Subaru DY35 Engine Service Manual PDF

ROBIN AMERICA, INC. ROBIN TO WISCONSIN ROBIN

ENGINE MODEL CROSS REFERENCE LIST

ROBIN

EY08 EYl5 EY 15V EY20 EY20V EY23 EY28 EY35 EY40 EY45V EY2 1 EY44

EY25 EY27

EY 1 8-3

EHl 1 EH12 EHl5 EH17 EH2 1 EH25 EH30 EH30V EH34 EH34V EH43V

EC13V

DY23 DY27 DY3O DY3 5 DY4 1

WISCONSIN ROBIN

S-

W 1-080 W1-145 W1-145V Wl-185 WP-185V Wl-230 W 1-280 W 1-340 Wl-390 W1-45OV EY2 1 W EY44W

EY25W EY27W

EY 18-3W

v WOl-115 wo1-120 WO1-150 WOI-I 70 wo1-210 WO1-250 WO1-300 WO1-3OOV WO 1-340 WO 1 -340V WO1-430V

TWO CYCLE

WT1-125V

DIESEL

WRDI-230 WRD 1 -270 WRDl-300 wRD1-350 WRD1-410

CONTENTS

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See ti0

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3 . 4 .

5 .

6 .

7 .

8 .

9 . 10 . 11 .

12 .

n Ti rle Page

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 2-1 Maximum Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 2-2 Continuous Rated Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 2-3 Maximum Torque and Fuel Consumption Ratio a t Maximum Output . . . . . . . 3

FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 GENERAL DESCRIPTION of ENGINE CONSTRUCTION . . . . . . . . . . . . . . . . . . 5 4- 1 Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 4 -2 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

4 -4 Cylinder and Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 4 - 5 Gear Case Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 4-6 Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

4 -8 Rocker Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 4 -9 Rocker Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 4-10 Governor System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 4-1 1 Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

4 - 13 Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 4-14 Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 4- 15 Combustion System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 4 - 16 Sectional View of Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

DISASSEMBLY and REASSEMBLY . . . . . . . . . . . . . . . . . ! . . . . . . . . . . . . . . . 13

5 -2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 5-3 Disassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 5-4 How to Reassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 6 - 1 Qualityof Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 GENERAL DESCRIPTION of AUXILIARY GADGETS and PARTS . . . . . . . . . . . 29 7 . 1 Fuel Injection Pump Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 7 - 2 Fuel Injection Nozzle Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 7 -3 Governor Mechanism and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 7-4 Lubrication System and Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 7-5 Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 7-6 Electric Apparatus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 8-1 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 8-2 Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 8-3 Exhaust Gas Discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 8-4 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 8 - 5 Power Transmission to Driven Machines . . . . . . . . . . . . . . . . . . . . . . . . . . 40

CHECKS and CORRECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

TABLE of CORRECTION STANDARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

MAINTENANCE and STORING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 11 - 1 Daily Checks and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 11 -2 Every 25 Hours Checks and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 45 11 - 3 Every 50 Hours (10 days) Checks and Maintenance . . . . . . . . . . . . . . . . . . . 45 11 -4 Every 100 - 200 Hours (Monthly) Checks and Maintenance . . . . . . . . . . . . . 45 11 -5 Every 500 - 600 Hours (Semiannual) Checks and Maintenance . . . . . . . . . . . 46 11 -6 Every 1000 Hours (Yearly) Checks and Maintenance . . . . . . . . . . . . . . . . . . 46 11 -7 Every 1500 Hours (Overhauls) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 11 - 8 Preparation for Long Abeyance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

REDUCTIONS for B TYPE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 12-1 Configuration of 1/2 Reducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . : 48 12-2 Structure of 1/2 Reducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 12-3 Disassembly and Reassembly of 1/2 Reducer . . . . . . . . . . . . . . . . . . . . . . . 51

4-3 Connecting Rod and Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

4-7 Tappet and Tappet Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

4 - 12 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

5- 1 Preparations and Suggestions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

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2. PERFORMANCE

2-1 MAXIMUM OUTPUT

The maximum ouput of an engine is such standard power as developed by the engine, after its initial break in period with all - the moving parts properly worn in, when operating with a fully open injection pump. Therefore, a new engine may not

develop the maximum output in the beginning because the moving parts are not in a properly worn-in condition.

2-2 CONTINUOUS RATED OUTPUT

The continuous rated output of an engine is such power as developed by that engine when running continuously at an opti-

mum speed, and most favorable from the viewpoint of engine life and fuel consumption ratio, with the governor in opera- tion. It is suggested, therefore, that when designing a driving system for any mechanism, with this engine as prime mover,

the continuous power requirement of that mechanism be kept below the continuous rated output specified.

2-3 MAXIMUM TORQUE and FUEL CONSUMPTION RATIO AT MAXIMUM OUTPUT

These mean the maximum torque of the output shaft and fuel consumption ratio at the maximum output of an engine,

PERFORMANCE CURVE MODEL DYBOD, B

HP

t I

10

9

8

7

6

5

4

3

2

1

1c ( 1 450) ( 1

2

1.5

1

kg-m

t

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- rpm.

-3-

PERFORMANCE CURVE MODEL DY35DtB ,

10 -

9-

8-

7-

rv

6-

5-

4-

3-

PERFORMANCE CURVE - MODEL DY41 D, B HP

MAX. TORQUE

I

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LIGWWEIGWTand COMPACT

1 . Lightweight because of aluminum alloy being used for various parts including the crankcase made of aluminum die casting

2. Compact in outside dimensions because-

a) the camshaft is assembled inside of the gear case cover, and accordingly total width of the engine is reduced,

b) the cooling fan and the flywheel are single piece die casting; and the cooling fan is set on the side of the case so that it

may breathe in cooling air from the front, which means that the size of the fan casing becomes smaller and total length of the engine is also reduced.

FUEL ECONOMY and NOISELESS TYPE ENGINE

Low fuel consumption owing to improved fuel combustion system having adopted direct fuel injection; and noiseless opera- tion owing to the highly effective muffler and air cleaner

As an optional part a balancer is available for minimizing vibration.

EASY to TAKE-OUT POWER

A faucet joint is set in the blower housing, which enables direct coupling with a machine. P.T.O. shaft is connected to the flywheel and accordingly this engine is very easy to handle. Furthermore, as cooling air is taken into from the front of case

(reverse side of the machine coupled), it is unnecessary to arrange air-intake on the side of the machine. Therefore, it is easy

to couple a machme to the engine.

4. GENERAL DESCRIPTION of ENGlME CONSTRUCTION

This engine is a Forced Air Cooled, 4-Cycle, Vertical, Single Cylinder, Overhead Valve Diesel Engine, and the combustion

system is direct injection type.

4-1 CRANKCASE

The crankcase is made of a one-piece aluminum alloy die

casting. On the side of pump, bearing is press-fitted; and on

the fan side cast iron bearing housing is arranged, and it sup-

ports the crankshaft by a ball bearing press-fitted to the

shaft. Also, on the fan side, blower housing of aluminum

die casting is fitted. This blower housing has a faucet joint and it enables direct coupling with a machine. (See Fig. 1 .>

1

I

I .

Fig. 1 - -5-

4-2 CRANKSHAFT

The crankshaft is made of a forged chrome and molybdic

steel piece with the crank pins and the journals ground t o

high precision after induction hardening. It is fitted to the

flywheel on the fan side, and connection of the drive shaft

to it is also possible. In the center of the pins and the jour-

nals, holes for forced lubrication are drilled through. (See Fig. 2.)

4-3 CONNECTING ROD and PISTON

4-3-1 CONNECTING ROD

The connecting rod is made of forged pieces of aluminum

alloy designed with sufficient strength to withstand buckling

and tensile forces inflicted on it under high-load operating

conditions. At the small end a bushing is forcefitted to with-

stand the pressure resultant from pitching during high-speed

operation. At the larger end thin kelmet is fitted for increas-

ing durability.

4-3-2 PISTON

Piston is made of cast aluminum alloy, and it has two com-

pression rings and an oil ring. Combustion chamber arranged

at the pistion head, where combustion gas is made up by

mixing atomized fuel and air, and ignites. (See Fig. 3.)

4-4 CYLINDER and CYLiNDERHEAD

4-4-1 CYLINDER

Cylinder is made of aluminum alloy die casting, in which

special cast iron liner is cast, and is provided with many cool-

Fig. 2

Fig. 3

ing fins designed for effective cooling.

4-4-2 CYLINDERHEAD

The most important part of the diesel engine is cylinderhead.

It is a one-piece of aluminum alloy die casting, in which in-

take and exhaust ports, and rocker chamber are cast in the

most ideal structure for the highest strength and the high-

est cooling efficiency. In the valve seats fine quahty heat re-

sistance seats are pressure-fitted considering high resistance

- to abrasion and corrosion at high temperature. (See Fig. 4.) Fig. 4

-

- 6 -

4-5 GEARCASE COVER

Gearcase cover is made of aluminum alloy die casting and is

fitted on the reverse side of the flywheel. This cover em-

braces the injection pump, timing gear, operating lever and

supports the camshaft as a bearing. To the gear case cover

the tappet guide is fitted and then the tappets are assembled, (See Fig. 5 .)

