This is a very practical manual

1. Service Information
Document Title: Function Group: Information Type: Date:
Engine, description 200 Service Information 2015/3/29
Profile:
Engine, description
(YANMAR 4TNE94–SM)


The engine is a 4–cycle, 4–cylinder, direct injected, water cooled diesel engine.
The engine produces powerful performance using direct injection type combustion chamber.
Figure 1
Top view, engine
1 Fuel injection nozzle 6 Valve rocker cover
2 Gear case 7 Cylinder head
3 Gear case cover 8 Inlet manifold
4 Starter motor 9 Flywheel housing
5 Exhaust manifold

2. Figure 2
Flywheel side view, engine
Figure 3
Fuel injection side view, engine
1 Inlet manifold 9 Fuel feed pump
2 Stop motor 10 Lubrication oil filter
3 Governor 11 Dipstick
4 Fuel injection pump 12 Oil pan
5 Fuel filter 13 Cooling water pump
6 Cooling water inlet 14 Alternator
7 Cooling fan 15 Cooling water outlet
8 Oil filler port

3. Figure 4
Fan side view , engine
Engine performance curve
Figure 5
Engine performance curve
Engine performance condition
Item Condition

4. Cooling fan φ430 blower
Exhaust pressure 1000 mmAq
Air cleaner 6 inch
Radiator Installed
Alternator No charge

5. Service Information
Document Title: Function Group: Information Type: Date:
Engine, specifications 200 Service Information 2015/3/29
Profile:
Engine, specifications
Specifications
Item Unit Specifications
Make – Yanmar diesel
Model – 4TNE94–SM
Type – Vertical, 4–cylinder, water cooling, upright series,
direct injection, diesel engine
Rated output PS (kW) / rpm 52 (38.2) / 2200
Maximum torque (Net) kgf·m / rpm
(lbf·ft / rpm)
18.5 ± 0.5 /1600
(134 ± 3 / 1600)
Number of cylinder – Bore × Stroke mm (in) 4 – 94 × 100 (3.7 × 3.9)
Total displacement cc (cu·in) 2776 (169)
Compression ratio – 18 : 1
Low idle (No–load) 900 ± 30
rpm
High idle (No–load) 2450 ± 30
Fuel consumption (rated) g/PS·h (g/kW·h) 165 (221)
Capacity Liter (gal) 90 (23.4)
Fuel tank
Filter – 60#
Firing order – 1 – 3 – 4 – 2
Nozzle pressure kgf / cm2 (psi) 220 ∼ 230 (3128 ∼ 3270)
Inlet 0.15 ∼ 0.25 (0.006 ∼ 0.010)
Valve
clearance
mm
(in)
Exhaust 0.15 ∼ 0.25 (0.006 ∼ 0.010)
Direction of rotation – Counterclockwise (viewed from flywheel)
Lubrication oil – SAE class CF
Oil pan capacity Maximum/Minimum Liter (gal) 9.7 (2.5) / 6.4 (1.7)
Weight of engine (dry ) kg/lb 230/506
Starter motor – 12 V – 2.3 kW
Alternator – 12 V – 40 A

6. Service Information
Document Title: Function Group: Information Type: Date:
Maintenance standards 200 Service Information 2015/3/29
Profile:
Maintenance standards
Engine tuning
Maintenance standard, engine tuning
Inspection item Unit Standard Limit
Gap at inlet/exhaust valve heads mm (in) 0.15 ∼ 0.25
(0.006 ∼ 0.010)
–
Used part mm (in) 10 ∼ 15 (0.39 ∼ 0.59) –
V–belt tension
98N finger pressure (10 kgf/cm2) New part mm (in) 7 ∼ 9 (0.28 ∼ 0.35) –
Fuel injection pressure kgf/cm2 (psi) 220 ∼ 230
(3124 ∼ 33266)
–
Fuel injection timing (FID, bTDC) (degree) bTDC 10 ∼ 12 –
Maximum rpm 2450 ± 30 –
No load rpm
Minimum rpm 900 ± 30 –
Compression at 250 rpm kgf/cm2 (psi) 35 ± 1 (497 ± 14.2) –
Top clearance mm (in) 0.737 ∼ 0.869
(0.029 ∼ 0.034)
–
Coolant capacity (engine only) Liter (gal) 4.2 (1.1) –
High Liter (gal) 9.7 (2.5) –
Lubricating oil capacity (oil pan)
Low Liter (gal) 6.4 (1.7) –
Maximum (in cold
state)
kgf/cm2 (psi) 6.0 (85) –
Lubricating oil pressure
At rated output kgf/cm2 (psi) 3.0 ∼ 4.0 (43 ∼ 57) –
At idling kgf/cm2 (psi) 1.0 (14) or above –
Oil pressure switch operating pressure kgf/cm2 (psi) 0.5 ± 0.1 (7 ± 1) –
Thermostat valve opening temperature °C (°F) 82.0 ∼ 95.0 (full open) (180
∼ 203)
–


