panel meters are functioning.

3.2 Pre-heatina Procedures

As an engine starting aid, preheating is required in a coldengine starting.

a. Turn the starter switch key counter-clockwise to thePREE-EAT position in order to heat the glow plugson the engine. A pre-heating time of 5 seconds is re-quired until the control resistance coil becomes red.

5

View fromengine fro

Push here

T.O. 38G1-127-1TM1-2815-262-1 3&PWP 004 00

Relationship between water temperature and pre-heatingtime.

50 0C (122 0 F)

200C (680 FT)

00 C (320 F)

-150 C (5-F)

About I sec.

About 2 sec.

About 3.5 sec.

About 5 sec.

d. When repeating starting operation, return the switch tothe OFF position and then pre-heat and start the en-gine once again.

e. If the engine still remains unstarted, something may bewrong with the engine. Check the appropriate parts tolocate the cause.

4. CHECK AND OPERATION AFTER THE ENGINESTART-UP

-310C (-25IF) About 7 sec. 4.1 Warming-up Operation

SWARNING |

DO NOT TOUCH THE RED (HOT) CONTROLRESISTANCE COIL OR ALLOW COMBUSTI-BLE MATERIALS ON IT. THIS COULD LEADTO A FIRE.

b. Turn the starter switch clockwise to the START posi-tion as soon as the control resistance coil glows red,approximately 5-7 seconds.

3.3 Engine Starting

Do not use starting "aids" in the air intake system.Such aids can cause immediate engine damage.

a. Turn the starter switch clockwise to the START posi-tion. The cranking period must not exceed ten sec-onds. Continuous starter operation of more than tenseconds will lead to overdischarge of the batteries aswell as starter seizure.

b. If the engine cannot be started in one attempt, keep thebatteries and the starter stationary at least 30 secondsfor their functional recovery; then repeat the pre-heat-ing and the starting operations.

NOTE

Continuous re-engagement of the starter to the fly-wheel ring gear without giving it a break will resultin a damaged starter pinion gear and flywheel ringgear.

c. If, despite repeated operations, the engine does notstart, wait for a minute or more until the functions ofthe batteries and starter are recovered; then repeat pre-heating and starting operations.

Do the warming-up operation at 1500 RPM for about tenminutes after the engine has started. While the lubricationfor the entire engine systems is warming-up, do not speedup and load it abruptly. Particularly, observe this in coldseason operation.

4.2 Check After the Engine Start-up

Check the following items in the engine warming-up opera-tion.

a. Engine oil pressure. Although the engine oil pressuregauge readings vary depending on ambient tempera-ture or type of oil, the gauge registers around 4 to 5kg/cm (57 to 71 psi) while the engine is warming-up.

b. Charge condition. The charge condition is normalwhen the ammeter registers on the plus side a largeamount after the engine is started, then gradually themeter will return to zero charge.

c. Engine noise and exhaust smoke color. Pay attention toengine noise and, if any abnormal noise is heard,check the engine to detect the cause. Check the fuelcombustion condition by exhaust smoke color. Theexhaust smoke color after engine warming-up and atno-load operation is as follows:

Colorless or light blue: Normal (Perfect combustion)

Black color: Abnormal (Imperfect combustion)

White color: Abnormal (Imperfect combustion)

NOTE

Engine noise after start-up might be noisier than thatof a warmed-up engine and, the exhaust smoke coloralso might be more blackish than the normal condi-tion. However, it will be normalized after warming-up the engine.

d. Leakage in the systems. Check the following items.

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

WP 004 00

4.2.1 Lube oil leakage

Check both sides and the bottom of the engine assemblyfor lube oil leaks, paying particular attention to the lube oilpressure gauge pipe joint, lube oil filter and lube oil pipejoints.

4.2.2 Fuel leakage

Check the fuel injection pumps, fuel lines and fuel filter forleakage.

4.2.3 Coolant leakage

Check the radiator and water pump hose connections andalso the water drain cocks on the radiator and cylinderbody for leakage.

4.2.4 Exhaust smoke or gas leakage

4.2.5 Checking coolant level

||WANNG |


The coolant level could drop, depending on the equipment,because the mixed air is expelled in about 5 minutes afterthe engine is started. Stop the engine, remove radiator cap,and add coolant, if necessary.

S. CARE IN THE ENGINE OPERATION

In the engine operation, always pay attention to the follow-ing items if the engine indicates any sign of abnormalities.

5.1 Engine Oil Pressure

Engine oil pressure is normal when the oil pressure gaugeshows 3 to 4 kg/cm2 (43 to 57 psi)) in a warmed-up en-gine. In the continuous engine operation, engine oil pres-sure is slightly lower than the pressure at start-up time.When the engine oil pressure gauge shows the followingabnormal condition, stop the engine immediately andcheck the engine oil amount in the oil sump and oil leak-age:

a. The engine oil pressure gauge shows below 2 kg/cm2

(28) psi), though the engine speed is raised.

b. The oil pressure gauge indicator oscillates greatly inthe engine low speed range.

When no lack of engine oil or no oil leakage is found, con-tact your equipment supplier to determine the cause of theabnormal reading.

5.2 Coolant Temperature

The engine performance will be adversely affected if en-gine coolant temperature is too hot or too cold. The normalcoolant temperature is 750 to 850C (1670 to 185 0F).

5.2.1 Overheating

|WARNING

IF THE ENGINE COOLANT TEMPERATUREGAUGE (TIl) SHOWS AN OVERHEAT CONDI-TION OR YOU HAVE OTHER REASON TOSUSPECT THE ENGINE MAY BE OVERHEAT-ING, CONTINUED OPERATION OF THE EN-GINE MAY RESULT IN A FIRE AND THE RISKOF PERSONAL INJURY.

If you see or hear escaping steam or have other reason tosuspect there is a serious overheat condition, stop and parkthe equipment as soon as it is safe to do so and then turnoff the engine immediately. Then move a safe distancefrom the equipment. The engine cooling system may over-heat, if the engine coolant level is too low, if there is a sud-den loss of engine coolant (such as hose splitting), or ifother problems occur. It may also temporarily overheat dur-ing severe operating condition such as rapidily stopping af-ter high rpm operation. If the engine Coolant Temperaturegauge shows an overheat condition, or you have reason tosuspect the engine may be overheating, take the followingsteps:

a. Don't turn off your engine.

b. Decrease the engine speed to about one-half full operat-ing speed or 1200 RPM, maximum.

c. Bring the idle speed back to normal after two or threeminutes.

d. If the engine coolant temperature does not start to dropwithin a minute or two let the engine run at normalidle speed for two or three minutes.

e. If the engine coolant temperature does not start to drop,turn off the engine and get a safe distance from theequipment and proceed as follows:

7

T.O. 38G1-127-1TM1-2815-262-1 3&PWP 004 00

IWARNING |

DO NOT OPEN THE ENGINE ACCESS COVERIF YOU SEE OR HEAR STEAM OR ENGINECOOLANT ESCAPING FROM THE ENGINECOMPARTMENT. WAIT UNTIL NO STEAMOR ENGINE COOLANT CAN BE SEEN ORHEARD BEFORE OPENING THE ENGINECOVER. DO NOT REMOVE THE RADIATORCAP WHEN THE ENGINE IS HOT.

If no steam or engine coolant can be seen or heard, tiltopen the engine access cover. If the engine coolant is boil-ing, wait until it stops before proceeding. If necessary pourengine coolant into the radiator.

Make sure the fan belts are not broken, or off the pulleys,and that the fan turns when the engine is started.

5.2.2 Overcooling

The engine operation at low coolant temperature will notonly increase the oil and fuel consumption but also willlead to premature parts wear, which may result in enginefailure.

5.2.3 Engine Hourmeter (Engine Operation Hour Indicat-

This meter indicates the engine operation hours. Make surethat the meter is always working during engine operation.Periodic engine maintenance is scheduled on the operationhours indicated on the hourmeter.

5.2.4 Liquid and Exhaust Smoke Leakage

Be careful with lubricant, fuel, coolant and exhaust smokeleakage.

5.2.5 Abnormal Engine Noise

I WARNING ||

DO NOT SPILL ANTIFREEZE OR ENGINE COOLANTON THE EXHAUST SYSTEM OR HOT ENGINEPARTS. UNDER SOME CONDITIONS THE ETHYL-ENE GLYCOL IN THE ENGINE COOLANT IS COM-BUSTIBLE.

If the engine coolant level is low, look for leaks at the ra-diator hoses and connections, heater hoses and connec-tions, radiator, and water pump. If you find major leaks, orspot other problems that may have caused the engine tooverheat, do not run the engine until these problems havebeen corrected. If you do not find a leak or other problem,carefully add engine coolant to the radiator. (Engine cool-ant is a mixture of 40% water and 60% ethylene glycol an-tifreeze.

If the engine coolant level in the radiator is at the correctlevel but there is still an indication on the instrument panelof an overheat condition YOU MUST LET THE ENGINECOOL FIRST. You may then add an engine coolant di-rectly to the radiator.

Once the Engine Coolant Temperature Gauge no longersignals an overheat condition, you can resume operating ata reduced speed. Return to normal operation after about tenminutes, if the gauge pointer does not again show an over-heat condition.

If no cause for the overheat condition was found, see aqualified service technician.

Pay attention to the noise from the engine or other relatedparts, checking if the noise is normal.

5.2.6 State of the Exhaust Smoke

Be careful with exhaust smoke color; check to see if it iswhitish or blackish.

5.2.7 Electrical System

Do not turn the switch to the OFF position while the en-gine is running at high rpm. This may cause electrical partsdamage.

6. ENGINE STOPPING

a. Make sure that all of the controls on the equipment arein their proper position for shutting down..

b. Before stopping the engine, cool down the engine byoperating it a low idle speed for about three minutes.During this time, check the engine noise and the en-gine oil pressure for abnormalities.

c. To stop the engine, turn the ignition switch to the OFFposition. Switch off the main circuit breaker.

NOTE

Leaving the ignition switch in the ON position for along while, after the engine has been stopped, willdischarge the battery wastefully.

T.O. 38G1-127-1TM1-281 5-262-13&P

WP 004 00

7. OPERATION AND CARE FOR NEW ENGINE

Your ISUZU engine is carefully tested and adjusted in thefactory, however, further, thorough run-in (i.e. break-in) op-eration is necessary.

If the new engine is harshly operated, lubricating oil filmwill be reduced, leading to abnormal wear or seizure. Par-ticularly, avoid a harsh engine operation within the initial100 operational hours observing the following notice.

a. Do the warming-up operation continuously until the en-gine is warmed-up. In this operation, do not race theengine.

b. Also, do not operate the engine with rapid acceleration,rapid machine starting and continuous high-speed op-eration.

8. ENGINE CARE FOR OVER-COOLING

Engine over-cooling causes premature wear and increasedfuel consumption. When the coolant temperature is notraised to 750 to 850C (1670 to 1850F) indefinitely, use theradiator baffle provided on the SGNSC equipment.

9. STARTING THE ENGINE AFTER LONGPERIODS OF NON-USE

When the vehicle or equipment is left unused for morethan three months without running the engine (warming-up), conduct a thorough inspection of the equipment beforestarting the engine. After starting the engine, be sure towarm it up for more than ten minutes at 1000 rpm.

10. ENGINE CARE IN COLD SEASON

I WARNING I

DO NOT SPILL ANTIFREEZE OR ENGINE COOLANTON THE EXHAUST SYSTEM OR HOT ENGINEPARTS. UNDER SOME CONDITIONS THE ETHYL-ENE GLYCOL IN THE ENGINE COOLANT IS COM-BUSTIBLE.

A 60/40 ethylene glycol base antifreeze/water mix shouldbe used at all ambient temperatures. Concentrations over65% adversely affect freeze protection, heat transfer rates,and silicate stability, which may cause water pump leak-age. Never exceed a 60/40 antifreeze/water mix. (whichprovides protection to about -50'C (-58 0F).

NOTEMethyl alcohol base antifreeze is not recommendedbecause of its effect on the non-metallic componentsof the cooling system and because of its low boilingpoint. High silicate antifreeze is ALSO not recom-mended because of causing serious silica gelationproblems. Usage and mixing ratio etc. should befollowed to the antifreeze manufacturer's recom-mendations.

Engine oil viscosity largely affects engine startability, sothe use of lubricant with selected viscosity according to theatmospheric temperature is important. (Refer WP 002 00for recommended viscosity grades.) At low atmospherictemperature, engine oil viscosity will increase causing hardengine starting.

10.1 FUEL

10.1.1 Fuel Selection

In cold zones, the fuel might be frozen, resulting in hard en-gine starting; therefore, select a suitable fuel for such en-gine operation. It is best to use JP-8 or Jet-A for sub-freez-ing temperatures.

10.2 COOLANT

Always pay attention to charging the battery completely incold season. As the discharge current from the battery islarge in cold engine starting, it takes a comparatively longwhile to recharge the batteries than the recharge after thenormal engine starting. Pay attention to keeping the batter-ies warm in the cold season.

10.5 ENGINE STARTING

Where the atmospheric temperature falls below the freez-ing point, the cooling system should be drained after en-gine operation. To eliminate the need for repeated drainingand refilling, the use of anti-freeze solution is highly rec-ommended.

In cold engine starting at ambient temperatures below 00 C(32 0 F), pay attention to the following items:

Do not use starting aids in the air intake system.Such aids can cause immediate engine damage.

T.O. 38G1-127-1TMI-2815-262-1 3&PWP 004 00

a. Do the preheating operation before cranking the enginewith the starter.

b. Set the engine throttle to the full position of the stroke.

c. If the engine does not start with the initial cranking,keep the battery stationary awhile to recover itspower and, re-attempt the preheating and the crankingoperation.

d. In order to protect the starter, one time cranking mustbe limited to within 10 seconds.

e. In cranking operation, when the phenomenon of thestarter pinion and the flywheel ring gear repeatedlyengaging and disengaging occurs, it is a sign of weak-ened battery power, charge the battery with an exter-nal electrical source.

f. In extreme cold temperature engine starting, do the en-gine cranking for no longer than 10 seconds at a time(2-3 times) while setting the throttle lever at no fuelposition to allow the engine rotating parts to freethemselves from the adhesive cold lubricant. Afterthat, do preheating and cranking at full throttle to startthe engine.

10

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

SWP 004 01

SUBORDINATE WORK PACKAGE

LIST OF EFFECTIVE SWP PAGES

Page No. Change No.

1-7 ... 08 Blank ... 0

Total number of pages in this SWP is 8Page No. Change No.

TABLE OF CONTENTS. P=age Paragraph

Foreword .......................... 2 3.2 Fuel F

Safety Summary .......................... 2 3.3 Gover

Lubricating System ........................ 3 4. Air In

Engine Oil and Filter Element Change ........ 3 4.1 Air Cl

Check After Oil and Filter Changes ........... 3 5. Engine

Engine Oil Additives ...................... 3 5.1 Batter.

Used Oil Disposal ......................... 3 5.2 Altern

Used Engine Oil .......................... 3 5.3 Wirinj

Cooling System............................ 4 6. Engine

Fan Belt Tension .......................... 4 6.1 Fuel I

Fan Belt Change .......................... 4 6.2 Valve

Coolant Change........................... 4 6.3 Adjusi

Cleaning Outside of Radiator ................ 5 6.4 Cylind

Cooling System Circuit Cleaning ............. 5 6.5 Startei

Fuel System.............................. 5 6.6 Radiai

Fuel System Air Bleeding ................... 5

LIST OF ILLUSTRATIONSP=g Eig=r

Checking Belt Tension ..................... 4 3 Engine

Belt Tension Adjustment Points .............. 4

Epailter Element Change ................. 5

nor Control Seals .................... 6

ake System ..................... 6

eaner ..................... 6

e Electrical ...................... 6

y Servicing ..................... 6

ator Servicing ..................... 6

g Connections ..................... 6

Assembly and Others ............... 6

ijection Nozzle ..................... 6

Clearance Adjustment ................ 7

tment of Injection Timning ............. 7

ler Compression Pressure Measurement. . 7

r and Alternator Servicing ............. 7

tor Pressurization Valve Check ......... 7

e Block Drain Plug ................... 5

1

PERIODIC INSPECTION AND MAINTENANCE


EFFECTIVITY: ISUZU DIESEL ENGINE MODEL 4LEIPWI4

Page No. Change No

Paragra=

1.

1.1

1.2

1.3

1.4

1.5

2.

2.1

2.2

2.3

2.4

2.5

3.

3.1

Figt

1

2

T.O. 38G1-127-1TMI-2815-262-1 3&PSWP 004 01

FOREWORD

This Subordinate Work Package (SWP) contains instruc-tions for general periodic maintenance of the diesel engine

used on the SGNSC. This SWP also provides guidelinesfor periodic inspection of the engine.

SAFETY SUMMARY

Some procedures in this SWP require draining of fluids.Some fluids may be hot if the engine was recently oper-ated. Use protective gloves when touching any hot orwarm surfaces on the engine. The engine should be al-lowed to cool down a minimum of one hour after stoppingbefore any maintenance is performed.

WARNING AND CAUTION STATEMENTSThe following warning and caution statements appear inthis Work Package:

EINGE

TO AVOID BEING BURNED, DO NOT DRAINOIL WHILE THE ENGINE IS STILL HOT.

EING

USED OIL CONTAINS HARMFUL CONTAMI-NANTS THAT HAVE CAUSED SKIN CANCERIN LABORATORY ANIMALS. AVOID PRO-LONGED SKIN CONTACT. CLEAN SKIN ANDNAILS THOROUGHLY USING SOAP ANDWATER - NOT MINERAL OIL, FUELS OR SOL-VENTS. LAUNDER OR DISCARD CLOTHING,SHOES, OR RAGS CONTAINING USED EN-GINE OIL.

IWARNING

NEVER CHECK AND ADJUST FAN BELT TEN-SION WITH THE ENGINE RUNNING.

IWARNING


IWARNING I

WHILE USING A NOZZLE TESTER, HIGH-PRESSURE COULD BLOW OFF THE FUELOIL. KEEP AWAY FROM NOZZLE END. USEEYE PROTECTION.

ICAUTION|

The rocker arm is made of die-cast aluminum.Therefore, be careful not to tighten the adjustingscrew to excess.

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

SWP 004 01

1. LUBRICATING SYSTEM

Servicing of the engine oil or the oil filter element will af-fect the engine performance as well as the engine life.Change the engine oil and the oil filter element peri-odically with the specified ones. Refer to WP 002 00 forthe recommended engine oil.

1.1 Engine Oil and Oil Filter Element Change

Engine oil change and oil filter element change must bemade according to the following change schedule.

1.1.1 Change Interval

* Engine Oil: Initial 50 hours and thereafter every250 operating hours

* Oil Filter Element: Initial 50 hours and thereafterevery 500 operating hours

1.1.2 Enngine Oil Draining

I WARNING]

TO AVOID BEING BURNED, DO NOT DRAINOIL WHILE THE ENGINE IS STILL HOT.

a. Wipe clean around the oil filler cap, taking care that noforeign particles enter. Remove the filler cap.

b. Connect a 3/8 inch hose to the oil pan drain valve.Open the oil pan drain valve and drain the engine oilcompletely. It is advisable that draining be done whilethe engine is warm to minimize the draining time.

NOTEUse a receptacle to receive the drained oil so that theengine and equipment may not be stained with thedrained oil.

1.1.3 Oil Filter Element Removal

Use a filter wrench to remove the cartridge type oil filterelement.

1.1.4 Oil Filter Element Installation

c. Use a filter wrench to further turn in the cartridge by 3/4

turn.

1.1.5 Engine Oil Refilling

a. Close the oil pan drain valve.

b. Fill with new engine oil by the oil filler port.

c. Wait about fifteen minutes until the oil gets down tothe oil pan. Then check the oil level with a dipstick.

1.2 Check After Oil and Filter Changes

1.2.1 Oil Leakage Check

Idle the engine to raise the oil pressure; then check for oilleakage.

1.2.2 Oil Level Recheck

a. Stop the engine and keep it stationary for about twentyminutes.

b. Use the dipstick to recheck the oil level.

c. Replenish with engine oil, if necessary, to the specifiedlevel.

NOTE

When the engine is started, the oil level will slightlydrop from the initial level as the oil fully comes intothe entire oil circuit.

1.3 Engine Oil Additives

Engine oils contain a variety of additives. Your engineshould not need any extra additives if you use the recom-mended oil quality and change intervals.

1.4 Used Oil Disposal

Do not dispose of used engine oil (or any other oil) in acareless manner, such as pouring it on the ground, into sew-ers, or into streams or bodies of water. Instead, recycle itby taking it to a used oil collection facility, which may befound in your locale.

1.5 Used Enaine Oil

a. Apply engine oil lightly to the O-ring. Discard used engine oil and other oils properly.

b. Turn in new cartridge until its sealed face comes in con-tact with the O-ring.

T.O. 38G1-127-1TMI-2815-262-1 3&PSWP 004 01

E|INGUSED OIL CONTAINS HARMFUL CONTAMI-NANTS THAT HAVE CAUSED SKIN CANCERIN LABORATORY ANIMALS. AVOID PRO-LONGED SKIN CONTACT. CLEAN SKIN ANDNAILS THOROUGHLY USING SOAP ANDWATER - NOT MINERAL OIL, FUELS OR SOL-VENTS. LAUNDER OR DISCARD CLOTHING,SHOES, OR RAGS CONTAINING USED EN-GINE OIL.

2. COOLING SYSTEM

2.1 Fan Belt Tension AdrJustment

Adjust fan belt tension when belt slackness is greater thanthe specified amount and when the belts are replaced.

EWINGNEVER CHECK AND ADJUST FAN BELT TEN-SION WITH THE ENGINE RUNNING

2.1.1 lBelt Tensio

Belt tension is normal when it is depressed 10 mm (0.39in) with the thumb midway between the fan pulley and al-ternator pulley with about 10 kg (22 lb) depressing force.See Figure 1.

2.1.1.1 Adzuqtingpnadnr

Figure 2. Belt Tension Adjustment Points.

Belt tension adjustment is made by pivoting the alternatorat the alternator mounting bolt. See Figure 2.

a. Loosen the alternator adjusting plate bolt and the alter-nator mounting bolt.

b. Pivot the alternator at the mounting bolt toward the en-gine left or right hand side, as required.

c. Tighten the mounting bolt and the adjusting bolt.

NOTEBelt tension may vary slightly after the alternator isfixed. Therefore, recheck the belt tension after tight-ening the bolts.

Figure 1. Checking Belt Tension.

d. After the adjustment, operate the engine about five min-utes at a low idle speed and recheck the belt tension.Particularly, pay attention to this matter when install-ing new belts. Belt tension may loosen due to the newbelt conforming to the pulleys.

2.2 Fan Belt Change

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

2.3 Coolant Change

The coolant must be changed at intervals of six months. Ifthe coolant is excessively fouled, it will lead to engine over-heating or coolant blow-off from the radiator.

View fromengine froi

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

SWP 004 01

2.3.1 Coolant Draining 2.4 Cleaning Outside of Radiator

WARNING|


a. Remove the radiator cap.

b. Open the drain cock at the radiator lower part to drainthe coolant in the radiator.

c. Drain away the coolant from the engine by looseningthe water drain plug at the rear of alternator on theleft side of cylinder body. See Figure 3.

Figure 3. Engine Block Drain Plug.

2.3.2 Filling With Coolant

a. Close or tighten the coolant drain plug.

b. Use a mixture of 40% water and 60% ethylene glycol(anti-freeze) as the coolant.

c. Fill the radiator with the coolant until the level comesup to 1/2 inch of the filler port neck. Fill gradually toprevent air entry. The engine and radiator coolant vol-ume is about 2-1/2 gallons.

d. Operate the engine about five minutes at a low idlespeed. This allows the air contained in the coolant cir-cuit to be bled. This causes the coolant level to drop.

e. Stop the engine and replenish with the coolant.

Mud or oily sludge caught between radiator fins will blockthe airflow, resulting in lower cooling efficiency. Clean theradiator fins with steam or pressurized water, as required.Further, if the fins are deformed, repair them or replace theradiator.

2.5 Cooling System Circuit Cleaning

When the cooling system circuit is fouled with water scalesor sludge particles, cooling efficiency will be lowered. Peri-odically clean the circuit interior with a cleaner. The recom-mended interval for cleaning is yearly.

3. FUEL SYSTEM

The fuel injection pumps and fuel injection nozzles are pre-cisely manufactured. Therefore, using fuel which containswater or dust particles will result in either injection pumpplunger seizure or injection nozzle seizure, and a fouledfuel filter element with sludge or dust particles will lead todecreased engine output. In addition, a clogged filter ele-ment can cause low output or automatic air bleeding fail-ure. Perform inspection and maintenance periodically asfollows.

3.1 Fuel System Air Bleeding

The entry of air into the fuel system will cause hard enginestarting or engine malfunction. Once the servicing such asemptying the fuel tank, draining the water separator, andthe fuel filter element change is done, be sure to performair bleeding.

Because of the "automatic air-bleeding system" employedon this engine, turn the ignition switch to the ON positionto begin bleeding the air. This activates the electromagneticfuel pump to bleed the air.

3.1.1 Air Bleeding Procedure

a. When the ignition switch is set to the ON position to ac-tivate the electromagnetic fuel pump, fuel is forciblysent to the fuel valve of each injection pump and fur-ther to the bleed-off pipe of each nozzle holder, whereair in the fuel bleeds off automatically to the fuel tank.

b. Start the engine and check the fuel system for fuelleaks.

3.2 Fuel Filter Element Change

The fuel filter element should be changed every 500 operat-ing hours. Follow the steps below for changing the fuel fil-ter.

5

T.O. 38G1-127-1TMI-2815-262-1 3&PSWP 004 01

a. Loosen the fuel filter turning it counterclockwise witha filter wrench.

b. With a rag wipe clean the fitting face on the uppercover, so that new fuel filter can be seated properly.

c. Lightly oil the seal on the new filter. To reinstall, turnthe filter assembly clockwise carefully, to prevent thefuel from spilling, until the seal is fitted against thesealing face of the filter cover. Turn 213 turn furtherwith the filter wrench.

3.3 Governor Control Seals

As the governor (timing gear case) is precisely adjusted atthe factory, most of the controls are sealed. Please do notbreak them. When an adjustment is necessary, contact yourequipment supply source.

NOTEThe manufacturer does not warrant the claim on theengine with broken governor seals.

4. AIR INTAKE SYSTEM

4.1 Air Cleaner

Engine performance and life vary with the air intake condi-tions. A dirty air cleaner element reduces the amount of in-take air, causing reduced engine output or a malfunctioningengine. Also, a damaged element leads to abrasion of cylin-ders and valves, resulting in increased oil consumption, re-duced output and shortened engine life. Perform periodicinspection and maintenance, following the equipmentmanufacturer's instructions.

NOTES1. Shorten the cleaning or change interval when the

equipment is used in dusty areas.

2. Change the element if element damage is found duringair cleaner cleaning.

3. Take care not to cause air leakage (sucking) when reas-sembling the air cleaner.

5. ENGINE ELECTRICAL

The ISUZU engine uses a 12 volt dc system and a negativegrounding type for the electrical system.

5.1 Battery Servicing

The equipment that this engine is used on (SGNSC) uses asealed battery which requires no water or electrolyte to

function. When the battery can no longer hold a charge, thebattery must be replaced.

5.1.1 Battery Terminal Connections

Periodically, check the battery terminals for loose connec-tions and corrosion. Loose connections will cause hard en-gine starting or deficient battery charging. If the terminalsare excessively corroded, disconnect the battery cables andpolish them with a wire brush or sandpaper. Never reversethe "+" and "-" terminals when reconnecting the cables.Even a short period of reverse connection could damagethe electrical parts.