4-6 CAMSHAFT

The camshaft is made of forged chrome steel wholly sintered

and then ground. It carries three cams, viz. one intake cam,

one exhaust cam, and one fuel injection pump cam, and the

shaft is supported by a ball bearing pressure-fitted in the

gear case cover and by the gear case. The camshaft is assem

bled inside the gear case cover. To the shaft the relief valve

and a pin are fitted. The pin is used when starting engine by

hand cranking. (See Fig. 6.)

4-7 TAPPET and TAPPET GUIDE

4 -7 - 1 TAPPET

Tappet is made of forged steel and wholly sintered, ground,

and then taftride finished. The camshaft has oil holes for

lubricating tappets.

4-7-2 TAPPET GUIDE

Tappet guide is made of aluminum alloy die casting and de-

termines tappet positionsand is fitted to the gear case cover.

In the crankcase there is a blow-by gas hole, which hole goes

through up till rocker chamber via push rod sleeve.

(See Fig. 6.)

Fig. 5

i

Fig. 6

4-8 ROCKER ARM

Rocker arm is made of forged steel and is wholly sintered and then ground, and it is supported by the rocker shaft. At the

one end it has valve clearance adjusting screw. With this screw valve clearance is adjusted to the specified gap and is fixed by

lock nut. Lubrication of the rocker arm is carried out by the oil splash contained in the blow-by gas from the crankcase. In-

take rocker arm has decompression mechanism. (See Fig. 6.)

-7-

4-9 ROCKER COWER

Rocker cover is made of aluminum ailoy die casting and it

is fitted to the cylinderhead and covers the rocker chamber.

Rocker cover has a breather; and the air breathed is brought

to the intake port. (See Fig. 7.)

Fig. 7

. .-

4-10 GOVERNOR SYSTEM !

The governor is a centrifugal flyweight type and is installed on the governor gear. Through the lever it adjusts the rack : of fuel injection pump and keeps constant operation at the 1

selected speed against load variations. (See Fig. 8.)

Fig. 8

4- I f LUBRICATION SYSTEM

Lubrication is wholly filtered and pressurized lubrication

system by trochoid type oil pump. From the main gallery

in the crankcase the pressurized oil runs through the crank

journals and crankpins, and from the larger part of the rod

the oil is supplied in the form of splash to the parts neces-

sary to be lubricated, while part of the oil also runs through

the bearings of camshaft to lubricate both intake and ex-

haust cams, and tappets. Ths system includes the governor

gears and it is installed in the crankcase.

(See Fig. 9.)

f ig . 9

- 8 -

4-12 COOLING SYSTEM CYLINDER BAFFLE

The cooling fan and the flywheel are a single piece casting

and it is fitted to the top end of the crankshaft. Cooling air produced by this fan blows through blower housing and cyl-

inder baffle, and cools cylinder and cylinderhead.

(See Fig. lo.)

4-13 INJECTION PUMP

The plunger of the fuel injection pump is operated by the

injection pump cam, and the fuel from the tank is pressur-

ized in the pump and supplied to the nozzle via the high

pressure pipe.

(See Fig. 11 .)

4-14 NOZZLE

Into the combustion chamber the nozzle injects the pressur- ized fuel supplied from the pump through the high pressure

pipe. (See Fig. 12.)

Fig. 70

U

Fig. 1 1

Fig. 12

- 9 -

4-15 COMBUSTION SYSTEM

For lower fuel consumption and easy starting of the engine,

the direct injection system is adopted in the combusition

chamber.

4-15-1 FORMING of COMBUSTION GAS and COMBUS-

TION

/INTAKE VALVE

INTAKE PORT

SWIRL

CYLINDER

PISTON

Fig. 13

SWIRL (Inspiring swirl)

In order to promote mixing injected fuel and air under

the direct injection system, swirl flow is utilized for

good Combustion. Swirl is spiral flow of air generated

in the cylinder during inspiring stroke, and it decreases

during compressing stroke but it still remains and pro-

motes mixing of fuel and air toward ignition timing.

Spiral flow of a ir (swirl) is generated by the shape of

intake port, which is called helical port or spiral port.

Tail end of intake port, i.e. upper part of intake valve

seat, is made in the spiral form; and while the inspired

air is passing through this part, swirl is generated

around the intake valve. Thus, intake port plays an im-

portant role in generating swirl. (See Fig. 13.)

SQUISH (Squished air flow)

In the piston, combustion chamber (dish type com-

bustion chamber) is formed. When the piston comes

up to TDC (top dead center), air in the gaps is squished

in the combustion chamber and air flow is generated,

which is called squish. (See Fig. 14.)

FORMING of COMBUSTION GAS and COMBUSTION

For igniting quickly the fuel injected from the nozzle, it is essential to atomize very fine oil particles for distributing

evenly in the combustion chamber. For t h s purpose, fuel should be injected through hole type nozzle by very high pressure, i. e. 195 kg/cm2. The fue!, thus injected, is mixed with air by the flow of swirl and squish while piston is

Coming Up. Accompanying crimb of the piston, combustion gas compressed further and finally it automatically begins igniting and while piston is going down, squish functions and promotes combustion.

Fig. 14

- 10 -

4-16 SECTIONAL VIEW of ENGINE

- 1 1 -

EXHAUST VALVE

\ \ ROCKER COVER

CYLINDER HEAD-\

INTAKE VALVE

AIR CLEANER

CY L

BA

OIL PAN-

- 12 -

5. DISASSEMBLY and REASSEMBLY

5-1 PREPARATIONS and SUGGESTIONS

1) When disassembling the engine, remember well the locations of individual parts so that they can be reassembled cor- ,-

rectly. If you are uncertain of identifying some parts, it is suggested that tags should be attached to them.

2 ) Have boxes ready to keep disassembled parts by group.

3) To prevent missing and misplacing, temporarily assemble as much as possible each group or set of disassembled small parts such as bolts and nuts, etc.

4) Carefully handle disassembled parts, and clean them with washing oil.

5) Use the correct tools in the correct way.

5-2 SPECIAL TOOLS

I Tool No. I I Tool Use I 228 95001 07 For pulling off the flywheel Flywheel puller with bolt

I 22895002 07 1 Box wrench For removing or fastening the flywheel nut

I 228 95003 07 I Piston ring expander I For placing piston ring I

/ PISTON RING EXPANDER

\ B O X WRENCH

Fig. 15

- 13 -

5-3 DISASSEMBLING SEQUENCE

b

Se- quence

1

2

I

3

4

5

6

7

*Length of the bolt indicates the length from the bolt head bottom surface to the threaded end. * * SW + Spring water * **W + Plain washer

Item Procedures Remarks Bolts, nuts etc. used ~~~~~~~ ~ ~~~ ~ ~ ~~~ ~ -

Engine oil Remove the oil drain plug and discharge oil. Oil drain plug locates under the gear case cover. (Remove oil filter.)

Fuel Fuel pipe locates on the side Discharge fuel from the tank.

