Subaru Robin Power Products DY30, DY35, DY41 User Manual

ROBIN

ENGINE

ROBIN

TO

MODEL

AMERICA,

WISCONSIN

CROSS

REFERENCE

INC.

ROBIN

LIST

ROBIN

EY08 EYl5 EY 15V EY20 EY20V EY23 EY28 EY35 EY40

EY45V

EY2 1 EY44 EY 1 8-3 EY25 EY27

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

EY 18-3W EY25W EY27W

EHl 1 EH12 EHl5 EH17 EH2 1 EH25 EH30

EH30V

EH34 EH34V EH43V

EC13V

DY23 DY27 DY3O DY3

5

DY4

1

v

TWO

DIESEL

CYCLE

WOl-115 wo1-120 WO1-150

WOI-I

wo1-210 WO1-250 WO1-300 WO1-3OOV

WO

WO 1 -340V WO1-430V

WT1-125V

WRDI-230

WRD

WRDl-300

wRD1-350 WRD1-410

70

1-340

1 -270

CONTENTS

See

ti0

n

SPECIFICATIONS

1

.

PERFORMANCE

2

.

2-1 Maximum Output

2-2 Continuous Rated Output

2-3 Maximum Torque and Fuel Consumption Ratio

FEATURES

3

.

GENERAL DESCRIPTION

4

.

4- 1 Crankcase

4-2 Crankshaft

4-3 Connecting Rod and Piston 4-4 Cylinder and Cylinder Head 4-5 Gear Case Cover

4-6 Camshaft

4-7 Tappet and Tappet Guide

4-8 Rocker Arm 4-9 Rocker Cover

4-10 Governor System

4-1 1 Lubrication System

4- 12 Cooling System

4- 13 Injection Pump

4-14 Nozzle

4-

15 Combustion System

4- 16 Sectional View of Engine

DISASSEMBLY

5

.

5-

1

Preparations and Suggestions 5-2 Special 5-3 Disassembly Sequence 5-4 How to Reassemble

6

.

FUEL

.

7

8

9

10

11

12

.

. .

.

......................................................

6-1

GENERAL DESCRIPTION

7

7-2

7-3 Governor Mechanism and Operation 7-4 Lubrication System and 7-5 Oil Filter 7-6 Electric Apparatus

INSTALLATION

8-1 Installing

8-2

8-3 Exhaust Gas Discharge

8-4

8-5

CHECKS TABLE MAINTENANCE

11

11 11 -4 Every 11 11 11 11

REDUCTIONS

12-1 Configuration 12-2 Structure 12-3 Disassembly and Reassembly

Qualityof Fuel

.

1 Fuel Injection

Fuel Injection Nozzle Holder

Ventilation

Fuel System

Power Transmission to Driven Machines

and

of

-1

Daily Checks and Maintenance

-2

Every

-3

Every

-5

Every

-6

Every

-7 Every

-8 Preparation for Long Abeyance

Ti

rle

.............................................

..............................................

.........................................

...................................

at

Maximum Output

.................................................

of

ENGINE CONSTRUCTION

..................

.............................................. 5

.............................................

..................................

..........................................

..............................................

....................................

............................................

.........................................

........................................

..........................................

................................................

.......................................

....................................

and

REASSEMBLY

Tools

............................................

......................................

........................................

..........................................

of

Pump

Mechanism

...............................................

........................................

..............................................

...............................................

.............................................

......................................

............................................

CORRECTIONS

CORRECTION STANDARDS

and

STORING

25

Hours Checks and Maintenance

50

Hours

(10

days) Checks and Maintenance

100

-

200 Hours (Monthly) Checks and Maintenance

500

-

600 Hours (Semiannual) Checks

1000

Hours (Yearly) Checks and Maintenance

1500

Hours (Overhauls)

for

B TYPE ENGINES

of

1/2 Reducer

of

1/2 Reducer

.................

!

...............

.................................

AUXILIARY GADGETS

and

PARTS

...........

...............................

.................................

.............................

Oil

Pump

..............................

..........................

.....................................

..............................

....................................

.................................

.........................

...................

.............

and

Maintenance

...........

..................

................................

....................................

of

1/2 Reducer

.......................

.......

:

Page

1

3

3 3

5 5

6

7

7 7

8

8 9 9

9

10 11

13 13

13

14

20 28

28

29

33 36 38 38 39

40 40

40 40 40 40

41

42

45 45

45 45 45 46 46 46 46

47 48

49

51

4

I

b

R

X

i?

p?

m

I

E

W

X

E E

N

a3

-

0

R

X

6,

t?

N

E

W

[D

X

E

W

r.

I

t

W

Y

P

.-

v)

X

m

-

-1

+

-

L

W

c

L

m

c

VI

V

.-

L

c

0

m

-

w

I

,

I

”

I

-2-

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

in

develop the maximum output in the beginning because the moving parts are not

2-2

CONTINUOUS

The continuous rated output mum speed, and most favorable

is

tion. It the continuous power requirement

2-3 MAXIMUM TORQUE

These mean the maximum torque

suggested, therefore, that when designing a driving system for any mechanism, with this engine as prime mover,

RATED

HP

OUTPUT

of

an engine

from

the viewpoint

of

that mechanism be kept below the continuous rated output specified.

and

FUEL CONSUMPTION

of

the output shaft and

10

9

is

such power as developed

of

engine life and fuel consumption ratio, with the governor in opera-

RATIO

fuel

consumption ratio at the maximum output of an engine,

PERFORMANCE CURVE

MODEL DYBOD,

by

that engine when running continuously at

AT MAXIMUM OUTPUT

B

a properly worn-in condition.

kg-m

2

an

opti-

-

t

I

8

7

6

5

4

3

2

1

1c

(1

450)

(1

1.5

1

t

JIHP-h

-

-3-

rpm.

PERFORMANCE CURVE

MODEL

DY35DtB

10

-

MAX.

,,,,

9-

8-

7-

rv

6-

5-

4-

3-

TORQUE

I

PERFORMANCE

MODEL

DY41

CURVE

D,

B

HP

g/H

P-

h

LIGWWEIGWTand

1.

Lightweight because of aluminum alloy being used for various parts including the crankcase made of aluminum

2.

Compact in outside dimensions becausea) the camshaft

b)

the cooling fan and the flywheel are single piece die casting; and the cooling fan may breathe in cooling air from the front, which means that the size of the fan casing becomes smaller and

of

the engine

FUEL

ECONOMY

Low

fuel consumption owing to improved fuel combustion system

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. flywheel and accordingly (reverse side

to couple a machme

of

COMPACT

is

assembled inside of the gear case cover, and accordingly total width of the engine

is

set on the side of the case

is

also reduced.

and

NOISELESS TYPE ENGINE

having

adopted direct fuel injection; and noiseless

P.T.O.

this

engine

the machine coupled), it

to

the engine.

is

very easy to handle. Furthermore, as cooling air is taken into from the front

is

unnecessary

to

arrange air-intake

on

the

side

of

the machine. Therefore, it

is

shaft is connected

reduced,

total

die

so

casting

that it

length

opera-

to

the

of

case

is

easy

4.

GENERAL DESCRIPTION

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

Also,

on

shaft. die casting

and

it enables direct coupling with a machine. (See Fig.

the fan side, blower housing of aluminum

is

fitted.

This

blower housing has a faucet joint

of

ENGlME

is

arranged, and

CONSTRUCTION

it

sup-

1

.>

Fig.

1

I

I.

-

-5-

4-2

CRANKSHAFT

The crankshaft is made of a forged chrome and molybdic steel piece with the crank pins and the journals ground to

high

precision after induction hardening. It is fitted

on

flywheel to it is also possible.

the fan side, and connection of the drive shaft

In

the center of the pins and the jour-

to

the

nals, holes for forced lubrication are drilled through.

(See Fig.

4-3

4-3-1

The connecting rod is made

2.)

CONNECTING ROD

CONNECTING

ROD

and

PISTON

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 withstand the pressure resultant from pitching during high-speed operation. At the larger end thin kelmet is fitted for increasing durability.

4-3-2

Piston pression rings and an oil at the pistion head, where combustion gas is made up mixing atomized fuel and air, and ignites. (See Fig.

PISTON

is

made of cast aluminum alloy, and it has

ring.

Combustion chamber arranged

two

3.)

com-

by

Fig.

2

3

4-4

CYLINDER

4-4-1

CYLINDER

Cylinder is made

and

CYLiNDERHEAD

of

aluminum alloy die casting, in which special cast iron liner is cast, and is provided with many cooling fins designed for effective cooling.

