WORKSHOP MANUAL. IHI Shibaura Diesel Engine N3LDI N4LDI

Transcription

1 株式会社 IHI シバウラ WORKSHOP MANUAL IHI Shibaura Diesel Engine N3LDI N4LDI

2 TABLE OF CONTENTS 1. General General notes before service Fundamental instructions on service Standard tightening torque Tightening torque of main parts Main specifications Parts name and position Summary of engine structure Disassembly diagram Engine maintenance Before start When engine service required Detail confirmation before disassemble Service interval Main parts Disassembly/Inspection/Repair Assembly Wire harness clamp position Engine trouble shooting Service standard data Diagnosis of failure

3 FOREWORD This workshop manual includes repair and adjustment procedures that required for the diesel engine. When servicing to keep the engine in the best condition, you will find this workshop manual very useful as a guidebook. Please understand the specifications contained in this workshop manual are subject to change without notice for subsequent engineering changes. First edition October 2014 Quality Assurance Department Engine Division IHI Shibaura Machinery Corporation 1.General 1.1.General notes before service 1 Wash the engine, and drain oil, fuel and coolant before disassembly. 2 Keep the service shop clean and free from dusts, and furnish with proper lighting equipment. 3 Remove oil and grease from disassembled parts, and place them in groups on a clean table. 4 Check equipments, tools and working clothes for the safety working. 5 Disconnect the battery before disassemble the engine. 1.2.Fundamental instructions on service 1 Keep the engine clean and don t disassemble it except those components that need to be disassembled because it is made and assembled very precisely. 2 Apply engine oil on slide parts and rotation parts when assembling the engine. 3 Tighten bolts and nuts to specified Standard tightening torque with proper tools, unless otherwise instructed. 4 Store faulty parts (due to wear) temporarily so that the customer can see them at a later date, and make sure machine model, engine model, engine serial number, parts name and parts number when ordering service parts. 2

4 1.3.Standard tightening torque Bolt size M5 M6 M8 M10 M12 M14 M16 M18 M20 Grade No, 4T, 4.8 Pitch [mm] Coarse thread 7T, 8T, Fine thread Tightening torque Pitch Tightening torque [N m] [kgf m] [mm] [N m] [kgf m] T, 11T T, T, 8T, T, 11T T, T, 8T, T, 11T T, T, 8T, T, 11T T, T, 8T, T, 11T T, T, 8T, T, 11T T, T, 8T, T, 11T T, T, 8T, T, 11T T, T, 8T, T, 11T Bolt head identification mark Strength grade 4.8 Description of strength grade [Example] Indicates yield point, 80% of tensile [32 kgf/mm 2 ] 10.9 Tensile strength [40 kgf/mm 2 ] 3

5 1.4.Tightening torque of main parts Tightening torque Part Position [Nm] [kgfm] Note Bolt Bearing holder (Lower/Upper) Bearing holder Hexagon bolt Bolt (Cylinder block/crankshaft) Hexagon socket head bolt Relief valve ASSY Bolt Fly wheel Nut Connecting rod Bolt Oil pan Bolt Drain: Oil pan Nut Crankshaft pulley Nut Camshaft Nut HP Gear Bolt HP Pump ASSY Bolt Head bolt 1 st : 48 52[Nm] 1 st : [Nm] 2 nd : [deg.] 2 nd : [deg.] Angle method Nut Rocker arm ASSY Nut Screw(Rocker arm) Cap nut Head cover Oil pressure unit Banjo bolt Oil pipe COMPL Glow plug Bolt Injector cramp Banjo bolt Return pipe Banjo bolt Common rail Bolt Common rail Injection pipe COMPL Banjo bolt Turbocharger Bolt DOC stay Check assembly instruction G sensor Water temperature sensor Intake temperature sensor Boost pressure sensor [Nm] = [kgfm] 4

6 1.5.Main specifications Item Specifications Engine model N3LDI N4LDI Engine type Water-cooled 4-cycle diesel engine Cylinder type Vertical in-line 3-cylinders Vertical in-line 4-cylinders Bore[mm] x Stroke[mm] φ84 x 100 displacement [cc] Compression ratio 18.0 : 1 Combustion system Direct Injection *Rated power [kw/min -1 ] Fuel Fuel injection system Air cleaner Turbocharger Diesel fuel (Ultra low sulfur) Common rail system Dry type Turbocharger with waste gate Intercooler *Alternator Without: N3LDI-T With: N3LDI-TA 12V 55A Without: N3LDI-T With: N3LDI-TA *Starter 12V 1.7kW 12V 2.0kW Lubrication method Engine oil *Lubrication oil volume [L] (Include oil filter) Coolant volume [L] (Only inside of engine) Pressurized circulation by trochoidal pump API grade:cj-4 Depending on the model *Engine dry weight [kg] *Overall length [mm] Dimensions *Overall width [mm] *Overall height [mm] The above specifications are subject to change without notice. 2. Asterisked(*) items may vary depending on the type of equipment in which the engine installed. 5

7 1.6.Parts name and position DOC 2. Throttle valve 3. EGR pipe 4. Crank pulley 5. HP pump 6. Injector 7. Oil cooler 8. Oil mist separator 9. Oil filter 10. Glow plug 11. Relief valve 12. Oil pressure unit 13. Fuel filter 14. Common rail 15. Speed sensor 16. EGR valve 17. Hose ASSY 6

8 EGR cooler 19. Engine serial plate 7

9 1.7.Summary of engine structure (1)Lubricant circuit and main parts Blow-by gas hose Turbocharger Oil mist separator Oil pressure unit Hose for separated oil (With check valve) Oil cooler Oil filter Relief valve Suction filter Oil pump Oil pan Suction filter Oil pump Relief valve Rocker arm ASSY Oil pipe Oil pressure unit Each bearing metal Oil filter (With safety valve) & Oil cooler Turbocharger Oil mist separator Blow-by gas 8

10 I.Suction filter & Suction pipe These are suctioned oil from oil pan, and filter out big contaminants. II.Relief valve If oil pressure exceed the setting value, relief valve adjust it by valve for oil release. *Oil pressure setting value : 402kP(at normal operation) III.Oil pump There is trochoidal oil pump at the inside of idle gear. Vane can move little in an axial direction. Therefore, oil pump cover seal up vane and rotor. IV.Oil cooler There is oil cooler between cylinder block and oil filter. Engine oil is cooled by cooling circuit. Coolant flow Oil cooler Oil filter V.Oil filter Oil filter is cartridge type, and high performance. And it is full flow type. Therefore, if oil filter was clogged, safety valve is opened for prevented from engine seizure or some another trouble. 1 Oil from oil pump arrive point A from gone through filter element. After that, oil of gone through point B arrive each bearing metal. 2 If oil filter was clogged, safety valve is open. Oil can arrive point A without gone through filter element *Have to replace oil filter with new one at every 500 hours. (Only first time, replace at 50 hours) Do not reuse it. 9 Safety valve

11 (2)Air circuit and main parts N3LDI and N4LDI have EGR (Exhaust Gas Recirculation) system for each country's emission regulation. Oil mist separator is separated off the blow-by gas to air and oil. Then, that air is reused at combustion chamber. Air cleaner Turbocharger Oil mist separator Throttle valve (Only N4LDI-TA) Intake manifold EGR valve Blow-by gas Cylinder Exhaust manifold EGR cooler Turbocharger I.Oil mist separator Oil mist separator is separated oil mist in blow-by gas. Because oil mist is became emissions of PM (Particulate matter) by burning at cylinder. In addition, that is reduced deposit of oil mist at intake manifold, intake valve and others. And oil of separated is returned to oil pan through check valve. And it has the function of PCV (Positive Crankcase Ventilation). *Essential of filter change at each 1500 hours. Body Cap Filter O-ring Case Flow direction Hose ASSY Check valve 10

12 II.Turbocharger Turbocharger is improved fuel consumption and power by using exhaust gas energy because much air is gone into cylinder by compressor vane. That vane coaxially mounted turbine vane is driven by exhaust gas energy. *Do not disassembly. Repair or adjust it at the manufacturer. Turbocharger III.Throttle valve Throttle valve is adjusted intake air mass flow for reduce emission of pollutants. Valve opening value is controlled by ECU (Electronic Control Unit). It is decided by engine condition (water temperature, atmosphere and others). In addition, throttle valve make hot exhaust gas condition by closed valve for DOC activation at idling. *Handle with care because it is a precision component. *Do not disassembly. Repair and adjust it at the manufacturer. *Only N4LDI-TA equips it. Boost sensor Throttle valve Intake manifold IV.EGR valve EGR is reduced NOx emission with lowered combustion temperature by returned a part of the exhaust gas to cylinder. A part of the exhaust gas is sent to the intake manifold from exhaust manifold that gone through EGR cooler, EGR pipe and EGR valve. Decided EGR gas flow rate by ECU is controlled by EGR valve. EGR valve EGR pipe EGR cooler 11