of injection pump.

~~~ ~ ~~

Be sure not to miss the 0 ring. The drain plug

6 mrn hex. bolt . . . 2 pcs.

(See Fig. 16.) serves as an oil fiIter too.

SW . . . 2 pcs.

Be sure not to miss the 17 mm hex. bolt. . . 1 pce. gasket. (See Fig. 17.)

Fuel tank Remove the fuel pipe.

Remove the fuel return pipe.

Remove the tank band.

~

Remove the banjo bolt

There are 2 sheets of on the side of the tank.

8 x 18 banjo bolt . . . 1 pce.

aluminum gasket. There are 2 sheets of aluminum gasket.

6 x 45 round head cross recess bolt . . . 2 pcs. No SW, W

Muffler 6 x X mm flange bolt Remove the muffler cover. . . . 4 pcs.

Remove the muffler. Be sure not to miss the gasket.

High pressure Pipe

Remove the high pressure pipe on the side of injection pump and the nozzle.

Be careful to keep the

joint of nozzle free of inside of the pipe, pump,

12 mm n u t . . . 2 pcs.

dust.

Air cleaner Remove the air cleaner from sw . . . 2 pcs. that of the muffler. the cylinder head. 8 mm nu t . . . 2 pcs. The gasket is same as

Tank bracket crankcase, left and right, each. Remove the bracket from the Just loosen 8 mm nut. 8 x 16 7T bo l t . . . 2 pcs.

Fig. 16

- 1 4 -

Fig. 17

- Se-

quence Item Bolts, nuts etc. used Remarks Procedures

8

9

10

Fly wheel

Blower housing

Remove the flywheel cover. Remove the driving shaft. Raise up lock washer, loosen lock nut (41 mm box spanner) and then remove the flywheel from the crankshaft using the flywheel puller.

Remove the blower housing from the crankcase.

Crankshaft, normal threading (See Fig. 18.)

Just loosen the flange bolts.

~~ ~~

Be sure not t o miss 5 mm nut.

5 x 10 round head cross recess screw . . . 1 pce.

~ ~~ ~~ ~~

Rocker cover 6 x 35 7T bolt. . . 3 pcs. Remove the rocker cover from the cylinderhead. sw . . . 3 pcs.

Nozzle holder 6 mm nu t . . . 2 pcs. At the top end the Remove the nozzle holder from the cylinderhead. sw . . . 2 pcs. gasket is fitted.

l 3 I Rocker arm I Loosen the nuts fastening the Loosen the tappet adjust- cylinderhead. ing bolt a d the decom-

pression adjusting bolt, which latter is on the side of the intake valve. (See Fig. 19.)

Pull out the rocker shaft from the cylinderhead and remove the rocker arm.

14 Cylinderhead Loosen 6 mm nut which is fastening the push rod sleeve on the side of cylinderhead. Pull out the push rod.

Just loosen 6 mm nut. 6 mm nu t . . . 2 pcs.

Fig. 78

6 x 8 flange bolt . . . 2 pcs. No W. 8 x 5 5 7T bo l t . . . 2 pcs. sw . . . 2 pcs. 8 x 40 7T bolt. . . 2 pcs. sw . . . 2 pcs.

Cylinder baffle Remove the cylinder baffle from the cylinder.

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b

l"2L quence

I l 5 ICylrnder

17 Tappet guide

18 Injection pump

19 Gear c se

Procedures

Remove the cylinder.

Remove the push rod sleeve from the gear case cover.

Remove the tappet guide from the gear case cover.

Remove oil filler cap. Put the control rack at the center. Remove the injection pump from the gear case cover.

Remove the handle guide.

Remove the gear case cover from the crankcase.

It

Fig. 20

. r- .c. . P

/"

Remarks I Bolts, nuts etc. used

are rubber "0" ring and copper shim. (See Fig. 20.)

6 mm nut . . . 2 pcs. sw . . . 2 pcs.

A holder is necessary for not let fall the tappet. (See Fig. 2 1 .)

Check the position of 8 mm nut . . . 3 pcs. control rack. sw . . . 3 pcs. (See Fig. 22.)

(See Fig. 23.) 6 x 6 hex. bolt . . . 2 pcs.

8 x 35 7T b o l t . . . 4 pcs. 8 x 80 7T bolt . . . 3 pcs. sw . . . 3 pcs.

sw . . . 2 pcs.

/."-

\ -

Fig. 22 Fig. 23

Procedures Remarks Bolts, nuts etc. used

20 Camshaft Pull out the camshaft. Between camshaft and gear case there is a shim. (See Fig. 24.)

21

22

23

Piston Remove the piston from the connecting rod. (Remove the clip and pull out the piston.)

Governor and From the crankcase remove oil pump the governor and oil pump in

the form of one piece.

Oil pan Remove the oil pan from the crankcase.

Watch the direction of the clip, also pay atten- tion t o the direction of the piston. ( "f mark indicates "to- ward the fan side.") (See Fig. 25.)

6 x 20 7T bolt . . . 2 pcs. sw . . . 2 pcs.

Be careful of the pack- 6 x 12 bolt . . . 8 pcs. ings. sw . . . 8 pcs.

/"-

Fig. 24 Fig. 25

- 17 -

Se- tuence

24 I_

25

Item

Connecting rod

Bearing hous- ing and crank- shaft

Procedures

Remove the connecting rod from the crankshaft.

From the crankshaft remove the key on the side of fan.

Remove the bolt fastening the bearing housing.

Pull the crankshaft together with the bearing housing. (Gently tap the side of crank gear with plastic hammer.)

Remarks

No lock washer. Be careful of the direc- tion of rod. (Fan mark is on the side of the flywheel.) Be careful of the setting mark of the cap. (See Fig. 26.)

Be careful of the copper shim and 0 ring be- tween the bearing hous- ing and the case.

Also be careful of the hole for oil.

Bolts, nuts etc. used

8 x 22 7T bolt . . . 6 pcs. SW . . . 6 pcs.

After pulling out the crankshaft from the case, remove housing.

The bearing remains on the crankshaft. (See Figs. 27, 28 and 29.)

Fig. 26 Fig. 27

Fig. 28

-18-

Fj quence Item

1 T 1 1

Intake and exhaust valve

Procedures I Remarks I Bolts, nuts ~Pc. used

Remove the intake and exhaust valves from the cylinderhead.

On the side of intake valve, there is a stem seal. Be sure not to miss retainer lock. (See Fig. 30.) J

Fig. 30

Se-

2

3

I tem

Snap ring

Balancer shaft

Balancer

Procedures

Remove the snap ring.

Remove the balancer shaft.

Remove the balancer from the case.

Remarks

Be sure not to miss the snap ring. (See Fig. 3 1 .)

Gently tap with plastic hammer.

Be careful not to damage the thrust metal on the side of the pump. The gear and the needle bearing are in one piece. (See Fig. 32.)

Bolts, nuts etc. used

/-

Fig. 31 Fig. 32

- 1 9 -

5-4 HOW TO REASSEMBLE

1. PRECAUTION IN REASSEMBLING

1) Every and each part should be cleaned thoroughly. Easpecially, pay utmost care and attention to the cleanliness of the

piston, cylinder, crankshaft, connecting rod and bearings.

2) Scrape completely off carbons from the cylinder head and the upper part of the piston; especially the carbon adhered

in the groove of the piston ring should be carefully and completely taken out.

3) Carefully check the lip portion of every oil seal. If faulty one is found, replace it without slight hesitation.

4) Replace all the gaskets with new ones.

5 ) Replace the key, pin, bolt, nuts, etc. with new one, if necessary.

6 ) Whenever tightening torque is specified, conform to the specified figures.

7) Apply oil to the revolutionary parts and friction surfaces, when reassembling.

8) Check and cidjust the clearances of variouts portions and then reassemble.

9) When some main Grtions are assembled in the course of reassembling, turn or move the gadgets by hand and pay at-

tntion to the frictional noise and resistance.

2. REASSEMBLING

1) Insert the crankshaft into the crankcase.

CAUTION: Be careful not t o damage bearing metal

on the side of injection pipe.

For the engine with the balancer, fit the balancer first

to the crankshaft, and then put it into the crankcase.

CAUTION: When fit t ing, check the match mark.

(See Fig. 33.)

Fig. 33

2) Assemble the bearing housing.

8 x 22 7T bolt . . . . . . . . . . . . 6 pcs.

Spring washer . . . . . . . . . . . . 6 pcs.

NOTE: Apply oil or grease inside the housing oil seal.

CAUTION: Be sure to put "0" ring on.

NOTE: Set the bearing housing so that its oil hole -q

may face upward.

(See Fig. 34.) 3

Fig. 34

- 20 -

NOTE: With the copper shim adjust the side clear-

ance of the crankshaft be 0.1 - 0.2 mm.

Three kinds of shim are available, viz. 0.1 mm, 0.2 mm,

and 0.3 mm thick. [Tightening toruque: 200 - 230 kg-cm]

(See Fig. 35.)

:-

Fig. 35 u

3 ) Assemble the connecting rod.

CAUTION: Pay attention to the direction of the rod.

(FAN mark is to be set on the side of the flywheel.)

NOTE: Check the match mark on the cap.

NOTE: The lock washer is not used when fastening

the bolt. [Tightening torque: 250 - 270 kg-cml

(See Fig. 36.)

Fig. 36

4) Assemble the oil pan.

6 x 12 bolt . . . . . . . . . . . . . . 8 pcs.

Spring washer . . . . . . . . . . . . 8 pcs.

NOTE: Pay attention to the packings.

(See Fig. 37.)

Fig. 37

- 21 -

Assemble the piston.

MOTE: + mark in the upper part of the piston is to

be faced to the fan side.

MOTE: Piston rings are not assembled.

MOTE: Shape of the piston pin.is (D . (See Fig. 38 .)

Assemble the cylinder

NOTE: Insert the piston into the cylinder (piston

ring is not inserted.), and measure the dimensions of

the head of piston and upper surface of the cylinder.

NOTE: The concave dimensions of the pistion is -0.6 - -0.7 mm from the upper Surface of the Piston. Fig. 38

