Daewoo Doosan 1760XL DSL802 Skid Steer Loader Shop Manual - PDF DOWNLOAD

SB2184E00 April 1999

SKID STEER LOADER

Shop Manual 1760XL/DSL802 Serial Number ------ and Up

Shop Manual 1760XL/DSL802 SKID STEER LOADER Serial Number ------ and Up

DOOSAN and the DOOSAN logo are registered trademarks of DOOSAN Corporation in the United States and various other countries around the world.

Copyright 1999 OperationDOOSAN and Maintenance Manual

SB2184E00 April 1999 Copyright Doosan 2011

Trim Out The Label Along The Lines And Insert Into Pocket On The Binder Spine

Pub. No. SB2184E00

1760XL/DSL802

Instructions

Serial Number ------ and Up

Pub.No. SB2184E00

Product Label

Important Safety Information

Most accidents involving product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills and tools to perform these functions properly.

Read and understand all safety precautions and warnings before operating or performing lubrication, maintenance and repair on this product.

Basic safety precautions are listed in the “Safety” section of the Service or Technical Manual. Additional safety precautions are listed in the “Safety” section of the owner/operation/maintenance publication.

Specific safety warnings for all these publications are provided in the description of operations where hazards exist. WARNING labels have also been put on the product to provide instructions and to identify specific hazards.

If these hazard warnings are not heeded, bodily injury or death could occur to you or other persons. Warnings in this publication and on the product labels are identified by the following symbol.

WARNING Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death.

Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information.

Operations that may cause product damage are identified by NOTICE labels on the product and in this publication.

DAEWOO cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are therefore not all inclusive. If a tool, procedure, work method or operating technique not specifically recommended by DAEWOO is used, you must satisfy yourself that it is safe for you and others. You should also ensure that the product will not be damaged or made unsafe by the operation, lubrication, maintenance or repair procedures you choose.

The information, specifications, and illustrations in this publication are on the basis of information available at the time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service given to the product. Obtain the complete and most current information before starting any job. DAEWOO dealers have the most current information available.

SB2003E00 A p r. 1 9 9 9

WARNING

SAFETY WARNING The proper and safe lubrication and malntenance for this machine, recommended by DAEWOO, are outilined in the OPERATION & MAINTENANCE GUIDE of this machine.

Improper performance of lubrication or maintenance procedures is dangerous and could result in injury or death. Read and understand the OPERATION & MAINTENANCE GUIDE before performing any lubrication or maintenance.

The serviceman or mechanic may be unfamitiar with many of the systems on this machine. This makes it important to use caution when performing service work A knowledge of the system an/ or components is important before the removal or disassembly of any component.

Because of the size of some of the machine components, the serviceman or mechanic should check the weights noted in this Manual, Use proper lifting procedures when removing any components.

Following is a list of basic precautions that should always be observed.

1. Read and understand all Waming plates and decals on the machine before operating, lubricating or repairing the product.

2. Always wear protective glasses and protective shoes when working around machines. In particular, wear protective glasses when pounding on any part of the machine or its attachments with a hmmer or sledge. Use welders gloves, hood/goggles, apron and other protective clothing appropriate to the welding job being performed. Do not wear loose-fitting or tom clothing. Remove all rings from fingers when working on machinery.

3. Do not work on any machine that is supported only by lift jacks or a hoist. Always use blocks or jack stands to support the machine before performing any disassembly.

4. Lower the bucket or other implements to the ground before performing any work on the

machine. If this cannot be done, make sure the forks or other im plements are blocked correctly to prevent them from dropping unexpectedly.

5. Use steps and grab handles (if applicable)when mounting or dismounting a machine. Clean any mud or debris from steps, walkways or work plaftorms before using. Always face machine when using steps, ladders and walkways. When it is not possible to use the designed access system, provide ladders, scaffolds, or work platforms to perfom safe repair operations.

6. To avoid back injury, use a hoist when lifting components which weigh 23 kg (50 lb.) or more.

Make sure all chains, hooks, slings, etc., are in good condition and are of the correct capacity. Be sure hooks are positioned correctly. Lifting eyes are not to be side loaded during a lifting operation.

7. To avoid bums, be alert for hot parts on machines which have just been stopped and hot fluids in lines, tubes and compartments.

8. Be careful when removing cover plates. Gradually back off the last two bolts or nuts located at opposite ends of the cover or device and pry cover loose to relieve any spring or other pressure, before removing the last two bolts or nuts completely.

9. Be careful when removing filler caps, breathers and plugs on the machine. Hold a rage over the cap or plug to prevent being sprayed or splashed by liquids under pressure. The danger is even greater if the machine has just been stopped because fluids can be hot.

10. Always use tools that are in good condition and be sure you understand how to use them before performing any service work.

11. Reinstall all fasteners with same part number. Do not use a lesser quality fastener if replacements are necessary. Do not mix metric fasteners with standard nuts and bolts.

12. If possible, make all repairs with the machine parked on a level, hard surface. Block machine so it does not roll while working on or under machine.

WARNING

13. Disconnect battery before starting to work on machine. Hang “Do Not Operate” tag in the Operator’s Compartment.

14. Repairs, which require welding, should be performed only with the benefit of the appropriate reference information and by personnel adequately trained and knowledgeable in welding procedures. Determine type of metal being welded and select correct welding procedure and electrodes, rods or wire to provide a weld metal strength equivalent at least to that of parent metal.

15. Do not damage wiring during removal operations.

Reinstall the wiring so it is not damaged nor will it be damaged in operation by contacting sharp corners, or by rubbing against some object or hot surface. Do not connect wiring to a line containing fluid.

16. Be sure all protective devices including guards and shields are properly installed and functioning correctly before starting a repair. If a guard or shield must be removed to perform the repair work, use extra caution.

17. Loose or damaged fuel, lubricant and hydraulic lines, tubes and hoses can cause fires. Do not bend or strike high pressure lines or install ones which have been bent or damaged. Inspect lines, tubes and hoses carefully. Do not check for leaks with your hands. Pin hole (very small) leaks can result in a high velocity oil stream that will be invisible close to the hose. This oil can penetrate the skin and cause personal injury. Use cardboard or paper to locate pin hole leaks.

18. Tighten connections to the correct torque. Make sure that all heat shields, clamps and guards are installed correctly to avoid excessive heat, vibration or rubbing against other parts during operation. Shields that protect against oil spray onto hot exhaust components in event of a line, tube or seal failure must be installed correctly.

19. Relieve all pressure in air, oil or water systems before any lines, fittings or related items are disconnected or removed. Always make sure all raised components are blocked correctly and be alert for possible pressure when disconnecting any device from a system that utilizes pressure.

20. Do not operate a machine if any rotating part is damaged or contacts any other part during operation. Any high speed rotating component that has been damaged or altered should be checked for balance before reusing.

Contents

1. FOREWORD 2. ENGINE 2.1. General Information 2.1.1. Introduction 2.1.2. Engine Identification

2.1.4. POWERPART Recommended Consumable Products

2.1.3. Safety

2.2. Specifications 2.2.1. Basic Engine Data

2.2.3. Compression Test Data

2.2.2. Recommended Torque Tensions

2.3. Cylinder Head Assembly 2.3.1. General Description

2.3.6. Cylinder Head Assembly

2.3.2. Rocker Cover

2.3.7. Valves and Valve Springs

2.3.3. Rocker Assembly

2.3.8. Valve Guides

2.3.4. Valve Tip Clearances

2.3.9. Cylinder Head

2.3.5. Valve Springs

2.3.10. Data and Dimensions

2.4. Piston and Connecting Rod Assembly 2.4.1. General Description

2.4.6. Piston and Piston Rings

2.4.2. Big End Bearing

2.4.7. Connecting Rod

2.4.3. Piston and Connecting Rod Assembly

2.4.8. Small End Bush

2.4.4. Piston Rings

2.4.9. Data and Dimensions

2.4.5. Piston and Connecting Rod Assembly

2.5. Crankshaft Assembly 2.5.1. General Description

2.5.5. Main Bearings

2.5.2. Crankshaft Pulley

2.5.6. Crankshaft

2.5.3. Rear Oil Seal

2.5.7. Data and Dimensions

2.5.4. Thrust Washers

2.6. Timing Case and Drive Assembly 2.6.1. General Description

2.6.6. Camshaft Assembly for the Fuel Injection Pump

2.6.2. Timing Case

2.6.7. Camshaft Assembly and Tappets for the Valve

2.6.3. Front Oil Seal

2.6.8. Crankshaft Gear

2.6.4. Idler Gear

2.6.9. Backplate for the Timing case

2.6.5. Idler Hub

2.6.10. Data and Dimensions

2.7. Cylinder Block Assembly 2.7.1. General Description

2.7.3. Data and Dimensions

2.7.2. Cylinder Block

2.8. Engine Timing 2.8.1. General Description

2.8.2. Data and Dimensions

2.9. Aspiration System 2.9.1. Closed Breather System

2.10. Lubrication System 2.10.1. General Description

2.10.5. Oil strainer and Suction Pipe Assembly

2.10.2. Filter Canister

2.10.6. Lubricating Oil Pump

2.10.3. Filter Head

2.10.7. Relief Valve

2.10.4. Sump

2.10.8. Data and Dimensions

2.11. Fuel System 2.11.1. General Description

2.11.5. Fuel Injection Pump

2.11.2. Fuel Filter Element

2.11.6. Fuel Injection Pump Controls

2.11.3. Atomisers

2.11.7. Data and Dimensions

2.11.4. Fuel Lift Pump

2.12. Cooling System 2.12.1. General Description

2.12.4. Fan

2.12.2. Thermostat

2.12.5. Cooling System

2.12.3. Coolant Pump

2.12.6. Data and Dimensions

2.13. Flywheel and Flywheel Housing 2.13.1. General Description

2.13.3. Ring Gear

2.13.2. Flywheel

2.14. Electrical Equipment 2.14.1. Alternators

2.14.3. Starting Aid

2.14.2. Starter Motors

2.14.4. Electrical Stop Solenoid

2.15. Auxiliary Equipment 2.15.1. General Description

2.15.3. Technical Data

2.15.2. Power Take-off Assembly

2.16. List of Special Tools

3. VEHICLE 3.1. Specifications 3.1.1. Dimensional & Performance Specifications

3.1.3. Special Torque etc.

3.1.2. Service Schedule

3.2. Disassembly & Assembly 3.2.1. Quick-Tach

3.2.10. Chain Drive System

3.2.2. Bucket Cylinder

3.2.11. Hydrostatic Pump

3.2.3. Boom Lock & Boom Cylinder

3.2.12. Control Valve

3.2.4. Boom Assemby & Boom Stopper

3.2.13. Oil Filter

3.2.5. Canopy

3.2.14. Hydraulic Motor

3.2.6. Drive Control System

3.2.15. Muffer

3.2.7. Hydraulic Control System

3.2.16. Radiator & Oil Cooler

3.2.8. Parking Lock Assembly

3.2.17. Flexible Coupling Assembly

3.2.9. Throttle Control

3.2.18. Wheel & Tire

4. HYDRAULIC & HYDROSTATIC SYSTEM 4.1. Systems Operation 4.1.1. Hydraulic System

4.1.4. Optional Bucket Self-Leveling System

4.1.2. HST System

4.1.5. HST Pump

4.1.3. Hydraulic Control Valve

4.1.6. HST Motor

4.2. Specifications 4.2.1. Hydrostatic Systems

4.2.2. Hydraulic Systems

4.3. Testing & Adjusting 4.3.1. Trouble shooting

4.3.3. Hydrostatic System

4.3.2. Hydraulic System

4.4. Disassembly & Assembly 4.4.1. HST Pump

4.4.4. Boom Cylinder

4.4.2. HST Motor

4.4.5. Bucket Cylinder

4.4.3. Hydraulic Control Valve

4.5. Hydraulic Schematic

5. ELECTRICAL SYSTEMS 5.1. E/G Starting & Stop System 5.2. Preheating System 5.3. Charging System 5.4. Instrument Panel Layout 5.4.1. Monitoring System

5.5. Operation of the related parts in momentary control & detent control-1760XL/DSL820 5.5.1. Thumb Control

5.6. LIGHTS and OPTIONS 5.7. Item Descriptions and Functions 5.8. Trouble shooting 5.8.1. Test Equipment 5.8.2. Trouble shooting Guide

•Amount of dirt in air cleaner elements and air leakage.

•Oil levels in the engine oil pan and status of oil (viscosity, color and mixed impurities).

•Water mixed in the oil and oil leakage.

•Clogging of the oil filter element.

•Deviations from designated adjusting points.

•Damaged parts and loosening of tightening fittings.

•Maintenance conditions of the machine in service, if possible.

1. Foreword How to Use This Manual This manual provides information for servicing the 1760XL(DSL802) skid steer loader. All service procedures are broken down into detailed steps, listed in their recommended sequence. The manual uses both photographs and drawings to help locate and itemize components.

3) Preparation for disassembly

The table of Contents on the preceding pages is your best tool for finding the service procedure you need.

To save unnecessary work, reserve the necessary facilities, tools, and parts racks as well as adequate floor space considering the extent of disassembly.

Keep the area and facilities clean.

Be certain to observe all Safety information included in these pages.

Precautions For Disassembly

General Precautions For Disassembly

1) Removal of parts

Preparations before disassembly

•Proceed with the disassembly by confirming the fitting conditions of the relative parts, their positions fore-and aft, left-and-right, upper-and-lower, and the sequence of their removal.

1) Wash the machine before moving it to into the repair shop.

Prior to moving the machine into the repair shop remove dust and dirt thoroughly by washing the machine. Dirt brought into the shop will degrade the cleanliness of the parts handled in the shop, will produce scratches, and can contaminate the inside of reassembled units.

•Confirm match marks for mating joints before separating parts and where necessary, punch match marks to clearly identify their relative position to prevent confusion during reassembly.

•For disassembly of certain designated parts, use specified special tools.

•When a part, after removal of fastening nuts and bolts, is still found to be unremovable, never force the part. Carefully check for the cause of the tightness and remove the cause.

•Keep the disassembled parts in an orderly condition.

Take special care to identify similar parts by attaching tags or markings.

•See that standard parts such as bolts and nuts are stored in good order with reference to quantity and where they are to be used.

2) Checking and inspection before disassembly.

Before attempting to disassemble, check thoroughly to determine the cause of the problem, and record it.

This will not only prevent needless disassembly and losses from needless replacement parts and manhour costs, but will also prevent repetition of the same problem.

It is important to keep records of problems and replacements in order to advise serviceman how to prevent trouble. Items to be checked and recorded are as follows:

2) Checking and inspecting during disassembly.

•The cause of the actual trouble is often discovered in the course of disassembly. Thus careful checking of sliding surfaces for any signs of seizing or interference, and their mating conditions, is important.

•Measure and record during disassembly the various end clearances, backflashes and protrusions that are necessary to determine the trouble.

•Model, machine serial number and service meter readings.

•Reason for disassembly.

•Components replaced.

Check for symptom, location and cause of problem. If necessary, try repeating the same problem.

Foreword

9

How to Use This Manual

3) Maintaining clearance adjustmnets

Procesures after disassembly

Keep each set of shims or washers stored in an orderly manner so that its original arrangement with the same clearances can be obtained at reassembly.

1) Cleaning •Wash disassembled parts clean, neatly arrange the parts according to each assembly, and keep in storage, free from dust and dirt.

Special care should be taken to remove sludge and dust thoroughly from oil holes in the parts and from the interior of the tubes.

•More effective cleaning can be achieved by use of two vessels filled with detergent, one for washing dirty parts and the other for rinsing.

When washing special parts, increase the number of vessels and keep the dirty detergent away from these parts.

•Kerosene or neutral-anhydride light oil is a suitable detergent for cleaning viscous bearing oils.

•When washing a large casting, immerse it in a vessel filled with detergent (alkalinity pH10 to 12, temperature 50 to 70 ˚C) (122˚ to 158 ˚F) for up 10 minutes. Then, rinse it thoroughly with water.

•If harmful chemical agents are used as the detergent, take care to protect the skin and eyes. Do not attempt to drain waste fluid into the sewage system.

4) Maintaining linkage adjustments Be careful to maintain the original adjustment of the rods unless some readjustment is necessary. When it is necessary to remove the rod end for disassembly, measure and record the length of the rod before disassembly.

5) disassembly of taper-fitted or force-fitted parts •Remove any scars or dents, clean well and reassemble.

•When looseness of fit exists in taper-fitted or forcefitted parts, carefully check for the cause of the faulty fit, remove the cause and reassemble.

6) Disassembly of bearings •Do not attempt to remove a bearing by force, but remove it with a suitable puller such as shown in the figure below.

2) Dust-proofing •Cover washed parts in storage to keep them free from dust and dirt. Cap all pipes.

•Apply suitable rust-preventive treatment to the parts if they are to be kept an extended period of time in storage before reassembly.

7) Safety •Keep the area where the machine is to be disassembled clean and orderly.

•When loosening a bolt or nut, use a correct size wrench and always pull the wrench toward you. Use of a mis-matched wrench because of confusion between the inch and metric system, or pushing the wrench away from your body may cause accidents through slipping of the wrench or the hand.

•For jobs involving two or more persons, keep close contact by mutual checking and exchange of necessary signals.

Foreword

10

General Precautions For Disassembly

•Remove remnants of loctite or any thread bonding agent from the removed bolts with appropriate solvent. Apply 2 or 3 drops of fresh loctite before retightening bolts.

General Precautions for Assembly Preparations before disassembly 1) Installation of parts

(3) Check in the course of assembly •Thoroughly clean all parts before assembly. Check for scratches and nicks on the surfaces of the parts, and repair if necessary.

Special care should be paid to the sliding surfaces of parts which, if left soiled, will cause reduced machine life.

•Use detergent to remove any rust preventive before assembly.

•Make sure to align match marks of those parts that are marked before attempting to assemble.

•Use the correct or a press-fitting tool or driver when assembling bearings, bushings and oil seals. Also, use the prescribed “special tool” for assembly of certain designated parts.

•Coat the surface parts to be press-fitted with moly bdenum disulfide grease.

During assembly, check and record end clearances, end plays, protrusions, steps and backflashes at each stage of assembly.

(4) Reinsertion of shims •Insert stored sets of shims or washers in their positions in the same order as disassembly.

•After inserting, check for correct values of clearances.

(5) Assembly of control linkage Assemble each control link to the same length as disassembly, unless adjustments are necessary.

Reassemble and properly adjust.

(2) Tightening bolts and nuts (6) Assembly of taper-fitted or force-fitted parts •Tighten the bolts and nuts fastening parts together by alternately (left-and-right and upper-and-lower) turning symmetrically opposite nuts and bolts, to apply even tightening force.

•Repair scratches and nicks, and thoroughly clean the parts before fitting.

•If proper fit cannot be obtained between the taperfitted parts, carefully check for the cause.

•Check and see that there is no dust, rust or scratches found on the surface of the shaft on which an oil seal is to be fitted and coat the shaft with grease or lubricating oil so that the oil seal can be installed smoothly.

•When installing an oil seal, use a suitable guide and jig as shown in the figure below to prevent oil seal damages.

Seal Seal •When tightening bolts on certain designated parts, tighten them in the prescribed sequence as shown in the figure, in order to exert even torque on every bolt. In this method called the “template methods”. the bolts are tightened stepwise and sometimes loosened, so that the bolts and nuts are well seated or the bearing comes into close and even contact.

•Apply engine oil to the screw threads of certain designated bolts so that smooth and even tightening of the bolts may be obtained.

•With wires, cotter pins or lock washers, securely lock those bolts and nuts which cannot be checked from the outside or are used for important parts that require locking.

Foreword

Guide

Jig

•After press-fitting an oil seal, check for alignment.

Allowable limit of misalignment : 0.2 mm per 100 mm dia. (1/64” per 3 15/16” dia.).

•When applying bonding agent on the circumference 11

General Precautions For Assembly

of an oil seal, avoid contact of the lip surface with the onding agent.

Remove excess bonding agent on the guide and jig before using them to install another oil seal.

Jig

(7) Handling of bearings

Pressure

Pay special attention to the following instructions so as not to damage bearing assemblies : a. Leave the bearings in their original package until just before installation.

Keep bearings free from dust and dirt. Dust affects bearing life significantly. b. Avoid impact loads and do not apply shocks to the bearings. Absolutely avoid such unreasonable handling like rotating a bearing excessively by blowing compressed air to remove detergent from the bearing.

(8) Handling of snap rings •When removing or installing snap rings, use a suitable ring plier, taking care not to over expand the snap ring.

•Make sure the snap ring is properly seated in its groove.

Observe the following precautions when installing the bearings :

(9) Assembly of keys and keyways

a. Do not attempt to hammer the bearing assembly or damage may occur. b. When installing a bearing assembly, use a suitable jig as shown in the figure below to apply pressure to the inner race.

Apply the shrink fit method to the bearings requiring large interference. Do not heat any bearings requiring large interference. Do not heat any bearing assemblies to over 120˚C(248˚F).

Excessively high temperature will deteorate the hardness of the heat treated bearing surface.

Outer Race

Check for looseness of the key in its keyway and for the contact of the keyhead.

If the keyhead contacts with keyway, remove the excess keyhead.

(10) Safety •Keep the working area, tools, worker’s hands, etc. clean and orderly during assembly work.

•Use the correct size wrench when tightening a bolt or nut to reduce the risk of injury and equipment damage.

•For jobs involving two or more persons, keep close contact by mutual checking and the exchange of necessary signs.

Jig

Pressure

Handling of Common Parts (1) Handling of packings and O-ring

Inner Race

•Replace all packings, gaskets O-rings, and copper packings.

•Coat certain gaskets designated in this manual with recommended sealant.

c. When installing a non-split type bearing with necesary interferences of the inner and outer races, use a suitable jig as shown in the figure below to apply the necessary pressure to both the inner and outer races.

Foreword

(2) Handling of O-rings •Use only the O-rings prescribed in the Service Parts Manual. Special care should be paid to the O-rings subjected to engine lubrication oil, since they are made of thermal resistant, aging-free special materials such as silicon rubber and cannot be 12

General Precautions For Assembly

replaced by any other ordinary O-rings.

•Coat the O-rings with oil to protect them from scratching during installation. Be careful not to expand the silicon rubber O-rings excessively, or they will be easily cracked.

(3) Handling of oil seals •Be careful to see that the oil seal lips face the proper directions.

Oil Pressure

Main Lip

Main LipDust Sealing Lip

•Keep the oil seals free from dust, and see that there is no rust or scratches on their surfaces (especially on the lips).

•Before installation, coat the oil seal with grease as outlined below, to prevent dry friction which may occur during the break-in operation of the machine. a. In case of a single-lip type oil seal: Uniformly and lightly coat grease around the lip on the opposite side of the sealing surface of the lip. b. In case of a double-lip type oil seal : Uniformly coat grease over the surface between the two lips so that about half of the space of the hollow found between the lips is filled with grease.

Foreword

13

General Precautions For Assembly

2. Engine

WARNING

2.1. General Information

This indicates that there is a possible danger to the person.

2.1.1. Introduction This workshop manual has been designed to provide assistance in the service and overhaul of Perkins 700 Series engines.

CAUTION : This indicates that there is a possible danger to the engine.

NOTE : Is used where the information is important, but there is not a danger.

WARNING Read and remember the "Safety precautions".

They are given for your protection and must be used at all times.

NOTE : The engine that are referred to in this manual are the UA (3,0 litre - direct injection), and the UB (2,6 litre - indirect injection).

Where the information applies only to one engine type, this will be indicated in the text.

When reference is made to the "left" or "right" side of the engine, this is as seen from the flywheel end of the engine.

POWERPART recommended consumable products are listed in section 10. Reference to the relevant consumable products is made at the beginning of operation.

Data and dimensions are included at the end of each section.

Danger is indicated in the text by two methods:

Engine

15

2.1. General Information

PU001

PU002

Engine

16

2.1. General Information

2.1.2. Engine Identification

UA80862U123456A

The 3,0 litre version, is a water cooled, naturally aspirated, four cylinder diesel engine with direct injection. It has been specifically designed for industrial and agricultural applications and is identified with the letters UA.

The components of the engine number are as follows : UA80862U123456A UA 80862 U 123456 A

Type code letters Build list number Build in the UK Engine serial number Year of manufacture

If you need parts, service or information for your engine, you must give the complete engine number to your Perkins distributor.

PU003

(A) The 2,6 litre version, is a water cooled, naturally aspirated, four cylinder diesel engine with indirect injection. It has been specifically designed for forklift truck applications and is identified with the letters UB. The engine number is stamped on a label (A) which is fastened to the right, rear side of the cylinder block.

An example of an engine number is :

Engine

17

2.1. General Information

•Do not wear clothing which is contaminated by lubricating oil. Do not put material which is contaminated with oil into the pockets.

•Discard used lubricating oil in accordance with local regulations to prevent contamination.

•Ensure that the control lever of the transmission drive is in the "out-of-drive" position before the engine is started.

•The combustible material of some components of the engine(for example certain seals) can become extremely dangerous if it is burned.

Never allow this burnt material to come into contact with the skin or with the eyes.

•Always use a safety cage to protect the operator when a component is to be pressure tested in a container of water. Fit safety wires to secure the plugs which seal the hose connections of a component which is to be pressure tested.

•Do not allow compressed air to contact your skin. If compressed air enters your skin, obtain medical help immediately.

•Do not clean an engine while it runs. If cold cleaning fluids are applied to a hot engine, certain components on the engine may be damaged.

•Fit only genuine Perkins parts.

2.1.3. Safety General Safety Precautions These safety precautions are important. You must refer also to the local regulations in the country of use. Some items only apply to specific applications.

•Only use these engines in the type of application for which they have been designed.

•Do not change the specification of the engine.

•Do not smoke when you put fuel in the tank.

•Clean away fuel which has been spilt. Material which has been contaminated by fuel must be moved to a safe place.

•Do not put fuel in the tank while the engine runs (unless it is absolutely necessary).

•Do not clean, add lubricating oil, or adjust the engine while it runs(unless you have had the correct training; even then extreme caution must be used to prevent injury).

•Do not make adjustments that you do not understand.

•Ensure that the engine does not run in a location where it can cause a concentration of toxic emissions.

•Other persons must be kept at a safe distance while the engine, auxiliary equipment is in operation.