13 *Totally closed at high temp. (3)Coolant circuit and main parts Coolant cools cylinder block and cylinder head. Also it cools engine oil and EGR gas by cooler. Water pump Cylinder block EGR cooler Oil cooler Radiator Sub tank Thermostat *Full flow at high temp. Thermostat case (Water temp. sensor) Cylinder head I.Water pump Water pump runs enough coolant. It is driven by crank pulley through fan belt. Set plate Water pump ASSY Gasket Gasket II.Thermostat & Thermostat case Thermostat controls coolant flow circuit with thermostat case. If coolant became hot, thermostat inside wax is melted. Then, coolant runs into the radiator. When coolant became high temperature, thermostat is fully opened and bypass is totally closed. Then all coolant runs into radiator. In addition thermostat case has a thermo sensor. *The thermostat is thermo pellet type. Gasket Gasket Thermostat case Thermo cover Thermostat Thermo sensor 12

14 (4)Injection system (common rail system) and main parts Pressure sensor Common rail Safety valve Fuel filter HP pump Injector Fuel tank ECU Accelerator signal Engine rev. signal Each of sensors signal and other I.General of common rail system 1 Common rail system is composed of HP pump, common rail, injector, and each of sensors. That injection system is controlled by ECU. It makes low fuel consumption and low emission by High injection pressure and adjustable injection control. *Without mechanical governor 2 ECU decides injection pressure, injection timing, Injection mass flow, and injection frequency by each of sensors signal (engine revolution, load condition and others). And controls HP pump, injector and others by electronic signal. 3 HP pump makes high pressure fuel. Then HP pump sends it to common rail. And HP pomp adjusts fuel pressure by ECU signal. 4 Common rail keeps high pressure fuel. And, distribute it to each of injectors. 5 Injectors spray high pressure fuel by ECU signal. Injection nozzle can injects it several times in one combustion cycle by quick opening and closing nozzle control. Common rail Injector HP pump 13

15 II.HP pump HP pump Supplies high pressure fuel to common rail. It is driven by crankshaft through the cam gear. Fuel suction mass is controlled by solenoid valve. Extra fuel quantity returns to fuel tank through return pipe. Pulser is assembled with HP pump gear for detecting combustion cycle of 1st cylinder by G sensor. O-ring HP pump gear Pulser HP pump ASSY Flange Nut Suction control valve Fuel temperature sensor III.Common rail Common rail keeps high pressure fuel. High pressure fuel from HP pump is kept by common rail, then supplied to each of injectors through each of injection pipes. If it pressure was over limit, safety valve is opened for release fuel pressure to return pipe. Banjo bolt Return pipe Gasket Safety valve Common rail IV.Injector Injector splays high pressure fuel of supplied by common rail to combustion chamber. Injection nozzle is composed of command piston, orifice, control chamber and solenoid. Spray timing and quantity are controlled by ECU because common rail system is electroniic control. In addition, injector has function of multi stage injection. Injector O-ring Gasket 14

16 V.ECU ECU decides the most suitable spray condition of injection pressure, injection quantity, injection timing and injection number of times by information from each of sensors. Then ECU controls the common rail system (HP pump and Injector). Also ECU controls EGR valve and throttle valve. VI.Fuel filter Fuel filter removes contaminants from fuel, before fuel is supplied to HP pump. Put on special fine fuel filter essential, because common rail system is ultra-precision instruments. Fuel filter 15

17 (5)Emission control system (Reduce air pollutant emission) and main parts Intercooler EGR : Exhaust Gas Recirculation DOC : Diesel Oxidation Catalyst EGR valve RGE cooler Throttle valve Turbocharger Common rail system DOC The engine has under feature for each country emission regulation (US EPA Tier4, EU Stage IIIB and others). 1 Reduce emission of PM, CO and HC by DOC. 2 Reduce emission of NOx by EGR. (Make lower temperature combustion conditions by recirculate a part of exhaust gas.) 3 Reduce emission of smoke by Common rail system. (Control to the most suitable combustion condition at any time.) I.DOC 1 DOC is able to oxidize emission of HC and CO then changes to CO2 and H2O. Also reduces PM by oxidation. 2 It is different with DPF (Diesel Particulate Filter). Therefore maintenance (parts replacement, regeneration and others) are unnecessary. 16

18 1.8.Disassembly diagram Disassembly diagram *This illustration is a general exploded view of N4LDI and may be different from a fact. No. Parts name 1 Alternator 2 Cylinder block ASSY 3 Oil filter / Oil cooler 4 Relief valve 5 Water drain 6 Fuel filter ASSY 7 Balancer ASSY 8 Oil pan / gasket / Suction filter / Suction pipe 9 Push rod / Tappet 10 Oil level gauge / Gauge guide 17

19 Disassembly diagram *This illustration is a general exploded view of N4LDI and may be different from a fact. No. Parts name 11 Return pipe / Injection pipe 12 Injector ASSY / Cramp / Washer *Please be careful about the handling because injector ASSY is very delicate. 13 Common rail ASSY 14 Connector / Glow plug 15 Oil pressure unit 16 Thermostat / Thermostat case / Gasket / Thermo cover 17 Intake manifold / Gasket / Spacer 18 Rocker arm ASSY / Gasket 19 Oil pipe 20 Cylinder head ASSY / Head gasket / Valve 21 EGR valve / EGR pipe / EGR cooler 22 Throttle valve 23 Head cover / Gasket 18

20 Disassembly diagram *This illustration is a general exploded view of N4LDI and may be different from a fact. No. Parts name 24 Cooling fan / Fan pulley 25 Water pump ASSY / Gasket / Hose 26 Turbocharger / Pipe / Gasket 27 Exhaust manifold / Gasket 28 Head bolt (Long / Short) 29 DOC ASSY / Stay 30 Oil mist separator / Hose ASSY / Hose 31 Exhaust elbow / Gasket 32 Cylinder block ASSY / Cylinder head ASSY / Head gasket 19

21 Disassembly diagram *This illustration is a general exploded view of N4LDI and may be different from a fact. No. Parts name 33 Cam shaft ASSY / Plate 34 HP pump ASSY / HP pump gear *Do not handle the part of HP pump pipe. *Please be careful about the handling because HP pump ASSY is very delicate 35 Pulser / Nut 36 Idle gear shaft / Idle gear / Oil pump ASSY 37 Timing gear case ASSY / Gasket 38 Sensor ; G 39 V-belt / Crankshaft pulley / Nut 40 Front plate / Gasket 41 Oil seal ; Front 20

22 Disassembly diagram *This illustration is a general exploded view of N4LDI and may be different from a fact. No. Parts name 42 Piston / Piston ring / Oil ring / Piston pin *Before extracting piston, remove the carbon deposit from the TDC in the cylinder. *Place the connecting rod, cap and bearing remove in order of the cylinders. 43 Connecting rod / Metal 44 Cylinder block ASSY 45 Crankshaft ASSY 46 Bearing holder / Metal 47 Gear ; balancer 48 Oil seal ; rear 49 Rear plate 50 Flywheel COMPL 51 Thrust washer 52 Key 21

23 2.Engine maintenance 2.1.Before maintenance start 1 Understand fault condition and check the repeatability. 2 Do the active test and check the fault code by service tool before disassembly. 3 Clean the engine before disassembly and be careful of entering dusts and foreign matters. 4 Cut off negative battery terminal before install/remove electric parts. 5 Check cylinder block and cylinder head for wear, leakage and damage. 6 Remove deposit in oil holes of each part with air and check for clogging. 7 Wash each of parts well to remove dust, contaminated oil, carbon and other foreign matter. 8 Remove carbon deposit on pistons, cylinder head, valves and others. 9 Take care not to damage parts. Great care to be required, specifically for aluminum alloy parts. 10 Valves, pistons, connecting rods, metals and others, should be attached match marks to them in advance to prevent miss assembly. 11 Apply oil to sliding and rotating parts (Cylinder bore, piston, bearing and others) before installing. 12 Replace gaskets with new ones. If necessary, use liquid gasket to prevent oil leakage. 13 Do not excessively tighten bolts and nuts to aluminum alloy parts. Tighten them with specified torque. 14 Do the maintenance on fuel injection system at inside building and clean condition because there is risk of break by dust and foreign matter from entering. 2.2.When engine service required When engine has following condition, follow the service manual instruction for engine service. Low power Excessive oil consumption Excessive smoke(black/white) Low fuel efficiency Fuel/Oil leakage Accidental engine start Abnormal noise Other *Do the troubleshooting at first. 22

24 2.3.Detail confirmation before disassemble Check following items and recording them before engine disassembly. Engine model Engine serial number Operating time Defect situation Oil amount / dirtiness Each filter clogging Abnormal noise Stock condition Coolant amount / dirtiness Operate environment Operate loading Other (1)Engine identification Engine serial number and engine model are stamped under starting motor. (See drawing below) Engine model Assembled Month / Year Engine serial number (2)Three major factors of engine combustion and major failure causes Appropriate engine may require above major three elements for perfect combustion, when even one is missing among three elements. The engine may not run smoothly. Three major factors Major failure causes Fuel Fuel shortage / filter clogging HP pump or injector failure Air Air filter clogging Incorrect valve clearance Compression Defect piston ring Gas leakage from head gasket (3)Service limit of cylinder compression pressure and cause of failures Show the chart of cylinder compression pressure service limit. Cylinder compression pressure [MPa] Note Brand new engine (Ref.) 2.94 Service limit 2.45 At engine revolutions : 250 [rpm] Major causes of compression pressure drop 1 Piston ring failures (Ring stick and others) 2 Excessive cylinder wall wearing 3 Gas leakage from head gasket 23