FID : Fuel Injection Degree
bTDC : before Top Dead Center
Engine body
Maintenance standard, cylinder head, unit : mm (in)
Inspection item Standard Limit
Combustion surface distortion Maximum 0.05 (0.002) 0.15 (0.006)
Inlet 0.5 ∼ 0.7(0.020 ∼ 0.027) 1.0 (0.039)
Valve seat Valve sink
Exhaust 0.6 ∼ 0.8 (0.024 ∼ 0.031) 1.1 (0.043)
Intake 1.3 (0.051) 2.0 (0.079)
Seat width
Exhaust 2.2 (0.087) 3.0 (0.118)
Intake 120 –
Seat angle (degree)
Exhaust 90 –
Seat correction angle (degree) θ1 : 40, θ2 : 150 –

7. Maintenance standard, inlet/exhaust valve guide, unit : mm (in)
Inspection item Standard Limit
Valve stem outside diameter 7.965 ∼ 7.980 (0.3136 ∼ 0.3142) 7.915 (0.3116)
Inlet
Guide inside diameter 8.015 ∼ 8.030 (0.3156 ∼ 0.3`61) 8.100 (0.3189)
Clearance 0.035 ∼ 0.065 (0.0014 ∼ 0.0026) 1.185 (0.0073)
Valve stem outside diameter 7.955 ∼ 7.970 (0.3132 ∼ 0.3138) 7.905 (0.3112)
Outlet
Guide inside diameter 8.015 ∼ 8.030 (0.3156 ∼ 0.3161) 8.100 (0.3189)
Clearance 0.045 ∼ 0.075 (0.0018 ∼ 0.0029) 0.195 (0.0077)
Valve guide driving–in method Cold–fitted –
Valve guide protection from cylinder head 14.7 ∼ 15.0 (0.5789 ∼ 0.591) –
Replacement valve guide inside diameter after insert 8.015 ∼ 8.030 (0.3156 ∼ 0.3161) –
Maintenance standard, valve spring, unit : mm (in)
Inspection item Standard Limit
Free length 47.5 (1.87) –
Inclination – 1.0 (0.039)
Load for compressing uneven pitch portion by 1 mm 2.257 kgf (4.97 lb) –
Maintenance standard, rocker arm and shaft, unit : mm (in)
Inspection item Standard Limit
Arm shaft hole diameter 18.50 ∼ 18.52 (0.7283 ∼ 0.7291) 18.57 (0.7311)
Shaft outside diameter 18.47 ∼ 18.49 (0.7272 ∼ 0.7279) 18.44 (0.7260)
Clearance 0.01 ∼ 0.05 (0.0004 ∼ 0.0020) 0.13 (0.005)
Maintenance standard, push rod, unit : mm (in)
Inspection item Standard Limit
Bend – 0.03 (0.0012)
Maintenance standard, cam shaft, unit : mm (in)
Inspection item Standard Limit
Side gap 0.05 ∼ 0.20 (0.002 ∼ 0.008) 0.30 (0.012)
Bending (1/2 the dial gauge reading) 0.0 ∼ 0.02 (0.00 ∼ 0.0008) 0.05 (0.002)
Cam height 42.435 ∼ 42.565 (1.6707 ∼ 1.6758) 42.185 (1.6608)
Camshaft outside diameter 49.925 ∼ 49.950 (1.9656 ∼ 1.9665) 49.890 (1.9642)
Gear side
Bushing inside diameter 49.990 ∼ 50.055 (1.9681 ∼ 1.9707) 50.130 (1.9736)
Clearance 0.040 ∼ 0.130 (0.0016 ∼ 0.0051) 0.240 (0.0094)
Camshaft outside diameter 49.910 ∼ 49.935 (1.9650 ∼ 1.9659) 49.875 (1.9636)
Intermediate
Block inside diameter 50.000 ∼ 50.025 (1.9685 ∼ 1.9695) 50.100 (1.9724)
Clearance 0.065 ∼ 0.115 (0.0026 ∼ 0.0045) 0.225 (0.0089)
Camshaft outside diameter 49.925 ∼ 49.950 (1.9656 ∼ 1.9665) 49.980 (1.9642)
Flywheel
Block inside diameter 50.000 ∼ 50.025 (1.9685 ∼ 1.9695) 50.100 (1.9724)
Clearance 0.050 ∼ 0.100 (0.0020 ∼ 0.0039) 0.210 (0.0083)
Maintenance standard, idle gear shaft and bushing, unit : mm (in)
Inspection item Standard Limit
Shaft outside diameter 49.950 ∼ 49.975 (1.8091 ∼ 1.9675) 45.900 (1.8071)