4-4-2

The most important part It is a one-piece of aluminum alloy die casting,

take and exhaust ports, and rocker chamber are cast

CYLINDERHEAD

of

the diesel engine is cylinderhead.

in

which in-

in

the most ideal structure for the highest strength and the highest cooling efficiency. In the valve seats fine quahty heat resistance seats are pressure-fitted considering

-

to

abrasion and corrosion at

high

temperature. (See Fig.

high

resistance

4.)

-6-

Fig.

4

4-5

GEARCASE COVER

Gearcase cover is made of aluminum alloy die casting and

fitted on the reverse side of the flywheel.

This

cover em-

is

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.

4-6

5

.)

CAMSHAFT

The camshaft is made of forged chrome steel wholly sintered

viz.

and then ground. It carries three cams,

one intake cam,

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

in

is

assem

the

shaft is supported by a ball bearing pressure-fitted gear case cover and by the gear case. The camshaft 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

Fig.

hand cranking. (See

6.)

Fig.

5

i

4-7

TAPPET

4

-7

-

1

TAPPET

Tappet is made and then taftride finished. The camshaft has

and

TAPPET GUIDE

of

forged steel and wholly sintered, ground,

oil

holes for

lubricating tappets.

4-7-2

Tappet guide is made termines tappet positionsand

In the crankcase there

through

(See Fig.

4-8

TAPPET GUIDE

up till rocker chamber via push rod sleeve.

6.)

ROCKER

Rocker arm

of

aluminum alloy die casting and de-

is

fitted

is

a blow-by gas hole, which hole goes

ARM

is

made of forged steel and

to

the gear case cover.

is

wholly sintered and then ground, and it

one end it has valve clearance adjusting screw. With this screw valve clearance

is

lock nut. Lubrication of the rocker arm

carried out by the

take rocker arm has decompression mechanism. (See Fig.

oil

splash contained in the blow-by

6.)

is

adjusted

Fig.

6

is

supported by the rocker shaft. At the

to

the specified gap and is fixed by

gas

from the crankcase. In-

-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.

is

Rocker cover has a breather; and the air breathed

brought

to the intake port.

(See Fig.

4-10

7.)

GOVERNOR

SYSTEM

Fig.

7

.

.-

!

The governor is a centrifugal flyweight type

on

the governor gear. Through

the

lever it adjusts the rack

and

is installed

of fuel injection pump and keeps constant operation at the selected speed against load variations.

(See Fig.

4-

8.)

I

f

LUBRICATION

SYSTEM

Lubrication is wholly filtered and pressurized lubrication

oil

system by trochoid type

pump. From the main gallery

in the crankcase the pressurized oil runs through the crank

of

journals and crankpins, and from the larger part

oil

is

the

supplied in the form

sary to be lubricated, while part

of

splash to the parts neces-

of

the

oil

also runs through

the rod

the bearings of camshaft to lubricate both intake and ex-

Ths

haust cams, and tappets.

system includes the governor

gears and it is installed in the crankcase.

Fig.

(See

9.)

’

:

1

Fig.

8

-8-

fig.

9

4-12

COOLING

SYSTEM

The cooling fan and the flywheel are a single piece casting

is

and it

fitted to the top end of the crankshaft.

produced by this fan blows

cools

inder baffle, and (See Fig.

4-13

lo.)

INJECTION

cylinder and cylinderhead.

PUMP

through

blower housing and cyl-

Cooling

air

The plunger of the fuel injection pump is operated by the injection pump cam, and the fuel

ized

in the pump and supplied to the nozzle

the tank

is

via

pressur-

the high

from

pressure pipe.

CYLINDER

Fig.

70

BAFFLE

11

(See Fig.

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.

U

11

-9-

Fig.

12

4-15

COMBUSTION

For

lower fuel consumption and easy starting of the engine,

SYSTEM

the direct injection system is adopted in the combusition chamber.

4-15-1

FORMING

TION

of

COMBUSTION GAS

and

COMBUS-

/INTAKE

INTAKE

SWIRL

VALVE

PORT

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

in

the cylinder during inspiring stroke, and it decreases

of

air generated

during compressing stroke but it still remains and pro-

air

motes mixing of fuel and

of

air

Spiral flow intake port, which

Tail

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

(swirl)

is

called helical port

toward ignition timing.

is generated by the shape of

or

spiral port.

Fig.

13

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

air

is

passing through this part, swirl around the intake valve. Thus, intake port plays an portant role in generating

SQUISH

(Squished air flow)

swirl.

(See Fig. 13.)

is

generated

im-

In the piston, combustion chamber (dish type com-

bustion chamber) is formed. When the piston comes

TDC

up to

in

the combustion chamber and air flow is generated,

which is called “squish.” (See Fig.

FORMING

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

14.)

of

COMBUSTION

GAS

and

COMBUSTION

Fig.

14

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

For

evenly in the combustion chamber. pressure, i. e.

195

kg/cm2. The fue!, thus injected,

ths purpose, fuel should be injected through hole type nozzle by very

is

mixed with

air

by

the flow of swirl and squish while piston

oil

particles

CYLINDER

PISTON

for

distributing

high

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.

-

10

-

4-16

SECTIONAL

VIEW

of

ENGINE

-

11

-

EXHAUST VALVE

ROCKER

COVER

INTAKE VALVE

CYLINDER HEAD-\

L

CY

BA

\\

AIR CLEANER

OIL

PAN-’

-

12

-

5.

DISASSEMBLY

5-1

PREPARATIONS

1)

When disassembling the engine, remember well the locations

rectly. If you are uncertain

2)

Have boxes ready to keep disassembled parts

3)

To

prevent missing and misplacing, temporarily assemble as much as possible each

parts such

4)

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

5)

Use the correct tools in the correct way.

5-2

SPECIAL

as

TOOLS

and

REASSEMBLY

and

SUGGESTIONS

of

identifying some parts, it

bolts and nuts, etc.

by

is

group.

of

individual parts

suggested that tags should be attached to them.

so

that they can be reassembled cor-

group

or set

of

disassembled

,-

small

I

228

I

22895002

I

228

Tool

95001

95003

No.

07

I

Flywheel puller with bolt

1

Box wrench

I

Piston ring expander

Tool

/

I

PISTON RING EXPANDER

Use

For pulling off the flywheel For removing or fastening the

flywheel nut

For placing piston ring

I

Fig.

-

13

\BOX

15

-

WRENCH

5-3

DISASSEMBLING

SEQUENCE

Se-

quence

1

2

I

3

4

*Length

Item Procedures Remarks

~~~~~~~

Engine

oil

Fuel

Fuel tank

of

the bolt indicates the length from the bolt head bottom surface

~ ~~~ ~ ~ ~~~ ~

Remove the discharge

oil

drain plug and

oil.

Oil

drain plug locates under the gear case cover. (Remove

oil

filter.)

Discharge fuel from the tank. Fuel pipe locates

of

injection pump.

on

the side

Remove the fuel pipe.

-

~~~ ~ ~~

Be sure not

“0”

ring. The drain plug serves as an (See Fig.

Be sure not gasket. (See Fig.

Remove the banjo bolt on the side

There are

aluminum gasket.

Remove the fuel return pipe.

There are

aluminum gasket.

Remove the tank band.

Muffler

Remove the muffler cover.

Remove the muffler.

Be sure not

gasket.

to

oil

16.)

to

17.)

of

2

sheets

2

sheets

to

miss

the

fiIter too.

miss the

the tank.

of

miss the

to

*

**W

Bolts,

nuts etc. used

6

mrn

hex. bolt

SW

.

. . 2

pcs.

17

mm hex. bolt.

8

x

18 banjo bolt

6

x

45

round head cross

recess bolt

No

SW,

W

6

x

X

mm flange bolt

. . .

4

pcs.

the threaded end.

SW

+

Spring

water

Plain washer

2

pcs.

.

1 pce.

.

1

pce.

. . .

+

. . .

~

2

pcs.

b

5

6

7

High

Pipe

Air

Tank

pressure

cleaner

bracket

high

Remove the

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

Be careful inside

of

joint

of

nozzle free

the pipe, pump,

dust.

Remove the

the

cylinder head.

air

cleaner from

The gasket

that of the muffler.

Remove the bracket from the Just loosen crankcase, left and right, each.

to

keep the

is

same as

8

mm nut.

of

12

mm nut.

8

mm nut.

sw

.

. .

8 x 16

2

7T

. .

