J08c руководство по ремонту

Models

1INDEX

ENGINE 3-1-1

J08C-TP and J08C-TR

3-228E-05

TROUBLESHOOTING ………………………………………………………

3- 1-3

SPECIAL TOOLS …………………………………………………………….

3- 2-1

ENGINE OVERHAUL CRITERIA ……………………………………….

3- 3-1

DISMOUNTING THE ENGINE ASSEMBLY …………………………

3- 4-1

REMOVAL OF THE ENGINE COMPONENT PARTS ……………

3- 5-1

CAMSHAFT HOUSING AND CYLINDER HEAD ………………….

3- 6-1

CRANKSHAFT FRONT END, OIL PAN, FLYWHEEL AND

FLYWHEEL HOUSING ……………………………………………………..

3- 7-1

TIMING GEAR …………………………………………………………………

3- 8-1

PISTON, CRANKSHAFT AND CYLINDER BLOCK ……………..

3- 9-1

LUBRICATING SYSTEM …………………………………………………..

3- 10-1

COOLING SYSTEM ………………………………………………………….

3- 11-1

FUEL SYSTEM ………………………………………………………………..

3- 12-1

AIR INTAKE AND EXHAUST SYSTEM ………………………………

3- 13-1

ENGINE CONTROL SYSTEM ……………………………………………

3- 14-1

ELECTRICAL PARTS ……………………………………………………….

3- 15-1

AIR COMPRESSOR AND POWER STEERING PUMP …………

3- 16-1

INSTALLATION OF THE ENGINE COMPONENT PARTS …….

3- 17-1

ENGINE TUNE-UP …………………………………………………………..

3- 18-1

MOUNTING THE ENGINE ASSEMBLY ………………………………

3- 19-1

LIQUID GASKET AND APPLICATION POINTS …………………..

3- 20-1

POWER TAKE-OFF (IF FITTED) ……………………………………….

3- 21-1

3-1-2 ENGINE

Models

1 page 1

J08C-TP and J08C-TR

Symptom

Possible cause

Remedy/Prevention

Engine overheating

Coolant

●

Insufficient coolant ………………………………….

Add coolant

`

●

Defective thermostat ……………………………….

Replace the thermostat

● Overflow of coolant due to leakage of ……….

Repair

exhaust into cooling system

●

Damaged rubber hose …………………………….

Replace rubber hose

● Coolant leakage due to deteriorated ………….

Replace rubber hose

rubber hose

● Coolant leakage from coolant pump ………….

Replace the coolant pump

● Coolant leakage from rubber hose ……………

Retighten or replace clamp

connection

● Coolant leakage from cylinder head ………….

Replace gasket

gasket

Coolant pump

●

Bearing seizure ………………………………………

Replace

●

Damaged (corroded) vane ……………………….

Replace vane

Radiator

● Clogged with rust and scale ……………………..

Clean radiator

● Clogged with iron oxide due to leakage ……..

Clean coolant passage and

of exhaust into cooling system

correct exhaust leakage

●

Coolant leakage ……………………………………..

Repair or replace radiator

●

Damaged cooling fan ………………………………

Replace cooling fan

● Clogged radiator core due to mud or …………

Clean radiator

other debris

● Defective radiator cap pressure valve ……….

Replace radiator cap

Abnormal combustion

●

Incorrect injection timing ………………………….

Adjust injection timing

●

Reduced injection pressure ……………………..

Adjust injection pressure

●

Poor fuel………………………………………………..

Use good quality fuel

●

Poor nozzle spray …………………………………..

Adjust or replace nozzle

●

Unsatisfactory automatic timer………………….

Repair or replace timer

advance angle

1 page 1

Models J08C-TP and J08C-TR

ENGINE 3-1-3

Symptom

Possible cause

Remedy/Prevention

Engine overheating

Other problems

●

Defective or deteriorated engine oil …………..

Change engine oil

●

Unsatisfactory operation of oil pump …………

Replace or repair

●

Insufficient oil …………………………………………

Add oil

●

Brake drag …………………………………………….

Adjust

Severe operating conditions

●

Lugging the engine …………………………………

Operate engine properly

Excessive oil consumption

Pistons, cylinder liners and piston rings

●

Wear of piston rings and cylinder liner ……….