•Do not permit loose clothing or long hair near moving parts.

•Keep away from moving parts during engine operation. Warning! Some moving parts cannot be seen clearly while the engine runs.

•Do not operate the engine if a safety guard has been removed.

•Do not remove the filler cap or any component of the cooling system while the engine is hot and while the coolant is under pressure, because dangerous hot coolant can be discharged.

•Do not allow sparks or fire near the batteries (especially when the batteries are on charge) because the gases from the electrolyte are highly flammable. The battery fluid is dangerous to the skin and especially to the eyes.

•Disconnect the battery terminals before a repair is made to the electrical system.

•Only one person must control the engine.

•Ensure that the engine is operated only from the control panel or from the operator`s position.

•If your skin comes into contact with high-pressure fuel, obtain medical assistance immediately.

•Diesel fuel and lubricating oil(especially used lubricating oil) can damage the skin of certain persons. Protect your hands with gloves or a special solution to protect the skin.

Engine

18

2.1. General Information

•To prevent damage to the rocker cover, ensure that there is clearance between the hooks and the rocker cover.

•Use lift equipment or obtain assistance to lift heavy engine components such as the cylinder block, the cylinder head, the flywheel housing, the crankshaft and the flywheel.

Engine Lift Equipment

Viton Seals Some seals used in engines and in components fitted to engines are made of Viton.

Viton is used by many manufacturers and is a safe material under normal conditions of operation.

If Viton is burned, a product of this burnt material is an acid which is extremely dangerous. Never allow this burnt material to come into contact with the skin or with the eyes.

If it is necessary to come into contact with components which have been burnt, ensure that the precautions which follow are used: •Ensure that the components have cooled.

•Use Neoprene gloves and discard the gloves safely after use.

•Wash the area with calcium hydroxide solution and then with clean water.

•Disposal of components and gloves which are contaminated must be in accordance with local regulations.

PA044

(A) CAUTION : If the sump contains engine lubricating oil and the engine is tilted to an extreme angle or turned onto its side or end faces, lubricating oil can enter the closed breather system, pass into the induction manifold and the cylinder bores. If this occurs, it will cause an hydraulic lock in the engine and the engine may be damaged. If it is necessary to move an engine in this way, the lubricating oil must first be drained.

If there is contamination of the skin or eyes, wash the affected area with a continuous supply of clean water or with calcium hydroxide solution for 15-60 minutes.

Obtain immediate medical attention.

The maximum weight of the engine without coolant, lubricant or a gearbox fitted will vary for different applications. It is recommended that lift equipment of 300 kg(662 lbs) minimum capacity is used.

Before the engine is lifted: •Always use engine lift equipment of the approved type and of the correct capacity to lift the engine.

It is recommended that lift equipment of the type shown in (A) is used to provide a vertical lift, directly above the engine lift brackets (A1).

Never use a single lift bracket to raise an engine.

•Check the engine lift brackets for damage and that they are secure before the engine is lifted.

The torque for the setscrews for the engine lift brackets is 22 N•m (16 lb•ft) 2,2 kg•m.

Engine

19

2.1. General Information

POWERPART Liquid gasket To seal flat faces of components where no joint is used. Especially suitable for aluminum components. Currently Loctite 518. Part number 21820518.

2.1.4. POWERPART Recommended Consumable Products Perkins have made available the products recommended below in order to assist in the correct operation, service and maintenance of your engine and your machine. The instructions for the use of each product are given on the outside of each container. These products are available from your Perkins distributor.

POWERPART Nutlock To retain and seal threaded fasteners and cup plugs where easy removal is necessary.

Currently Loctite 242e. Part number 21820242.

POWERPART Platelock Medium strength anaerobic threadlock for tight fitted metal surfaces. Suitable for metal plated surfaces and stainless steel. Currently Loctite 243.

Part number 21826039.

NOTE : Only use the POWERPART products that are shown at the start of the respective operation.

POWERPART Antifreeze Protects the cooling system against frost and corrosion. Part number 1 litre 21825166 or 5 litres 21825167.

POWERPART Repel Dries damp equipment and gives protection against corrosion. Passes through dirt and corrosion to lubricate and to assist removal of components.

Currently Loctite repel. Part number 21825164.

POWERPART Atomizer thread sealant To seal the threads of the atomizer into the cylinder head. Currently Hylomar Advance Formulation.

POWERPART Retainer (high strength) To retain components which have an interference fit. Currently Loctite 638. Part number 21820638.

POWERPART Chisel Allows easy removal of old gaskets and joints.

Currently Loctite chisel. Part number 21825163.

POWERPART Retainer (oil tolerant) To retain components which have a transition fit.

Currently Loctite 603. Part number 21820603.

POWERPART Compound To seal the outer diameter of seals. Currently Loctite Forma Gasket No 2. Part number 1861147.

POWERPART Silicone adhesive An RTV silicone adhesive for application where low pressure tests occur before the adhesive sets.

Used for sealing flange where oil resistance is needed and movement of the joint occurs.

Currently Loctite 5900. Part number 21826038.

POWERPART Easy Flush Cleans the cooling system. Part number 2182501.

POWERPART Gasket eliminator Improves flange sealing when a gasket is not used.

It provides a seal with temperature resistance that is flexible in positions where vibration and pressure occur. Currently Loctite 515. Part number 21826040.

POWERPART Silicone rubber sealant Silicone rubber sealant which prevents leakage through gaps.

Currently Hylosil. Part number 1861108.

POWERPART Jointing compound Universal jointing compound which seals joints.

Currently Hylomar. Part number 1861155 or 1861117.

POWERPART Studlock To permanently retain large fasteners and studs.

Currently Loctite 270. Part number 21820270.

POWERPART Lay-Up 1 A diesel fuel additive for protection against corrosion.

Part number 1772204.

POWERPART Threadlock To retain small fasteners where easy removal is necessary. Currently Loctite 222e. Part number 21820222.

POWERPART Lay-Up 2 Protects the inside of the engine and of other closed systems. Part number 1762811.

POWERPART Threadlock(heavy duty) To provide a heavy duty seal to components that have a light interference fit. Currently Loctite 262.

Part number 21820262.

POWERPART Lay-Up 3 Protects outside metal parts. Part number 1734115.

Engine

20

2.1. General Information

POWERPART Threadlock(hydraulic/pneumatic) To retain and seal pipe connections with fine threads.

Especially suitable for hydraulic and pneumatic systems. Currently Loctite 542. Part number 21820542.

2.2. Specifications 2.2.1. Basic Engine Data Cycle .........................................................Four stroke Number of cylinders ..................................................4 Cylinder arrangement ........................................in line Firing order .......................................................1,3,4,2 Direction of rotation ..............Clockwise from the front Induction system ...........................Naturally aspirated

POWERPART Threadlock(pipe) To retain and seal pipe connections with coarse threads. Pressure systems can be used immediately.

Currently Loctite 575. Part number 21820575.

Cubic capacity: UA engines .......................................2956 cc (183 in3) UB engines.......................................2602 cc (159 in3) Compression ratio: UA engines ........................................................17.5:1 UB engines........................................................22.0:1 Combustion system : UA engines ..........................................Direct injection UB engines........................................Indirect injection Nominal bore: UA engines......................................97.0 mm (3.82 in) UB engines .....................................91.0 mm (3.58 in) Stroke............................................100.0 mm (3.94 in) Valve tip clearances (cold): -Inlet and exhaust .........................0.35 mm (0.014 in) Lubricating oil pressure (at normal engine temperature): -Minimum pressure at maximum engine speed .........................280 kPa (41 lb/in2) 2.86 kg/cm2 Typical dry installed engine weight (1) ............................................200 kg (440 lb) (1) Engine weight may alter with final specification.

Engine

21

2.2. Specifications

2.2.2. Recommended Torque Tensions General Information Thread Sealant When setscrews or studs are fitted into holes which are tapped through into the inside of the engine, a suitable sealant must be used.

M.E.A.S.(Micro encapsulated anaerobic sealant) fasteners are fitted into the holes that are open to the inside of the engine. A thin layer of sealant is applied to the threads of the fasteners when they are manufactured. The colour of the sealant can be red, yellow or blue.

With M.E.A.S. sealed studs, the sealed end must be fitted into the cylinder head/cylinder block etc.

Ensure that the threaded holes have a 1,59 mm (0.0625 in) 45° chamfer, such that when the new fasteners are fitted the M.E.A.S. sealant is not removed. If the fasteners have to be removed and fitted again, remove the old sealant and apply Nutlock to the same threads.

Engine

22

2.2. Specifications

Procedures referred to in this manual will have the torque tensions(standard or special) shown in the text and also listed in the tables for special torque tensions.

Recommended Torque Tensions Most of the fasteners referred to in this manual have standard torque tensions which in the table follow.

Those fasteners that need special torque tensions are listed in separate tables together with some standard torque tensions most frequently used.

The torque tensions that are shown in this manual apply to fasteners with dry threads.

Standard Torque Tensions for Setscrews, Studs and Nuts Torque tension setscrews and nuts

Thread size M6 B 1.00

Torque tension - studs (metal end)

N•m

lb•ft

kg•m

N•m

lb•ft

kg•m

9

7

0.9

5

4

0.5

M8 B 1.25

22

16

2.2

11

8

11

M10 B 1.50

44

33

4.5

18

13

1.8

M12 B 1.75

78

58

8.0

25

18

2.5

M14 B 2.00

124

91

12.6

-

-

-

M16 B 2.00

190

140

19.3

-

-

-

Thread

Torque tension

Special Torque Tensions for Setscrews and Nuts

Description

size

N•m

lb•ft

kg•m

Cylinder head assembly Setscrews, cylinder head to cylinder block Setscrews, rocker shaft bracket Nuts, rocker shaft bracket Cap nuts, rocker cover M8 Setscrews, inlet manifold to cylinder head Setscrews, exhaust manifold to cylinder head Setscrews, engine lift brackets

M6 M8 M8 M8 M8 M8

See 9 22 11 22 18 22

page 7 16 8 16 13 18

12A.10 0.9 2.2 1.1 2.2 1.8 2.2

Piston and connecting rod assembly Nuts, connecting rod big end caps

M9

54

40

5.5

Crankshaft assembly Setscrews, main bearing caps Setscrews, crankshaft pulley to crankshaft

M14 M16

147 185

108 136

15.0 19.0

Timing case and drive assembly Setscrews, timing case to cylinder block Setscrews, timing case to cylinder block Setscrews, retainer plate-camshaft for fuel injection pump Setscrews, thrust washer-camshaft for the engine Setscrews, timing case to blanking plate Nuts, timing case to blanking plate Setscrews, timing case to blanking plate

M8 M10 M6 M6 M8 M8 M10

22 44 9 9 22 22 44

16 33 7 7 16 16 32

2.2 4.5 0.9 0.9 2.2 4.5 4.5

Engine

23

2.2. Specifications

Torque tension

Thread

Description

size

N•m

lb•ft

kg•m

M6

9

7

0.9

Nuts, high-pressure fuel pipes

M12

22

16

2.2

Setscrews, atomizer clamps

M8

12

9

1.2

Injector - 704.26(UB) engines

M20

39

29

4.0

Nuts, low-pressure fuel pipes

M12

20

15

2.0

Setscrews, fuel lift pump to cylinder block

M8

22

16

2.2

Setscrews, cassette pump to cylinder block

M8

22

16

2.2

Nuts, cassette pump to cylinder block

M8

22

16

2.2

Screw, fuel leak-off

M6

12

9

2.2

Aspiration system Setscrews, breather cover Fuel system

Nuts, maximum fuel adjustment screw

M8

14

10

1.4

Angleich unit

M16

18

13

1.8

Governor assembly to camshaft gear

M5

7

5

0.7

3/4 UNF

34

25

3.5

Cap screws, oil pump to timing case

M6

9

7

0.9

Setscrews, lubricating oil sump

M8

22

16

2.2

Relief valve assembly to timing case

M18

20

15

2.0

Nuts/screws, coolant pump to cylinder block

M8

22

16

2.2

Setscrews, fan and pulley to coolant pump hub

M8

22

16

2.2

Setscrews, fan and pulley to coolant pump hub

M6

9

7

0.9

M12

100

77

10.7

Nut, alternator pulley

M17

60

44

6.1

Bolt/nut, alternator to timing case

M10

24

18

2.4

Setscrew, adjusting lever to alternator

M8

12

9

1.2

Glow plugs

M10

17

13

1.7

Glow plug connections

M4

1.5

1

0.2

Lubrication system Plug, lubricating oil sump

Cooling system

Flywheel and housing Setscrews, flywheel to crankshaft Electrical equipment

Engine

24

2.2. Specifications

2.2.3. Compression Test Data

2.3. Cylinder Head Assembly

Tests have shown that many factors affect compression pressures. Battery and starter motor condition, ambient conditions and the type of gauge used can give a wide variation of results for a given engine.

2.3.1. General Description NOTE : •The front of the engine is when seen from the end with the timing case assembly.

•Number one cylinder is at the front of the engine.

It is not possible to give accurate data for compression pressure, but tests have shown that the results should be within 2000/3500 kPa (300/500 lb/in2) 21,0/35,0 kg/cm2 for diesel engines.

Compression tests should only be used to compare between the cylinders of an engine. If one or more cylinders vary by more than 350 kPa (50 lb/in2) 3.5 kg/cm2, then those cylinders may be faulty.

Compression tests should not be the only method used to show the condition of an engine, but they should be used together with other symptoms and tests.

PU057

(A)

How to do a Compression Test In a diesel engine, there is little carbon deposit and for this reason, the number of hours run is no indication of when to overhaul a cylinder head assembly. The factors which indicate when an overhaul is necessary are how easily the engine starts and its general performance.

CAUTION : Before the compression test, ensure that the battery is in good condition and that it is fully charged. Also ensure that the starter motor is in good condition .

1. Ensure that the valve tip clearances are set correctly.

The cylinder head assemblies for both the UA and UB engines contain two valves for each cylinder.

From the front of the engine, the sequence for valves is first inlet and then exhaust.

2. Remove the atomisers.

3. Fit a suitable gauge into the hole in the cylinder for the atomizer.

The cylinder head for the UB engine contains a precombustion chamber(A1) that is made from a hardened manganese alloy. It will not be possible to renew this chamber or to machine the bottom face of the cylinder head.

4. Ensure that the engine cannot start: Disconnect the stop solenoid or put the stop control in the no-fuel position.

Operate the starter motor and note the pressure indicated on the gauge.

Included in the cylinder head assembly for UA and UB engines, there is a valve guide and a valve seat insert for each valve. The inserts and guides can be renewed if necessary. The new valve guides are prefinished.

5. Repeat for each cylinder.

The face angle for all of the valves is 45° and the angle for all of the valve seats is 45°.

The inlet and the exhaust valves are each fitted to the cylinder head with a single valve spring and an oil seal that is fitted over the top of the valve guide.

The valve and valve spring are held in position with a hardened steel cap and two collets.

Engine

25

2.3. Cylinder Head Assembly

1. Disconnect the breather pipe (B1).

The glow plugs and the atomisers are both fitted into the top of the cylinder head. The tip of the glow plug and the atomizer protrude through the bottom face of the cylinder head (A2) on UA engines, and into the pre-combustion chamber (A3) on UB engines.

2. Remove the cap nuts (A1), the steel washers (A2) and the rubber seals (A3).

3. Lift off the rocker cover (B).

CAUTION : The amount of protrusion for both atomizer and glow plug is important for the performance of the engine, therefore only Perkins parts should be used in service.

To Fit 1. Check the condition of the rubber seals (A3) and the steel washers (A2) for the cap nuts (A1). If necessary, the seals for the cap nuts can be renewed.

2.3.2. Rocker Cover To Remove and to Fit

2. If necessary, check, clean and renew the components of the breather system, operation 18A-02.

12A-01

The engine is fitted with an aluminum rocker cover which includes a closed breather assembly and a connection for the breather pipe. A composite rubber seal is fitted into a machined groove (B2) in the flange face of the cover.

3. Check the condition of the rocker cover seal (B2) and renew the seal if necessary.

4. Clean the seal face of the cylinder head and fit the rocker cover. When the cover is put on the cylinder head, ensure that the seal remains in the groove.

To Remove

CAUTION : If the cap nut (A1) is overtightened, the stud and plate assembly (B3), for the rocker pedestal may be damaged.

5. Fit the rocker cover. Ensure that the cap nuts, washers and the rubber seals are fitted correctly.

Tighten the cap nuts to 11 N•m (8 lb•ft) 1.1 kg•m.

Fit the breather pipe.

PU017

(A)

PU019

(B)

Engine

26

2.3. Cylinder Head Assembly

NOTE : A hardened steel pin (B1) is fitted in the lower part of the front bracket. The purpose of this pin, is to ensure that the bracket is in the correct position on the rocker shaft. The hole in the bracket will align with the oil hole (B2) in the cylinder head and ensure correct lubrication of the rocker assembly. Protect these holes to ensure that dirt cannot enter.

2.3.3. Rocker Assembly To Remove and to Fit

12A-02

To Fit CAUTIONS : •Before the rocker assembly is fitted, ensure that the oil holes (B1) and (B2) are free of dirt.

•Check that the push rods(B3) fit correctly in the sockets of the tappets.

PU015

(A)

1. Put the rocker assembly (B) onto the cylinder head.

2. Fit the plates (A2) to the correct brackets for the rocker shaft.

3. Fit the fasteners (A1), (A3) and (A4) finger tight.

CAUTION : As the fasteners are gradually tightened, ensure that the ends of the adjustment screws (B4) fit correctly in the sockets (B3) of the push rods.

4. Tighten gradually and evenly, the nuts (A4) and then the nuts (A3) to 22 N•m (16 lb•ft) 2.2 kg•m.

PU016

(B) To Remove

5. Tighten gradually and evenly, the eight setscrews (A1) to 9 N•m (7 lb•ft) 0.9 kg•m. Tighten the inner setscrews first and then the outer setscrews.

1. Remove the rocker cover, operation 12A-01.

6. Adjust the valve tip clearances, 12A-05.

2. Release the eight setscrews (A1) for the brackets of the rocker shaft. Release gradually and evenly the nuts (A3) and then the nuts (A4) for the brackets of the rocker shaft.

7. Fit the rocker cover, operation 12A-01.

NOTE : The rocker assembly contains three plates (A2) which include the studs for the rocker cover. The plates must be fitted to the correct rocker brackets (A).

3. Remove the nuts and lift off the rocker assembly (B).

Engine

27

2.3. Cylinder Head Assembly

To Dismantle and to Assemble

To assemble

12A-03

1. Ensure that the oil holes in the rocker shaft and in the rocker-levers are not restricted.

To Dismantle

2. Before assembly, lubricate the components with clean engine lubricating oil. Assemble the components in the correct sequence; the rocker levers should be fitted in the original sequence. Fit the spacers and clips to the ends of the rocker shaft.

To Inspect

12A-04

1. Clean and inspect all the components for wear and any other damage. Check the clearance between the rocker levers and the rocker shaft. If the clearance is more than 0.124 mm (0.0048 in), either renew the rocker lever or the rocker shaft, or both if necessary.

PU018

(A)

PU016

(B)

1. Remove the clips (A5) from both ends of the rocker shaft. Ensure that the ends of the rocker shaft are not damaged.

2. Remove the spacer (A4), the rocker levers (A2), the brackets (A3) and the springs (A1).

NOTE : The bracket (A6), is fitted to the rocker shaft with a hardened steel pin (B1) which aligns the oil holes. If either the rocker shaft or the bracket have to be renewed, a new pin must also be used.

Engine

28

2.3. Cylinder Head Assembly

1. Rotate the crankshaft in a clockwise direction until the valve (B7) has just opened and the valve (B8) has not closed completely. Check the clearances of the valves (B1) and (B2) and adjust them, if necessary.

2.3.4. Valve Tip Clearances To Check and to Adjust

12A-05

2. Rotate the crankshaft in a clockwise direction until the valve (B3) has just opened and the valve (B4) has not closed completely. Check the clearances of the valves (B5) and (B6) and adjust them, if necessary.

3. Rotate the crankshaft in a clockwise direction until the valve (B1) has just opened and the valve (B2) has not closed completely. Check the clearances of the valves (B7) and (B8) and adjust them, if necessary.

PU012

4. Rotate the crankshaft in a clockwise direction until the valve (B5) has just opened and the valve (B6) has not closed completely. Check the clearances of the valves (B3) and (B4) and adjust them, if necessary.

(A)

PU013

(B) NOTES : •The valve tip clearance is checked with a feeler gauge between the top of the valve stem and the rocker lever (A), with the engine cold. The correct clearance for both the inlet and the exhaust valves is 0.35 mm (0.014 in).

•The arrangement of the valves is shown in (B).

Valve numbers (B1) and (B2) are for number one cylinder which is at the front of the engine.

•Clockwise rotation is when seen from the front of the engine.

Engine

29

2.3. Cylinder Head Assembly

6. Release the valve spring compressor and remove the valve spring caps and the valve spring.

2.3.5. Valve Springs To Change The Valve Springs (with cylinder head fitted)

7. Put the new valve spring in position.

12A-06

8. Fit the valve spring cap.

Special Tools : Valve spring compressor, PD.6118B Stud adaptor PD.244

CAUTION : Ensure that the valve spring is compressed squarely or damage can occur to the valve stem.

WARNING

9. Fit the valve spring compressor, compress the valve spring and fit the collets. Remove the valve spring compressor.

Wear eye protection when the valve spring is compressed.

10. Fit the rocker assembly, operation 12A-02.

NOTE : Paragraphs 1 to 12 refer to a change of valve springs for a single cylinder.

11. Check the valve tip clearances, operation 12A-05.

12. Fit the rocker cover, operation 12A-01.

NOTE : If other or all of the valve springs are to be changed, they can be changed one cylinder at a time in the sequence of cylinders 1 and 4, 2 and 3.

PU036

(A) 1. Remove the rocker cover, operation 12A-01.

2. Turn the crankshaft in the normal direction of rotation until the inlet valve of the relevant cylinder has just opened and the exhaust valve has not fully closed. In this position the piston will be at approximately top dead centre (TDC).

3. Remove the rocker assembly, operation 12A-02.

4. Fit the valve spring compressor (A1) and the adaptor (A2).

5. Compress the valve spring and remove the collets.

Ensure that the valve spring is compressed squarely or damage to the valve stem can occur.

CAUTION : Do not rotate the crankshaft while the valve springs are removed.

Engine

30

2.3. Cylinder Head Assembly

If the rocker assembly has been removed, piston TDC can be found as follows:

PU037

(A) 1. Fit the valve spring compressor and compress the valve spring to open the valve.

2. Turn the crankshaft, by hand, in the normal direction of rotation until the piston touches the valve.

3. Continue to turn the crankshaft, and at the same time, release pressure on the valve spring compressor until the piston is at TDC(A).

Engine

31

2.3. Cylinder Head Assembly

1. Drain the cooling system, operation 21A-04.

2.3.6. Cylinder Head Assembly To Remove and to Fit

2. Disconnect the battery.

12A-07

3. Remove the rocker cover, operation 12A-01.

Special Tools : 14 mm extended socket spanner

CAUTION : Use a separate spanner to prevent movement of the outlet connections of the fuel injection pump when the high-pressure pipes are released or tightened.

4. Remove the high-pressure fuel pipes. Fit suitable covers to all open connections on the fuel injection pump and the atomisers.

5. Remove the exhaust manifold and gasket (A).

6. Remove the induction manifold and gasket (B).

7. Remove the pipe which is fitted between the fuel filter and the connections for the atomiser leak-off.

PU024-1

(A) 8. Remove the atomisers, see operation 20A-02A/B. Fit suitable covers to the nozzles and to the open connections.

9. Remove the glow plugs, operation 23C-01.

10. Release the clips on the hose which is fitted between the water pump and the thermostat housing and remove the hose.

11. Disconnect the sender unit for the coolant temperature.

PU025

12. Remove the rocker cover, operation 12A-01.

(B) 13. Remove the rocker assembly, operation 12A-02.

To Remove

14. Remove the push rods and note their relative positions.

WARNING Do not remove the filler cap or any component of the cooling system while the engine is hot and while the coolant is under pressure, because dangerous hot coolant can be discharged.

CAUTION : Some coolant may enter the cylinder bores and the threaded holes for the cylinder head setscrews when the cylinder head is removed.

Ensure that any coolant is removed immediately to prevent corrosion.

Engine

32

2.3. Cylinder Head Assembly

CAUTION : Do not use a lever to separate the cylinder head from the cylinder block.

CAUTIONS: •There is a rubber grommet (B2) fitted in the cylinder head gasket for UB engines.

•To prevent damage to the cylinder head gasket, ensure that the dowels are fitted in the cylinder block before the gasket and head are fitted.

•Jointing compound must not be used with the cylinder head gasket.

16. Remove the cylinder head and put it on a surface that will not damage the face of the cylinder head.

2. Put the cylinder head gasket in position; it is stamped "top"(B3) and "front" (B4) for correct assembly.

15. Release the cylinder head setscrews evenly and gradually in the reverse sequence to that shown in (A). To release the four setscrews (A1). It spanner. Check the setscrews for damage and renew them if necessary.

3. Put the cylinder head in position.

4. Lightly lubricate the threads of the cylinder head setscrews and the thrust faces of the setscrew heads. Engage all the setscrews finger tight.

5. Gradually and evenly tighten the setscrews to 70 N•m (52 lb•ft) 7.1 kg•m in the sequence shown in (A). To tighten the four setscrews (A1), It will be necessary to use a 14 mm extended socket spanner.

6. Gradually and evenly tighten the setscrews to 100 N•m (74 lb•ft) 10.2 kg•m in the same sequence.

PU020

(A)

7. Repeat paragraph 6 to ensure that all of the setscrews are tightened to the correct torque.

8. Put the push rods into the sockets of the tappets from which they were removed.

9. Fit the rocker shaft assembly, see operation 12A-02.

10. Set the valve tip clearances, see operation 12A-05.

11. Fit the rocker cover, operation 12A-01 and tighten the fasteners finger tight only.

PU021

12. Connect the sender unit for the coolant temperature.

(B) To Fit

13. Fit the hose between the water pump and the thermostat housing and tighten the clips.

1. Clean the bottom face of the cylinder head and top face of the cylinder block. Ensure that there is no debris in the cylinder bores or pre-combustion chambers.