25 2.4.Service interval When performing following recommended items, daily inspection items should also be carried out.. Item Daily Initial 50 Service/Inspection interval [hour] Every 250 Every 500 Every 1000 Every 1500 Every 2000 Every 3000 Note 1 Oil level and oil fouling 2 Oil leakage check 3 Oil pressure warning lamp 4 Engine oil replacement 5 Oil filter element replacement 6 Fuel leakage check 7 8 Draining water in fuel filter (With water Sedimenter) Fuel filter element replacement (Main and Pre) 9 Fuel hose check 10 Fan belt tension check (Replace if necessary) 11 Coolant level and fouling check 12 Coolant leakage check 13 Coolant replacement 14 Cooling system circuit cleaning *Or 1 year (Either early time) *Or 1 year (Either early time) *Or 1 year. And replace fuel (Either early time) *Or 2 years (Either early time) 15 Overheat warning lamp 16 Radiator external face cleaning 17 Battery fluid level check Battery charge condition (Charge warning lamp) Starter and alternator check and cleaning 20 Wiring and connection check 21 Preheating condition check (Glow plug lamp) 22 Air cleaner element cleaning 23 Air cleaner element replacement 24 Engine starting condition and noise condition 25 Exhaust smoke condition 26 Valve clearance check 27 Oil mist separator element replacement and check 28 EGR system cleaning and check *Do the service at initial 50 hours only once. *Or 1 year (Either early time) *Do the service at above it for anytime best performance (Power, Durability and Exhaust gas) of the engine. *Replace oil, fuel, coolant and others regularly, even if the machine was not used in much time because they are ageing deterioration in non-working condition. 24

26 2.5.Main parts Disassembly / Inspection / Repair (1)Common rail system inspection I.Inspection 1 Check DTC (Diagnostic Trouble Code) by service tool. Inspect the engine by looking attached Diagnosis manual at service tool software if engine having DTC. 2 Do the active test by referring to Diagnosis manual. (2)Speed sensor I.Inspection and repair Measure the resistance by tester or multimeter. If the result is failure, replace it with new one. Standard resistance of speed sensor Temperature [ ] Resistance [Ω] (3)Radiator I.Inspection and repair 1 Check coolant leakage from radiator core, radiator tank and sub tank. If the result is failure, replace it with new one or repair it. 2 Remove clogged matter of mud, dust and others from the radiator, and check radiator fin. 3 Check coolant leakage and motion of valve (positive pressure and negative pressure) at radiator cap. If the result is failure, replace it with new one. 4 Check damage and deterioration at radiator hose. If the result is failure, replace it with new one. 5 If radiator net is clogged, remove and clean it. 6 Clean the sub tank for checking coolant volume any time. Radiator tank Radiator cap Radiator core Sub tank 25

27 (4)Oil mist separator I.Disassemble 1 Remove oil mist separator from the engine and clean the body and the case. 2 Remove the hose ASSY. 3 Remove the case. 4 Remove filter element and O-ring. *Do not remove the cap. Body Cap Filter O-ring Case II.Inspection and repair 1 Check oil leakage from the case or part of connection. 2 If the case or O-ring is failure, replace it with new one. 3 Clean them and reassemble with new filter element. Tightening torque of case [Nm] *Do not use chemical at cleaning because there is risk of damage for parts. *Be careful the direction of hose ASSY because it has a check valve. Flow direction Hose ASSY Check valve (5)Turbocharger I.Disassemble 1 Remove DOC, exhaust elbow and oil pipe. 2 Remove the turbocharger form exhaust manifold. II.Inspection and repair 1 Check oil leakage from around the turbine shaft. 2 Check damage at each part. 3 Check the play of turbine circumferential direction and check that there is clearance between vane and housing. 4 Replace the turbocharger with new one if there is problem of oil leakage, damage and contact with vane and housing. Turbocharger Oil pipe Exhaust elbow DOC Exhaust manifold 26

28 (6)EGR valve I.Disassembly 1 Remove bolts and remove EGR pipe and EGR valve from the engine. II.Inspection and repair 1 Do the active test by service tool and check EGR Valve Target Position and EGR Valve Actual Position. Replace the EGR valve if there are big difference between target value and actual value. 2 Clean the deposits (soot and any other matters) of EGR valve, intake manifold, EGR cooler and EGR pipe by waste clothes. Clean inside of EGR pipe and EGR cooler by neutral detergent, and be dried it. 3 Finally, initialize EGR maintenance time by service tool. *Do not use tools that give damage to parts. EGR valve EGR pipe (7)Throttle valve I.Disassembly Remove bolts and remove the throttle valve from intake manifold. II.Inspection and repair Do the active test by service tool and check Throttle Valve Target Position and Throttle Valve Actual Position. Replace the throttle valve if there is big difference between target value and actual value. Throttle valve Boost sensor Intake manifold 27

29 (8)Intake temperature sensor I.Disassembly 1 Remove the intake temperature sensor from intake manifold. 2 Clean the tip of sensor. II.Inspection and repair Measure the resistance by tester or multimeter. If the result is failure, replace it with new one. Standard resistance of intake temperature sensor Temperature [ ] Resistance -40± [kω] 100± [kω] 250± [Ω] (9)Boost pressure sensor I.Disassembly Remove the boost pressure sensor form intake manifold. II.Inspection and repair 1 Measure the voltage and the pressure by to supply power of DC5V to Vcc. 2 Replace the sensor if there is big difference between measure value and standard value. *Do not supply overmuch pressure to the sensor because there is risk of break. Supply pressure [kpa] Standard output voltage(vout) [V] Vcc GND Vout (10)Fuel pump I.Inspection and repair 1 Check the sound and the vibration. Replace it if does not work. 2 Check the inlet and the outlet. Remove the blockage if clogged. 3 Check the air suction and the air discharge. Replace it if does not flow air. 4 Check the fuel leakage. If the result is failure, replace it with new one. Outlet Inlet 28

30 (11)Pre fuel filter Replace the filter element if clogged by foreign matters. Also, replace the filter element at every 500 hours or every 1 year operations. And, drain water from the sedimenter at every 250 hours operations. *The pre filter is installed at machine. In addition, some engine models are installed different type pre fuel filter. (This section writes for parts No ) I.Inspection and repair 1 Drain water and fuel from the sedimenter drain cock. 2 Remove the sedimenter and check operation of level switch by tester or multimeter. Operation of sedimenter level switch At normally : Insulation At full water : Conduction 3 Remove the filter element. *Do not reuse it. Should be replaced it with new one. 4 To replace the filter element, tighten with hand about 3/4 turn after gasket contacts mounting surface. *Do not use tools. 5 Bleed air from the pre fuel filter by using own hand pump. Inlet Main fuel filter Hand pump Outlet Filter element Sedimenter Drain cock Level switch (12)Main fuel filter Replace the filter element if clogged by foreign matters. Also, replace the filter element at every 500 hours or every 1 year operations. And, drain water from the sedimenter at every 250 hours operations. *Some engine models are installed different type main fuel filter. Also it position are different. (This section writes for parts No ) I.Repair 1 Close the cock and drain water and fuel from the sedimenter drain cock. 2 Remove the filter element. *Do not reuse it. Should be replaced it with new one. 3 To replace the filter element, tighten with hand about 3/4 turn after gasket contacts mounting surface. *Do not use tools. 4 Bleed air from the main fuel filter by using the air bleeding bolt. Inlet Cock Drain cock Air bleeding bolt Outlet Filter element Sedimenter 29

31 (13)Common rail *Do the maintenance on fuel injection system at inside Injector building and clean condition because there is risk of break by entering dust and foreign matter. I.Disassembly 1 Remove injection pipes and return pipe. 2 Remove bolts and remove the common rail from the engine. II.Inspection and repair 1 Do the active test of Fuel Leak Check by service tool and check Target Rail Pressure and Actual Fuel Pressure. Change the common rail if there are big difference between target value and actual value. 2 Check fuel leakage. If the result is failure, replace gaskets or the pipe with new one. Banjo bolt Common rail Return pipe HP pump Common rail Gasket 30

32 (14)Injector *Do the maintenance on fuel injection system at inside building and clean condition because there is risk of break by entering dust and foreign matter. I.Disassembly Remove clamps and injectors carefully. Do not clean the tip of injector because there are possibility of break and clog. Do not hit it somewhere. II.Inspection and repair 1 Check fuel leakage. 2 Do the active test of Cylinder Injector Injection Check to each of injectors by service tool. And, check the engine speed changing by the engine sound and the graph of Engine speed. 3 Measure the resistance by tester or multimeter. If the result is failure, replace it with new one. Resistance of injector solenoid Temperature [ ] Resistance [Ω] If replace injectors with new one, have to set "Compensation Code" on top of injector to ECU by service tool. *Refer to Operation manual of service tool software. Injector O-ring Gasket (15)Glow plug I.Disassembly Remove glow plugs from the cylinder head and clean it. II.Inspection and repair 1 Do the active test by service tool and check Glow Relay signal. Replace glow plug if there are big difference between target value and actual value. 2 Measure the resistance between body and electric pole by tester or multimeter. Replace glow plug if there is big difference between measure value and standard value. Glow plug resistance(reference value) Temperature [ ] Resistance [Ω] At normal temperature About