5.1.2 Cleaning of Battery

When the battery surfaces are dirty, clean them with cleanwater or warm water and wipe them with a dry cloth to re-move the water. Apply a light coat of grease to the batteryposts.

5.2 Alternator Servicina

The polarity of the alternator is a negative grounding type.When an inverted circuit connection takes place (swappingthe positive and negative cables), the circuit will be inshort circuit instantaneously resulting in the alternator fail-ure. Do not put water directly on the alternator. Entry ofwater into the alternator leads to electrolyte corrosion, caus-ing an alternator failure. When the battery is charged withan external electric source, be sure to disconnect the bat-tery cables.

5.3 Wiring Connections

Frequently check all of the electric wiring connections forlooseness and damage.

6. ENGINE ASSEMBLY AND OTHERS

To continue trouble free engine operation over a long pe-riod of time, the servicing items need a skilled maintenancetechnician; therefore, consult your equipment supplysource on the following items when necessary.

6.1 Fuel Injection Nozzle

WARNING

WHILE USING A NOZZLE TESTER, HIGH-PRESSURE COULD BLOW OFF THE FUELOIL. KEEP AWAY FROM NOZZLE END. USEEYE PROTECTION

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

SWP 004 01

Use an injection nozzle tester to check the static injectionstarting pressure and the fuel spray conditions.

* Injection nozzle pressure test interval: Every 500operation hours.

When the injection starting pressure is too high or too lowor the fuel spray pattern is improper, an abnormal fuel com-bustion takes place in the engine, leading to a lowered out-put and blackish exhaust smoke. Further, it causes a pistonseizure or piston damage etc. In such cases, the injectionnozzle test or the nozzle replacement is required.

* Injection starting pressure: 12.7-13.7 Mpa (1850-1990 psig)

6.2 Valve Clearance Adjustment

d. On completion of the valve clearance adjustment in (c)above, make the mark alignment as in (a) above byturning the crankshaft in the normal direction(counter-clockwise, facing the flywheel). Then meas-ure and adjust the clearance of the other valves.

| AUIN |

The rocker arm is made of die-cast aluminum.Therefore, be careful not to tighten the adjustingscrew to excess.

6.3 Adjustment of Injection Timing

The injection timing may not be readjusted. Take care notto forget to insert a shim on the mounting surface when re-assembling the injection pump after it is removed.

The valve clearance should be adjusted every 1000 operat-ing hours, or whenever the valve rocker is abnormallynoisy, or in an engine malfunction, even though the fuelsystem is properly working.

* Valve clearance: 0.40mm (0.0157 in) (When theengine is cold.)

6.2.1 AdjustmentProcedure

a. Turn the crankshaft clockwise so that the mark grooveon the crank pulley is aligned with the TDC mark(cast mark) on the timing gear case cover.

b. Remove the cylinder head cover and check to see if cyl-inder No. 1 is at TDC in the compression stroke or atTDC in the exhaust stroke. When the intake and ex-haust valves are closed, the cylinder is at TDC in thecompression stroke, and when only the exhaust valveis open, it is at TDC in the exhaust stroke.

c. In accordance with the conditions of cylinder No. 1,measure and adjust, if required, the clearance of thevalves marked with either e or (D in the table below.

6.4 Cylinder Compression Pressure Measurement

The cylinder compression pressure measurement should bedone every 1000 operation hours, or whenever the engineoutput is reduced.

* Compression pressure: 3.04 MPa (441 psi)

* Test condition: Cranking speed 250 rpm

* Coolant temperature: 750C (167 0F)

6.5 Starter and Alternator Servicing

Do the starter and the alternator servicing every 1000 oper-ating hours on the following items.

* Starter commutator cleaning.

* Alternator slip ring cleaning.

* Carbon brushes and the brush contact check.

6.6 Radiator Pressurization Valve Check

A pressurization valve is incorporated in the radiator capassembly. Check the valve actuating pressure with a radia-tor compression tester. For the pressurization valve actuat-ing pressure and the check interval, follow the equipmentmanufacturer's standards.

7/(8 blank)

Cylinder No. 1 2 3 4

ValveArrangement I E I E I E I E

No. I cylinder TDC _ _ ® _for compression

No. 4 cylinder TDC ff E e eDfor compression

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

SWP 004 02



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

1-4 . 0

TABLE OF CONTENTS

Engine Maintenance Schedule ............

PA= Paragraph -w

... 2 2. Explanation of Maintenance Schedule ........ 3

FOREWORD

This Subordinate Work Package (SWP) provides informa-tion on maintenance functions required on the diesel en-

gine and the periodic schedule for performing those mainte-nance functions.

ENGINE MAINTENANCE SCHEDULE



Page No. Page No.

ParagraW

1.

Change No

T.O. 38G1-127-1TM1 -281 5-262-13&PSWP 004 02

1. ENGINE MAINTENANCE SCHEDULE

When performing the following items, the daily inspectionitems should also be carried out.

NO. Description of Check and Maintenance Pre-stt prating Hours RemarkDescription 50 250 50To 750 1000

1 I Oil level and oil fouling I X

2 Oil leakage check X

3 Oil pressure gauge indication X

4 Replace engine oil (X)X X X X

5 Replace oil filter cartridge (X) X X

6 Fuel leakage check X

7 Drain water in fuel/water separator X

8 Replace fuel filter cartridge X X

9 Replace fuel/water separator element X

10 Check fuel injection nozzle (*) X

11 Coolant level and fouling check X

12 Coolant leakage check X

13 Radiator filler cap condition X

14 Fan belt tension check (replace if necessayX

15 Coolant temperature indication X

16 Replace coolant (see equipment T.O.) _ _ -

17 Clean radiator external face (as required)

18 Clean coolant system circuit (yearly) _

19 Radiator filler cap function check (*) (as reqd)

20 Clean battery X

21 Battery charge condition (ammeter indication) X

22 Starter and alternator check and cleaning (*) X

23 Wiring and connection check X

24 Preheating condition check (glow plug condition) X

25 Replace air cleaner element X

26 Engine starting conditions and noise conditions X

27 Exhaust smoke condition X

28 Cylinder compression pressure _ X

29 1 Check valve clearance (*) I X

See "2. EXPLANATIONOF MAINTENANCESCHEDULE"

Note:

1. The service intervals after 1000 hours should also bemade every 250 operation hours in accordance withthis check and maintenance schedule.

2. When the servicing on the asterisked (*) items are nec-essary, consult the equipment supplier.

3. The items designated (X) are required on new enginesonly.

\ S l l l x ffi

T.O. 38G1 -1 27-1TM1-2815-262-1 3&P

SWP 004 02

2.EXPLAN ATIONOFMAINTENANCE SCHEDULE

The following is a brief explanation of the services listed inthe preceding Engine Maintenance schedule charts.

Oil level and oil foul-ing

Oil leakage check

Oil pressure gauge in-dication

Replace engine oil

Replace oil filter car-tridgeFuel leakage check

Draining water infuel/water separator

Replace fuel filter car-tridge

Replace fuellwaterseparator element

Injection nozzle check

Coolant level and foul-ing check

Coolant leakage check

Radiator filler capcondition

Fan belt tension check

Coolant temperatureindication

Replace coolant

Clean radiator exter-nal face

Clean cooling systemcircuitRadiator filling capfunction check

Clean battery

Battery charge condi-tion

Starter and alternatorcheck and cleaning

Check that the oil level is between the maximum level mark and the minimum level mark. Drainoil to the maximum level mark if oil level is above the maximum level mark. Add oil to the maxi-mum level mark if oil is below the minimum level mark.

Replace any damaged or malfunctioning parts which could cause leakage.

Engine oil pressure is normal at about 43 to 71 psi in warmed-up condition. Check and repair thelubrication oil system, if it is abnormal.

Change oil at every 250 hours.

Change cartridge at every 500 hours.

Inspect the fuel lines for damage which could cause leakage. Replace any damaged or malfunction-ing parts.

Drain water in fuel/water separator if water reaches the fuel/water separator.

Change cartridge at every 500 hours.

Change element at every 1000 hours.

Check and adjust injection opening pressure and spray condition. (This is a recommended mainte-nance)

Check coolant level and add coolant if necessary.

Repair part for coolant leakage.

The radiator cap must be installed tightly.

Check and adjust fan belt deflection. Look for cracks, fraying and wear.

Coolant temperature is normal at about 75 to 850C (167 to 1850F). Check and repair the coolingsystem if coolant temperature is abnormal.

Change coolant at intervals of 6 months or 12 months respectively if coolant is plain water, or longlife coolant (LLC).

According to the equipment manufacturer's specification.

Clean the cooling system circuit yearly.

Check radiator pressure cap periodically for proper operation according to the equipment manufac-turer's specification.

Clean the terminals.

Ammeter indication goes to plus (+) side while engine is running.

Check wear condition of brush and commutator every 1000 hours of operation.

T.O. 38G1 -1 27-1TM1-2815-262-1 3&PSWP 004 02

Wiring and connec-tion check

Preheating conditioncheck

Replace air cleanerelement

Engine starting condi-tion and noise condi-tion

Exhaust smoke condi-tionCylinder compressionpressureValve clearance check

Check according to the equipment specifications.

Check preheating condition of the system and the health of the glow plugs.

Change element every 1000 hours of operation.

Check engine stability and noise.

Check exhaust smoke color.

Check at every 1000 hours.

Incorrect valve clearance will result in increased engine noise and lower engine output. Therebyadversely affecting engine performance. Check and adjust at every 1000 hours.

T.O. 38G1 -1 27-1TM1-281 5-262-1 3&P

SWP 004 03



Total number of pages in this SWP is 6Page No. Change No. Page No. Change No.

1-6 . 0

TABLE OF CONTENTSparagraph F=

1. Simple Engine Trouble Shooting ............. 2

ENGINE TROUBLESHOOTING


EFFECTIVITY: ISUZU DIESEL ENGINE MODEL 4LE1PW14

Page No. Change No

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

1. SIMPLE ENGINE TROUBLESHOOTING

This item contains a simple troubleshooting table (Table 1)for when the engine is installed in the SGNSC. When a fail-ure takes place on your engine, diagnose the cause refer-

ring to this troubleshooting table. If the cause of the failurecannot be detected or you are unable to remedy the failure,consult your equipment supply source or nearest ISUZUengine service outlet.

Table 1. Simple Engine Trouble Shooting (Sheet I of 5).

TROU-LE IPROBABLE CAUSE -REMEDY

Engine does not turn over.

Engine cranks but does notstart.

Battery is discharged.

Loose battery cables.

Starter or ignition switch (SW3) failure.

Safety relay failure (R102) failure.

Engine fault delay timer (TR1) hastimed out.

Feed air compressor high air tempera-ture switch (TS5) is open.

Engine fuel stop solenoid is sticking orhas failed.

Fuel tank empty.

Clogged fuel filter element.

Air in the fuel system.

Control rack is stuck in the off position.

Fuel is too cold.

Glow plug failure.

Engine fuel stop solenoid is malfunc-tioning.

Incorrect injection timing.

Low cylinder compression pressure.

Charge the battery.

Tighten the cables.

Replace the starter or ignition switch.

Replace the safety relay.

Turn the ignition switch off then backon again and start the engine before 30seconds has elapsed.

Determine cause of open switch and re-pair. The problem is usually a result oflow compressor coolant. Service com-pressor coolant or replace TS5.

Repair or replace the fuel stop solenoid.

Fill the tank.

Replace the element.

Purge the air from the fuel system. De-termine the source of the air leak and re-pair it.

Repair sticking control rack.

Hold the ignition switch (SW3) in thepreheat position for the proper period oftime before attempting to start the en-gine.

Replace the glow plug(s).

Repair or replace the fuel stop solenoid.

Adjust injection timing.

Engine probably in need of an overhaulor a leaky head.

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

SWP 004 03

Table 1. Simple Engine Trouble Shooting (Sheet 2).

TROUBL- RBLECAUSE IMB

Engine starts but stalls quickly.

Engine suddenly stops whilein normal operation.

Engine idles roughly.

Low idle speed is too high.

Engine is hunting (surging) inthe medium speed range.

Engine runs poorly at highspeeds.


Water in the fuel.

Idle speed is too low.

Low oil pressure switch closed andcaused the fault timer to close the fuelstop solenoid.

The engine over temperature switchclosed and caused the fault timer toclose the fuel stop solenoid.

The feed air compressor high air tem-perature (HAT) switch opened andclosed the fuel stop solenoid.

Crack or leak in injection pipe.

Defection injection nozzle.

Faulty engine fuel stop solenoid.

Uneven compression between the cylin-ders.

Incorrect control lever adjustment.

Governor malfunction.

Governor spring has deteriorated.


Clogged fuel filter element.

Fuel piping leaking or restricted(pinched or flattened).

Deteriorated or broken governor spring.

Uneven fuel injection amount betweenplungers.


Drain the water from the fuel/waterseparator (F6). Drain the water from thefuel tank.

Increase the idle speed.

Add oil to the engine or determine thecause of the low oil pressure.

Add coolant to the radiator or deter-mine the cause of the high temperature.

Add compressor coolant to the coolantseparator tank or determine the causefor the switch to open.

Tighten or replace the injection pipe.

Repair or replace the injection nozzle.

Replace the fuel stop solenoid.

Engine probably in need of an overhaulor a leaky head gasket.

Adjust the control lever.

Repair or replace the governor.

Replace the governor spring.


Replace the fuel filter element.

Tighten or replace the piping.


Repair or replace the injection pump(s).l

I I

-

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


TROU PRABLCAUSE REMEDY

Engine runs poorly at highspeeds (continued).

Engine speed cannot be re-duced.

Engine overheats.

Low oil pressure.

Incorrect valve clearance.

Deteriorated or broken valve spring(s).

Engine control malfunction.

Radiator low temperature operation baf-fle is deployed.

The enclosure warming door is open.

Insufficient coolant.

Fan belt is slipping or is broken.

Thermostat is faulty.

Broken radiator hose causing loss ofcoolant.

Radiator filler cap malfunctioning.

Cooling system interior is fouled.

Exterior radiator fins clogged.

Intake air filter element (F1) is clogged.

Malfunctioning water pump.

Low oil level.

Improper oil.

High coolant temperature.

Clogged oil filter.

Clogged oil pump inlet strainer.

Worn bearings.

Faulty oil pump.

Adjust the valve clearance.

Replace the valve spring(s).

Repair or replace the malfunctioningcomponent (governor, control rack,throttle cable, etc.).

Lift the baffle away from the radiatorand latch in the up position with thespring pin.

Close the enclosure warming door.

Fill the radiator with coolant.

Tighten the fan belt or replace it.

Replace the thermostat.

Replace the radiator hose.

Replace the radiator cap.

Flush the cooling system.

Clean the exterior surfaces of the radia-tor.

Replace the intake air filter element.

Replace the water pump.

Add oil to the crankcase.

Drain the oil and replace it with theproper viscosity according to the ambi-ent conditions.

Determine and repair the cause for theengine to overheat.

Replace the oil filter element.

Clean the strainer.

Replace the bearings.

Replace the oil pump.

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

SWP 004 03


TROU- BABLE CAUSE I EEY

Low oil pressure (continued).

Low engine power.

Excessive oil consumption.

Faulty relief valve.

Incorrect injection timing.

Injection nozzle malfunction.

Low fuel in tank.

Air in the fuel.

Fuel filter clogged.

Injection pump overflow valve malfunc-tion.

Governor engine control out of adjust-ment.

Faulty governor spring.

Low compression due to impropervalve clearance.

Low compression due to a misalignedinjector nozzle holder.

Low compression due to cylinder borewear.

Low compression due to a clogged in-take filter.

Crankcase is over-filled.

Improper oil viscosity.

Faulty cylinder liner and/or piston rings.

Faulty valve stem seal(s).

Oil leakage due to a damaged gasket.

Oil leakage due to loose bolts.

Oil leakage due to an improperly in-stalled oil filter.

Replace the relief valve.

Adjust the injection timing.

Repair or replace the injection nozzle(s).

Fill the tank.


Replace the fuel filter element.

Repair or replace the overflow valve.

Adjust the governor engine control.


Adjust the valve clearance.

Align the nozzle holder.

Overhaul the engine.


Drain some oil to achieve the proper oillevel.

Drain the oil and replace it with theproper viscosity according to the ambi-ent conditions.


Replace the valve stem seal(s).

Replace the gasket.

Tighten the bolts.

Re-install (or tighten) the oil filter car-tridge.

I

I -

T.O. 38G1-127-1TM1-2815-262-1 3&PSWP 004 03


- I- PROBA L CAUSE I REMEDY

Excessive fuel consumption.

Excessive black smoke fromthe exhaust.

Excessive white smoke fromthe exhaust.

Excessive discharging of thebattery.

Fuel leakage.

Excessive fuel injected into the cylinder.

Clogged intake air filter.

Injector nozzle damage.

Injection nozzle is misadjusted.

Injection timing failure.

Improper fuel.

Oil coming down from the valve stems.

Oil bypassing the piston rings.

Injection timing failure.

Low coolant temperature.

Loose or damaged fan belt causing thealternator to slip.

Faulty alternator.

Damaged or loose wiring.

Locate the source of the leakage and re-pair it.

Adjust the injection pump(s).


Replace the injector nozzle.

Adjust the injection nozzle.

Repair the injection timing.

Use the proper fuel.

Replace the valve stem seals.


Repair the injection timing.

Use the radiator baffle for low ambienttemperature operation.

Adjust the fan belt or replace it.

Replace the alternator.

Tighten the terminals or replace the wir-ing.

I

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

WP 005 00

WORK PACKAGE

Page No. Change No.

1-4 . 0


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

TABLE OF CONTENTSParagraph Fg

Foreword ..................... 2

Safety Summary ...................... 2

1. Views of Engine ....................... 3

2. General Repair Instructions ................. 3

3. Main Engine and Specifications .............. 4

LIST OF ILLUSTRATIONSEigum EWg

1 Left Side View of the Engine ............... 4

2 Right Side View of the Engine ............... 4

GENERAL REPAIR INSTRUCTIONS



Change No

T.O. 38G1-127-1TM1-2815-262-1 3&PWP 005 00

FOREWORD

This Work Package (WP) contains general instructions foroverhauling the diesel engine used on the SGNSC.

SAFETY SUMMARY

There are no specific safety related issues in this WP. Gen-eral shop safety practices should be observed when over-hauling the diesel engine.

WARNING STATEMENTSThe following warning statements appear in this WorkPackage:

E ARINGSDO NOT DIRECT AIR STREAMS TOWARDSSELF OR OTHER PERSONNEL. AIR PRES-SURE SHALL BE REDUCED TO LESS THAN 30PSIG AND USED WITH EFFECTIVE CHIPGUARDING AND PERSONAL PROTECTIVEEQUIPMENT.

2

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

WP 005 00

1. VIEWS OF ENGINE

Figure 1 shows the left side view of the engine. Figure 2shows the right side of the engine.

2. GENERAL REPAIR INSTRUCTIONS

a. Before performing any service operation with the en-gine mounted, disconnect the grounding cable fromthe battery. This will reduce the chance of cable dam-age and burning due to short-circuiting.

b. Always use the proper tool or tools for the job at hand.Where specified, use the specially designed tool ortools.

c. Use genuine ISUZU parts referring ISUZU PARTSCATALOG for the engines.

d. Never reuse cotter pins, gaskets, O-rings, lock washers,and self-locking nuts. Discard them as you removethem. Replace them with new ones.

Figure 1. Left Side View of the Engine.

Figure 2. Right Side View of the Engine.

-Thermostat housing

Engine control lever

oil

Nater pump

Starter

T.O. 38G1 -1 27-1TM1-2815-262-1 3&PWP 005 00

e. Always keep disassembled parts neatly in groups. Thiswill ensure a smooth reassembly operation. It is espe-cially important to keep fastening parts separate.These parts vary in hardness and design, dependingupon their installation position.

IWARNING

DO NOT DIRECT AIR STREAMS TOWARDSSELF OR OTHER PERSONNEL. AIR PRES-SURE SHALL BE REDUCED TO LESS THAN 30PSIG AND USED WITH EFFECTIVE CHIPGUARDING AND PERSONAL PROTECTIVEEQUIPMENT.

f. All parts should be carefully cleaned before inspectionor reassembly. Oil ports and other openings should becleaned with compressed air to make sure that theyare completely free of obstructions.

g. Rotating and sliding part surfaces should be lubricatedwith oil or grease before reassembly.

h. If necessary, use a sealer on gaskets to prevent leakage.

i. Nut and bolt torque specifications should be carefullyfollowed.

j. Always release the air pressure from any machine-mounted air tanks(s) before dismounting the engineor disconnecting pipes and hoses.

k. Always check and recheck your work. No service op-eration is complete until you have done this.

3. MAIN ENGINE DATA AND SPECIFICATIONS

Work Package WP 002 00, Table 1 shows the main dataand specifications for this engine.

4

T.O. 38G1 -1 27-1TM1-281 5-262-13&P

SWP 005 01



Page No.

1-10 ...............

Paragraph

1. Tightening TorqStandard Bolts.

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

......0

TABLE OF CONTENTSP= Paraph

ue Specifications for 4. Tightenii........................... 2 4.1 Cooling

2. Tightening Torque Specifications forFlanged Bolts ............................ 3

3. Angular Nut and Bolt Tightening Method ..... 4

4.2 Cylinder

4.3 Cylinder

Page No. Change No

P-a

ng Torque on Major Components .....

Fan and Water Pump ...............

r Head and Cylinder Head Cover ......

-Block and Other Components .......

LIST OF ILlFigum Ea1 Applying Grease to Threads ................. 4

2 Snug Torquing Nut or Bolt .................. 4

3 Marking Bolt Head or Nut .................. 4

4 Marking Initial Alignment Line ......... ..... 4

5 Marking Angular Alignment Line ........ .... 4

6 Rotating Bolt or Nut to Angular AlignmentLine ................... 5

7 Degrees of Angular Rotation ............... 5

Tabl

1 Torque Specifications For Standard Bolts

.-USTRATIONSEigue=12 Cylinder Block and Other Components

Torque Values (3) .... ...... 10

8 Cooling Fan and Water Pump Torque Values .. 6

9 Cylinder Head and Cylinder Head CoverTorque Values ........ 7

10 Cylinder Block and Other ComponentsTorque Values (1) . ......... 8

11 Cylinder Block and Other ComponentsTorque Values (2) ... ....... 9

LIST OF TABLESae Iabl

2 2 Torque Specifications For Flanged Bolts

TIGHTENING TORQUE SPECIFICATIONS



6

6

7

7

1

T.O. 38G1-127-1TM1-2815-262-1 3&PSWP 005 01

1. TIGHTENING TORQUE SPECIFICATIONS FORSTANDARD BOLTS

The tightening torque values given in Table 1 below are ap-plicable to the bolts, unless otherwise specified.

An asterisk (*) indicates that the bolts are used for femalethreaded parts that are made of soft materials, such as castiron. Those shown in parentheses in the strength class indi-cate the classification by the old standard.

Table 1. Torque Specifications For Standard Bolts.

Strength Class 4.8 (4T) (7T) 8.8 9.8 (9T)

Refined Non-Refined

Bolt .&hIdentification 7

S i'No mark

Bolt Size Torque Value - kg-m (lb-ft)

M6 x 1.0 0.4 - 0.8 0.5 - 1.0(2.9 - 5.8) (3.6 - 7.2)

M8 x 1.25 0.8 - 1.8 1.2 - 2.3 1.7 - 3.1(5.8 - 13.0) (8.7 - 16.6) (12.3 - 22.4)

M10 x 1.25 2.1 - 3.5 2.8 - 4.7 3.8 - 6.4(15.2 - 25.3) (20.3 - 34.0) (27.5 - 46.3)

M12 x 1.25 5.0 - 7.5 6.2 - 9.3 7.7 - 11.6(36.2 - 54.2) (44.8 - 67.3) (55.7 - 83.9)

M14x 1.5 7.8- 11.7 9.5- 14.2 11.6- 17.4(56.4 - 84.6) (68.7 - 102.7) (83.9 - 125.6)

M16 x 1.5 10.6 - 16.0 13.8 - 20.8 16.3 - 24.5(76.7 - 115.7) (99.8 - 150.4) (118.9 - 177.2)

M18 x 1.5 15.4 - 23.0 19.9 - 29.9 23.4 - 35.2(111.1 - 166.4) (143.9 - 216.3) (169.3 - 254.6)

M20 x 1.5 21.0 - 31.6 27.5 - 41.3 32.3 - 48.5(151.9 - 228.6) (198.9 - 298.7) (233.6 - 350.8)

M22 x 1.5 25.6 - 42.2 37.0 - 55.5 43.3 - 64.9(185.2 - 305.2) (267.8 - 401.4) (313.2 - 469.4)

M24 x 2.0 36.6 - 55.0 43.9 - 72.5 56.5 - 84.7(264.7 - 397.8) (317.5 - 523.9) (408.7 - 612.6)

*MIO x 1.5 2.0 - 3.4 2.8 - 4.6 3.7 - 6.1(14.5 - 24.6) (20.3 - 33.3) (26.8 - 44.1)

*M12 x 1.5 4.6 - 7.0 5.8 - 8.6 7.3 - 10.9(33.3 - 50.6) (42.0 - 62.2) (52.8 - 78.8)

*M14 x 2.0 7.3 - 10.9 9.0 - 13.4 10.9 - 16.3(52.8 - 78.8) (65.1 - 96.9) (78.8 - 118.9)

T.O. 38G1-1 27-1TM1-281 5-262-1 3&P

SWP 005 01

2. TIGHTENING TORQUE SPECIFICATIONS FORFLANGED BOLTS

The tightening torque values given in the table below areapplicable to the bolts, unless otherwise specified.

Table 2. Torque Specifications For Flanged Bolts.

Bolt HeadMarking

Bolt Size Torque Value - kg-m (lb-ft)

M6 x 1.0 0.5 - 0.9 0.6 - 12(3.6 - 6.5) (4.3 - 8.7)

M8 x 1.25 1.1- 2.0 1.4 - 2.9 1.9 - 3.4(7.9 - 14.5) (10.1 - 20.9) (13.7 - 24.6)

MLO x 1.25 2.3 - 3.9 3.6 - 6.4 4.3 - 7.2(17.3 - 28.2) (26.0 - 44.1) (31.1 - 52.1)

*M1O x 1.5 2.3 - 3.8 3.5 - 5.8 4.1 - 6.8(16.6 - 27.5) (25.3 - 41.9) (29.6 - 49.2)

M12 x 1.25 5.6 - 8.4 7.9 - 11.9 8.7 - 13.0(40.5 - 60.7) (57.1 - 86.1) (62.9 - 94.0)

*M12 x 1.75 3.5 - 9.5 7.3 - 10.9 8.1 - 12.2(37.6 - 56.4) (52.8 - 78.8) (58.6 - 88.2)

M14 x 1.5 8.5- 12.7 11.7 - 17.6 12.6- 18.9(61.5 - 91.9) (84.6 - 127.3) (91.1 - 136.7)

*M14 x 2.0 7.6 - 11.5 11.1 - 16.6 11.8 - 17.7(57.1 - 85.3) (80.3 - 120.1) (85.3 - 128.0)

M16 x 1.5 11.8 - 17.7 17.1 - 26.5 18.0 - 27.1(85.3 - 128.0) (125.8 - 189.5) (130.2 - 196.0)

A bolt with an asterisk (*) is used for female threaded partsof soft material, such as cast iron.