Replace piston rings and

cylinder liner

●

Worn, sticking or broken piston rings …………

Replace piston rings and

cylinder liner

●

Insufficient tension on piston rings …………….

Replace piston rings and

cylinder liner

●

Unsatisfactory break-in of piston rings ……….

Replace piston rings and

cylinder liner

●

Unsuitable oil (viscosity too low) ……………….

Change oil as required and

replace piston rings and

cylinder liner

●

Incorrectly fitted piston rings (upside down) ..

Replace piston rings

●

Gaps of piston rings in line with each other ..

Reassemble piston rings

Valves and valve guides

●

Worn valve stem …………………………………….

Replace valve and valve guide

●

Worn valve guide ……………………………………

Replace valve guide

●

Incorrectly fitted valve stem seal ……………….

Replace the stem seal

●

Excessive lubricant on rocker arm …………….

Check clearance of rocker arm

and shaft

Excess oil feed

●

Defective oil level gauge ………………………….

Replace oil level gauge

●

Oil level too high …………………………………….

Drain excess oil

3-1-4 ENGINE

Models

1 page 1

J08C-TP and J08C-TR

Symptom

Possible cause

Remedy/Prevention

Excessive oil consumption

Oil leakage from miscellaneous parts

● Oil leakage from oil seal…………………………..

Replace oil seal

● Cracks or blowhole in cylinder block ………….

Replace cylinder block

● Oil leakage from connections of oil lines ……

Tighten connections of oil lines

● Oil leakage from oil cooler ……………………….

Replace oil cooler

● Oil leakage from oil pan gasket ………………..

Replace oil pan gasket

● Oil leakage from O-ring ……………………………

Replace O-ring

Other problems

●

Overcooled engine ………………………………….

Warm up engine before moving

(low temperature wear)

vehicle

Check cooling system

Piston seizure

Pistons, cylinder liners and piston rings

● Incorrect clearance between piston …………..

Replace piston, piston rings

and cylinder liner

and cylinder liner

● Unsatisfactory installation of piston pin ………

Replace piston, piston rings,

cylinder liner and piston pin as

required

●

Broken piston ring …………………………………..

Replace piston, piston rings

and cylinder liner

● Difference in expansion due to use of ………..

Replace piston, piston rings

wrong piston

and cylinder liner

1 page 1

Models J08C-TP and J08C-TR

ENGINE 3-1-5

Symptom

Possible cause

Remedy/Prevention

Piston seizure

Coolant

●

Reduction in capacity of coolant pump ………

Replace the coolant pump

(due to vane corrosion)

●

Leakage of coolant………………………………….

Repair

●

Insufficient coolant ………………………………….

Add coolant

●

Dirty coolant …………………………………………..

Clean and replace coolant

●

Defective radiator ……………………………………

Repair or replace the radiator

(coolant leakage, clogging)

●

Defective rubber hose (leakage) ……………….

Replace rubber hose

●

Defective thermostat ……………………………….

Replace the thermostat

●

Leakage of exhaust into cooling system …….

Repair

Operation

●

Abrupt stoppage of engine after running ……

Operate engine properly

at high speed

●

Hill climbing using unsuitable gear ……………

Select suitable gear

Oil

●

Insufficient oil …………………………………………

Add oil

●

Dirty oil ………………………………………………….

Change oil

●

Poor quality oil ……………………………………….

Replace with proper engine oil

●

High oil temperature………………………………..

Repair

●

Low oil pressure ……………………………………..

Repair

●

Defective oil pump ………………………………….

Repair oil pump

●

Reduced performance due to worn …………..

Replace oil pump

oil pump

●

Suction strainer sucking air ………………………

Add oil and/or repair strainer

Abnormal combustion

●

Use of defective fuel ……………………………….

Change fuel

●

Incorrect injection timing ………………………….

Adjust injection timing

●

Engine overheating …………………………………

See Symptom: “Engine

overheating”

3-1-6 ENGINE

Models

1 page 1

J08C-TP and J08C-TR

Symptom

Possible cause

Remedy/Prevention

Lack of power

Injection pump

Refer to “FUEL INJECTION

……………………………………..