14. Fit the glow plugs, operation 23C-01.

15. Fit the atomisers, see operation 20A-02A/B.

NOTE : Two dowels (B1) are fitted to the cylinder block to ensure that the cylinder head gasket and the cylinder head remain in the correct position when the setscrews are tightened.

Engine

16. Fit the pipe which is fitted between the fuel oil filter and the connections for the atomizer leadoff.

33

2.3. Cylinder Head Assembly

17. To ensure correct alignment of the exhaust manifold (A1), fit two guide studs (A2) and a new gasket without jointing compound. The gasket can be fitted two ways, ensure the gasket is fitted the correct way up (A4). Fit the exhaust manifold.

NOTE : To retain the exhaust manifold, earlier engines were fitted with two studs and six setscrews.

If these are found to be loose, remove them and fit the manifold with eight of the latest type setscrews(A3). The threaded part of the new setscrews is machined to a three lobe shape.

18. Fit the setscrews and remove the guide studs.

Tighten first the inner setscrews, and then the outer setscrews, to 18 N•m (13 lb•ft) 1.8 kg•m.

The torque for the earlier fasteners is 22 N•m (16 lb•ft) 2.2 kg•m.

The new setscrew was introduced from engine number U801620. The threaded part of the old setscrew (A5) is the standard shape.

CAUTION : If the latest setscrews are fitted instead of the old fasteners, and the bosses on the manifold have been machined. a plain washer, part number 0920003, 1.83 mm (0.072 in) thick must be fitted under the head of each new setscrew. This is to prevent contact of the new setscrew, which is longer, with the bottom of the tapped hole in the cylinder head. If the manifold bosses have not been machined, it is not necessary to use the plain washer.

19. To ensure correct alignment of the inlet manifold, fit two guide studs (B2) and a new gasket without jointing compound. The gasket may be fitted either way around. Fit the setscrews and remove the guide studs Tighten the setscrews to 22 N•m (16 lb•ft) 2.2 kg•m.

CAUTIONS : •If there is a leakage from the union nut, ensure that the pipe is correctly aligned with the atomiser inlet.

•Do not tighten the union nuts of the high-pressure pipes more than the recommended torque tension as this can cause a restriction at the end of the pipe.

This can affect the fuel delivery.

20. Fit the high-pressure fuel pipes and tighten the connection nuts to 22 N•m (16 lb•ft) 2.2 kg•m.

21. Fit the breather hose to the connections of the cylinder head cover and the induction manifold.

22. Fill the cooling system, operation 21A-05.

PU024/1-1

(A)

23. Connect the terminals of the battery.

24. Connect the air filter.

25. Eliminate air from the fuel system, operation 20A-07.

26. Remove the rocker cover.

27. Start the engine, run it at low speed and check that oil flows from all the rocker levers.

28. If the oil flow from the rockers is correct, stop the engine and fit the rocker cover, see operation 12A-01. If the oil flow is not correct, find the fault.

PU025-1

(B)

Engine

34

2.3. Cylinder Head Assembly

1. Remove the cylinder head, see operation 12A-07.

2.3.7. Valves and Valve Springs To Remove and to Fit

2. Clean the bottom face of the cylinder head and check the depth of the valve heads below the face of the cylinder head, operation 12A-09.

12A-08

Special Tools : Valve spring compressor, MS. 1519A

3. Make a suitable mark on the head of each valve to ensure that the valves can be fitted in their original positions.

To Remove

CAUTION : Ensure that the valve springs are compressed squarely or the valve stem can be damaged.

WARNING Wear eye protection during this operation.

4. Use the valve spring compressor (A) to compress the valve spring (B3) and remove the collets (B2).

5. Release the valve spring compressor and remove the valve spring cap (B1), valve spring (B3), valve stem seal (B4) and the valve (B5).

6. Repeat paragraphs 3 and 4 to remove the remainder of the valves.

To Fit

WARNING

PU023

(A)

Wear eye protection during this operation.

CAUTIONS : •Genuine Perkins valve stem seals must be used.

If they are not, damage can occur to the valve stems and valve seats.

•Ensure that the valve springs are compressed squarely or damage can occur to the valve stem.

1. Lubricate the valve stem (B5) with clean engine oil and fit the valve into the valve guide.

2. Fit a new valve stem seal (B4) onto the valve guide. Fit the valve spring (B3) and the valve spring cap (B1). The valve spring can be fitted with either end toward the cylinder head.

3. Use the valve spring compressor to compress the valve spring. Fit the collets (B2).

4. Repeat paragraphs 1, 2 and 3 to fit the remainder of the valves.

PU022

(B) Engine

35

2.3. Cylinder Head Assembly

To Inspect and to Correct

12A-09

2.3.8. Valve Guides

Special Tool: Gauge, valve depth, PD.41D Dial gauge for use with PD.41D, PD.208

To Inspect

12A-10

To check the valve guides for wear: The maximum clearance (A5), between the valve stem and the bore of the guide is 0,107 mm (0.042 in) for inlet valves and 0,14 mm (0.006 in) for exhaust valves. If the clearance, with a new valve fitted, is more than the limit, then a new valve guide (A4) must be fitted.

It is recommended that the procedure given below is used to check the valve guide clearance:

PC038

(A) 1. Check the depth of the valves below the face of the cylinder head before the valve spring are removed. Ensure that the heads of the valves and the bottom face of the cylinder head are clean. Put the valve depth gauge on the face of the cylinder head and set the dial gauge to zero. Carefully put the valve depth gauge in position over the head of each valve (A) and make a note of the measurement. The maximum depth in service is given in Data and dimensions at the end of this section.

PA298

(A) 1. Put a new valve in the valve guide.

2. Put a dial test indicator with a magnetic base (A1) onto the face of the cylinder head.

2. If a valve is below the depth limit, check the valve depth with a new valve in position. If the valve depth is still below the limit, the valve seat insert (s) must be renewed, see operation 12A-14.

3. With the valve lifted 15.0 mm (0.6 in) and the gauge (A2) in contact with the edge of the valve head (A3), move the valve radially away from the gauge. With the valve held in this position, set the gauge zero.

3. Check the valves for cracks. Check the stems of the valves for wear and for correct fit in their valve guides.

4. Move the valve radially across the axis of the cylinder head towards the gauge. Make a note of the reading on the gauge. If the reading is equal to or greater than the data given below, a new valve guide (A4) must be fitted.

Maximum permissible clearance with a valve lift of 15.0 mm(0.6 in):

4. Check that the seat faces of the valves are not burnt or damaged. Seat faces which are damaged can be ground on a special machine. Valves which have only a little damage can be lapped to their valve seats. When new valves are fitted, the valve depths must be checked, see paragraph 1.

•Inlet guide •Exhaust guide

5. Check that the load on the valve springs is correct at their fitted length, see Data and dimensions. Fit new valve springs at every complete engine overhaul.

Engine

36

0.24 mm(0.009 in) 0.28 mm(0.011)

2.3. Cylinder Head Assembly

To Remove and to Fit

To Fit

12A-11

Special Tools: Remover/replacer for valve guides(main tool), PD.1D/1 Spacer PD.1D/2, used with main tool PD.1D/1 Adaptor PD.249, used with PD.1D-13 Adaptor PD.1D-13 used with main tool PD.1D/1

PA065/1

(B) 1. Clean the parent bore in the cylinder head for the valve guide.

2. Lubricate the outer surface of the new valve guide (B6) with clean engine lubricating oil.

3. Fit the adaptor (B5) into the remover/replacer tool (B3).

PA064

(A)

4. With the adaptor fitted to the tool, put the spacer (B4) in position on the tool. Pass the adaptor through the cylinder head and put the spacer and tool assembly in position on the valve seat.

To Remove 1. Fit the adaptor (A4) into the remover/replacer tool (A3).

5. Put the new valve guide in position on the adaptor and fit the distance piece (B7). Fit the attachment (B8) to secure the valve guide to the adaptor.

2. With the adaptor fitted to the tool, put the spacer (A5) in position on the tool. Pass the adaptor through the valve guide (A6) and put the spacer and tool in position on the valve seat.

NOTE : The internal recess in the valve guide must be towards the tool.

3. Fit the attachment (A7) to secure the adaptor to the valve guide.

6. Hold the top handle (B1) and turn the bottom handle (B2) clockwise to pull in the valve guide until the distance piece touches the cylinder head.

4. Hold the top handle (A1) and turn the bottom handle (A2) clockwise to pull the valve guide out of the cylinder head.

Engine

7. When the valve guide is fitted correctly, the top of the valve guide will have a protrusion of 7.7/7.9 mm (0.30/0.31 in) above the valve spring seat (B9).

37

2.3. Cylinder Head Assembly

8. Use a straight edge and feeler gauges to check the cylinder head for distortion as shown in Data and dimensions at the end of section 12.

2.3.9. Cylinder Head To Inspect and to Correct

12A-12

CAUTIONS : •If the cylinder head of a UA engine has been machined, the maximum nozzle protrusion must not exceed 2.7 mm (0.11 in), when measured with the nozzle seat washer fitted.

•If the cylinder head has been machined, check the depth of each valve head, below the bottom face of the cylinder head. If necessary, cut the valve seat to obtain the correct dimension, see Data and dimensions at the end of section 12. It is better to work to the minimum limit to allow for later wear.

•Before any work is done on the valve seats, new valve guides must be fitted, operation 12A-11.

•If a new valve seat insert is to be fitted, the back face must be surface ground to ensure that there is no protrusion above the bottom face of the cylinder head, operation 12A-14.

CAUTION : The bottom face of the cylinder head for the UB engine should not be machined. If it is, the edge of the pre-combustion chamber will be too thin and could break off during the combustion process. If the bottom face of the cylinder head is damaged or the distortion exceeds the service limits, the cylinder head assembly must be renewed.

9. Check the valve seats for wear and for damage.

10. Where there is little damage, the valve and valve seat can be lapped. When the valve seats are lapped, keep the seat as narrow as possible and ensure that all the compound used to lap the valve and the seat is removed.

PU057/1

(A) 1. Remove the cylinder head assembly, operation 12A-07.

11. More badly damaged valve seats can be corrected by use of the cutter tool, operation 12A-13, or new inserts can be fitted, operation 12A-14.

2. Inspect the cylinder head for signs of gas or coolant leakage.

3. Remove the valve springs and the valves, operation 12A-08.

4. Clean the face of the cylinder head and the passages for coolant and for lubricating oil. The water jacket can be cleaned with a special solvent which must be used in accordance with the manufacturer's instructions.

5. Test the cylinder head for leaks at the pressure given in data and dimensions at the end of the section.

6. When the cylinder head is thoroughly clean, check it for cracks. Check carefully the areas around the valve seats, the holes for the atomizer nozzles and glow plugs (A2), and the port (A1) in the precombustion chambers. If there are cracks in these areas, the cylinder head assembly should be renewed.

7. The bottom face of the cylinder head for UA engines (only) can be machined if, there is distortion, deep scratches or the valve depths are below the service limit.

Engine

38

2.3. Cylinder Head Assembly

To Correct a Valve Seat With a Valve Seat Cutter 12A-13

NOTE : If a valve seat has become too damaged or too worn to correct, a valve seat insert can be fitted, operation 12A-14.

Special Tools: Valve seat cutting tool-kit

To Fit a Valve Seat Insert

12A-14

CAUTION : A new valve guide must be fitted to the cylinder head before a new valve seat insert is fitted.

This is necessary to maintain concentricity between the valve guide and the seat for the valve.

Note: Cylinder heads that are fitted with new valve seat inserts and new valve guides(pre-finished) are available.

1. Remove the valve guide and clean the bore into which the guide is to be fitted.

2. Fit new valve guides, operation 12A-11.

3. With the bore of the new valve guide used as a pilot, machine out the old valve seat insert.

Remove all debris and clean the recess for the insert.

CAUTION : If the bottom face of the cylinder head has been machined, the depth of the recess for the valve seat may have changed.

PC040

4. Measure the depth of the recess in two places 90° apart. The correct depths are:

(A)

1. Before any work is done on the valve seats, new valve guides must be fitted, operation 12A-11.

-UA engines: 8.35/8.55 mm (0.329/0.337 in) -UB engines: 8.20/8.40 mm (0.320/0.330 in)

2. Fit the pilot(A3) in the valve guide and tighten the pilot.

5. If the depth of the recess has been reduced, surface grind the bottom face of the insert by an equivalent amount. Check the depth of the insert and ensure that it is fitted correctly.

3. Select the relevant cutter(A2). Set the blades of the cutters to the diameter of the valve seat to be cut. Fit the cutter on the pilot and fit the handle(A1). Ensure that the cutter is not allowed to fall on to the seat as this can damage the blades.

6. If the insert has been surface ground, ensure that the outer edge of the back face of the insert has a 0.7/1.2 mm (0.03/0.05 in) chamfer at 30°C L 1°C to the vertical.

4. Carefully rotate the cutter in a clockwise direction(A4). Remove only the minimum material to ensure a good seat. Keep the seat as narrow as possible.

7. With the bore of the valve guide used as a pilot, and with the rear face of the insert towards the cylinder head, press the insert into the recess with the valve seat insert tool, see Data and dimensions.

5. When the seat is cut, remove the cutter and the pilot. Remove any debris from the area of the valve seat and the port.

CAUTION : Do not use a hammer or use lubrication to fit the insert. Use a hydraulic press or a hand press in one continuous movement.

6. Fit the valve and lightly lap the valve and the seat.

7. Check that the valve depth is within limits, see Data and dimensions at the end of this section.

Engine

39

2.3. Cylinder Head Assembly

8. Ensure that when fitted, the bottom face of the insert is in contact with the bottom of the recess in the cylinder head. When fitted correctly, the depth of the insert, below the bottom face of the cylinder head should be: -UA engines: 2.15/2.45 mm(0.085/0.096 in) -UB engines: 2.4/2.7 mm(0.09/0.11 in) The depth of the insert should be measured in two places, at 90° to each other.

9. Cut the valve seat at 45° (an included angle of 90°) for the inlet and the exhaust valves (UA and UB engines), operation 12A-13. Ensure that the depth of the valve head below the face of the cylinder head is within the production limits, see Data and dimensions. Work as near as possible to the minimum figure to allow for future wear on the valve seat.

Engine

40

2.3. Cylinder Head Assembly

2.3.10. Data and Dimensions Introduction NOTE : This information is given as a guide for personnel engaged on engine overhauls. The dimensions which are shown are those which are mainly used in the factory. Unless it is indicated to be different, the data shown below is the same for both UA and UB engines.

Cylinder head assembly Angle of Valve Seats -Inlet.......................................................................................................................................45° (90° included angle) -Exhaust ................................................................................................................................45° (90° included angle) Diameter of parent bores for valve guides ......................................................12,000/12,027 mm (0.4724/0.4735 in) Leak test pressure ........................................................................................................200 kPa (29 lb/in2) 2.0 kg/cm2 Cylinder head thickness ..........................................................................................79.95/80.05 mm (3.148/3.151 in) Minimum permissible thickness after cylinder head has been machined -UA engines ...................................................................................................................................79.8 mm (3.142 in) -UB engines ......................................The cylinder head for this engine must not be machined, see caution on page 12A.17 Maximum protrusion of the atomizer nozzle......................................................................................2,7 mm (0.11 in) Valve guides Inside diameter ....................................................................................................7.027/7.052 mm (0.2767/0.2776 Outside diameter .............................................................................................12.034/12.047 mm (0.4738/0.4743 Interference fit of guide in cylinder head ........................................................-0.007/-0.047 mm (-0.0003/-0.0019 Length..............................................................................................................................45.2/45.7 mm (1.78/1.80 Protrusion above the valve spring seat .............................................................................7.7/7.85 mm (0.30/0.31

in) in) in) in) in)

Inlet valves Diameter of valve stem........................................................................................6.970/6.985 mm (0.2704/0.2750 in) Clearance fit of valve in guide .............................................................................0.042/0.082 mm (0.0017/0.0032 in) Maximum permissible clearance in valve guide ........................................................................0.107 mm (0.0042 in) Diameter of valve head -UA engines .....................................................................................................................43.9/44.1 mm (1.73/1.74 in) -UB engines .....................................................................................................................41.9/42.1 mm (1.65/1.66 in) Angle of valve face .................................................................................................................................................45° Depth of valve head below cylinder head face -UA engines .........................................................................................................0.306/0.806 mm (0.0120/0.0317 in) -UB engines .........................................................................................................0.325/0.675 mm (0.0128/0.0266 in) Service limit -UA engines ...................................................................................................................................0.93 mm (0.037 in) -UB engines ...................................................................................................................................0.72 mm (0.028 in) Overall length of valve ............................................................................................106.275/106.625 (4.184/4.197 in) Seal arrangement.....................................................................................................Rubber seal fitted to valve guide Exhaust valves Diameter of valve stem........................................................................................6.945/6.960 mm (0.2734/0.2740 in) Clearance fit of valve in guide .............................................................................0.067/0.107 mm (0.0026/0.0042 in) Maximum permissible clearance in valve guide ..........................................................................0.15 mm (0.0059 in) Diameter of valve head -UA engines .....................................................................................................................37.1/37,3 mm (1.46/1.47 in) -UB engines .....................................................................................................................33.9/34,1 mm (1.33/1.34 in) Angle of valve face .................................................................................................................................................45° Depth of valve head below cylinder head face -UA engines .........................................................................................................0.317/0.817 mm (0.0125/0.0322 in) -UB engines .........................................................................................................0.425/0.775 mm (0.0165/0.0305 in) Engine

41

2.3. Cylinder Head Assembly

Service limit -UA engines ...................................................................................................................................0.94 mm (0.037 in) -UB engines ...................................................................................................................................0.72 mm (0.028 in) Overall length of valve -UA engines ........................................................................................................106.125/106.475 (4.1781/4.1919 in) -UB engines .................................................................................................106.275/106.625 mm (4.1841/4.1978 in) Seal arrangement.....................................................................................................Rubber seal fitted to valve guide Valve springs Fitted length .....................................................................................................................................32.0 mm (1.26 in) Load at fitted length .........................................................................................375/415 N (84.4/93.2 lb) 38.3/42.3 kg Number of active coils.............................................................................................................................................3.9 Direction of coils............................................................................................................................................Left hand Tappets Diameter of tappet stem ..................................................................................26.959/26.980 mm (1.0613/1.0622 in) Diameter of tappet bore in cylinder block ........................................................27.000/27.021 mm (1.0631/1.0641 in) Clearance of tappet in cylinder block ..................................................................0.020/0.062 mm (0.0008/0.0024 in) Rocker shaft Outside diameter .............................................................................................21.962/21.987 mm (0.8646/0.8656 in) Rocker levers Bore diameter ..................................................................................................22.013/22.051 mm (0.8667/0.8681 Clearance fit on rocker shaft ...............................................................................0.026/0.084 mm (0.0010/0.0033 Maximum permissible clearance ...............................................................................................0.124 mm (0.0048 Valve tip clearances (cold).............................................................................................................0.35 mm (0.014

Engine

42

in) in) in) in)

2.3. Cylinder Head Assembly

Exhaust - UA engines B1 ..................Radius 0.38 mm (0.015 in) maximum B2 ..................45° chamfer B3 ..................42.5/42.3 mm (1.67/1.79 in) B4 ..................38.475/38.500 mm (1.5148/1.5157 in) B5 ..................8.35/8.55 mm (0.329/0.337 in)

Maximum permissible distortion of cylinder head (A)

Inlet - UB engines B1 ..................Radius 0.38 mm (0.015 in) maximum B2 ..................45° chamfer B3 ..................46.9/47.1 mm (1.84/1.85 in) B4 ..................43.325/43.350 mm (1.7057/1.7067 in) B5 ..................8.2/8.4 mm (0.32/0.33 in) Exhaust - UB engines B1 ..................Radius 0,38 mm (0.015 in) maximum B2 ..................45° chamfer B3 ..................38.7/38.9 mm (1.52/1.53 in) B4 ..................35.125/35.150 mm (1.3828/1.3838 in) B5 ..................8.2/8.4 mm (0.32/0.33 in)

PU040

(A) A1 ..................0.08 mm (0.003 in) A2 ..................0.15 mm (0.006 in) A3 ..................0.15 mm (0.006 in) AX..................40 mm (1.6 in) AY..................106 mm (4.2 in) AZ..................106 mm (4.2 in)

PC111

(B) Dimensions of a recess for a valve seat insert (B) Inlet - UA engines B1 ..................Radius 0.38 mm (0.015 in) maximum B2 ..................45° chamfer B3 ..................49.0/49.2 mm (1.93/1.94 in) B4 ..................45.175/45.200 mm (1.7785/1.7795 in) B5 ..................8.35/8.55 mm (0.329/0.337 in)

Engine

43

2.3. Cylinder Head Assembly

Exhaust: UB engines A1 ..................1.5 mm (0.06 in) A2 ..................19.0 mm (0.7 in) A3 ..................6.1 mm (0.26 in) A4 ..................60.0 mm (2.4 in) A5 ..................28.95/29.02 mm (1.139/1.143 in) A6 ..................35.08/35.10 mm (1.38/1.38 in) A7 ..................0.8 mm (0.031 in) A8 ..................1.5 mm (0.06 in) A9 ..................1.5 mm (0.06 in) A10 ................6.95/6.97 mm (0.273/0.274 in)

Dimensions for a valve seat insert tool(A)

PA069

(A) Inlet : UA engines A1 ..................1.5 mm (0.06 in) A2 ..................19.0 mm (0.7 in) A3 ..................6.5 mm (0.26 in) A4 ..................60.0 mm (2.4 in) A5 ..................38.82/38.85 mm (1.528/1.529 in) A6 ..................44.6/45.1 mm (1.76/1.78 in) A7 ..................0.8 mm (0.03 in) A8 ..................1.5 mm (0.06 in) A9 ..................1.5 mm (0.06 in) A10 ................6.95/6.97 mm (0.273/0.274 in) Exhaust : UA engines A1 ..................1.5 mm (0.06 in) A2 ..................19.0 mm (0.7 in) A3 ..................6.5 mm (0.26 in) A4 ..................60.0 mm (2.4 in) A5 ..................31.42/31.45 mm (1.237/1.238 in) A6 ..................38.43/38.45 mm (1.513/1.514 in) A7 ..................0.8 mm (0.031 in) A8 ..................1.5 mm (0.06 in) A9 ..................1.5 mm (0.06 in) A10 ................6.95/6.97 mm (0.273/0.274 in) Inlet: UB engines A1 ..................1.5 mm (0.06 in) A2 ..................19.0 mm (0.7 in) A3 ..................6.1 mm (0.26 in) A4 ..................60.0 mm (2.4 in) A5 ..................37.15/37.22 mm (1.46/1.47 in) A6 ..................42.75/43.25 mm (1.683/1.703 in) A7 ..................0.8 mm (0.03 in) A8 ..................1.5 mm (0.06 in) A9 ..................1.5 mm (0.06 in) A10 ................6.95/6.97 mm (0.273/0.274 in)

Engine

44

2.3. Cylinder Head Assembly

There are two types of piston used in the 700 Series engines. The UA engine, which has direct injection, has a combustion chamber (A1) in the top of the piston. This chamber is designed to give an efficient mix of fuel and air.

2.4. Piston and Connecting Rod Assembly 2.4.1. General Description

The UB engine, which has indirect injection,has a piston with a different design (B1). This works with the pre-combustion chamber in the chamber head to give an efficient mix of fuel and air.

Both piston types have two compression rings and an oil control ring.

The pistons and connecting rods are matched to the relevant cylinder.

Axial location of the fully floating gudgeon pin is by two circlips.

PU038

CAUTION : The big end bolts are fitted to the connecting by a special process and must not be removed. If the bolts are removed, the connecting rod, and the bolts will be damaged.

(A)

The connecting rods (C) are machined from “H” section forgings of molybdenum steel. The bearing cap is retained by two special bolts and flange face nuts. The big end bearings have a steel back and an aluminum / tin face. The small end bearings are a lead-bronze bush.

In the factory, the correct piston height is obtained by the use of six lengths of connecting rod and one piston. The small end bush is machined eccentrically to obtain the different connecting rod lengths.

PU046

(B) In servjce, three pistons of different heights are supplied and one connecting rod. The small end bush is machined concentrically. Pistons with a larger diameter are also supplied, to be fitted if the cylinder bores are bored oversize. See Data and dimensions at the end of this section, and section 16, cylinder block assembly.

NOTE : Always use the full engine number to order new parts.

PU039

(C)

Engine

45

2.4. Piston and Connecting Rod Assembly

To Remove

2.4.2. Big End Bearing To Remove and to Fit

CAUTIONS: •Ensure that the bolts(A1) for the connecting rod do not damage the crank pin when the connecting rod is moved. If necessary, fit a temporary plastic sleeve to the big end bolts.

•The big end bolts are fitted to the connecting by a special process and must not be removed. If the bolts are removed, the connecting rod, and the bolts will be damaged.

13A-01

1. Drain the engine lubricating oil.

2. Remove the lubricating oil sump, operation 19A-03.

PU059

3. Remove the lubricating oil strainer and suction pipe, operation 19A-04.

(A)

4. Rotate the crankshaft until the relevant connecting rod is at its lowest position.

5. Release the nuts and remove the bearing cap.

6. Remove the lower half of the shell bearing from the cap, but keep it with its relevant cap.

7. Carefully push the connecting rod up the cylinder bore just enough to allow access to the upper half of the shell bearing. Remove the bearing from the connecting rod. Keep the bearings from the connecting rod and cap together.

PU043

(B) Notes on Connecting Rods: •The left side refers to the side of the engine when seen from the flywheel end.

•The cylinder number (B1) is etched on the left side of the connecting rod and cap.

•The letter that indicates the length grade for the connecting rod is also etched on the left side (B2).

•The letter (B3) which is etched on the right side of the connecting rod is the manufacturers reference number.

•The part number shown on the connecting rod should always be towards the front of the engine.

•Location tags (A1) for the shell bearings will always be towards the right side of the engine.

Engine

46

2.4. Piston and Connecting Rod Assembly

6. After each connecting rod is tightened, ensure that the crankshaft rotates freely.

To Fit

7. Fit the lubricating oil stainer and suction pipe, operation 19A-04.

8. Fit the lubricating oil sump, operation, 19A-03 and fill the sump to the correct level with lubricating oil of an approved grade.