8. Bushing inside diameter 46.000 ∼ 46.025 (1.8110 ∼ 1.8120) 46.075 (1.8140)
Clearance 0.025 ∼ 0.075 (0.0010 ∼ 0.0030) 0.175 (0.007)
Maintenance standard, backlash of each gear, unit : mm (in)
Inspection item Standard Limit
Crank gear, cam gear, idle gear, fuel injection pump, gear
and PTO (power take-off) gear
0.08 ∼ 0.14 (0.0031 ∼ 0.0055) 0.16 (0.0063)
Lubricating oil pump gear 0.09 ∼ 0.15 (0.0035 ∼ 0.0059) 0.17 (0.0067)
Maintenance standard, cylinder block, unit : mm (in)
Inspection item Standard Limit
4TNE94 94.000 ∼ 94.030 (3.7008 ∼ 3.7020) 94.130 (3.7059)
Cylinder bore Inner diameter
4TNE98 98.000 ∼ 98.030 (3.8583 ∼ 3.8594) 98.130 (3.8634)
Roundness 0.01 (0.0004) or less 0.03 (0.012)
Cylindricity 0.01 (0.0004) or less 0.03 (0.012)
Maintenance standard, crank shaft, unit : mm (in)
Inspection item Standard Limit
Bending (1/2 the dial gauge reading) – 0.02 (0.0008)
Pin outside diameter 57.952 ∼ 57.962 (2.2816 ∼ 2.2820) 57.902 (2.2796)
Crank pin
– 1.492 ∼ 1.500 (0.0587 ∼ 0.0591) –
Metal thickness
US 0.25 1.617 ∼ 1.625 (0.0637 ∼ 0.0640) –
Clearance 0.038 ∼ 0.074 (0.0015 ∼ 0.0029) 0.150 (0.0059)
Journal outside diameter 64.952 ∼ 64.962 (2.5572 ∼ 2.576) 64.902 (2.5552)
Crank journal
– 1.995 ∼ 1.980 (0.0760 ∼ 0.0780) –
Metal thickness
US 0.25 2.125 ∼ 2.130 (0.0872 ∼ 0.0839) –
Clearance 0.038 ∼ 0.074 (0.0015 ∼ 0.0027) 0.150 (0.0059)
Maintenance standard, thrust bearing, unit : mm (in)
Inspection item Standard Limit
Crankshaft side gap 0.11 ~ 0.21(0.0043 ~ 0.0083) –
Thrust bearing thickness 1.930 ~ 1.980(0.0760 ~ 0.0780) 1.850 (0.0728)
Oversize 0.25 2.055 ~ 2.105(0.0809 ~ 0.0829) –
Maintenance standard, piston and ring, unit : mm (in)
Inspection item Standard Limit
– 93.945 ~ 93.955 (3.6986 ~ 3.6990) 93.900 (3.6969)
Piston outside
diameter
Standard
Oversize 0.25 94.195 ~ 94.205 (3.7085 ~ 3.7089) –
Oversize 0.50 94.445 ~ 94.455 (3.7183 ~ 3.7187) –
Clearance with cylinder bore
Note) Measure at 22 mm above the piston bottom face in
vertical direction to the piston pin.
0.050 ~ 0.080 (0.0020 ~ 0.0031) 0.120 (0.0047)
Pin outside diameter 29.989 ~ 30.000 (1.1807 ~ 1.1811) 29.959 (1.1795)
Piston pin
Hole inside diameter 30.000 ~ 30.009 (1.1811 ~ 1.1815) 30.039 (1.1826)
Clearance 0.000 ~ 0.020 (0.000 ~ 0.0008) 0.080 (0.0031)
Ring groove width 2.040 ~ 2.060 (0.0803 ~ 0.0811) –
Top ring
Ring width 1.940 ~ 1.960 (0.0764 ~ 0.0772) 1.920 (0.0756)