MOTE: Adjustment of the concavedimensions is to be made by the shim underneath the cylinder, and available thick-

ness of the shim are 0.1 mm and 0.2 mm.

MOTE: Fit the piston rings on the piston.

Punched mark "N" are to be faced up. Open end of each ring must avoid the direction toward the thrust side and it is

to be set to the different three directions.

NOTE: Set the cylinder.

Be sure to fit rubber "0" ring and shim.

Notched portion of the cylinder skirt must be set on the side of the gear case cover. (See Figs. 39-1 and 39-2.)

TOP RING D SECOND R I N G I OIL RING 2 3

1

Fig. 39- 7

7 ) ' Install the flywheel.

(Use 41 mm box wrench.)

NOTE: When putting lock washers on, be sure to

bend the tabs securely.

[Tightening torque: 2,000 - 2,200 kg-cml

(See Fig. 40.)

Fig. 39-2

f ig . 40

- 22 -

8) Install the camshaft.

NOTE: Apply oil or grease to the inside of oit seal for the gear case cover.

NOTE: Set the match mark of the camshaft so as to fit to tha t of the crank gear. Side clearance is to be adjusted to

0.1 - 0.3 mm. Three kinds of shim are available, viz. 0.8 mm, 1 .O mm and 1.2 mm. r

Fig. 41

9) Assemble the oil pump and the governor.

6 x 2 0 7Tbol t . . . . . . . . . . . . 2 pcs.

Spring washer . . . . . . . . . . . . 2 pcs.

NOTE: The hole in the oil pump cover is to face

downward.

NOTE: Check i f the governor sleeve moves smoothly.

Outer surface of the trochoid pump must face the case

side. (See Fig. 43.)

[Tightening torque: 80 - 100 kg-crn]

Fig. 42

\

10) Assemble the gear case cover. Fig. 43 8 x 5 7T bolt , . . . , . . . . . . . . 4 pcs.

Spring washer . . . . . . . . . . . . 4 pcs.

NOTE: When the pin is replaced, apply "Three Bond" at the both ends of the pin for cranking. This pin locates a t the

top of the camshaft.

8 x 65 7T bolt . . . . . . . . . . . . 3 pcs.

Spring washer . . . . . . . . . . . . 3 pcs.

NOTE: Check if the governor link operates.

[Tightening torque: 200 - 230 kg-cm]

- 23 -

Assemble the injection pump.

8 mm nut . . . . . . . . . . . . . . . 3 pcs. Spring washer . . . . . . . . . . . . 3 pcs.

NOTE: Measure the distance between the face of the cam base and the surface to which the injection pump is to be

fitted. And adjust it may become 76 k 0.05 mm, using the shims. Two kinds of the shim are available, viz. 0.1 mm, and

0.3 mm.

CAUTION: Remove the oil filler cap and check if the control rack comes off from the governor lever.

(See Figs. 44 and 45 .) - . .- l._l ___ "I ~ ." , , -

Fig. 45

Assembe the tappet guide.

CAUTION: Be careful not le t the tappet fal l i n

case.

NOTE: The roll pin of the tappet guide is to be

a t the right side as viewed from the gear case side.

(See Fig. 46.)

the

set

Fig. 46

13) Temporarily assemble the push rod sleeve.

6 mm nut . . . . . . . . . . . . . . . 2 pcs.

Spring washer . . . . . . . . . . . . 2 pcs.

NOTE: 2 pcs. of the plate (push rod sleeve) are to be assembled temporarily.

- 24 -

a

Assemble the cylinderhead.

10 mrn flange nut . . . . . . . . . . 4 pcs.

Washer . . . . . . . . . . . . . . . . . 4 pcs.

NOTE: Install the intake and exhaust valves. On the

intake side there i s a stem seal.

NOTE: Insert the push rod. (Exhaust is on the side

of the gear case.) Pay attention to the valve facing, UP-

ward or downward, and direction of intake and ex-

haust.

NOTE: Install the rocker arm to the cylinder.

It is advisable to insert the rocker shaft before clamp-

ing the head.

(See Fig. 47 .)

NOTE: Clamp the head to the cylinder.

Apply "Three Bond #I 21 5" to two pieces of the stud

bolt (on the side of the rocker shaft) and upper and

reverse surfaces of the washer, and then tighten the

nuts.

[Tightening torque: 350 kg-cm]

. Tightening of the nuts is to be done in three rounds,

I. e.:

1 s t round . . . . . . . . . . . . . . . 100 kg-cm

2nd round . . . . . . . . . . . . . . . 200 kg-crn

3rd round . . . . . . . . . . . . . . . 330 - 350 kgcm

NOTE: Fasten tightly the plate (push rod sleeve).

6 mm nut . . . . . . . . . . . . . . . 4 pcs. (See Fig. 48.)

15) Adjust the valve clearance.

NOTE: Turn the flywheel by hand to the compres-

sion a t TDC (top dead center). At TDC the camshaft

cranking pin stands vertically.

NOTE: Adjust the valve clearance to anywhere be-

tween 0.07 - 0.10 mm (both intake and exhaust),

when the engine is cold.

(See Fig. 49.)

Fig. 47

I

DECOMPRESSiON \, ADJUSTING SCREW

Fig. 49

- 25 -

INTAKE, EXHAUST VALVE TIMING

When valve clearance is at 0.4 mm and the engine is

heated,

intake valve opens a t 16O before TDC,

intake valve closes a t 54' after BDC,

exhaust valve opens a t 54' before BDC, and

exhuast valve closes a t 14" after TDC.

(See Fig. 50.)

Adjust the decompression clearance.

TDC (TOP DEAD CENTER)

I N T A K E V A L V

INTAKE VALV AUST VALVE

BDC (BOTTOM DEAD CENTER)

Fig. 50

NOTE: The decompression device locates in the rocker arm on the intake valve side.

NOTE: Set the decompression lever at the position of decompression. (Push the lever to the horizontal position.)

NOTE: Clearance is about 0.5 mm. Turn the adjust screw until it touches the decompression shaft, and then make

another half turn. Threading of this screw is 1 .O mm.

Turn the f lywheel by hand and check a contact between the valve and the piston.

Assemble the rocker cover.

6 x 3 5 7 T b o l t . . . . . . . . . . . . 3pcs.

Spring washer . . . . . . . . . . . . 3 pcs.

NOTE: Check if there is an "0" ring for breather hole on the surface of the head (intake breather's side).

NOTE: Check if the gasket for the rocker cover is put correctly in the groove.

Install the nozzle holder.

6 mm nut . . . . . . . . . . . . . . . 2 pcs.

Spring washer . . . . . . . . . . . . 2 pcs.

NOTE: Pay at tent ion to the gasket at the top. It is advisable to uti l ize the driver foreasy installation.

[Tightening torque: 90 - 100 kg-cml

Install the blower housing.

Upper part: 8 x 55 7T bolt . . . 2 pcs.

Spring washer . . . . 2 pcs.

Lower part: 8 x 40 7T bolt . . . 2 pcs.

Spring washer . . . . 2 pcs.

10 x 30 bolt . . . . . . . . . . . . . 4 pcs.

8 x 16 bolt . . . . . . . . . . . . . . 4 pcs.

6 x 8 flange bolt . . . . . . . . . . . 2 pcs.

bolt and nut 5 mm . . . . . . . . . 1 pce. each

Install the driving shaft.

Assemble the flywheel cover.

Assemble the cylinder baffle.

5 x 75 round head cross recess

(See Fig. 5 1 .) Fig. 51

26 -

Install the tank brackets, left and right.

8 x 16 7T bolt . . . . . . . . . . . . 2 PCS.

Spring washer . . . . . . . . . . . . 2 pcs.

8 mm nut bolt . . . . . . . . . . . . 2 pcs. each

Connect the fuel pipe and fuel return pipe securely.

8 x 18 banjo bolt . . . . . . . . . . 2 pcs.

Aluminum packing . . . . . . . . . 2 pcs. NOTE: Connect the pipe to the nozzle first, and then connect the fuel pipe to the tank.

Install the air cleaner. 8 mm nut . . . . . . . . . . . . . . . 2 pcs.

Spring washer . . . . . . . . . . . . 2 pcs.

NOTE: Pay attention to the gasket.

Install the muffler and the muffler cover. Muffler: 8 mm brass nut . . . . . 2 pcs.

Spring washer . . . . . . . 2 pcs.

Muffler cover: 6 x 8 flang bolt. . 4 pcs.

NOTE: Pay attention to the gasket.

Connect the high pressure pipe. (See Fig. 52.) It is advisable to remove the cap of the air cleaner and

I.-

then connect.

Mount the fuel tank.

6 x 45 round head cross recess

screw . . . . . . . . . . . . . . . . . . 2 pcs.

When installing the fuel filter once removed from the

tank, fasten the filter by hand and then make 1/4 turn

with a spanner.

Install the oil filter

6 x 12 bolt . . . . . . . . . . . . . . 2 pcs.

Spring washer . . . . . . . . . . . . 2 pcs.

The oil filter serves as the oil drain plug too.

Be sure to install "0" ring.

Install the handle guide.

6 x 12 bolt . . . . . . . . . . . . . . 2 pcs.

Spring washer . . . . . . . . . . . . 2 pcs.

Supply engine oil.

Upper level . . . . . . . . . . . . . . 1 .O R max.

Lower level . . . . . . . . . . . . . . 0.6 II min.

Also pour oil into the air cleaner, watching oil level.

Supply diesel light oil.

Fuel tank capacity . . . . . . . . . 4.5 R

Fig. 52

- 27 -

6. FUEL

0-1 QUALITY Of FUEL

Because of the high speed diesel engine, be sure to use the good quality diesel light oil. If improper fuel is used, the injection

pump, nozzle, and piston develop troubles. (See Fig. 53.)

i FUEL RETURN PIPE

NOZZLE

HIGH PRESSURE PIPE

FUEL INJECTION PUMP

f T \ /

AIR RELEASE f U E L TANK

/ \

"

FUEL FILTER

FUEL PIPE

PIPE

TANK FILTER PIPE PUMP PRESSURE PIPE

t FUEL RETURN PIPE

Fig. 53

- 28 -

7. GENERAL DESCRIPTION of AUXILIARY GADGETS and PARTS

7-1 FUEL INJECTION PUMP MECHANISM

It is not too much to say that the fuel injection pump is the heart of the diesel engine, and it must be precise enough t o sat-

isfy the following functions.

Function

Injecting fuel, starting with high pressure and ending with low pressure.