To Inspect

13A-02

Check the bearings and the crank pin for wear or other damage.

PU042

(A)

PU043

(B) 1. Clean the bearing faces of the connecting rod and the crank pin.

2. Clean the upper half of the shell bearing and fir it to the connecting rod; ensure that the location tag is fitted correctly in its recess(A2). Lubricate the bearing surfaces with clean engine lubricating oil. Fit the connecting rod to the crank pin; ensure that the assembly number(B1) and the letter for the length grade(B2) are on the correct side of the engine.

3. Clean the bearing face of the cap and the lower half of the shell bearing and fit it into the cap; ensure that the location tag is fitted correctly in its recess(A1). Lubricate the threads of the bolts.

4. Lubricate the bearing surfaces with clean engine lubricating oil and fit the cap to the connecting rod.

Ensure that the assembly number on the cap is the same as that on the connecting rod and that both of the assembly numbers are on the same side(B). Fit the nuts and tighten them finger tight.

5. Tighten the nuts gradually and evenly to the recommended torque of 54 N•m(40 lb•ft) 5.5 kg•m.

Engine

47

2.4. Piston and Connecting Rod Assembly

2.4.3. Piston and Connecting Rod Assembly

To Remove

To Remove and to Fit

1. Drain the lubricating oil.

13A-03

2. Drain the cooling system, operation 21A-04.

Special Tools: Piston ring compressor, No.8

3. Remove the cylinder head assembly, operation 12A-07.

Notes on Connecting Rods:

4. Remove all carbon from the top of the cylinder bores.

5. Remove the lubricating oil sump, operation 19A-03.

6. Remove the lubricating oil strainer and suction pipe, operation 19A-04.

7. Remove the big end caps and the big end bearing from the connecting rods, operation 13A-01.

CAUTIONS : •The big end bolts are fitted to the connecting rod by a special process and must not be removed.

If the bolts are removed, the connecting rod, and the bolts will be damaged.

•Ensure that the bolts(A1) for the connecting rod do not damage the crank pin when the connecting rod is removed or fitted. If necessary, fit a temporary plastic sleeve to the big end bolts.

•The pistons and connecting rods are matched to the relevant cylinder. Note the position of each connecting rod and piston for correct assembly.

PU59

(A)

8. Push the piston and the connecting rod out through the top of the cylinder. Keep the bearings and caps together to ensure that they can be fitted in their original positions.

PU043

(B)

9. Inspect the crank pins for damage.

•The left side refers to the side of the engine when seen from the flywheel end.

•The cylinder number (B1) is etched on the left side of the connecting rod and cap.

•The letter that indicates the length grade for the connecting rod is also etched on the left side (B2).

Some early engines had the length grade etched on the right side of the connecting rod and cap.

•The letter (B3) which is etched on the right side of the connecting rod is the manufacturers reference number.

•The part number shown on the connecting rod should always be towards the front of the engine.

•Location tags (A1) for the shell bearings will always be on the right side of the engine.

Engine

48

2.4. Piston and Connecting Rod Assembly

1. Ensure that the piston, the cylinder bore, the crank pin and the big end of the cylinder liner with clean engine lubricating oil.

To Fit CAUTION : The correct piston height must be maintained in service to prevent damage to the pistons and valves, and ensure that the engine conforms to emissions legislation.

NOTE : Rotate the crankshaft counter-clockwise to ensure that the shell bearing in the big end remains in position.

2. Rotate the crankshaft until the relevant crank pin is at its highest position. Lubricate the crank pin with clean engine lubricating oil.

3. Fit the upper half of the shell bearing to the connecting rod. Ensure that the location tag is fitted correctly in its recess. Lubricate the bearing with clean engine lubricating oil. Lubricate the threads of to two bolts for the big end.

4. Put the piston ring gaps 120° apart. Lubricate the piston rings with clean engine lubricating oil. Fit the tool(A1) to compress the piston rings.

PU044

(A)

CAUTIONS : •Ensure that the bolts for the connecting rod do not damage the crank pin when the connecting rod is removed or fitted. If necessary, fit a temporary plastic sleeve to the big end bolts.

•Ensure that the piston and connecting rod assembly is fitted to the same cylinder bore from which it was removed.

5. The arrows(B1/C1) must be towards the front of the engine. Fit the piston and connecting rod assembly into the correct cylinder bore. In this position the combustion bowl/recess(B2/C2) will be towards the right side of the engine when seen from the rear.

PU045

(B)

6. Carefully push the piston through the piston ring compressor and check that the connecting rod is onto the crank pin.

7. Rotate the crankshaft counter-clockwise, when seen from the front, until the crank pin is at its lowest position. At the same time carefully apply pressure to the top of the piston with a suitable piece of wood or plastic. This will keep the big end in contact with the crank pin.

PU046

(C)

Engine

49

2.4. Piston and Connecting Rod Assembly

To Check the Piston Height Above the Cylinder Block

13A-03A

Special Tools: Piston height tool, PD.41D Dial gauge for use with PD.41D,PD.208

PU042

(A) 8. Clean the connecting rod cap and the lower half of the shell bearings. Fit the bearing to the cap; ensure that the location tag is fitted correctly in its recess(A1). Lubricate the bearing with clean engine lubricating oil.

PC045

9. Fit the cap and ensure that the assembly number and length grade letters are in the correct position, see notes, page 13A.05. Fit the nuts and tighten the them gradually and evenly to the recommended torque of 54 N•m (40 lb•ft) 5.5 kg.

(A) CAUTION : The correct piston height must be maintained in service to prevent damage to the pistons and valves and ensure that the engine conforms to emissions legislation.

10. Check that the crankshaft will rotate freely.

11. Check the piston height above the top face of the cylinder block, operation 13A-03A.

1. Put the piston height tool (A) on the face of the cylinder block and rotate the dial of the gauge to the zero position.

12. Fit the lubricating oil strainer and suction pipe, operation 19A-04.

2. Rotate the crankshaft until the piston is just before top dead centre(TDC).

13. Fit the lubricating oil sump, operation 19A-03.

3. Carefully put the tool (A) over the top of the piston with the plunger of the gauge in contact with the piston above the axis of the gudgeon pin.

Rotate the crankshaft to ensure that the piston is at the highest piston and make a note of the gauge indication.

The piston height above the top face of the cylinder block should be 0.38/0.51 mm (0.015/0.020).

14. Fit the cylinder head assembly, operation 12A-07.

15. Fill the sump to the correct level with lubricating oil of an approved grade.

16. Fill the cooling system, operation 21A-05.

Engine

50

2.4. Piston and Connecting Rod Assembly

To Fit

2.4.4. Piston Rings To Remove and to Fit

Use a suitable piston ring expander to fit the piston rings.

13A-04

1. Fit the spring (A3) of the oil control ring in the bottom groove of the piston, with the latch pin (B1) inside both ends of the spring. Fit the oil control ring over the spring. Ensure that the ring gap is at 180° to the latch pin. The manufacturers symbol or the word 'TOP' must be towards the top of the piston.

2. Fit the cast iron ring with the taper face (A2) into the second groove of the piston. The manufacturers symbol or the word 'TOP', must towards the top of the piston.

New rings for the second groove have a green identification mark which must be on the left of the ring gap when the ring is fitted and the piston is upright.

The second ring has a chamfer (A4) on the inner, bottom face.

PU095

(A)

3. Fit the top, the manufacturers symbol or the word 'TOP', must be towards the top of the piston. New rings for the top groove have a red identification mark on the outer edge. This mark must be on the left of the ring gap when the ring is fitted and the piston is upright. The top ring has a small curve on the outer face (A1).

PU060

4. Ensure that the ring gaps are 120° apart.

(B) The pistons used in the 700 Series engines have two compression rings and an oil control ring. All the piston rings are above the gudgeon pin. To ensure that the correct piston rings are obtained, always use the full engine number to order new parts.

NOTE : The piston shown in (A) and (B) is for UA engines.

CAUTION : Only expand the ring gaps enough to ensure that the ends of the rings do not damage the piston when the ring is removed or put into position.

To remove Remove the piston rings with a suitable ring expander. Keep the rings with their relevant piston.

Engine

51

2.4. Piston and Connecting Rod Assembly

4. Push the gudgeon pin out by hand. If the gudgeon pin is tight, heat the piston to 40/50˚C (100/120˚F) for easy removal of the gudgeon pin.

2.4.5. Piston and Connecting Rod Assembly To Dismantle and to Assemble

13A-05

To Assemble 1. Clean the bore of the small end bush and lubricate it with clean engine lubricating oil.

2. Fit a new circlip in the circlip groove of one of the gudgeon pin bosses. Ensure that it fits correctly in the groove.

3. Fit the connecting rod to the piston. The piston and connecting rod are correctly assembled when: the arrow(A4) is towards the front of the engine; the bowl/recess(A1) and the reference number(A2) are on the right side of the engine; the assembly number(A3) is on the left side of the engine(right side on some early engines).

4. Lubricate the gudgeon pin bosses with clean engine lubricating oil and push in the gudgeon pin towards the circlip. If the gudgeon pin is a tight fit in the piston, heat the piston to 40/50˚C (100/120˚F) before the gudgeon pin is fitted.

5. Fit a new circlip in the groove in the other gudgeon pin boss. Ensure that it fits correctly in the groove.

6. Fit the piston rings, operation 13A-04.

PU947

(A)

CAUTION : The big end bolts are fitted to the connecting rod by a special process and must not be removed. If the bolts are removed, the connecting rod, and the bolts will be damaged.

NOTE : The pistons and connecting rods are matched to the relevant cylinder. Note the position of each connecting rod and piston for correct assembly.

To dismantle 1. Remove the piston rings, operation 13A-04.

2. Remove the circlips which retain the gudgeon pin.

3. Put a mark on the piston to indicate the cylinder number as shown on the connecting rod. Put the mark on the piston on the same side as the mark on the big end (A3) to ensure that they are assembled correctly.

Engine

52

2.4. Piston and Connecting Rod Assembly

Piston and Connecting Rod Assembly To Renew

NOTE : If any of the components listed below are renewed and the correct piston height cannot be obtained, it may be necessary to fit a new piston and/or new small end bush: -The connecting rod -The small end bush -The Cylinder block -The crankshaft

13A-05A

1. Check the length grade of the original connecting rod and select the correct piston, operation 13A05B. CAUTION : Do not use a letter stamp to mark the connecting rod.

PU096

NOTE : If it is necessary, fir a new small end bush, operation 13A-08.

(A)

3. Put the correct cylinder number(B1) onto the connecting rod.

CAUTION : If the original piston is used, ensure that it is assembled to the correct connecting rod and is used in the original cylinder.

4. Assemble the piston and connecting rod, operation 13A-05.

5. Fit the piston and connecting rod assembly, operation 13A-03.

PU043/1

(B)

CAUTION : The top of the piston must not be machined to obtain the correct height.

CAUTION : The big end bolts are fitted to the connecting rod by a special process and must not be removed. If the bolts are removed, the connecting rod, and the bolts will be damaged.

6. Check the piston height above the cylinder block, operation 13A-03A.

In service, pistons are supplied in three height grades, high, nominal and low. Identification is by a letter shown on the piston crown(A). H is for high and L is for low. The nominal grade(same as used in production) is not marked.

Oversize pistons are identified in the same way. For details of oversize pistons, see Technical data.

In service, only one length of connecting rod is supplied. They are identified by an 'X' etched onto the side of the big end(B2). The manufacturers reference number will be on the right side(B3).

These connecting rods are fitted with a concentric small end bush. Small end bushes supplied loose also have a concentric bore.

Engine

53

2.4. Piston and Connecting Rod Assembly

To Check the length of a Connecting Rod

Connecting rod Dimensions 13A-05B Grade

Length minimum/maximum mm (in)

A

1132.08/132.11 (5.200/5.201)

B

132.05/132.08 (5.100/5.200)

C

132.02/132.05 (5.198/5.199)

D

131.99/132.02 (5.196/5.198)

E

131.96/131.99 (5.195/5.196)

F

131.93/131.96 (5.194/5.195)

X

131.99/132.02 (5.196/5.198)

Piston selection data

PU097

(A) CAUTION : The big end bolts are fitted to the connecting rod by a special process and must not be removed. If the bolts are removed, the connecting rod, and the bolts will be damaged.

NOTE : To ensure that the piston height above the cylinder block is correct in production, one of six different length grades of connecting rod is fitted, see table opposite. if a connecting rod is renewed in service, an 'X' grade (similar to grade 'D') is supplied and is fitted with concentric small end bush.

Grade

Original connecting rod grades

H(high)

A and B

Nominal

C and D

L(low)

E and F

Piston dimensions

Production grades are identified by a letter, etched onto the left side of the rod (right side on some early engines).

If the grade letter on the side of the connecting rod cannot be seen, the length can be checked by the measurement of the dimension shown in (A). The dimensions for each grade are shown in the table opposite.

Grade

Length minimum/maximum mm (in)

H

53.545/53.500 mm

H

2.1080/2.1063 in

Nominal (2)

53.455/53.500 mm

Nominal (2)

2.1045/2.1063 in

L

53.410/53.455 mm

L

2.1027/2.1045 in

(1) Measured from centre line of gudgeon pin to piston crown (2) The nominal grade piston and the production grade piston have the same dimensions.

NOTES : •Before the length of the connecting rod is measured, ensure that the large and small end bores are square and parallel, operation 13A-07.

•The dimension(A1) is measured from the inside face of the big end parent bore, to the centre line of the small end bush. For accuracy, measure the dimension(A1) as close as possible to the connecting rod.

To select the correct piston •If a new connecting rod or small end bush is fitted, use the table opposite to select the correct piston.

•If the piston is the only component to be renewed, the nominal grade must always be used.

CAUTION : All small end bushes supplied for service are concentric.

Engine

54

2.4. Piston and Connecting Rod Assembly

2.4.6. Piston and Piston Rings To Inspect

2.4.7. Connecting Rod 13A-06

To Inspect

PC049

13A-07

PU062

(A)

(A) CAUTION : The big end bolts are fitted to the connecting rod by a special process and must not be removed. if the bolts are removed, the connecting rod, and the bolts will be damaged.

1. Check the connecting rod for distortion (A1).

NOTE : The large and small end bores must be square and parallel with each other within the limits of +/-0.20 mm (0.0007 in) measured 130 mm (5.1 in) each side of the connecting rod axis on a test mandrel.

PC050

(B) 1. Check the piston for wear and other damage.

2. Check the small end bush for wear or for other damage and renew it, if necessary.

2. Check that the piston rings are free to move in their grooves and that they are not broken.

3. Check the fit of the gudgeon pin in the small end bush and check the gudgeon pin for wear, see the Data and dimensions.

3. Remove the piston rings, operation 13A-04, and clean the piston ring grooves and the piston rings.

If necessary, renew the connecting rod, operation 13A-05A.

4. Fit new piston rings in the grooves in the piston and check for wear of the grooves in the piston and check for wear of the grooves with feeler gauges (A). Compare the piston ring clearance in the groove to that given for new components in Data and dimensions. Renew the piston, if the grooves are worn too much.

5. Clean all carbon from the top of the cylinder bores. Fit each of the piston rings in the top part of the cylinder bore and measure the ring gap with feeler gauges (B).

6. The coil spring must be fitted to the oil control ring when the gap of this piston ring is measured.

The piston ring gaps for new and oversize components are given in Data and dimensions.

Engine

55

2.4. Piston and Connecting Rod Assembly

2.4.8. Small End Bush To Remove and to Fit

13A-08

NOTES : The small end bush that is supplied for service has been machined concentrically. When it is fitted to the connecting rod, the new length will become “X”, which is similar to production grade “D”.

Correct piston height must be maintained in service to prevent damage to the piston and the valves, and to ensure that the engine will conform to emissions legislation.

1. Press out the old bush with a suitable adapter.

2. Clean the connection rod bore and remove any sharp edges.

3. Press in the new bush. Ensure that the lubrication holes in the bush are aligned with the holes in the connecting rod.

4. Ream the bush to get the correct clearance between the gudgeon pin and the bush, see the Data and dimensions.

CAUTION : Do not use a letter stamp to mark the connecting rod.

5. Remove the original grade mark for the connecting rod and etch an “X” instead to show that a service small end bush has been fitted to the connecting rod.

Engine

56

2.4. Piston and Connecting Rod Assembly

2.4.9. Data and Dimensions NOTE : This information is given as a guide for personnel engaged on engine overhauls. The dimensions which are shown are those which are mainly used in the factory. The information applies to all engines, unless an engine type code is shown.

Pistons Type -UA engines ....................................................................................................................Re-entrant combustion bowl -UB engines .................................................................................................................Flat top with recess for valves Height of piston above top face of cylinder block................................................0.386/0.511 mm (0.0152/0.0201 in) Diameter of bore for gudgeon pin ...................................................................30.003/30.009 mm (1.1812/1.1814 in) Width of groove for top ring -UA engines .................................................................................................................2.06/2.08 mm (0.081/0.082 in) -UB engines.................................................................................................................2.08/2.10 mm (0.082/0.083 in) Width of groove for second ring ..................................................................................2.06/2.08 mm (0.081/0.082 in) Width of groove for third ring.......................................................................................4.04/4.06 mm (0.159/0.160 in) Service height grades .................................................................................H, Nominal/Production (no marks) and L Oversize piston .....................................................................................................0.5 mm (0.020 in) on the diameter Piston rings Top compression ring ..............................................................................................................Chromium/barrel faced Second compression ring............................................................................................................Taper face, cast iron Oil control ring .....................................................................................................Coil spring loaded, chromium faced Width of top ring ..........................................................................................................1.97/1.99 mm (0.077/0.078 in) Width of second ring....................................................................................................1.97/1.99 mm (0.077/0.078 in) Width of third ring ........................................................................................................3.97/3.99 mm (0.156/0.157 in) Clearance of top ring in groove -UA engines .................................................................................................................0.07/0.11 mm (0.003/0.004 in) -UB engines.................................................................................................................0.003/0.005 mm (0.09/0.13 in) Clearance of second ring in groove.............................................................................0.07/0.11 mm (0.003/0.004 in) Clearance of third ring in groove .................................................................................0.05/0.09 mm (0.002/0.004 in) Gap of top ring.............................................................................................................0.20/0.48 mm (0.008/0.019 in) Gap of second ring ......................................................................................................0.30/0.63 mm (0.012/0.025 in) Gap of third ring...........................................................................................................0.20/0.48 mm (0.008/0.019 in) Connecting rods Type............................................................................................................................................................"H" section Diameter of parent bore for big end ................................................................56.000/56.015 mm (2.2047/2.2053 in) Diameter of parent bore for small end ............................................................32.930/32.955 mm (1.2964/1.2974 in) Length between centres (parent bores) ......................................................159.975/160.025 mm (6.2982/6.3002 in) Length grades see operation .........................................................................................................................13A-05B Big end bearings Type ..............................................................................................................................Steel back, aluminum/tin face Width........................................................................................................................22.87/23.13 mm (0.900/0.911 in) Clearance on big end ..........................................................................................0.018/0.064 mm (0.0007/0.0025 in) Thickness at centre of bearings ..........................................................................1.500/1.506 mm (0.0591/0.0593 in) Available undersizes bearings ....................................................................................................-0.25 mm (-0.010 in) ....................................................................................................................................................-0.51 mm (-0.020 in) ....................................................................................................................................................-0.76 mm (-0.030 in)

Engine

57

2.4. Piston and Connecting Rod Assembly

Gudgeon pins Type .........................................................................................................................................................Fully floating Outside diameter .............................................................................................29.995/30.000 mm (1.1809/1.1811 in) Clearance fit in piston boss .................................................................................0.003/0.014 mm (0.0001/0.0006 in) Small end bushes Type................................................................................................................................Steel back, lead bronze face Inside diameter (reamed) ................................................................................30.012/30.025 mm (1.1816/1.1821 in) Clearance fit on gudgeon pin ..........................................................................0.008/0.023 mm (0.00031/0.00091 in)

Engine

58

2.4. Piston and Connecting Rod Assembly

2.5. Crankshaft Assembly 2.5.1. General Description The induction hardened crankshaft a forging of alloy steel and has five main bearing journals.

The crankshaft rotates in five pre-finished shell bearings which have a steel back and an aluminum/tin face. The shell bearings are held in position by tags which fit into recesses machined in the bearing housing and the bearing caps.

The end-float of the crankshaft is controlled by two half thrust washers, fitted into the cylinder block, either side of number four main bearing housing.

The crankshaft webs are drilled to give full rotation balance.

To seal the crankshaft pulley and the palm of crankshaft, Viton seals are fitted in the timing case and in the rear faces of the cylinder block / housing for the rear main bearing. The seals include a dust lip to the outside of the main lip and oil return grooves on the face of the main lip.

WARNING Read the safety precautions for “Viton” seals on page 10A.07.

For location, the crankshaft pulley is fitted to the nose of the crankshaft with a single key and is retained by a plain washer and setscrew.

Engine

59

2.5. Crankshaft Assembly

To Fit

2.5.2. Crankshaft Pulley To Remove and to Fit

1. Lubricate the main lip of the seal with clean engine oil.

14A-01

2. Fit the pulley onto the key (B1) in the crankshaft nose.

3. Lubricate lightly the threads of the setscrews with engine lubricating oil. Fit the thick washer (A1) to the setscrew (A2) and fit the thick washer (A1) to the setscrew (A2) and fit the setscrew finger tight.

4. Lock the crankshaft to prevent its clockwise movement.

5. Tighten the setscrew to 185 N•m (136 lb•ft) 19.0 kg m

PU048

(A)

CAUTION : Remove the device used to lock the crankshaft.

6. Fit the drive belt, operation 23A-03.

PU049

(B) To remove 1. Remove the drive belt, operation 23A-03.

2. Lock the crankshaft to prevent its counterclockwise movement.

3. Release the setscrew (A2) which retains the pulley and remove the setscrew and the thick washer (A1). Remove the pulley.

CAUTION : Remove the device used to lock the crankshaft.

4. Clean the components and check for damage.

Renew damaged components.

NOTE : If the surface for the oil seal is damaged or there is a deep groove that has been caused by the seal, it may be possible to fit a wear sleeve to the pulley, operation 14A-01A.

Engine

60

2.5. Crankshaft Assembly

To Fit a Wear Sleeve

14A-01A

NOTE : It is not possible to fit a wear sleeve to the type of pulley shown (A). If the surface on this pulley is damaged or there is a deep groove that has been caused by the oil seal, the pulley will have to be renewed. If the pulley fitted to the engine is the type shown in (B), then a wear sleeve can be fitted.

To Fit With the pulley removed, carefully fit the wear sleeve (C1) in accordance with the manufacturers instructions (supplied with the sleeve).

PU124

Ensure that the sleeve (C1) is fitted correctly (D1) to the pulley.

(A)

PU123

(B)

PU122

(C)

PU120

(D) Engine

61

2.5. Crankshaft Assembly

To Fit

2.5.3. Rear Oil Seal To Remove and to Fit

1. Clean the crank palm and the recess for the oil seal and inspect them both for damage and wear.

If there is a deep groove in the crankshaft palm that has been caused by the oil seal, it may be necessary to fit a wear sleeve to the palm of the crankshaft, operation 14A-10A.

14A-02

2. Lubricate the lip of the oil seal with clean engine lubricating oil. Carefully the seal over the crank palm and up to the rear face of the recess.

NOTE : Lubrication of the seal is necessary to prevent damage to the lip of the seal when the engine is first started.

PU065

CAUTION : Do not damage the crank palm when the seal is fitted.

(A)

3. With tool NUMBER PD.255 (A1), fit the new oil seal into the recess.

NOTE : The seal will be fitted correctly when it protrudes 1.5 mm (0.06 in) (B2) from the rear face of the cylinder block / bearing cap.

4. Remove any excess oil from the seal and crank palm.

PU066

(B) SPECIAL TOOLS : Replacer tool for the rear oil seal, PD.255

To Remove 1. Remove the drive components from the rear end of the engine.

2. Remove the starter motor 3. Remove the flywheel and the flywheel housing, see section 22.

CAUTION : When the screws are fitted to the seal, do not damage the crankshaft palm or the recess for the oil seal.

4. Fit two small self-tapping screws and flat washers (A3) into the front face of the oil seal (A1).

NOTE : Fit the screws 180° apart 5. Use suitable levers (A2) and remove the seal.

Engine

62

2.5. Crankshaft Assembly

If the end-float is more than the tolerance allowed, oversize thrust washers are available to reduce the end float.

2.5.4. Thrust Washers To Check Crankshaft End-Float

14A-04

To Remove and to Fit

14A-05

To Remove The thrust washers fit in recesses machined into the cylinder block (A1) each side of number four main bearing cap. Ensure that the correct size thrust washers are fitted.

1. Remove the flywheel and flywheel housing, see section 22.

2. Drain the lubricating oil and remove the lubricating oil sump, operation 19A-03.

PU050

(A)

3. Release the two setscrews which retain number four main bearing cap. Remove the setscrews and carefully remove the bearing cap. Ensure that the shell bearing remains fitted correctly to the cap and is kept clean.

CAUTION : If the crankshaft is rotated, the shell bearing in the cylinder block may be pulled into an incorrect position.

4. Remove the two thrust washers (A1). Use of a suitable piece of plastic (A2) to push them out.

PU051

(B)

PU052

(C) The end-float of the crankshaft is controlled by two half thrust washers, fitted into the cylinder block (A1), either side of number four main bearing housing. The end-float can be checked with a feeler gauge (A2) between a thrust washer and the crankshaft or by the use of a dial test indicator (B1) on one end of the crankshaft.

Engine

63

2.5. Crankshaft Assembly

6. Fit the sump, operation 19A-03. Fill the sump to the correct level with an approved lubricating oil.

To Fit

7. Fit the flywheel housing and the flywheel, see section 22.

PU052

(A)

PU053

(B) 1. Lightly lubricate the two thrust washers with clean lubricating oil. Push (A2) each thrust washer into position in the recess (A1) on each side of the main bearing housing. The oil grooves (B1) in the thrust washers must be towards the crankshaft web.