33 (16)Water pump I.Disassembly 1 Remove the water pump from cylinder block. 2 Remove the set plate and peel off gaskets. II.Inspection and repair 1 Check coolant leakage. 2 Check wobble of pump shaft and other damages. 3 If the result is failure, replace it with new one. Gasket Gasket Set plate Water pump ASSY (17)Water temperature sensor I.Inspection and repair Measure the water temperature sensor resistance by tester or multimeter. If the result is failure, replace it with new one. Resistance of water temperature sensor Temperature [ ] Resistance [Ω] Gasket Gasket Thermostat case Thermo cover Thermostat Water temperature sensor (18)Thermostat / Thermostat cover I.Disassembly 1 Remove the thermostat cover and remove the thermostat. 2 Remove the thermostat case and peel off gasket. II.Inspection and repair 1 Check the thermostat at normal temperature. Replace if the valve is opened even slightly. 2 Put the thermostat in vessel filled with water and increase water temperature. Inspect the valve opening temperature and the valve lift. *There are few minutes until valve fully opened. Valve opening temperature [ ] 71 Valve fully opened temperature [ ] 82 Valve lift [mm] 8 3 If the result is failure, replace it with new one. 32

34 (19)Oil pressure unit I.Inspection and repair 1 Measure the oil pressure unit resistance by tester or multimeter and check value is almost zero. If the result is unstableness, replace it with new one. 2 Supply air of 69 to 138 kpa to the pressure measure port and measure the resistance by tester or multimeter and check value that is very large. If the result is unstableness or almost zero, replace it with new one. *Do not supply high pressure because there is risk of break. Pressure measure port (20)Rocker arm ASSY I.Disassemble 1 Remove a screw. 2 Put a M8 bolt into rocker arm shaft tip and pull it out. 3 Remove spring, shim and rocker arm. Shim Spring Rocker arm II.Inspection and repair 1 Measure the rocker arm shaft outside diameter. If the result exceeds service limit, replace it with new one. Diameter of rocker arm shaft ø [mm] Standard value Service limit Less than Screw Rocker arm shaft 2 Measure the each of rocker arms inside diameter. If the result exceeds service limit, replace it with new one. Clearance between rockerarm and rocker arm shaft [mm] Standard value Service limit More than Check the uneven wear down and damage at the valve cap contact surface. Repair the surface by oilstone or grinder if there is light damage. Clearance 33

35 (21)Cylinder head ASSY I.Disassembly 1 Remove valve cotter, retainer, spring and valve by using valve spring compressor. Cap Retainer Valve cotter Spring Valve guide seal 2 Remove valve seal guide. *Valve guide seal are different from intake side and exhaust side. Valve II.Inspection and repair 1 Inspect distortion of the cylinder head bottom surface. Apply straightedge to it and insert thickness gauge at 6 point from A to F in the right figure and measure the distortion. If the distortion value exceeds the repair value, repair it by surface grinder or the like. Distortion of cylinder head bottom surface [mm] Standard value Repair value Less than 0.05 More than Measure the valve stem diameter of I to III. If the result exceeds service limit, replace it with new one. Valve stem wear ø [mm] Standard value Service limit Less than 6.89 Ⅲ Ⅱ Ⅰ 3 Measure the valve head thickness. If the result exceeds service limit, replace it with new one. Standard value Valve head thickness [mm] Service limit Valve head thickness Less than Measure the clearance between the valve stem and the stem guide. If the result exceeds service limit, replace it with new one. Clearance between valve stem and stem guide [mm] Standard value Service limit Clearance Less than

36 (22)Valve seat I.Inspect and repair 1 Repair the valve seat to standard values of the contact width by using seat cutter of 15, 45 and 75 degree. *Check the valve guide condition before repairing the valve seat. Standard value Valve seat contact width [mm] Service limit Intake More than 2.7 Exhaust More than 2.5 Contact width 2 Measure the valve recess. If the result exceeds service limit, replace it with new one. Valve recess [mm] Standard value Service limit More than 1.6 Valve recess 3 Polish the contact surface by valve lapper and check uniform the valve contact width and the center position by using red lead. *If replace the cylinder head with new one, adjust the seat contact width and the seat recess to standard values by using seat cutter before lapping. Valve lapper (23)Valve spring I.Inspection and repair 1 Check damage on the valve springs by looking. If there is any damage, replace it with new one. 2 Measure squareness, free length and spring force of the spring. If the result exceeds service limit, replace it with new one. Standard value Service limit Squareness [mm] Less than 1.2 More than 2.0 Free length [mm] Less than 33.5 Spring force [N] (Spring length:30.4 mm) 79.4 Less than 68.6 Squareness Free length 35

37 G sensor waveform Pulser waveform (24)G sensor I.Inspection and repair If there is the G sensor error code, inspect it according to Diagnosis manual. <Reference>Normal waveform of the G sensor G sensor 360 degrees (Crank angle 720degrees) (25)Gear case I.Disassembly 1 Remove the crank shaft pulley and the key. 2 Remove the oil pump (or cover) from the PTO (Power Take Off). 3 Remove bolts and nuts. 4 Remove the gear case with paying attention to damage to the oil seal. *Cover the key way of crankshaft by some tapes for protecting to the oil seal. II.Inspection and repair 1 Clean the gear case and check damages or others. 2 Check that the gear case inside pin did not come off. Gear case PTO Pin (Inside gear case) Oil seal (26)Timing gear I.Inspection and repair 1 Check the gear teeth. Replace each of gears if they are worn down. 2 Measure each of gears backlash. If the result exceeds service limit, replace it with new one. Standard value Timing gear backlash [mm] Service limit 0.08 More than 0.25 HP pump Cam gear Idle gear Crank gear 36

38 (27)HP pump *Do the maintenance on fuel injection system at inside building and clean condition because there is risk of break by dust and foreign matter from entering. I.Disassembly 1 Remove bolts and remove the HP pump from the front plate. 2 Remove the nut and remove the pulser and the HP pump gear from the HP pump. 3 Remove bolts and remove the flange from the HP pump. O-ring HP pump ASSY Flange Nut II.Inspection and repair 1 Check oil leakage. If the result is failure, replace it with new one. 2 Check fuel leakage. If the result is failure, replace it with new one or repair it at the HP pump maker. 3 Do the active test of Fuel Leak Check by service tool as same as item of the "common rail". 4 Measure the resistance of suction control valve by tester or multimeter. If the result is failure, replace it with new one. Resistance of suction control valve Temperature [ ] Resistance [Ω] Measure the resistance of the fuel temperature sensor by tester or multimeter. If the result is failure, replace it with new one. Resistance of fuel control valve HP pump gear Pulser Fuel temperature sensor HP pump Suction control valve Temperature [ ] Resistance [Ω] If replace the HP pump with new one, Do the Fuel Pump Leaning by service tool at first. Refer to Operation manual of service tool software. *Do not hold the pipe of HP pump because there is risk of damage for the HP pump. And do not disassembly it. 37

39 (28)Camshaft ASSY I.Disassembly 1 Remove the tappets from the cylinder block. 2 Remove bolts by using the hole of cam gear and remove a plate. 3 Pull the camshaft out from the cylinder block. II.Inspection 1 Check the camshaft of cam and journal. If there is damage or worn down, replace it with new one. Hole of came gear 2 Measure the camshaft run-out. If the result exceeds service limit, replace it with new one. Camshaft run-out [mm] Plate Standard value Service limit Less than 0.03 More than Measure the valve cam height. If the result exceeds service limit, replace it with new one. Intake/Exhaust valve cam height [mm] Standard value Service limit Less than Repair the surface of cam by oilstone or grinder if there is light damage or small gap. (29)Oil pump I.Disassembly 1 Remove the snap ring and remove collar, spring and shim. 2 Remove the idle gear ASSY and the oil pump cover at same time. 3 Remove the rotor and the thrust washer. II.Inspection 1 Check oil pump cover, rotor and vane. If there is damage, replace it with new one. 2 Measure the clearance between rotor and vane by thickness gauge. If the result exceeds service limit, replace it with new one. Clearance between rotor and vane [mm] Thrust washer Vane Rotor Oil pump cover Shim Spring Collar Snap ring Clearance Idle gear ASSY Standard value Service limit More than

40 (30)Balancer ASSY I.Disassembly 1 Remove banjo bolts and the oil pipe. 2 Remove bolts of fasten the balancer ASSY to the cylinder block. 3 Mark the shims to prevent misses assembling if there is it. Shim Cylinder block Shim Balancer ASSY Bolt Oil pipe Banjo bolt (31)Piston / Piston ring / Piston pin I.Disassembly 1 Remove carbon deposit on the cylinder. 2 Remove nuts and the cap from the connecting rod and remove the connecting rod with the piston from the cylinder block. 3 Remove snap rings and push the piston pin toward out of the piston. 4 Remove piston rings by using piston pliers. Snap ring Piston Connecting rod Bolt Piston ring Piston pin Snap ring Bush Cap Metal Nut 39