Injecting the predetermined amount of fuel accurately at each stroke.

Injecting fuel at specified time within a specified time interval.

Quantity being injected is closely vaned by the governor to suit to varying load.

This engine has no automatic advancing device, but in starting (max. delivery), the injection timeing is to be delayed.

Theory of the injection pump mechanism

The plunger of the injection pump is pushed up by the cam of the camshaft, and it is pushed down by the plunger spring. By

this up and down motion in a stroke, suction and forced supply of fuel are conducted. (See Fig. 54.)

Suction of fuel

Through the filter in the fuel tank, fuel is supplied and is in full around the intake port of the plunger barrel. When

the top of the cam lobe passed the tappet and cam function ended, plunger spring pushes down the plunger.

When the plunger is pushed down passing the fuel intake, fuel is sucked into the barrel, and suction is continued until

arrival of the plunger at the bottom of its stroke. This is on the stage of "suction."

Forced supply of fuel.

The camshaft rotates and pushes up the plunger. Forced supply of the fuel is started only when the upper part of the

plunger closed the fuel intake in the course of being pushed up by the cam rotation. The fuel in the barrel is pressur-

ized by a,very strong force (100 kg/cm2 and up), and as a result, the force of the fuel pushes up the delivery valve and

the damping valve, and then it injects the fuel into combustion chamber. This is on the stage of "pressurized supply."

DAMPING VALVE

DELIVERY VALVE VERTICAL HOLE

PLUNGER BARREL

INTAKE PORT (EXHAUST PORT)

PLUNGER

LEAD

EFFECTIVE STROKE

Fig. 54

- 29 -

3. Variation in quantity of fuel to be injected

The quantity of fuel injected vanes according to the condition of the engine, i. e. high speed or low speed operation and

loaded or unloaded operation. (See Figs. 55 and 56.)

The plunger lead is engraved on the surface of plunger in an inclined curve. By rotating the plunger, the distance between

the upper part of the plunger and the suction port is varied. (Variation in effective stroke)

Rotation of the plunger is made by the control rack. When this control rack is shifted to left and/or right, the geared pinion

rotates, which is connected to the plunger by means of the control sleeve. In other words, the plunger turns as much amount

as the rack rotates. Accordingly, the effective stroke varies coincident with the position where the rack is set.

1) Relation between the plunger and the barrel

EFFECTIVE STROKE

PLUNGER BARREL

INTAKEEXHAUST PORT

INJECTION INJECTION INJECTIO INJECTIO STARTS. ENDS. STARTS. ENDS.

MAX. DELIVERY HALF DELIVERY NO DELIVERY

Fig. 55

2) Relation between the plunger and the rack

CONTROL SLEEVE

MAX. DELIVERY HALF DELIVERY NO DELIVERY

Fig. 56

- 30 -

4. Injection timing and effective starting

When the plunger closes suction port of the barrel, forced

delivery of fuel starts. But fuel is not injected from the noz-

2le.at ence because of contraction of,fuel,'etc. .

Injection timing of this engine is fixed constant ( 2 3 O before

TDC) irrespective of engine rpm. On the other hand, in start-

ing, a proper delay from the timing for high speed running

and increased fuel injection is indispensable for effective

starting. For this purpose a notch is made at the plunger

head, whch reserves to delay the injection timing by nearly

8" to facilitate starting. (See Fig. 57.)

INSTALLED ONLY TO DY30

Fig. 57

5. Function of the delivery valve

By the plunger stroke, fuel pressure is raised. And when it becomes higher than the pressure remained in the high pressure

pipe, the delivery valve spring is pushed down and the valve opens. As the result, the fuel in the high pressure pipe is delivered

forcibly.When the plunger lead meets suction port of the plunger barrel, deliveryof fuel ends, and the delivery valve is closed

by the spring tension of the valve. At this time, delivery valve prevents reverse flow of the fuel. Also suction back motion

around the upper part of the plunger sucks back the fuel in the equal amount of the stroke [A] and decreases remaining pressure in the high pressure pipe. The nozzle jets the fuel clearly off and prevents after dripping. (See Fig. 58.)

! I ! / DELIVERY ALVE SPRING

DELIVERY VALVE

ION BACK STROKE

Fig. 58

6. Function of the damping valve

The damping valve is assembled in the end of injection

pump and it reaches the seat before arrival of delivery valve

at the seat. The small orifice in the valve is the passage of fuel t o the chamber in the delivery valve holder. Accordhg-

ly, descending velocity of the delivery valve is decreased,

which prevents the negative pressure being produced sud-

denly. As a result, proper injection is conducted and the DEL,VERY VALVE

DAMPING VALVE

engine noise is decreased. (See Fig. 59.)

- 31 -

Fig. 59

0 FUEL INJECTION PUMP

PUMP

DAMPING VALVE DAMPING VALVE SPRING

DELIVERY VALVE

DELIVERY VALVE AIR RELEASE BOLT HOLDER

HOUSING

DELIVERY VALVE

CONTROL RACK PLUNGER ASSEMBLY - STOP

CONTROL SLEEVE PLUNGER SPRING

SPRING SEAT PIN

Fig. 60

0 SPECIFICATIONS of FUEL INJECTION PUMP for THIS DIESEL ENGINE

Model

Maker

PFRIKD55/2NP1

5.5 mm Plunger diameter

Diesel Kiki K.K.

Lead

2.46 kg/cm Plunger spring arbitrary

Right twist lead

Delivery valve opening pressure

0.51 kg/mm Delivery valve spring constant

27.5 kg/cm2

Pump rack friction load

16 mm Rack stroke

0.062 kg

-32 -

7-2 FUEL INJECTION NOZZLE HOLDER

1. Specifications

Part Name ~ ~~

I NOZZLE HOLDER I Part No.

4 No. of nozzle hole

C Identification mark

105 11840 00

(Diameter)

13.2 kg/cm2 Spring constant

195 kg/cm2 Valve opening pressure

(0.22 mm)

-

a

2. Features

Both the injection nozzle and the injection pump are very important parts for producing fuel fog for combustion. There are

two types of injection nozzle, one is hole type and the other is pintle type. The injection nozzle for DY30 and DY35 Diesel

engine is developed as a result of joint research and development project by Diesel Kiki, K. K. and our company, and it is

direct combustion system, having the special hole type nozzle.

For producing better combustion gas, it utilizes swirl and squish flows and for producing the most proper fuel fog, injection

pressure is raised up to 195 kg/cm2.

3. Structure of the ignition nozzle hold r IDENTIFICATION MARK

T h s consists of the nozzle holder and nozzle. The nozzle \ FUEL INLET /

holder fixes the nozzle to the cytinderhead and at the same

time it plays the role of fuel passage to the nozzle. (The

valve opening pressure of nozzle is adjustable. However, the

nozzle for DY30 and DY35 engines includes spacer in it and

it is unadjustable.)

The nozzle consists of the nozzle body and needle valve;

and when the pressure reaches the limit to open the valve,

nozzle for this diesel engine includes spacer in it and it is

unadjustable.)

4. Function of nozzle

Through the injection pump, fuel is delivered forcibly into

the nozzle body and it raise up the needle valve and is at-

omized in the combustion chamber through the holes of

the nozzle body. In case of the hole type nozzle, the size of

the opening of the holes does not alter. (See Fig. 62.)

TlNG WASHER

NOZZLE SPRING

NOZZLE BODY

Fig. 61

V A L V E CLOSED VALVE OPENED

/-

Fig. 62

- 33 -

5. Fuel passage

From the plunger pump fuel is sent through the highpres-

sure pipe 1 to the fuel passage 2. Then, at the nozzle body 3, it is pressurized up till 195 kg/cm2 and it lifts up the needle

valve 4 for 0.18 mm, and is sprayed into the combustion

chamber via the jet hole 5.

An excess fuel which lubricated the inside of the nozzle and

nozzle holder returns to the fuel tank via the needle valve +

nozzle spring 6 + overflow pipe 7 + fuel tank,

(See Fig. 63 .)

6. Inspection and maintenance

1

2 7

6 3

4 5

Fig. 63

Fuel spraying condition of the nozzle and the state of pressure at starting injection are quite influential to the engine mal-

function, insufficient output, increase of noise and exhaust smoke. Use of improper fuel and contaminated fuel is one of the main courses of the nozzle trouble. Therefore, exert good care for managment of fuel. As the nozzle is one of the very pre-

cisely processed parts, utmost care and attention must be paid when inspecting and checking.

1 ) Inspection

After cleaning nozzle holder outside, inspect in the be-

low sequence.

a) Visual inspection

*Whether or not injection hole is damaged, or clog-

ged with carbon.

*Whether or not injection hole is clogged with dust

and carbon.

b) Inspection by nozzle tester

*Fit the nozzle holder to the nozzle tester.

CAUTION: When removing the nozzle from the

engine or fitting it to the tester, be sure t o keep