T.O. 38G1 -1 27-1TM1-2815-262-1 3&PSWP 005 01

3. ANGULAR NUT AND BOLT TIGHTENINGMETHOD

The following instructions show the anglular method oftightening nuts and bolts.

a. Carefully wash the nuts and bolts to remove all oil andgrease.

b. Apply a coat of molybdenum disulfide grease to thethreads and setting faces of the nuts and bolts. SeeFigure 1.

Figure 1. Applying Grease to Threads.

c. Tighten the nuts and bolts to the specified torque (snugtorque) with a torque wrench. See Figure 2.

Figure 2. Snug Torquing Nut or Bolt.

d. Draw a line [A-B] across the center of each bolt. SeeFigure 3.

e. Draw another line [C-D] on the face of each of theparts to be clamped. This line should be an extensionof the line [A-B]. See Figure 4.

Figure 3. Marking Bolt Head or Nut.

Figure 4. Marking Initial Alignment Line.

f. Draw another line [F-G] on the face of each of the partsto be clamped. This line will be in the direction of thespecified angle [Q] across the center [E] of the nut orbolt. See Figure 5.

Figure 5. Marking Angular Alignment Line.

Center line

Coinciding line

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

SWP 005 01

g. Use a socket wrench to tighten each nut or bolt to thepoint where the line [A-B] is aligned with the line[F-G]. See Figure 6.

Figure 6. Rotating Bolt or Nut to Angular Alignment Line.

Example: Specified Angle and Tightening Rotation. SeeFigure 7 and the table below.

Figure 7. Degrees of Angular Rotation.

A 300 1/12 of a turn

B 600 1/6 of a turnC 900 . 1/4 of a turnD 1800 1/2 of a turnE 3600 One full turn

T.O. 38G1-127-1TMI-2815-262-1 3&PSWP 005 01

4. TIGHTENING TORQUE ON MAJOR 4.1 COOLING FAN AND WATER PUMP

The following figures show the recommended tightentorque for assembling and installing the major componentsof the engine.

Figure 8 shows the tightening torque for the coolin fan andwater pump.

Figure 8. Cooling Fan and Water Pump Torque Values.kg-m Ob-ft)

-s

/

T.O. 38G1-127-1TM1-281 5-262-1 3&P

SWP 005 01

4.2 CYLINDER HEAD AND CYLINDER HEADCOVER

Figure 9 shows the tightening torque for cylinder head andcylinder head cover.

4.3 CYLINDER BLOCK AND OTHERCOMPONENTS

Figures 10, 11 and 12 show the tightening torque for thecylinder block and other components.

1 0.8-1.2

2.5 -3.51118.0 - 26.3)

(Apply engine oil.)

(lApply locktite No.262 to this part.)

1 1.9-2.91[13.7 -21.01

Figure 9. Cylinder Head and Cylinder Cover Torque Values.kg-rn (lb-ft)

T.O. 38G1 -1 27-1TM1-281 5-262-1 3&PSWP 005 01

(*): Apply Locktite No.262 to set up side of stud.(Important)

Figure 10. Cylinder Block and Other Components Torque (1).kg-rn (lb-ft)

8

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

SWP 005 01

I10.8-18.0)

i 1129.0-36.21

Figure 11. Cylinder Block and Other Components Torque (2).kg-rn (lb-ft)

I i-Z t -. 9 - -2.-9 1-'' ~ 1. - 2-)

T.O. 38G1-127-1TM1-2815-262-1 3&PSWP 005 01

(With PTO provided)

Figure 12. Cylinder Block and Other Components Torque (3).kg-rn (Ib-ft)

10

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

SWP 005 02


Page No. Change No.

1-3 ... 04 Blank ... 0

Paragrap

1.

2.

Figure

1

Tabk

1



TABLE OF CONTENTS2h EwGasket Locations ...................... 2

Sealant Application Locations ............... 3

LIST OF ILLUSTRATIONS

Gasket Locations on Engine ................. 2

LIST OF TABLES

Locations of Sealant Application ....... ...... 3

ENGINE GASKETS



Page No. Change No

T.O. 38G1-127-1TM1-2815-262-1 3&PSWP 005 02

1. GASKET LOCATIONS

Figure 1 shows the location for all of the gaskets on the en-gine.

Gasket; joint boltGasket; nozzle holder

G asket; nozzle holder

Gasket; headcover/,, Sealant should not be

.t-S / { m y applied.

Corrugated washer { 9_> |

Gasket; _Cheat shield

Seal; valve

Gasket;water outlet p)ipe AZGasket;

cylinder headGasket;idle spring set screw

0-ring; .fuelcutlever Gasket; H O s

i04O,^>governor$ mI i~1cover ~ -crankshaft

_ ~~~rear

0-ring; -v, '. U yu. Gasket;Oil pump exhaust silencer

Figure 1. Gasket Locations on Engine.

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

SWP 005 02

2. SEALANT APPLICATION LOCATIONS

Table 1 shows the locations where it is necessary to applysealant, the purpose for the sealant and the type of sealantto be used.

Table 1. Locations of Sealant Application.

3/(4 blank)

Location Condition For UseNo. Name of Sealant

Name of Part Name of Mating Part Object to be Groove to beSealed Applied

1 Oil pan Cylinder block Engine oil Not provided TB1207C(lOW-30)

2 Rocker bracket Cylinder head Engine oil Provided TB1 207C(IOW-30)

3 Air inlet pipe Cylinder head cover Air Provided TB1207C

4 Front plate Cylinder block Engine oil Provided TB1207C(lOW-30)

5 Timing case Front plate Engine oil Provided TB1207C(IOW-30)

6 Water pump assembly Cylinder block Cooling water Not provided TB1207C

7 Water pump rear cover Water pump body Cooling water Provided TB1207C

8 Housing cover; injection Cylinder block Engine oil Provided TBI207Cpump (1OW-30)

9 Fuel stop solenoid Cylinder block Engine oil Provided TB1207C(lOW-30)

10 Oil seal retainer Cylinder block Engine oil Provided TB1207C___________ _ ._____ ______ __ _ (1OW -30)

Change No.

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

SWP 005 03




1-7 ... 08 Blank ... 0

TABLE 01haragrob EgForeword ......................... 2

Safety Summary ........................ 2

1. Valve Clearance and Adjustment ..... ........ 3

2. Lubrication System ........................ 3

2.1 Oil Filter Cartridge ........................ 3

3. Cooling System ........................ 4

3.1 Cooling Fan Belt Adjustment ................ 4

Fi gure

1

2

3

4

5

6

7

8

I CONTErParagra

4.

4.1

5.

6.

6.1

6.2

7.

ITS

LIST OF ILLUSTRATIONS

Top Dead Center (TDC) Mark ..... .......... 3 9 Injecti

No. 1 Cylinder Intake and Exhaust Valves ...... 3 10 Injecti

Valve Adjustment Chart .................... 3 11 Comp

Loosening Valve Clearance Screw ............ 3 12 Comp

Oil Filter Cartridge ......................... 4 13 Fuel F

Cooling Fan Drive Belt Tension .............. 4 14 . Injecti

Injection Pump Delivery Valve ..... ......... 4 15 Injecti

TDC Timing Mark ......................... 5

EM

Injection Timing ........................ 4

Bleeding Air From Fuel .................... 5

Compression Pressure Measurement .......... 5

Fuel System ......................... 6

Fuel Filter Replacement ................... 6

Injection Nozzle ........................ 6

Recommended Lubricating Oil ...... ........ 7

Rnon Pump Timing Adjustment Shim .....

.on Pumps and Fuel Flow..............

ression Gauge and Adapter ............

ression Gauge Pulsation..............

Filter Cartridge ......................

ion Nozzle Spray Pattern .........X .

ion Nozzle Tester ....................

5r

5

6

6

6

7

7

I

ENGINE MAINTENANCE AND ADJUSTMENTS


EFFECTIVITY: ISUZU DIESEL ENGINE MODEL 4LElPWI4

Page No. Page No. Change No

T.O. 38G1-127-1TM1-2815-262-13&PSWP 005 03

FOREWORD

This Subordinate Work Package (SWP) contains proce-dures for adjusting engine and valves on the diesel engine.

It also contains procedures for checking the cylinder com-pression and the injection nozzle spray pattern.

SAFETY SUMMARY

Some procedures in this SWP requires the use of dieselfuel for checking the injection nozzle spray pattern. Do not

allow the fuel to contact hot surfaces. Do not smoke or al-low any open flames within 50 feet of the work area.

1. VALVE CLEARANCE AND ADJUSTMENT

NoteThe cylinder head bolts were previously tightenedwith the "Angular Tightening method." Therefore,it is not necessary to retighten the cylinder headbolts before adjusting the valve clearance.

a. Bring the piston in either the No. 1 cylinder or the No.3 cylinder to Top Dead Center on the compressionstroke by turning the crankshaft until the TDC markon the front cover aligns with the groove mark on thecrankshaft pulley (see Figure 1).

Figure 1. Top Dead Center (TDC) Mark.

b. Check to see if there is play in the No. 1 intake and ex-haust valve rocker arms (see Figure 2). If the No. 1cylinder intake and exhaust valve rocker arms haveplay, the No. 1 piston is at TDC on the compression

No.1 cyl~nder ~ ~ Noo11cy inderNo.1 r1ldr 1 exhaustinta(

Figure 2. No. 1 Cylinder Intake and Exhaust Valves.

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

SWP 005 03

Cylinder No. 2 3 4Valve I E I E I E I EArrangement

No. 1 cylinderTDC for com- ® ®3pressionNo. 4 cylinderTDC for com- @ Epression II I I

Figure 3. Valve Adjustment Sequence Chart.

c. Loosen each valve clearance, adjusting the screw asshown in Figure 4.

Figure 4. Loosening Valve Clearance Screw.

d. Insert a 0.40 mm (0.015 in) feeler gauge between therocker arm and the valve stem end.

e. Turn the valve clearance adjusting screw until a slightdrag can be felt on the feeler gauge.

f. Tighten the lock nut securely.

g. Rotate the crankshaft 360°. Realign the crankshaft pul.ley.

h. Adjust the clearances for the remaining valves asshown in Figure 3.

2. LUBRICATION SYSTEMstroke. If the No. 1 cylinder intake and exhaust valverocker arms are depressed, the No. 4 piston is at TDCon the compression stroke. Adjust the '®' or 'D'marked valves as shown in Figure 3, while the No. 1or the No. 4 cylinder is at TDC on compression stroke.

2.1 Oil Filter Cartridge

2.1.1 Removal

Refer to Figure 5.

Remover and Installer Tool: Filter Wrench p/n 5-8840-9015-0

Intake and Exhaust Valve 10.40 ±0.05 mmClearance (cold) |(0.015 ±0.002 in)

T.O. 38G1 -I 27-1TM1-2815-262-1 3&PSWP 005 03

Figure 5. Oil Filter Cartridge.

a. Loosen the used oil filter by turning it counterclock-wise with the filter wrench.

b. Discard the used oil filter.

2.1.2 Inistallatio

a. Wipe the oil filter mounting face with a clean rag. Thiswill allow the new oil filter to seat properly.

b. Lightly oil the O-ring.

c. Turn in the new oil filter until the sealing face is fittedagainst the O-ring.

d. Use the filter wrench to turn in the oil filter an addi-tional 34 of a turn or one turn.

e. Check the engine oil level and replenish to the speci-fied level if required.

f. Start the engine and check for oil leakage from the oilfilter.

3. COOLING SYSTEM

3.1 Cooling Fan Drive Belt AdJustment

a. Check the cooling fan drive belt for cracking and otherdamage.

b. Check the drive belt tension by exerting a force of 10kg (22 lb) midway between the fan pulley (1) and thegenerator pulley (2). Refer to Figure 6.

c. Adjust the belt tension by loosening the generatormounting bolt and the generator adjusting bolt andpivoting the generator.

Figure 6. Cooling Fan Drive Belt Tension.

d. Be sure to retighten the bolts after adjusting the belttension.

Cooling Fan Drive | 8.0 - 12.0 mmn lBelt Deflection (0.3 - 0.5 in)

4. INJECTION TIMING

NoteTake care to avoid entry of dust or foreign particlesinto the pump interior when the timing adjustmentis made.

a. Remove the injection pipe of the No. 1 cylinder.

b. Remove the delivery valve holder of the injectionpump of the No. 1 cylinder, and then pull out the de-livery spring. Refer to Figure 7.

Figure 7. Injection Pump Delivery Valve.

c. With the spring removed, install the delivery valveholder.

d. Slowly turn the crankshaft pulley clockwise and, at thesame time, continue to feed the fuel. When the fuelstops flowing out of the No. 1 delivery valve holder,

4

Delivery valve_ holder

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

SWP 005 03

stop turning the crankshaft. This crank angle positionis the starting point of injection.

e. In the condition at step (d) above, confirm what degreethe "groove mark" of the crank pulley is at, whenseen by the "timing mark" (see Figure 8), provided inthe timing gear case. When the value is out of therange of the normal injection timing, adjust it accord-ingly.

Figure 8. TDC Timing Mark.

I Injection timing I BTDC 160 l

f. Adjust the injection timing with a shim between the in-jection pump and the cylinder block (see Figure 9).The shim is available in the following 9 types, and the"identification mark" is stamped (or imprinted) on thetop face.

Figure 9. Injection Pump Timing Adjustment Shim.

Identification mark of shim and its thickness - mm

Mark Thickness Mark Thickness Mark Thickness

2 0.2 5 0.5 8 0.8

3 0.3 6 0.6 10 1.0

4 0.4 7 0.7 12 1.2

NoteFor each of the injection pumps of the four cylin-ders, the shim adjustment is made at the same time.When a shim is missing, while overhauling the en-gine, and the shim thickness is unknown, assemblethe engine with the provisional shim inserted. Afterassembling the engine, check the injection timingand adjust the shim until the normal injection timingis obtained.

Reference:Each 0.1 mm (0.0039 in.) shim thickness corresponds to 1°of crankshaft angle advance.

4.1 Bleeding Air From Fuel

When the starter switch is set to "IGN," the electromag-netic pump is activated to force-feed fuel to the fuel pipeand the leak-off pipe, and the air in the fuel system is auto-matically bled. Refer to Figure 10 for fuel flow direction.

Figure 10. Injection Pumps and Fuel Flow.

5. COMPRESSION PRESSURE MEASUREMENT

a. Operate the engine to warm-up until the coolant tem-perature reaches to 750C (1670F).

b. Remove all of the glow plugs and the injection pipes.

c. Attach a compression gauge to the No. 1 cylinder glowplug installation threads. Refer to Figure 11.

NoteCompression pressure may be measured starting atany cylinder and in no particular cylinder order.However, it is very important that the compressionpressure be measured in each cylinder. Therefore,start at the No. 1 cylinder and work back. In thisway, you will be sure to measure the compressionpressure in each cylinder.

T.O. 38G1-127-1TM1-2815-262-1 3&PSWP 005 03

Figure 11. Compression Gauge and Adapter.

Special tools required:

Compression Gauge p/n 5-8840-2008-0

Compression Gauge Adapter p/n 5-8840-2009-0

d. Crank the engine with the starter motor and take thecompression gauge reading. The values in the tablebelow is with the engine speed at 250 rpm. The pres-sure gauge may pulsate (see Figure 12) so take the av-erage reading (midpoint of the pressure swing).

Figure 12. Compression Gauge Pulsation.

Standard Limit I

31.0 kg/cm (441 psig) 26.0 (370 psig)

exceeding 2.0 kg/cm2 (28 psi) is unacceptable. If themeasured value exceeds the specified limit, the re-lated parts must be checked.

6. FUEL SYSTEM

61 Fuel Filter Replacement

6.1.1 Removal

a. Loosen the fuel filter by turning it counterclockwisewith the filter wrench or your hand. Discard the usedfilter. Refer to 13.

Figure 13. Fuel Filter Cartridge.

Tool required: Filter Wrench p/n 5-8840-9015-0

b. Wipe the fuel filter fitting face clean with a rag. Thiswill allow the new fuel filter to seat properly.

6.1.2 Installation

a. Apply a light coat of engine oil to the O-ring.

b. Supply fuel to the new filter. This will facilitate airbleeding.

c. Turn in the new fuel filter until the filter O-ring is fittedagainst the sealing face.

d. Use the filter wrench to turn in the fuel filter an addi-tional 2/3 of a turn.

6.2 Injection Nozzle

Check to see if the spray condition and the injection pres-sure are normal. Adjust them to the specified value respec-tively when they don't meet the standard value. Refer toFigure 14.

I

0i

FT~~~~~~. * ',

e. Repeat the procedure, steps (b) and (c), for the remain-ing cylinders. The compression pressure should be ap-proximately the same for each cylinder. A variation

-

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

SWP 005 03

Figure 14. Injection Nozzle Spray Pattern.

Using a nozzle tester, adjust the injection pressure with ashim. Refer to Figure 15.

Special tool: Nozzle tester p/n 5-8840-9016-0

Figure 15. Injection Nozzle Tester.

7. RECOMMENDED LUBRICATING OIL

See Work Package WP 002 00, paragraph 3.2, for the rec-ommended lubricating oil for this engine.

7/(8 blank)

good No good No good No good

/ I I

About 40,

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

WP 006 00

WORK PACKAGE


Total number of pages in this WP is 2

Change No. Page No. Change No. Page No. Change No

1.. 02 Blank. 0

TABLE OF CONTENTSParagraph Page

1. Engine Disassembly ....................... 1

2. Inspection and Repair. 1

2. Engine Reassembly. 1

1. ENGINE DISASSEMBLY

Subordinate Work Package SWP 006 01 shows the disas-sembly steps for the engine. Work Package WP 005 00 out-lines the general format used in these instructions.

2. INSPECTION AND REPAIR

Subordinate Work Package SWP 006 02 shows the inspec-tion and repair steps for the engine. Work Package WP 00500 outlines the general format used in these instructions.

3. ENGINE REASSEMBLY

Subordinate Work Package SWP 006 03 shows the reas-sembly steps for the engine. Work Package WP 005 00 out-lines the general format used in these instructions.

1/(2 blank)

ENGINE DISASSEMBLY, INSPECTION AND REPAIR, AND REASSEMBLY



Page No.

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

SWP 006 01



Total number of pages in this SWP is 14

Change No. Page No. Change No.Page No. Page No. Change No

1-14 . 0

TABLE OF CONTENTSparagraph Ea Paragraph PEge

Foreword ....................... 2 2. Internal Parts ........................... 6

Safety Summary ........................-. 2 2.1 Rocker Bracket and Push Rod .............. 10

1. Engine Disassembly 3.................... 3 2.2 Cylinder Head Assembly. 10

1.1 Left Hand Side External Parts ............... 3 2.3 Valve Mechanism .10

1.2 Right Hand Side External Parts .4.. 4 2.4 Timing Gear .10

1.3 Fuel Piping and Injections Pumps .5 2.5 Camshaft .10

1.4 Backlash of Timing Gear ................... 5 2.6 Piston and Connect Rod .10

1.5 Idler Gear End Play.. 6 2.7 Piston Ring...................... 11

1.6 Crankshaft End Play ....................... 2.8 Piston Pin .11

LIST OF ILLUSTRATIONSFigure Em Eiur Ea=

1 Left Side External Parts .................... 3 11 Cylinder Head Assembly. 10

2 Right Side External Parts ................... 4 12 Cylinder Head Bolt Removal Sequence . 10

3 Injection Pump and Fuel Piping .5 13 Cylinder Head Assembly .................. 11

4 Fuel Stop Lever.5 14 Timing Gear Parts. ............... 12

5 Injection Pump Control Link ................ 5 15 Camshaft .13

6 Injection Pump and Shim ................... 5 16 Piston and Connecting Rod .13

7 Engine Internal Parts (1).7 ..................... 717 Crankshaft .13

8 Engine Internal Parts (2) .................... 8 18 Removing Piston Ring .14

9 Engine Internal Parts (3) .................... 9 19 Removing Piston Pin .14

10 Rocker Bracket .10

ENGINE DISASSEMBLY PROCEDURES



T.O. 38G1-127-1TM1-2815-262-1 3&PSWP 006 01

FOREWORD

This Subordinate Work Package (SWP) contains instruc-tions for complete disassembly of the diesel engine used onthe SGNSC.

SAFETY SUMMARY

There no specific safety related issues in this SWP. Gen-eral shop safety practices should be observed when disas-sembling the diesel engine.

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

SWP 006 01

1. ENGINE DISASSEMBLY(9) Water pump assembly

1.1 Left Hand Side External Parts

Figure 1 shows the sequence of disassembly for the exter-nal components on the left side of the engine.

Legend for Figure 1:

(1) Cooling fan and spacer

(2) Fan belt

(3) Fan pulley

(4) Generator

(5) Starter

(6) Exhaust manifold and gasket

(7) Cylinder head cover and air intake pipe

(8) Water outlet pipe and thermostat

Figure 1. Left Side External Parts.

(5)

T.O. 38G1-127-1TMI-2815-262-1 3&PSWP 006 01

1.2 Right Hand Side External Pats

Figure 2 shows the sequence of disassembly for the exter-nal components on the right side of the engine.


(10) Injection pipe; 4 pcs.

(11) Fuelhose

(12) Fuel leak off pipe

(13) Fuel pipe

(14) Engine stop solenoid

(15) Injection pump housing cover

(16) Injection pump and shim; 4 sets

(17) Oil filter

(18) Oil level gauge

(17) _

(18)

Figure 2. Right Side External Parts.

(16)

(15)

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

SWP 006 01

1.3 Fuel Piping and Injection Pumps

1.3.1 Injection Pipe, Leak Off Pipe, and Fuel Pipe

a. Loosen the sleeve nuts on the nozzle holder side and onthe injection pump side, and then disconnect the injec-tion pipes. Refer to Figure 3.

Figure 3. Injection Pump and Fuel Piping.

b. Disconnect the leak off pipe together with gaskets.

c. Remove the eyebolt and then disconnect the fuel pipe.

1.3.2 lpffection Pumnp

a. Align the hole of the fuel cut lever with the hole of thegovernor cover. Then insert a pin (6 0 mm) into thishole to hold the fuel cut lever. Refer to Figure 4.

Figure 4. Fuel Stop Lever.

Figure 5. Injection Pump Control Link.

NOTEMark each injection pump as to the cylinder fromwhich it was removed.

Do not reuse the shim; replace it with the samethickness that was removed.

Figure 6. Injection Pump and Shim.

1.4 Backlash Of Timina Gear

b. Check to see if the pin groove of the control link is atthe center of the injection pump. Refer to Figure 5.

c. Remove the injection pump, and then take out theshim. Refer to Figure 6.

injection pumpControl link center position

I i p

Injection pump rackI pinInjection pipe

Leak off pipeAs I ; g e'~Eye bolt

vat\ 1 . Fuel pipe

11 , @% ZNozzle holder

, - Injection pump

*

STANDARD LIMIT

CRANK 0.04 mm 0.20 mmGEAR/ IDLER (0.0017 in) (0.0079 in)GEAR II

CAM GEAR/ 0.03 mm 0.20 mmIDLER GEAR (0.0012 in) (0.0079 in)

T.O. 38G1-127-1TM1-2815-262-1 3&PSWP 006 01

1.5 Idler Gear End Play

STANDARD LIMIT

0.058 - 0.208 mm 0.20 mm(0.0023 - 0.0048 in) (0.0079 in)

1.6 Crankshaft End Play

STANDARD LIMIT

0.058 - 0.115 mm 0.30 mm(0.0023 - 0.0082 in) (0.0118in)

(15) Oil Pump Assembly

(16) Idler Gear and Shaft

(17) Cam Gear

(18) Camshaft

(19) Rear Seal Retainer

(20) Piston Assemblies

(21) Crankshaft

2. INTERNAL PARTS

Figures 7, 8 and 9 show the sequence of disassembly forthe internal components of the engine.

Legend for Figures 7, 8 and 9:

(1) Rocker Bracket Assembly

(2) Push Rods

(3) Rear Hanger

(4) Front Hanger

(5) Cylinder Head Assembly

(6) Cylinder Head Gasket

(7) Tappets

(8) Oil Pan

(9) Oil Strainer

(10) Oil Pipe

(11) Crank Pulley

(12) Flywheel

(13) Flywheel Housing

(14-1) Timing Gear Case

(14-2) Front Plate

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

SWP 006 01

't

Q'\N

(7)

16)

Figure 7. Engine Internal Parts (1).

a

(3)

I-.-- 5)

-

T.O. 38G1-127-1TM1-2815-262-1 3&PSWP 006 01

(13)Do not pull outthis bolt.

RearI ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~I! i.I

I 19)I

I I

Figure 8. Engine Intemnal Parts (2).

8

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

SWP 006 01

(14-2)

(15)

Figure 9. Engine Internal Parts (3).I

T.O. 38G1-127-1TMI-2815-262-1 3&PSWP 006 01

2.1 Rocker Bracket and Push Rod

a. Remove the rocker bracket assembly. (M6 X 1.0; 5bolts and 6 nuts.) Refer to Figure 10.

b. Pull out the push rods (8 pcs.)

Figure 10. Rocker Bracket.

2.2 Cylinder Head Assembly

a. Remove the rear and front hangers. Refer to Figure 11.

Figure 11. Cylinder Head Assembly.

b. When removing the cylinder head bolts, loosen themslowly (a little at a time) starting with the outside andworking in a circular pattern inward (see Figure 12).

c. Remove the cylinder head assembly and the head gas-ket.

d. Pull out the tappet from the cylinder body. Refer to Fig-ure 13.

2.3 Valve Mechanism

Figure 12. Cylinder Head Bolt Removal Sequence.

a. Before disassembling the valve mechanism, remove theconnector, glow plugs and nozzle holder assemblies.

b. Compress the valve spring, then remove the split col-lar, spring seat, valve spring and valve.

2.4ZTiming Ga

Refer to Figure 14.

a. Remove the idle gear and the idle gear shaft.

b. Pull out the sleeve from the top end of the camshaft.

c. Remove the lock nut of the camshaft gear. Then re-move the flyweight assembly and the cam gear.

2.5 Camshaft

Refer to Figure 15.

a. Remove the snap ring, which holds down the frontbearing of the camshaft, from the ring groove of thecylinder block.

b. Pull out the camshaft from the cylinder block, togetherwith the bearings.

c. Remove the bearings from the camshaft using the re-moval tool.

Bearing removal tool: p/n 5-8840-0015-0

2.6 Piston and Connecting Rod

Refer to Figures 16 and 17.

a. Turning the crankshaft, position the piston to be re-moved at the bottom dead center.

10

5 4 3 2 1

, 0 -- -G - -: -

- - - * 4a. - 16

Refer to Figure 13.

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

SWP 006 01


b. Loosen the cap nut of the connecting rod, and then re-move it.

c. Give another rotation to the crankshaft to position thepiston at the top dead center.

d. With the handle of a hammer placed at the bottom ofthe connecting rod, push the piston assembly upwardout of the cylinder block.

NoteBefore removing the piston, scrape the carbon de-posit off the cylinder wall.

When pushing out the piston assembly, care shouldbe taken not to damage the cylinder wall.

Attach a tag with a cylinder number to the removedcaps and bearings to keep them in order.

Remove the piston ring with ring pliers.

Piston ring pliers: p/n 1-8522-1029-0

2.8 Piston Po

Refer to Figure 19.

a. Remove the snap rings with a commercially availabletool.

b. With a brass bar attached to the piston pin, push it outby hammering it lightly.

Drive bar: p/n 5-8840-0007-0

NoteKeep the piston, piston pins and connecting rods inorder for each cylinder.

2.7 Piston RIg

Refer to Figure 18.

Seal; valvew (1) Glow plug (2)

.CD %R- Split collar (4)

Studs are applied withsealing agent.Do not pull them out._ (5 locations) e

Seat; valve insert

T.O. 38G1-127-1TM1-2815-262-1 3&PSWP 006 01

Wear ring

Cam

Bearing

Snap ring (7)

Cam gear (6)

Lock nut

Sleeve (4)

Shaft; idle

Idle gear (2)

Thrust collar

Key

Crank gear

Crank pulley (1)

Washer

Figure 14. Timing Gear Parts.