41 II.Inspection and repair 1 Check the piston. If there is crack, streak or remarkable burnout, replace it with new one. 2 Measure the piston skirt diameter and the cylinder thrust side diameter. If the result exceeds service limit, replace it with new one. piston skirt diameter ø [mm] (Measure at above about 10mm from piston lower end) Standard value Service limit More than 83.7 Clearance between cylinder and piston [mm] Standard value Service limit More than Measure the piston pin hole diameter and the piston pin outside diameter. If the result exceeds service limit, replace it with new one. Piston pin diameter ø [mm] Standard value Service limit Less than Clearance between piston pin hole diameter and piston pin outside diameter [mm] Standard value Service limit More than Check the piston ring. If there is damage or worn down, replace it with new one. 5 Insert the piston ring to the cylinder lower end of least worn out position by using piston. Measure the clearance of piston ring end gap. If the result exceeds service limit, replace it with new one. Clearance of piston ring end gap [mm] Kind of ring Standard value Service limit Top ring More than 1.0 Second ring More than 1.0 Oil ring More than 1.2 Piston ring Piston Clearance of piston ring end gap 40

42 6 Measure the clearance between piston ring groove and piston ring. If the result exceeds service limit, replace it with new one. Clearance between piston ring groove and piston ring [mm] Kind of ring Standard value Service limit Top ring More than 0.25 Second ring More than 0.25 Oil ring More than There are two kind repair kits that Piston ring kit and Piston kit (Include Piston ring kit ). Choose the kit of the most suitable, if replace the piston ring. *There are not oversize kits. Size Piston ring kit Piston kit STD (32)Relief valve I.Disassembly Remove the relief valve from the cylinder block. II.Inspection and repair 1 Check the relief valve. Replace it if the valve is opened even slightly. 2 Check the oil flow way. If it is clogged, remove and clean it. O-ring Relief valve (33)Crankshaft I.Disassembly *Remove the Relief valve before removing the crankshaft. 1 Remove the flywheel and the rear plate from the cylinder block. 2 Remove bolts of fasten the crankshaft to the cylinder block from the cylinder block bottom side. 3 Check that the relief valve is removed already, and remove the crankshaft to rear side. 4 Remove the bearing holders from the crankshaft. Rear side Front side 41

43 II.Inspection and repair 1 Support the crankshaft by V block and measure run-out to each of journals by dial gauge. If the result exceeds service limit, replace it with new one. Crankshaft run-out [mm] Standard value Service limit Less than 0.03 More than Check the oil seal contact surface damage and the oil hole clogging. 3 Check the journals and the pins of damage and irregular wear (ellipticity and cone). And measure the diameter of journals and pins by the right figure position and A direction. (Measure the direction AA and BB of the position 1 and 2.) If the result exceeds service limit, B B replace it with new one. Ellipticity wear limit of journal and pin ø [mm] Journal A More than 0.05 Pin Journal diameter ø [mm] Standard value Service limit Less than 67.9 Pin diameter ø [mm] Standard value Service limit Less than 51.9 (34)Connection rod ASSY I.Inspection and repair 1 Check damage and corrosion of the connecting rod. If the result is failure, replace it with new one. 2 Measure the torsion and the parallelism. If the result exceeds service limit, replace it with new one. Torsion and parallelism of connecting rod [mm] (Per 100mm) Standard value Service limit Torsion Less than 0.08 More than 0.2 Parallelism Less than 0.05 More than 0.15 Gauge Piston pin Flat part of aligner Pin Gauge Torsion Piston pin Flat part of aligner 42

44 3 Measure the inside diameter of the connecting rod small end bush. If the result exceeds service limit, replace it with new one. Clearance between bush and piston pin [mm] Standard value Service limit More than Install the connecting rod to the engine, and measure the axial play. If the result exceeds service limit, replace it with new one. Axial play of connecting rod and crank pin [mm] Standard value Service limit More than 0.7 (35)Connecting rod metal I.Inspection and repair 1 Check the metal and if there is peeling, melting, uneven wear, improper contact or other damage. If the result is failure, replace it with new one. 2 Remove oil dust or other foreign matter from the metal and the crank pin. 3 Cut the plastic gauge (Plastic precision clearance gauge) to length same as the metal width and put it on the crank pin in parallel with the crankshaft avoiding the oil hole. 4 Install the connecting rod metal and the connecting rod cap and tighten with the specified tightening torque. Connecting rod cap tighten torque [Nm] *Never turn the connecting rod at this time. 5 Remove the connecting rod cap, and measure the plastic gauge width by printed paper of included the gauge. If the result exceeds service limit, replace it with new one. Clearance between connecting rod and crank pin [mm] Standard value Service limit More than 0.2 Plastic gauge 3Set plastic gauge Crashed gauge 5Measure clearance 43

45 (36)Bearing holder I.Inspection and repair 1 Check the metal by looking and replace it with new one, if there is peeling, melting, uneven wear, improper contact or other damage. 2 Measure the clearance of the crankshaft center journal and the metal by using the plastic gauge. (Refer to item of the connecting rod.) If the result exceeds service limit, replace it with new one. Clearance between center journal and metal [mm] Standard value Service limit More than Check the thrust washer and replace it with new one, if there is wear, improper contact, seizure or other damage. And measure the thickness. If the result exceeds service limit, replace it with new one. Thrust washer thickness [mm] Standard value Service limit Less than 2.8 (37)Cylinder block I.Inspection and repair 1 Check crack, damage and distortion on the cylinder block top surface in the same way as in the cylinder head. Distortion on cylinder block top surface [mm] Standard value Repair value Less than 0.05 More than Check the cylinder bore. There should be no scratch, rust, corrosion and other damage. If the result is failure, replace it with new one. 3 Measure the cylinder bore at top, center and bottom respectively in the crankshaft direction (A) and the direction at right angle to it (B). If the result exceeds service limit, replace it with new one. Standard value Cylinder bore diameter ø [mm] Service limit More than 84.2 Ring sliding range Crankshaft direction 44

46 4 Check the bush and replace it if there is peeling, melting, uneven wears, improper contact, or other damage. 5 Measure the dimensions in A and B directions at position 1 and 2 in the right figure avoid the oil hole of the bush and calculate difference from the maximum value of the crankshaft journal. If the result exceeds service limit, replace it with new one. Clearance between bush and crankshaft center journal [mm] Standard value Service limit More than 0.2 *When replacing the bush, push it up by using a press or the like. At this time, align oil holes and push it up until the bush end surface becomes level with the outside machined surface of the cylinder block (see the arrow mark in the right figure). Does not the bush stick out from the machined surface (38)Oil cooler I.Disassembly 1 Remove the oil filter. 2 Remove the filter joint and remove the oil cooler. II.Inspection and repair 1 Check the oil leakage. If the result is failure, replace it with new one. 2 Check the blockage. If the result is failure, replace it with new one. Coolant flow (39)Flywheel / Ring gear I.Inspection and repair 1 Check the ring gear. If there is damage or remarkable wear, replace it with new one. 2 When the wear is limited to small area, remove the ring gear, turn it about 90 degrees and shrinkage-fit to reuse it. To shrinkage-fit the ring gear, heat it to degrees C to allow it to expand. 45

47 2.6.Assembly (1)Crank shaft / Bearing holder 1 Install the bearing metal with oil groove to upper side and install the bearing metal without oil groove to the lower side. And, check that the bearing metal claw fit into bearing holder's claw groove (Refer to figure below). 2 Apply oil on the bearing metal. 3 Check the bearing holder position and direction by reference to under figure, and assemble the bearing holder to the crankshaft from the front side. If assembly is mistake, cause to bearing seizure because oil hole be blocked by bearing metal. *N3LDI bearing holder is one less than N4LDI (Refer to figure below). 4 The most rear side bearing holder install to the crankshaft with applied oil on thrust washers (Refer to figure below). The oil groove side of the thrust washer touches the crankshaft. 5 Tighten bolts with the specified tightening torque. Bearing holder tighten torque [Nm] Bearing holder (upper side) Thrust washer (Upper 1 piece, lower 2 piece) Bearing holder (upper side) Upper bearing metal (with oil groove) Upper bearing metal (with oil groove) *Without this bearing holder at N3LDI Lower bearing metal (without oil groove) Rear side Front side Cutting mark (big) Cutting mark (small) Stepped side 46

48 (2)Cylinder block / Bearing holder 1 Apply oil on the bush of the cylinder block. 2 Install the crankshaft with the bearing holder from the rear side and tighten bolts. 3 The most rear side bearing holder is tightened by hexagon socket head bolts to the cylinder block. 4 Tighten bolts with the specified tightening torque. Rear side B Front side Bearing holder tighten torque [Nm] A Hexagon socket head bolt B Bolt A 5 Check the crankshaft axial play. Crankshaft axial play [mm] Standard value Repair limit More than 0.5 (3)Relief valve 1 Replace o-ring with new one and install to the cylinder block. 2 Tighten it with the specified tightening torque. Relief valve tighten torque [Nm] O-ring Relief valve 47

49 (4)Oil seal 1 Apply little amount oil on around of the oil seal lip. 2 Install the oil seal to the cylinder block with paying attention to deforming or damaging to the oil seal lip. 3 Apply suitable amount liquid gasket to around of the oil seal and the screw holes for the rear plate. Dowel pin Oil seal Liquid gasket (5)Rear plate Install the rear plate and tighten bolts with the specified tightening torque. Rear plate tighten torque [Nm] Rear plate (6)Fly wheel 1 Align the flywheel hole to the dowel pin on the crankshaft and install the flywheel. 2 Tighten bolts with the specified tightening torque. Flywheel tighten torque [Nm] Flywheel 48