.

pcs.

bolt..

2

pcs.

.

2

pcs.

Fig.

16

-14-

Fig.

17

-

Se-

quence

8

Fly

Item

wheel

Procedures

Remove the flywheel cover. Remove the driving shaft.

Raise up lock washer, loosen lock nut and then remove the flywheel from the crankshaft using the flywheel puller.

(41

mm box spanner)

Crankshaft, normal threading (See Fig. 18.)

Bolts,

nuts etc. used Remarks

Blower housing

9

Cylinder baffle Remove the cylinder baffle

10

Rocker cover

Nozzle holder

l3

I

14

Rocker

Cylinderhead

arm

Remove the blower housing from the crankcase.

from the cylinder.

Remove the rocker cover from the cylinderhead.

the cylinderhead. Loosen the nuts fastening the Loosen the tappet adjust-

cylinderhead. ing bolt and

I

Pull

out

the rocker shaft from the cylinderhead and remove the rocker

Loosen

fastening

on

the side

Pull

arm.

6

mm

the

out the push rod.

nut

which

push rod sleeve

of

cylinderhead.

Just loosen the flange bolts.

~~ ~~

Be sure not to miss 5 mm nut.

At the top end the Remove the nozzle holder from gasket

is

fitted.

the

decompression adjusting bolt, which latter

side

of

(See Fig.

is

Just loosen

is

on the

the intake valve.

19.)

6

mm nut.

6

x

8

flange bolt

No

W.

8

x

55

7T bolt..

sw

.

..

2

pcs.

8

x

40

7T bolt.

sw .

.

2

pcs.

~ ~~ ~~ ~~

5

x

10

round head cross

recess screw

6

x

35 7T bolt.

sw

. . . 3

6

mm nut.

sw

. . .

6

mm nut.

2

. .

pcs.

.

pcs.

. . 2

.

2

.

pcs.

.

2

.

2

1 pce.

.

3 pcs.

2

pcs. pcs. pcs.

Fig.

78

-

15

-

l"2L

quence

I

l5

ICylrnder

Procedures

Remove the cylinder.

Remarks

are rubber copper shim. (See

Fig.

"0"

20.)

ring and

I

Bolts,

nuts

etc.

used

b

17

18

19

Tappet guide

Injection pump

Gear case

Remove the push rod sleeve

from the gear case cover.

Remove the tappet guide from the gear case cover.

Remove

Put

center. Remove the injection pump

from the gear case cover. Remove the handle guide.

Remove the gear case cover

from the crankcase.

It

oil

filler cap.

the control

rack

at the

.

r-

.c.

.P

A

holder not let (See Fig.

Check the control rack. (See

(See Fig.

fall

Fig.

is

necessary for

the tappet.

2

1

.)

position

22.)

23.)

6

mm

nut

. . .

2

pcs.

sw

. . .

2

pcs.

of

8

mm

sw

6 x 6

sw

8

x

8

x

sw

nut

. . .

3

pcs.

hex. bolt

. .

.

2

35

7T

80

7T

.

3

.

pcs.

bolt.. bolt.

pcs.

3

pcs.

.

.4

. .

2

3

pcs.

pcs. pcs.

/."-

Fig.

20

22

/"

\-

Fig.

23

Procedures Remarks

20

Camshaft Pull out the camshaft. Between camshaft and

gear case there (See Fig.

24.)

is

a shim.

Bolts,

nuts etc. used

Piston Remove the piston from the

21

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

22

23

Governor

oil

Oil

and

pump

pan Remove the

From the crankcase remove the governor and the

form

of

one

oil

crankcase.

oil

pump

in

piece.

pan from the

Watch the direction of the clip, also pay attention to the direction of the piston.

(

"f

mark indicates "to-

ward the fan side.")

(See Fig.

Be careful

25.)

of

the pack-

ings.

6

x

20

sw

.

6 x 12

sw

. . .

.

7T

.

2

bolt

8

bolt

pcs.

.

pcs.

. .

.

8

.

pcs.

2

pcs.

/"-

Fig.

24

Fig.

25

-

17

-

Se-

tuence

I_

24

Item

Connecting rod

Procedures

Remove the connecting rod from the crankshaft.

Remarks

No

lock washer. Be careful of the direction of rod. (Fan mark

is on the side of the

flywheel.) Be careful mark

(See Fig.

of

the

26.)

cap.

the setting

Bolts,

nuts etc.

used

25

Bearing housing and 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.)

Be careful of the copper

shim

and

“0”

ring

between the bearing housing and the case.

Also

be careful

hole for

oil.

of

the

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

The bearing remains on the crankshaft. (See Figs.

27,

28

and

29.)

8

x

SW

22

. .

7T

.6

bolt.

pcs.

.

6

pcs.

Fig.

26

28

-18-

Fig.

27

1

quence

T

Item

Procedures

1

I

Remarks

1

I

Bolts,

nuts

~Pc.

used

Intake and exhaust valve

Fj

Remove the intake and exhaust

valves

from

the cylinderhead.

Fig.

of is

30.)

intake

a stem

On the side valve, there seal. Be sure not to miss retainer lock. (See Fig.

30

J

Se-

2

3

I

tem

Snap ring

Balancer shaft

Balancer

Procedures

Remove the

Remove the balancer shaft.

Remove the balancer from

the case.

snap

ring.

Remarks

Be sure not

snap

(See Fig. Gently tap with plastic

hammer. Be careful not

the

thrust

side of the pump.

The gear and the needle

bearing are

(See

ring.

Fig.

to

3

1

.)

metal

in

32.)

miss the

to

damage

on

the

one piece.

Bolts,

nuts etc.

used

Fig.

31

-19-

Fig.

/“-

32

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

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

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-

oil

seal.

If

faulty one is found, replace it without slight hesitation.

to

the specified figures.

tntion to the frictional noise and resistance.

2.

REASSEMBLING

1)

Insert the crankshaft into the crankcase.

CAUTION:

on the side

Be careful not to damage bearing metal

of

injection pipe.

For the engine with the balancer, fit the balancer first

it

to the crankshaft, and then put

CAUTION:

(See Fig.

33.)

When

fitting,

check the match mark.

into the crankcase.

2)

Assemble the bearing housing.

8

x

22

7T

bolt

............

Spring washer

NOTE: CAUTION:

NOTE:

............

Apply

oil

Be sure

Set

the

or

bearing housing

may face upward.

(See Fig.

34.)

6

pcs.

6

pcs.

grease inside the housing oil seal.

to

put

"0"

ring

on.

so

that

its

oil

hole

Fig.

33

-q

3

Fig.

34

-

20

-

NOTE: With the copper shim adjust the side clear-

of

ance

Three kinds

and

[Tightening toruque:

the crankshaft be

of

shim

0.3

mm

thick.

0.1

-

are available,

200

-

230

0.2

mm.

viz.

kg-cm]

0.1

mm,

0.2

mm,

:-

(See Fig.

Assemble the connecting

3)

CAUTION: Pay attention to the direction

(FAN

NOTE: Check the match mark NOTE: The lock washer the bolt. [Tightening torque: 250

(See Fig.

35.)

mark

36.)

is

to be

rod.

set

on the side

is

not used when fastening

of

the flywheel.)

on

the cap.

-

270

of

the

kg-cml

rod.

Fig.

35

u

4)

Assemble the

6 x 12

Spring washer

NOTE:

(See Fig.

oil

pan.

bolt

..............

............

Pay

attention to the packings.

37.)

8

pcs. pcs.

Fig.

36

Fig.

37

-

21

-

Assemble the

MOTE:

be faced to the fan side.

MOTE:

(See

Fig.

piston.

+

mark in the upper part

Piston rings are not assembled.

Shape of the piston pin.is

38

.)

Assemble the cylinder

NOTE:

ring

the head

NOTE:

Insert the piston into the cylinder (piston

is

not inserted.), and measure the dimensions of

of

piston and upper surface of the cylinder.

The concave dimensions of the pistion

of

the piston

(D

.

is

to

-0.6

-

Fig. 38

-0.7

mm from the upper Surface of the Piston.

MOTE:

ness

MOTE:

Punched mark

to be

NOTE:

Be sure to Notched portion

Adjustment

of

the shim are

Fit the piston rings on

set

to the different three directions.

Set

the cylinder.

fit

rubber

TOP

RING

SECOND

OIL

RING

of

the concavedimensions

0.1

mm and

"N"

are to be faced up. Open end

"0"

ring and

of

the cylinder skirt must

0.2

the

mm.

piston.

shim.