9. Side clearance 0.080 ~ 0.120 (0.0031 ~ 0.0047) –
End clearance 0.250 ~ 0.450 (0.0098 ~ 0.0177) 0.540 (0.0213)
Ring groove width 2.080 ~ 2.095 (0.0819 ~ 0.0825) 2.195 (0.0864)
Second ring
Ring width 1.970 ~ 1.990 (0.0776 ~ 0.0783) 1.950 (0.0768)
Side clearance 0.090 ~ 0.125 (0.0035 ~ 0.0049) 0.245 (0.0096)
End clearance 0.450 ~ 0.650 (0.0177 0.0256) 0.730 (0.0287)
Ring groove width 3.015 ~ 3.030 (0.1187 ~ 0.1193) 3.130 (0.1232)
Oil ring Ring width 2.970 ~ 2.990 (0.1169 ~ 0.1177) 2.950 (0.1161)
Side clearance 0.025 ~ 0.060 (0.0010 ~ 0.0024) 0.180 (0.0071)
End clearance 0.250 ~ 0.450 (0.0098 ~ 0.0177) 0.550 (0.0217)
Maintenance standard, connecting rod, unit : mm (in)
Inspection item Standard Limit
Thrust clearance 93.945 ~ 93.955 (3.6986 ~ 3.6990) 93.900 (3.6969)
Bushing inside diameter 94.195 ~ 94.205 (3.7085 ~ 3.7089) –
Small end of rod
Pin outside diameter 94.445 ~ 94.455 (3.7183 ~ 3.7187) –
Clearance 0.050 ~ 0.080 (0.0020 ~ 0.0031) 0.120 (0.0047)
Maintenance standard, tappet, unit : mm (in)
Inspection item Standard Limit
Tappet stem outside diameter 11.975 ~ 11.990 (0.4715 ~ 0.4720) 11.955 (0.4707)
Tappet hole (block) inside diameter 12.000 ~ 12.018 (0.4724 ~ 0.4731) 12.038 (0.4739)
Clearance 0.010 ~ 0.043 (0.0004 ~ 0.0017) 0.083 (0.0033)
Maintenance standard, trochoid pump (lubrication oil pump), unit : mm (in)
Inspection item Standard Limit
Clearance between outer rotor and gear case 0.100 ~ 0.155 (0.0039 ~ 0.0061) 0.25 (0.0098)
Side clearance between outer rotor and gear case 0.05 ~ 0.10 (0.0020 ~ 0.0039) 0.15 (0.0059)
Shaft outer diameter 12.955 ~ 12.970 (0.5100 ~ 0.5106) 12.945 (0.5096)
Rotor shaft
and gear case Bearing inside diameter 12.980 ~ 13.020 (0.5110 ~ 0.5126) 13.050 (0.5138)
Clearance 0.010 ~ 0.065 (0.0004 ~ 0.0026) 0.105 (0.0041)

10. Service Information
Document Title: Function Group: Information Type: Date:
Periodic maintenance chart 200 Service Information 2015/3/29
Profile:
Periodic maintenance chart
CAUTION
Make a periodic inspection plan according to the state of use. Perform periodic inspection accurately so that inspection will
not be skipped. If periodic inspection is neglected, failures may occur or durability may be lost. Inspection and maintenance
after 1000 hours require expertise and skill, so consult our dealer or distributor.
Periodic maintenance chart
Part Item Daily Every month
or Every 50
hours
Every 3
month or
Every 200
hours
Every 6
month or
Every 400
hours
Every
year or
Every
1000
hours
Check the fuel level and refill O (before operation)
Fuel oil
system Drain the fuel tank sediment O
Clean the fuel filter O
Replace the fuel filter element O
Drain the water separator if applicable O
Check for fuel oil leakage O (after operation)
Check the injection condition of fuel
injection nozzle.
S
Check the fuel injection timing S
Check the fuel injection pump S
Check the lube oil level in the oil pan
and refill
O (before operation)
Lube oil
system
Replace the lube oil O (1st time) O (2nd time
and
thereafter)
Replace lube oil filter element O (1st time) O (2nd time
and
thereafter)
Check for lube oil leakage O (after operation)
Check the coolant level and refill O (before operation)
Cooling
system Clean the cooling system O
Replace the coolant O
Check for coolant leakage O (after operation)
Check radiator fin for clogging O (before operation)
Clean the radiator fin O
Adjust the fan belt tension O (1st time) O (2nd time
and
thereafter)
Check the fan belt O (before operation)
Check the air cleaner element O
Air
induction Replace the air cleaner element O

11. system
Check the battery electrolyte level and
refill
O (before operation)
Electric
system
Check warning lamps O (when the engine is
started)
Engine
body
Adjust the inlet and exhaust valve
clearance
S
CAUTION
Item marked "S" should be serviced by an authorized Volvo Construction Equipment dealer, unless the owner has proficient
mechanical ability and the proper tools.