PUMP”

Intake

●

Clogged air cleaner …………………………………

Clean element or replace

element

Overheating

See Symptom: “Engine

………………………………………..

overheating”

Fuel and nozzle

●

Poor nozzle spray …………………………………..

Adjust or replace injection

nozzle

● Nozzle clogged with carbon ……………………..

Clean nozzle

● Wear or seizure of nozzle ………………………..

Replace nozzle

● Air in fuel system…………………………………….

Repair and bleed air from fuel

system

●

Clogged fuel filter ……………………………………

Replace element

● Use of poor fuel………………………………………

Use good quality fuel

Pistons, cylinder liners and piston rings

● Seized or wear of piston ………………………….

Replace the piston, piston rings

and liner

● Worn or broken piston rings, ……………………. Replace piston rings, piston

piston and cylinder liner

and liner

1 page 1

Models J08C-TP and J08C-TR

ENGINE 3-1-7

Symptom

Possible cause

Remedy/Prevention

Lack of power

Other problems

● Exhaust brake butterfly valve stuck……………

Replace or repair exhaust

in half-open position

brake

●

Connecting rod bent ………………………………..

Replace or repair connecting

rod

● Exhaust pipe or muffler crushed ……………….

Replace exhaust pipe or

(increased back-pressure)

muffler

● Breakage of turbine or blower …………………..

Refer to TURBOCHARGER in

CHAPTER 51

Leakage of exhaust

Head gasket

●

Fatigued gasket (aging) …………………………..

Replace gasket

●

Damage…………………………………………………

Replace gasket

●

Improper installation ………………………………..

Replace gasket

Head bolts

●

Loose bolts …………………………………………….

Tighten bolts

●

Elongated bolts ………………………………………

Replace bolts

● Improper tightening torque or ……………………

Tighten properly

tightening sequence

Cylinder block

●

Cracking ………………………………………………..

Replace cylinder block

●

Surface distortion ……………………………………

Repair or replace

● Fretting of cylinder liner insertion portion ……

Replace cylinder block

(insufficient projection of cylinder liner)

Cylinder head

●

Cracking ………………………………………………..

Replace cylinder head

●

Surface distortion ……………………………………

Repair or replace

Cylinder liners

●

Cracking ………………………………………………..

Replace cylinder liner

●

Corrosion……………………………………………….

Replace cylinder liner

● Insufficient projection of cylinder liner ………..

Replace cylinder liner

3-1-8 ENGINE

Models

1 page 1

J08C-TP and J08C-TR

Symptom

Possible cause

Remedy/Prevention

Leakage of exhaust

Other problems

●

Incorrect injection timing ………………………….

Adjust injection timing

Difficulty starting engine

Electrical system

●

Discharged battery ………………………………….

Charge battery

● Defective wiring in starter-circuit ……………….

Repair wiring of starter

● Loose or open-circuit battery cable ……………

Tighten battery terminal

connections or replace battery

cable

●

Breakdown of starter ……………………………….

Replace starter

●

Broken glow plug ……………………………………

Replace

Injection pump

………………………………………

Refer to “FUEL INJECTION

PUMP”

Air cleaner

●

Clogged element …………………………………….

Clean the element or replace

the element

Fuel system

● No fuel in tank ………………………………………..

Supply fuel

●

Clogged fuel line …………………………………….

Clean fuel line

● Air sucked into fuel system through …………..

Tighten fuel line connections

fuel line connections

●

Clogged fuel filter ……………………………………

Replace element

● Loose connection in high-pressure line ……..

Tighten sleeve nut of high

pressure line

●

Water in fuel …………………………………………..

Drain and clean fuel system

1 page 1

Models J08C-TP and J08C-TR

ENGINE 3-1-9

Symptom

Possible cause

Remedy/Prevention

Difficulty starting engine

Nozzles

●

Seized nozzle…………………………………………

Replace nozzle

● Broken or fatigued nozzle spring ………………

Replace spring

Oil system

● Oil viscosity too high ……………………………….

Use proper viscosity oil, or

install an oil immersion heater

and warm up oil

Other problems

●

Seized piston …………………………………………

Replace piston, piston rings,

and liner

●

Seized bearing ……………………………………….