D

RING

I

23

is

to be made by the shim underneath the cylinder, and available thick-

of

each ring must avoid the direction toward the thrust side and

be

set

on the side

of

the gear case cover.

(See

Figs.

39-1

and

39-2.)

it

is

1

7)

'

Install

the

41

(Use

NOTE:

bend the tabs securely.

[Tightening

(See

mm

When putting lock washers on, be sure to

Fig.

40.)

flywheel.

box

wrench.)

torque:

Fig. 39-

7

2,000 - 2,200

kg-cml

Fig. 39-2

fig.

40

-

22

-

8)

Install the camshaft.

NOTE: NOTE:

0.1

Apply Set the match mark

-

0.3

oil

mm.

Three kinds

or

grease

to

the inside

of

the camshaft

of

shim are available, viz.

of

oit

seal

so

for

the gear case cover.

as

to

fit

to

that

0.8

mm,

1

of

the crank gear. Side clearance

.O

mm

and

1.2

mm.

is

to

be adjusted

to

r

9)

Assemble the

6

x20

Spring

NOTE:

downward.

NOTE:

Outer surface side. (See

[Tightening torque:

10)

Assemble the gear case cover.

8

x

5

7T

Spring washer

NOTE:

top

of

the camshaft.

8 x 65

Spring

NOTE:

[Tightening torque:

oil

7Tbolt.

washer

The hole

Check

of

Fig.

bolt,

When

7T

bolt.

washer

Check

pump

...........

............

if

the governor sleeve moves

the

43.)

...

............

the pin

...........

............

if

Fig.

41

and the governor.

2

pcs.

2

pcs.

in

the

oil

pump

cover is

trochoid

80 - 100

,

........

the governor link operates.

200

pump

must face the case

kg-crn]

4

pcs.

4

pcs.

is

replaced, apply "Three Bond" at the

3

pcs.

3

pcs.

-

230

kg-cm]

to

smoothly.

face

both

ends

of

the

Fig.

42

Fig.

43

for

cranking. This

\

locates at the

-

23

-

Assemble the injection pump.

8

mm

nut

...............

Spring washer

NOTE:

fitted. And adjust

0.3

mm.

CAUTION:

(See Figs.

............

Measure the distance between the face

it

may become

Remove the

44

and

45

oil

filler cap and check

.)

-

.

.-

l._l

3

pcs.

3

pcs.

76 k 0.05

___

of

the cam base and the surface to which the injection pump

mm, using the shims. Two kinds of

if

the control rack comes off from the governor lever.

"I

~

."

,

,-

the

shim are available,

viz.

0.1

is

to be

mm, and

Assembe the tappet guide.

CAUTION:

case.

NOTE:

at

the right side

(See

Fig.

13)

Temporarily assemble the push rod sleeve.

6

mm

Spring washer

NOTE:

Be careful not

The roll pin of the tappet guide

as

viewed from the gear case side.

let

46.)

nut

...............

............

2

pcs.

of the plate (push rod

the tappet

2

pcs.

2

pcs.

sleeve)

fall

in

the

is

to

be

set

are to be assembled temporarily.

Fig.

45

46

-

24

-

Assemble

10

Washer

NOTE: Install the intake and exhaust intake side there NOTE: Insert the push rod. (Exhaust of

the

ward or downward, and direction haust.

NOTE: Install the rocker arm

It

is

ing the head.

(See

NOTE: Clamp the head to the cylinder. Apply "Three Bond bolt (on the side of the rocker

reverse

nuts.

[Tightening torque:

.

Tightening of the nuts

I.

e.:

1

st

2nd round 3rd round NOTE: Fasten tightly the plate (push rod sleeve).

6

mm

(See

the

cylinderhead.

mrn

flange

nut

..........

.................

is

a

stem

seal.

gear case.) Pay attention to the

advisable to insert the rocker shaft before clamp-

Fig.

47

.)

#I

21

5"

surfaces

round

of

the

washer, and then tighten

350

kg-cm]

is

to be done in three rounds,

...............

nut

...............

Fig.

48.)

4

pcs.

4

pcs.

valves.

is

valve

of

intake and ex-

to

the cylinder.

to two pieces

shaft)

and upper and

100

kg-cm

200

kg-crn

330

-

4

pcs.

on the side

of

350

On the

facing,

the stud

kgcm

UP-

the

a

Fig.

47

I

15)

Adjust

the

valve

clearance. NOTE: Turn the flywheel by hand sion

at

TDC (top dead center). At TDC cranking pin stands vertically. NOTE: Adjust the tween when the engine

(See

0.07

Fig.

-

49.)

valve

0.10

mm (both intake and exhaust),

is

cold.

to

the compres-

the

camshaft

clearance to anywhere be-

-

25

DECOMPRESSiON ADJUSTING

Fig.

49

\,

SCREW

-

INTAKE, EXHAUST VALVE TIMING

TDC

(TOP

INTAKE VALV

DEAD CENTER)

When valve clearance heated, intake valve opens at intake valve closes exhaust valve exhuast valve closes at

(See

Fig.

opens

50.)

at

is

16O

54'

14"

at

0.4

mm

before TDC, after BDC,

before BDC, and after TDC.

Adjust the decompression clearance.

NOTE: NOTE: NOTE:

another half

Turn

The

decompression device locates

Set

the

decompression lever at

Clearance

turn.

the flywheel

is

about

0.5

mm.

Threading

by

of

this

hand and check a contact between the valve and the

Assemble the rocker cover.

6

x35

7Tbolt.

Spring washer

NOTE:

Check Check

...........

............

if

there

is

an

"0"

if

the gasket

for

3pcs.

3

ring

the

and the engine

in

the rocker arm

the

position

Turn

the adjust screw

screw

is

1

.O

mm.

pcs.

for

breather hole

rocker cover

is

INTAKE VALV AUST

BDC

(BOTTOM

on

the intake valve side.

of

decompression. (Push the lever

until

it

touches the decompression shaft, and then make

piston.

on

put

correctly

the surface

of

the head (intake breather's side).

in

the groove.

DEAD CENTER)

Fig.

50

to

the

VALVE

horizontal position.)

Install the nozzle holder.

6

mm

nut

...............

Spring washer

NOTE:

[Tightening torque:

............

Pay attention

90

to

the gasket at the top.

-

100

Install the blower housing.

8

x

55

7T

shaft.

bolt

....

bolt

....

Upper part:

Lower part:

Install the

10

x

30

bolt

Spring washer

8

x

40

Spring washer

driving

.............

Assemble the flywheel cover.

8

x

16 bolt

..............

Assemble the cylinder baffle.

6 x 8

flange bolt

5

x

75

round head cross recess

bolt and nut

(See

Fig. 5 1

...........

5

mm

.........

.)

2

kg-cml

...

2

...

2 2

4

2

pcs. pcs.

pcs. pcs. pcs. pcs.

pcs.

1

pce. each

It

is

advisable

to

utilize the driver foreasy installation.

Fig.

51

26

-

Install the tank brackets, left

8

x

16

7T

bolt

............

Spring washer

8

mm nut bolt

............

and

right.

2 PCS. 2 pcs.

2

pcs. each

Connect the fuel pipe and fuel return pipe securely.

8

x

18 banjo

Aluminum packing

NOTE:

bolt

..........

.........

Connect the pipe to the nozzle first, and then connect the fuel pipe to

2

pcs.

2 pcs.

Install the air cleaner.

8

mm

nut

Spring washer

NOTE:

Pay attention to the gasket.

...............

............

2

pcs.

Install the muffler and the muffler cover.

8

Muffler:

mm brass nut

Spring washer

Muffler cover:

NOTE:

Pay attention

Connect the

It

is

advisable

then connect.

6

x

8

high

pressure pipe. (See Fig.

to

remove the cap of the

.....

.......

flang bolt.

to

the

gasket.

2

2 pcs.

.

4

pcs.

52.)

air

cleaner and

Mount the fuel tank.

x

45

round head cross recess

6

..................

screw

When installing tank, fasten the filter by hand and then make

with

a

spanner.

Install the

6

x

12 bolt

Spring washer

The

oil

filter serves

Be sure to install

the

fuel filter once removed from the

oil

filter

..............

............

as

the oil drain plug too.

"0"

ring.

2

pcs.

pcs. pcs.

1/4

turn

Install the handle guide.

6

x

12

bolt

Spring washer

..............

............

2

pcs.

2 pcs. Supply engine oil. Upper level Lower level

Also

pour oil into the

..............