the nozzle free of dust.

*Move the lever of the nozzle up and down for 2 - 3 times and suck the air inside the hozzle.

CAUTION: Never bring your face near the pres-

surized fog from the nozzle. Also keep away your

hands from the fog.

*Gently push down the lever of the nozzle tester

and read the pressure gauge just before the fuel

being injected. If the figure coincides with the stan-

dard value, the nozzle is in a good condition,

*Push further and check whether or not the fuel fog

is injected straight.

CAUTION: Good injection is straight forward.

Fig. 64

NOZZLE

Just af ter injection, check "after dripping." Fig. 65

- 34 -

2) Maintenance

If the test results are found not good (poor injection and "after dripping"), carefully check and repair in the following manner:

a) Disassemble the nozzle holder and nozzle, and wash

in clean light oil. When washng, use a wooden chip

(for instance, wooden chopstick is servicable.) for

peeling off the carbon adhered t o the nozzle.

b) After washing, pull out the needle halfway from NEEDLE

the body of nozzle with your fingers and then let

it go. And check if the needle sinks by its own dead BODY

weight.

c) If it does not sink, replace it in the form of a set.

d) Frinction surfaces of both the needle and nozzle

body are ultra precise finish. So, be sure t o keep

the parts free of dust.

e) If "after dripping" is found, it is poor contact be-

tween the needle valve and the seat. In such a case,

it is advisable to replace it in the form of a set, ee- Fig. 66

dle valve and nozzle body. However, it is possible

to coat chrome oxide on the tapered surface of the needle and get a good contact. Wash very carefully after correc-

tion.

f ) Adjustment of the valve opening pressure of the nozzle spring in the nozzle holder is unnecessary because it was al- ready adjusted by the adjusting washer.

g) The spacer is an important part to set positions of the nozzle holder and the nozzle body. Pay attention to the posi-

tion of the pin.

h) When fitting the nozzle body to the nozzle holder, conform to the specified tightening toruqe, viz. [Tightening torque: 400 - 500 kg-cml

i) Recheck with the nozzle tester, if necessary.

-35 -

7-3 GOVERNOR MECHANISM and OPERATION

1. Mechanism

The governor is centrifugal flyweight type, which means a flyweight is fitted to the governor gear. The governor sleeve is as-

sembled so that it may slide toward the direction of the axis of the pump shaft, and it is in contact with the flyweight. The

governor sleeve gets in touch with the governor yoke, and through the governor lever it makes the control rack of injection

pump operate. This mechanism enables to maintain constant operation irrespective of load variation.

GOVERNOR

FUELDECREASE

7 INJECTION PUMP

FUEL INCREASE

GOVERNOR

GOVERNOR YOKE START SPRl

OBLONG HOLE

GOVERNOR LEVER 1

GOVERNOR SPRING

CONTROL LINK

SPEED CONTROL LEVER

LOW SPEED

SHAFT

NG

HIGH SPEED

FUNCTION at STARTING

FUNCTION at OPERATING =I>

Fig. 67

- 36 -

2. Operation

1) Starting

When the speed control lever is set on the side of high speed, the governor spring is pulled via the control link. The

governor levers 1 and 2 are pulled by the tension of the governor spring. The control rack of injection pump is pushed

toward fuel increase. The governor lever 1 has an oblong hole, and the governor lever 2 moves to the extent of this

oblong hole by means of the start spring tension. The control rack of injection pump is pushed toward the maximum

of fuel increase. This movement within the extent of oblong hole is called revolution playing angle, for which we

will explain later.

2) After starting and during operation

When engine starts up, centrifugal force acts on the flyweight and it pushes the governor sleeve. The governor yoke,

governor shaft, and governor lever 2 are assembled in one piece, and accordingly the motion of the governor sleeve

pushes the control rack of the injection pump toward fuel decrease. The governor lever again moves to the extent

of the oblong hole. Thereafter, the governor lever 1 and the governor lever 2 move simultaneously and are balanced at

the specified revolution. Suppose that a load is put suddenly on, the fuel supply is as it is at that instance, accordingly

the fuel supply is insufficient against the load. As a resut, engine revolution decreases, which means that the centrifugal

force on the flyweight decreases. Then the governor lever 2 moves to the position where it balances the tension of the

governor spring. The control rack of injection pump is pushed toward fuel increase and engine revolution revives.

3) Stopping

The governor plays a role exactly reverse to that of starting. When the speed control lever is set at the position of Stop, it pushes the control rack of injection pump toward No Injection and the engine stops.

3. Revolution Playing Angle

This mechanism is to supply more fuel than the maximum supply for normal high speed operation. This mechanism is devel-

oped for the purpose of improving starting ability.

Required amount of fuel supply is set by the governor lever 1. The governor lever 1 has an oblong hole, to which pins of the

governor lever 2 is fitted. As the start spring is pulling the governor lever 2, it moves toward the arrow mark A. Then the

control rack of the injection pump is pushed to Maximum supply. The angle the governor lever 2 moves within the extent

of oblong hole is called Revolution Playing Angle .

At the time of starting, the governor does not function as yet and the governor lever 2 functions.However, during operation,

the governor functions and accordingly the governor lever 2 moves toward the arrow mark B within the extent of oblong

hole. The governor levers 1 and 2 incroporate each other and pushes the control rack of the injection pump.

,-

- 37 -

7-4 LUBRICATION SYSTEM and OIL PUMP

Lubrication is forced lubrication and wholly fdtered system by trochoid type oil pump. The oil pump, and the governor are

assembled in one piece, which is fitted to the crankcase.

Revolution of the crankshaft is reduced by the reduction gear (1 : 1.4) of the pump; and from the main gallery oil is forcibly

lubricated to the crank journal. That oil wil further be supplied to the crankpin, large end of the connecting rod, and then

splashed to the piston, small end of the connecting,rod, cylinder, etc. Also from the main gallery oil is forcibly supplied to

the cam shaft bearing and is sent t o cam lobe of intake and exhaust valves and lubricate the tappets. In the camshaft oil relief valve is assembled, and it adjusts the oil pressure at 3 kg/cm2. Lubrication in the rocker chamber is conducted by the

splash of oil pushed up by blow-by gas, which lubricates rocker arm, etc. Furthermore, blow-by gas containing oil will pass through the breather, intake port and the cylinder, where it is finally burnt.

LUBRICATION CHART

r I r I

BREATHER 1-1 INTAK: PORT1

I

t COMBUSTION

I *

t 1 I $=I! CYLINDER k PISTON, BEARING

SMALL END

OIL F ILTER

Fig. 68

7 - 5 . OIL FILTER

Oil filter is made of double sheets of wire netting, and it is less flow resistance type, and is called full-flow type. As the

element is made of wire, it can be washed and used for many times.

- 38 -

7-6 ELECTRIC APPARATUS (Electric Starter)

1. Wiring diagram KEY SWITCH

GENERATOR

ELECTRIC STARTE

1) Circulation 12V35AH

When starting by the electric starter, (Key is at the position of start.)

Battery (+) -+ BAT of key + ST of key + Starter + Battery (-) (earth)

Charging, operating (Key is at the position of operation.)

Generator "f Rectifier + IC of key +. BAT of key +. Battery (+)

2. Lead wire for electric starter

When mounting the engine, location of the battery may comes into question, but set the lead wire following method:

BATTERY StDE TERMINAL ELEC RIC STARTER SIDE TERMINAL JIS BA-508 JIS BA-508

3. Earth band Plain woven lead wire sectional area 20 mm2 and up.

I" L

Approx. 25

Fasten tightly to the place made of metal and not paint coated. The place must be electrically conducted completely to the

crankcase of the engine.

4, Other remarks

1) All lead wires are classified by coloring, so when connecting, select and connect by color.

Meantime, insert the connectors each other up till the roots.

2) The wire from (+) terminal of the battery must be connected t o (+) terminal of the electric starter, and the wire from

the (-) terminal must be connected to the earth of the engme body.

3) Select the wire from the below Table A, based on the required length of the wire.

4) When the key switch is set apart from the engine body, select the wire from below Table B, based on the required

length of the wire between the key switch and the magnetic switch on the side of engine.