50 (7)Piston / Connecting rod 1 Install the piston rings in the order of oil ring, second ring and top ring by using piston ring pliers. Install the oil ring and put the oil ring gap to the coil expander jointed part opposite. *Piston rings has the top mark at near the ring gap (Oil ring is symmetrical shape). 2 Apply oil to the piston pin hole and the piston pin. Connect the connecting rod and the piston by the piston pin. Correct position is state that the arrow mark of piston top face towards right side, and the connecting rod match mark face toward near side (Refer to right figure). *If difficult to install the piston pin, heat the piston by piston heater or others. 3 Install the snap rings to groove securely. 4 Install the bearing metals to the connecting rod and the cap. And, check that the bearing metal claw fit into the claw groove. 5 Apply enough amount oil to cylinder, crank pin, piston sliding surfaces, piston rings and bearing metals. 6 Put each the piston ring gaps to the position differently by 120 degree each. 7 Turn the direction of arrow mark on piston top to front side and install the piston by using piston ring compressor. *Install the piston from the cylinder block front side by order of number on the connecting rod surface. 8 Install the cap and nuts. Tighten nuts with the specified tightening torque. Cap tighten torque [Nm] Check the connecting rod axial play of crankshaft direction. Connecting rod axial play [mm] Coil expander jointed part Match mark Arrow mark (Front mark) Snap ping Piston Connecting rod Cap Top ring Second ring Oil ring Top face mark Oil ring gap Arrow mark (Front mark) Front side Piston rings Piston pin Snap ring Bush Metal 49

51 (8)Balancer ASSY (Some model of N4LDI) 1 Apply oil to the balancer ASSY s gear and bush. 2 Put No.1 and No.4 pistons at top dead center. 3 Put the cylinder block top surface towards directly above. 4 Put the weights of balancer toward directly below. 5 Install the balancer to the cylinder block correctly by using dowel pins. And, adjust the backlash between drive gear and balancer gear by using the shim. *Shim thickness is 0.2mm. Backlash between drive gear and balancer gear [mm] Tighten M10x70mm bolts with the specified tightening torque. M10x70mm bolt tighten torque [Nm] Install the oil pipe with banjo bolts and tighten the banjo bolts with the specified tightening torque. Banjo bolt tighten torque [Nm] Top dead center Balancer ASSY Balancer weight Shim Balancer ASSY Oil pipe Banjo bolt M10x70mm bolt (9)Suction filter / Suction pipe 1 Remove contaminants and others from suction filter. 2 Check the O-ring of suction pipe. Replace it there is damage or hardening. 3 Install the O-ring to the O-ring groove of oil pipe and apply oil on it. And, Install the suction pipe to the engine. 4 Install the suction filter as the suction pipe tip fits into the suction filter. And, tighten bolts. Suction pipe Suction filter O-ring 50

52 (10)Oil pan 1 Install the oil pan with gasket and tighten bolts temporarily in order of the corner from the center. 2 Tighten bolts with the specified tightening torque in order of above item. And, tighten all bolts again for equal tightening torque. Oil pan tighten torque [Nm] Tightening order of N3LDI Tightening order of N4LDI (11)Level gauge / Level gauge guide 1 Install the level gauge guide with two O-ring to cylinder block. And, tighten a bolt. 2 Install the level gauge. (12)Front plate Install the front plate with gasket and tighten bolts. Front plate Gasket 51

53 (13)HP pump / Pulser *Do the maintenance on fuel injection system at inside building and clean condition because it has risk of broken by entering dust and foreign matter. 1 Install the O-ring to the flange and install the HP pump. And, tighten bolts with the specified tightening torque. HP pump tighten torque [Nm] Assemble the HP pump and the pulser by pins. 3 Install the HP pump gear to the HP pump by a nut. And, tighten the nut with the specified tightening torque. Nut tighten torque [Nm] Install the O-ring to the flange. And install the HP pump to the engine and tighten bolts. *Do not hold the HP pump pipe because there is risk of breaking it. Flange HP pump O-ring HP pump gear Pulser HP pump gear Pulser Pin O-ring 52

54 (14)Camshaft / Idle gear / Oil pump 1 Assemble the camshaft with the cam gear and tighten the nut with the specified tightening torque. Match mark Nut tighten torque [Nm] Apply oil to gears. And, install the camshaft to the engine as the camshaft gear match mark matches with the HP pump gear match mark. 3 Apply oil to the thrust washer and Install it to the idle gear shaft. 4 Apply oil to the idle gear. And, rotate the cam gear and the crank gear for matching with the idle gear and install Plate the idle gear to the engine. 5 Apply oil to the vane and the rotor. And, install the rotor to the vane. 6 Install oil pump cover, shims, spring and collar and fix with the snap ring. 7 Adjust side clearance between the oil pump cover and the vane by using shims. Side clearance between oil pump cover and vane [mm] Rotate Match mark 8 The oil pump cover hole matches with the gear case spring pin. Therefore, turn the oil pump cover clockwise and counterclockwise, and hold it at center position. *Do not rotate gears until install the gear case, because there is risk of breaking the idle gear shaft. Thrust washer Vane Rotor Oil pump cover Hole Shims Spring Collar Snap ring Idle gear ASSY Shims Oil pump cover Rotor and vane 53

55 (15)Gear case 1 Check that dusts and deposits are not sticking to the gear case. 2 Check the position of oil pump cover hole for matching to the gear case. 3 Cover the key way of crank shaft by tape because protecting to the oil seal. 4 Apply little amount oil on around of the oil seal lip. 5 Install the gear case with gasket to the engine with pay attention to deforming or damaging to the oil seal lip. And, install the gear case spring pin to the oil pump cover hole with pay attention. *If the oil pump cover position was wrong, the gear case cover spring pin touches to the oil pump cover top surface, and do not install it. 6 Tighten bolts and nuts. 7 Install the oil pump (or cover plates) to the PTO part with o-ring and gasket. 8 There is a small window on the gear case for match mark confirmation of the HP pump gear and the cam gear. Check the match mark from here if change the HP pump. 9 Install the G sensor and tighten a bolt with the specified tightening torque. G sensor tighten torque [Nm] Spring pin Idle gear ASSY Hole Oil pump cover Oil pump cover hole Match mark O-ring Cover 54

56 (16)Crankshaft pulley 1 Install the key to the key way of crankshaft. 2 Install the crankshaft pulley to the crankshaft and tighten a nut with the specified tightening torque. Crankshaft pulley nut tighten torque [Nm] Nut Crankshaft Key Key way Crankshaft pulley (17)Oil filter 1 Apply little amount oil to o-ring by finger. 2 Tighten the oil filter by hand. (18)Tappet 1 Apply enough amount oil to tappet holes of the cylinder block. 2 Install tappets and apply oil to tappet holes again. 55

57 (19)Cylinder head ASSY 1 Set the piston at TDC position. And measure the piston projection from the top face of cylinder block by using dial gauge. At this time, pushing the piston top face lightly and measure it above the piston pin. Measure all piston projection and decide the piston projection depending on the largest value. *Normally piston projection value is less than 0.1mm. 2 Select the head gasket according to the measured value N3LDI below. Piston projection [mm] Head gasket part cord No, Thickness when tightened [mm] t = t = 1.4 Piston projection t = 1.1 N4LDI t = t = Install the head gasket to the cylinder block. The side with part number is the top side. *The cylinder head gasket has part number on the top face. 4 Install the cylinder head to the cylinder head along to spring pins. 5 Apply oil to thread of head bolts, and apply little amount oil to head bolts seating face. Then install head bolts to the cylinder head. *Install short head bolts to under injectors. 6 Tighten the head bolts by using angle method. First, tighten all bolts with the specified tightening torque. Next, tighten all bolts with the specified angle. *Tightening order refer to the right figure. Head bolt tighten method (Angle method) 1st : [Nm] 2nd : [ ] *Do not reuse the head bolts because they are deformed (plastic-deformation). Replace them with new bolts every time. *Tightening angle method for the head bolts is different from conventional engines. Distinguish angle method bolts and conventional bolts with referring right figure. Head bolt For conventional engine Without mark (Torque method) Head bolt type Long bolt (L=101.5mm) Short bolt (L=82.5mm) Part code For N3LDI,N4LDI With mark on top face (Angle method) Tightening order of N3LDI head bolts Tightening order of N4LDI head bolts Part code

58 (20)Rocker arm 1 Install the valve caps to the valves and apply oil to the Rocker arm ASSY Nut top face of valve caps. 2 Install the push rods to the tappet holes and apply oil to Gasket Bolt the bowl part of push rods. 3 Check that the gasket fitting in groove of rocker arm Push rod ASSY and install the rocker arm ASSY to the cylinder head. Then tighten nuts with the specified tightening Valve cap torque. *Check that the rocker arm fits with the bowl part of push rods, because there is risk of breaking the push rod. After that, tighten bolts and nuts. Rocker arm ASSY nut tighten torque [Nm] (21)Valve clearance adjustment 1 Set the piston of 1st cylinder to TDC by rotated the crankshaft to normal rotation (clockwise looking from Top mark front side) and match the top mark of the crankshaft pulley with the top mark of the gear case. Top mark 2 Check the TDC of 1st cylinder by rotating clockwise and counterclockwise a little angle of the crankshaft. If the intake and exhaust valve do not move, it is TDC. Adjust screw Lock nut Valve clearance *If the valves move, rotate the crankshaft 360 degree and check the TDC again, and match the top mark again. 3 Adjust the valve clearance to specific value by using wrench, screwdriver and clearance gauge, and tighten the lock nut with the specified tightening torque. Refer to Push rod the valve position and crankshaft angle on next page. *Adjust it in the condition of the tappet touching to the camshaft. Screwdriver Wrench *Adjust it in the condition of the engine of normal temperature. *Rotate the crankshaft to the normal rotation. Clearance gauge Valve clearance of intake/exhaust valve [mm] Lock nut tighten torque [Nm]