Supply diesel light Fuel tank capacity

air

cleaner, watching oil

oil.

.........

1

.O

0.6

4.5

R

max.

II

min.

R

level.

the

tank.

Fig.

I.-

52

-

27

-

6.

0-1

FUEL

QUALITY

Of

FUEL

Because

pump, nozzle, and

HIGH

of

the

high

NOZZLE

PRESSURE PIPE

speed diesel engine, be sure to use the good quality diesel light

piston

develop troubles. (See

Fig.

53.)

FUEL RETURN PIPE

i

f

T

"

\

/

f

UEL

TANK

/

\

oil.

If

improper fuel

is

used, the injection

AIR RELEASE

FUEL

FILTER

PIPE

FUEL INJECTION PUMP

TANK FILTER PIPE PUMP PRESSURE

t

FUEL RETURN

PIPE

Fig.

53

FUEL PIPE

PIPE

-

28

-

7.

GENERAL DESCRIPTION

7-1

FUEL

INJECTION

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 to sat-

PUMP

of

AUXILIARY

MECHANISM

GADGETS

and

PARTS

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

Theory

The

plunger of the injection pump

this up

of

the

injection pump mechanism

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

is

pushed up by the cam of the camshaft, and it is pushed down

54.)

is

to be delayed.

by

the plunger spring. By

Suction of fuel Through the filter in the fuel tank, fuel

supplied and is

in

full around the intake port of the plunger barrel. When

is

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

is

When the plunger is pushed down passing the fuel intake, fuel

of

arrival

the plunger at the bottom of its stroke.

This

is on the stage of "suction."

sucked into the barrel, and suction is continued until

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

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

(100

ized by a,very strong force

the damping valve, and then it injects the fuel into combustion chamber.

kg/cm2 and up), and as a result, the force of the fuel pushes up the delivery valve and

This

is on the stage of "pressurized supply."

of

the

VERTICAL

INTAKE

(EXHAUST PORT)

HOLE

PORT

DAMPING VALVE

DELIVERY VALVE

PLUNGER BARREL

PLUNGER

LEAD

Fig.

-

29

EFFECTIVE STROKE

54

-

3.

Variation in quantity

The quantity

of

fuel injected vanes according to the condition loaded or unloaded operation. (See Figs. The plunger lead is engraved

of

the upper part Rotation rotates,

of

which

the plunger and the suction port

the plunger

is connected to the plunger

of

fuel

to

be injected

of

the engine, i. e. high speed or low speed operation and

55

and

56.)

on

the surface of plunger in

is

made by the control rack. When this control rack

by

means of the control sleeve. In other words, the plunger turns as much amount

an

inclined curve. By rotating the plunger, the distance between

varied. (Variation in effective stroke)

is

shifted to left and/or right, the geared pinion

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

2)

Relation between the plunger and the rack

PORT

INJECTION INJECTION INJECTION INJECTION

STARTS. ENDS. STARTS. ENDS.

MAX.

DELIVERY

Fig.

55

HALF DELIVERY

NO DELIVERY

MAX.

DELIVERY

CONTROL SLEEVE

HALF

Fig.

-

DELIVERY

56

30

-

NO DELIVERY

4.

Injection timing and effective starting

When the plunger closes suction port of the barrel, forced

is

delivery of fuel starts. But fuel

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

Injection timing of this engine is fixed constant

TDC)

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

a

proper delay from the timing for

ing,

not injected from the noz-

.

(23O

before

high

speed running

INSTALLED ONLY

TO

DY30

and increased fuel injection is indispensable for effective starting.

this purpose a notch is

made

at the plunger

Fig.

57

For

head, whch reserves to delay the injection timing by nearly

8"

to facilitate starting. (See Fig.

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 pipe, the delivery valve spring is pushed down and the valve opens.

57.)

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

spring

by the

tension of the valve. At this time, delivery valve prevents reverse

around the upper part of the plunger sucks back the fuel

high

pressure in the

pressure pipe. The nozzle jets the fuel clearly off and prevents after dripping. (See Fig.

in

the equal amount of the stroke [A] and decreases remaining

flow

of the fuel.

Also

suction back motion

58.)

pressure

is

closed

!I!

6.

Function

The damping valve is assembled in the end pump and it reaches the at the seat. The fuel to the chamber ly, descending velocity of the delivery valve

of

the damping valve

seat

small

orifice

in

the delivery valve holder. Accordhg-

before arrival of delivery valve

in

the valve

/

DELIVERY VALVE SPRING

DELIVERY VALVE

of

injection

is

the passage

is

decreased,

Fig.

of

which prevents the negative pressure being produced suddenly. engine noise is decreased. (See Fig.

As

a result, proper injection is conducted and the

59.)

58

DAMPING VALVE

DEL,VERY

VALVE

ION BACK

Fig.

59

STROKE

-

31

-

0

FUEL

INJECTION PUMP

DAMPING VALVE DAMPING VALVE

SPRING

DELIVERY VALVE

PUMP

HOUSING

-

STOP

AIR RELEASE BOLT HOLDER

CONTROL RACK PLUNGER ASSEMBLY

CONTROL SLEEVE

SPRING

SEAT

Fig.

DELIVERY VALVE

PLUNGER SPRING

60

0

SPECIFICATIONS

of

FUEL INJECTION PUMP

Model Maker Plunger diameter

Lead Plunger spring arbitrary

valve

Delivery Delivery valve spring constant

Pump rack friction load

opening pressure

for

THIS

DIESEL ENGINE

-32

-

PFRIKD55/2NP1

Diesel Kiki

5.5 mm

Right twist lead

2.46 kg/cm

27.5 kg/cm2

0.51

0.062 kg

K.K.

kg/mm

16 mm Rack stroke

7-2

FUEL

1.

Specifications

INJECTION

~ ~~

Part

Name

Part No.

NOZZLE

HOLDER

I

NOZZLE

105

11840

HOLDER

00

I

(0.22

195

kg/cm2

13.2

C

4 No.

mm)

kg/cm2

-

a

fog

for combustion. There are

Identification

of

nozzle

mark

hole

(Diameter)

Valve opening pressure

Spring constant

2.

Features

Both the injection nozzle and the injection pump are very important parts for producing fuel

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

engine

developed as a result

of

joint research and development project by Diesel Kiki,

K. K.

and our company, and it is

is

direct combustion system, having the special hole type nozzle. For producing better combustion gas, it utilizes

up

to

195

pressure is raised

3.

Structure

Ths consists

of

the the nozzle holder and nozzle. The nozzle

kg/cm2.

ignition

nozzle holder

swirl

and

squish

flows

and for producing the most proper fuel fog, injection

IDENTIFICATION

\

MARK

FUEL

/

INLET

holder fixes the nozzle to the cytinderhead and at the same

of

time it plays the role

valve opening pressure

fuel passage

of

nozzle is adjustable. However, the

nozzle for DY30 and DY35 engines includes spacer

to

the nozzle. (The

in

it and

TlNG WASHER

it is unadjustable.)

The nozzle consists

of

the nozzle body and needle valve;

NOZZLE SPRING

and when the pressure reaches the limit to open the valve, nozzle unadjustable.)

for

this diesel engine includes spacer

in

it and it is

Fig.

61

NOZZLE

BODY

/-

4.

Function

of

nozzle

Through the injection pump, fuel is delivered forcibly into

up

the nozzle body and it raise

the needle valve and is at-

omized in the combustion chamber through the holes of

of

the nozzle body. In case

of

the opening

the holes does not alter. (See

the hole type nozzle, the size of

Fig.

62.)

-

33

-

VALVE

CLOSED

Fig.

VALVE OPENED

62

5.

Fuel

passage

1

From the plunger pump fuel is sent through the highpressure pipe

to the fuel passage

2.

Then, at the nozzle body

3,

2

1

it is pressurized up till 195 kg/cm2 and it lifts up the needle

4

for

0.18

valve chamber via the jet hole

An

excess fuel which lubricated the inside of the nozzle and nozzle holder returns to the fuel tank via the needle valve nozzle spring

(See Fig.

6.

63

Inspection and maintenance

Fuel spraying condition function, insufficient output, increase

main courses of the nozzle trouble. Therefore, exert good care for managment

mm, and is sprayed into the combustion

5.

6

+

overflow pipe

7

+

fuel tank,

.)

of

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

of

noise and exhaust smoke. Use

+

3

4

Fig.

of

improper fuel and contaminated fuel is one of the

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

in

After cleaning nozzle holder outside, inspect

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

Fig.