I Length Outside dia. Description Length. Outside dia. Description

1.5 m or shorter

1.4 mm AV3 3 m " 5 m 10.8 mm AV30 2.5 m - 3 m

1.9 mm AV2 'i.5m-31-17 8.5 mm AV20 1.5 m - 2.5 m

1.5 mm AV 1 -25 1.5 m or shorter 7.3 mm AV15

Table A Table B -39 -

I-

,"-

8. INSTALLATION

Engine life, ease of maintenance and inspection, frequency of checks and repairs, and operating cost all depend on the way

in which the engine is installed. Carefully observe the following instructions for installing the engine.

8-1 INSTALLING

When mounting the engine, carefully examine its position, the method of connecting it to a load (machine), the foundation,

and the method of supporting the engine.

8-2 VENTILATION

Fresh air is necessary for cooling the engine and burning the fuel.

In cases where the engine is operated under a hood or in a small room, temperature rise in the engine room can cause vapor

lock, oil deterioration, increased oil consumption, loss of power, piston seizure, shorter engine life, etc., making it impossi-

ble to operate the engine properly. It is necessary, therefore, t o provide a duct or baffle t o guide cooling air to the engine to

prevent recirculation of the hot air used for engine cooling, and temperature rise of the load (machine).

Take steps as necessary t o keep the engine room temperature below 60C even in the hottest period of the year.

8-3 EXHAUST GAS DISCHARGE

Exhaust g a s is noxious. When operating the engine indoors, be sure t o discharge the exhaust gas outdoors. If a long exhaust

pipe is used in such a case, the internal resistance increases causing loss of engine power. Thus pipe inside diameter must in

crease in proportion t o exhaust pipe length.

Exhaust pipe: Less than 3 m long, pipe inside diameter 30 mm,

Less than 5 m long, pipe inside diameter 38 mm.

8-4 FUEL SYSTEM

If the fuel tank is removed from the engine when mounting the engine with a machine, set the fuel tank 50 - 500 mm

above the fuel injection pump. If the tank is set too low, the fuel will not be supplied.

When piping be careful of heat conduction, pipe size, bends, and leaks from the joints and make the fuel pipe as short as

possible to prevent air and vapor from being trapped.

8-5 POWER TRANSMISSION to DRIVE MACHINES

1. Belt Drive

Take the following notes into consideration.

1) V-belts are preferable to flat belts.

2) The driving shaft of the engine must be parallel to the driven shaft of the load.

3) .The driving pulley of the engine must be in line with the driven pulley of the load.

4) Install the engme pulley as close to the engine as possible.

5 ) If possible, span the belt horizontally.

6) Disengage the load when starting the engine.

If no clutch is used, use a belt tension pulley or the llke.

2. Flexible Coupling

When using a flexible coupling, runout and misalignment between the driven shaft and engine shaft must be minimized.

Runout and misalignment tolerance are specified by the coupling manufacturer,

- 40 -

9. CHECKS and CORRECTIONS

After disassembling and cleaning the engine, check and repair, if necessary, according to the correction table. The correction

table applies whenever the engines are repaired. It is important for the servicemen to be familiar with the contents of tlus

table. Correct maintenance is recommended by observing the correction standards specified.

The meanings of the terms used in the correction table are as follows:

1) Correction

Repair, adjustment or replacement of any engine parts.

2) Correction Limit

The limit on wear, damage or functional deterioration of engine parts beyond which normal engine performance can-

not be expected without repairing such parts.

3) Use Limit The limit beyond which parts can no longer be used in respect of performance or strength.

4) Standard Dimensions

The design dimensions of new parts minus tolerance.

5 ) Correction Tolerance

Tolerance on the dimensions of engine parts refinished or adjusted.

,

,--

- 4 1 -

10. TABLES of CORRECTION STANDARDS

r ITEM :ORRECTIOP METHOD

STANDARD CORRECTION

LIMIT

0.05

2.2

Flatness 0.03

Intake

Exhaust Valve seat contact width 1.4

Valve guide I.D. I 7 dia. to.015 0.1 5

1 DY30D. 6 I 76dia. +0.019

Inside dia. 0.1 0.25 DY35D. B DY41 D, B 82 dia'

+0.022

+" Roundness after boring

0.01 5 Cylindricity after boring

0.01

I DYSOD, B I 75.96 1 S. 1. D. I

CY-35D. B DY41 D. B 81.94

~

DY30D, B 76.21 Oversize A -0.02

DY41 D. B

O.D. at skirt, in thrust direction (Incl. over size)

-0.1

0.1 3

0.1

1 DY30D. B 1 76.46 I Oversize 0

DY35D, DY4t D, B 82.44

+O ,060 +O .040

Width of groove for the rings

+0.025 +O .005

Piston pin hole 21 dia. 1 M .008 to.001 0.03

0.1 5

0.2

0.15 I Skirt portion Clearance between piston and cylinder

DYSOD, B

DY350,B

0.04OL-0.079L

DY41 D, B 0.060L -0.1 02L 0.2 1 0.1 5

Clearance between piston ring and ring groove

0.05L - 0.09L

0.01 5L-0.055L

0.1 5

1 0.05L

0.1

0.05L F i t between piston and piston pin 0.005L-O.008L

te"j 0.3 - 0.5 Piston ring gap

Oil 0.25 - 0.45

-42 -

r I I u CORRECTION REMARKS :ORRECTlO!

METHOD ITEM DIMENSIONS STANDARD USE

L I M I T

-0.1 I TOLERANCE L IMIT

-0.1 Piston ring width

Oil 4

+0.006 0 -0.02 Piston pin O.D. 21 dia.

Large end I .D. 43 dia.

Metal thickness of large end 1.5

Clearance between large end and crankpin

Small end I.D. after the bush i s force fitted. 21 dia.

Clearance between small end and piston pin

Large end side clearance

end and small end bores Parallelism between large

Crankpin O.D. 40 dia.

roundness

Crankpin O.D. cylindricity

parallelism

Journal diameter 42 dia.

Journal roundness

I.D. after main bearing being force fitted

Main bearing

Clearance between journal and main bearing

Intake and exhaust cams

40 Injection pump cam

36.495 Cam lobe height

Rear 22 dia.

Journal 0.0.

Front 35 dia.

Intake

Valve stem O.D. 7 dia.

Exhaust

-0.02

+0.016 0

-0.005 -0.01 8

0.01 L-0.068L

Metal in centei 1.4

0.1

1.4

0.1

+0.034 +0.013 0.05 0.05

0.007L-0.034L

0.07L - 0.33L

0.08

0.5

0.08

0.5

0.06 0.1

0.1 5

0.1 5

0.1

0.5

0.1 5

+0.040 +O .024

0.005

0.008

0 -0.01 6

0.005

+0.020 +0.076

0.101 L-0.06OL

0.02OL-0.092L

0.1 5

-0.2

0.15

-0.2 +O .05

-0.1 5 -0.1 5

-0.020 -0.041

-0.01 2 -0.023

-0.063 -0.078

and adjust Use searcher

with adjust screw.

-0.1 5

- -0.1 5

-0.083 - 0.098

-43 -

ITEM STANDARD I , 1 USE I CORRECTION CORRECTIOP I TOLERANCE LIMI REMARKS METHOD

Intake 0.063 L - 0.093 L

- Exhaust 0.083L-0.113L

Clearance between valve stem dia. and valve guide 0.3 0.3

5 Valve clearance both intake and exhaust 0.07 - 0.1 (cool condition) I l l

Stem O.D. I -0.01 3 -0.033 I -0.07 I -0.07 I

c 8 dia.

Guide I.D. +0.015 0 N.08 M.08

Tapet guide clearance 0.013L-0.048L 0.15 0.15

Rocker shaft O.D. -0.01 6 E -0.034 a . 12 dia.

-0.08 -0.08

L

Y Rocker arm hole dia. al *.Of 8 0 0 E

+O .07 +O .07

I Rocker arm shaft clearance I I 0.016L-0.052L I I 0.15 I I 0.15

Valve spirng free length I 36.5 I P

$ From injection pump a. flunge surface t o cam base .- 0 '

.% Static iniection timing 23" before TDC * l o

76 ?O .05 Adjust E

4.l

- I Injection starting pressure

0 - N -

nozzle Nozzle dia. x number of 0.22 dia. x 4 pcs.

TABLE of TIGHTENING TORQUE

Description

200 - 230 kg-cm Gear case cover

Tightening torque

Blower housing fastening bolt

330 - 350 kg-cm Cylinder head fastening bolt

200 - 230 kg-cm

I Connecting rod cap fastening bolt I 250 - 270 kg-crn I I Flywheel fastening nut I 2,000 - 2,200 kg-cm I I Rear bearing fasteni bolt I 200 - 230 kg-cm I I Oil pump cover fastening bolt I 80 - 100 kg-cm I I Nozzle bracket fastening nut 90 - 100 kg-cm

- 44 -

11. MAINTENANCE and STORING

The following maintenance jobs apply when the engine is operated correctly under normal conditions. The indicated main- tenance intervals are by no means guarantees for maintenance free operations during these intervals.

For example, if the engine is operated in extremely dusty conditions, the air cleaner should be cleaned every day instead of

every 50 hours.

11 - 1 DAI LY CHECKS and MAINTENANCE

I

I Checks and maintenance

Remove dust from whatever parts which

Check external fuel leakage. If any, retighten or replace.

Check screw tightening. If any loose one is found,

re-tighten.

1 Check oil level in crankcase and add up as necessary.

11-2 EVERY 25 HOURS CHECKS and MAINTENANCE

Reasons for requiring them I To be contaminated with dust when disassembling each

Not only wasteful but .also dangerous

Loose screws and nuts will result in vibration

accidents.

If the engine is operated without sufficient oil, it will

fail.

Checks and maintenance Reasons for requiring them

Change crankcase oil. To remove run-in wear particles

11-3 EVERY 50 HOURS (IO DAYS) CHECK and MAINTENANCE