12

T.O. 38G1 -1 27-1TM1-2815-262-1 3&P

SWP 006 01

Figure 15. Camshaft.

Piston ring (4)

Pis

Piston pin (6) -

Con'rod bolt(The drawing-out of the con'rod boltmust be limited to only when replaced.)

Figure 17. Crankshaft.

Snap ring (5)

Bush) -U~ (The drawing-out of the bush must

be limited to only when replaced.)

Connecting rod (7)

Figure 16. Piston and Connecting Rod.

Camshaft ZN

Snprn

T.O. 38G1-127-1TM1-2815-262-13&PSWP 006 01

Figure 18. Removing Piston Ring.

Figure 19. Removing Piston Pin.

T.O. 38G1-127-1TM1-281 5-262-1 3&P

SWP 006 02



Total number of pages in this WP is 18Change No. Page No. Change No. Page No.

1-18 . 0

TABLE OF CONTENTSPg Paragraph

List of Illustrations ........................ 2

Foreword ........................... 3

Safety Summary .......................... 3

Inspection and Repair ...................... 4

Cylinder Block ........................... 4

Checking Cylinder Block .......... ......... 4

Checking Cylinder Bore .................... 4

Cylinder Body Upper Face Warpage ......... 5

Cylinder Head ............................ 5

Cylinder Head Inspection ................... 5

Hot Plug ........................... 6

Heat Shield Replacement ........... ........ 8

Valve, Valve Seat Insert and Valve Seal ...... 8

Inspection of Valve Seat .................... 8

Valve Seat Insert Replacement ............... 9

Valve Spring ........................... 10

rag5.1 Valve Spring Inclination .................. 10

5.2 Valve Spring Tension .................... 11

5.3 Valve Spring Free Length ................. 11

6. Tappet and Push Rod ..................... 11

6.1 Tappet ........................ 11

6.2 Push Rod .......................... 12

7. Camshaft ........................ 12

8. Rocker Ann Shaft and Rocker Ann ......... 13

9. Piston, Piston Pin and Piston Ring ..... -... 14

10. Connecting Rod and Connecting RodBearing ........................ 15

10.1 Connecting Rod Bearing Inspection ......... 16

11. Crankshaft and Crankshaft Bearing ......... 16

12. Flywheel and Ring Gear .................. 17

13. Timing Gear ........................ 18

ENGINE INSPECTION AND REPAIR PROCEDURES



Page No.

Paragraph

Change No

1.

2.

2.1

2.2

2.3

3.

3.1

3.2

3.3

4.

4.1

4.2

5.

T.O. 38G1-127-1TM1 -2815-262-13&PSWP 006 02

LIST OF ILLUSTRATIONSPE Fuig

Cylinder Block ......................... 4 30

Measuring Cylinder Bore .................... 4 31

Cylinder Bore Grade Marks .................. 4 32

Checking Cylinder Face Warpage ............ 5 .33

Cylinder Face Inspection Pattern ............. 5 34

Cylinder Body Height ...................... 5 35

Cylinder Head ...... .. .................... 5 36

Checking Cylinder Head Warpage .6 37

Cylinder Head Inspection Pattern .6 38

Cylinder Head Height. 6 39

View Showing Hot Plug Depression .6 40

View Showing Combustion Chamber .7 41

Removing Hot Plug .7 42

Aligning Hot Plug .7 43

Installing Hot Plug .7 44

Tapping Hot Plug into Head .8 45

Removing Heat Shield .8 46

Installing Heat Shield .8 47

Valve Seat Dimensions .8 48

Valve Thickness .9 49

Measuring Valve Stem Diameter .9 50

Valve Seat Insert Removal .9 51

Installing Valve Seat Insert .10 52

Valve Seat Angle .10 53

Valve Seat Angle Cutter .10 54

Checking Valve Seat Contact .10 55

Checking Valve Spring Straightness .11 56

Checking Valve Spring Tension .11 57

Checking Valve Spring Length .11

PageMeasuring Tappet Diameter ................ 11

Measuring Tappet Travelling Bore ........... 12

Checking Push Rod Run-out ............... 12

Camshaft ............................ 12

Measuring the Camshaft ................... 12

Camshaft Inspection Locations .............. 12

Inspecting Camshaft Run-out ............... 12

Rocker Arm Shaft and Rocker Arm .......... 13

Measuring Rocker Arm Shaft ................ 13

Rocker Arm............................. 13

Rocker Ann Shaft ..................... 14

Measuring Piston Diameter ................ 14

Location of Piston Grade Mark ............. 14

Measuring Piston Pin ..................... 15

Checking Piston Ring Gap ................. 15

Checking Piston Ring Groove Clearance ...... 15

Checking Connecting Rod Straightness ....... 15

Checking Pin to Connecting Rod Clearance. . . 1 6

Checking Connecting Rod Bearing .......... 16

Checking Connecting Rod Bearing Bore ...... 16

Checking Crankshaft Journal ............... 16

Checking Crankshaft Bearing Bore .......... 17

Checking Crankshaft Runout ............... 17

Crankshaft Gear ......................... 17

Front Oil Seal ........................... 17

Removing Ring Gear ..................... 18

Measuring Idle Gear Shaft ................. 18

Measuring Idle Gear Bore .................. 18

Eigt

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

T.O. 38G1 -1 27-1TM1-281 5-262-13&P

SWP 006 02

FOREWORD

This Subordinate Work Package (SWP) containns proce-dures for inspecting critical components of the diesel en-gine for the SGNSC. It also has procedures for the repairof some components and resurfacing metal parts to complywith the manufacturer's specifications.

SAFETY SUMMARY

Some of the procedures in this SWP require the use of heatto aid in the maintenance of the engine. Always handle hotparts with heavy gloves. Use general shop safety practicesfor any maintenance operation.

WARNING STATEMENTSThe following warning statements appear in this Subordi-nate Work Package:

Si WARNING |

USE EYE PROTECTION WHEN USING AGRINDER.

||WANNG |

USE EYE PROTECTION WHEN USING HAM-MER AND CHISEL.

| WRNNG|

USE EYE PROTECTION WHEN USING HAM-MER.

T.O. 38G1-127-1TM1-2815-262-1 3&PSWP 006 02

1. INSPECTION AND REPAIR

Make the necessary adjustments, repairs, and part replace-ments, if excessive wear or damage is discovered during in-spection.

2. CYLINDER BLOCK

2.1 Checking Cylinder Block

Refer to Figure 1.

Figure 1. Cylinder Block.

a. Check the cylinder block for wear, damage or anyother defects.

b. Use the hydraulic gauge to check the water jacketwater pressure.

c. Apply water pressure to the water jacket at 5 kg/cm2

(71.1 psi) for three minutes.

2.2 Checking Cylinder Bore

Measure the cylinder bore as shown in Figure 2.

Measurement position: 13mm below the top(Measure in X-X and Y-Y direc-tions.) (Near the No. 1 compres-sion ring.)

LIMIT REPAIR METHOD

0.20 mm (0.0079 in.) Perform boring and honingof the inside diameter.

2.2.1 Cylinder Bore Diameter and Grade Mark

The grade mark is stamped on the top surface of the cylin-der block (on the mating face with the cylinder head). Re-fer to Figure 3.

Figure 3. Cylinder Bore Grade Marks..

Figure 2. Measuring Cylinder Bore.

Bore grade mark/Stamp position)

+~~~~~a

BORE DIAMETER GRADE MARK

85.000 - 85.010mm A(3.3464 - 3.3468 in.)

85.011 - 85.020 mm B(3.3468 - 3.3472 in.)

85.021 - 85.030 mm C(3.3472 - 3.3476 in.) I

y

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

SWP 006 02

2.3 Cylinder Body Upper Face Warpage

a. Use a straight edge (1) and a feeler gauge (2) to meas-ure the four sides and the two diagonals of the cylin-der body upper face (see Figures 4 and 5).

Figure 4. Checking Cylinder Face Warpage.

Figure 5. Cylinder Face Inspection Pattern.

b. Regrind the cylinder body upper face if the measuredvalues are greater than the specified limit but lessthan the maximum grinding allowance.

If the measured values exceed the maximum grinding al-lowance listed below, the cylinder body must be replaced.

Cylinder Body Upper Face Warpage Allowance

MAXIMUMSTANDARD LIMIT GRINDING

ALLOWANCE

0.075 mm 0.150 mm 0.300 mm(0.0029 in.) (0.0059 in.) (0.0118 in.)

If the measured value is less than the limit listed above, thecylinder body may be reground

Figure 6 shows the measurement location for the cylinderheight inspection.

Figure 6. Cylinder Body Height.

Cylinder Bodv Height (MH (Reference)Ad Jo ~~~~~---^2 --- a_-_---I_

ENGINE STANDARD

4LEIPW14 307.94- 308.06 mm(12.123 -12.128 in.)

3. CYLINDER HEAD

3.1 Cylinder Head Inspection

Remove carbon deposit on the bottom surface of the headwith care not to damage the valve seat. Figure 7 shows thecylinder head.

Figure 7. Cylinder Head.

Leakage: Water pressure test 5 kg/cm2 (71.5 psig) for 3minutes.

3.1.1 Cylinder Head Lower Face WarpaPe

a. Use a straight edge and a feeler gauge to measure thefour sides and the two diagonals of the cylinder head

T.O. 38G1-127-1TM1-2815,262-1 3&PSWP 006 02

lower face (see Figures 8 and 9). Figure 10 shows themeasurement location for the cylinder head height.

Figure 8. Checking Cylinder Head Warpage.

Figure 9. Cylinder Head Inspection Pattern.

Figure 10. Cylinder Head Height.

b. Regrind the cylinder head lower face, if the measuredvalues are greater than the specified limit but lessthan the maximum grinding allowance.

NoteIf the measured values exceed the maximum grind-ing allowance, the cylinder head must be replaced.

Cylinder Head Lower Face Warpage

MAXIMUMSTANDARD LIMIT GRINDING

ALLOWANCE

0.075 mm 0.150 mm 0.300 mm(0.0029 in.) (0.0059 in.) (0.0118 in.)

Cylinder Head Height (H) (Reference)

ENGINE STANDARD

4LEIPWI4 63.90 - 94.10 mm(2.515 - 2.523 in.)

NoteIf the cylinder head lower face is reground, the valveseat depth must be checked.

3.2 Hot Plug

3.2.1 Checking Hot Plug Depression

a. Clean the cylinder head lower face, taking care not todamage the hot plug surfaces.

b. Use a straight edge and a feeler gauge to measure thehot plug depression in a straight line from the No. 1hot plug to the No. 3 hot plug. If the measured valueexceeds the specified limit, the hot plugs must be re-placed (see Figure 11).

Figure 11. View Showing Hot Plug Depression.

Hot Plug Depression

LIMIT

0.05 mm (0.002 in.)

-_Ie- A

E i FI

I 11::: '4�' 1 8 1.�'

I---- I

Ih.

T.O. 38GI-127-1TM1 -2815-262-13&P

SWP 006 02

3.2.2 Combustion Chamber Inspection

a. Remove the carbon adhering to the inside of the com-bustion chamber. Take care not to damage the hotplug fitting positions (see Figure 12).

Figure 12. View Showing Combustion Chamber.

b. Inspect the combustion chamber, the hot plug hole,and the hot plug machined faces for cracking andother damage.

c. If cracking or damage is present, the cylinder headmust be replaced.

NoteBe absolutely certain that there are no scratches orprotuberances on the combustion chamber surfaceswhich will be in contact with the hot plug after it isinstalled. These flaws will prevent the hot plug fromseating correctly.

3.2.3 Hot Plug Replacement

3.2.3.1 Hot Plug Removal

a. Insert a 3.0 - 5.0 mm (0.12 -0.20 in) diameter brassbar into the nozzle holder fitting hole until it makescontact with the hot plug (see Figure 13).

b. Lightly tap the bar with a hammer to drive the hot plugfree.

3.2.3.2 Hot Plug Inspection

Inspect the hot plugs for excessive wear and other damage.Replace the hot plugs if either of these conditions is discov-ered. Refer to "3.2.3.3 Hot Plug Installation."

3.2.3;3 Hot Plug Tnstallation

Figure 13. Removing Hot Plug.

a. Align the hot plug knock ball (1) with the cylinderhead groove (2) and tap it temporarily into positionwith a plastic hammer (see Figure 14).

Figure 14. Aligning Hot Plug.

b. Place a metal plate (3) approximately 25 mm (1 in)thick over the hot plug upper surface (4). Refer to Fig-ure 15.

Figure 15. Installing Hot Plug.

c. Use a bench press (5) to exert a pressure of 4,000 -5,000 kg (8,819 - 11,023 lb) on the metal plate cover-

- - \

MU _9 9 M-mW -a g

T.O. 38G1-127-1TM1-2815-262-13&PSWP 006 02

ing the hot plug upper surface. This will drive the hotplug into position. A

d. Lightly tap the hot plug head to make sure that it isfirmly seated.

e. Repeat the procedure, steps (a) thru (d), for the remain-ing hot plugs. I

E|ARING| __

USE EYE PROTECTION WHEN USING A Figure 17. Removing Heat Shield.GRINDER.

f. Use a surface grinder to grind off any hot plug surfaceprotuberances. The hot plug surfaces must be per-fectly flush with the cylinder head lower face.

g. After grinding, make sure that the hot plug surfaces arecompletely free of protuberances. The hot plug sur-faces must also be free of depressions.

h. Once again, lightly tap the hot plug heads to make sure

Figure 18. Installing Heat Shield.

NoteAlways install a new heat shield. Never reuse the oldheat shield.

4. VALVE- VALVE SEAT INSERT AND VALVESEAL

Figure 16. Tapping Hot Plug into Head.4.1 Inspectlon Of Valve Seat

that they are firmly seated (see Figure 16). Refer to Figure 19.

3.3 Heat Shield ReplacementCylinder head

3.3.1 Heat Shield Removal Cl

After removing the hot plugs, use a hammer (1) and a brassbar (2) to lightly tap the lower side of the heat shield (3)and drive it free (see Figure 17).

3.3.2 Heat Shield Installation

Install the heat shield to the cylinder head from the nozzle 45holder installation hole side. Lightly tap the heat shieldflange into place with a hammer and a brass bar. The heat Figure 19. Valve Seat Dimensions.shield flange side must be facing up (see Figure 18).

T.O. 38G1 -1 27-1TM1-2815-262-1 3&P

SWP 006 02

A - Contact width: B - Valve depression

STANDARD LIMIT

A - Contact width 2.0 mm 2.5 mm(0.0787 in.) (0.0984 in.)

B - Valve depression 0.7 mm 1.2 mm(0.0276 in.) (0.0427 in.)

4.1.1 Valve Thickness

Refer to Figure 20.

Figure 20. Valve Thickness.

NOMINAL LIMIT REPAIR METHOD

1.0 mm 0.7 mm Replace(0.0394 in.) (.0276 in.)

4.1.2 Valve Stem Outside Diameter

Measure the valve stem diameter at three points (see Fig-ure 21).

Figure 21. Measuring Valve Stem Diameter.

Valve Stem Outside Diameter

STANDARD LIMIT

Intake Valve 7.0 mm (0.2756 in.) 6.85 mm (0.2697 in.)

Exhaust Valve 7.0 mm (0.2756 in.) 6.80 mm (0.2677 in.)

4.2 Valve Seat Insert Replacement

4.2.1 Valve Seat Insert Removal

a. Arc weld the entire inside circumference (1) of thevalve seat insert (2). Refer to Figure 22.

Figure 22. Valve Seat Insert Removal.

b. Allow the valve seat insert to cool for a few minutes.This will induce contraction and make removal of thevalve seat insert easier.

c. Use a screwdriver (3) to pry the valve seat insert free.Take care not to damage the cylinder head (4).

d. Carefully remove carbon and other foreign materialfrom the cylinder head insert bore.

4.2.2 Valve Seat Insert Installation

a. Carefully place the attachment (1) (having a smalleroutside diameter than the valve seat insert) on thevalve seat insert (2). Refer to Figure 23.

Note

The smooth side of the attachment must contact thevalve seat insert.

b. Use a bench press (3) to gradually apply pressure to theattachment and press the valve seat insert into place.4,000 kg (8,819 lbs.)

If the measured value is less than the specified limit, thevalve must be replaced.

9

_)

4-~~~~~~~~~~~~~a

-

T.O. 38G1-1 27-1TM1-2815-262-1 3&PSWP 006 02

Figure 23. Installing Valve Seat Insert.

NoteDo not apply an excessive amount of pressure withthe bench press. Damage to the valve seat insert willresult.

4.2.3 Valve Seat Insert Correction

Figure 25. Valve Seat Angle Cutter.

d. Apply abrasive compound to the valve seat insert sur-face.

e. Insert the valve into the valve guide.

f. Apply light pressure to the valve while turning it to fitthe valve seat insert.

a. Remove the carbon from the valve seat insert surface.

b. Use a valve cutter (150, 450, and 750 blades) to mini-mize scratches and other rough areas. This will bringthe contact width back to the standard value. Refer toFigures 24 and 25.

Figure 24. Valve Seat Angle.

c. Remove only the scratches and rough areas. Do not cutaway too much. Take care not to cut away unblem-ished areas of the valve seat surface.

d. The required valve seat angle is 450.

NoteUse an adjustable valve cutter pilot. Do not allowthe valve cutter pilot to wobble inside the valveguide.

g. Check that the valve contact width is correct. Refer toFigure 26.

Figure 26. Checking Valve Seat Contact.

h. Check that the valve seat insert surface is in contactwith the entire circumference of the valve.

i. Clean the head and valves to remove the abrasive corn-pound and metal particles.

5. VALVE SPRING

5.1 Valve Spring Inclination

Use a surface plate and a square to measure the valvespring inclination. If the measured value exceeds the speci-fied limit, the valve spring must be replaced (see Figure27).

10

I f:;,%~~~~

@4 i to~~~~~~~4(D~v=

I

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

SWP 006 02

Figure 27.,Checking Valve Spring Straightness.

STANDARD LIMIT

Valve spring 1.8 mm 2.5 mminclination (0.071 in.) (0.098 in.)

5.2 Valve Spring Tension

Use a spring tester to measure the valve spring tension. Ifthe measured value is less than the specified limit, thevalve spring must be replaced. Refer to Figure 28.

Figure 28. Checking Valve Spring Tension.

5.3 Valve Spring Free Length

Use a vernier caliper to measure the valve spring freelength. If the measured value is less than the specifiedlimit, the valve spring must be replaced (see Figure 29).

Figure 29. Checking Valve Spring Length.

6. TAPPET AND PUSH ROD

6.1 Tappet

Inspect the tappets for excessive wear, damage and any ab-normalities.

Use a micrometer to measure the tappet diameter. Refer toFigure 30.

Figure 30. Measuring Tappet Diameter.

STANDARD

Tappet diameter 20.967 - 20.980 mm(0.8255 - 0.8260 in.)

Use a dial indicator to measure the clearance between thetappet and cylinder body tappet travelling bore. Refer toFigure 31.

11

STANDARD LIMIT

Exhaust and in- 42.1 mm 40.0 mmtake valve spring (1.658 in.) (1.575 in.)free length _ _ _ _ - -- I__ _ I

STANDARD LIMIT

Valve spring ten- 17.0 kg. 15.0 kg.sion at 29.9 mm (37.48 lb.) (33.07 lb.)

1(1.177 in.) length I j

A'~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~

T.O. 38G1-127-1TM1-2815-262-1 3&PSWP 006 02

Figure 31. Measuring Tappet Travelling Bore.

6.2 Push Rod

Use a feeler gauge to measure the valve push rod runout.

Roll the push rod along a smooth flat surface (see Figure32).

Figure 33. Camshaft.

Figure 34. Measuring the Camshaft.

Figure 35. Camshaft Inspection Locations.Figure 32. Checking Push Rod Run-out.

I I LIMIT

Push rod run-out 0.3 mm (0.012 in.)

7.1 Inspection of Cam Shaft

Check the journal and the cam for evidence of wear, dam-age or any other defect. Refer Figures 33, 34, 35 and 36. Figure 36. Inspecting Camshaft Run-out.

12

Camshaft

STANDARD ILIMIT

Tappet and tappet 0.020 - 0.054 mm 0.08 mmtravelling bore (0.0008 - 0.0021 in.) (0.0032 in.)clearanceI I

A 4 Be @ Bz | A

1-11

I

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

SWP 006 02

NoteWith the front and rear parts of the camshaft pressedin with ball bearings, and with the cylinder blockpressed in with roller bearings as the center bearing,check to see if the camshaft rotates smoothly withno play at each bearing.

7.2 Measurement of Journal and Cam

Cam height (A - B)

STANDARD LIMIT REPAIRMETHOD

Intake 6.13 mm 5.83 mm Replace(0.2413 in.) (0.2295 in.)

Exhaust 6.43 mm 6.13 mm Replace(0.2531 in.) (0.2413 in.)

Center journal diameter

NOMINAL LIMIT REPAIRMETHOD

52.00 mm 51.92 mm Replace(2.0472 in.) (2.0441 in.)

Uneven wear of journal


52.00 mm .05 mm Replace(2.0472 in.) (0.002 in.)

Runout of camshaft


0.02 mm 0.10mm Replace(0.0008 in.) (0.004 in.)

8. ROCKER ARM SHAFT AND RQCKER ARM

Inspect all the disassembled parts for wear, damage andany abnormalities. Figure 37 shows the rocker arm parts.

8.1 Rocker Arm Shaft Outside Diameter

Use a micrometer to measure the rocker arm outside diame-ter. Refer to Figure 38.

Figure 37. Rocker Arm Shaft and Rocker Arm.

Figure 38. Measuring Rocker Arm Shaft.

If the measured value is less than the specified limit, theshaft must be replaced.

STANDARD

Rocker arm shaft diameter I 11.935 - 11.955 mm((0.4699 - 0.4707 in.)

8.2 Rocker Arm Shaft and Rocker Arm Clearance

a. Use a vernier caliper to measure the rocker arm bush-ing inside diameter. Refer to Figure 39.

Figure 39. Rocker Arm.

*~~

0

) I

T.O. 38G1-127-1TM1-2815-262-1 3&PSWP 006 02

STANDARD

Rocker arm bushing inside 11.960 - 11.980 mmdiameter (0.4709 - 0.4717 in.)

b. Measure the rocker arm shaft outside diameter. Re-place either the rocker arm or the rocker arm shaft ifthe clearance exceeds the specified limit. Refer to Fig-ure 40.

Figure 40. Rocker Arm Shaft.

c. Check that the rocker arm oil port is free of obstruc-tions. If necessary, use compressed air to clean therocker arm oil port.

9. PISTON, PISTON PIN AND PISTON RING

9.1 Clearance Between Piston and Cylinder Bore

a. Measure the outside diameter of the piston at about 60mm (2.36 in.) from the top in a right angle to the pis-ton pin (in the unit of 1/1,000 mm). Refer to Figure41.

b. Calculate the clearance based on the measurements ofthe cylinder bore and the outside diameter of the pis-ton.

Clearance 0.015 - 0.035 mm (0.0006-0.0014 in.)I

9.1.1 Outside Diameter Of Piston And Grade Mark

Figure 41. Measuring Piston Diameter.

Figure 42. Location of Piston Grade Mark.

Wear of piston pin (outside diameter) (see Figure 43)

NOMINAL LIMIT REMARKS |

25.0 mm 24.97 mm Replace if worn(0.9843 in.) (0.9831 in.) beyond limit I

Clearance between piston pin and position pin hole

ENGINE I STANDARD

4LElPW14 0.002 -.0.012 mm (0.00008 - 0.00047 in.)

The grade mark is stamped on the top surface of the piston.Refer to Figure 42.

-( -f_ __x a __ _

60

rade mark (Stamped)

STANDARD LIMIT

Rocker arm bushing 0.005 - 0.045 mm 0.2 nunand rocker arm shaft (0.0002 - 0.018 in.) (0.0079 in.)clearance

OUTSIDE DIAMETER OF PISTON GRADE

84.975 - 84.985 mm A(3.3454 - 3.3458 in.)

84.986 - 84.995 mm B(3.3459 - 3.3465 in.) _

84.996 - 85.005mm C(3.3463 - 3.3466 in.)

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

SWP 006 02

Figure 43. Measuring Piston Pin. Figure 45. Checking Piston Ring Groove Clearance.

If worn beyond the limit, replace the rings or piston.

With the ring inserted into the cylinder bore, push it inwith the piston head so that it becomes a right angle to thecylinder. Then measure the gap of the piston ring. Refer toFigure 44.

If worn beyond the limit, replace the rings.

Figure 44. Checking Piston Ring Gap.

10. CONNECTING ROD AND CONNECTING RODBEARING

Torsion and Parallelism of Connecting Rod (see Figure46)

Per 100 mm (3.94 in.) STANDARD LIMIT

Torsion 0.05 mm 0.20 mm(0.002 in.) (0.0079 in.) (

Parallelism 0.05 mm 0. 15 mm()_______________ (0.002 in.) (0.0059 in.)

Figure 46. Checking Connecting Rod Straightness.

9.2 Piston Ring Gap

STANDARD LIMIT

1st compression 0.085 - 0.105 mm 0.20 mmring (0.0033 - 0.0041 in.) (0.0078 in.)

2nd compression 0.050 - 0.085 mm 1.50 mmring (0.0020 - 0.0033 in.) (0.0590 in.)

Oil ring 0.030 - 0.070 mm 1.50 mm(0.0011 -0.0027 in.) (0.0590 in.)

STANDARD LIMIT

1st compression 0.20 - 0.35 mm 1.500mmring (0.0079 - 0.0138 in.) (0.0590 in.)

2nd compression 0.35 - 0.50 mm 1.50 mmring (0.0138 - 0.0197 in.) (0.0590 in.)

Oil ring 0.20 - 0.40 1.00 mm(0.0079 - 0.0157 in.) (0.0394 in.)

9.3 Clearance Between Piston Ring Groove andB10

Measure clearance at several places on the circumference.Refer to Figure 45.

T.O. 38G1-127-1TMl-2815-262-13&PSWP 006 02

If worn beyond the limit, repair or replace.

Clearance between small end pin hole of connecting rodand piston pin, inside diameter of bushing (see Figure47)

STANDARD LIMIT

Clearance 0.008 - 0.020 mm 0.05 mm(0.0003 - 0.0008 in.) (0.002 in.)

Inside diameter 25.00 mm(0.9843 in.) I

Figure 47. Checking Pin to Connecting Rod Clearance.

10.1 Connecting Rod Bearing Inspection

a. Fit the connecting rod bearing lower half into the con-necting rod bearing cap. Refer to Figure 48.

Figure 48. Checking Connecting Rod Bearing.

b. Check the connecting rod bearing lower half tension. Ifthe tension is insufficient, the bearing must be re-placed.

c. Tighten the connecting rod and the bearing cap to thespecified torque. Refer to Figure 49.

Figure 49. Checking Connecting Rod Bearing Bore.

Tightening torque 7.5 - 8.5 kg-rn (54 - 61 ft-lb)

Clearance between bearing and crank pin, inside diame-ter with bearing installed and without.

. STANDARD LIMIT

Clearance 0.035 - 0.073 mm 0.10 mm(0.0014 - 0.0029 in.) (0.0039 in.)

11. CRANKSHAFT AND CRANKSHAFT BEARING

Inspect outside diameters of journal and pin. Refer to Fig-ure 50.

If worn beyond the limits - replace

Figure 50. Checking Crankshaft Journal.