12. Service Information
Document Title: Function Group: Information Type: Date:
Precautions 200 Service Information 2015/3/29
Profile:
Precautions
Make preparation as follows before starting engine inspection and service.





Fix the engine on a horizontal base.
WARNING
Be sure to fix the engine securely to prevent injury or damage to parts due to falling during the work.
Remove the cooling water hose, fuel oil pipe, wire harness, control wires etc. connecting the driven machine and
engine, and drain cooling water, lubricating oil and fuel.
Clean soil, oil, dust, etc. from the engine by washing with solvent, air, steam, etc. Carefully operate so as not to let
any foreign matter enter the engine.
WARNING
Always wear glasses or other protectors when using compressed air or steam to prevent any foreign matter
from getting in the eyes.
Any part which is found defective as a result of inspection or any part whose measured value does not satisfy the
standard or limit shall be replaced.
Any part predicted to dissatisfy the standard or limit before the next service as estimated from the state of use
should be replaced even when the measured value then satisfies the standard or limit.

13. Service Information
Document Title: Function Group: Information Type: Date:
Special tools 200 Service Information 2015/3/29
Profile:
Special tools
Special tools
Special tools
Tool name Applicable model and tool size Illustration
Valve guide tool (for removing valve
guide) 



l1 : 20 mm
l2 : 75 mm
d1 : 7.5 mm
d2 : 11 mm
Valve guide tool (for inserting valve
guide) 



l1 : 15 mm
l2 : 65 mm
d1 : 14 mm
d2 : 20 mm
Connecting rod bushing replacer (for
removal/ installation of connecting
rod bushing)




l1 : 10 mm
l2 : 100 mm
d1 : 30 -0.3/-0.6 mm
d2 : 20 -0.3/-0.6 mm
Valve spring compressor (for
removal/installation of valve spring)
Part number : 129100–92630
Stem seal inserter (for inserting stem
seal) 



l1 : 19 mm
l2 : 65 mm
d1 : 16.5 mm
d2 : 23 mm
Filter wrench (for removal/installation
of lubrication oil filter)
Available on the market
Camshaft bushing tool (for removing
camshaft bushing) 



l1 : 18 mm
l2 : 70 mm
d1 : 50 -0.3/-0.6 mm
d2 : 53-0.3/-0.6 mm

14. Flex–hone (for re–honing of cylinder
liner) 


Applicable engine model :
4TNE94
Part number : 129400–92430
Applicable bore : 83 ∼ 95
Piston insertion tool (for inserting
piston)
Part number : 95550–002476
The above piston insertion tool is
applicable to 60 ∼ 125 (mm) diameter
piston
Piston ring replacer (for removal/
installation of piston ring)
Available on the market
Measuring tools
Measuring tools
Instrument name Application Illustration
Dial gauge Measurements of shaft bending, strain
and gap of surface
Test indicator Measurements of narrow or deep
portions that cannot be measured by dial
gauge.
Magnetic stand For holding the dial gauge when
measuring using a dial gauge, standing
angles adjustable
Micrometer For measuring the outside diameter of
crankshaft, pistons, piston pins, etc.
Cylinder gauge For measuring the side diameters of
cylinder liners, rod metal, etc.
Callipers For measuring outside diameters, depth,
thickness, etc.
Depth micrometer For measuring of valve sink

15. Square For measuring valve spring inclination
and straightness of parts
V–block For measuring shaft bend
Torque wrench For tightening nuts and screws to the
specified torque
Feeler gauge For measuring gaps between ring and
ring groove, and shaft joints during
assembly
Cap tester For checking radiator cap relief valve and
cooling system leakage
Battery/coolant tester For checking concentration of antifreeze
and specific gravity of the battery
electrolyte
Nozzle tester For measuring injection spray pattern of
fuel injection nozzle and injection
pressure
Digital thermometer For measuring temperature
Speedometer (contact type) For measuring revolution by contacting
the mortise in the revolving shaft
Speedometer (photoelectric type) For measuring revolution by sensing the
reflecting mark on the outer periphery of
the revolving shaft
1 : Revolving shaft
2 : Reflection mark

16. Speedometer Measuring the revolution regardless of
the center or periphery of the revolving
object
1 : High pressure pipe
Circuit tester For measuring resistance voltage and
continuity of electrical circuits
Compression gauge kit For measuring compression pressure
part number : TOL–97190080