Replace bearing and crankshaft

●

Reduced compression pressure ……………….

Overhaul engine

● Ring gear damaged or worn …………………….

Replace the ring gear and/or

accelerator cable

starter pinion

● Improperly adjusted or broken ………………….

Adjust or replace the

accelerator cable

Rough idling

Injection pump

……………………………………..

Refer to “FUEL INJECTION

PUMP”

Nozzles

●

Uneven injection pressure ……………………….

Adjust

●

Poor nozzle spray …………………………………..

Adjust or replace nozzle

● Carbon deposit on nozzle tip ……………………

Remove carbon

●

Seized needle valve ………………………………..

Replace nozzle

Engine proper

●

Improper valve clearance ………………………..

Adjust valve clearance

● Improper contact of valve seat ………………….

Replace or repair valve and

valve seat

● Idling speed too low ………………………………..

Adjust idling speed

● Coolant temperature too low …………………….

Warm up engine

● Compression pressure of cylinders……………

Overhaul engine

markedly different from one another

3-1-10 ENGINE

Models

1 page 1

J08C-TP and J08C-TR

Symptom

Possible cause

Remedy/Prevention

Rough idling

Other problems

● Clogged high pressure injection line ………….

Replace line

● Leakage due to improper tightening ………….

Tighten sleeve nut

of high pressure injection line

● Improperly adjusted or broken ………………….

Adjust or replace accelerator

accelerator cable

cable

●

Engine seizure ……………………………………….

Replace pistons, piston rings

and liners

●

Incorrect valve timing ………………………………

Replace camshaft

Diesel knock

Refer to “FUEL INJECTION

Injection pump………………………………………..

PUMP”

Nozzles

●

Incorrect injection pressure ………………………

Adjust

●

Poor nozzle spray …………………………………..

Adjust or replace nozzle

●

Sticking of nozzle ……………………………………

Check and/or replace

● Fatigued or broken nozzle spring ……………..

Replace spring

Fuel system

● Use of poor fuel………………………………………

Use good quality fuel

● Fuel leakage into combustion chamber ……..

Adjust nozzles

(during engine starting)

Other problems

● Excessively cooled or heated engine ………..

Warm up or cool engine

●

Insufficient air intake ……………………………….

Correct

●

Insufficient compression pressure …………….

Repair

● Compression pressure leaks at ………………..

Replace head gasket

cylinder head gasket

● Improper valve clearance or valve sticking …

Adjust or repair

●

Tappet sticking ……………………………………….

Replace tappet and camshaft

1 page 1

Models J08C-TP and J08C-TR

ENGINE 3-1-11

Symptom

Possible cause

Remedy/Prevention

Unusual engine noise

Piston

●

Wear of piston pin boss or piston pin …………

Replace piston and/or piston

pin

●

Seized, damaged, or worn piston pin ………..

Replace piston pin bushing.

bushing

●

Worn pistons or cylinder liners ………………….

Replace piston or cylinder liner

●

Damaged or seized piston ……………………….

Replace piston and cylinder

liner

●

Foreign matter on top surface of the piston ..

Remove foreign matter and

repair or replace piston, cylinder

liner, and/or cylinder head

Valve mechanism

●

Incorrect valve clearance …………………………

Adjust valve clearance

●

Valve cotter out of place …………………………..

Replace valve cotter

●

Seized valve stem …………………………………..

Replace valve and valve guide

●

Broken valve ………………………………………….

Replace valve

●

Damaged rocker arm support …………………..

Replace rocker arm support

●

Broken valve spring ………………………………..

Replace valve spring

Bearings seizure

●

Insufficient lubricating oil ………………………….

Add oil

●

Excessive or insufficient tightening of ………..

Retighten to specified torque

bearing housings

●

Pits and scratches on bearing surface ……….

Replace bearing and crankshaft

●

Oil film formed on back of bearing …………….

Replace bearing

●

Improper installation of bearing ………………..

Replace bearing

●

Reduction of spread dimension of bearing …

Replace bearing

●

Distorted bearing housing ………………………..