Crank journal (see Figure 51)

I STANDARD I LIMIT

| 60.0 mm (2.3622 in.) | 59.86 mm (2.3567 in.)

16

I* . .

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SWP 006 02

Crank pin

STANDARD LIMIT

49.0 mm (1.9291 in.) 48.87 mm (1.9240 in.)

NoteWhen there occurs an uneven wear to the crank-shaft, replace it with a new one without grinding itfor reuse.

Clearance between journal and bearing inside diameterwith and without bearing instafled (see Figure 51)

L _m I STANDARD I LIMIT

0.029 - 0.072 mm(0.0011 - 0.0028 in.)

0.11 mm(0.0043 in.)I

11.1 Crankshaft gear

Check the crankshaft gear visually for damage and anyother defects. Refer to Figure 53.

Figure 53. Crankshaft Gear.

11.2 Oil seal

When the lip of an oil seal is found defective, replace itwith a new one.

11.2.1 Oil Seal Installation

Use the crankshaft front oil seal installer to install thecrankshaft front oil seal. Refer to Figure 54.

Figure 51. Checking Crankshaft Bearing Bore. Tool required: 5-8840-2061-0

Runout of crankshaft (see Figure 52)

STANDARD LIMIT

0.025 mm (0.001 in.) 0.05 mm (0.002 in.) I

Replace if beyond limit

Figure 54. Front Oil Seal.

12. FLYWHEEL AND RING GEAR

12.1 Ring Gear Replacement

a. Inspect the ring gear.

b. If the ring gear teeth are broken or excessively worn,the ring gear must be replaced.

Figure 52. Checking Crankshaft Runout.

T.O. 38G1-127-1TM1-2815-262-1 3&PSWP 006 02

12.2 Ring Gear Removal

EINGUSE EYE PROTECTION WHEN USING HAMMERAND CHISEL.

Strike around the edges of the ring gear with a hammer andchisel to remove it. Refer to Figure 55.

Figure 55. Removing Ring Gear.

12.3 Ring Gear Installation

Figure 56. Measuring Idle Gear Shaft.

Figure 57. Measuring Idle Gear Bore.

a. Heat the ring gear evenly to invite thermal expansion.Do not allow the temperature of the ring to exceed100-C (212 0F).

E WARNING I

USE EYE PROTECTION WHEN USING HAMMER.

b. Use a hammer to install the ring gear when it is suffi-ciently heated.

13. TIMING GEAR

Uneven wear of idle gear shaft (see Figure 56)

NOMINAL LIMIT |

45.0 mm (1.7717 in.) I 0.10 mm (0.0039 in.) _

Clearance between idle gear bushing and shaft (see Fig-ure 57) .

STANDARD LIMIT

0.025 - 0.085 mm 0.20 mm(0.001 - 0.0033 in.) (0.0079 in.)

18

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

SWP 006 03


ENGINE REASSEMBLY PROCEDURES





1-24. 0

TABLE OF CONTENTS.Paragraph EPag

List of Illustrations ........................ 2

Foreword .............................. 3

Safety Summary .......................... 3

1. Engine Reassembly ........................ 4

2. Cylinder Head Assembly .......... ......... 4

2.1 Important Operations in Cylinder HeadAssembly .............................. 4

3. Piston And Connecting Rod ......... ........ 6

3.1 Important Operations in Assembling Piston ..... 6

4. Engine Internal Parts ....................... 8

4.1 Reassembly Steps ......................... 8

5. External Parts Reassembly ................. 18

5.1 Right Hand Side External Parts ....... ...... 18

5.2 Left Hand Side External Parts ....... ....... 19

5.3 Detail Reassembly Instructions ...... ...... 20

T.O. 38G1-127-1TM1-2815-262-1 3&PSWP 006 03

LIST OF ILLUSTRATIONSPa Eig=

Cylinder Head Assembly .4 36

Installing Valve Stem Oil Seal .4 37

Installing Valve in Cylinder Head .4 38

Valve Spring .5 39

Installing Spring Seat Split Collar .5 40

Injection Nozzle Holder Assembly .5 41

Glow Plug and Connector .5 42

Piston and Connecting Rod Assembly .6 43

Piston Heater .6 44

Orientation of Piston Assembly Parts .6 45

Installing Piston Pin Snap Ring .7 46

Installing Piston Rings .7 47

Engine Internal Parts (1) .9 48



Crankshaft Bearing.5................1.... 12 51

Crankshaft and Bearings .12 52

Crankshaft Bearing Cap and Bolt .12 53

Positioning of Piston Rings .12 54

Installing Piston in Cylinder Bore .13 55

Connecting Rod Cylinder No. Marks .13 56

Seal Retainer Bolt Tightening Sequence . 13 57

Camshaft Bearing Retaining Ring .14 58

Cam Gear and Sleeve .14 59

Idle Gear................................ 14 60

Camshaft Timing Marks .14 61

Front Plate with Oil Pump Assembly .14 62

Front Plate. ............................. 15

Front Oil Seal .15

Timing Gear Case .15

Flywheel Housing .16

Flywheel Bolts .16

Crank Pulley Installation .16

Oil Pipe and Oil Strainer .16

Oil Pan.................................. 17

PEHead Gasket ............................ 17

Cylinder Head Bolt Tightening Sequence ..... 17

Rocker Arm Bracket Assembly ............. 17

Rocker Bracket Oil Gallery ....... ......... 17

Installing Lifting Hangers .................. 18

Right Hand Side External Parts ............. 18

Left Hand Side External Parts .............. 1 l9

Oil Filter Cartridge and Dipstick ............ 20

Fuel Stop Lever .......................... 20

Installing Injection Pump and Shim .......... 20

Injection Pump Control Link ............... 29

Injection Pump Housing Cover ............. 21

Applying Sealant to Housing Cover .......... 21

Fuel Stop Solenoid Installation .............. 21

Applying Sealant to Solenoid ............... 21

Fuel Pipes ............................. 21

Injection Pipe ........................... 22

Water Pump Assembly .................... 22

Thermostat and Water Outlet Pipe ........... 22

Cylinder Head Cover ..................... 23

Air Inlet Pipe ...... ........ 23

Exhaust Manifold ............... 23

Starter ............... 23

Generator ............... 23

Fan Pulley and Fan Belt ............... 24

Tensioning Fan Belt ............... 24

Cooling Fan ............... 24

Eigs

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

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

SWP 006 03FOREWORD

This Subordinate Work Package (SWP) contains for reas-sembling the diesel engine used on the SGNSC.

SAFETY SUMMARY

There are no specific safety related issues in this SWP.General shop safety practices should be observed when re-assembling the diesel engine.

T.O. 38G1-127-1TMI -2815-262-13&PSWP 006 03


1. ENGINE REASSEMBLY

2. CYLINDER HEAD ASSEMBLY

2.1 Important Operations In Cylinder HeadAssembly

Refer to Figure 1.

2.1.1 Valve Stem Oil Seal

a. Lubricate the oil seals and valve stem sealing area withengine oil.

b. Use a valve stem oil seal installer to install the oil seal(see Figure 2).

Valve Stem Oil Seal Installer pin 5-8840-9007-0

2.1.2 ITntake and Fxhaust Valves

a. Place the cylinder head on a flat wooden surface.

b. Lubricate valve stems with engine oil (see Figure 3).

c. Install the valves to the intake or exhaust guides. Installthe valves to their original lapped valve seats.

Figure 2. Installing Valve Stem Oil Seal.

Figure 3. Installing Valve in Cylinder Head.

ORev n

%4

La L

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SWP 006 03

- 2.1.3 Intake and Exhaust Valve Springs

Install the valve springs with their painted end (the closepitched end) facing down. Refer to Figure 4.

Figure 4. Valve Spring.

2.1.4 SnrinL- Seat Split Collar

b. Assemble to the cylinder head the gasket (heat shield),heat shield, corrugated washer and gasket (nozzleholder) in this order. Refer to Figure 6.

Figure 6. Injection Nozzle Holder Assembly.

c. Install the nozzle holder assembly, and then tighten itto the specified torque.

a. Use a spring compressor to push the valve spring intoposition (see Figure 5).

Figure 5. Installing Spring Seat Split Collar.

b. Install the spring seat split collar.

c. Set the spring seat split collar by tapping lightly aroundthe head of the collar with a rubber hammer.

I Tightening torque | 4.0 - 5.0 kg-m (29 - 36 lb-ft) I2.1.6 Glow Plug and Connector

a. Assemble the glow plug to the cylinder head, and thentighten it to the specified torque. Refer to Figure 7.

Figure 7. Glow Plug and Connector.

Spring Compressor Commercially available tool b. Install the connector to the glow plug, and then tightenuntil snug.

2.1.5 Nozzle Holder Assembly

a. Before assembling the nozzle holder assembly, checkto see if the spray condition and the spray pressure ofthe injection nozzle are appropriate (refer to SWP 00503, paragraph 6.2).

PART TIGHTENING TORQUE

Glow plug 1.5 - 2.0 kg-m (11 -14 lb-ft)

Nozzle holder ASM

Gasket.. Corrugated washer

Split collar Spring compressor

Glow plug .

Connector

0

T.O. 38G1-127-1TM1-2815-262-1 3&PSWP 006 03

Figure 8. Piston and Connecting Rod Assembly.

Figure 9. Piston Heater.

3. PISTON AND CONNECTING ROD

3.1 Important Operations In Assembling Piston

3.1.1 Piston

Use a piston heater to heat the pistons to approximately1000 C (212TF). Figure 9 shows a conventional pistonheater, available commercially.

3.1.2 Connecting Rod

a. Install the connecting rod to the piston with setting themarks as illustrated in Figure 10.

b. Install the piston pin into the piston and the connectingrod bushing.

Figure 10. Orientation of Piston Assembly Parts.

(Hot plug side)

Front mark -

Enginefront vdireotio n/)

Isuzu mark

Cylinder number,stamped side

3.1.3 Piston Pin Snap Ring

a. Use a pair of snap ring pliers to install the piston pin

snap ring. Refer to Figure 11.

T.O. 381-127-1TM1 -2615-262-1 3&P

SWP 006 03

* The marked side of the two compression ringsmust be facing up.

* The undercut side of the second compression ring

will be facing down.

* As the oil ring has no facing mark, it may face in

either direction.

c. Lubricate the piston ring surface with engine oil.

d. Check that the piston rings rotate smoothly in the pis-ton ring grooves.

Figure 11. Installing Piston Pin Snap Ring.

b. Check that the piston moves smoothly on the piston

pin.

3.1.4 Piston iing

a. Use a piston ring installer to install the three piston

rings.

Piston Ring Pliers p/n 1-8522-1029-0

b. Install the piston rings in the following order. Refer to

Figure 12.

(1) Oil ring

(2) 2nd. compression ring

(3) 1st compression ring

Figure 12. Installing Piston Rings.

I st

2 st

CE oil

T.O. 38G1-127-1TMI-2815-262-1 3&PSWP 006 03

4. ENGINE INTERNAL PARTS

4.1 Reassembly Steps

Refer to Figures 13, 14, and 15 for the corresponding stepnumber and part.

Legend for Figures 13, 14 and 15

(1) Crankshaft

(2) Piston Assembly

(3) Rear Seal Retainer

(4) Camshaft

(5) Cam Gear

(6) Idler gear and Shaft

(7) Oil Pump Assembly

(8-1) Front Plate

(8-2)

(9)

(10)

(11)

(12)

(13)

(14)

(15)

(16)

(17)

(18)

(19)

(20)

Timing Gear Case

Flywheel Housing

Flywheel

Crank Pulley

Oil Pipe

Oil Strainer

Oil Pan

Tappets

Cylinder Head Gasket

Cylinder Head Assembly

Push Rods

Rocker Bracket Assembly

Engine Hangers

T.O. 38G1 -1 27-1TM1-2815-262-1 3&P

SWP 006 03

r -- - - - - - - - - - - - - I

i ii

Figure 13. Engine Internal Parts (1).I

I me~

T.O. 38G1-127-1TM1-2815-262-1 3&PSWP 006 03

(20)

~(18)

tJ" {41)\(17)

115)

(161

Figure 14. Engine Internal Parts (2).j

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

SWP 006 03

(8-1)

(8-2)

Figure 15. Engine Internal Parts (3).

11

T.O. 38G1-127-1TM1-2815-262-1 3&PSWP 006 03

4.1.1 Crankshaft Bear ng 4.1.3 Crankshaft Bearing Cap

a. Lubricate the bearing cap bolts with engine oil.

Note that there is an oil hole and an oil groove in the upperbearing (on the block side), but not in the lower bearing(on the bearing cap side).

Fit the bearing tang firmly into the slot machined on thecylinder body bearing arches.

Figure 16. Crankshaft Bearing.

4.1.2 Crankshaft and Bearing

Refer to Figure 17.

Lubricate the bearing with engine oil, install the crank-shaft, and install the thrust bearings with the groove facingthe crankshaft.

b. Install the bearing caps to the crankshaft. The arrowmark must be pointing to the front of the engine.

c. Tighten the bearing cap bolts to the specified torque, alittle at a time, in the numerical order shown in Figure18.

Figure 18. Crankshaft Bearing Cap and Bolt.

I Crankshaft bearing 18.5 - 9.5 kg-m (61 - 69 lb-ft)| cap bolt torque I

. Chc tha th rnsattrssotl ymnal

d. Check that the crankshaft turns smoothly by manuallyrotating it.

4.1.4 Piston and Connecting Rod

I

Figure 17. Crankshaft and Bearings.

a. Before installing the pistons, position the rings asshown in Figure 19, making sure the ring gaps areaway from the thrust side.

I St

.-Fu 2 st

oil

Figure 19. Positioning of Piston Rings.

Refer to Figure 16.

I Aro ark

I Front |

Thrust bearing

12

T.O. 38G1-127-1TM1-281 5-262-13&P

SWP 006 03

b. Lubricate the piston, the piston rings, and the connect-ing rod bearings with engine oil.

c. Position the piston front mark toward the front of theengine. Refer to Figure 20.

Special tool

W Front mark

Figure 20. Installing Piston in Cylinder Bore.

d. Use the piston ring compressor to compress the pistonrings.

Piston ring compressor p/n 5-8840-9018-0

e. Use a hammer grip to push the piston in until it makescontact with the crank pin.

f. At the same time, rotate the crankshaft until the crank-pin reaches its highest point.

g. Set the bearing cap cylinder number marks and the con-necting rod cylinder number marks. Refer to Figure21.

Figure 21. Connecting Rod Cylinder No. Marks..

h. The marks must be facing the injection pump side.

Connecting rod bearing cap bolts

I Tightening torque | 7.5 - 8.5 kg-m (54 - 61 lb-ft)i

NoteAfter installation, confirm that the crankshaft rotatessmoothly.

4.1.5 Installation of Retainer

a. After applying engine oil to the lip of the oil seal, in-stall the retainer. Apply sealant.

b. Tighten bolts on the retainer to the specified torque inthe order as shown in Figure 22.

(Do2

Figure 22. Seal Retainer Bolt Tightening Sequence..

Tightening torque 7.5 - 8.5 kg-mr (54 - 61 lb-ft)

4.1.6 Camshaft Assembly

a. Apply engine oil to the inside of the bearing of the cyl-inder block, and then install the camshaft assembly.

NoteWhen installing the assembly, care should be takennot to damage the bearing.

b. After installation of the snap ring to the outside of thefront bearing, check to see if the camshaft rotatessmoothly. Refer to Figure 23.

4.1.7 Cam Gear and Sleeve

a. Install the cam gear to the camshaft so that the timingpoint (a dot mark "*") comes to the front side. Referto Figure 24.

b. With the flyweight installed, tighten the cam gear witha lock nut.

I Tightening Torque 7.0 - 9.0 kg-m (51 - 65 lb-ft)

T.O. 38G1-127-1TMI-2815-262-1 3&PSWP 006 03

Figure 23. Camshaft Bearing Retaining Ring.

Figure 24. Cam Gear and Sleeve.

c. Apply engine oil to the shaft of the sleeve and the slideof the flyweight.

d. With the lip of the sleeve placed in the cavity of the fly-weight, insert the shaft of the sleeve into the tip endof the camshaft.

Note

Check to see if the sleeve moves smoothly.

4.1.8 Idle Gear

a. Install the idler gear shaft with the oil hole facing up-ward. Refer to Figure 25.

b. Lubricate the shaft with oil.

c. Install the idler gear.

d. Align the timing marks as shown in Figure 26.

e. Install the thrust collar and tighten the bolts to the speci-fied torque.

Figure 25. Idle Gear.

Figure 26. Camshaft Timing Marks.

Tightening Torque 2.1 - 3.1 kg-m (15.2 - 22.4 lb-ft)

4.1.9 Oil Pump Assembly

Install the oil pump to the front plate. Refer to Figure 27.

Figure 27. Front Plate with Oil Pump Assembly.

Tightening Torque | 0.8 - 1.2 kg-m (6 -9 lb-ft)

14

Cam gear

Timing point

Sleeve

I~~~f ~ ~ly weight

I ~~~~~Lock nut

A0

Front plate

A& 1A

T.O. 38G1 -1 27-1TM1-2815-262-1 3&P

SWP 006 03

4.1.10 Frnt Plate

Apply liquid gasket to the front plate incorporated with theoil pump before installing it to the cylinder block. Refer toFigure 28.

Figure 28. Front Plate.

I Tightening Torque | 1.9 - 2.9 kg-m (14 - 21 lb-ft) I

4.1.11 Front Oil Seal

Install the front oil seal to the timing gear case.

Installation is made according to the "L" dimension shownin Figure 29.

Figure 29. Front Oil Seal.

| 'L' dimension 1 40.2 - 40.8 mm (1.582 - 1.606 in.) I

a. Install the timing gear case to the front plate.

b. Put the link plate of the governor incorporated in thegear case through the connecting hole of the injectionpump in advance.

c. Apply engine oil to the bushes provided on both endsof the main spring lever of the governor.

d. Apply sealant to the gear case, and then install it to thefront plate.

Figure 30. Timing Gear Case.

e. Assemble the gasket and the governor cover to the topof the gear case. Then tighten them to the specifiedtorque.

Cover tightening torque 0.8 - 1.2 kg-m ll (6 - 9 lb-ft) l

4.1.13 Flywheel ~ousing

Refer to Figure 31.

Install the flywheel housing to the cylinder body.

| Tightening torque 4.2 - 5.6 kg-mr(30 - 40 lb-ft)

0 nt plate

(with PTO)gear case

Front oil sealTiming gear case

Case tightening torque [ 1.9 - 2.9 kg-mrI (14 - 21 lb-ft)

Refer to Figure 30.

4.1.12 Timing Gear Case with GoveMror

T.O. 38G1 -1 27-1TM1-2815-262-1 3&PSWP 006 03

Figure 31. Flywheel Housing.

4.1.14 Flywheel

Lubricate the bolts with any grade of engine oil.,

Tighten a little at a time in the sequence shown in Figure32.

Figure 32. Flywheel Bolts.

Figure 33. Crank Pulley Installation.

a. Install the oil pipe from the oil pump assembly to thecylinder block and tighten the sleeve nuts.

b. Install the oil strainer to the oil pump. Then tighten thebracket of the strainer to the No. 2 bearing cap. Referto figure 34.

Figure 34. Oil Pipe and Oil Strainer.

Tightening torque 9.0 - 11.0 kg-m(65 - 80 lb-ft)

4.1.15 Crank Pulley

a. Lubricate the lip of the front seal with any grade of en-gine oil.

b. Install the crank pulley, lock the crankshaft and tightenthe front bolt. Refer to Figure 33.

I Tightening torque 17.0 - 19.0 kg-m l

4.1.16 Oil Pipe and Oil Strainer

Tightening torque 1.9 - 2.9 kg-m(14 - 21 lb-ft)

4.1.17 Oil Pan

Refer to Figure 35.

a. Apply type TB1207C sealant (see WP 003 00, Table2) to the oil pan.

b. Install the oil pan to the cylinder block and tighten fix-ing bolts evenly.

| Tightening torque | 0.8 -1.2 kg-mrI ~~~~~~~~~~~(6 -9 lb-ft)

16

To 2nd bearing cap i

I Oii strainer

Oil pipe

T.O. 38G1 -1 27-1TM1-281 5-262-1 3&P

SWP 006 03

Figure 35. Oil Pan..

4.1.18 Tappet and Head Gasket

a. Install the tappet to the cylinder block.

b. When installing the head gasket, turn up the stampmark of the parts number (last 4 digits), which is be-tween the No. 2 and No. 3 cylinders of the gasket. Re-fer to Figure 36.

Figure 36. Head Gasket.

4.1.19 Cylinder Head Assembly

Figure 37. Cylinder Head Bolt Tightening Sequence.

4.1.21 Rocker Arm Bracket Assembly

a. Apply liquid gasket to the bottom of the rocker armbracket assembly (see Figure 38), being careful not toget any in the groove around the oil gallery as shownin Figure 39.

a. Lubricate the bolts with any grade of engine oil.

b. Tighten the bolts in the sequence shown in Figure 37 tothe specified torque.

Figure 38. Rocker Arm Bracket Assembly.

4.1.20 Pushl RodFigure 39. Rocker Bracket Oil Gallery.

Install the push rods.

Parts number (Last 4 digits)Stamp mark position

Rocker armbracket

BOLT SIZE TIGHTENING TORQUE

M12 x 1.5 8.5 - 9.5 kg-m X 600 - 900(8 each) (61 - 69 lb-ft)

M8 x 1.25 2.5 - 3.5 kg-m(4 each) (18 - 25 lb-ft)

T.O. 38G1-127-1TM1-2815-262-13&PSWP 006 03

b. Install the rocker arm bracket assembly making surethe push rods align with the rocker arms and tightento the specified torque.

I Tightening torque I 0.8 - 1.2 kg-m (6 - 9 lb-ft)

Refer to SWP 005 03, paragraph 1 for the valve adjust-ment procedures.

4.1.23 Front Hanger and Rear Hanger

Tighten the front and rear hanger mounting bolts to thespecified torque shown below. Refer to Figure 40.

4.1.22 Adjustment of Valve Clearance

Figure 40. Installing Lifting Hangers.

| Tightening torque | 1.9 - 2.9 kg-m (14 - 21 lb-ft) |

5. EXTERNAL PARTS REASSEMBLY

5.1 RIGHT HAND SIDE EXTERNAL PARTS

Figure 41 shows the assembly sequence for the externalparts on the right hand side of the engine.


(1) Dipstick

(2) Oil Filter

(5)

(3)

12)

(1)

Figure 41. Right Hand Side External Parts.

(4)

Rear hanger

hanger

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

SWP 006 03


(3) Injection Pump

(4) Injection Pump Housing Cover

(5) Fuel Pipe

(6) Leak Off Pipe

(7) Fuel Hose

(8) Injection Pipe

5.2 LEFT HAND SIDE EXTERNAL PARTS

Figure 42 shows the assembly sequence for the externalparts on the LEFT hand side of the engine.


(9) Water Pump

(10) Thermostat and Water Outlet Pipe

(11) Cylinder Head Cover

(12) Exhaust Manifold

(13) Starter

(14) Generator

(15) Fan Pulley

(16) Fan Belt

(17 Cooling Fan

Figure 42. Left Hand Side External Parts.

(10) (11)

(16)

(9)

(13)

T.O. 38G1-127-1TM1-2815-262-1 3&PSWP 006 03

5.3 DETAIL REASSEMBLY INSTRUCTIONS

5.3.1 Dipstick and Oil Filter Cartridge

Refer to Figure 43.

Figure 43. Oil Filter Cartridge and Dipstick.

a. Insert the dipstick.

b. Apply engine oil thinly to the gasket of the cartridge.

c. Screw in the cartridge until the gasket comes into con-tact with the seal, and then tighten it by giving itabout 3/4 turns.

d. Install the cartridge with a filter wrench (commerciallyavailable).

Filter wrench p/n 5-8840-9015-0

5.3.2 InijctionPinnmp

a. Align the two (2) holes in the fuel cut lever and thegovernor and lock into place with a pin (6 0 mm).Refer to Figure 44.

Figure 44. Fuel Stop Lever.

b. This will center and hold the control link for the instal-lation of the injection pumps.

c. Install a new shim with the same thickness as the onethat was removed. (Refer to SWP 005 03, paragraph4, on shim selection.) Refer to Figure 45.

Figure 45. Installing Injection Pump and Shim.

d. Install the injection pump, making sure the rack in is inthe groove of the control rack before tightening the in-jection pump to the specified torque.

I Tightening torque 1.9- 2.9 kg-rn (14- 21 lb-ft) I

f. Remove the rack pin (6 0 mm), which is inserted intothe fuel cut lever. Then confirm that the fuel stoplever moves smoothly. Refer to Figure 46.

Figure 46. Injection Pump Control Link.

5.3.3 Tijection Pump Housing Cover

After applying sealant (TB1207C) to the housing cover, in-stall it to the cylinder block by the side of the injectionpump. Refer to Figures 47 and 48. Tighten the bolts to thespecified torque.

20

Injection pump ASM

- Shim

Cylinder block

Injection pumpcenter position Fuel cut lever

pinControl link (6 # I ~ 1

Figure 47. Injection Pump Housing Cover.Figure 49. Fuel Stop Solenoid Installation.

Figure 48. Applying Sealant to Housing Cover.

I Tightening torque | 0.8 - 1.2 kg-m (6 - 9 lb-ft) I

Figure 50. Applying Sealant to Solenoid.

5.3.5 Fuel Pipe and Leak Off Pipe

Note

The areas of the housing cover to which liquidgasket is applied are about 4 mm (0.16 in.) in widthfrom the cover edge and about 2 mm (0.08 in.)around the bolts.

5.3.4 Solenoid Assembly

a. Apply sealant (TB 1207C) to the surface (bite groove)in which the solenoid is installed. Refer to Figures 49and 50.

Note

Avoid the application of sealant to the screw thread.

b. Screw in the solenoid from the rear of the cylinderblock (the rear of the No. 4 injection pump rack).Then tighten it to the specified torque.

I

a. Install the fuel pipe to the injection pump. Then tightenit to the specified torque. Refer to Figure 51.

b. Install the leak off pipe to the nozzle holder. Thentighten it to the specified torque.

Figure 51. Fuel Pipes.