2. Inspect the main bearing setscrews for damage or distortion, renew them if necessary.

3. Ensure that the shell bearing is fitted correctly in the cylinder block.

4. Lubricate the bearing in the cap with clean engine lubricating oil and put the bearing cap into position.

5. Lightly lubricate the setscrew threads with clean engine lubricating oil. Fit the setscrews and tighten them gradually and evenly to 147 N•m (108 lb•ft) 15.0 kg•m. Rotate the crankshaft and check the end-float, see operation 14A-04.

Engine

64

2.5. Crankshaft Assembly

NOTES : •The rear bearing cap provides half of the recess for the rear oil seal. When the cap is removed, remove the seal and check for wear, renew if necessary, operation 14A-02.

•The procedure to remove number four cap is the same as for numbers two and three except that it will not be necessary to remove the suction pipe.

Ensure also that the thrust washers remain in position.

2.5.5. Main Bearings To Remove and to Fit (with the crankshaft in position)

14A-06

Special Tool: Seal replacer tool, pd.243 Consumable products: POWERPART Silicone adhesive

5. To remove the second or third bearing cap, remove the suction pipe from the cylinder block, operation 19A-04. Release the setscrews of the bearing cap and remove the bearing cap. Remove the lower half of the shell bearing from the cap.

6. Use a suitable tool (A1) to push the upper half of the shell bearing from the side opposite to the location tag. Carefully rotate the crankshaft to release the bearing from its housing. Keep the bearing halves in their relevant positions.

PU054

(A) NOTE : The front and rear, bearing caps are fitted to the cylinder block with special seals, see page 14A.13.

To Remove 1. Drain the lubricating oil and remove the sump, operation 19A-03.

2. If the front main bearing cap is to be removed, proceed as follows: -Remove the timing case and backplate, section 15.

3. Release the setscrews of the front bearing cap and remove the bearing cap. Remove the lower half of the shell bearing from the cap.

4. If the rear main bearing caps is to be removed, proceed as follows: -Remove the flywheel and the flywheel housing, see section 22.

-Release the setscrews of the bearing cap and remove the bearing cap. Remove the lower half of the shell bearing from the cap.

Engine

65

2.5. Crankshaft Assembly

To Fit

8. If the front or rear main bearings were removed:

CAUTION : The shell bearings (A1) which do not have an oil hole must only be fitted to the cap. If they are fitted to the cylinder block, the bearing will not receive lubrication oil and cause a seizure of crankshaft and bearings

•Fit the special seals to the front and rear bearing caps, see page 14A.13 •Fit the rear oil seal, operation 14A-02.

•Check the alignment of the bearing caps with the faces of the block, page 14A.12 •Fit the backplate for the timing case assembly, operation 15A-09 •Fit the timing case assembly, operation 15A-01 9. Fit the lubricating oil sump, operation 19A-03. Fill the sump to the correct level with an approved lubricating oil.

10. Fit the flywheel housing and the flywheel, see section 22.

To Inspect PU063

14A-07

Inspect the bearings for wear and for other damage.

If a bearing is worn or damaged, renew both halves of the shell bearings and check the condition of the other bearings.

(A) 1. Clean the upper half of the shell bearing and lubricate the bearing surface with clean engine lubricating oil.

2. Put the bearing (with the oil hole) onto the journal and slide the plain end around between the journal and the cylinder block until the tag is fitted correctly into the recess (A3).

3. Clean the lower half of the bearing and the bearing cap, lubricate the bearing surface with clean engine lubricating oil.

4. Fit the bearing into the cap with the tag of the bearing fitted correctly in the recess (A2) in the cap.

5. Fit the bearing cap with the location tags of both bearings on the same side.

6. Inspect the setscrews for damage and for distortion and renew them if necessary. Lightly lubricate the setscrew threads with clean engine lubricating oil. Fit the setscrews and tighten them gradually and evenly to 147 N•m (108 lb•ft) 15.0 kg•m.

7. After each cap is tightened, ensure that the crankshaft turns freely. If the thrust washers have been removed and fitted, check the crankshaft endfloat, operation 14A-04.

Engine

66

2.5. Crankshaft Assembly

7. Remove the starter motor, operation 23B-01.

2.5.6. Crankshaft To remove and to Fit

8. Remove the flywheel and the flywheel housing, see section 22.

14A-08

Consumable Products: Silicone adhesive

9. Remove the lubricating oil sump, operation 19A-03.

Special Tools : Seal replacer tool, PD.243

10. Remove the lubricating oil suction pipe, operation 19A-04.

11. Release and remove the nuts of the connecting rods. Remove the big end bearing caps and keep the bearings with the relevant caps, operation 13A-01.

WARNING Use lift equipment or obtain assistance to lift heavy engine components such as the flywheel, the flywheel housing and the crankshaft.

NOTE : Numbers two, three and four main bearing caps have an arrow and number (A2) on the top to indicate front and sequence. The front and rear caps because of their shape, are easy to identify. The rear cap (A1) has no marks and the front cap (A3) has a number only.

12. Release and remove the setscrews for the main bearing caps. Remove the main bearing caps together with the lower halves of the shell bearings. Keep the bearings with the relevant caps.

NOTE : When the rear cap is removed, the rear oil seal will be exposed and should be removed.

13. Remove the thrust washers.

PU056

(A)

14. Lift out the crankshaft. Remove the upper halves of the bearings and keep them with the relevant caps.

To Remove NOTE : Perkins recommend, for safety reasons, that this operation is done with the engine upside down.

This will ensure that the crankshaft can be lifted out and that the pistons will be retained in the cylinder bores.

NOTE : If the main bearings are to be used again, they must be fitted in the same positions from which they were removed. The rear oil seal should be renewed.

1. Drain the lubricating oil.

2. Drain the cooling system, operation 21A-04.

3. Remove the fan, operation 23A-03 and the drive belt.

4. Remove the crankshaft pulley, operation 14A-01.

5. Remove the timing case, operation 15A-01.

6. Remove the idler gear, operation 15A-03.

Engine

67

2.5. Crankshaft Assembly

1. Ensure that all lubricating oil passages in the crankshaft and cylinder block are clean and free from restriction.

To Fit CAUTION : The shell bearings (A1) which do not have an oil hole must only be fitted to the bearing cap. If they are fitted to the cylinder block, the bearing will not receive lubricating oil which will cause a seizure of crankshaft and bearings.

2. Clean the main bearing housing and the upper halves of the shell bearings. Fit the bearings to the cylinder block. Ensure that the location tags are correctly fitted into the recesses (A3). Lubricate the bearings with clean engine lubricating oil.

3. Ensure that the main journals of the crankshaft are clean. Carefully put the crankshaft into position on the upper bearings.

4. Clean and lubricate the thrust washer. Slide them into the recesses in the the cylinder block either side of number four journal. The grooves in the thrust washers must be towards the crankshaft (B1).

5. Clean the bearing caps and the lower half of the bearings. Fit the bearings to the caps with the location tags fitted correctly in their recesses (A2).

Lubricate the bearings with clean engine lubricating oil.

PU063

(A)

6. Apply a small amount of silicone adhesive to the corners of the cylinder block (C) for the rear main bearing cap.

PU053

(B)

PU067

(C)

Engine

68

2.5. Crankshaft Assembly

10. After each cap is tightened, ensure that the crankshaft is free to rotate.

NOTE : Numbers two, three and four main bearing caps have an arrow and number (A2) on the top to indicate front and sequence. The front and rear caps because of their shape, are easy to identify. The rear cap (A1) has no marks and the front cap (A3) has a number only.

CAUTION : After the rear cap has been tightened, it is important to remove any sealant from inside the recess for the rear oil seal. If this is not done, the oil seal will not fit correctly and will cause oil leakage.

11. Fit the connecting rods and caps, operation 13A-01.

12. After each cap is tightened, ensure that the crankshaft is free to rotate.

PU056

(A)

PU064

(B) 7. Put the bearing caps in their correct positions.

8. Check the main bearing setscrews for distortion and thread damage and renew them as necessary.

Ensure that only the correct setscrews are used.

NOTE : Before the front and rear bearing caps are fully tightened, use a straight edge (B) to check their alignment with the front / rear faces of the cylinder block.

9. Fit the setscrews to the main bearing caps and tighten them gradually and evenly to 147 N•m (108 lb ft) 15.0 kg•m.

Engine

69

2.5. Crankshaft Assembly

CAUTIONS : •The seals for the front and rear bearing caps have a curve at one end (A1) which must be fitted towards the side of the engine (A2), and with the curve inserted first into the hole.

•The seals have a soft metal insert Be careful not to bend the seal when it is first inserted into the hole.

PU068/C

(C)

PU068/A

(A)

PU068/D

(D) 16. Use a small drift (C1) to push the seal below the surface of the cap until a resistance is felt; the seal is now fitted to the bottom of the hole. Remove any excess sealant from around the holes.

17. Fit the two smaller seals to the holes (D), in the front main bearing cap.

PU068/B

(B)

18. Fit the lubricating oil suction pipe and strainer, see section 19. Fit the lubricating oil sump, operation 19A-13.

13. lnject a small quantity of sealant (A4) into the holes for the seals, each side of the front and rear main bearing caps.

19. Fit the fear oil seal, operation 14A-12.

20. Fit the flywheel housing and the flywheel, see section 22.

14. Fit the seals initially by hand (A3) and push,approximately 30% of the seal into the hole.

21. Fit the starter motor, operation 23B-01.

15. Slide the tool, over each seal (B2) and press the seals fully into their holes (B1).

22. Fit the backplate for the timing case assembly,operation 15A-09.

23. Fit the timing case assembly, operation 15A-01.

24. Fit the crankshaft pulley, operation 14A-01.

25. Fit the drive belt,operation 23A-03 and the fan, operation 21A-04.

26. Fill the lubricating oil sump to the correct level with an approved oil.

27 Fill the cooling system, operation 21A-05.

Engine

70

2.5. Crankshaft Assembly

To Inspect

Crankshaft Overhaul

14A-09

14A-10A

NOTE : •Check the crankshaft for cracks before and after it is ground. Demagnetise the crankshaft after it has been checked for cracks.

•After the crankshaft has been machined, remove any sharp corners from the lubricating oil holes.

•Surface finish and fillet radii must be maintained.

•Further information can be found in data and dimensions at the end of this section.

Check the crankshaft for wear and other damage.The maximum permissible wear and ovality on the crankshaft journals and crank pins is 0,04 mm (0.0016 in).

The main journals and the crank pins of standard size crankshafts can be machined to 0.25mm (0.010 in), 0.50mm (0.020 in) or 0.75mm (0.030 in) undersize on diameter, see data and dimensions at the end of this section. Special undersize bearings are available.

CAUTION : After the crankshaft has been overhauled, it must be thoroughly cleaned and the oil holes inspected for debris.

If the seal position on the crankshaft palm is worn, a wear sleeve can be fitted to the palm, operation 14A10A.

Crankshaft heat treatment : The heat treatment is induction hardened.

NOTE : Induction hardened crankshafts need not be hardened after they have been machined undersize. continued

NOTE : Induction hardened crankshafts need not be hardened after they have been machined undersize.

Crankshaft Overhaul The finished sizes for crankshaft journals (A) which have been ground undersize are given in the table below:

PU121

(A) To Fit a Wear Sleeve

14A-10

Item

0.25 mm(0.010 in)

1

64.70/64.72(2.547/2.548)

64.45/64.47(2.537/2.538) 64.20/64.22(2.527/2.528)

2

52.70/52.72(2.075/2.076)

52.45/52.47(2.065/2.066) 52.20/52,22(2.055/2.056)

3

33.00/33.04(1.29/1.300)

4

32.8/34.2(1.29/1.35)

5

32.95/33.05(1.297/1.301)

6

30.05/32.95(1.183/1.297)

7

94.965/95.000(3.7837/3.7401)

8

3.3/3.7(0.3/0.14)

0.50 mm(0.020 in)

0.75 mm(0.030 in)

To Fit 1. Remove the crankshaft, operation 14A-08.

2. Fit the wear sleeve (A2), in accordance with the manufacturer’s instructions, supplied with the sleeve. Ensure that the sleeve (A2) is fitted to the crank palm (A4) to a dimension (A3) of 12,0 mm (0,47 in).

PU058

(A)

CAUTION : After the sleeve has been fitted, the curved part(A1)which is used to fit the sleeve, must be removed. If this is not done, when the crankshaft is fitted, the sleeve will be in contact with the cylinder block and the oil seal will be damaged.

Engine

NOTE : The surface finish for the journals, the crank pins and the fillet be 0,4 microns (16 micro inches).

The surface finish for the seal area of crankshaft palm must be 0.4/1.1 microns (16/43 micro inches).

14A.15

71

2.5. Crankshaft Assembly

2.5.7. Data and Dimensions Introduction NOTE : This information is given as a guide for personnel engaged on engine overhauls. The dimensions which are shown are those which are mainly used in the factory.

Crankshaft Diameter of main journals ...............................................................................64.951/64.970 mm (2.5571/2.5578 Maximum wear and ovality on journals and crank pins .............................................................0.04 mm (0.0016 Width of front journal .................................................................................................. 32.80/34.20 mm (1.29/1.35 Width of number four journal ..................................................................................32.95/33.05 mm (1.299/1.300 Width of all other journals........................................................................................32.95/33.05 mm (1.297/1.301 Diameter of crank pins ............................................................................................52.95/52.97 mm (2.085/2.085 Width of crank pins..................................................................................................30.05/32.95 mm (1.183/1.297 Diameter of crankshaft palm ...........................................................................94.965/95.000 mm (3.7837/3.7401 Depth of recess for spigot bearing ..................................................................................11.6/12.6 mm (0.46/0.50 Bore of recess for spigot bearing ....................................................................40.000/40.025 mm (1.5748/1.5757 Crankshaft end-float ...........................................................................................0.040/0.275 mm (0.0015/0.0108 Maximum permissible end-float.................................................................................................0.405 mm (0.0159 Fillet radii of journals and crank pins ..................................................................................3.3/3.7 mm (0.13/0.14 Undersizes journals and crank pins ............................................................................................-0.25 mm (0.010 .....................................................................................................................................................-0.50 mm (0.020 .....................................................................................................................................................-0.70 mm (0.030

in) in) in) in) in) in) in) in) in) in) in) in) in) in) in) in)

Crankshaft heat treatment ......................................................................................................................................................induction hardened Crankshaft run-out With the crankshaft on mountings at the front and rear journals, the maximum run-out (total indicator reading) at the journals must not be more than the figures in the table shown below.

Run-out must mot be opposite. The difference in run-out between one journal and the next must not be more than 0.10 mm (0.004 in) Journal

Crankshaft

1

Mounting

2

0.08 mm (0.003 in)

3

0.15 mm (0.006 in)

4

0.08 mm (0.003 in)

5

Mounting

Main bearings Type ..............................................................................................................................Steel back, aluminum/tin face Width of bearing .........................................................................................................25.70/26.00 mm (1.01/1.02 in) Thickness at centre of bearing ............................................................................1.993/1.999 mm (0.0784/0.0787 in) Clearance between bearing and journal ............................................................ 0.032/0.092 mm (0.0013/0.0036 in) Available undersizes bearings......................................................................................................-0.25 mm (0.010 in) .....................................................................................................................................................-0.50 mm (0.020 in) .....................................................................................................................................................-0.75 mm (0.030 in) Crankshaft thrust washers Type ..........................................................................................................Steel back, lead / bronze bearing material Position ......................................................................In cylinder block only, each side of number four main bearing Thickness .....................................................................................................................................................................

-Standard ...................................................................................................................................2.38/2.44 mm (0.0 in) -Oversize ....................................................................................................................2.58/2.64 mm (0.102/0.104 in)

Engine

72

2.5. Crankshaft Assembly

The drive from the crankshaft gear (B4). Passes through the idler gear (B2) to the gear (B3) for the camshaft for the valves and the gear (B1) for the camshaft for the fuel injection pump. It also passes to the gear that drives the lubricating oil pump (A5) A gear for a power take-off can be driven from the gear (B3). The camshafts for the valves and the fuel injection pump both rotate at half the speed of the crankshaft gear.

2.6. Timing Case and Drive Assembly 2.6.1. General Description

The camshaft for the fuel injection pump is made from steel with induction hardened cams.

Generally, the camshaft for the valves is made of cast iron with chill-hardened cams. if the engine is fitted with a high-rated power take-off, a camshaft is used that has a steel nose.

PU099

The oil seal (A2) which is made of viton, operates on the spigot of the crankshaft pulley. The seal has a dust lip which protrudes from the front of the seal This lip protects the main lip of the oil seal.

(A)

WARNING Read the safety precautions for “Viton” seals in section 10

PU119

(B) The aluminium timing case assembly contains: the oil seal (A2) for the crankshaft pulley; the support bush(A1) for the camshaft gear; the lubricating oil pump assembly (A5); the lubricating oil relief valve assembly(A6); the adjustment screw (a4) to set the maximum fuel position; and the fuel injection pump linkage (A3). The governor weight assembly (B5) is fitted to the front of the gear for the fuel injection pump.

The timing case assembly also covers the hardened steel timing gears that have helical tooth to reduce noise.

Engine

73

2.6. Timing Case and Drive Assembly

8. Clean around the edge of the joint face of the timing case assembly.If this is not done, dirt may fall onto the timing gears when the timing case assembly is removed.

2.6.2. Timing Case To Remove and to Fit

15A-01

CAUTION : The maximum fuel setting will be affected if; a sealant is used on the joint faces of the timing case or backplane; the joint faces are damaged when the old joint is removed.

9. Remove the setscrews for the timing case assembly. Note the position of the setscrews as they are of different lengths and thread sixes. To prevent damage to the threads, they must be fitted to the correct holes.

10. Hold the control link (A1) and carefully remove the timing case assembly.

PU100

(A)

To Fit 1. If a new gear has been fitted, check the backlash (B). The backlash between the crankshaft gear and the other gears that are in mesh with it is 0.076 mm (0.003 in). The backlash between the idler gear and the gears for the camshafts is 0.05 (0.002). continued

PU106

(B)

To Remove 1. Disconnect the battery.

2. Release the fasteners and remove the drive belt and the alternator, section 23A. 3. If one is fitted, remove the fan, operation 21A-03 4. Remove the crankshaft pulley, operation 14A-01 5. If one is fitted, remove the auxiliary drive assembly, operation 24A-01 6. Record the maximum fuel position of the fuel control rack, 20A-11.

7. Disconnect the link (A1) for the governor control, operation 20A-06

Engine

74

2.6. Timing Case and Drive Assembly

5. Hold the control oink (B3), and put the timing case assembly together with the new joint into position on the studs (B6/B10), the dowels (B9), and the spigot (B7) on the camshaft gear. At the same time, it may be necessary to align the teeth on the gear for the oil pump with teeth on the cranKshaft gear.

6. fit, finger tight, the fasteners to retain the timing case assembly.

7. Fit the governor control link (A1) and the cover plate, operation 20A-06.

PU100

(A) CAUTION : To ensure that there will be no side loads on the camshaft gear, tighten the fasteners for the timing case 8. Tighten gradually and evenly, the M8 fasteners for the timing case assembly to 22 N•m (16 lb•ft).

9. Tighten the M8 setscrew in the centre of the timing case assembly to 22 N•m (16 lb•ft) 2.2 kg•m.

10. Check that the camshaft gear has a minimum backlash of 0.05 mm (0.002 in).

PU101

11. If one is fitted, fit the auxiliary drive assembly, operation 24A-01

(B)

12. Fit the crankshaft pulley, operation 14A-01.

CAUTION : the maximum fuel setting will be affected if : a sealant is used on the joint faces of the timing case or back plate; the joint faces are damaged when the old joint is removed.

13. Fit the alternator and the drive belt, section 23A. 14. If one is fitted, fit the fan, operation 21A-03.

2. Clean the faces of the timing case assembly and the backplane (B1). Fit a new joint (B2), without sealant, to the timing case assembly.

15. Set the adjustment screw for the maximum fuel setting.

3. Ensure that the joint between the cylinder block and the backplane is not damaged. Fit a new “o” ring (B8) into the front of the idler gear hub.

4. Ensure that the oil hole (B5) is not restricted and lubricate the bush (B4) with clean engine.

Lubricate the teeth on all the gears with clean engine oil.

NOTE : Before the timing case is fitted, fit the adjustment screw for the maximum fuel to its original setting and then release by two full turns. Fit the sealing washer and the lock nut.

Engine

75

2.6. Timing Case and Drive Assembly

To Renew

3. Fit these components to the new timing case assembly. Fit the adjustment screw for the maximum fuel setting to its original position. Fit the adjustment screws for the high and low idle.

15A-01A

CAUTION : When the fuel injection pump linkage is removed/renewed, or a new timing case is fitted, the setting for the maximum fuel may be affected.

4. Fit the timing case assembly, operation 15A-01.

PU099-1

(A)

PU146

(B) 1. Remove the timing case assembly, operation 15A01 2. Remove from the timing case assembly, the components listed below : •Lubricating oil pump assembly (A4), operation 19A-06 •Lubricating oil relief valve assembly (A5).

•Engine speed control lever assembly (A3)., operation 20A-09 •The fuel injection pump linkage (A1), operation 20A-01.

•The adjustment screws for the maximum fuel setting (B1), and the high idle (B2) and the low idle (B3).

Engine

76

2.6. Timing Case and Drive Assembly

5. Fit a rod through the hole (A1) in the end of the threaded bar to prevent movement of the bar when the nut is tightened.

2.6.3. Front Oil Seal To Remove and to Fit

15A-02

6. Tighten the nut with the washer (A2) against the adapter (A3) to push the seal into the housing.

Special Tools : Replacer tool for front oil seal (main tool), PD.170 Adapter for use with PD.170, PD.259 Adapter plate for use with PD.170, PD260-4

NOTE : When the seal is fitted correctly, the rear face of the seal will be against the back face of the recess (A5) in the seal housing.

7. Remove the replacer tool and lightly lubricate the seal location area of the crankshaft pulley with clean engine lubricating oil. Fit the crankshaft pulley, operation 14A-01.

8. Fit the drive belt, operation 23A-03.

9. Connect the battery and start the engine. When it has reached its normal temperature of operation, stop the engine and check for oil leakage around the seal.

PU125

(A) To Remove 1. Disconnect the battery.

2. Remove the drive belts, operation 23A-03.

3. Remove the crankshaft pulley, operation 14A-01.

4. Remove the oil seal with a suitable lever behind the main lip of the oil seal. Do not damage the edge of the oil seal housing.

To Fit 1. Clean the oil seal housing. Inspect the new seal for damage. If a scratch can be seen across the lip of the seal, do not fit the seal.

2. Lubricate the outer circumference of the oil seal with clean engine lubricating oil and enter the seal into the housing. Ensure that the spring loaded lip of the oil seal is towards the inside of the timing case assembly and that the oil seal is square to the bore of the seal housing.

3. Fit the adapter (A8) to the nose of the crankshaft (A7) and tighten the nut (A6) Put the adapter, (A3) over the nose of the crankshaft and against the seal (A4). Ensure that the adapter has the side stamped 700, towards the seal.

4. Fit the threaded bar, (A9) onto the adapter (A8).

Engine

77

2.6. Timing Case and Drive Assembly

4. Inspect the gear, the hub, the bushes (B3), and the thrust washers (B4) for wear and other damage.

If necessary, renew the bushes, operation 15A-04.

If necessary, renew the idler gear hub, operation 15A-05.

2.6.4. Idler Gear To Remove and to Fit

15A-03

To Fit 1. Ensure that the oil hole (B6) is not restricted and that the hub is clean.

2. Ensure that the bushes (B3) are clean and apply a small amount of clean engine lubricating oil to their surfaces.

PU091

3. Fit the two thrust washers (B4) correctly to the idler gear with the oil grooves (B5), away from the gear.

(A)

4. Slide the idler gear (B2) onto the hub (B1) with the marked teeth of the idler gear, aligned with the marked teeth of the crankshaft gear, the camshaft gear and the gear for the fuel pump camshaft (A).

5. Fit the timing case assembly, operation 15A-01.

PU103

(B)

To Remove NOTE : When the timing marks on the gears are aligned and the idler gear is removed, do not rotate the crankshaft. If the crankshaft is rotated, top dead centre (TDC) will have to be set on number 1 cylinder, operation 17A-01.

1. Remove the timing case assembly, operation 15A01.

2. Rotate the crankshaft until the marked teeth of the crankshaft gear, the gear for the camshaft for the valves, and the gear for the camshaft for the fuel injection pump, are aligned with the marked teeth of idler gear (A).

3. Remove the idler gear assembly (B2) from its hub (B1).

Engine

78

2.6. Timing Case and Drive Assembly

To Remove and to Fit the Bushes for the Idler Gear

To Fit 15A-04 •The new bushes are supplied with an internal diameter of 27.425/27.610 mm (1.0797/1.0870 in).

After the new bushes have been fitted, they must be reamed to a finished size (B1) of 28,077/2,.098 mm (1.1054/1.1062 in).

•The fitted position of the cut-outs (A1/B3) is not important.

1. Ensure that the bore of the gear is clean and is not damaged, Press a new bush into each side of the gear until the edges with the cut-outs (A1/B3), protrude (B2) 1.5/2.0 mm (0.06/0.08) above the side face of the gear.

PU104

2. Ream the bushes to the correct size, see note above.

(A)

PU105

(B) To Remove CAUTION : When the bushes for the idler gear are removed and fitted, ensure that the teeth on the gear are not damaged.

1. With the idler gear removed, use a suitable tool to press out the old bushes (A2).

Engine

79

2.6. Timing Case and Drive Assembly

2.6.5. Idler Hub To Remove and to Fit

15A-05

Special Tools : Remover tool (slide hammer) PD.184 Adapter for use with PD.184,PD.258 Replace tool for use with MS550, PD.256 Universal drive handle, MS.550

PU110

(D) To Remove 1. Remove the timing case assembly, operation 15A01.

2. Remove the idler gear, operation 15A-03.

PU107

3. Fit the adapter (A2), and the slide hammer (A1), to the hub (A4) for the idler gear. Note the position of the oil hold (A3) in the hub.

(A)

4.Use the slide hammer to remove the old hub from the cylinder block.

To Fit 1. Before the new hub is fitted, ensure that : the oil hold (B4) is not restricted : the bore for the hub is clean and free of debris : the edges (B5) of the bore are smooth such that they will not damage the new hub when it is fitted.