17. Service Information
Document Title: Function Group: Information Type: Date:
Tightening torque 200 Service Information 2015/3/29
Profile:
Tightening torque
Tightening torque, unit : kgf·m (lbf·ft)
Item Nominal
size
Tighten torque
Thermostat case M8 2.3 ~ 2.9 (16.6 ~ 20.9)
Cylinder head
Intake manifold M8 2.3 ~ 2.9 (16.6 ~ 20.9)
Exhaust manifold M8 2.3 ~ 2.9 (16.6 ~ 20.9)
Rocker cover M8 2.3 ~ 2.9 (16.6 ~ 20.9)
Valve arm support M10 4.5 ~ 5.5 (32.5 ~ 39.7)
* Fuel injection nozzle M6 0.7 ~ 0.9 (5.1 ~ 6.5)
Engine hoisting hook M8 2.3 ~ 2.9 (16.6 ~ 20.9)
* L Cylinder head M11 10.5 ~ 11.5 (75.8 ~ 83.0)
Cylinder block
Gear case M8 2.3 ~ 2.9 (16.6 ~ 20.9)
Idle gear shaft M8 2.3 ~ 2.9 (16.6 ~ 20.9)
Camshaft thrust bearing M8 2.3 ~ 2.9 (16.6 ~ 20.9)
Oil pan M8 2.3 ~ 2.9 (16.6 ~ 20.9)
Mounting flange M10 M8 4.5 ~ 5.5 (32.5 ~ 39.7) 2.3 ~ 2.9
(16.6 ~ 20.9)
* L Bearing cap M11 11.0 ~ 12.0 (79.4 ~ 86.6)
Lubricating oil suction pipe M8 2.3 ~ 2.9 (16.6 ~ 20.9)
Power take-off lubrication pipe M8 1.3 ~ 1.7 (9.4 ~ 12.3)
Fuel injection pump inlet pipe M8 1.3 ~ 1.7 (9.4 ~ 12.3)
Fuel injection pump rear stay M8 1.3 ~ 1.7 (9.4 ~ 12.3)
Cooling water pump M8 1.8 ~ 2.3 (13.0 ~ 16.6)
Gear case
Alternator M10 4.5 ~ 5.5 (32.5 ~ 39.7)
Gear case cover M8 1.8 ~ 2.3 (13.0 ~ 16.6)
Fuel injection pump M10 3.5 ~ 4.5 (25.3 ~ 32.5)
Oil pan M8 1.8 ~ 2.3 (13.0 ~ 16.6)
Lubricating oil pump assembly M8 1.8 ~ 2.3 (13.0 ~ 16.6)
Fuel injection pump drive gear cover M8 1.8 ~ 2.3 (13.0 ~ 16.6)
Power take-off lubrication pipe M8 1.3 ~ 1.7 (9.4 ~ 12.3)
* L Flywheel M14 19 ~ 21 (137 ~ 152)
Crankshaft
* L Crankshaft pully M14 11 ~ 13 (79.4 ~ 93.9)
Connecting rod * L Rod screw M10 5.5 ~ 6.0 (39.7 ~ 43.3)
Mounting flange Starting motor M12 8.0 ~ 10.0 (57.8 ~ 72.2)
Main bearing cap Lubricating oil suction pipe stay M8 2.3 ~ 2.9 (16.6 ~ 20.9)
Intake manifold Fuel filter M10 3.5 ~ 4.5 (25.3 ~ 32.5)
Cooling water pump Cooling fan M8 1.8 ~ 2.3 (13.0 ~ 16.6)
Fuel injection pipe M12 2.0 ~ 2.5 (14.4 ~ 18.1)
Fuel injection pump
Delivery valve holder – 6.0 ~ 7.0 (43.3 ~ 50.5)

18. Drive gear M14 8.5 ~ 9.5 (61.4 ~ 68.6)
Fuel pipe (inlet) M14 2.0 ~ 2.5 (14.4 ~ 18.1)
Fuel pipe (return) M14 2.0 ~ 2.5 (14.4 ~ 18.1)
Feed pump M6 0.8 ~ 0.96 (5.8 ~ 6.9)
Inlet pipe M10 1.0 ~ 1.3 (7.2 ~ 9.4)
Rear stay M10 4.5 ~ 5.5 (32.5 ~ 39.7)
Fuel injection pipe M12 2.0 ~ 2.5 (14.4 ~ 18.1)
Fuel injection nozzle
Nozzle holder – 4.0 ~ 4.5 (28.9 ~ 32.5)
Fuel pipe (inlet) M14 2.0 ~ 2.5 (14.4 ~ 18.1)
Fuel feed pump
Fuel pipe (outlet) M14 2.0 ~ 2.5 (14.4 ~ 18.1)
Priming pump M16 4.0 ~ 4.5 (28.9 ~ 32.5)
Plug M26 8.0 ~ 9.0 (57.8 ~ 65.0)
Fuel pipe 2.5 ~ 3.5 (18.1 ~ 25.3)
Fuel filter
Fuel return pipe M14 4.0 ~ 4.5 (28.9 ~ 32.5)
Alternator Bracket M8 2.3 ~ 2.9 (16.6 ~ 20.9)
NOTE!
* Marked : Reinforced type screw, L : Lubrication oil applied tightening torque.