*Fit the nozzle holder to the nozzle tester.

CAUTION: When removing the nozzle from engine or fitting the nozzle free of dust.

it

to the tester, be sure

*Move the lever of the nozzle up and down for

3

times and suck the air inside the hozzle.

CAUTION: Never bring your face near the pressurized

hands from the fog.

fog

from the

nozzle.

Also

keep away your

to

the

keep

2

-

*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 standard value, the nozzle is in a good condition,

*Push

further and check whether or not the fuel fog

NOZZLE

is injected straight.

CAUTION: Good injection Just

after

injection, check "after dripping."

is

straight forward.

Fig.

7

6

5

63

64

65

-

34

-

2)

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

a) Disassemble the nozzle holder and nozzle, and wash

oil.

in clean light

(for instance, wooden chopstick is servicable.) for peeling off the carbon adhered to the nozzle.

b) After washing, pull out the needle halfway from

the body of nozzle with your fingers and then let

go.

And check

it

weight. c) If it does not sink, replace d) Frinction surfaces of both the needle and nozzle

body are ultra precise finish.

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

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

is

advisable to replace it in the form of a set, nee-

it

dle valve and nozzle body. However,

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

ready adjusted

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,

[Tightening torque:

i)

Recheck with the nozzle tester, if necessary.

When washng, use a wooden chip

if

the needle sinks by its own dead

it

in the form of a set.

So,

be sure to keep

of

dust.

it

is possible

by

the adjusting washer.

400

-

500

kg-cml

Fig.

66

is

unnecessary because

in

NEEDLE

BODY

viz.

the

following

it

was

al-

-35

-

7-3

GOVERNOR MECHANISM

1.

Mechanism

The governor sembled

is

centrifugal flyweight type, which means a flyweight is fitted to the governor

so

that it may slide toward the direction

governor sleeve gets

This

pump operate.

mechanism enables to maintain constant operation irrespective

and

OPERATION

gear.

The governor sleeve is as-

of

the axis

in

touch with the governor yoke, and through the governor lever it makes the control rack

FUEL INCREASE

of

the pump shaft, and it

FUELDECREASE

is

in

contact with the flyweight. The

of

load variation.

7

INJECTION PUMP

of

injection

GOVERNOR

FUNCTION

GOVERNOR

at

STARTING

at

OPERATING

YOKE

OBLONG HOLE

GOVERNOR

GOVERNOR SPRING

LEVER

SPEED CONTROL LEVER

=I>

1

CONTROL LINK

LOW

HIGH SPEED

SPEED

GOVERNOR

START

SPRl

SHAFT

NG

-

36

-

Fig.

67

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

1

governor levers

and 2 are pulled by the tension

toward “fuel increase.” The governor lever

of

the governor spring. The control rack

1

has an oblong hole, and the governor lever 2 moves to the extent of this

of

injection pump is pushed

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

of

of ”fuel increase.” This movement within the extent

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 pushes the control rack of the injection pump toward “fuel decrease.’’ The governor lever again moves of the oblong hole. Thereafter, the governor lever the specified revolution. Suppose that a load

2

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

to

1

and the governor lever 2 move simultaneously

is

put suddenly on, the fuel supply is as it

is

at that instance, accordingly

and

are balanced at

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 governor spring. The control rack of injection pump

3)

Stopping

2

moves to the position where it balances the tension

is

pushed toward “fuel increase” and engine revolution revives.

The governor plays a role exactly reverse to that of starting. When the speed control lever is set at the position

“Stop,” it pushes the control rack

of

injection pump toward

“No

Injection” and the engine stops.

link.

The

the extent

of

the

of

,“-

3.

“Revolution Playing Angle”

This mechanism is to supply more fuel than the maximum supply for normal high speed operation. This mechanism is developed for the purpose of improving starting ability.

1.

Required amount of fuel supply is set by the governor lever

2

governor lever control rack

is fitted.

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,

As

the start spring

is

pulling the governor lever

.”

the governor functions and accordingly the governor lever

1

hole. The governor levers

and 2 incroporate each other and pushes the control rack

The governor lever 1 has an oblong hole, to which pins of the

2,

it moves toward the arrow mark

2

moves toward the arrow mark B within the extent of oblong

of

the injection pump.

A.

Then the

-

37

-

7-4

LUBRICATION SYSTEM

and

OIL

PUMP

Lubrication assembled in one piece, which Revolution of the crankshaft is reduced by the reduction gear lubricated to the crank journal. That splashed to the piston, small end of the connecting,rod, cylinder, etc. Also from the main gallery oil the cam shaft bearing and is sent to cam lobe relief valve is assembled, and it adjusts the splash of

Furthermore, blow-by gas containing oil

LUBRICATION CHART

is

forced lubrication

oil

pushed up by blow-by gas, which lubricates rocker arm, etc.

and

wholly fdtered system by trochoid type oil pump. The oil pump, and the governor are

is

fitted to the crankcase.

oil

will

further be supplied to the crankpin, large end of the connecting rod, and then

of

oil

pressure at 3 kg/cm2. Lubrication

will

pass through the breather, intake port and the cylinder, where

(1 : 1.4)

intake and exhaust valves and lubricate the tappets.

of the pump; and from the

in

the rocker chamber is conducted by the

r

BREATHER

I

main

I

1-1

*

gallery oil

is

forcibly supplied to

In

r

INTAK: PORT1

is

forcibly

the camshaft

it

is finally burnt.

I

t

COMBUSTION

oil

I

7-5.

OIL

Oil

filter

element

t

I

OIL FILTER

FILTER

is

made of double sheets of wire netting, and it

is

made

of

wire, it can be washed and used for many times.

1

$=I”!

PISTON, BEARING CYLINDER

SMALL END

Fig.

68

is

less flow resistance type, and

k’

is

called full-flow type. As the

-

38

-

7-6

ELECTRIC APPARATUS (Electric Starter)

1.

Wiring diagram

KEY SWITCH

GENERATOR

ELECTRIC STARTE

1)

Circulation When starting by the electric starter, (Key is at the position

(+)

-+

BAT

of

Battery

Charging, operating (Key is

Generator

2.

Lead wire

for

electric starter

"f

Rectifier

key + ST

at

the position

+

IC

of

key + Starter + Battery

of

operation.)

of

key

+.

BAT

of

key

of

+.

start.)

Battery

(-)

(+)

12V35AH

(earth)

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

3.

Earth band

BATTERY

StDE

TERMINAL ELECTRIC STARTER

JIS

Plain woven

Approx.

BA-508

lead

wire

I"

25

sectional

area

20

mm2

and

up.

L

Fasten tightly crankcase

4,

Other remarks

1)

All

Meantime, insert the connectors each other up till the

2)

The wire

the

3)

Select the wire

4)

When the key switch is set apart from the engine body, select the wire length

m

1.5

to

of

the engine.

the place made

of

metal and not paint coated. The place must be electrically conducted completely to the

lead wires are classified by coloring,

from

(+)

terminal

(-)

terminal must be connected to the earth

from

of

the wire between the key switch and the magnetic switch

I

Length

or shorter

Description

of

the battery must be connected to

the below Table

AV15

so

when connecting, select and connect by color.

roots.

of

the engme body.

A,

based

on

the required length

Outside dia.

7.3

mm

(+)

1.5

terminal

of

on

the side

Length.

m

or

shorter

JIS

of

the wire.

from

below Table B, based on the required

of

SIDE

BA-508

TERMINAL

the electric starter, and the wire from

engine.

Description

1

-25

Outside dia.

1.5

mm AV

I-

2.5

m

-

2.5 3

m

AV30

Table A Table

8.5

mm AV20 1.5

10.8 mm

-39

'i.5m-31-17

3m "5m

-

AV2

B

1.9

1.4

mm

mm AV3

,"-

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

oil

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

prevent recirculation of the hot air used Take steps as necessary to keep the engine room temperature below

8-3

deterioration, increased

EXHAUST GAS DISCHARGE

oil

consumption,

for

engine cooling, and temperature rise of the load (machine).

or

in a small room, temperature rise in the engine room can cause vapor

loss

of power, piston seizure, shorter engine life, etc., making it impossi-

60°C

even in the hottest period of the year.

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 to exhaust pipe length.

8-4

If the fuel tank is removed from the engine when mounting the engine with a machine, set the fuel tank above the fuel injection pump. If the tank is set too low, the fuel When piping be careful of heat conduction, pipe size, bends, and leaks from the joints and make the fuel pipe as short as possible

8-5

1.