PU108

2. With the oil hole (B2) towards the top, fit the new hub (B3) initially, with a soft hammer (B1) until the edge of the hub is just inside the bore. Ensure that it is square to the front face of the cylinder block.

(B)

CAUTION : Ensure that the replacer tool is clean and smooth, and does not damage the new hub when it is fitted.

3. Fit the replacer tool (C2) onto the hub (C1), and continue to fit the hub to the cylinder block. The new hub will be fitted correctly when the front face of the tool (D1) is in contact with the cylinder block.

PU109

4. Ensure that the new hub is not damaged. Fit the idler gear, operation 15A-03.

(C)

5. Fit the timing case assembly, operation 15A-01.

Engine

80

2.6. Timing Case and Drive Assembly

2.6.6. Camshaft Assembly for the Fuel Injection Pump To Remove and to Fit

15A-06

PU113

(D) To Remove 1. Remove the timing case assembly, operation 15A01.

PU114

(A) 2. Check that the camshaft end-float (A) is within the limits shown in Data and dimensions.

NOTE : When the gear and the fuel pump camshaft are removed, do not rotate the crankshaft. If the crankshaft is rotated, top dead centre (TDC) will have to be set on number one cylinder, operation 17A-01.

3. Rotate the crankshaft until the marked teeth of the crankshaft gear, the gear for the camshaft for the valves, and the gear for the camshaft for the fuel injection pump, are aligned with the marked teeth of idler gear (B).

PU091

(B)

4. Remove the lift pump, operation 20A-03.

5. Remove the fuel injection pump, operation 20A-06.

6. Remove the governor weight assembly, 20A-08.

7. Release the setscrew (C1) for the plate (C2) that retains the camshaft bearing. Rotate the plate 180˚ and tighten the setscrew. This will hold the plate away from the bearing.

8. Remove the camshaft assembly (D), ensure that the cams on the camshaft are not damaged.

PU112

NOTE : If the bearings, the cams or the gear is worn, a new camshaft assembly will have to be fitted. If this occurs, the fuel injection timing will have to be set, operation 17A-03.

(C)

Engine

81

2.6. Timing Case and Drive Assembly

To Fit

4. Fit the governor assembly, operation 20A-08.

5. Fit the fuel injection pump, operation 20A-06.

6. Fit the lift pump, operation 20A-03.

7. Fit the timing case assembly, operation 15A-01.

PU091

(A)

PU113

(B)

PU112

(C) 1. Ensure that all bearing surfaces are clean.

2. Fit the camshaft assembly (B). When the camshaft gear and the idler gear are in mesh, ensure that the marks on the gears are aligned (A).

3. Release the setscrew (C1) for the plate that retains the camshaft bearing. Rotate the plate (C2) 180˚ and tighten the setscrew. The plate will now be across the edge of the bearing and prevent it from moving.

Engine

82

2.6. Timing Case and Drive Assembly

2.6.7. Camshaft Assembly and Tappets for the Valve To Remove and to Fit

15A-07

PU117

(D) To Remove 1. Remove the cylinder head assembly, operation 12A-07.

PU091

(A)

2. Remove the timing case assembly, operation 15A01.

NOTE : When the timing marks on the gears are aligned and the gear and the camshaft are removed, do not rotate the crankshaft. If the crankshaft is rotated, top dead centre (TDC) will have to be set on number 1 cylinder, operation 17A-01.

3. Rotate the crankshaft until the marked teeth of the crankshaft gear, the gear for the camshaft for the valves, and the gear for the camshaft for the fuel injection pump, are aligned with the marked teeth of idler gear (A).

PU115

(B)

4. Check that the camshaft end float (B) is within the limits shown in Data and dimensions.

5. Remove the tappets (C1) and note their correct position for assembly.

6. Remove the two setscrews (D1) that retain the thrust plate for the camshaft.

7. Remove the camshaft assembly (D3) from the cylinder block, ensure that the cams (D2) are not damaged.

PU116

8. Inspect the camshaft and the tappets for wear, also inspect the gear and the camshaft bush.

Renew these components as necessary.

(C)

Engine

83

2.6. Timing Case and Drive Assembly

To Fit

PU116-1

(D) PU117-1

1. Ensure that all the oil holes in the cylinder block and on the camshaft (A4) are not restricted. Clean the camshaft and lubricate the journals, the cams and the teeth of the gears with clean engine oil.

(A)

2. With the marked teeth on the camshaft gear aligned with the marked teeth on the idler gear (B), fit the camshaft assembly (A3) to the cylinder block, ensure that the cams (A2) are not damaged during this operation.

3. Fit the two setscrews (A1) that retain the thrust plate for the camshaft.

4. Check that the camshaft end float (C) is within the limits shown in Data and dimensions.

PU091

(B)

5. Ensure that tappets are clean and that the oil drain holes (D2) are not restricted. Lubricate the tappets with clean engine oil and fit them in the correct positions and with the flat face (D1) towards the cams.

6. Fit the timing case assembly, operation 15A-01.

7. Fit the cylinder head assembly, operation 12A-07.

PU115

(C)

Engine

84

2.6. Timing Case and Drive Assembly

To Fit

2.6.8. Crankshaft Gear To Remove and to Fit

15A-08

WARNING Heat is used to fit the gear, ensure that suitable leather gloves are worn to protect the hands.

1. To fit the gear, it will be necessary to heat the gear before it will fit onto the crankshaft. heat the gear gradually to not more than 300 ˚C (572 ˚F). Do not use a flame as this can cause local damage.

Fit the gear with the timing marks towards the front.

PU091

2. Fit the idler gear, operation 15A-03 and ensure that all the timing marks are correctly aligned.

(A)

3. Fit the timing case assembly, operation 15A-01.

To Remove 1. Remove the timing case assembly, operation 15A-01.

2. Rotate the crankshaft until the marked teeth of the crankshaft gear, the gear for the camshaft for the valves, and the gear for the camshaft for the fuel injection pump, are aligned with the marked teeth of idler gear (A).

3. Remove the idler gear, operation 15A-03.

4. The crankshaft gear is an interference fit on the crankshaft. It may be removed with a suitable puller. If this is not possible, it will be necessary to remove the crankshaft, operation 14A-08, and press the gear off.

Engine

85

2.6. Timing Case and Drive Assembly

To Fit

2.6.9. Backplate for the Timing case To Remove and to Fit

1. Remove the old joint from the faces of the cylinder block (A5), and the backplane (A2).

15A-09

2. Ensure that the joint faces are completely free of the old joint. Fit the backplane with a new joint (A3), of the correct specification and without sealant, onto the studs (A1/A4) and the dowels (A6).

3. Fit the tappets and the camshaft assembly for the valves, operation 15A-07.

4. Fit the the camshaft assembly for the fuel injection pump, operation 15A-06.

PU118

5. Fit the idler gear, operation 15A-03.

(A)

6. Fit the timing case assembly, operation 15A-01.

CAUTIONS : The setting for the maximum fuel position may be affected when the timing case is removed.

1. Remove the timing case assembly, operation 15A-01.

2. Remove the idler gear, operation 15A-03.

3. Remove the camshaft assembly for the fuel injection pump, operation 15A-06.

4. Remove the tappets and the camshaft assembly for the valves, operation 15A-07.

5. Remove the backplane from the engine.

CAUTION : The maximum fuel setting will be affected if : sealant is used on the joint faces of the timing case or back plate : the joint faces are damaged when the oil joint is removed.

Engine

86

2.6. Timing Case and Drive Assembly

2.6.10. Data and Dimensions Introduction NOTE : This information is given as a guide for personnel engaged on engine overhauls. The dimensions which are shown are those which are mainly used in the factory.

Timing Case and Drive Assembly Camshaft Diameter of camshaft journals ..............................................................................47.945/47.975 m (1.8876/1.887 in) Clearance of journals in cylinder block : -Number one ........................................................................................................0.025/0.155 mm (0.0010/0.0060 in) -Numbers two, three, four and five ......................................................................0.050/0.115 mm (0.0020/0.0040 in) Maximum permissible camshaft journal wear................................................................................0.05 mm (0.002 in) Cam lift : -Inlet .............................................................................................................................7.06/7.16 mm (0.278/0.282 in) -Exhaust.......................................................................................................................7.35/7.45 mm (0.289/0.293 in) End-float : -Production limit ...........................................................................................................0.10/0.25 mm (0.004/0.010 in) -service limit ...................................................................................................................................0.35 mm (0.014 in) Camshaft thrust washer Type.......................................................................................................................................................................360˚ Thickness.......................................................................................................................2.30/2.40 mm (0.091/0.95 in) Camshaft Gear Number of teeth........................................................................................................................................................60 Fuel Pump Gear Number of teeth........................................................................................................................................................60 End float for fuel pump camshaft.............................................................................0.00/0.02 mm (0.0000/0.0008 in) Crankshaft Gear Number of teeth........................................................................................................................................................30 Diameter of bore ..........................................................................................................31.936/31.961 mm (1.2583 in) Diameter of crankshaft nose............................................................................31.979/32.000 mm (1.2590/1.2600 in) Interference fit of gear on crankshaft ..............................................................-0.018/-0.064 mm (-0.0007/-0.0025 in) Idler gear and hub Number of teeth........................................................................................................................................................59 Diameter of bore of bushes in gear .....................................................................28.077/28.098 mm (1.054/1.062 in) Diameter of hub fitted to cylinder block ...........................................................28.048/28.061 mm (1.1043/1.1048 in) Clearance fit of gear on hub ................................................................................0.016/0.050 mm (0.0006/0.0020 in) Backlash for gears : -Grankshaft to oil pump and idler gears.........................................................................0.76 mm (0.003 in) minimum -Gears other than those referred to above ...................................................................0.05 mm (0.002 in ) minimum

Engine

87

2.6. Timing Case and Drive Assembly

2.7. Cylinder Block Assembly

To Dismantle

2.7.1. General Description

1. Disconnect the battery.

The cast iron cylinder block is made without cylinder liners. The cylinder bores are plateau honed with silicon carbide tools to a controlled finish to ensure long life and low oil consumption.

A bush is fitted in the cylinder block for the camshaft front journal, the other journals run directly in the cylinder block. cylinder blocks that are supplied for service, are fitted with a steel back, copper / led bush for the camshaft front journal, and a new hub for the idler gear.

16A.02

2. Drain the cooling system, operation 21A-04.

3. Drain the lubricating oil.

4. Disconnect as necessary, any electrical cables, control wires, hoses and note where they are fitted.

5. Remove the engine from the vehicle or machine.

6. Remove the alternator drive belt, the alternator and the mounting brackets, section 23.

7. Remove the fan, the water pump and the thermostat housing, section 21.

2.7.2. Cylinder Block To Dismantle and to Assemble

8. Remove the starter motor, operation 23B-01.

16A-01

9. Remove the electrical stop solenoid, operation

Consumable Products: Nutlock Hylosil

10. Remove the high-pressure and the low-pressure fuel pipes, the fuel filter, the fuel lift pump, the atomisers and the fuel injection cassette pump, section 20.

NOTES : •If the cylinder block is to be renewed, it may be necessary to fit new pistons and small end bushes, operation 13A-05A. This will occur if the correct piston height above the block face cannot be maintained with the original piston and connecting rod assemblies, operation 13A-03A. If all or most of the original pistons and connecting rod assemblies cannot be used it may be cost effective to fit a short engine.

•If the cylinder block is renewed, it will be necessary to check the timing of the fuel injection pump.

11. Remove the glow plugs, operation 23C-01.

12. Remove the cylinder head assembly, operation 12A-07.

13. Remove the auxiliary drive assembly, operation 24A-01.

14. Remove the crankshaft pulley, operation 14A-01.

15. Remove the timing case assembly, operation 15A-01.

16. Remove the backplane for the timing case assembly, operation 15A-09 17. Remove the lubricating oil filter assembly, the dipstick tube, the lubricating oil sump and the lubricating oil suction pipe, section 19.

18. Removle the piston and connecting rod assemblies, operation 13A-03.

19. Removle the flywheel and the flywheel housing, section 22.

20. Remove the crankshaft and the rear oil seal, section 14.

21. Inspect the cylinder block, operation 16A-02.

Engine

88

2.7. Cylinder Block Assembly

To Assemble

20. Fill the cooling system, operation 21A-05.

1. Clean thoroughly the cylinder block. Ensure that all the oil and all the coo!ant passages are clean and free from debris.

21. Fill the lubricating oil sump to the correct level with an approved lubricating oil.

22. Connect the battery.

2. If a new cylinder block is to be fitted, remove the threaded plugs form the old cylinder block and clean the threads. Seal the threads with nutlock, or a similar sealant, and fit the threaded plugs into the new cylinder block.

23. Eliminate air from the fuel system, section 20.

24. Start the engine and check for fuel, lubricating oil and coolant leaks. Allow the engine to reach the normal temperature of operation before it is stopped.

3. Fit the crankshaft and the rear oil seal, section 14.

4. Fit the flywheel housing and the flywheel, section 22.

5. Fit the piston and connecting rod assemblies, operation 13A-03.

6. Fit the lubricating oil suction pipe, the lubricating oil sump and the lubricating oil filter assembly, section 19.

7. Fit the backplane for the timing case assembly, operation 15A-09.

8. Fit the timing case assembly, operation 15A-01.

9. Fit the crankshaft pulley, operation 14A-01.

10. Fit the auxiliary drive assembly, operation 24A-01.

11. Fit the cylinder head assembly, operation 12A-07.

12. Fit the glow plugs, operation 23C-01.

13. Fit the fuel injection pump, the atomisers, the fuel lift pump, the fuel filter, and the high and the low pressure fuel pipes, section 20.

14. Fit the electrical stop solenoid, operation 23D-01.

15. Fit the starter motor, operation 23B-01.

16. Fit the thermostat housing, the water pump and the fan, section 21.

17. Fit the alternator, its mounting brackets and the alternator drive belt, section 21.

18. Install the engine into the vehicle or machine.

19. Connect electrical cables, control wires and hoses.

Engine

89

2.7. Cylinder Block Assembly

To Inspect

To check the Condition of a Cylinder Bore

16A-02

1. Inspect the surface for cracks and deep scratches.

2. Check for areas where the honed finish has been polished away. Check especially the area around the top of the bore just below the carbon ring. in this area, there is maximum thrust form the top piston ring.

CAUTION : An engine can have high oil consumption with very little wear of the bores, if the surfaces of the bores are glazed.

3. Check the cylinder bores for wear and other damage. The bores should be checked at the top, the centre, the bottom and in two directions, across the engine and along the centre line.

If the cylinder bores are worn by more than 0,25 mm (0.01 in), the bores can be bored and honed 0,5 mm (0.02 in) oversize in diameter and oversize pistons fitted. To ensure that the engine will conform to emissions legislation after it has been bored, the bores must bored and then diamond honed, silicon carbide base honed and then silicon carbide plateau honed to the surface finish shown in Data and dimensions.

PU098

(A) 1. Clean the passages for the coolant and for the oil.

2. Check the cylinder block for cracks and for other damage.

3. The top face of the cylinder block must not be machined as this will affect the piston height above the top face of the cylinder block.

4. Check the condition of the cylinder bores. The condition of a cylinder bore is decided by:

CAUTION : If the cylinder block is to be bored, all cylinders must be bored and new pistons fitted as a complete set.

•The amount and location of any polished areas.

•The amount of wear.

•Damage to the cylinder wall.

Specialist training and equipment is needed to machine the cylinder bores. For further information contact your nearest Perkins Distributor.

5. Check the camshaft bush for wear. if the bush is to be renewed, use a suitable adapter to remove the old bush. Do not damage the bore in the cylinder block.

CAUTION : Ensure that the oil holes in the bush are aligned with the oil holes (A1) in the cylinder block.

6. When the new bush is fitted, check in six places, that the diameter (A2) of the bush is correct.

Engine

90

2.7. Cylinder Block Assembly

2.7.3. Data and Dimensions Introduction NOTE : This information is given as a guide for personnel engaged on engine overhauls. The dimensions which are shown are those which are mainly used in the factory.

Cylinder Block Assembly Cylinder block Height between top and bottom faces .............................................................360.95/361.05 mm (14.211/14.214 in) Diameter of parent bore for main bearing .......................................................69.000/69.019 mm (2.7165/2.7173 in) Diameter of bores for camshaft: -Number one (for bush) ..........................................................................................51.84/51.87 mm (2.041/2.042 in) -Numbers two three four and five .......................................................................48.025/48.50 mm(1.8907/1.9094 in) Diameter of cylinder bores: -UA engines .....................................................................................................97.000/97.025 mm (3.8189/3.8199 in) -UB engines .....................................................................................................91.000/91.025 mm (3.5827/3.5837 in) Maximum permissible wear in cylinder bore ..................................................................................0.25 mm (0.01 in) Oversize bores Diameter of oversize cylinder bores before they are honed -UA engines .............................................................................................................97.35/97.42 mm (3.833/3.835 in) -UB engines .............................................................................................................91.35/91.41 mm (3.596/3.599 in) Surface finish...............................................................................................................................................RA 3.0/5.0 Surface finish of the diamond hone Hone angle (cross hatch) .................................................................................................................................30°/35° Surface finish size, diamond honed: -UA engines .....................................................................................................97.467/97.472 mm (3.8373/3.8374 in) -UB engines .....................................................................................................91.467/91.472 mm (3.6011/3.6012 in) Grade of surface finish ..........................................................................................................RA 2.2/3.0 micro-meters Maximum ovality and taper........................................................................................................0.012 mm (0.0005 in) Surface finish of the silicone carbide base hone Hone angle (cross hatch) .................................................................................................................................30°/35° -UA engines .............................................................................................................................97.507 mm (3.8388 in) -UB engines .............................................................................................................................91.507 mm (3.6026 in) Grade of surface finish ..........................................................................................................RA 1.3/1.6 micro-meters Maximum ovality and taper........................................................................................................0.020 mm (0.0008 in) Surface finish of the silicone carbide plateau hone Final surface finish size, silicon carbide (plateau hone): -UA engines .....................................................................................................97.500/97.525 mm (3.8386/3.8396 in) -UB engines .....................................................................................................91.500/91.525 mm (3.6024/3.6033 in) Final surface finish grade, silicon carbide (plateau hone) .......................................................0.65/1.3 micro-meters

Engine

91

2.7. Cylinder Block Assembly

To adjust the timing of the fuel injection pump, a shim (B1) of a specific size is fitted between the flange of the pump and the flange on the cylinder block, six different size shims are available.

2.8. Engine Timing 2.8.1. General Description NOTES: •The front of the engine is when seen from the end with the timing case assembly.

•Number one cylinder is at the front of the engine.

included within the thickness dimension of each shim, is an amount of sealant that is necessary to prevent oil leakage from the flange.

The timing gears for the engine are stamped with timing marks to ensure that they are assembled correctly (A).

When the timing for the fuel pump has been set, it should only alter if the camshaft for the fuel pump, or the cylinder block are renewed. if this occurs, it will be necessary to check the timing.

If the original fuel injection pump is removed and fitted for any other purpose, and a shim of the same size is fitted, the injection timing should not alter.

The part number and code letters for the pump are shown on the plate (B2). For timing details, see Data and dimensions.

PU091

(A)

PU026

(B) When the engine is set at top dead centre (TDC) on the compression stroke for number one cylinder, operation 17A-01, the timing marks on the fuel pump, the camshaft and the crankshaft gears may the gears rotate at different speeds.

The mark on the crankshaft pulley will be aligned with the mark on the timing case when the piston for number one cylinder is at TDC, see operation 17A-01.

The fuel injection pump fitted to this engine is of the in-line cassette type.

The gear for the fuel pump, the roller bearings and the camshaft for the fuel pump, are supplied as an assembly.

Engine

92

2.8. Engine Timing

To set Accurately Number 1 Piston to TDC on the Compression Stroke

17A-01

Special Tools: Valve spring compressor, PD.6118B Stud adapter for use with PD.6118B, PD.244

WARNING Wear eye protection during this operation PU092

(C)

NOTE : Clockwise / counter-clockwise direction is when seen from the front of the engine.

1. Remove the rocker cover, operation 12A-01.

2. Rotate the crankshaft, clockwise, until the push rod for the inlet valve of the rear cylinder just tightens. The piston for number one cylinder will be near to TDC and the mark on the crankshaft pulley should be near to the mark on the timing case (A1).

3. Remove the spring clip and the spacer from the front of the rocker shaft. Release the fasteners of the first two pedestals of the rocker shaft. Release the tappet adjustment screw and remove the front rocker lever. Tighten the fasteners of the rocker shaft pedestals.

PU048/1

(A)

CAUTION : When the valve spring is removed, ensure that the collets do not fall into the holes for the push rods.

4. Remove the valve spring and the cap from the front valve with the valve spring compressor PD.6118 (B1)and the adapter PD.244 (B2), for the pedestal studs. Allow the valve to be held by the top of the piston.

5. Fasten a dial test indicator with its plunger in contact with the top of the valve stem (C1) and with a reading shown on the gauge. Rotate slowly, the crankshaft counter-clockwise 45°, Then rotate slowly, the crankshaft clockwise until the clockwise movement of the dial gauge pointer stops.

PU036

(B)

6. With the pointer in the maximum clockwise position, the piston for number one cylinder will be at TDC on the compression stroke.

Engine

93

2.8. Engine Timing

To Check the Valve Timing

CB P 360

17A-02

Where: -C = The circumference of pulley -P = 2.5° 7. Rotate the crankshaft, clockwise from the front, until the valve (B7) has just opened and the valve (B8) has not closed completely. Set the valve tip clearance of the valves (B1) and (B2) to 0.35 mm (0.014 in).

8. Fit the rocker cover, operation 12A-01.

PU048/1

(A)

PU013

(B) 1. Check and, if necessary, adjust the valve tip clearances, operation 12A-05.

2. Rotate the crankshaft, clockwise from the front, until the valve (B) is fully open. The piston for number one cylinder is now on the compression stroke.

3. Set the valve tip clearance for valve (B1) to 0,59 mm (0.023 in).

5. Rotate the crankshaft, clockwise from the front, until the push rod for valve (B1) just tightens. In this position, check if the mark (A1) on the crankshaft pulley is within L2.5° of the mark on the timing case. If it is, the valve timing is correct.

6. If the timing is more than 2.5° out of position, the timing gears are probably not in correct mesh.

NOTE: Use the formula below to find the measurement on the pulley which is equal to 2.5°.

Engine

94

2.8. Engine Timing

1. Disconnect the battery.

To Check the Timing of the Fuel Injection Pump 17A-03

2. Set the piston for number one cylinder to top dead centre (TDC) on the compression stroke, operation 17A-01.

The method used to check the timing of the fuel injection pump is spill timing.

3. With the dial gauge still on the first valve, rotate the crankshaft counter-clockwise until the dial gauge pointer moves counter-clockwise 5,08 mm (0.20 in).

4. Remove the electrical stop solenoid, operation 23D-01.

5. Disconnect from the fuel injection pump, the fuel inlet pipe (B3).

6. Disconnect the high-pressure fuel pipe (B1) for number one outlet (B2).

PU048/1

(A)

CAUTIONS : •When the delivery valve holder (B2) is removed from the pump, the crankshaft must not be rotated. If this does occur, the injection pump will be permanently damaged.

•Extreme care must be used with the components (C) when the delivery valve assembly is removed and fitted during the spill timing procedure.

•The area inside the delivery valve chamber must remain completely clean at all times.

7. Remove the delivery valve holder (B2/C1) for number 1 cylinder and remove the delivery valve (C4), the spring (C3) and the location pin (C2).

Keep these components in clean diesel fuel.

PU027

(B)

NOTE : Because the pump is fitted at an angle, when the delivery valve, spring and location pin are removed, the delivery valve seat (C6) will slide to the side of the delivery valve chamber, This will make it difficult to fit the holder (C1) to the pump.

8. To ensure that the valve seat will remain centred, dry thoroughly the bottom face of the valve seat and the top face of the plunger assembly. Put the valve seat onto the top face of the plunger and slowly rotate the seat. The seat should then remain centred when the delivery valve holder is fitted.

PU093

(C) NOTES : •The timing marks on the crankshaft pulley and on the timing case (A1) are not accurate enough when the engine is spill timed.

•Clockwise / counter-clockwise direction is when seen from the front of the engine.

Engine

95

2.8. Engine Timing

15. Turn the crankshaft slowly in a clockwise direction, until the flow of fuel from the swan neck pipe, is reduced to one drop every 7-10 seconds.

CAUTION : Do not tighten the delivery valve holder unless the components are aligned. If they are not, the injection pump will be permanently damaged.

16. Note the reading on the dial test indicator (A2).

NOTES : •The reading on the indicator shows piston displacement. For the correct displacement / static timing angles, see Data and dimensions.

•If it is necessary to adjust the timing, remove the pump and fit a shim of the correct thickness, operation 20A-06.

•To retard the timing; fit a thicker shim. To advance the timing; fit a thinner shim.

•The timing will change approximately 1° for each 0,10 mm (0.004 in) of shim thickness.

•If the shim has to be changed, it will be necessary to repeat paragraphs 14 to 20.

•When the timing is correct, remove the swan neck pipe and the tank assembly.

PU094

(A)

17. Remove the delivery valve holder from the pump.

18. Assemble the components of the delivery valve assembly in the correct sequence (B) and fit the assembly to the pump. Tighten the holder to 43 N•m (32 lb•ft) 4.3 kg•m.

19. Fit the high-pressure fuel pipes and tighten the union nuts to 22 N•m (16 lb•ft) 2.2 kg•m.

PU093

20. Fit the low-pressure fuel pipes and tighten the union nuts to 22 Nm (16 lb ft) 2.2 kg m and the nut to 12 N•m (9 lb•ft) 1.2 kg•m.

(C) 9. Fit in the correct sequence, the holder (B1), the washer (B5,) and the seat (B6) to the pump.

21. Remove the dial test indicator.

10. Connect a swan neck pipe (A1) to the delivery valve holder for number one cylinder. Put a suitable container below the swan neck pipe to retain the spilt fuel.

22. Fit the valve spring and cap, the rocker lever, the washer and the circlip and set the valve clearance for number one inlet valve to 0,35 mm (0.014 in).

11. Connect a swan neck pipe (A1) to the delivery valve holder for number one cylinder. Put a suitable container below the swan neck pipe to retain the spilt fuel.