21

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

SWP 006 03

Housing cover

Apply portion of sealant

~~~~~ T

About 4mm in width

around the bolt hole. from the cover edge

Solenoid ASM Installed surface(Apply surface, of sealant )

Screw threadAvoid the application'A

( of sealant )

Leak off pipe i

t ~Fuel pipe

Fuel hose %-Nozzle holder pump

I~~~~~~~~~

I Tightening torque 1 1.5 - 2.5 kg-m (11 - 18 lb-ft)

T.O. 38G1-127-1TM1-2815-262-1 3&PSWP 006 03

Note

When tightening the pipe, hold it securely by handso that it will not rotate.

c. Connect the fuel pipe and the leak off pipe with thefuel hose and fix them with clips.

Install the injection pipe to the injection pump and the noz-zle holder and tighten them with sleeve nuts. Refer to Fig-ure 52.

Figure 52. Injection Pipe.

Tightening torque 1.5 - 2.5 kg-m (11 - 18 lb-ft)

Note

Set thread of the sleeve nut securely before tighten-ing it.

5.3.7 Water Pump Assembly

Refer to Figure 53.

a. Put sealant on the water pump where it contacts theblock and head.

b. Tighten to the specified torque.

Figure 53. Water Pump Assembly.

5.3.8 Thermostat and Water Outlet Pipe

Assemble the thermostat and install the gasket and thewater outlet pipe (see Figure 54). Then tighten it to thespecified torque.

Figure 54. Thermostat and Water Outlet Pipe.


5.3.9 Adjustment of Valve Clearance

Refer to SWP 005 03, paragraph 1 for the valve adjust-ment procedures.

5.3.10 Cylinder Head Cover

Refer to Figure 55.

a. Install the gasket to the cylinder head cover.

NoteMuch care should be taken for the gasket not to getdislocated or twisted when installing the head cover.Avoid the application of sealant to the rubber gas-ket.

22

TIGHTENING TORQUE

Fuel pipe 2.0 - 2.5 kg-m (14 - 18 lb-ft)

Leak off pipe 2.5 - 3.5 kg-m (18 - 25 lb-ft)

Injection pipe

.ozeholder

Injection pur


5.3.6 14jction lie=

T.O. 38G1-127-1TM1-281 5-262-1 3&P

SWP 006 03

Figure 55. Cylinder Head Cover.

b. Install the cylinder head cover to the rocker armbracket and tighten it to the specified torque.

I Tightening torque | 0.2 -0.4 kg-m (1.4 - 2.9 lb-ft)

Figure 57. Exhaust Manifold.

5.3.13 Starter

Install the starter to the flywheel housing and tighten it tothe specified torque. Refer to Figure 58.

I

5.3.11 Air Inlet Pipe

a. Apply sealant (TF1207C) to the surface in which theair inlet pipe is installed.

b. Install the air inlet pipe to the cylinder head cover andtighten it to the specified torque. Refer to Figure 56.

Cylinder head

cover

Air inlet pipe

Figure 56. Air Inlet Pipe.

I Tightening torque 1 0.8 - 1.2 kg-m (6 - 9 lb-ft)

5.3.12 Exhaust Manifold

Assemble the gasket to the cylinder head, install the ex-haust manifold along the stud bolts and tighten it to thespecified torque. Refer to Figure 57,

Figure 58. Starter.

I Tightening torque | 9.5 - 11.5 kg-m (68.7 - 83.2 lb-ft)

5.3.14 Generato

Refer to Figure 59.

Figure 59. Generator.I Tightening torque 1.9 -2.9 kg-rn (14 -21 lb-ft) I

23

.

T.O. 38G1 -1 27-1TM1-2815-262-1 3&PSWP 006 03

a. Tighten the adjust plate together with the water pump.Then install them temporarily.

b. Install the bottom of the generator to the timing gearcase. Then tighten it temporarily with bolts and nuts.

- c. Install the fixing bolts onto the top of the generatorthrough the adjusting plate. (Temporary tightening.)

5.3.15 Fan Pulley And Fan Belt

a. Install the fan pulley to the water pump and thentighten. (2 locations.) Refer to Figure 60.

Figure 60. Fan Pulley and Fan Belt.

I Tightening torque 1 0.8 - 1.2 kg-m (6 -9 lb-ft)

b. Set the fan belt to each pulley.

5.3.16 Fan Belt Tension

Adjust the alternator as specified and tighten to the speci-fied torque. Refer to Figure 61.

5.3.17 Cooling.Fan

Refer to Figure 62.

I Figure 62. Cooling Fan.

a. Assemble the spacer before tightening the cooling fan.

b. Tighten it to the specified torque. (4 locations)

Tightening torque 1.9 - 2.9 kg-m (14 - 21 lb-ft)

Figure 61. Tensioning Fan Belt.

24

Deflection amount. (Press the belt at 0.8 - 1.2 kg-mits center between the pulleys with 10 (6 - 9 lb-ft)Ig (22 lbs.) force.)

BOLT LOCATION TIGHTENING TORQUE

Generator upper 1.9 - 2.9 kg-m (14 - 21 lb-ft)

Generator lower 3.5 - 4.7 kg-m (25 - 34 lb-ft)

Adjusting plate 1.9 - 2.9 kg-m (14 - 21 lb-ft)

Page No. Change No.

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

WP 007 00

WORK PACKAGE


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

1-4 . 0

TABLE OF CONTENTSparagraph pap

Foreword ......................... 2

Safety Summary ......................... 2

1. Lubricating Oil Circulation System ........... 4

2. Oil Pump . ......................... 4

2.1 Inspection and Replacement ................. 4

LIST OF ILLUSTRATIONSEiugn E

1 Lubricating Oil Circulation Diagram .......... 3

2 Oil Pump .......... ............... 4

ENGINE LUBRICATING SYSTEM



Page No. Change No

T.O. 38G1-127-1TM1-2815-262-1 3&PWP 007 00

FOREWORD

This Work Package (WP) contains instructions for inspec-tiong and replacing the lubricating oil pump in the dieselengine used on the SGNSC.

SAFETY SUMMARY

There are no specific safety related issues in this WP. Gen-eral shop safety practices should be observed when per-forming any procedures in this WP.

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

WP 007 00

Valve opening pressure lkg/cm 2 (14.0 PSI)

Olftr

|Connecting rod ||G

, -1 Injectionpmp -.* :I

S ::

: a:5

: Piston :

L.. * *S~~ ~ ~ .

i ~~~~~~~~~~~* i a

-- Pressure feeding

II

IIw

l aI - ----- It | ~Volvo stem end|

II

II~~~~~~~~~~~

II I~~~~~~~~~~~

-i - W.~~~~~~~~~~~

Oil pan

---------------, Non pressure feeding

Figure 1. Lubricating Oil Circulation Diagram.

II

I

-

I

II

I

I

II

T.O. 38G1-127-1TM1-2815-262-1 3&PWP 007 00

Figure 2. Oil Pump.

1. LUBRICATING OIL CIRCULATION SYSTEM Clearance between the periphery of the outer rotor and

Figure 1 shows a schematic diagram of the lubricating sys-tem on the engine.

2. OIL PUMP

2.1 Inspection and Replacement

When there is wear, damages or any other defects found,repair or replace the rotor.

Clearance between the outer rotor or inner rotor andthe pump cover

the pump body

STANDARD LIMIT |

0.10-0.185 mm (0.0039-0.0073 in.) 0.15 mm (0.0059 in.)

Clearance between the inner rotor and the outer rotor

STANDARD LIMIT

Front plate(Body; integral structure)

PinRotor; outer

Rotor; inner

0dring _

Relief valve

Oil pump

STANDARD LIMIT

0.040-0.085 mm (0.0016-0.0033 in.) 0.15 mm (0.0059 in.)

T.O. 38G1 -1 27-1TM1-2815-262-13&P

WP 008 00

WORK PACKAGE

ENGINE COOLING SYSTEM





1-5 .. 06 Blank ... 0

TABLE OF CONTENTSParagraph PE=

Foreword ............................... 2

Safety Summary .......................... 2

1. Cooling Water Circulation System ............ 4

2. Water Pump ............................. 4

2.1 Disassembly ............................. 4

2.2 Reassembly .............................. 4

2.3 Clearance, Play and Tightening AllowanceBetween Parts ........................... 5

3. Thermostat ............................ 5

3.1 Inspection and Replacement ................. 5

LIST OF ILLUSTRATIONSEig PA=

1 Cooling Water Circulation System Diagram .... 3

2 Water Pump ............................ 3

3 Fan Hub and Pump Cover ................... 4

4 Bearing and Impeller ....................... 4

5 View of Bearing Unit and Alignment Holes .... 4

6 View of Impeller and Seal Unit ....... ....... 4

7 View of Pump Cover ...................... 5

8 Thermostat .............................. 5

T.O. 38G1-127-1TMI-2815-262-1 3&PWP 008 00

FOREWORD

This Work Package (WP) contains procedures for inspect-ing and overhauling the cooling water circulating pump onthe diesel engine used on the SGNSC.

SAFETY SUMMARY


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

WP 008 00

Figure 2. Water Pump.

WaterRadiator pump

Figure 1. Cooling Water Circulation System Diagram.

Seal unit

Fan center

Cover

T.O. 38G1-127-1TM1-2815-262-1 3&PWP 008 00

1. COOLING WATER CIRCULATION SYSTEM

Figure 1 shows a diagram of the engine coolant circulationsystem. Figure 2 shows an exploded view of the waterpump.

2. WATER PUMP

2.1 Disassembly

2.1.1 Fan Center and Cover

a. Loosen the setscrew. Refer to Figure 3.

Figure 3. Fan Hub and Pump Cover.

b. Remove the cover.

NoteThe cover is applied with sealant (TB 1207B). Whenremoving the cover, much care should be taken notto deform it by applying an excessive force to it.

2.1.2 Impeller, Seal Unit and Bearing Unit

2.2 Reassembly

2.2.1 Bearing Unit

With a hole in the bearing unit set in line with one in thebody, lock the bearing unit with a setscrew. Refer to Figure5.

Figure 5. View of Bearing Unit and Alignment Holes.

Set screw tightening torque | (6 - 9 lb-t) l

2.2.2 Seal Unit And Impeller

a. Apply BELCO bond No. 4 to the surface where theseal unit comes into contact with the body, and thenassemble the seal unit.

b. Press in the impeller with a press until the clearance be-tween the pump impeller and the body gets to thespecified value (see paragraph 2.3).

Remove the impeller, seal and bearing unit from the pumphousing. Refer to Figure 4.

Figure 6. View of Empeller and Seal Unit.

~A$ Body

7 4)-WSetscrew

Impeller

0t

Seal unit

Figure 4. Bearing and Impeller.

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

WP 008 00

2.2.3 Cover

a. Apply liquid gasket (TB1207B) to the surface to whichthe cover is installed. Then install the cover. Refer toFigure 7.

Figure 8. Thermostat.

Figure 7. View of Pump Cover.

b. Apply Loctite No. 262 to the cover installation screws.Then tighten them.

2.3 Clearance, Play and Tightening AllowanceBetween Parts

Clearance between the pump impeller and the body

I Standard | 0.53 - 2.17 mm (0.0209 - 0.0854 in.)I

in the water nump ball bearina

STANDARD I LIMIT I

0.008 -0.010 mm(0.0003 - 0.0004 in.)

0.2 mm(0.0079 in.)

Tightening allowance between the fan center and thebearing shaft

Standard | 0.26 - 0.061 mm (0.001 - 0.0024 in.)

3. THERMOSTAT

3.1 Inspection And Replacement

Replace the thermostat when there is wear, damages or anyother defects found. Refer to Figure 8

51(6 blank)

Cover

Thermometer

Agitating rod -

Thermostat

Wooden piece

Opening temperature 74.50 - 78.50C(1660 - 1740F)

Valve lift 8 mm or more at 90'CI _______________ (0.312 in. or more at 1940F) I

-- I

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

WP 009 00

WORK PACKAGE


Total number of pages in this WP is 12Change No. Page No. Change No.

1-12 . 0

TABLE OF CCR=gParagrah

Foreword .............................. 2

Safety Summary .......................... 2

1. Fuel Circulation System .................... 4

2. Governor .............................. 4

2.1 Reassambly of Control Lever Related Parts ..... 6

2.2 Reassembly of Shifter ...................... 8

LIST OF ILLUS

Fuel Circulation System Diagram ...... ...... 3

Structural Drawing of Governor (1) ...... ..... 4

Structural Drawing of Governor (2) ...... ..... 5

Control Lever Related Parts ........ ......... 6

Assemblying Control Lever to Governor ...... 7

Governor Shifter Assembly ................. 8

)NTENTSParagrophb

2.3 Reassembly of Governor Cover ....... ...... 9

2.4 Reassembly of Full-Load Stopper ........... 10

2.5 Reassembly of Governor RelatedComponents ............................ 11

3. Nozzle Holder Assembly .................. 12

4. Nozzle Assembly ........................ 12

,TRATIONSEigre PI

7 Governor Cover .......................... 9

8 View Z-Z From Figure 6 ......... .......... 9

9 Full-Load Stopper ....................... 10

10 Governor Lever Related Parts ....... 11....... 1

11 Nozzle Holder Assembly and Fuel Piping .... 12

12 Inspecting Nozzle Body and Needle Valve .... 12

ENGINE FUEL SYSTEM



Page No. Page No. Change No

1

2

3

4

5

6

T.O. 38G1-127-1TM1-281 5-262-1 3&PWP 009 00

FOREWORD

This Work Package (WP) contains procedures for inspect-ing, overhauling and replacing components in the diesel en-gine used on the SGNSC. The procedures are included for

the governor and related components, and for the injectionnozzles.

SAFETY SUMMARY


Nozzle holder

Injection pump

T.O. 38G1 -1 27-1TM1-2815-262-1 3&P

WP 009 00

Nozzle

Figure 1. Fuel Circulation System Diagram.

1I

Fuel filter

I -

T.O. 38G1 -1 27-1TM1-2815-262-1 3&PWP 009 00

1. FUEL CIRCULATION SYSTEM

Figure 1 shows a diagram of the engine fuel circulation sys-tem.

2,GOYERNOR

a. The adjustments of the governor-related parts requirethe engine performance test.

b. Before disassembling the governor, measure the dimen-sions "A" and "B" given in the structural drawing toensure the same dimensions in reassembly. Refer toFigures 2 and 3.

c. Do not disassemble the governor when the perform-ance test cannot be conducted after reassembly.

Idle speed screw

Injection pump _-

, Governor shaft

< Set spring

Governor cover

- Guide lever

% Timing gear case

- Tensioner lever

kngleich

Full load stopper

Figure 2. Structural Drawing of Governor (1).

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

WP 009 00

Start spring

Figure 3. Structural Drawing of Governor (2).i

T.O. 38G1-127-1TM1-2815-262-1 3&PWP 009 00

2.1 Reassembly of Control Lever Related Parts

Refer to Figure 4.

a. Put the lever (main spring) through the hole of the tim-ing gear case lever.

NoteBefore hammering in the bushes, put both shafts ofthe lever through the holes of the timing gear caselever, respectively.

b. Pit the return spring of the control lever through theshaft of the lever (main spring).

c. Assemble the bushes. Assemble the bush of the lever(main spring) first, and then the control lever bush.

NoteWhen assembling the bushes, apply Loctite No. 601to the periphery of the bushes.

d. Hook both ends of the return spring (control lever) se-curely to the protrusion and the pin of the lever (mainspring), respectively.

Lever; Main spring

Bush( Apply Loctite No.601 Protrusion\ to the periphery )

Return spring

Timing gear case

Bush( Apply Loctite No.601( to the periphery

Figure 4. Control Lever Related Parts.

)

O-ring

Washer

Control lever

Spring washer

Nut

Figure 5. Assembling Control Lever to Governor.

e. Assemble the control lever (see Figure 5).

f. Assemble the O-ring to the groove of the bushes (con-trol lever) first; then assemble the washers and thecontrol lever before tightening up the control leverwith a nut.

Control lever tightening torque 1.2 - 1.8 kg-m(9 -13 lb-ft)

NoteTighten the control lever after locking the controllever firmly. (Do not tighten the control lever afterlocking the main spring lever.) After assembly, con-firm that the control lever moves smoothly.

T.O. 38G1-127-1TM1-281 5-262-1 3&P

WP 009 00

Bush

T.O. 38G1-127-1TM1-2815-262-1 3&PWP 009 00

b. After assembly, confirm that the shaft moves smoothly.

a. Assemble the shifter to the guide lever, put the shaftthrough it, and assemble the snap ring (see Figure 6).

c. Also, confirm that the shifter shakes smoothly.

Guide lever

Shifter

Snap ring

Shaft

Figure 6. Governor Shifter Assembly.

2.2 Reassembly of shifter

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

WP 009 00

Governor cover

(Bent-up part) Retun

.\ . -I

Shaft

[Stopl [Operate]

Governor

C

Washer /f

Washer

L

0, Cap

I Cap nut

/ Packing

-, Lock nut

ase (t)

- Gasket

er Idle screw

Governor lever

* Tensioner lever

it Idle spring

Snap ring

(Z view of the drawing above)

Figure 8. View Z-Z From Figure 6.

Figure 7. Governor Cover.

| 2.3 Reassembly of Governor Cover

a. Assemble the related parts such as the fuel stop leverand the idle spring to the governor cover. Refer to Fig-ure 7.

b. When assembling the shaft, apply engine oil to the slid-ing portion with the governor cover.

c. Set both ends of the return spring securely to thenotched groove at the bottom of the cover and thebent-up arm of the lever, respectively.

d. After reassembling the governor cover, confirm thatthe governor moves smoothly.

e. When assembling the timing gear case to the governorcover, tighten the "A" dimension shown in the illustra-tion to 2 - 3 mm (.079 - .118 in.), temporarily.

The parts shown in the rectangle indicated by (*) in Figure8 are assembled after the performance test.

"A" dimension (When assembly temporarily)2 2-3mm(0.079-0..118 in.)

9

I

A

I

M

MN 0

r7N 0,

I

T.O. 38G1-127-1TM1-2815-262-1 3&PWP 009 00

2.4 Reassembly of Full-Load Stopper

Install the full-load stopper to the timing gear case; thentighten it with a nut temporarily. Refer to Figure 9.

Figure 9. Full-Load Stopper.

10

'- Timing gear case

Full load stopper

- Nut; setscrew

T.O. 38G1 -1 27-1TM1-2815-262-1 3&P

WPOO9 00

2.5 Reassembly of Governor Lever RelatedComponents

Assemble each lever and spring to the timing gear case(see Figure 10).

2.5.1 Notes When Assembling Governor Related Compo-nenlts

a. When assembling components, apply engine oil to eachslide (such as the end face of the lever, the hole in theshaft, and the periphery of the shaft).

b. Install the set spring securely to the groove of the pin,connecting the floating lever, with much care to its as-sembling direction.

c. Confirm that each lever moves by its dead weight be-fore installing the start spring.

d. After assembly, confirm that each lever movessmoothly. And also confirm that each spring operatesproperly.

Figure 10. Governor Lever Related Parts.

11

T.O. 38G1-127-1TM1-2815-262-1 3&PWP 009 00

Figure 11. Nozzle Holder Assembly and Fuel Piping.

3. NOZZLE HOLDER ASSEMBLY

Disassembly of the nozzle holder assembly is shown in Fig-ure 1 1.

4. NOZZLE ASSEMBLY

them thoroughly (see Figure 12). Then check to see if thevalve moves smoothly in the body.

If it does not move smoothly, repair or replace the nozzle.

4.2 Adiustment of Inlection Pressure

4.1 Inspection and replacement

Place the removed nozzle in the clean light oil, disassembleit into the nozzle body and the needle valve, and clean

For the adjustment of the injection pressure and the spraycondition of fuel, refer to Subordinate Work Package SWP005 03 "ENGINE MAINTENANCE".

Figure 12. Inspecting Nozzle Body and Needle Valve.

)era -HHeat shield

Gasket

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

WPO10 00

WORK PACKAGE

Page No. Change No.

1-6 . 0


Total number of pages in this WP is 6Page No. Change No. Page No.

TABLE OF CONTENTSParagp Pa

1. Troubleshooting Charts ..................... 2

LIST OF TABLESiTahoi Car

1 Engine Trouble Shooting Charts........2

ENGINE TROUBLESHOOTING CHARTS


EFFECTIVITY: ISUZU DIESEL ENGINE MODEL 4LE1PW14

Change No

T.O. 38G1-127-1TM1-2815-262-1 3&PWP010 00

1. TROUBLESHOOTING CHARTS

The following charts describe some problems that may oc-cur and the logical steps for solving those problems. Also

see T.O. 35D29-7-6-1/TM1-3655-230-12, WP 006 00, Ta-ble7.

Table 1. Engine Trouble Shooting Charts (Sheet 1 of 5).

* Note: 'Bring it to a specialty shop' means that defective parts of the injection pumpand electricals must be brought to a specialty shop for repair. (This note Isapplicable to all the following procedures.)

7r l I

Defective starter(Bring It to a specialty

shop for repair)

T.O. 38G1 -1 27-1TM1-2815-262-1 3&P

WP010 00

Table 1. Engine Trouble Shooting Charts (Sheet 2).

Defective I valve returnI (Adjust) i

Check high pressure Defective injectionpipe for cracking. pump (Bring it to a! clogging or bending specialty shop for

repair)Defective injectionpump (Bring it to aspecialty shop for

repair)

Defective injectionpump (Bring it to aspecialty shop for

repair)

T.O. 38G1-127-1TM1 -2815-262-13&PWP010 00

Table 1. Engine Troubling Shooting Charts (Sheet 3).

Insufficient output

Fuel system

Check fuel for air1I mixing I

air

Check fuel filteror fuel hose for

clogging

Clogged ! K'(Clean or'Replace)

Check high Iipressure pipe for

clogging or! bending

i Mechanical

i system I

T.O. 38G1 -1 27-1TM1-2815-262-1 3&P

WPO10 00


Air cleaner clogged

* Replace air I OK

cleaner element:

Check air hose for crash

I . Defective injection pumpI Low | It OK r (Bring it to a specialty

.r I Pshop for repair)

l as bakfo Check up andIExcessive valve and down u

blow-by gas: asket (Repai movement of oil

|Stuck (Overhaul

| Abnormal i

I Bring it to a battery shop

T.O. 38G1 -1 27-1TMI-2815-262-1 3&PWPO10 00


Oil pressure too low

Check oil level

Low (Replenish) OK

Check cooling water temperature

High OK(See 'Overheat')

Check oil in crankcase

Improper !Kviscosity

Water or fuel mixed. Check fuelsystem and cooling system

Check relief valve

Defective OK(Repair or replace)

1. Oil pump malfunction2. Loosened or cracked pipe3. Wear of sliding part4. Oil pump clogged

{Overhaul)

iil consumption too much

Check for oil leakage l

Leaking (Retighten. OKreplace packing seal)

r- _Check nozzle

Defective(Repair or replace)

| Ch-ck njection timing

Abnormal (Adjust)

Check compression ratio

Low OK

Defective injection pump,I1ring it to a specialty I

shop for repair)

Excessive Gas leak fromblow-by gas valve and gasket

(Repair orreplace)

*pii consumption too muchl

IICheck for oil leakage

Leaking (Retighten. OKreplace packing seal)

Check oil qualityI

Poor quality _7(Change to specified oil)

Check bleeder for clogging

Clogged (Clean) i O7K

lCheck up and down movement of oill

.1. Oil pump malfunction2. Loosened or cracked pipeI 3. Wear of sliding part

,4. Oil pump clogged5. Defective valve stem seal

(Overhaul)

() Worn boreand worn or brokenring (Measure compressionpressure, and check entrance ofdust)

1I Engine knocking - .

Mechanical system

Check up movement of oilI

.Oil stained (Overhaul)|

Check compression pressurei

Low OK

To fuel system

r ~~~~~~~~~~~~~~~~~~~~~~~~IExcessive Gas leak from

- blow-by gas valve and gasket( {Overhaul) (Repair or

replace)

K Fuel system -_-__

Check injection timing

Abnormal (Adjust) OK

Check nozzle

Defective O| K(Repair or replace)

Note: Fuel used is of poor quality.

Page No. Change No. Page No.

1-4 . 0

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

WP 998 00

WORK PACKAGE


Total number of pages in this WP is 4

Change No.

TABLE OF CONTENTSParagraph Page

1. General .......................... 2

2. Supporting Documents ..................... 2

3. Finding Part Number Using Assembly Name .. 2

4. Finding an Illustration For a Known PartNumber .......................... 2

5. Table of Contents ......................... 2

6. List of Illustrations ........................ 2

7. Maintenance Parts List (SWP 998 01) ........ 2

8. Maintenance Parts List Arrangement .... ...... 3

9. Numerical Index (SWP 998 02) .... ......... 3

ILLUSTRATED PARTS BREAKDOWN



Page No. Change No

T.O. 38G1-127-1TM1-2815-262-1 3&PWP 998 00

1.GENERAL c. Go to the page determined in step (b).

This Illustrated Parts Breakdown (IPB) section lists and de-scribes, in as close to disassembly order as possible, all as-semblies and parts of the diesel engine for the Self Generat-ing Nitrogen Servicing Cart (SGNSC), NSN 3655-01-463-3338. The engine is manufactured by Isuzu Motors. Thepart number is 4LEIPW14, NSN 2815-01-470-8023.

2. SUPPORTING DOCUMENTS

This IPB amplifies information given in companion hand-books by providing part numbers for items mentioned bydescription only. The companion handbooks are,

T.. 35D29-7-6-ITIMl-3655-230-12 - Operation andMaintenance Instructions

d. Find the index number determined in step (b) on theparts breakdown for the full description of the part.

e. Find the index number on the illustration for the loca-tion of the part on the assembly.

5. TABLE OF CONTENTS

The table of contents lists the paragraphs and sub-para-graphs of the text portion of the IPB. Also listed are the as-semblies illustrated in the IPB. The page numbers repre-sent the page that the parts list for the applicable illustra-tion begins.

6. LIST OF ILLUSTRATIONS

T.Q. 35D29-7-6-3TMl-3655-230-30 - Overhaul Instruc-tions

T.O. 35D29-7-6-4/TM1-3655-230-23&P - IllustratedParts Breakdown

The List of Illustrations on the Maintenance Parts Lists(SWP 998 01) lists the figure number, the description ofthe illistration and the page where the figure can be located.

7. MAINTENANCE PARTS LIST (SWP 998 011

3. FINDING PART NUMBER USING ASSEMBLYNAME

When only the name of an assembly in which the part isused is known, the following steps should be used to findthe part number of the part.

a. Turn to the Table of Contents and find the pagenumber for the parts breakdown of the assembly inwhich the part is used.

b. Turn to the page determined in step (a).

c. Locate the part and its index number on the illustration.

d. Find the index number on the parts breakdown of the il-lustration for the part number and complete descrip-tion of the part.

4. FINDING AN ILLUSTRATION FOR A KNOWNPART NUMBER

The Maintenance Parts List, SWP 998 01, lists the parts ofthe diesel engine. Parts lists are shown on the same page asthe applicable illustration or immediately following the ap-plicable illustration. Where possible, the illustration will beon the same page as the applicable parts list or on the leftpage with the parts list on the facing right page.