Replace or correct bearing

housing

●

Excessive oil clearance……………………………

Replace bearing

3-1-12 ENGINE

Models

1 page 1

J08C-TP and J08C-TR

Symptom

Possible cause

Remedy/Prevention

Unusual engine noise

Various other parts

● Exhaust gas leakage from exhaust ……………

Retighten joints

pipe joints

● Loosen or missing intake manifold ……………

Retighten or replace

flange gasket

● Intake valve seating is not concentric ………..

Replace or correct the valve

and valve seat

●

Intake gas leakage ………………………………….

Retighten

Other problems

● Loose cooling fan mounting bolts or ………….

Tighten the fan and

fan pulley nut

crankshaft pulley

● Lack of lubricating oil ………………………………

Lubricate

(coolant pump, valves, etc.)

●

Worn timing gear …………………………………….

Replace the timing gear

● Breakage of turbine or blower …………………..

Refer to TURBOCHARGER in

CHAPTER 51

1 page 1

Models J08C-TP and J08C-TR

ENGINE 3-1-13

Symptom

Possible cause

Remedy

Engine does not start

Fuel not reaching injection pump

● Fuel lines clogged or damaged …………………

Clean or replace fuel lines

●

Fuel filter clogged …………………………………..

Clean or replace the filter

element

● Air in fuel caused by improper ………………….

Repair connections

connections of fuel line between

fuel tank and feed pump

● Filter incorporated in inlet side ………………….

Remove foreign material

of feed pump clogged

● Faulty feed pump check valve ………………….

Repair or replace it

● Feed pump piston spring broken ………………

Replace it

● Feed pump push rod or tappet sticking ……..

Repair or replace it

Fuel reaching injection pump

● Faulty connection of accelerator cable ………

Repair connection

to pump adjusting lever

● Control rack faulty or sticking ……………………

Repair it

●

Damaged camshaft bearing ……………………..

Repair it

● Plunger worn or sticking…………………………..

Correct or replace it

● Faulty connection of engine ……………………..

Repair it

stop cable to pump stop lever

Nozzle faulty

● Fuel leakage caused by loosened …………….

Inspect and tighten it

nozzle holder

● Low opening pressure of nozzle ……………….

Adjust it

● Nozzle pressure spring broken …………………

Replace it

● Nozzle needle sticking to nozzle body ……….

Correct or replace it

Pump out of timing

● Improperly retarded injection timing …………..

Correct injection timing

● Incorrect timing caused by improper ………….

Check engine timing and

installation of pump

correct it

● Woodruff key for pump camshaft cut off. ……

Replace it

●

Improper pre-stroke adjustment ………………..

Correct it to obtain specified

injection timing

3-1-14 ENGINE

Models

1 page 1

J08C-TP and J08C-TR

Symptom

Possible cause

Remedy

Engine starts and stops

Fuel lines clogged …………………………………..

Clean or replace fuel lines

Air in fuel caused by damaged

Repair fuel lines or replace fuel

fuel lines or improper connection of

lines and gaskets

fuel lines

Engine has low power

Pump out of timing

●

Excessive advanced timing………………………

Check and correct it

resulting in loud knocking

●

Excessively retarded timing ……………………..

Check and correct it

resulting in black smoke

● Defective injection pump overflow valve …….

Repair or replace it

● Feed pressure too low …………………………….

Repair the feed pump

● Improper accelerator cable adjustment ……..

Adjust it

Nozzle faulty

● Fuel leakage from nozzle holder ……………….

Check and repair nozzle holder

● Bad nozzle spray characteristic ………………..

Repair or replace it

● Loosened adjusting screw in nozzle ………….

Adjust it

holder, resulting in low opening pressure

● Nozzle pressure spring broken …………………

Replace it

Pump faulty

● Fuel leakage from delivery valve ………………

Retighten the delivery valve

holder

holder if it is loosened or replace

O-ring if the O-ring is defective

● Defective seat of delivery valve assembly ….

Repair or replace it

● Delivery valve spring broken …………………….

Replace the spring

●

Plunger worn ………………………………………….

Replace it

● Large spread in fuel delivery …………………….

Adjust it

● Wear of tappet roller ……………………………….

Replace the roller

● Camshaft bearing worn or broken……………..