23. Fit the rocker cover.

24. Fit the electrical stop solenoid, operation 23D-01.

25. Connect the battery and start the engine. Check for fuel and lubricating oil leaks.

NOTE : The outlet from the tank should be approximately 152 mm (6 in) above the pump. This will ensure that the fuel is supplied to the pump at a constant pressure.

12. Add 0.5 litres (0.9 pints) of clean fuel to the container.

13. Open the valve.

14. Ensure that the lever (A3) is held in the maximum fuel position during this procedure.

Engine

96

2.8. Engine Timing

2.8.2. Data and Dimensions Introduction NOTE : This information is given as a guide for personnel engaged on engine overhauls. The dimensions which are shown are those which are mainly used in production.

Timing Data Fuel Injection Pump Make ...................................................................................................................Zexel PFR-KX in-line cassette type Direction of rotation ............................................................................................................Clockwise from drive end Fuel pump code letters ......................................................................................................................See table below For identification purposes, a plate which shows the part number of the pump and the rating code letters is fitted to the side of the pump (17A.02/B2). An example of this is: -Pump part number......................................................................................................................................2644D051 -Pump code-letters...................................................................................................................................................AJ Timing details for fuel injection ...........................................................................................................See table below Timing data for 700 Series engines Piston displacement

Engine type

Fuel pump code letters

Static timing position in degrees before TDC

mm

in

UA

AJ

16

2.54

0.100

UA

BJ

16

2.54

0.100

UB

CJ

14

1.93

0.076

UB

DJ

10

1.004

0.040

Timing shims Part number

Thickness mm (in)

3621F011

0.1 (0.004)

3621F012

0.2 (0.008)

3621F013

0.3 (0.012)

3621F014

0.4 (0.016)

3621F015

0.5 (0.020)

Engine

97

2.8. Engine Timing

1. Release the four setscrews and remove the breather cover.

2.9. Aspiration System 2.9.1. Closed Breather System

2. Remove the diaphragm and location ring assembly (A6). Remove the spring (A5).

3. Release the clips that retain the breather pipe and remove the breather pipe.

The engine breather assembly is fitted to the top of the rocker cover and consists of: the breather cover (A3); four setscrews (A2) to retain the cover; the diaphragm and location ring assembly (A6) and the spring (A5). The crankcase gases pass from the breather assembly, through a pipe (A1) and into the induction manifold.

To Renew the Engine Breather Assembly

4. Clean the breather cavity (A4) in the rocker cover, the breather pipe (A1) and the vent hole (A7).

Ensure that the vent hole is not restricted.

5. Fit a new spring (A5) into the cavity in the rocker cover.

18A-01

6. Fit a new location ring (B2) onto the new diaphragm (B1) and fit this assembly onto the spring. Ensure that the location ring is on the spring (A5).

7. Fit the breather cover, Fit and tighten the four setscrews.

8. Fit the breather pipe and tighten the clips.

NOTES : •The breather assembly (component numbers A5 and A6) should be renewed every 2000 hours.

•The breather pipe should be removed and cleaned every 1000 hours.

PU015

(A)

PU033

(B) CAUTIONS : •It is important that the area around the vent hole (A7) is kept clean and the vent hole is not restricted.

•Ensure that the pipe (A1), when fitted, does not contact other components as this may cause the failure of the pipe.

•Ensure that the components of the breather assembly are fitted their correct positions (A). If they are fitted incorrectly, the engine can be damaged.

Engine

98

2.9. Aspiration System

An extra hole in the bore for each main bearing, allows oil to pass through passages to lubricate the journals of the camshaft for the valves. The bush for the front journal has an oil supply from the front main journal of the crankshaft. The camshaft for the fuel injection pump is lubricated by splash and oil mist.

Lubricating oil also passes from the upper pressure rail through a hole drilled across the front of the cylinder block, which connects with a vertical passage to the front of the cylinder head.

2.10. Lubrication System 2.10.1. General Description Pressure lubrication is supplied by a rotor type pump contained within the timing case. The pump is driven by the crankshaft gear.

Lubricating oil from the sump passes through a strainer and pipe to the suction side of the pump.

The pump has an inner rotor and an outer rotor which are off-centre to each other. The inner rotor has four lobes which mesh with the five lobes of the outer rotor. When the inner rotor rotates, the space between the lobes of the inner and outer rotors increases to cause a suction as it passes the inlet chamber. The space between the lobes is then filled with oil. As the rotors pass the outlet chamber, the space decreases which causes a pressure increase.

This forces the oil into the outlet chamber and into the relief valve.

Oil passes through a passage from the front of the cylinder head to restriction in the first pedestal of the rocker shaft. The restriction reduces the oil pressure to lubricate the rocker assembly. The oil passes through the rocker shaft to the bore of each of the rocker levers and leaves the bores through holes in the top of the rocker levers. Oil passes along channels in the top of the rocker levers to the valve stems, the valve springs and the tappets which are lubricated by splash and oil mist.

The hub of the idler gear is lubricated by oil from the pressure rail and the timing gears are splash lubricated. Lubricating oil from the timing case returns to the sump.

The lubricating oil, at increased pressure, passes from the outlet of the pump to the relief valve, which is contained within the timing case. As engine speed increases the output of the oil pump increases, and more oil flows into the system. The increase in flow causes an increase in pressure in the system. When the oil pressure on the plunger of the relief valve is greater than the spring pressure, the valve will open.

When the valve opens, surplus oil is returned to the sump. This action will reduce the oil pressure and the valve will close.

Lubricating oil, at pressure, passes from the relief valve chamber, along an oil pressure rail, which is drilled the full length of the right side of the cylinder block, and into the full oil filter. The oil passes through the filter and up the centre tube into another pressure rail, parallel to, but above the other pressure rail. The oil filter can be fitted in one of two positions on the right side of the engine. The filter canister is either fitted to the cylinder block or is fitted to a filter head, which is fitted to the cylinder block.

Lubricating oil passes through drilled holes in the upper pressure rail, through passages in the main journals of the crankshaft, to the main bearings.

Lubricating oil also passes through passages in the crankshaft to the big end bearings. The small end bearings, the pistons and the cylinder bores are lubricated by splash and oil mist.

Engine

99

2.10. Lubrication System

2.10.2. Filter Canister To Renew

19A-01

WARNING Discard the used canister and lubricating oil in a safe place and in accordance with local regulations.

CAUTIONS : •Ensure that the application is on a level surface to ensure an accurate reading on the dipstick.

•When the sump is filled with lubricating oil, ensure that the level of the oil is not above the notch (B2) on the dipstick. If the engine operates with too much oil in the sump, the engine will be damaged.

PU006

(B) NOTE : Some applications have a separate filter head that is fitted to the cylinder block, directly onto the filter mounting face. The filter canister is then fitted to the filter head. Use the same procedure given below to change this type of filter.

1. Put a tray under the filter to retain spilt lubricating oil. Clean thoroughly the outside surfaces of the filter assembly.

2. Use a strap wrench or similar tool to loosen the filter canister. Remove and discard the canister.

Ensure that the adaptor (A1) is secure in the filter head.

3. Clean inside the filter head, or the mounting face.

4. Lubricate the seal (A2) on top of the canister with clean engine lubricating oil.

5. Fit the new canister and tighten by hand until the seal contacts the filter head, or the mounting face.

Tighten the canister a further 1/2 to 3/4 of a turn by hand only. Do not use a strap wrench.

6. Ensure that there is lubricating oil in the sump.

Ensure that the engine will not start and operate the starter motor until oil pressure is obtained. To ensure that the engine will not start, disconnect the electrical stop control of the fuel injection pump.

Oil pressure is indicated when the warning light is extinguished or by a reading on the gauge.

PU004

(A)

CAUTION : Do not fill the sump past the notch (B2) on the dipstick.

7. Start the engine and check for leakage from the filter. Stop the engine. After 15 Minutes, check the oil level on the dipstick and, if necessary, put more lubricating oil into the sump. Fill the sump to the notch (B2) on the dipstick (B1) with an approved lubricating oil.

Engine

100

2.10. Lubrication System

2.10.3. Filter Head To Remove and to Fit

19A-02

PU090

(A) 1. Put a tray under the filter head to contain split lubricating oil.

2. Remove the filter canister, operation 19A-01.

3. Release the setscrew (A1) and remove the filter head (A3) from the cylinder block. Discard the "O" rings (A2) on the setscrew. Discard the "O" ring (A4) on the filter head.

4. Thoroughly clean the flange face of the filter head and the flange face of the cylinder block. Fit the filter head together with a new "O" ring. Fit new "O" rings to the setscrew tighten the setscrew to 80 N•m (59 lb•ft) 8.2 kg•m.

5. Fit a new filter canister, operation 19A-01.

Engine

101

2.10. Lubrication System

NOTE : Some agricultural applications have an engine with a divided sump to allow for a drive shaft.

If this sump is used, both drain plugs must be removed to ensure that all of the lubricating oil is drained from the sump.

2.10.4. Sump To Remove and to Fit

19A-03

Consumable Products:

1. Remove the sump drain plug(s) and the "O" ring(s) and drain the oil. If necessary, remove the dipstick and the dipstick tube.

Silicone adhesive

WARNING

2. Provide a support for the sump. Remove the setscrews and the two nuts which fasten the sump to the cylinder block and to the timing case. Lower the sump.

•Discard the used lubricating oil in a safe place and in accordance with local regulations.

•If a cast iron sump is used, it will be heavy, ensure that there is enough support for the sump or obtain assistance when it is removed or fitted.

3. Wash the sump with an approved cleaning fluid, ensure that all of the cleaning fluid is removed.

Thoroughly clean the flange faces of the sump and the cylinder block and ensure that they are free of oil or grease.

4. Put a bead of Silicone adhesive (A1) along the flange of the sump.

5. Carefully fit the sump onto the cylinder block. Fit a setscrew on each side of the sump to ensure that it is in the correct position. Loosely fit the remainder of the setscrews.

6. Tighten all the fasteners to 22 N•m (16 lb•ft) 2.2 kg•m. Fit the drain plug (s) together with a new "O" ring and tighten the plug (s) to 34 N•m (25 lb•ft) 3,5 kg•m. Where necessary, fit the dipstick tube and the dipstick. Fill the sump to the notch (B2) on the dipstick (B1) with an approved lubricating oil.

PU074

(A)

PU006

(B) CAUTIONS : •Ensure that the application is on a level surface to ensure an accurate reading on the dipstick.

•When the sump is filled with lubricating oil, ensure that the level of the oil is not above the notch (B2) on the dipstick. If the engine operates with too much oil in the sump, the engine will be damaged.

Engine

102

2.10. Lubrication System

4. Fit a new "O" ring into the groove (A6) in the hole in the cylinder block for the suction tube.

Lubricate the "O" ring with clean engine lubrication and fit the suction tube. Put the bracket in position and tighten the setscrew to 22 N•m (16 lb•ft) 2.2 kg•m. Ensure that there is no stress on the suction pipe.

2.10.5. Oil strainer and Suction Pipe Assembly To Remove and to Fit

19A-04

The oil strainer (A1) is an integral part of the suction pipe (A2). No regular service is necessary, but wash the strainer assembly when it is removed.

5. Some engines have a different suction pipe to that shown in (A). The other type has two support brackets, one as in (A4). and a second one that is fitted to the centre main bearing cap. Tighten both setscrews to 22 N•m (16 lb•ft) 2.2 kg•m.

CAUTIONS: •Ensure that the application is on a level surface to ensure an accurate reading on the dipstick.

•When the sump is filled with lubricating oil, ensure that the level of the oil is not above the notch (B2) on the dipstick. If the engine operates with too much oil in the sump, the engine will be damaged.

PU075

6. Fit the sump, operation 19A-03, and fill the sump to the notch (B2) on the dipstick (B1) with an approved lubricating oil.

(A)

To Inspect

19A-05

1. Wash the assembly in an approved cleaning fluid and dry it thoroughly.

2. Check the pipe, the strainer and the welded joints for cracks and other damage. Check that the mounting bracket is secure.

3. If the strainer assembly is cracked or damaged, it must be renewed.

PU006

(B) 1. Remove the sump, operation 19A-03.

2. Release the setscrew (A4) which holds the bracket (A3) to the cylinder block. Remove the suction pipe and strainer.

3. Remove the "O" ring (A5) from the hole in the cylinder block for the suction pipe.

CAUTION: When the setscrew for the suction pipe bracket is tightened, ensure that a downward load (towards the block), is applied to the pipe (A2).

When fitted, it should not be possible to move the pipe by hand.

Engine

103

2.10. Lubrication System

2.10.6. Lubricating Oil Pump To Remove and to Fit

19A-06

PU076

(A) To Remove 1. Remove the timing case, operation 15A-01.

2. Release the three cap screws (A1) and remove the oil pump (A2).

To Fit 1. Ensure that the flange face of the oil pump and the flange face of the timing case for the oil pump are clean. Align the two dowels (A3) and put the oil pump in position. Fit and tighten the cap screws (A1) to 22 N•m (16 lb•ft) 2.2 kg•m.

2. Fit the timing case, operation 15A-01.

Engine

104

2.10. Lubrication System

To Inspect

19A-07

If any part is worn enough to have an effect on the performance of the oil pump, the complete oil pump must be renewed.

1. Remove the oil pump, operation 19A-06.

2. Remove the outer rotor and clean thoroughly all the parts. Check for cracks and any other damage.

3. Fit the outer rotor and check the outer rotor to body clearance with a feeler gauge (A).

4. Check the inner rotor to outer rotor clearance (B).

5. Check the rotor end-float with a straight edge and a feeler gauge (C). For all the above clearances, see data and dimensions at the end of this section.

PU077

(A)

6 Fit the oil pump, operation 19A-06.

PU078

(B)

PU079

(C)

Engine

105

2.10. Lubrication System

2.10.7. Relief Valve

To Dismantle and to Assemble

The relief valve (A) is fitted in the timing case and prevents too much pressure in the lubricating oil system.

1. Apply pressure to the end of the plunger (B2), release and discard the circlip (B1). Carefully release the pressure to remove the plunger and the spring (B3) from the valve body (B4). Remove the "O" ring (B5).

As engine speed increases the output of the oil pump increases, and more oil flows into the system. The increase in flow causes an increase in pressure in the system. When the oil pressure on the plunger of the relief valve is greater than the spring pressure, the valve will open. When the valve opens, surplus oil is returned to the sump.

19A-09

2. Ensure that all the components are cleaned and then lubricated lightly with clean engine lubricating oil.

3. Fit the spring into the plunger and fit the plunger into the bore of the valve body. Apply pressure to the end of the plunger and fit the circlip into its groove in the valve body. Release the plunger. Fit a new "O" ring.

This action will reduce the oil pressure and the valve will close. Oil which passes the relief valve reaches the oil filter.

To Inspect

19A-10

Do not try to change the operation pressure of the relief valve. If necessary, fit new components.

1. Check the spring for wear and other damage and, if possible, check the load necessary to compress the spring to its fitted length, see data and dimensions at the end of this section.

2. Check the plunger for wear and other damage and ensure that it slides easily in the bore of the relief valve.

PU080

(A)

3. Check the body for wear and other damage.

4. Renew worn or damaged components.

PU081

(B) To Remove and to Fit

19A-08

1. Release the relief valve (A2) from the timing case (A1) and discard the "O" ring (A3).

2. Fit a new "O" ring to the relief valve and fit the relief valve into the timing case. Tighten the relief valve to 20 N•m (15 lb•ft) 2.0 kg•m.

Engine

106

2.10. Lubrication System

2.10.8. Data and Dimensions Introduction NOTE : This information is given as a guide for personnel engaged on engine overhauls. The dimensions which are shown are those which are mainly used in the factory.

Lubrication System Lubricating oil pump Type ................................................................................................................................Differential rotor, gear driven Number of lobes .................................................................................................................Inner rotor 4, outer rotor 5 Maximum permissible clearance of outer rotor to pump body........................................................0.19 mm (0.007in) Inner rotor to outer rotor..................................................................................................................0.25 mm (0.010in) Inner and cuter rotor end clearance................................................................................................0.15 mm (0.006in) Lubricating oil relief valve Diameter of bore in pump body .........................................................................11.000/11.018 mm (0.5605/0.5625in) Outside diameter of plunger..............................................................................10.970/10.982 mm (0.5585/0.5595in) Clearance fit of plunger in bore.............................................................................0.018/0.048 mm (0.0007/0.0019in) Length of spring (fitted) ...................................................................................................................25.5 mm (1.004in) Load on spring (fitted) ............................................................................................26.2/27.7 N (5.9/6.2 lb) 2,7/2.8 kg Pressure to open valve ...........................................................................240/290 kPa (34.8/42.1 lb/in2) 2,4/3,0 kg•m2 Lubricating oil filter Type...........................................................................................................................Full flow, screw-on type canister Pressure to open by-pass valve........................................................................55/83 kPa (8/12 lb/in2) 0.6/0.8 kg/cm2

Engine

107

2.10. Lubrication System

To assist cold starts, the rack of the fuel injection pump is returned automatically to the excess fuel position when the engine stops.]

2.11. Fuel System 2.11.1. General Description

A data plate (A2) if fitted to the side of the pump flange. The plate shows the part number and the code letters of the pump. an example of this is:

CAUTIONS : •The fuel injection equipment must only be checked and adjusted by personnel who have had the correct training.

•Do not allow dirt to enter the fuel system. Clean thoroughly the area around all of the components before they are removed and fit suitable covers to all open connections.

2644D051AJ For full details of all pump codes, see Data and dimensions.

The two stage atomiser for the UA engine is fitted to the cylinder head with a clamp assembly. The single stage atomiser for the UB engine has a threaded body and fits directly into the cylinder head.

The atomisers are set in the factory and must be checked in accordance with the preventive maintenance schedules shown in the users’s handbook. The pressure at which the atomisers operate can be adjusted by a change of shim, fitted above the spring. The setting pressures for both types of atomiser are listed in Data and dimensions.

The fuel lift pump is a diaphragm type and is mechanically driven from an eccentric on the camshaft for the fuel injection pump. The pump is fitted to the right side of the cylinder block and has a priming lever.

PU026

(A) The fuel injection pump used on the 700 Series engine is a Zexel PFR cassette type pump (A) which is fitted directly into the cylinder block. The cassette, contains the delivery valves, the pump elements and the fuel control rack.

The fuel filter is a separate element type that is held between the filter head and a bottom cover. The filter head is fitted to the right, rear side of the cylinder block.

The pump elements are operated by a separate camshaft that is part of an assembly that is fitted into the front of the cylinder block. The drive gear is driven by the idler gear.

The governor weight assembly is fitted to the front of the gear for the camshaft for the fuel injection pump.

The linkage that operates the fuel injection pump is contained within the timing case assembly.

The fuel injection timing, is set at the factory and should only alter if the cylinder block or the camshaft for the fuel injection pump are renewed. If this occurs, the timing will have to be checked and if necessary, set to the correct figure. The timing is controlled by the use of a specific size shim (A1) that is fitted between the flange of the fuel injection pump and the cylinder block. If the injection pump is removed, if can be fitted with a new shim, of the same size, and the timing will not alter.

Engine

108

2.11. Fuel System

5. Clean the inside surfaces of the filter head and the cover.

2.11.2. Fuel Filter Element To Renew

20A-01 6. Renew the seals (A2 and A5) and the ‘O’ ring (A3) and lightly lubricate them with clean fuel. The larger seal is fitted to the filter head and the smaller seal is fitted to the bottom cover.

CAUTIONS : •It is important that only the genuine Perkins fuel filter element is used. The use of a wrong element can damage the fuel injection pump.

•Do not allow dirt to enter the fuel system. Clean thoroughly the area around all of the components before they are removed and fit suitable covers to all open connections

7. Put the bottom cover under the new element and hold the element squarely to the filter head.

Ensure that the element is fitted in the centre against the ‘O’ ring in the filter head. With the assembly in this position, engage and tighten the setscrew.

Eliminate the air from the fuel filter, see operation 20A-07.

PU009

(A) 1. Clean the outside surfaces of the fuel filter assembly.

2. Hold the bottom cover of the filter element and release the setscrew (A1) which is fitted through the filter head above the centre of the element.

3. Lower the bottom cover (A6) of the filter.

4. Remove the element (A4) and discard it.

WARNING Discard the used canister and fuel in a safe place and in accordance with local regulations.

Engine

109

2.11. Fuel System

2.11.3. Atomisers Atomiser Fault

WARNING •If your skin comes into contact with high-pressure fuel, obtain medical assistance immediately.

•Keep away from moving parts during engine operation. Some moving parts cannot be seen clearly while the engine runs.

An atomiser fault can cause an engine misfire.

PU026

(A)

PU127

(B) In order to find which atomiser is defective, operate the engine at a fast idle speed. Loosen and tighten the union nut (A1/B1) of the high-pressure fuel pipe at each atomiser. Do not loosen the union nut more than half a turn. When the union nut of the defective atomiser is loosened, it will have little or no effect on the engine speed.

Engine

110

2.11. Fuel System

To Fit

To Remove and to Fit: -UA Engines

20A-02A CAUTION : A new clamp (A5) must be used every time the atomiser if fitted to the engine.

NOTE : Identification letters for the atomiser are shown on the nozzle holder (A2).

1. Put the new atomiser in position together with a new seat washer and a new ‘O’ ring (A1), ensure that the sharp edges (A4) do not damage the new ‘O’ ring. Fit the atomiser into the cylinder head with a new clamp (A6) and spacer (A5). Engage the screw, ensure that the atomiser is not tilted and tighten the setscrew to 22 N•m (16 lb•ft) 22.2 kg•m.

CAUTION : Do not allow dirt to enter the fuel system.

Before a connection is disconnected, clean thoroughly the area around the connection. After a component has been disconnected, fit a suitable cover to all open connections.

CAUTIONS: •If there is a leakage from the union nut, ensure that the pipe is correctly aligned with the atomiser inlet.

•Do not tighten the union nuts of the high-pressure pipes more than the recommended torque tension as this can cause a restriction at the end of the pipe.

This can affect the fuel delivery.

2. Fit the high-pressure fuel pipe and tighten the union nuts to 22 N•m (16 lb•ft) 2.2 kg•m. If necessary, fit the pipe clamps.

PU008

3. Renew the sealing washers and fit the leak-off pipe. Tighten the banjo bolts to 9 N•m (7 lb•ft) 0.9 kg•m.

(A) To Remove

4. Eliminate air from the fuel system, operation 20A-07.

1. Remove the fuel leak-off pipe.

5. Operate the engine and check for leakage of fuel and air.

CAUTION : Use a separate spanner to prevent movement of the outlets of the fuel injection pump when the high-pressure pipes are released or tightened.

2. Remove the union nuts of the high-pressure pipe from the atomiser and from the fuel injection pump. Do not bend the pipe. If necessary, remove the pipe clamps.

3. Remove the setscrew (A7) of the atomiser clamp and remove the clamp (A6), the spacer (A5), the atomiser (A2) and its seat washer (A3).

Engine

111

2.11. Fuel System

To Fit

To Remove and to Fit: -UB Engines

20A-02B 1. Apply a 2 mm bead of atomiser thread sealant to extend 6 mm around each of the first two thread (A6). Ensure that the sealant does not contact the body (A2) of the atomiser.

Consumable Products: Atomiser thread sealant

CAUTION : Do not move the atomiser after it has been tightened, the seal that is made when torque has been applied will be broken and corrosion of the threads may occur.

NOTE : Identification mark for the atomiser are stamped onto the side face of the nut (A4).

CAUTION : Do not allow dirt to enter the fuel system.

Before a connection is disconnected, clean thoroughly the area around the connection. After a component has been disconnected, fit a suitable cover to all open connections.

2. Fit a new flame shield washer (A1) with the red identification mark to the top. Put the atomiser in position together with a new seat washer (A5).

Tighten the nut (A4) of the atomiser to 39 N•m (29 lbf ft) 4.0 kg•m.

CAUTIONS : •If there is a leakage from the union nut, ensure that the pipe is correctly aligned with the atomiser inlet.

•Do not tighten the union nuts of the high-pressure pipes more than the recommended torque tension as this can cause a restriction at the end of the pipe.

This can affect the fuel delivery.

3. Remove the plastic caps and fit the high-pressure fuel pipes. Tighten the union nuts to 22 N•m (16 lb•ft) 2.2 kg•m. If necessary, fit the pipe clamps.

PU069

(A)

4. Renew the sealing washers and fit the leak-off pipe. Tighten the banjo bolts to 9 N•m (7 lb•ft) 0.9 kg•m.

To Remove 1. Remove the fuel leak-off pipe.

5. Operate the engine and check for leakage of fuel and air.

CAUTION : use a separate spanner to prevent movement of the outlets of the fuel injection pump when the high-pressure pipes are released or tightened.

6. Eliminate air from the fuel system, operation 20A07.

2. Remove the union nuts of the high-pressure pipe from the atomiser and from the fuel injection pump. Do not bend the pipe. If necessary, remove the pipe clamps.

CAUTION : The atomiser must be loosened and tightened with the nut (A4). Do not use the nut (A3) as this will split the body of the atomiser assembly.

3. Use a 22 mm extended socket spanner to remove the atomiser from the cylinder head.

4. Clean thoroughly the threads on the body of the atomiser.

Engine

112

2.11. Fuel System

2.11.4. Fuel Lift Pump To Remove and to Fit

20A-03

PU128

(A) 1. Disconnect the fuel pipes from the fuel lift pump.

2. Release the setscrews and remove the fuel lift pump (A).

3. Ensure that the camshaft eccentric is in the minimum lift position before the lift pump is fitted.

Clean the joint face of the lift pump and the cylinder block and fit the lift pump together with a new joint. Fit the setscrews and tighten them gradually and evenly to 22 N•m (16 lb•ft) 2.2 kg•m.

4. Connect the fuel pipes.

5. Release the banjo bolt on the fuel filter head and operate the priming lever of the fuel lift pump to eliminate any air between the lift pump and the fuel filter. Operate the lift pump until fuel, free of air, comes from the banjo connection. Tighten the banjo bolt.

6. Operate the engine and check for any fuel or air leakage.

Engine

113

2.11. Fuel System

To Dismantle and to assemble

5. The valves (A2/A9) are peened into the upper part of the pump body and can be removed with a suitable lever. Some of the peened metal will have to be removed before the valves can be removed.