59 < Valve clearance adjustment > First, adjust valve clearance to marked valve in the under table at 1st cylinder TDC. After that, rotate the crankshaft for 360 degree to normal rotation, and adjust valve clearance to marked valve in the under table at 1st cylinder overlap (Refer to table below). *The valve overlap is that the intake valve with the exhaust valve opening a little at same time. < N3LDI > Cylinder No, Valve In Exh In Exh In Exh 1 st cylinder TDC 1 st cylinder overlap < N4LDI > Cylinder No, Valve In Exh In Exh In Exh In Exh 1 st cylinder TDC 1 st cylinder overlap If it is necessary to adjust the valve clearance frequently in short term, irregular parts might be worn excessively. Should inspect and repair for preventing the fatal damage. Refer to the item below. <<Less valve clearance>> <Cause> There is high probability that valve seat was worn excessively. Refer to the item below of real cause. - Oil fouling - Injection system fault - Using unsuitable fuel - Air cleaner clogging or dirty by oil - Excessive load <Influence> - Rapid wears to the camshaft or the tappet <<Too much valve clearance>> <Cause> - Wear of the camshaft or the tappet - Wear of the rocker arm - Bending or breaking of the push rod <Influence> - Breaking of the valve stem, the spring or the retainer 58

60 (22)Head cover 1 Check that the gasket fitting in the groove of head cover and then install the head cover to the engine. 2 Install the cap nuts with gasket and tighten the cap nuts with the specified tightening torque. Cap nut tighten torque [Nm] Gasket and cap nut Head cover (23)Oil pressure unit 1 Wrap the seal tape around the oil pressure unit screw thread with pay attention to not cover the pressure port. 2 Install the oil pressure unit to the rocker arm ASSY and tighten it with the specified tightening torque. Oil pressure unit tighten torque [Nm] Oil pressure unit (24)Oil pipe 1 Put the fitting part of oil pipe between gaskets and install it to the engine and the rocker arm ASSY with banjo bolts. 2 Tighten banjo bolts with the specified tightening torque. Banjo bolt tighten torque [Nm] Gasket Banjo bolt Oil pipe 59

61 (25)Injector / Common rail / Glow plug *Do the maintenance on fuel injection system at inside building and clean condition because there is risk of broken by entering dust and foreign matter. *Should be assembled following steps below, because there are risks of damage and fuel leakage. 1 Install the glow plugs and tighten it with the specified tightening torque. Injector O-ring Gasket Glow plug tighten torque [Nm] Install new O-ring to injector and apply little amount oil to O-ring and install injectors to cylinder head with gasket. *Pay attention that the Injector tip does not contact to the cylinder head. 3 Fit the washer (bowl shape) to spherical surface of clamp and install it to the injector and tighten bolt temporarily. 4 Tighten the common rail temporarily and tighten banjo bolts with the return pipe to the injectors, the common rail and the HP pump temporarily. At this time, put the fitting part of return pipe between gaskets. *Common rail banjo bolt only has circular mark on top. 5 Tighten the clamp with specified tightening torque. Injector clamp tighten torque [Nm] Tighten the return pipe with specified tightening torque. *Tighten all banjo bolts. (For injector, common rail and HP pump) Return pipe banjo bolt tighten torque [Nm] Washer Clamp Banjo bolt (With tool mark) Gasket Return pipe Common rail Tighten injection pipes connecting HP pump and common rail, common rail and injectors temporarily. *Replace the injection pipes every time because there is risk of fuel leakage. 8 Tighten the common rail with specified tightening torque. Common rail tighten torque [Nm] Tighten injection pipes with specified tightening torque. Injection pipe tighten torque [Nm] Injection pipes (Common rail to injectors) Injection pipe (HP pump to common rail) 60

62 (26)Intake manifold / Boost sensor 1 Install the intake manifold with the spacer and gaskets. Intake manifold Spacer Gaskets 2 Check the O-ring of boost sensor and install it to the intake manifold. And tighten it with specified tightening torque. Boost sensor tighten torque [Nm] 3.1 Gasket Throttle valve Boost sensor 3 Install the throttle valve with gasket to the intake manifold. * For N4LDI-TA model only (27)Intake temperature sensor Install the intake temperature sensor to the intake manifold and tighten it with specified tightening torque. Intake temperature sensor tighten torque [Nm] Intake temperature sensor (28)Exhaust manifold Install the exhaust manifold with gasket. *Replace the gasket every time. Cylinder head Gasket Exhaust manifold 61

63 (29)EGR 1 Install the EGR cooler with gasket to the exhaust manifold. *Replace the gasket every time. Exhaust manifold Gasket EGR cooler 2 Put the EGR valve between gaskets and install it with the EGR pipe to the intake manifold. And, install the EGR pipe with gasket to the EGR cooler. EGR valve Gasket Intake manifold EGR pipe Gasket EGR cooler (30)Turbocharger 1 Install the turbocharger with gasket to the exhaust manifold. 2 Check the O-ring of oil pipe and install the oil pipe to the cylinder block. 3 Put the banjo fitting part of oil pipe between gaskets and install the oil pipe with banjo bolt to the turbocharger. 4 Tighten the banjo bolts with specified tightening torque. Banjo bolt tighten torque [Nm] Banjo bolt Gaskets Turbocharge r Oil pipe Exhaust manifold 62

64 (31)Water pump / Thermostat 1 Install the water pump with gasket to the cylinder block. Then, install the water hose and the pipe. 2 Install the thermostat case with gasket to the cylinder head. Then, connect it and the water pump by the bypass hose. 3 Install the thermostat to the thermostat case. *Match the jiggle valve with the jiggle valve groove of thermostat case. 4 Install the thermostat cover with gasket to the thermostat case. 5 Install the water temperature sensor with gasket to the thermostat case. And tighten it with specified tightening torque. Water temperature sensor tighten torque [Nm] Connect the oil cooler with the water pump and the oil cooler with the cylinder block by hoses. 7 Connect the EGR cooler with the cylinder block and the EGR cooler with the pipe by hoses. Thermostat case Gasket Water pump Gasket Bypass hose Thermostat cover Gasket Jiggle valve Thermostat Jiggle valve groove Thermostat case Gasket Water temperature sensor Hose Oil cooler Water pump EGR cooler Pipe Hose 63

65 (32)DOC *The DOC install position differs by engine models. 1 Fit the DOC to stays temporarily and install it with gasket to the exhaust elbow. And install them with gasket to the exhaust manifold. 2 Adjust the clearance between the upside stay and the downside stay to 3 mm at one side. And tighten lock nuts with specified tightening torque at another side. Stay DOC Gasket DOC stay lock nut tighten torque [Nm] Exhaust elbow (33)Fan belt 1 Install the fan belt with fan, pulley and alternator. 2 Adjust the deflection amount having 5 to 10 mm between the crank pulley and the alternator pulley with specified the belt tension force. And fix the alternator. Fan belt tension force [N] At new belt At readjust (34)Wire harness 1 Install the wire harness orderly by clamps. 2 Check each of connectors connection. *Refer to the item of the clamp position Deflection amount 64

66 (35)ECU 1 Check the breathing hole clogging. 2 Install the ECU to the specified position securely. 3 If replacing the ECU with new one, reset it. Also when replacing the HP pump or the injector with new one, reset the ECU such as the pump learning and the injector correction. *Refer to Operation Manual of the service tool software. Breathing hole If connection by service tool is possible Save the injector correction number by service tool Write saved the injector correction number to new ECU Do the pump learning Case of connection impossible by service tool Input the injector correction number on injector top face to new ECU by service tool. Do the pump learning 65

67 2.7.Wire harness clamp position N3LDI N4LDI 66

68 3.Engine trouble shooting Condition Cause Remedy Engine dose not start Defective key switch Battery voltage reduction Out of gas Air mixed into fuel system Clogged fuel filter Clogged air cleaner Defective glow plug Improper viscosity of lubricating oil Low compression pressure Using unsuitable fuel Electronic control error Repair or replace it Charge or replace the battery Replenish fuel Repair the air entrance to the fuel or replace it, and remove air Replace the fuel filter element Clean the filter or replace it Replace the glow plug Replace with correct oil Repair the leakage Replace with correct fuel Check the ECU by service tool Starting motor dose not operate Engine stop after starting immediately Loosened or disconnected wiring Battery voltage reduction Defective safety switch Blow fuse Trouble in starting motor Clogged fuel filter Clogged fuel hose or fuel pipe Air mixed into fuel system Clogged breather of fuel tank cap Electronic control error Correctly the wire and tighten by correctly torque. Charge or replace the battery Replace it Check the short circuit and replace the fuse Replace the starting motor Replace the fuel filter element Clean or replace it Repair the air entrance to fuel or replace it, and remove air Clean or replace it Check the ECU by service tool 67