Take the following notes into consideration.

2)

3)

4)

5)

6)

If

gas

is

noxious. When operating the engine indoors, be sure to discharge the exhaust gas outdoors. If a long exhaust

Less

Exhaust pipe:

FUEL SYSTEM

to

prevent air and vapor from being trapped.

POWER

Belt Drive

1)

V-belts are preferable to flat belts.

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

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

Install the engme pulley as close to the engine as possible. If possible, span the belt horizontally.

Disengage the load when starting the engine.

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

TRANSMISSION

than 3 m long, pipe inside diameter

Less

than 5 m long, pipe inside diameter

to

DRIVE MACHINES

30

38

mm,

mm.

will

not be supplied.

of

the load.

50

-

500

mm

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

is

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

1)

Correction Repair, adjustment

2)

Correction Limit The limit on wear, damage not be expected without repairing such parts.

3)

Use Limit The limit beyond which parts can no longer be used in respect

4)

Standard Dimensions

The

design dimensions of new parts

5)

Correction Tolerance Tolerance on the dimensions

recommended

or

replacement

or

functional deterioration of engine parts beyond which normal engine performance can-

of

by

observing the correction standards specified.

of

any engine parts.

minus

tolerance.

engine parts refinished

or

adjusted.

of

performance

to

the correction table. The correction

or

strength.

of

tlus

,

,--

-41

-

10.

TABLES

of

CORRECTION STANDARDS

r

ITEM

Flatness

Valve seat contact width

Valve guide I.D.

Inside dia.

Roundness after boring

Cylindricity after boring

S.

~

O.D.

at

skirt,

in

thrust direction

(Incl. over size)

Oversize

1.

D.

1

I

A

1

0

Intake

Exhaust

DY30D.

DY35D. DY41 D,

DYSOD, CY-35D.

DY41 D. DY30D,

DY41 D.

DY30D.

DY35D,

DY4t D,

STANDARD

I

6

I

B

I

B

B B

B

1

B

1.4

7

dia.

76dia.

82

dia'

75.96

81.94

76.21

76.46

82.44

CORRECTION

to.015

+0.019

+0.022

1

-0.02

I

0.03

0.01

0.01 5

LIMIT

0.05

2.2

0.1

-0.1

:ORRECTIOP

METHOD

5

0.25

+"

Width

of

groove for the rings

Piston

hole

Clearance between piston and cylinder

Clearance between piston ring and ring groove

Fit between piston and piston

Piston ring gap

DYSOD, DY350,B

DY41 D,

21 dia.

B

1

te"j

Oil

+O

,060

+O

.040

+0.025

+O

.005

M.008 to.001

0.04OL-0.079L

0.060L -0.1 02L

-

0.3

0.25

-

0.09L

0.5

0.45

0.05L

0.01 5L-0.055L

0.005L-O.008L

0.1

0.03

0.1

0.2

0.1

0.05L

3

5

0.15 I Skirt portion

0.2

1

5

0.1 5

1

0.05L

-42

-

r

ITEM

I

STANDARD

DIMENSIONS

CORRECTION

TOLERANCE

LIMIT

USE

LIMIT

REMARKS

I

:ORRECTlO!

METHOD

u

Piston ring width

Piston pin

Large end

Metal thickness of large end

Clearance between large end and crankpin

Small end

Clearance between small end and piston

Large end side clearance Parallelism between large

end and small end

Crankpin

O.D.

I

.D.

I.D.

O.D.

after the

bores

bush

is

force fitted.

roundness

cylindricity

Oil 4

21

dia.

43

dia.

1.5

21

dia.

40

dia.

-0.1

+0.006

I

0

+0.016

0

-0.005

-0.01

8

0.01

L-0.068L

+0.034 +0.013

0.007L-0.034L

0.07L

-

0.33L

0.06

+0.040

+O

.024

0.005

-0.02

1.4

0.1

0.05

0.08

0.5

0.1

5

-0.1

-0.02

1.4

0.1

0.05

0.08

0.5

0.1

0.5

Metal

in

centei

parallelism

Journal diameter

Journal roundness

I.D.

after main bearing being force fitted

Main bearing

Clearance between journal and main bearing

Cam lobe height

Journal

Valve

0.0.

stem

Intake and exhaust cams

pump

O.D.

cam

Rear

Front

Intake

Exhaust

42

dia.

36.495

40 Injection

22

dia.

35

dia.

7

dia.

0.008

0

-0.01

6

0.005

+0.076

+0.020

0.101

L-0.06OL

0.02OL-0.092L

+O

.05

-0.020

-0.041

-0.01

2

-0.023

-0.063

-0.078

-0.083

-

0.098

0.1

-0.2

-0.1

-

0.1

0.15

-0.2

-0.1

5

Use

searcher

5

and adjust

with

adjust

screw.

5

-43

-

ITEM

Clearance between valve stem dia. and valve guide

-

5

Valve clearance both intake and exhaust

(cool

condition)

Stem

O.D.

c

Guide I.D.

Intake

Exhaust

STANDARD

I

0.07

-

8

dia.

0.1

CORRECTION

I

TOLERANCE LIMIT

0.063 L - 0.093 L

0.083L-0.113L

-0.01

3

-0.033

I

+0.015

0

,

1

USE

0.3 0.3

I

REMARKS

CORRECTIOP

METHOD

Ill

I

-0.07

I

-0.07

I

N.08

M.08

Tapet guide clearance

Rocker

shaft

E

a.

L

al

Y

Rocker arm hole dia.

0

E

Rocker arm shaft clearance

I

Valve spirng free length

P

$

From injection pump

a.

flunge surface to cam base

E

.-

0'

4.l

.%

Static iniection timing

-

I

Injection starting pressure

0-

-

N

Nozzle dia. nozzle

O.D.

x

number of

12

dia.

I I

I

36.5

76

23"

before

TDC

0.22

dia.

x

4

pcs.

0.013L-0.048L 0.15 0.15

-0.01 6

-0.034

*.Of

8

0

0.016L-0.052L

I

?O

.05

-0.08

+O

.07

0.15

I I

-0.08

+O

.07

0.15

I I

*lo

Adjust

Description

Gear case cover Blower housing fastening bolt Cylinder head fastening bolt

I

Connecting rod cap fastening bolt

I

Flywheel fastening nut

I

Rear bearing fastening bolt

I

Oil

pump cover fastening bolt

I

Nozzle

bracket fastening nut

TABLE

of

TIGHTENING TORQUE

I

I I

-

44

-

Tightening torque

200

-

230

kg-cm

200

-

230

kg-cm

330

-

350

kg-cm

250

-

270

kg-crn

2,000

-

2,200 kg-cm

200 - 230 kg-cm

80

-

100

kg-cm

90 - 100

kg-cm

I

I I

11.

MAINTENANCE

and

STORING

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

For

example, if the engine

every

50

hours.

11 - 1

DAI

LY

CHECKS

I

Remove dust from whatever parts which

Check external fuel leakage. If any, retighten replace.

Check screw tightening. If any loose one is found, re-tighten.

1

Check

oil

level

is

operated in extremely dusty conditions, the air cleaner should be cleaned every day instead

and

MAINTENANCE

Checks and maintenance

in

crankcase and add up as necessary.

or

Reasons for requiring them

To

be

contaminated with dust when disassembling each

only

Not

Loose screws and nuts will result in vibration accidents.

If the engine is operated without sufficient oil, fail.

wasteful but .also dangerous

it

will

main-

I

of

I

11-2

EVERY

11-3

EVERY

,

11-4

EVERY

Clean fuel

Clean air filter,

25

HOURS

Checks and maintenance

Change crankcase

50

HOURS

Checks and maintenance Change crankcase Clean

oil

filter.

100

-

200

Checks

filter

and fuel tank.

and

CHECKS

oil.

(IO

and

MAINTENANCE

DAYS) CHECK

and

MAINTENANCE

oil.

HOURS (MONTHLY) CHECKS

2nd

maintenance

replenish engine

oil.

Reasons for requiring them

To

remove run-in wear particles

Reasons for requiring them

Contaminated oil accelerates wear.

If

the engme is operated without sufficient

and

MAINTENANCE

Reasons for requiring them

If

the fuel

and injection pump as well Clogged air filter and shortage

trouble and make engine life shorter.

is

contaminated, engine will be out

oil,

as

nozzle are seized.

of

oil

will cause engine

it

will

of

fail.

order,

Check and adjust Check and clean nozzle.

valve

clearance.

-45

The engine output drops. Engine will be out of order.