7.1 Repair PartKits

When repair parts kits are supplied for an assembly, thestatement "(Repair kit available)" will follow the descrip-tion of the applicable assembly. All parts that are includedin the kit will have the description indented one positionfrom the applicable assembly and will have an SMR codeof KF or KD. The kit part number will follow the last partlisted for the applicable assembly and the description willhave the same indentation as the applicable assembly. Therepair kit will have an SMR code of PAFZZN. The kit willnot be illustrated.

7.2 Symbols Used in Parts List

When the part number of a part is known, the followingsteps should be used to locate the illustration of the assem-bly that it is used on.

a. Refer to SWP 998 02, Numerical Index and find thepart number.

b. Turn to the List of Figures and find the page numberfor the figure number listed in the Numerical Indexfor that part.

The following symbols may be used in the parts list to de-scribe special characteristics for the part number.

a. An equal sign (=) preceding the part number one spaceto the left denotes that the part is an acceptable alter-nate part for the preceding part number. The part willhave the same index number as the preceding part.

T.O. 38G1 -1 27-1TM1-2815-262-13&P

WP 998 00

8. MAINTENANCE PARTS LIST ARRANGEMENT

The following sub-paragraphs describe the columnar ar-rangement for the Maintenance Parts List, SWP 998 01.

8.1 Figure and Index No. Column

The first number (before the dash) refers to the illustrationnumber in the Maintenance Parts List. The second number(after the dash, or find number) refers to the location of thepart on the illustration (corresponding find number on theillustration). The first number will only appear on the firstentry for the assembly of the applicable parts list and onthe first entry of a new page when the parts list is morethan one page long.

8.2 Part Number Column

This column contains the Government Standard, vendorand Pacific Consolidated Industries part numbers.

8.3 CAGE Code Column.

The Commercial and Government Entity (CAGE) code is afive digit code that is published in H4-1, H4-2 and H4-3Cataloging handbooks. This code appears in this column.

8.4 Description Column.

This column lists the complete description by GovernmentStandard, vendor and drawing title. Abbreviations are perMIL-STD-12.

8.4.1 Indentation System.

For proper identification of detail parts and next higher as-semblies (NHA), the description listings are in the systemof indentation.

1234567ASSEMBLY

DETAIL PARTS FOR ASSEMBLYSUBASSEMBLY

DETAIL PARTS FOR SUBASSEMBLYSUB-SUBASSEMBLY

... DETAIL PARTS FOR SUB-SUBASSEMBLY

The next higher assembly for any detail part may be deter-mined by locating, in the next column to the left, the firstitem above the detail in question. For example, if a detailpart or subassembly has two leader points (..) preceding itsdescription, the next higher assembly will be the first itemabove it that has one leader point (.) preceding its descrip-tion.

8.4.2 Attaching Paits.

Any parts used exclusively for attaching subassemblies ordetail parts will immediately follow the applicable part andbe indented the same as the part that it attaches to theNHA. The description of the attaching part will be fol-lowed by the description "(AP)".

8.5 Units Per Assembly Column.

These numbers are the total quantity used in the nexthigher assembly. The detail parts indented under assem-blies indicate only the quantity used on the applicable as-sembly, and are not necessarily the total quantity used inthe generating plant. When "REF" appears in this column,it indicates that the part is shown and listed on another il-lustration. Refer to paragraph 4 for instructions on locatingthe illustration for a known part number.

8.6 SMR Code Column.

The Source, Maintenance and Recoverability (SMR) Codesused in this manual are the Joint Military Services UniformSMR Codes only. Definitions of the SMR codes are avail-able in T.O. 00-25-195. The codes that appear in this col-umn describe, among other things, the level of mainte-nance and recoverability for the part or assembly.

8.7 Usable on Code Column.

Items of a like nature, listed under the same index number,are interchangeable when no code appears in the "Usableon Code" column opposite such listings.

9. NUMERICAL INDEX (SWP 998 02)

The numerical index (SWP 998 02) lists all part numberscontained in the Maintenance Parts List. Some part num-bers will appear more than once in this list. This is becausesome assemblies and subassemblies use the same parts.Part numbers appearing with no index number followingthe dash, are separate breakdowns of subassemblies that ap-pear on the parts list of the next higher assembly and canbe located on its NHA's illustration..

9.1 Part Number Column.

This column lists in alphabetical and numerical sequence,all Government Standard, vendor and Pacific ConsolidatedIndustries part numbers required to overhaul and maintainthe engine. No part numbers are listed unless they appearin the Maintenance Parts List.

9.1.1 Part Number Arrangement.

The part numbers are arranged from the extreme lefthandposition and continue from left to right, one position at a

T.O. 38G1 -1 27-1TM1-2815-262-1 3&PWP 998 00

time. The order of precedence for the first position is as fol-lows,

letters A through N and P through Z, then, numerals 0through 9

NoteThe alphabetic 0 is considered to be a numeric 0.

The second and succeeding characters in the part numberhave precedence as the following sequence shows,

Space, diagonal (/), period (.), dash (-), letters Athrough N, P through Z, numerals 0 through 9.

9.2 Figure and Index Number Column.

This column contains the figure and index number(s)where the part is listed in a parts list and shown on an illus-tration. The first number is the figure number for the illus-tration that shows the part. The number following the dashis the index number on the applicable illustration and in theparts list for the applicable illustration. When the figurenumber is preceded by "F' it indicates that the part numberfollows the applicable figure and index number in theMaintenance Parts List.

4

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

SWP 998 01




Change No. Page No. Change No. Page No. Change No

1-32 . 0

TABLE OF CONTENTSPargraph Page EPaga

List of Illustrations ......... ............... 2 Injection Pump Assembly Parts List .... ..... 28

1. Maintenance Parts List ....... .............. 3 Injection Nozzle Assembly Parts List ........ 29

Diesel Engine Parts List ...... .............. 5 Starter Assembly Parts List ...... .......... 30

Cylinder Head Parts List .................... 7 Generator Assembly Parts List ............. 31

Cylinder Block Parts List ...... ............. 9

Timing Gear Case Parts List ................ 10

Flywheel Housing Parts List ................ 13

Oil Pan Parts List ........................ 14

Oil Pump Parts List ....................... 15

Crankshaft, Flywheel, Piston and ConnectingRod Parts List ........................ 17

Valve Mechanism Parts List ................ 19

Oil and Fuel Filter Parts List ................ 20

Cooling System Parts List .................. 21

Exhaust System Parts List .................. 23

Fuel System Parts List .................... 24

Engine and Generator Brackets Parts List ..... 25

Injection Pump and Camshaft Parts List ..... 26

Electrical Components Parts List .... ........ 27

MAINTENANCE PARTS LIST WITH ILLUSTRATIONS


EFFECTIVITY: ISUZU DIESEL ENGINE MODEL 4LEIPWl4

Page No.

T.O. 38G1-127-1TM1-2815-262-1 3&PSWP 998 01

LIST OF ILLUSTRATIONSEig= Ea1 Diesel Engine Group Breakdown ...... ....... 4

2 Cylinder Head, Cover and Other Parts ..... .... 6

3 Cylinder Block and Other Parts ....... ....... 8

4 Timing Gear Case and Other Parts (Sh 1 of 2). 10

4 Timing Gear Case and Other Parts (Sh 2) ..... 11

5 Flywheel Housing and Other Parts ...... ..... 13

6 Oil Pan and Other Parts .................... 14

7 Oil Pump and Fixing Parts ................. 15

8 Crankshaft, Flywheel, Piston and ConnectingRod .............................. :. 16

9 Valve Mechanism, Rocker Arm ....... ...... 18

10 Oil and Fuel Filters and Fixing Parts ..... .... 20

11 Cooling System (Sh 1 of 2) ................. 21

1 1 Cooling System (Sh 2) .................... 22

12 Exhaust System .......................... 23

13 Fuel System, Injectors and Fuel Pipe ..... .... 24

14 Engine and Generator Brackets .............. 25

15 Injection Pump, Camshaft and Other Parts ..... 26

16 Electrical Parts ........................... 27

17 Injection Pump Assembly ......... ......... 28

18 Injection Nozzle Assembly ......... ........ 29

19 Starter Assembly ......................... 30

20 Generator Assembly .............. ........ 31

T.O. 38G1 -1 27-1TM1-2815-262-1 3&P

SWP 998 01

1. MAINTENANCE PARTS LIST

This Maintenance Parts List shows the illustrations andparts lists for all groups and subassemblies of the diesel en-gine for the Self Generating Nitrogen Servicing Cart(SGNSC), NSN 3655-01-463-3338. The engine is manufac-tured by Isuzu Motors. The part number is 4LElPWl4,NSN 2815-01-470-8023.

T.O. 38G1-127-1TMI-2815-262-1 3&PSWP 998 01

(FAR SIDE)

Figure 1. Diesel Engine Group Breakdown.

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

SWP 998 01

Figure & Part Number CAGE Description Units Per SMR UsableIndex No. 1234567 Assy Code on Code

1- 4LEIPW14-1 FIG. 1-2 FIG. 2-3-4-5-6-7-8-9-10-11-12-13-14-15

FIG. 3FIG.4FIG. 5FIG. 6FIG. 7FIG. 9FIG. 12FIG. 13FIG. 15FIG. 16FIG. 18FIG. 19FIG. 10

4N530 ENGINE, Diesel- 4 cylinder- 54 hp ...... ........... REF4N530 CYLINDER HEAD, Cover and other parts ..... ...... 14N530 . CYLINDER BLOCK AND OTHER PARTS ..... ..... 14N530 TIMING GEAR CASE AND OTHER PARTS ..... 1.... 4N530 . FLYWHEEL HOUSING AND OTHER PARTS ........ 14N530 . OIL PAN AND OTHER PARTS ....... ............. 14N530 . OIL PUMP AND FIXING PARTS ...... ............ 14N530 . CRANKSHAFT, Flywheel- piston & connecting rod .... 14N530 . VALVE MECHANISM, Rocker arm ...... ........... 14N530 . COOLING SYSTEM, Fan and water pump ..... ...... I4N530 . EXHAUST SYSTEM ............................. 14N530 . FUEL SYSTEM, Injectors and fuel pipe ..... ......... 14N530 . BRACKETS, Engine and generator .................. 14N530 . INJECTION PUMP, Camshaft and other parts .... ..... I4N530 . ELECTRICAL PARTS .......... .................. 14N530 . OIL FILTER, Fuel filter and fixing parts (not shown) .... 1

PAFDDTXCXCXCXCXCXCXCXCXCXCXCXCXCXCXC

T.O. 38G1-127-1TM1-2815-262-1 3&PSWP 998 01

SEE FIG 16

SEE FIG 14 16

I4\ SEEFIG"V SEE SEE FIG

I-24

lcirX 23

20E$ 1 /

Figure 2. Cylinder Head, Cover and Other Parts.

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

SWP 998 01

Figure & Part Number CAGE Description Units Per SMR UsableIndex No.

2- FIG.1-1 897114-7130-2 109600-0112-3 109600-0051-4 511119-0090-5 897031-7490-6 897126-1390-7 897045-3920-8 897115-3150-9 897094-6410-10 904110-8400-11 509300-0650-12 894110-5591-13 509605-0050-14 897136-3240-15 894463-7840-16 897036-9591-17 897118-2052-18 894329-5490-19 903910-4100-20 894133-2075-21 894123-6231-22 897119-2990-23 028080-6200-24 028080-6450

1234567 Assy

4N530 CYLINDER HEAD, Cover and other parts ..... ...... REF4N530 . HEAD ASSEMBLY, Cylinder ....................... 14N530 .. CUP, Sealing- d=22. 64N530 .. CLIP, Sealing- d=44.5. 1

4N530 . . PLUG, Drilled passage- d=8. 54N530 . . GUIDE, Valve exhaust and inlet. 84N530 .. SEAT, Valve insert- inlet. 44N530 .. SEAT, Valve insert- exhaust. 44N530 .. PLUG, Glow .......... 44N530 . STUD, Rocker bracket. 64N530 . STUD, Water pump. 14N530 . STUD, Manifold- 1=79. 24N530 . SEAL, Valve. 84N530 . PLUG, Heater- switch- left .I4N530 . GASKET, Cylinder head. 14N530 . BOLT, Cylinder head- 1=25. 54N530 . BOLT, Cylinder head- 1=89 .104N530 . COVER ASSEMBLY, Cylinder head .14N530 . VALVE ASSEMBLY, Ventilator .14N530 . SCREW, Valve. 44N530 . CAP ASSEMBLY, Oil filler .14N530 .. PACKING, Oil filler cap .14N530 GASKET, Cylinder head cover .14N530 . BOLT, Head cover. 54N530 . BOLT, Head cover. 5

on CodeCode

XCXBXBXBXBXBXBXBXBXBXBXBXBXBPAFZZNXBXBXBXBXBPAFZZNXAPAFZZNXBXB

T.O. 38G1-127-1TM1-2815-262-1 3&PSWP 998 01

Figure 3. Cylinder Block and Other Parts.

8

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

SWP 998 01

Figure & Part Number CAGE Description Units Per SMR UsableIndexNo. 1234567 Assy Code on Code

3- FIG.2-1 897169-1920-2 894167-4701-3 894229-8530-4 109600-0112-5 509600-0130-6 109600-0121-7 897047-0560-8 897047-1421-9 909664-0010-10 909204-5100-11 109605-0040-12 109605-0190-13 897118-9891-14 091150-2060-15 028080-6140-16 028080-6200-17 904110-6160-18 894343-8960-19 904110-6160-20 897102-5501-21 897039-4953-22 908160-8160-23 911229-0581-24 908160-6160-25, 509604-0160-26 909572-0140-27 894200-8190-28 911229-0581-29 909878-5320-30 109305-0050-31 904110-8400-32 509300-0650-33 904110-8500-34 897166-9600-35 897231-0300-36 509625-0940-37-38 028080-6200-39 897106-4150-40 909571-4160-41 909524-6220-42 894368-5010

4N530 CYLINDER BLOCK AND OTHER PARTS ..... .... REF4N530 . BLOCK ASSEMBLY, Cylinder ..................... I4N530 .. BOLT, Metal cap .104N530 .. CUP, Sealing- d=35. 54N530 .. CUP, Sealing- d=22. 14N530 .. CUP, Sealing- d=12. 74N530 .. CUP, Sealing- d=32. 14N530 . BEARING, Needle- cam ............... 1........... 4N530 . PLUG, Thrust cam ............................... 14N530 . PLUG, Water drain ............................... 14N530 . PLUG, Oil gallery- 1/8 npt ......................... 34N530 . PLUG, Oil gallery- 1/8 npt ......................... 14N530 . PLUG, Oil gallery- 1/4 npt ............. 1............ 4N530 . COVER, Injection pump housing ..................... 14N530 . NUT, Cover ................................. 24N530 . BOLT, Cover ................................. 44N530 . BOLT, Cover ................................. 24N530 . STUD, Injection pumphousing cover ...... ......... 14N530 . STUD, Injection Pump- housing cover ...... ......... 14N530 . STUD, Oil pan ................................. 24N530 . STUD, Oil filter .......................... 14N530 . PIN, Control link .......................... 24N530 . PIN, Straight- housing............................ 24N530 . DOWEL, Oil pump .......................... 24N530 . PIN, Straight- retainer .......................... 24N530 . PLUG, Cylinder block- m14 ....................... 14N530 . PACKING, Plug ............... ........... I4N530 . DOWEL, Cylinder head .......................... 24N530 . DOWEL, Front plate .......................... 24N530 . PIN, Straight- injection pump ....................... 84N530 . STUD, Injection pump- 11=20 ...... ................ 84N530 . STUD, Water pump- 11=40......................... 14N530 . STUD, Timing case- 11=79 ......................... 14N530 . STUD, Timing case- 11=50 ......................... 14N530 . LEVEL GAUGE, Oil- 1=121 ....... ................ 14N530 . RETAINER, Crank- rear ........................... 14N530 . SEAL, Oil- crank- rear .......................... 14N530 . PACKING, Retainer- bonded .................... A/R4N530 . BOLT, Retainer .......................... 64N530 . VALVE ASSEMBLY, Check ....................... 14N530 . GASKET, Check valve .......................... 14N530 . CLIP, Fuel pump lead wire ......................... 14N530 . NUT, Stud- oil cooler .......................... 1

XCXBXBXBXBXBXBXBXBXBXBXBXBXBXBXBXBXBXBXBXBXBXBXBXBXBXBXBXBXBXBXBXBXBXBXBXBXBXBXBXBXBXB

T.O. 38G1-127-1TM1-2815-262-1 3&PSWP 998 01

22

0-460-44

FIG 15

31 33

87x,0037

86

Figure & - Part NumberIndex No.

4- FIG. 3-1 897045-6175-2 897147-4890-3 908160-8500-4 897034-5945-5 897034-6382-6 908213-6250-7 909185-4040-8 897093-5491-9 897034-6374-10 897034-6422-11 8941304380-12 897076-9040-13 897148-5480-14 908160-5450-15 109605-0500

Figure 4. Timning Gear Case and Other Parts.(Sheet 1 of 2)

CAGE Description Units Per SMR Usable1234567 Assy

4N530 TIMING GEAR CASE AND OTHER PARTS ....... REF4N530 . FLYWEIGHT ASSEMBLY ....... ................. 14N530 . SLEEVE ASSEMBLY . ........................... 14N530 . SHAFT, Lever- d=8, 1=50 .......................... 14N530 . LEVER ASSEMBLY, Guide ...... ................. 14N530 . SHIFTER, Governor .............................. 14N530 SHAFT, Shifter- d=6, 1=25 ....... .................. 14N530 . RING, Snap ..................................... 14N530 . LEVER KIT, Governor ............................ 14N530 .. LEVER, Tension- governor .14N530 .. LEVER, Main spring .14N530 . NUT HOLDER . ................................. 14N530 . SPRING, Main . ................................. 14N530 LEVER ASSEMBLY, Floating ...................... 14N530 SHAFT, Floating lever ...... ...................... 14N530 PLUG, Shaft- 1/8 npt ....... ...................... 1

Code on Code

XCXBXBXBXBXBXBXBXBXBXBXBXBXBXBXB

10

18

' T.O. 38G1 -1 27-1TM1-2815-262-1 3&P

SWP 998 01

V57

.56

58

63

Figure & Part NumlIndex No.

4 -16 897112-2650-17 109747-0020-18 897148-5500-19 897034-6432-20 897083-7140-21 897148-8650-22 109747-0020-23 897164-3340-24 897016-9400-25 894369-5450-26 897038-8021-27 894454-6150-28 897049-3280-29 109623-0550-30 509503-1350-31 909110-5080-32 908160-4360-33 909150-5080-34 894317-6381-35 909111-4060-36 897039-5841

72

Figure 4. Timing Gear Case and Other Parts.(Sheet 2)

ber CAGE Description Units Per SMR Usable1234567 Assy

4N530 . PIECE, Guide- pin- governor lever ...... ............ 14N530 . PIN, Spring- governor lever ......................... I4N530 . PLATE ............................... 14N530 . SPRING, Start ............................... 14N530 . SPRING, Set .............................. 14N530 . LINK ASSEMBLY, Control ........................ 14N530 . PIN, Snap- link plate .............................. 14N530 . ANGLEICH KIT .............................. 14N530 . SPRING, Return .............................. 14N530 . BUSH, Lever- main spring ......................... 14N530 . BUSH, Lever- main spring ......................... 14N530 . CUP, Sealing- bushing- d=10 ....................... 14N530 . LEVER, Governor control ......................... 14N530 . O-RING, Control shaft ............................ 14N530 . WASHER, Thrust .............................. 14N530 . NUT, Lever to shaft ............................. I4N530 . PIN, Control spring ............................... 14F040 . WASHER, Spring .............................. 14N530 . SCREW, Control- L-38 ........................... 24N530 . NUT, Screw .............................. 24N530 . SCREW, Set- full load ............................ 1

Code on Code

XBXBXBXBXBXBXBXBXBXBXBXBXBXBXBXBXBPAF2ZNXBXBXB

61 6

T.O. 38G1-127-1TM1-2815-262-1 3&PSWP 998 01

Figure & Part Number CAGE Description Units PerIndex No. 1234567 Assy

909110-4060515729-2391897016-4410909160-5040909160-7040909185-4030509503-1320509400-0480909111-4060515669-0021897016-9361897016-4460897039-5461897016-4492109623-OSS0509503-1350909110-5080909150-5080897125-9740897064-6881028080-6200897085-1771509605-0192897169-1941897169-1971109605-0500897039-2644511129-0060909561-2530028080-6140897072-8300911229-0581028080-8800028090-8600091150-2080028080-8450028080-8300894425-6852894123-6231511321-0910511321-0360511322-0180509302-0081091150-2100897169-8890900006-0070900006-2070

4N530 . NUT, Screw ............................. 14N530 . EYE, Start spring ............................ 14N530 . SCREW, Set- idle spring ........................... 14N530 . WASHER, Idle spring- lower ....................... 14N530 . WASHER, Idle spring- upper ....................... 14N530 . RING, Snap- idle spring ........................... 14N530 . PACKING, Set screw ............................ 24N530 . NUT, Cap- set screw ............................ 14N530 . NUT, Set screw ....................... 1..... 4N530 . CAP, Idle set ................. 1........... 4N530 . SPRING, Idle ................... ......... I4N530 . SHAFT ASSEMBLY, Fuel stop ..................... 14N530 . SPRING, Return- fuel stop ......................... 14N530 . LEVER, Fuel stop ............................. 14N530 . O-RING, Shaft ............................. 14N530 . WASHER, Thrust ............................ 14N530 . NUT, Shaft- lever ............................ 14F040 . WASHER, Spring ............................. 14N530 . COVER, Governor lever ........................... I4N530 . PACKING COVER ............................. 14N530 . BOLT, Cover ............................ 44N530 . CASE, Gear- timing ............................ I4N530 . PLUG, Timing case ............................ 14N530 . PLATE ASSEMBLY, Sub- front ..................... 14N530 .. PLATE, Front. 14N530 .. PLUG, Front plate. I4N530 . COVER, Angleich ............................ 14N530 . CUP, Sealing- d=16 ............................. 14N530 . O-RING, Cover- angleich .......................... 14N530 . BOLT, Cover fix .................... ....... I4N530 . BOLT, W/detent hole- 1=16 ...................... 1.. 4N530 . DOWEL, Timing case ........................... 14N530 . BOLT, Timing case-block .......................... 64N530 . BOLT, Timing case- block ......................... 24N530 . NUT, Timing case ........................ ... 24N530 . BOLT, Timing case- front plate ..................... 44N530 . BOLT, Front plate- body ........................... 34N530 . CAP ASSEMBLY, Oil filler ........................ I4N530 .. PACKING, Cap .14N530 . SPACER, Plate- pump- t=18 ........................ 14N530 . COVER, Plate right reart .......................... 14N530 . PACKING, Plate- pump ......................... 14N530 . STUD, Timing case ......................... 24N530 . NUT, Cover ......................... 24N530 . GEAR, Pto- z=30 ............... 1.......... 4N530 . BEARING, Ball- gear- front ........................ 14N530 . BEARING, Ball- gear- rear ........................ 1

. SMR UsableCode

XBXB

XBXBXBXBXBXBXBXBXBXBXBXBXBXBXB

PAFZZNXBPAFZZNXBXBXBXBXBXBXBXBPAFZZNXBXBXBXBXBXBXBXBPAFZZNXAXBXBPAFZZNXBXBXBXBXB

on Code

4 -37-38-39-40-41-42-43-44-45-46-47-48-49-50-51-52-53-54-55-56-57-58-59-60-61-62-63-64-65-66-67-68-69-70-71-72-73-74--75-76-77-78-79-80-81-82-83

12

T.O. 38G1-127-1M1-281 5-262-13&P

SWP 998 01


4N530 . GEAR, Idle- z=66 ................................ I4N530 . BEARING, Ball- idle gear ........ ................. 24N530 . SEAL, Lead ..................................... 24N530 . WIRE, Lead seal ................................. 24N530 . BRACKET, Start spring ........................... 14N530 . PLUG, Cover- governor ........................... 14N530 . PACKING, O-ring- oil ........ .................... 14N530 . SEAL, Oil- crank- front ........ ................... 3

Figure 5. Flywheel Housing and Other Parts.

Figure & Part NumberIndex No.

5- FIG.4-1 897171-8380-2 028181-0250-3 109302-1070-4 091150-2100

CAGE Description Units Per SMR Usable1234567 Assy Code on Code

4N530 FLYWHEEL HOUSING AND OTHER PARTS ....... REF XC4N530 . HOUSING, FLYWHEEL- L=100 .... ............... 1 XB4N530 . BOLT, HOUSING- BLOCK ..... .................. 4 XB4N530. STUD, BLOCK- HOUSING ..... .................. 2 XB4N530 . NUT ....................................... 2 XB

4 -84-85-86-87-88-89-90-91

897081-9280900006-0070115739-0020981325-4460897047-0521109605-0190909565-2130509625-0790

XBXBXBXBXBXBXBXB

4

I

T.O. 38G1-127-1TM1-2815-262-1 3&PSWP 998 01

.4

Figure 6. Oil Pan and Other Parts.


6- FIG. 5-1 897147-9990-2-3 109623-0570-4-5 897135-1410-6 897137-8360


4N530 OIL PAN AND OTHER PARTS ....... ........... REF XC4N530 . PAN ASSEMBLY, Oil- w/find no. 4 packing ........... 1 XB

. . VALVE, Oil drain (refer to 35D29-7-6-4 find 2-58) . REF XB4N530 . . O-RING, Drain plug ............... .............. I XB4N530 .. PACKING, Oil pan (bonded to find no. 1) .REF XA4N530 . BOLT, Oil pan ............... 20 XB4N530 .NUT, Oil pan ............... 2 XB

14

T.O. 38GI-127-1TM1-2815-262-1 3&P

SWP 998 01

Figure 7. Oil Pump and Fixing Parts.


7- FIG.6-1 897083-5761-2 894235-5671-3 894104-6150-4 897113-3320-5 897102-3071-6 908160-6160-7 897109-6790-8 028080-6300-9 028080-6500-10 897117-2990-11 028080-8160-12 109623-4960

CAGE Description Units Per SMR1234567 Assy Code

4N530 OIL PUMP AND FIXING PARTS ... ............. REF XC4N530 . PUMP SUB-ASSEMBLY, Oil ....................... 1 XB4N530 . VALVE, Relief .............................. XB4N530 . PLUG, Valve .............................. 1 XB4N530 . SPRING, Valve .............................. 1 XB4N530 . PIPE, Oil pump-cylinder block ..................... 1 XB4N530 . PIN, Oil pump .......................... 2 XB4N530 .O-RING, Oil pump ........................... 1 XB4N530 .BOLT, Oil pump ............... ........... 2 XB4N530 . BOLT, Oil pump ............... 1........... XB4N530 . STRAINER ASSEMBLY, Oil ...................... 1 XB4N530 . BOLT, Strainer ............. ............. 1 XB4N530 . O-RING, Strainer- id=13.8 ......................... 1 XB

Usableon Code

-

Figure & Pan Number

-

T.O. 38G1-127-1TM1-2815-262-13&PSWP 998 01

.4

10

19

Figure 8.Crankshaft, Flywheel, Piston and Connecting Rod.

16

1514

I

I