69 Condition Cause Remedy Engine stop at operating Irregular engine speed Out of gas Clogged fuel filter Air mixed into fuel system Engine main body failure Electronic control error Water mixed into fuel system Air mixed into fuel system Clogged fuel filter Engine main body failure Electronic control error Replenish fuel Replace the fuel filter element Repair the air entrance to fuel or replace it, and remove air Overhaul it, and inspect and repair it Check the ECU by service tool Replace fuel and the filter element Remove water if engine has the sedimenter Repair the air entrance to fuel or replace it, and remove air Replace the fuel filter element Overhaul, and inspect and repair Check the ECU by service tool Engine overheat Lack of coolant Replenish coolant Repair the leakage part or replace it Break fan belt Slip fan belt Clogged radiator Clogged radiator fin Clogged coolant circuit Thermostat failure Lack oil Overload Replace the fan belt Remove oil, dust and others Adjust the belt tension force Clean or replace it Clean the radiator fin Clean the coolant circuit Replace the thermostat Replenish oil Decrease the load 68

70 Condition Cause Remedy Bad exhaust color (White or blue) Bad exhaust color (Black or dark gray) Oil leakage from muffler Battery charging failure Oil pressure lamp does not light up with the key switch turned ON (While engine stop) Oil pressure lamp does not go out Too much oil Too low viscosity of oil Using unsuitable fuel Clogged air cleaner Too much fuel injection quantity Engine main body failure Overload Turbocharger failure Clogged oil mist separator Break fan belt Slip fan belt Wire disconnection Deterioration of battery Alternator failure Burn out lamp Wire disconnection Low oil quantity Oil pressure unit failure Oil leakage Wire disconnection Adjust correct oil quantity Replace with correct oil Replace with correct fuel Clean the filter element or replace it Inspect and replace it Overhaul it, and inspect and repair Decrease the load Replace the turbocharger Replace the filter element and the clean hoses Replace the fan belt Remove oil, dust and other Adjust the belt tension force Repair the wire Replace the battery Replace the alternator Replace the lamp Repair the wire Replenish oil Replace the oil pressure unit Check the oil circuit and repair it Repair the wire 69

71 PISTON RING MAIN MORVING SYSTEM PISTON PIN PISTON BLOCK ENGINE CYLINDER NEAD Unit Part *Units for values without unit are "mm". 4.Service standard data Inspection Items Standard Dimension Standard Value To be Repair Service Limit Note Compression pressure of cylinder [MPa] Cylinder head tightening 1 st Torque [Nm] 2 nd Angle [Degree] Distortion of cylinder head bottom surface More than st nd Less than 0.05 Less than 2.45 More than rpm Apply oil to threads Do not reuse the bolt Angle method Valve seat recess Width More than 1.6 Valve sheet angle 45 Recess Width of valve seat Liner type Intake Exhaust Cylinder bore diameter Φ84 Φ Distortion of cylinder block top face Piston skirt bottom longer diameter Clearance between cylinder and piston Clearance between piston pin hole and piston pin Φ Less than 0.05 Φ Φ More than 2.7 More than 2.5 More than 0.12 More than Φ 84.2 Less than Φ 83.7 More than 0.25 More than 0.02 Wet type (Integral type) At 20 Piston pin outside diameter Φ Less than Φ Clearance between small end bush and piston pin More than 0.08 Oil clearance Top ring More than 1.0 Piston ring end gap 2 nd ring More than 1.0 Oil ring More than 1.2 Clearance between piston ring groove and ring Top ring nd ring Oil ring More than 0.25 More than 0.25 More than 0.25 Top ring 2 Ring thickness 2 nd ring 1.5 Oil ring 2 70

72 VALVE VALVE SYSTEM CAMSHAFT MAIN MORVING SYSTEM CRANK SHAFT CONNECTING ROD Unit Part Inspection Items Standard Dimension Standard Value To be Repair Service Limit Note Torsion between small and large end holes Parallelism between small and large end holes Axial play of connecting rod and crank pin Less than 0.08 Less than 0.05 More than 0.2 More than More than 0.7 Per 100mm Per 100mm Clearance between crank pin and connecting rod metal More than 0.2 Oil clearance Diameter of journal Diameter of crank pin Roughness of main journal and crank pin Φ68 Φ52 1.6Z Φ Φ Φ Φ Crankshaft run out Less than 0.03 More than 0.06 Less than Φ 67.9 Less than Φ 51.9 Axial play of crankshaft More than 0.5 Thickness of thrust washer Less than 2.8 Outside diameter x Inside diameter of bush (journal metal) Clearance between crankshaft journal and bearing (bush) Outside diameter x Inside diameter of center bearing Clearance between crankshaft journal and center bearing Height of cam Φ72x68 Φ72x More than 0.2 Oil clearance More than 0.2 Oil clearance Less than 34.1 Camshaft run out Less than 0.03 More than 0.1 Cam gear (each gear) backlash Diameter of valve stem Φ6.97 Clearance between valve stem and valve guide 0.08 Φ6.955 Φ6.970 More than 0.25 Less than Φ More than 0.2 Thickness of valve Less than

73 LUBRICATION SYSTEM OIL PUMP ROCKER ARM VALVE SYSTEM PUSH ROD VALVE Valve spring Unit Part Inspection Items Standard Dimension Standard Value Valve clearance Spring force [N] 79.4 To be Repair More than 0.5 Less than 68.6 Service Limit Note Cold condition At Spring length 30.4mm Free length Less than 33.5 Squar eness Less than 1.2 More than 2.0 Overall length Outer diameter Φ6.3 Diameter of rocker arm shaft Φ14.96 Φ14.95 Φ Less than Φ Clearance between rocker arm and shaft More than 0.2 Oil clearance Discharge rate [L/min] 16.2 Discharge pressure [kpa] Tip clearance (Rotor to vane) Side clearance (Rotor to cover) Oil pressure unit operating pressure [kpa] Relief valve operating pressure [kpa] Lubrication oil capacity [L] Specified engine oil More than More than Differ by engine model Engine speed : 2500 [rpm] Oil temperature : [ ] Oil filter capacity : 0.2 [L] JASO DH-2 or API CJ-4 72

74 COOLING SYSTEM COOLING INJECTOR FUEL SYSTEM COMMO N RAIL HP PUMP Unit Part Inspection Items Standard Dimension Standard Value To be Repair Service Limit Note Type HP3 supply pump DENSO Plunger Φ8.5 x 2 Capacity [L] 0.25 Voltage [V] Type G3 type DENSO Injection pressure [MPa] Voltage [V] Tightening torque [Nm] Injector cramp Cooling method Forced circulation water cooling Coolant volume [L] Thermostat open temperature [ ] Thermostat full open temperature [ ] Fan belt tension farce [N] (At new belt) Fan belt tension farce [N] (At readjust) Differ by engine model When the deflection amount having 5 to 10 mm between the crank pulley and the alternator pulley. 73

75 5.Diagnosis of failure This is important process to resolve the electric problem. Explain diagnosis method of failure by using the IHI shibaura electronic service tool D (Service Tool) and the service tool software of installed at PC. But, have to doing the diagnosis of failure by legwork to user if could not reach to the cause by using service tool. (1)Process of the diagnosis failure 1 Inspect the actual failure condition. 2 Reproduce the failure condition. 3 Check the failure code of DTC information by using service tool. 4 Inspect the item of failure code of DTC information by referring to Operation manual of service tool software of installed at PC. 5 If can not find the cause by using service tool, diagnose the failure by legwork to user. (2)Diagnosis of failure by legwork 1 Understand the failure condition by the failure report from user. 2 Get the details of the failure condition and the estimated cause by asking to user. 3 Diagnose the failure by the detailed information. (3)The point of diagnosis of failure by legwork Do legwork of diagnosis of failure by using the 5W1H method. 1 Who Machine and user (Construction, Agriculture or other), Operating hours, Operator skill and others 2 What Work, Working condition, Engine condition, Using fuel and others 3 When Day and time, Weather, Temperature, Frequency and others 4 Where Place, Altitude, Outdoor or Indoor, Surrounding environment and others 5 Why Purpose of work, Operating condition, Engine condition and Environment 6 How Concrete moving at failure, Behavior, Sound, Smell and others *Sometimes, there are situations that failure does not reproduce at service shop because failure occurs rarely. And, not all failure reports from user are connected with the failure condition or the failure cause. Collect the information actively to prevent unnecessary repair and misunderstanding caused by less information. 74

76 (4)Structure of service tool Engine Install PC Service tool software ECU Cable IHI Shibaura service tool (Communication adapter) Cable DI ADAPTER KID WC Part number : *Refer to Operation Manual of the service tool software for how to use the service tool. *When using the service tool software, it needs the activation ID. Therefore, contact the machine manufacturer service agent for the ID issue. *Use the service tool with the newest firmware always. Therefore, contact the machine manufacturer service agent for update file. 75

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78 Quality Assurance Department Engine Division Ishishiba, Matsumoto, Nagano, , Japan TEL FAX URL :