-

11-5 EVERY 500

-

600

HOURS

(SEMIANNUAL) CHECKS

and

MAINTENANCE

Checks and maintenance

Remove cylinder head and remove carbon deposit.

Replace fuel fdter.

Check

valve seats both intake and exhaust and

grind,

if

necessary.

11-6 EVERY

I

Change piston Replace fuel pipe once a year.

11-7

EVERY

I

Performoverhauls, clean, correct or replace parts.

1000

HOURS (YEARLY) CHECKSand MAINTENANCE

Checks and maintenance Reasons for requiring them

rings.

1500

HOURS

Checks and maintenance

(OVERHAULS)

Reasons for requiring them

of

out of

order. order. order.

by

the fuel leakage.

The engine will be out The engine will be out The engine

The engine output drops and become out To prevent from danger caused

I

The engine output drops and become out of order.

will

be

Reasons for requiring them

of

~~

~

order.

I

11-8 PREPARATION

1)

Perform the above

2)

Drain fuel

3)

To prevent

cranking for the combustion chamber

4)

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

5)

Clean the engine outside with oiled cloth. Put a vinyl

from

for

11

the fuel tank.

rust

in

2

-

3

LONG ABEYANCE

-

1

and 1 1-2

the cylinder bore, apply

times and then fit the rocker cover. Don't apply too much

of

maintenance job.

the piston.

oil

through the breather hole on the surface of rocker cover and made

or

oil

as

the excess oil will be collected in

other cover over the engine and store the engine in dry place.

-46

-

12.

1/2

REDUCER

MUFFLER

AIR CLEANER

OIL GAUGE

STARTING HANDLE

FUEL FILTER

OIL FILTER

(DRAIN PLUG)

STOP LEVER

.”-

FUEL TANK

REDUCTION GEAR

P.T.O. SHAFT

-

47

-

12-1

CONFIGURATION

01L

CHECKING PLUG

(M18

x

of

1/2

13)

REDUCER

OIL EXHAUSTING PLUG

(M8

x

13)

Fig.

12-

1

-

48

-

12-2

STRUCTURE

Of

1/2

REDUCER

BEARING (#6205)

THRUST WASHER

OIL

FILLER

OUTPUT SHAFT

BEARING (#6206)

PLUG

CRAN

THRUST WASHER

BEARING (#6204)

INPUT SHAFT

BEARING

GEAR CASE

(#6205)

I

Fig.

-

72-2

49

-

/"

12-2-1 INPUT SHAFT

The input shaft is a wholly carburized. product in which chrome-molybudenum steel

in

built

12-2-2 OUTPUT

The output shaft is made

12-2-3 SHAFT

The shaft

12-2-4 GEAR C and GEAR

it.

B

is

B

made

SHAFT

of

carbon steel, and the gear C is fitted

of

chrome-molybudenum steel, and wholly carburized.

€3

in

spline engagement.

is

used, and the gear A and spline are

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

of

with module

12-2-5 ADAPTOR and GEAR CASE

The.adaptor and the gear case are components of a body

12-2-6

The

coupling is a component to deliver output from the engine to the

engagement. The coupling

NOTE:

Grease is stored in the spline section, and the section

2.

COUPLING

of

the

1/2

reducer, and are made of aluminum alloyed dicast.

1/2

reducer, and

is

a wholly carburized product in which molybudenum steel

is

sealed with a packing and

is

fitted to the input shaft in spline

is

used.

an

O-ring.

-50-

12-3

DISASSEMBLY and REASSEMBLY

of

1/2

REDUCER

12-3-1

Se-

quence

1

2

3

4

7

DISASSEMBLY

Procedures

Drain the gear

SEQUENCE

Length

*SW = Spring washer

oil.

~~ ~~

Remove the clamping bolt from the adaptor.

Remove the 1/2 reducer assembly from the engine.

Remove the clamping bolts from the coupling.

Remove the clamping bolts

of

the gear case.

Remove the O-ring the input shaft.

Wind vinyl tape around

the input/output shafts.

of

the

bolt

indicates the length from the bold head bottom surface

Main Item to be

disassembled

The oil drain plug

is

under the gear case cover.

8

mm bolt

10

mm bolt

7

bolts on the gear case

- -

4

pcs.

4

pcs.

surface.

located

Remarks

Replace the gasket with a new one.

Be careful not

to

lose

the packing. Be carefult not

to

lose the

sws.

Cover whole surface shafts to protect the seal.

of

oil

8mm

Opposite side:

I

8

10 mm

4

8

8 x 50

with

the

to

the threaded end.

Bolts,

etc. Used

hexagonal bolt

mm

x

65

bolt

x

30

pcs.

x

40

7T

bolt

7T

bolt

SWs

9T

13

--

bolt

-

mm

4

pcs.

--

6 pcs.

1

pce.

Separate the gear from

8

the adaptor.

I

"

Pull out the gear

9

assembly from the case.

10

Disassemble the input Separate the gear from

11

shaft assembly.

Disassemble the shaft assembly.

P.T.O.

the bearings.

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

I

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.

If

inserted,

they may be damaged.

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

Pull out the bearings by

or

using a gear puller

a

press.

-

51

-

12-3-2

1.

2.

REASSEMBLING SEQUENCE

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 Replace the bolts, if necessary, with new ones.

As

Apply oil to the revolutionary parts and friction surfaces, when reassembling. Check and adjust the clearances When some main portions are assembled in the course attention to the frictional noise and resistance.

Reassembling

a) Pressure-fit the bearings into the input shaft

(#6204) between the two bearings after they have been pressure-fitted is from 49 mm to 48.9 mm. Two types

0.3

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.)

all

the gaskets with new ones.

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

of

in

the edge face side. Then, insert the shim between the bearing (#6205) and the gear

mm thick and

0.1

mm thick are available. (See Fig.

various portions and then reassemble them.

of

reassembling, turn

so

that the bearing

12-3

.)

(#6205)

is set in the spline side and the bearing

or

move the gadgets by hand, paying

so

that the clearance

of

shm;

INPUT SHAFT SHIM ADJUSTING POSITION

49

-

48.9

rnrn

-

SH

BEARING #6205 BEARING #6204

Fig.

12-3

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

so

the output shaft in the output side, the bearing (#6205) in the edge face side, and the 60 beveling of the gear spline is faced to the bearing (#6206). Then, insert the shim between the bearing and the gear ings after they have been pressure-fitted is from

52

mm to

thick and

12-5.)

51.9

0.1

that the bearing (#6206) is set

so

that the clearances between bear-

mm. Two types of shim;

mm thick are available. (See Fig.

IM SETTING

POSITION

C

bore

(#6205)

0.3

mm

VINYL

TAPE

/

Fig.

12-4

OUTPUT SHAFT SHIM ADJUSTING POSITION

,

52 - 51.9

rnrn

,,GEAR

SHIM SETTING POSITION

BEARING

Fig.

72-5

#6206

AFT

-

52

-

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

with the thrust washer in the adaptor. (See Fig.

12-6.)

B

Set the gear A and the gear B in the adaptor, under the condition that their teeth are engaged

12-7

Fig. Set the thrust washer onto the edge face Set the output shaft assembly in the adaptor. (See Fig. Put the packing on the mating face of the case. (It

Cover the gear case. (Don't give physical impacts with such tools as a hammer

.)

of

the gear

B.

12-8.)

is

not necessary

to

supply sealing compund to the mating face.)

to

compulsorily set it.) (See Fig.

12-9.) Clamp the case with six Tightening torque:

250

M8-40

kg.-cm

7T

bolts and an

+50

kgcm.

M8-

50

7T

bolt. Never forget to set thrust washers for the bolts.

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

in

each other. (See

/-

Fig. 12-6

Fig.

12-

,"-

7

Fig.

12-8

Fig.

72-9

,-

-

53

-

3.

Mounting

a)

b) Set the packing in the coupling, and then clamp

c)

d) Set the

to

Engine

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

Tightening torque: Apply grease to the coupling and spline gear teeth

1/2

8

mm

x

65

7T

550-700

reducer in the engine under the condition that the spline teeth are engaged,

bolts. Tightening torque:

kg-cm‘

200

r

it

to

of

-

230

kg-cm.”

FLYWHEEL

the engine’s flywheel with

the input shaft.

four

10

mm

x

30

9T

bolts.

and

clamp it with four

Fig.

12-

70

\

GREASE

COUPLING

FILLER

T

SHAFT

HOLE

-

54

-

Industrial

Engines

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