19. Service Information
Document Title: Function Group: Information Type: Date:
Troubleshooting chart 200 Service Information 2015/3/29
Profile:
Troubleshooting chart
The following table summarizes the general trouble symptoms and their causes. If any trouble symptom occurs, take
corrective action before it develops into a serious problem so as not to shorten the engine service life.
Figure 1
Engine troubleshooting chart (1)

20. Figure 2
Engine troubleshooting chart (2)

21. Service Information
Document Title: Function Group: Information Type: Date:
Adjusting operation 210 Service Information 2015/3/29
Profile:
Adjusting operation
Perform adjusting operation as follows after the maintenance job :
 Supply the fuel oil, lubricating oil and coolant.
CAUTION
Check the levels of the lubricating oil and coolant again after test running (for about 5 minutes) and add as required.



Start the engine, and carry out idling at a low revolution (from 700 to 900 rpm) for a few minutes.
Run in the engine for about five minutes at the rated revolution (no–load). Check for coolant, fuel or oil leaks and
existence of abnormal vibration or noise. Also check the oil pressure, coolant temperature and exhaust gas color.
Adjust the no–load minimum and maximum revolutions according to the specifications.
Long storage
Observe the following instructions when the engine is to be stored for a long period without operation :
 Always drain cooling water in a cold season or before a long storage. (This is unnecessary when antifreeze is used.)
CAUTION
Negligence of water draining will cause the water remaining inside the engine to freeze and expanded, damaging the engine
cooling system components.
 Coolant draining procedure
1.
2.
3.
4.
Remove the radiator cap.
Loosen the draining cock under the radiator to drain coolant.
Loosen the drain cock on the side of the engine block to drain coolant.
After draining coolant, tighten the radiator cap and drain plug and cocks.







Remove all mud, dust, oil deposits and thoroughly clean the engine and attached components.
Perform the nearest periodic inspection before the storage.
Drain or fill the fuel oil fully to prevent condensation in the fuel tank.
Disconnect the battery cable from the battery negative terminal.
Cover the silencer, air cleaner and electric parts with PVC cover to prevent water and dust from depositing or
entrance.
Select a well–ventilated location without moisture and dust for storage.
Perform battery recharging once a month during storage to compensate for self–discharge.

22. Service Information
Document Title: Function Group: Information Type: Date:
Compression pressure
inspection
210 Service Information 2015/3/29
Profile:
Compression pressure inspection
Compression pressure drop is one of major causes of increasing blowby gas (lubricating oil contamination or increased
lubricating oil consumption as a resultant phenomenon) or starting failure. The compression pressure is affected by the
following factors :
1.
2.
3.
Degree of clearance between piston and cylinder
Degree of clearance at intake/exhaust valve seat
Gas leak from nozzle gasket or cylinder head gasket
In other words, the pressure drops due to increased parts wear and reduced durability resulting from long use of the engine.
A pressure drop may also be caused by scratched cylinder or piston by dust entrance from the dirty air cleaner element or
worn or broken piston ring. Measure the compression pressure to diagnose presence of any abnormality in the engine.
Compression pressure measurement method
1.
2.
3.
4.
5.
After warming up the engine remove the fuel injection nozzle from the cylinder to be measured.
Before installing the compression gauge, cut off the fuel supply by the adjusting lever and check if fuel comes out
while rotating the flywheel manually.
Install the compression gage and compression gage adapter at the cylinder to be measured.
Figure 1
Measuring the compression pressure
1. Compression gauge
CAUTION
Do not forget to install a gasket at the tip end of the adapter.
Install the compression gage and compression gage adapter at the cylinder to be measured.
Crank the engine by the starting motor until the compression gage reading is stabilized.
Standard compression pressure



Standard : 35 ± 1 kgf/cm2 (497 ± 14.2 psi)
Limit : 27 kgf/cm2 (383.4 psi)
Difference among cylinders : 2 ~ 3 kgf/cm2 (28.4 ~ 42.6 psi)
Engine speed and compression pressure