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

SWP 998 01


8- FIG.7-1 897141-2100-2 511599-0031-3 897146-9960-3 897170-4010-4 897141-2080-4 897141-2090-5 897047-0240-6 894216-2064-7 894224-2362-8 512251-0070-9 512211-0180-10 894114-0491-11 897115-1770-12 897164-5300-13 894419-6020-14 897023-2680

--15 894133-3281-16 894201-6410-17 897034-5920-18 897109-3721-19 894386-0790-20 894134-7920-21 894156-0840

4N530 CRANKSHAFT, Flywheel, piston and connecting rod.. REF4N530 . BEARING KIT, Crank ............................ 14N530 . METAL, Thrust ................................ 24N530 . PISTON, Standard ............................... 44N530 . PISTON, Oversize 0.25 mm ........................ 44N530 . RING SET, Piston standard ............ ............ 44N530 . RING SET, Piston oversize 0.25 mm ....... ......... 44N530 . ROD ASSEMBLY, Connecting rod ........ .......... 44N530 .. BOLT, Connecting rod. 24N530 .. NUT, Connecting rod. 24N530 .. BUSH, Connecting rod .14N530 . PIN, Piston ........... ................ 44N530 . RING, Snap ........................... 84N530 . CRANKSHAFT ASSEMBLY ................ 1...... 4N530 . FLYWHEEL ASSEMBLY ......................... 14N530 . GEAR, Ring- z=108 ........................... 14N530 . WASHER, Flywheel ........................... 64N530 . BOLT, Flywheel .................... ....... 64N530 . KEY, Woodruff ........................... 14N530 . GEAR, Crankshaft- z=37 .......................... 14N530 . PULLEY, Crankshaft ........................... 14N530 . BOLT, Pulley ............... 1............ 4N530 . WASHER, Pulley ..................... 1...... 4N530 . METAL SET, Connecting rod ...................... 4

XCXBXBXBXBXBXBXBXAXAXAXBXBXBXBXBXBXBXBXBXBXBXBXB

T.O. 38G1-127-1TM1-2815-262-1 3&PSWP 998 01

13 7'6 8

1 0

I-_ I n I 1 1

3 N46 -,

I

EXHAUST

Figure 9. Valve Mechanism, Rocker Arm.

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

SWP 998 01


9- FIG.9-1 897118-1964-2 897118-6561-3 911129-0830-4 897039-5260-5 908160-5160-6 897116-4480-7 897116-4500-8 897010-4850-9 909111-5060-10 897070-6982-11 999202-3140-12 909571-4140-13 091150-2060-14 028080-6250-15 028080-6500-16 897102-1230-17 897045-4102-18 897034-6291-19 894251-0311-20 894239-5010-21 897124-3690-22 897069-5752

4N530 VALVE MECHANISM, Rocker arm ....... ........ REF4N530 . BRACKET, Rocker .............................. 14N530 . SHAFT, Rocker ............................... 14N530 . CUP, Sealing- d=12 .............................. 14N530 . CUP, Sealing- d=8 ............................... 14N530 . PIN, Rocker shaft ...................... . . 14N530 . ARM, Rocker- inlet .......... ........... 44N530 . ARM, Rocker- exhaust ..................... 44N530 . SCREW, Adjusting ..................... 84N530 . NUT, Adjusting screw .......... .......... 84N530 . SPRING, Rocker ..................... 44N530 . PLUG, Rocker shaft ........ ............ 14N530 . PACKING, Plug ...... .............. 14N530 . NUT, Rocker bracket ........... .......... 64N530 . BOLT, Rocker bracket ............. ........ 54N530 . BOLT, Rocker bracket .......... .......... 54N530 . VALVE, Inlet .... ................. 44N530 . VALVE, Exhaust ..................... 44N530 . SPRING, Valve ..................... 84N530 . SEAT, Valve spring ..................... 84N530 . COLLAR, Split .................... 164N530 .TAPPET .................... 84N530 . ROD, Push ..................... 8

XCXBXBXBXBXBXBXBXBXBXBXBXBXBXBXBXBXBXBXBXBXBXB

T.O. 38G1-127-1TM1-2815-262-1 3&PSWP 998 01

OIL FILTER

FUEL FILTER

11

12

Figure 10. Oil Filter, Fuel Filter and Fixing Parts.


10- FIG. 10-1 894456-7411-2 897014-2040-3 894132-9471-4 894132-9480-5 909906-3251-6 909572-0140-7 509674-0810-8 999202-3140-9 909571-4140-10 894148-3900-11 897111-5520-12 028181-0200-13 028081-0300

4N5304N5304N530S02264N5304N5304N5304N5304N5304N5304N5304N5304N530

OIL FILTER, Fuel filter and fixing parts ............ REF. CARTRIDGE, Oil filter ........................... 1. FILTER ASSEMBLY, Fuel ......................... 1.. CARTRIDGE, Fuel filter .1

BODY, Filter- fuel .1BOLT, Eye joint- in ..... ............. 2

PACKING, Eye joint- out .................. 4JOINT, Eye- filter out ...... ............ 1

PLUG, Fuel filter ..... ............. 1

PACKING, Plug- fuel filter ............ 1...... . JOINT, Eye- filter in ...... ............ 1

. BRACKET, Fuel filter ....... ........... 1BOLT, Bracket .................. 2

4N530 . BOLT, Fuel filter ................. 2

XCPAFZZNXBPAFZZNXBXBXBXBXBXBXBXBXBXB

20

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

SWP 998 01

NSS= NOT SEPARATELY SUPPLIED

14

13

Figure 11. Cooling System.(Sheet 1 of 2)


11- FIG. 12-1 897182-8530-2 509605-0050

028080-8400091150-2080897211-2090894365-6741897169-0150109605-0500028680-8300897038-4030028080-8500897063-4001989136-4230028080-8450

1234567 Assy

4N530 COOLING SYSTEM, Fan and water pump ..... ..... REF4N530 . PUMP ASSEMBLY, Water- w/find no. 3 packing ....... 14N530 . PLUG, Heater- 3/8 npt .......... .................. 14N530 . PACKING, Water pump (bonded) ...... .......... REF4N530 . BOLT, Water pump- 1=40 ......... ................. 34N530 . NUT, Water pump ................................ 24N530 . THERMOSTAT . ................................ 1

4N530 . PACKING, Outlet pipe ............................ 14N530 . PIPE, Water- upward outlet ........................ 14N530 . PLUG, Switch- 1/8 npt ............................ 14N530 . BOLT, Outlet pipe ................................ 24N530 .PULLEY, Fan- d=103 ............................. 14N530 . BOLT, Clip fix . ................................. 14N530 . SPACER, Fan- pulley- t=4.5 ........ ............... 14N530 . SPACER, Fan- pulley- t=18 ........ ................ 14N530 . BOLT, Fan ...................................... 4

Code

XCPAFZZNXBXAXBXBPAFZZNPAFZZNXBXBXBXBXBXBXBXB

on Code

-3-4-5-6-7-8-9

-10-11-12-13-14-15

-

T.O. 38G1-127-1TM1-2815-262-1 3&FSWP 998 01

23/ /~~~~~~~~~-

22

20

Figure 11. Cooling System.(Sheet 2)


11 -16 020800-6120-17 897162-0810-18 897102-8790-19 894466-3820-20 897102-3200-21 894370-8280-22 897102-3080-23 909915-2811-24 894241-9620-25 897148-3430-26 897148-3450-27 109701-0411-28 515419-0360

4N530 . BOLT, Pulley-water pump ......................... 24N530 . BELT, Cooling fan- 1=901 ......................... 14N530 . HOSE, Connection to water pump .......... 1......... 4N530 . CLIP, Oil cooler hose ............................. 44N530 . COOLER ASSEMBLY, Oil ........................ 14N530 . PACKING, Oil cooler ............................. 14N530 . JOINT, 3-way ............... 1............. 4N530 .CLIP ........ .................... 24N530 . CONNECTOR, Cylinder head .............. 1........ 4N530 . HOSE, Head to oil cooler .......................... 14N530 . HOSE, Oil cooler to connector ...................... 14N530 . CLIP, Hose .............. ............... 14N530 . SPACER, Clip . ............................ 1

XBPAFZZNXBXBXBXBXBXBXBXBXBXBXB

1

Figure 12. Exhaust System.

Figure & Part Number CAGE Description I Units Per SMR UsableIndex No. 1234567 Assy Code on Code

12- FIG. 13-1 897117-5900-2 897126-1860-3 091150-2080-4 028080-8700-5 904110-8200-6 897042-0280

4N530 EXHAUST SYSTEM ......................... REF4N530 . MANIFOLD, Exhaust ......................... 14N530 . GASKET, Exhaust manifold ....................... 14N530 . NUT, Exhaust manifold ......................... 24N530 . BOLT, Exhaust manifold ......................... 64N530 . STUD, Exhaust pipe ......................... 44N530 . GASKET, Exhaust pipe ......................... 1

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

SWP 998 01

26

XCXBPAFZZNXBXBXBPAF2ZN

T.O. 38G1-127-1TM1-2815-262-1 3&PSWP 998 01

1

9

12

1

;rK 2

o'EE FIG 17Figure 13. Fuel System, Injectors and Fuel Pipe.


13- FIG. 15-1 897079-9761-2 894106-0551-3 894257-5920-4 894257-5930-5 894106-0403-6 897102-1371-7 509707-0051-8 897144-7240-9 897126-1880-10 897046-7940-11 894379-6880-12 894144-5880

4N530 FUEL SYSTEM, Injectors and fuel pipe ...... ...... REFS0226 . NOZZLE ASSEMBLY, Injector ..................... 44N530 . HEAT SHIELD, Nozzle ........................... 44N530 . GASKET, Nozzle holder ........................... 44N530 . GASKET, Heat shield ............................. 44N530 . WASHER, Cormgated ............................ 44N530 . PIPE ASSEMBLY, Injection ........................ 44N530 . CLIP, Fuel hose ................................. 24N530 . PIPE ASSEMBLY, Fuel suction ..................... 1 4N530 . PIPE ASSEMBLY, Fuel- leak off .......... 1.......... 4N530 . HOSE, Fuel feed- leak off .......................... 14N530 .BOLT, Eye ................................. 44N530 . GASKET ................................. 8

XCPAFZZNXBPAFZZNPAFZZNXBXBXBXBXBXBXBPAFZZN

24

11I

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

SWP 998 01

2

SEE FIG 20

6Figure 14. Engine and Generator Brackets.


14- FIG. 16-1 897085-3890-2 897085-3900-3 028080-8160-4 897161-9690-5 028081-0700-6 028080-8200-7 091150-2100

CAGE Description Units Per1234567 Assy

4N530 BRACKETS, Engine and generator ................. REF4N530 . HANGER, Front .............................. 14N530 . HANGER, Rear .............................. 14N530 . BOLT, Front and rear hanger ....................... 24N530 . PLATE, Adjusting- generator ....................... 14N530 . BOLT, Generator ............................... 14N530 . BOLT, Adjusting plate- generator . ................. 14N530 . NUT, Generator ............................... 1

Usableon Code

SMRCode

XCXBXBXBXBXBXBXB

T.O. 38GI-127-1TMI-2815-262-1 3&PSWP 998 01

18 _

2'

12

10

11 \ f

INLET,1

Figure 15. Injection Pump, Camshaft and Other Parts.

Figure & Part NumlIndex No.

15- FIG. 18-1 897147-5800-2 897126-3560-3 091150-2080-4 028080-8200-5 897145-1980-6 897062 0480-7 909878-6260-8 900090-6100-9 900090-6570-10 897102-2880-11 509400-0530-12 909180-1620-13 897129-7800-14 897129-7820

)er CAGE Description Units Per SMR Usable1234567 Assy

4N530 INJECTION PUMP, Camshaft and other parts ....... REF4N530 . PUMP ASSEMBLY, Injection ........ .............. 44N530 . SHIM, Injection pump- t=0.2 ......... .............. 44N530 . NUT, Injection pump ............... .............. 84N530 . BOLT, Injection pump ............ ................ 84N530 . SHAFT, Cam- injection pump and valve ...... ........ 14N530 . . RING, Wear- camshaft .14N530 .. PIN, Camshaft .14N530 .. BEARING, Ball- front .14N530 . . BEARING, Ball- rear. I

4N530 . GEAR, Injection pump and valve- z=74 ..... ......... 14N530 . NUT, Cam gear .................................. 14N530 . RING, Snap- camshaft front ....... ................. 14N530 . SHAFT ASSEMBLY, Idle gear ...... ............... 14N530 . GEAR, W/bush- idle- z=44 ....... ................. 1

Code on Code

XCPAFFFPPAFZZNXBXBXBXBXBXBXBXBXBXBXBXB

22

I

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

SWP 998 01


. COLLAR, Thrust- idle gear ........................ 1

. BOLT, Shaft ...... .................. 2

. PUMP ASSEMBLY, Fuel- electric ................... 1

. BRACKET, Fuel pump ........................ 1. BOLT, Fuel pump ......... ............... 2. HOSE, Fuel pump- fuel pipe ....................... 1. HOSE, Pump- fuel filter ........................ 1. CLIP, Fuel hose ........................ 4

5

,1

8 9 10 14

Figure 16. Electrical Parts.

Figure & Part Number CAGEIndex No.

16- FIG. 19-1 897135-3430-2 028181-2300-3 909150-5080-4 909111-4080-5 897048-9681-6 982720-0690-7 109605-0500-8 897183-0140-9 897106-5490-10 897138-6070-11 897125-6001

4N5304N5304N5304F0404N5304N5304N5304N5304N5304N5304N5304N530

Description Units Per SMR1234567 Assy Code

ELECTRICAL PARTS .......................... REF XCSTARTER ASSEMBLY ........................... 1 PAFZZNBOLT, Starter .......... ................. 2 XBWASHER, Lock- starter cable ...................... 1 PAFZZNNUT, Starter cable ........................... 1 XBGENERATOR ASSEMBLY ........................ 1 PAFZZNSWITCH, Oil pressure .......................... 1 PAFZZN

.PLUG . .......................... 1 XBSOLENOID ASSEMBLY, Engine stop ..... .......... 1 PAFZZNPLUG, Glow ........ .................. 4 PAFZZNCONNECTOR, Glow plug ........................ 1 XBSWITCH, Overheat warning ........................ 1 PAFZZN

15 -15-16-17-18-19-20-21-22

512535-0051028090-8450897183-0130897166-4750028080-6120897166-4820897111-5701509707-0041

4N5304N5304N5304N5304N5304N5304N5304N530

XBXBPAFZZNXBXBXBXBXB

7

Usableon Code

T.O. 38G1-1 27-1TM1-2815-262-1 3&PSWP 998 01

v--19

.2

SEE FIG 13

Figure 17. Injection Pump Assembly.


17- 897147-5800-1 897170-8680-2 897083-3460-3 894128-9110-4 894128-9120-5 894132-7461-6 897083-3470-7 894128-9150-8 894128-9160-9 897083-3490-10 897083-3500-11 894128-9190


4N530 PUMP ASSEMBLY, Injection .................... REF4N530 . PLUNGER ASSEMBLY .......................... 14N530 . VALVE ASSEMBLY, Delivery ............. 1........ 4N530 . SPRING, Delivery ............................ 14N530 GASKET ............................ 14N530 . HOLDER, Delivery ............................ 14N530 . SEAT, Spring ............................ 14N530 .O-RING ........................... I4N530 . TAPPET ........ ................... 1

4N530 . PIN ....... ..................... 1

4N530 . RING, Snap ............................ 14N530 . SPRING, Plunger ............................ 1

PAFFFPXBXBXBXBXBXBPAFZZNXBXBXBXB

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

SWP 998 01


17 -12 894128-9200-13 894128-9210-14 894128-9310-15 897083-3551-16 894128-9230-17 897083-3480-18 894379-6920-19 894379-6910

1234567 Assy

4N530 . SEAT, Spring- upper .................... 14N530 .SEAT, Spring- lower .................... 14N530 . PLATE, T=2.60 .................... A/R4N530 . RACK, Control .................... I4N530 . SLEEVE, Control ...... ............. 1

4N530 . SLEEVE, Flange .................... 14N530 . O-RING ................... 24N530 .BOLT .................... 2

2

Code on Code

XBXBXBXBXBXBXBXB

Figure 18. Injection Nozzle Assembly.

Figure & Part Number CAGE DescriptionIndexNo. 1234567

897079-9761894130-5320

894104-9930

894128-9640894128-9630897083-3580897084-6170894129-0060894176-9620

S02264N5304N5304N5304N5304N5304N5304N5304N5304N5304N530

Units fAssy

NOZZLE ASSEMBLY, Injection .................. REF.NOZZLE ....................... 1.HOLDER ASSEMBLY, Nozzle .................. REF.. GASKT. 1.. BODY, Nozzle holder .REF

SPRING, Nozzle .1. SEAT, Spring. 1

..SPACER ...... 1NUT, Retaining .1

...NUT.1SHIM, T=0.10. . A/R

Per SMR UsableI Code on Code

PAFZZNXBNSSXBNSSXBXBXBXBXBXB

18--1-2-3-4-5-6-7-8-9-10

T.O. 38G1-127-1TMI-2815-262-1 3&PSWP 998 01

1

13

<-24

Figure 19. Starter Assembly.


19- 897135-3430-1 897136-9090-2 897136-9080-3 894377-2400-4 897112-9540-5 897112-8700-6 897112-8710-7 897112-8720-8 897112-8730-9 897112-8800-10 897112-8750-11 897078-6490-12 897112-8790-13 581129-0990-14 894377-2460

4N530 STARTER ASSEMBLY, 12v-1.8kw ....... ........ REF4N530 . YOKE ASSEMBLY .............................. 14N530 . ARMATURE ASSEMBLY .1........................ 4N530 .. BEARING, Ball .14N530 .. BEARING, Ball. 1

4N530 . CLUTCH SUB-ASSEMBLY ....................... 14N530 .HOUSING ASSEMBLY .......................... 14N530 . SWITCH ASSEMBLY, Magnetic .......... 1......... 4N530 . HOLDER ASSEMBLY, Brush .............. 1........ 4N530 .. SPRING, Brush. 44N530 .FRAME, End ................. 1

4N530 . PINION ................. 1

4N530 . PINION ................. 14N530 . ROLLER, Clutch .... ............. 54N530 . RETAINER ................. 1

30

8 19

'21

1717

PAFZZNXAXAXAXAXAXAXAXAXAXAXAXAXAXA

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

SWP 998 01


19 -15-16-17-18-19-20-21-22-23-24

581129-0920894377-2450897112-8810897136-9100897112-8830894377-2380581119-0290894109-7630894170-2140897041-4210

1234567 A:

4N530 . BALL, Steel ....................................4N530 . SPRING, Return .................................4N530 . BOLT, W/washer ................................4N530 .BOLT, Through.................................4N530 . SCREW, W/o-ring ...............................4N530 .NUT ..........................................4N530 . CAP, Terminal- rubber ............................4N530 .NUT ..........................................4N530 . O-RING ......................................4N530 . BUSHING, Drain ................................

ssy Code on Code

2:2:2:

1.:1I

2:.1

XAKAKAKA

KAKAXAKAXAXA

6

Figure 20. Generator Assembly.


20- 897048-9681-1 897075-9650-2 894455-1540-3 897072-8390-4 897072-8380

4N530 GENERATOR ASSEMBLY, 12v-35amp ............. REF4N530 . FRAME ASSEMBLY, Drive end .................... 14N530 .. PLATE, Retainer .14N530 .. SCREW. 44N530 . . BEARING, Ball ................ 1

PAFZZNXAXAXAXA

T.O. 38G1-127-1TM1-2815-262-1 3&PSWP 998 01


894455-1560897072-8410897072-8420894159-7810894123-0560894123-0570894455-1600897072-8430897072-8350894455-1660894455-1640894123-0610894123-0640894206-1860897072-8400894135-7530894123-0510897072-8340897072-8360894455-1630894455-1620894455-1610

4N530 .. STUD ........... 2

4N530 . FRAME, Rear end .14N530 . HOLDER ASSEMBLY, Rectifier .14N530 . HOLDER ASSEMBLY, Brush .14N530 .. BRUSH .... 2

4N530 .. SPRING .... 2

4N530 . REGULATOR ASSEMBLY .14N530 . COVER, Rear end .14N530 . NUT .14N530 . BUSH, Insulation .14N530 . BOLT, Flange. 2

4N530 . SCREW, W/washer. 2

4N530 .NUT. 24N530 . NUT. I

4N530 . ROTOR ASSEMBLY. 1

4N530 .. BEARING, Ball ........... 14N530 .. COVER, Bearing ........... 14N530 .PULLEY .14N530 . COLLAR, Space .14N530 . BOLT. 3

4N530 .SCREW .14N530 . SCREW. 6

20 -5-6-7-8-9-10-11-12-13-14

-15-16-17-18-19-20-21-22-23-24-25-26

XAXAXAXAXAXAXAXAXAXAXAXAXAXAXAXAXAXAXAXAXAXA

32

T.O. 38G1-127-1TM1-281 5-262-13&P

SWP 998 02


Page No. Change No.

1-5 ..... O6 Blank . 0



Page No. Change No. Page No.

TABLE OF CONTENTSParagtph P=

1. Numerical Index ........... 1

1. NUMERICAL INDEX

The numerical index on the following pages is a list of allof the part numbers shown on the master parts list of the il-lustrated parts breakdown (SWP 998 01).

Change No

T.O. 38G1-127-1TM1-2815-262-1 3&PSWP 998 02

Part Number Figure & Part Number Figure & Part Number Figure &Index No. Index No. Index No.

020800-6120028080-6120028080-6140028080-6140028080-6200028080-6200028080-6200028080-6200028080-6250028080-6300

028080-6450028080-6500028080-6500

028080-8160028080-8160028080-8200028080-8200028080-8300028080-8400028080-8450

028080-8450028080-8500028080-8700028080-8800028081-0300028081-0700028090-8450028090-8600028181-0200028181-0250

028181-2300028680-8300091150-2060091150-2060091150-2080091150-2080091150-2080091150-2080091150-2100091150-2100

091150-2100109302-1070109305-0050109600-0051109600-0112109600-0112109600-0121109605-0040109605-0190109605-0190

109605-0500109605-0500109605-0500109605-0500109623-0550109623-0550

7-1114-314-615-44-7311-44-72

11-1511-1212-44-6910-1314-515-164-7010-125-2

16-211-103-149-134-7111-512-315-34-805-4

14-75-33-302-32-23-43-63-113-124-89

4-154-6211-916-74-294-51

109623-0570109623-4960109701-0411109747-0020

109747-0020115739-00204LElPW14509300-0650509300-0650509302-0081509400-0480509400-0530509503- 1320509503-1350

509503-1350509600-0130509604-0160509605-0050509605-0050509605-0192509625-0790509625-0940509674-0810509707-0041

509707-0051511119-0090511129-0060511321-0360511321-0910511322-0180511599-0031512211-0180512251-0070512535-0051

515419-0360515669-0021515729-2391581119-0290581129-0920581129-0990894104-6150894104-9930894106-0403

6-37-1211-274-17

4-224-861-2-113-324-794-4415-114-434-30

4-523-53-252-1311-24-594-913-3610-715-22

13-72-44-644-774-764-788-28-98-815-15

11-284-464-3819-2119-1519-137-318-313-5

FIG. 1FIG. 1FIG. 10FIG. 10FIG. 12FIG. 12FIG. 13FIG. 13FIG. 15FIG. 15

1-12-1-1510-1-911-1-1012-1-1113-


1-1214-1-1315-1-1416-1-23-1-34-


1-45-1-56-1-67-1-78-1-89-

11-1615-193-154-662-233-163-384-579-147-8

2-247-99-15

I

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

SWP 998 02

Part Number Figure & Part Number Figure & Pa Number Figure &Index No. I Index No. I Index No.

894106-0551

894109-7630894110-5591894114-0491894123-0510894123-0560894123-0570894123-0610894123-0640894123-6231894123-6231

894128-9110894128-9120894128-9150894128-9160894128-9190894128-9200894128-9210894128-9230894128-93 10894128-9630

894128-9640894129-0060894130-4380894130-5320894132-7461894132-9471894132-9480894133-2075894133-3281894134-7920

894135-7530894144-5880894148-3900894156-0840894159-7810894167-4701894170-2140894176-9620894200-8190894201-6410

894206-1860

894216-2064894224-2362894229-8530894235-5671894239-5010894241-9620894251-0311894257-5920894257-5930

894317-6381894329-5490894343-8960894365-6741894368-5010894369-5450894370-8280894377-2380894377-2400894377-2450

894377-2460894379-6880894379-6910894379-6920894386-0790894419-6020894425-6852894454-6150894455-1540894455-1560

894455-1600894455-1610894455-1620894455-1630894455-1640894455-1660894456-7411894463-7840894466-3820897010-4850

897014-2040897016-4410897016-4460897016-4492

8-68-73-37-29-2011-249-1913-313-4

4-342-183-1811-73-424-2511-2119-2019-319-16

19-1413-1117-1917-188-198-134-744-2720-220-5

20-1120-2620-2520-2420-1520-1410-12-1511-199-8

10-24-394-484-50

897016-9361897016-9400897023-2680897031-7490897034-5920897034-5945

897034-6291897034-6374897034-6382897034-6422897034-6432897036-9591897038-4030897038-8021897039-2644897039-4953

897039-5260897039-5461897039-5841897041-4210897042-0280897045-3920897045-4102897045-6175897046-7940897047-0240

4-474-248-142-58-174-4

9-184-94-54-104-192-1611-114-264-633-21

9-44-494-3619-2412-62-79-174-113-108-5

897047-0521897047-0560897047-1421897048-9681897048-9681897049-3280897062 0480897063-4001897064-6881897069-5752

897070-6982897072-8300897072-8340897072-8350897072-8360897072-8380897072-8390

4-883-73-816-520-4-2815-611-134-569-22

9-104-6720-2220-1320-2320-420-3

13-2

19-222-128-1020-2120-920-1020-1620-172-214-75

17-317-417-717-817-1117-1217-1317-1617-1418-6

18-518-94-1118-117-510-310-42-208-158-20

20-2013-1210-108-2120-83-219-2318-103-278-16

20-18I

T.O. 38G1-127-1TM1 -2815-262-13&PSWP 998 02

Part Number Figure & Part Number Figure & Part Number Figure &Index No. Index No. Index No.

897072-8400897072-8410897072-8420

897072-8430897075-9650897076-9040897078-6490897079-9761897079-9761897081 -9280897083-3460897083-3470897083-3480

897083-3490897083-3500897083-3551897083-3580897083-5761897083-7140897084-6170897085-1771897085-3890897085-3900

897093-5491897094-6410897102-1230897102-1371897102-2880897102-3071897102-3080897102-3200897102-5501897102-8790

897106-4150897106-5490897109-3721897109-6790897111-5520897111-5701897112-2650897112-8700897112-8710897112-8720

897112-8730897112-8750897112-8790897112-8800897112-8810897112-8830897112-9540897113-3320897114-7130897115-1770

897115-3150897116-4480897116-4500897117-2990897117-5900897118-1964897118-2052897118-6561897118-9891897119-2990

897124-3690897125-6001897125-9740897126- 1390897126-1860897126-1880897126-3560897129-7800897129-7820897135-1410

897135-3430897135-3430897136-3240897136-9080897136-9090897136-9100897137-8360897138-6070897141-2080897141-2090

897141-2100897144-7240897145-1980

19-819-1019-1219-919-1719-1919-47-42-18-11

2-89-69-77-1012-19-12-179-23-132-22

9-2116-114-552-612-213-915-215-1315-146-5

16-119-2-1419-219-119-186-616-108-4F8-4

8-113-815-5

897146-9960897147-4890897147-5800897147-5800897147-9990897148-3430897148-3450

897148-5480897148-5500897148-8650897161-9690897162-0810897164-3340897164-5300897166-4750897166-4820897166-9600

897169-0150897169-1920897169-1941897169-1971897169-8890897170-4010897170-8680897171-8380897182-8530897183-0130

897183-0140897211-2090897231-0300900006-0070900006-0070900006-2070900090-6100900090-6570903910-4100904110-6160

904110-6160904110-8200904110-8400904110-8400904110-8500908160-4360

8-34-215-117-6-111-2511-26

4-134-184-2114-411-174-238-1215-1815-203-34

11-83-14-604-614-81F8-317-15-111-115-17

16-811-63-354-824-854-8315-815-92-193-17

3-1912-52-103-313-334-32

20-1920-620-7

20-1220-14-1219-1113-118-4-8417-217-617-17

17-917-1017-1518-77-14-2018-84-5814-114-2

4-82-99-1613-615-107-511-2211-203-2011-18

3-3916-98-187-710-1115-214-1619-519-619-7

4

T.O. 38G1-127-1TM1-281 5-262-1 3&P

SWP 998 02

Part Number Figure & Part Number Figure & Part Number Figure &Index No. I Index No. Index No.

908160-5160 9-5 999202-3140 9-11908160-5450 4-14908160-6160 3-24 999202-3140 10-8908160-6160 7-6

908160-8160 3-22908160-8500 4-3908213-6250 4-6909110-4060 4-37909110-5080 4-31909110-5080 4-53909111-4060 4-35909111-4060 4-45909111-4080 16-4909111-5060 9-9

909150-5080 4-33909150-5080 4-54909150-5080 16-3909160-5040 4-40909160-7040 4-41909180-1620 15-12909185-4030 4-42909185-4040 4-7909204-5 100 3-10909524-6220 3-41

909561-2530 4-65909565-2130 4-90909571-4140 9-12909571-4140 10-9909571-4160 3-40909572-0140 3-26909572-0140 10-6909664-0010 3-9909878-5320 3-29909878-6260 15-7

909906-3251 10-5909915-2811 11-23911129-0830 9-3911229-0581 3-23911229-0581 3-28911229-0581 4-68981325-4460 4-87982720-0690 16-6989136-4230 11-14

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