Replace it

● Improper adjustment of governor ………………

Adjust it

full load stopper screw

1 page 1

Models J08C-TP and J08C-TR

ENGINE 3-1-15

Symptom

Possible cause

Remedy

Excessive smoke

Black smoke

● Excessive fuel delivery caused by …………….

Adjust fuel delivery on test stand

incorrect adjustment of full load

stopper screw

● Excessively advanced injection timing. ………

Correct it

● Large spread in fuel delivery …………………….

Adjust it

● Bad nozzle fuel spray characteristics ………..

Check and correct them

White smoke

● Unused after glow system………………………..

Use it

● Improperly retarded injection timing …………..

Advance injection timing

●

Water in fuel …………………………………………..

Check and clean fuel lines

● Glow plug not operating …………………………..

Check glow plug circuit. Refer

to ELECTRICAL EQUIPMENT

in CHAPTER 20

Low idle speed

Improper adjustment of throttle control knob

Correct it

irregular

Bad fuel spray characteristic of nozzles. ……

Check and repair them

Incorrect injection timing ………………………….

Correct it

Incorrect initial tension setting of……………….

Adjust or replace it

idling spring or the spring broken.

Control rack does not move smoothly………..

Disassemble pump and repair it

Large spread in fuel delivery …………………….

Adjust it

Plunger worn ………………………………………….

Replace it

Governor linkage does not move smoothly…

Correct it

Defective feed pump ……………………………….

Disassemble and repair it

Engine always runs

Accelerator cable sticking ………………………..

Check and correct it

at high speed

Governor linkage sticking ………………………..

Disassemble and repair the

governor

Control rack sticking………………………………..

Check and correct it

Loud knocking

Improper injection timing ………………………….

Correct it

Bad fuel nozzle spray pattern . …………………

Check and correct it

after-dribble

High nozzle opening pressure ………………….

Adjust the opening pressure

Incorrect fuel deliveries to ………………………..

Readjust the fuel deliveries

some nozzles.

Models J08C-TP and J08C-TR

ENGINE 3-2-1

Shape

Parts No.

Parts name

No./unit

Application

09491 — 1010

Wire cable

1

Lifting engine

SM3-J052

09433 — 1070

Eye bolt

2

Lifting cylinder head

SM3-J048

(2) Related parts of cylinder head

Shape

Parts No.

Parts name

No./unit

Application

09472 — 1210

Bar

1

Caulking nozzle seat

(Use together with 9800 — 06100)

SM3-J050

9800-06100

(Steel ball)

1

Caulking nozzle seat

(Use together with 09472-1210)

SM3-J054

09552-1090

Compression gauge

1

Measuring compression

adaptor

(for size PF3/8)

SM3-J021

1 page 1

3-2-2 ENGINE

Models J08C-TP and J08C-TR

Shape

Parts No.

Parts name

No./unit

Application

09552 — 1060

Press gauge adaptor

1

Measuring compression

09552 — 1030

SM3-J022

09472 — 2100

Bar

1

Strike-fitting valve stem seal

SM3-J055

09471 — 1520

Guide

1

Strike-fitting valve guide

SM3-J051

09420 — 1100

Sliding hammer

1

Removing main idle gear shaft

SM3-J131

09420 — 1442

Removing suband cam idle

(Same as tool

Sliding hammer

1

gear shafts (Remove the

for pulling out

adaptor from the top before use)

injection nozzle)

SM3-J132

(3) Related parts of valve

Shape

Parts No.

Parts name

No./unit

Application

09431 — 1020

Valve wrapping tool

1

Valve wrapping

SM3-J053

1 page 1

Models J08C-TP and J08C-TR

ENGINE 3-2-3

Shape

Parts No.

Parts name

No./unit

Application

09470 — 1170

Valve spring press

1

Removing and installing valve

spring

SM3-J049

(4) Related parts of flywheel

Shape

Parts No.

Parts name

No./unit

Application

09481 — 1340

Guide

1

Removing and installing

flywheel

SM3-J116

(5) Related parts of cylinder block

Shape

Parts No.

Parts name

No./unit

Application

09407 — 1030

Oil seal press

1

Press-fitting front oil seal

09407 — 1040

Oil seal press

1

Press-fitting rear oil seal

SM3-J118

09420 — 1731

Oil seal puller

1