Checks and maintenance Reasons for requiring them

Change crankcase oil.

If the engme is operated without sufficient oil, i t will fail. Clean oil filter.

Contaminated oil accelerates wear.

,

11-4 EVERY 100 - 200 HOURS (MONTHLY) CHECKS and MAINTENANCE

Checks 2nd maintenance

If the fuel is contaminated, engine will be out of order, Clean fuel filter and fuel tank.

Reasons for requiring them

and injection pump as well as nozzle are seized.

Clean air filter, and replenish engine oil. Clogged air filter and shortage of oil will cause engine

trouble and make engine life shorter.

Check and adjust valve clearance.

Engine will be out of order. Check and clean nozzle.

The engine output drops.

- 4 5 -

11-5 EVERY 500 - 600 HOURS (SEMIANNUAL) CHECKS and MAINTENANCE

Checks and maintenance Reasons for requiring them

Remove cylinder head and remove carbon deposit.

Check valve seats both intake and exhaust and

The engine will be out of order. Replace fuel fdter.

The engine will be out of order.

The engine will be out of order.

grind, if necessary.

~~

11-6 EVERY 1000 HOURS (YEARLY) CHECKSand MAINTENANCE

I Checks and maintenance Reasons for requiring them ~

Change piston rings.

To prevent from danger caused by the fuel leakage. Replace fuel pipe once a year.

The engine output drops and become out of order.

11-7 EVERY 1500 HOURS (OVERHAULS)

I Checks and mainte ance Reasons for requiring them

I Performoverhauls, clean, correct or replace parts. I The engine output drops and become out of order. I

11-8 PREPARATION for LONG ABEYANCE

1) Perform the above 1 1 - 1 and 1 1-2 maintenance job.

2) Drain fuel from the fuel tank.

3) To prevent rust in the cylinder bore, apply oil through the breather hole on the surface of rocker cover and made

cranking for 2 - 3 times and then fit the rocker cover. Don't apply too much oil as the excess oil will be collected in

the combustion chamber of the piston.

4) Turn cranking handle and leave it where the restance is the heaviest.

5 ) Clean the engine outside with oiled cloth. Put a vinyl or other cover over the engine and store the engine in dry place.

- 4 6 -

12. 1/2 REDUCER

AIR CLEANER

MUFFLER

OIL GAUGE STARTING HANDLE

FUEL FILTER

OIL FILTER STOP LEVER

(DRAIN PLUG)

.-

FUEL TANK

REDUCTION GEAR

P.T.O. SHAFT

- 47 -

12-1 CONFIGURATION of 1/2 REDUCER

01L CHECKING PLUG (M18 x 13)

OIL EXHAUSTING PLUG (M8 x 13)

Fig. 12- 1

- 48 -

12-2 STRUCTURE Of 1/2 REDUCER

CRAN

OIL FILLER PLUG

BEARING (#6205)

THRUST WASHER

OUTPUT SHAFT

BEARING (#6206)

THRUST WASHER

BEARING (#6204)

INPUT SHAFT

BEARING (#6205)

GEAR CASE

Fig. 72-2

- 49 -

I

/"

12-2-1 INPUT SHAFT

The input shaft is a wholly carburized. product in which chrome-molybudenum steel is used, and the gear A and spline are

built in it.

12-2-2 OUTPUT SHAFT

The output shaft is made of carbon steel, and the gear C is fitted in spline engagement.

12-2-3 SHAFT B The shaft B is made of chrome-molybudenum steel, and wholly carburized.

12-2-4 GEAR C and GEAR 3

The gear C and the gear B are wholly carburized products, in which chrome-molybudenum steel is used, and are helical gears

with module of 2.

12-2-5 ADAPTOR and GEAR CASE

The.adaptor and the gear case are components of a body of the 1/2 reducer, and are made of aluminum alloyed dicast.

12-2-6 COUPLING

The coupling is a component to deliver output from the engine to the 1/2 reducer, and is fitted to the input shaft in spline

engagement. The coupling is a wholly carburized product in which molybudenum steel is used.

NOTE: Grease is stored in the spline section, and the section i s sealed with a packing and an O-ring.

-50-

12-3 DISASSEMBLY and REASSEMBLY of 1/2 REDUCER

12-3-1 DISASSEMBLY SEQUENCE

Length of the bolt indicates the length from the bold head bottom surface to the threaded end. *SW = Spring washer

Procedures Main Item to be disassembled

Se- quence

1

2

Remarks Bolts, etc. Used

Replace the gasket with a new one.

8mm hexagonal bolt Opposite side: 13 mm

Drain the gear oil. The oil drain plug is located under the gear case cover.

Remove the clamping bolt from the adaptor.

~~ ~~

8 mm bolt - - 4 pcs. I 8 mm x 65 bolt - - 4 pcs.

3 Remove the 1/2 reducer assembly from the engine.

Remove the clamping 10 mm bolt - - 4 pcs. bolts from the coupling.

Remove the clamping 7 bolts on the gear case bolts of the gear case. surface.

Remove the O-ring of the input shaft.

4 Be careful not to lose

8 x 40 7T bolt - - 6 pcs. Be carefult not to lose the

4 pcs. the packing. 10 mm x 30 9T bolt - -

sws. 8 x 50 7T bolt - - 1 pce. with SWs

7 Wind vinyl tape around the input/output shafts.

Cover whole surface of the shafts to protect the oil seal.

8 Separate the gear from the adaptor.

Hold the output shaft and strike the adaptor with a wood hammer or a plastic hammer, and then separate the gear case from the adaptor. Don't insert a driver between the mating faces. I f inserted, they may be damaged.

I "

Pull out the gear assembly from the case.

Disassemble the input Separate the gear from shaft assembly. the bearings.

9

10 Pull out the bearings by using a gear puller or a press.

Disassemble the P.T.O. shaft assembly.

Separate the gear and the bearings from the P.T.O. shaft.

Pull out the bearings by using a gear puller or a press.

1 1

I

- 51 -

12-3-2 REASSEMBLING SEQUENCE

1. Precautions in Reassembling

Every and each part should be thoroughly cleaned. Especially, pay utmost care and attention to cleanliness of the

bearing.

Carefully check the lip portion of every oil seal. If damaged one is found, replace it with a new one.

Replace all the gaskets with new ones.

Replace the bolts, if necessary, with new ones.

As for the places where tightening torque is specified, apply the specified torque.

Apply oil to the revolutionary parts and friction surfaces, when reassembling.

Check and adjust the clearances of various portions and then reassemble them.

When some main portions are assembled in the course of reassembling, turn or move the gadgets by hand, paying

attention to the frictional noise and resistance.

2 . Reassembling

a) Pressure-fit the bearings into the input shaft so that the bearing (#6205) is set in the spline side and the bearing

(#6204) in the edge face side. Then, insert the shim between the bearing (#6205) and the gear so that the clearance

between the two bearings after they have been pressure-fitted is from 49 mm to 48.9 mm. Two types of s h m ;

0.3 mm thick and 0.1 mm thick are available. (See Fig. 12-3 .) When installing the spline and the O-rings in the case, wind vinyl tape around their grooves to protect the oil seals.

(See Fig. 12-4.)

INPUT SHAFT SHIM ADJUSTING POSITION

4 9 - 48.9 rnrn

- SH IM SETTING POSITION

BEARING #6205 BEARING #6204

Fig. 12-3

b) Pressure-fit the bearings and install the gear C into

the output shaft so that the bearing (#6206) is set

in the output side, the bearing (#6205) in the edge

face side, and the 60 beveling of the gear C bore

spline is faced to the bearing (#6206).

Then, insert the shim between the bearing (#6205)

and the gear so that the clearances between bear-

ings after they have been pressure-fitted is from

52 mm to 51.9 mm. Two types of shim; 0.3 mm

thick and 0.1 mm thick are available. (See Fig.

12-5.)

/ VINYL TAPE

Fig. 12-4

OUTPUT SHAFT SHIM ADJUSTING POSITION , 52 - 51.9 rnrn ,,GEAR

SHIM SETTING POSITION

BEARING #6206

Fig. 72-5

AFT

- 52 -

Pressure-fit the oil seals into the adaptor and the gear case.

Set the shaft B with the thrust washer in the adaptor. (See Fig. 12-6.)

Set the gear A and the gear B in the adaptor, under the condition that their teeth are engaged in each other. (See

Fig. 12-7 .)

Set the thrust washer onto the edge face of the gear B. Set the output shaft assembly in the adaptor. (See Fig. 12-8.)

Put the packing on the mating face of the case. (It is not necessary to supply sealing compund to the mating face.)

Cover the gear case. (Don't give physical impacts with such tools as a hammer to compulsorily set it.) (See Fig.

/-

12-9.)

Clamp the case with six M8-40 7T bolts and an M8- 50 7T bolt. Never forget to set thrust washers for the bolts.

Tightening torque: 250 kg.-cm +50 kgcm.

Remove the vinyl tape around the input shaft, and then set the O-ring.

Fig. 12-6

,"-

Fig. 12- 7

Fig. 12-8 Fig. 72-9 ,-

- 53 -

3. Mounting to Engine

a) Supply grease into the grease filler hole (the section shown with inclined lines in the figure) of the input shaft.

b) Set the packing in the coupling, and then clamp it to the engines flywheel with four 10 mm x 30 9T bolts.

Tightening torque: 550-700 kg-cm c) Apply grease to the coupling and spline gear teeth of the input shaft.

d) Set the 1/2 reducer in the engine under the condition that the spline