23. Figure 2
Engine speed and compression pressure


P : Compression pressure
N : Engine speed
Check items
When the measured compression pressure is below the limit value, inspect each part by referring to the table below.
Compression pressure check items
Item Cause Corrective action
Air cleaner element Clogged element
Broken element
Defect at element seal portion
Clean the element
Replace the element
Valve clearance Excessive or no clearance Adjust the valve clearance
Valve timing Incorrect valve clearance Adjust the valve clearance
Cylinder head gasket Gas leak from gasket Replace gasket
Retighten the cylinder head screws to the
specified torque
Inlet/exhaust valve
Valve seat
Gas leak due to worn valve seat or foreign
matter
Sticking valve
Lap the valve seat
Replace the inlet/exhaust valve
Piston
Piston ring
Cylinder
Gas leak due to scoring or wear Perform honing or boring/honing and use
an oversized part

24. Service Information
Document Title: Function Group: Information Type: Date:
Cylinder head,
disassembly/assembly
2111 Service Information 2015/3/29
Profile:
Cylinder head, disassembly/assembly
Disassemble in the order of the numbers shown in the illustration. (service point)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
Remove the alternator assembly. (service point 1)
Remove the fan, pulley and V–belt.
Remove the thermostat case. (service point 2)
Remove the fuel filter and fuel oil piping. (service point 3)
Remove the oil level gauge assembly.
Remove the oil filter. (service point 4)
Remove the fuel injection pipes. (service point 5)
Remove the intake manifold assembly.
Remove the exhaust manifold assembly.
Remove the rocker cover.
Remove the rocker shaft assembly, push rods and valve caps. (service point 6)
Remove the cylinder head assembly and head gasket. (service point 7)
Remove the fuel injection valves and fuel return pipe. (service point 8)
Remove the intake/exhaust valves, stem seals and valve springs. (service point 9)
Remove the rocker arms from the rocker shaft.
For assembly, reverse the procedure.
Service points
Point 1
Disassemble :
 Loosen the mounting screw while supporting the alternator.
CAUTION
Do not tilt the alternator toward the cylinder block in a haste since it may damage the alternator or pinch a finger.
Reassemble :
 The belt deflection shall be between 10 ~ 15 mm (7 ~ 9 mm for a new belt).
Figure 1
V–belt tension
1.
2.
3.
Cooling water pump
Crankshaft pulley
Alternator

25. 

Replace the belt with a new one if cracked, worn or damaged.
Carefully prevent the belt from being smeared with oil or grease.
Figure 2
Tension adjustment
1.
2.
3.
Adjuster
Alternator
Adjust the V–belt tension by inserting a bar
Point 2
Reassemble :
 Check the thermostat function.
Point 3
Reassemble :
 Replace the fuel filter element with a new one.
Disassemble :
 Cover the fuel pipe opening with tape to prevent intrusion of foreign matter.
Point 4
Reassemble :


Replace the oil filter with a new one.
After fully tightening the filter manually, retighten it with a filter wrench by 3/4 turn.
Point 5
Disassemble :
 Cover the fuel injection pipe and pump inlets and outlets with tape or the like to prevent intrusion of foreign
matter.
Point 6
Disassemble :
 Keep the removed push rods by attaching tags showing corresponding cylinder numbers.
Reassemble :
 Always apply oil to the contact portions of the push rods and valve clearance adjusting screws.
Point 7
Disassemble :

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27. 

Loosen the cylinder head screws in two steps in the illustrated order.
Figure 3
Head screw disassembly order
1. Fan side
Place the cylinder head assembly on card board to prevent any damage to the combustion face.
Reassemble :



Replace the head gasket with a new one.
Uniformly install the head screws manually after applying oil on the threads and seat portions.
Figure 4
Head screw tightening order
1. Fan side
They shall be tightened in two steps in the reverse of the order for disassembly.
Tightening torque :


First step : 5 ~ 6 kgf·m (36.1 ~ 43.3 lbf·ft)
Second step : 10.5 ~ 11.5 kgf·m (75.8 ~ 83.0 lbf·ft)
Point 8
Disassemble :
 Carefully remove the fuel injection valve so as not to leave the tip end protector from being left inside the cylinder.
Reassemble :
 Replace the fuel injection valve protector with a new one.
Point 9
Disassemble :



When removing each inlet/exhaust valve from the cylinder head, use a valve spring compressor and compress the
valve spring and remove the valve cotter.
Figure 5
Valve spring compressor
Keep each removed inlet/exhaust valve after attaching a tag showing the corresponding cylinder number.
If cotter burr is seen at the shaft of each inlet/exhaust valve stem, remove it with an oil stone and extract the valve
from the cylinder head.
Reassemble :