20A-04

NOTE : The only components that can be renewed are : the inlet and the outlet valves and seals ; the diaphragm ; the joint to fit the pump to the cylinder block.

6. Check the components for wear and other damage. If components other than the valves and the diaphragm are worn, the complete pump will have to be renewed.

To Assemble 1. Thoroughly clean the valve housings. Fit new seat washers (A1/A8) and push the new valves (A2/A9) into position. As the valves are the same, but one valve is fitted in reverse of the other, it is possible to fit the valves upside down. To ensure that the valves are fitted correctly, fit them as shown in A. When the valves are correctly fitted, peen the edge of the valve housings in six places, evenly divided, to keep the valves in position. Ensure that no metal debris remains in the pump body.

2. Carefully fit the diaphragm spring (A7) into its location under the diaphragm (A3) and put the spring seat washer (A5) and the stem seal (A4) into position on the pull rod. Ensure that the small diameter at the top of the seal is on the round section of the pull rod.

3. Put the diaphragm assembly in position over the lower half of the body with the blade of the pull rod aligned with the slot in the link arm. Press lightly on th diaphragm until the notch in the pull rod is in the slot in the link arm and rotate the diaphragm 90° in either direction. This action will engage and retain the pull rod in the slot of the link arm.

PU129

(A) To Dismantle 1. Clean the outside surfaces of the fuel lift pump.

4. Push the rocker arm towards the pump body until the diaphragm is level with the body flange and fit the top half of the body in position with the marks on the flanges aligned. Keep the pressure on the rocker arm; fit the spring washers and the screws and tighten them evenly.

2. Make a mark across the flanges of the two halves of the pump to ensure correct relationship when the pump is assembled.

3. Release the setscrews and separate the two halves of the pump.

4. Turn the diaphragm assembly (A3) 90° to release the pull rod from the link arm (A6) and remove the diaphragm assembly. Carefully remove the stem seal (A4), the spring seat washer (A5) and the spring (A7) from the pull rod. The diaphragm and pull rod are renewed as an assembly.

Engine

114

2.11. Fuel System

To test

20A-05

1. Disconnect the fuel outlet pipe from the fuel lift pump. Fit a 0-70 kPa (0-10 lb/in2) 0-0.7 kg/cm2 pressure gauge to the outlet of the lift pump.

Release the connection at the gauge and operate the priming lever of the lift pump to eliminate air from the pipe. When fuel, free of air, flows from the pipe tighten the connection. Ensure that there are no leaks at the connections between the pump and the gauge.

2. Operate the starter motor for 10 seconds with the engine stop control in the stop position or with the stop solenoid disconnected.

3. Note the maximum pressure indicated on the gauge. If the pressure indicated is less that the test pressure of 31 kPa (4.5 lb/in2) 0.32 kg/m2, repair or renew the pump. Also check the rate at which the pressure reduces to half the maximum pressure obtained. If this is less than 30 seconds, repair or renew the pump.

4. Remove the gauge and connect the outlet pipe to the lift pump. Released the vent screw on the fuel filter head and operate the priming lever until fuel, free of air, flows from the vent screw. Tighten the vent screw.

5. Connect the engine stop solenoid.

Engine

115

2.11. Fuel System

To Remove

2.11.5. Fuel Injection Pump To Remove and to Fit

20A-06

The fuel injection pump is fitted directly into the cylinder block and is retained in position by two dowels, four flanged setscrews and two flanged nuts.

The fuel injection timing is set at the factory and should only alter if the cylinder block or the camshaft for the fuel injection pump are renewed. If this occurs, the timing will have to be checked and if necessary set to the correct figure. The timing is controlled by the use of a specific size shim that is fitted between the flange of the fuel injection pump and the cylinder block.

PU027

(A)

If the fuel injection pump is removed for any other reason, if can be fitted again with a new shim, of the same size, and the timing will not have altered. For this operation, the position of the crankshaft is not important.

CAUTIONS : •Clean around the edges of the fuel injection pump before it is removed. Dirt may enter the inside of the engine if this is not done.

•Use a separate spanner to prevent movement of the outlets of the fuel injection pump when the highpressure pipes are released or tightened.

PU029

(B) 1. Disconnect the battery.

2. Remove the fuel pipe (A3) that is fitted between the fuel injection pump and the fuel filter.

3. Remove the fuel pipe (A1) that is fitted between the fuel pump and the leak-off connection on top of the fuel filter.

CAUTIONS : Use a separate spanner to prevent movement of the outlets of the fuel injection pump when the high-pressure pipes are released or tightened.

4. Release the union nuts (A2) of the high-pressure pipes from the atomisers and from the fuel injection pump and remove the pipes. Do not bend the pipes.

5. Remove the electrical stop solenoid, operation 23D-01.

6. Remove the support bracket/blanking plate (B1) from the side of the cylinder block. Record the position of the four setscrews because on some earlier engines, they are of different lengths.

Engine

116

2.11. Fuel System

7. Disconnect the spring (A1) from the groove in the peg (A2) on the.

Timing Shims Part number

Thickness mm (in)

3621f011

0.1 (0.004)

3621f012

0.2 (0.008)

3621f013

0.3 (0.012)

3621f014

0.4 (0.016)

3621f015

0.5 (0.020)

CAUTION : When the spring (A3) is disconnected from the peg (A2), it is possible for the spring to become disconnected from the pin (A4). If this occurs, the spring can fall into the sump!

8. Disconnect the spring (A3) from the groove in the peg on the rack.

9. Disconnect the governor control link (A5) from the peg on the rack.

10. Remove the four flanged setscrews (A6), the two flanged nuts (A7) and lift the pump from the cylinder block.

To Fit CAUTIONS : •Debris may fall into the engine if the hole in the cylinder block for the pump is not protected.

•When the pump is fitted, new shim of the correct size must be fitted, without sealant. A thin layer of sealant is included within the final thickness of each new shim. Extra sealant will affect the timing of the fuel injection.

PU030

(A)

1. Clean the surface of the flanges for both the pump and the cylinder block. Fit a new shim (B1) of the correct size (see table opposite) to the flange on the cylinder block.

2. Ensure that the peg (B2) is aligned with the cutout (B3) and that the shim is fitted onto the two dowels (B4). Carefully fit the pump onto the studs and the dowels and ensure that the link (A5) is not damaged.

PU032

(B) 3. Fit the nuts (A7) and setscrews (A6) and tighten them evenly to 22 N•m (16 lb•ft) 2.2 kg•m.

4. Fit the governor control link (A5) onto the peg (A2) on the rack.

5. Fit the spring (A3) to the groove in the peg (A2) on the rack.

CAUTION : The spring (A1) must retain at all times, the spring (A3) and the governor control link (A5) onto the peg (A2). If the governor control link becomes separated from the peg, control of the engine speed will be lost!

6. Fit the spring (A1) into the groove on the peg.

Engine

117

2.11. Fuel System

7. Clean the surfaces for the joint for the blanking plate (A1). Fit a new joint and the blanking plate to the side of the cylinder block.

12. Eliminate air from the system, operation 20A-07.

8. Fit the stop solenoid, operation 23D-01.

14. Operate the engine and check for leakage of fuel and air.

13. Connect the battery.

9. Fit the high-pressure fuel pipes and tighten the union nuts (B2) to 22 N•m (16 lb•ft) 2.2 kg•m.

PU029

(B)

PU027-1

(A) CAUTIONS : •If there is a leakage from the union nut, ensure that the pipe is correctly aligned with the atomiser inlet.

•Do not tighten the union nuts of the high-pressure pipes more than the recommended torque tension as this can cause a restriction at the end of the pipe.

This can affect the fuel delivery.

10. Fit the fuel pipe (b1) that is fitted between the pump and the leak-off connection on the top of the fuel filter, and tighten the union nuts to 20 N•m (15 lb•ft) 2.0 kg•m.

11. Fit the fuel pipe (B3) that is fitted between the pump and the fuel filter and tighten the union nuts to 20 N•m (15 lb•ft) 2.0 kg•m.

Engine

118

2.11. Fuel System

To Eliminate air From the Fuel System

4. Operate the starter motor for intervals of 15 seconds until the engine starts. If the engine runs correctly for a short time and then stops or runs roughly, check for air in the fuel system. If there is air in the fuel system, there is probably a leakage in the low pressure system. Stop the engine and turn the start key to the “OFF” position.

20A-07

If air enters the fuel system, it must be eliminated before the engine can be started.

Air can enter the system if: •The fuel tank is drained during normal operation.

•The low-pressure fuel pipes are disconnected.

•A part of the low-pressure fuel system leaks during engine operation.

In order to eliminate air from the fuel system, proceed as follows:

PU007

(A) 1. Loosen the vent plug (A1) on the side of the fuel injection pump.

2. Operate the priming lever of the fuel lift pump (A2) until fuel, free from air, comes from the vent point.

Tighten the vent plug.

3. Turn the start key to the “ON” position.

Engine

119

2.11. Fuel System

4. Check the components for wear and renew them as necessary.

2.11.6. Fuel Injection Pump Controls

To Fit 1. Fit the weight assembly (B4) with the four flange face setscrews (B1) to the front of the gear and tighten the setscrews (B1) to 7 N•m (5 lb•ft).

2. Lubricate with clean engine lubricating oil, the spigot on the gear and fit the thrust sleeve (B2).

Ensure that the flange of the sleeve is fitted into the recess (B3) in each weight.

PU130

3. Move the thrust sleeve backwards and forwards along the shaft, to ensure that the four weights (B5) operate correctly.

(A) The components listed below are part of the timing case assembly and are used to control the engine speed, performance and emissions: the governor control lever (A1); the Angleich (torque control) unit (A2); the adjustment screw for the maximum fuel setting (A3); the engine speed control lever (A4); the fuel control level (A5); the governor control link (A6). Items (A1), (A2), (A5) and (A6) are referred to as “the fuel pump linkage” in operation 20A-10A. The governor weight assembly (A7), is fitted to the front of the gear for the camshaft for the fuel injection pump.

To Remove and to Fit the Governor Weight Assembly

20A-08

To Remove

PU111

(B) 1. Remove the timing case assembly, operation 15A-01.

2. Remove the thrust sleeve (B2) from the spigot on the gear.

3. Remove the four flange face setscrew (B1) and withdraw the weight assembly (B4) from the front of the gear.

Engine

120

2.11. Fuel System

To Remove and to Fit the Engine Speed Control Lever Assembly

To Fit 20A-09 1. Clean and lubricate the shaft (B1) and the ‘O’ ring (B2) with a small quantity of grease. Fit the lever assembly (B4) into the bush (B3).

Consumable Products Platelock

2. Ensure that both ends of the spring (A5) are fitted securely to both levers.

To Remove

3. Fit the lever (A1) with the spring onto the flat section (A3) of the shaft.

CAUTION : Ensure that Loctite does not enter the bush (A2).

4. Apply a small quantity of Platelock to the threads of the shaft (A4). Fit the plain washer, the spring washer and the nut and tighten the nut to 10.5 N•m (8 lb•ft) 1.1 kg•m.

PU131

(A)

PU132

(B) 1. Remove the timing case assembly, operation 15A-01.

2. Remove the nut, the spring washer and the plain washer from the shaft (A4) and withdraw the lever (A1) from the shaft. Unless the lever or the spring (A5) are to renewed, it will not be necessary to disconnect the spring from the lever.

3. Withdraw the lever assembly (B4) from the bush (B3). Check the components for wear or damage.

CAUTION : The bush (B3) is fitted to the timing case with a special adhesive and must not be removed. If the bush is removed, the threads in the timing case will be damaged.

Engine

121

2.11. Fuel System

To Renew the Components of the Engine Speed Control Lever Assembly 20A-09A To Renew

PU133

(A) 1. Remove the engine speed control lever assembly, operation 20A-09.

2. Remove the nut (A3).

3. Remove the lever (A2) from the shaft (A1).

4. Remove the ‘O’ rings (A6) from the shaft.

5. Renew the components as necessary.

6. Fit the ‘O’ rings to the shaft.

7. Fit the lever to the shaft. Ensure that the lever is fitted correctly to the key (A5) on the shaft.

8. Ensure that the slot (A4) is clean. fit the nut and tighten to a torque of 45 N•m (33 lb•ft) 4.6 kg•m.

9. Fit the engine speed control lever assembly, operation 20A-09.

Engine

122

2.11. Fuel System

To Remove and to Fit the Fuel Injection Pump Linkage

20A-10

Consumable Products: Platelock NOTE : The fuel injection pump linkage is contained within the timing case assembly. The linkage contains two lever assemblies, one for the governor control and one for the fuel control.

CAUTION : When the fuel injection pump linkage is removed/renewed, or a new timing case if fitted, the setting for the maximum fuel may be affected.

PU135

(C) 1. Remove the timing case assembly., operation 15A-01.

To remove

2. Remove the nut, the spring washer and the flat washer from the shaft (A4) and remove the lever (A1) from the shaft.

3. Remove the brass plug (B1) from the side of the timing case (B2).

4. Remove the two spring clips (C5) that hold the levers (C3) and (C4) in position. Remove the outer shaft (C1) that retains the inner shaft (C2).

Remove the inner shaft.

5. Remove the governor control lever assembly (C3) and the fuel control lever assembly (C4). Check the components for wear and renew as necessary, operation 20A-10A.

PU131

(A)

PU134

(B)

Engine

123

2.11. Fuel System

To Renew The Fuel Injection Pump Linkage

NOTE : The fuel injection pump linkage is contained within the timing case assembly. The linkage contains two lever assemblies, one for the fuel control (A) and one for the governor control (20A.20/A).

20A-10A

Consumable Products: Platelock

CAUTION : When the fuel injection pump linkage is removed/renewed, or a new timing case is fitted, the setting for the maximum fuel may be affected.

To dismantle the fuel control lever assembly 1. Remove the fuel injection pump linkage, operation 20A-10.

2. Disconnect the spring (A3) from the pegs (A1/A2).

3. Remove carefully, the spring (B3) from the Angleich (torque control) unit (B1).

PU138

4. Remove the angleich unit.

(A)

5. Inspect the components for wear and renew as necessary.

To Assemble the Fuel Control Lever Assembly CAUTION : Ensure that adhesive does not enter the joint line (C2).

1. Apply a small amount of POWERPART Platelock to the first two threads (C1) and fit the Angleich unit to the lever. Tighten the Angleich unit to 18 N•m (13 lb•ft) 1.3 kg•m.

PU139

(B)

2. Fit carefully, the spring to the Angleich unit. Ensure that the closed coils (B3) are towards the arm (B2).

3. Fit the spring (a3) to the pegs (A1/A2).

PU142

(C)

Engine

124

2.11. Fuel System

To Fit

1. Clean and lubricate the shafts (A1) and (A2) with clean engine lubricating oil.

2. Fit the inner shaft (A1) and then the outer shaft (A2) into the timing case assembly until the inner shaft has just entered the lever assembly (A3).

3. Align the holes in the lever (B1) with the holes in the lever (B3). Continue to push the outer shaft into the timing case assembly until the inner shaft has passed through both the levers and into the boss (B2). Fit the clips (B4).

4. fit the plug (C1) with the sealing washer to the timing case (C2). Tighten the plug to 13 N•m (10 lb•ft) 1.3 kg•m.

PU136

(A)

5. Move the levers in both directions to ensure that there is no restriction to their movement.

6. Ensure that both ends of the spring (D5) are fitted securely to the levers and fit the lever (D1) onto the flat section (A3) of the shaft (D4).

CAUTION : Ensure that Loctite does not enter the bush (D2).

7. Apply a small quantity of Platelock to the threads of the shaft (B4). Fit the plain washer, the spring washer and the nut and tighten the nut to 10.5 N•m (8 lb•ft) 1.1 kg•m.

PU135-1

(B)

8. Operate the lever for the engine speed control to ensure that there is no restriction to movement.

9. Fit the timing case assembly, operation 15A-01.

PU134

(C)

PU131

(A) Engine

125

2.11. Fuel System

To Dismantle the Governor control Lever Assembly

4. Fit the circlip (B2). To check that it is fitted correctly in the groove, rotate the circlip.

5. Fit the fuel injection pump linkage, operation 20A-10.

PU141

(A) 1. Remove the circlip (B2) from the end of the pin (A3).

2. Compress the spring (a4) and remove the pin from the lever (A2).

3. Release the spring and remove it from the link (A1).

4. Remove the spring (A5) from the link.

5. Inspect the components for wear and renew as necessary.

To Assemble the Governor Control Lever Assembly

PU140

(B) 1. Fit the spring (B6) to the link (B1). Ensure the large hook is furthest from the lever (B3).

NOTE : The purpose of the large hook is to retain the governor link to the peg on the fuel control rack.

2. Fit the spring (B5) to the link.

3. Compress the spring and hold the link against the outside of the lever (B3) and insert the pin (B4).

Engine

126

2.11. Fuel System

The maximum fuel position of the fuel lever (and fuel control rack) is controlled by the adjustment screw fitted to the top of the timing case. The position of this screw is set at the factory and under normal conditions of operation, it must not be altered. if the timing case and fuel pump linkage are removed/renewed, the adjustment screw must be set to give the correct setting for maximum fuel.

To Record the Maximum Fuel Position of the Fuel Control Rack 20A-11 Special Tool: Lever clamp and rack setting tool

1. Disconnect and remove the return spring from the engine speed control lever.

CAUTION : Ensure that the components behind the ‘D’ plug are not damaged.

2. Remove the ‘D’ plug (A4) from the timing case (A1).

3. Remove the access plate (B1) from the cylinder block.

PU148

(A)

4. Put the tool into the timing case such that the end of the tool (C1) points downwards.

5. When the end of the tool (C2) is entered far into the timing case, rotate the tool counter-clockwise 90° (C5) to engage the lever (C3). The end of the tool (C6) should now be behind the lever (C8).

6. Tighten the adjustment screw (C4), finger tight, to compress the Angleich unit between the two levers. Ensure that the sides of the tool do not touch the bore (A1) for the ‘D’ plug.

PU029

NOTES : •The Angleich, is a spring loaded component.

•The levers (C7/C8) should be compressed between the end of the tool (A2/3).

•To ensure that the tool has compressed both the levers, move the tool backwards and forwards. The peg should move with the tool.

(B)

7. Remove the low-pressure fuel pipes and the fuel filter assembly.

PU143

(C) The two lever assemblies of the fuel pump linkage operate together to control the fuel settings and the governor control of the engine.

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127

2.11. Fuel System

8. Remove the electrical stop solenoid, operation 23D-01. Ensure that the joint is removed.

9. Fit the setting tool (A3) to the flange for the electrical stop solenoid.

CAUTION : during the setting procedure, ensure that the fuel control rack (B2) is held in the maximum fuel position.

10. Push (towards the rear of the engine) the tool (B3) and the rack (b2) to the maximum (excess) fuel position. With the rack held in this position, turn carefully the adjustment screw (B1) of the setting tool until the tip (A2) is felt to just touch the end of the rack (A1). Tighten the nut (B5) to lock the tool in this position.

PU144

(A)

11. Remove the clamp tool from the levers in the timing case.

12. Disconnect the governor link from the peg (B2) operation 20A-06, paragraphs 7, 8 and 9.

13. Remove the cap nut and record the setting position for the screws for the maximum fuel (C1), the high idle (C2) and the low idle (C3).

PU145

To Set the Adjustment Screw for the Maximum Fuel Setting

(B)

20A-11A

Special Tool: Lever clamp and rack setting too PD.254 Consumable products: Platelock Liquid gasket 1. Fit the timing case assembly, operation 15A-01.

2. Fit carefully, the clamp tool and tighten finger tight only, the screw to compress the two levers (D).

PU146

(C)

PU143

(D) Engine

128

2.11. Fuel System

CAUTION : during the setting procedure, ensure that the fuel control rack (B2) is held in the maximum fuel position (towards the rear of the engine).

3. Push the tool (B3) and the rack (B2) such that it just touches the tip of the setting tool (A2). The rack will now be in the maximum (excess) fuel position. With the rack and tool held in this position (C2) turn carefully the adjustment screw (C1) for the maximum fuel setting until it just touches the lever (D1).

4. Use a screwdriver (C3) to hold the adjustment screw (C5) in this position, and tighten the lock nut (C4) to 12 N•m 99 lb•ft) 1.2 kg•m.

PU144

(A)

5. Check that the rack and tool are still in the maximum fuel position (B).

6. Fit the sealing washer and the cap nut (C60 and tighten the cap nut to 12 N•m (9 lb•ft) 1.2 kg•m.

7. Set to their original settings, the adjustment screw for the high and the low idle speeds.

8. Carefully remove the clamp tool for the levers.

PU145

9. Apply liquid gasket to the side faces of the ‘D’ plug and fit the plug to the timing case.

(B)

10. Remove the setting tool and fit the electrical stop solenoid, operation 23d-01.

11. Fit the fuel filter assembly and the low pressure fuel pipes.

12. Check again that the governor link and springs are fitted securely and fit the access plate and joint.

13. Fit the return spring to the engine speed control lever.

PU147

(C)

14. Eliminate air from the fuel system, operation 20A07.

15. Connect the battery and control cables. Start the engine and check for oil leakage, the maximum no-load and idle speeds.

16. When the speeds are correct, seal against interference, the adjustment screws for the maximum no-load speed and the maximum fuel setting.

PU149

(D) Engine

129

2.11. Fuel System

2.11.7. Data and Dimensions Introduction NOTE : This information is given as a guide for personnel engaged on engine overhauls. The dimensions which are shown are those which are mainly used in the factory.

Fuel injection pump Make.....................................................................................................................Zexel PFR-KX in-line cassette type Direction of rotation ..............................................................................................................Clockwise from drive end Fuel pump code letters: -UA engines........................................................................................................................................................AJ, BJ -UB engines .......................................................................................................................................................CJ, DJ Code letters, see table below: Fuel lift pump Type ............................................................................................................................................................Diaphragm Method of drive....................................................................................Eccentric on camshaft for fuel injection pump.

Static pressure-no delivery...............................................................................42/70 kPa (6/10 lb/in2) 0.4/0.7 kg/cm2 Test pressure 75% of minimum static pressure0 ........................................................31 kPa (4.5 lb/in2) 0.32 kg/cm2 Atomisers Atomiser code letters -UA engines (two stage injection)............................................................................................................................UA -UB engines (single stage injection)........................................................................................................................UB Setting pressures for atomisers

Engine

Code

Set pressure (1) Bar (lb/in2) Mpa

Re-set pressure (2) Bar (lb/in2) Mpa

Stage one

Stage two

Stage one

Stage two

UA

UA

190(2793) 19.25

230(3381).23.3

200(2940)20.3

243(3572)24.6

UB

UB

120(1764)12.2

-

130(1911)13.2

-

(1) For original atomisers (2) For atomisers which have been overhauled (for example, fitted with new springs)

Engine

130

2.11. Fuel System

2.12. Cooling System

2.12.2. Thermostat

2.12.1. General Description

To Remove, to Fit and to Test

Coolant from the bottom of the radiator passes through the centrifugal coolant pump, which is fitted onto the front of the cylinder block to assist the flow of the coolant through the system.

The pump is driven by a "V" belt from the crankshaft pulley.

21A-01

To Remove

From the pump, the coolant passes into the front of the cylinder block.

The coolant then passes around the cylinders and up into the cylinder head.

The coolant leaves the cylinder head at the front and passes into the thermostat housing.

When the engine is cold the thermostat is fully closed and the coolant goes directly through a by-pass valve in the thermostat to the inlet side of the coolant pump. As the engine warms the thermostat begins to open and some of the coolant flows to the top of the radiator. The thermostat will open fully when the engine reaches the normal temperature of operation.

When the thermostat is open, the by-pass valve is closed and the coolant passes to the top of the radiator.

The thermostat maintains the correct engine temperature by a balance lf by-pass flow and full flow to the top of the radiator.

PU070

(A) 1. Drain the cooling system, operation 21A-04.

2. Release the clip (A1)from the outlet connection and remove the hose.

3. Release the two setscrews (A2)and remove the cap (A3) from the thermostat housing. Remove the thermostat (A4)

To Fit

Air passes over the radiator fins and heat is removed from the coolant as it passes through the radiator.

The coolant leaves the radiator the bottom hose and returns to the coolant pump.

1. Ensure that the seat in the thermostat housing for the thermostat is clean. Put the thermostat (A4) into position in the housing. Ensure that the jiggle pin (A5) is at the top, see the arrow in A, and is free to move.

2. Ensure that the joint faces of the housing and the cap are clean. Fit a new joint to the cap and fit the cap to the housing. Tighten the two setscrews to 22 N•m (16 lb•ft) 2.2 kg•m.

Ensure that the outlet connection is clean and fit the hose. Tighten the hose clip. Fill the cooling system, operation 21A-05.

To Test 1. Hang the thermostat unit in a suitable container filled with coolant.

2. Heat the coolant gradually. Use a thermometer to check the temperature at which the valve starts to open and at which it is fully open, The correct temperature is given in the Data and dimensions.

CAUTION : If the thermostat does not operate correctly, it must be renewed. Do not try to adjust the settings.

Engine

131

2.12. Cooling System

To Fit

2.12.2. Coolant Pump To Remove and to Fit

21A-02

To Remove

PU073

(C) 1. Thoroughly clean the mounting faces of the cylinder block, the spacer (C1) and the rear plate for the coolant pump.

PU071

(A)

2. Renew the “O” ring (C2) on each side of the spacer and fit the spacer.

3. Fit the coolant pump to the timing case and tighten the four nuts to 22 N•m (16 lb•ft) 2.2 kg•m.

4. Connect the hoses to the coolant pump and tighten the clips.

5. Put the pulley onto the hub and the fan extension onto the pulley and fit the fan, operation 21A-03.

6. Fit the drive belt, operation 23A-03.

PU172

(B)

7. Fill the cooling system, operation 21A-05.

1. Drain the cooling system, operation 21A-04.

2. Remove the drive belt, operation 23A-03.

3. Remove the fan, operation 21A-03, the fan extension and the pulley.

4. Release the hose clips (A1). Remove the hoses from the coolant pump.

5. Remove the four nuts (A2) that fasten the pump to the cylinder block and remove the pump (B1) from the engine.

6. Remove the spacer (B2).

Engine

132

2.12. Cooling System

2.12.3. Fan To Remove and to Fit

21A-03

To Remove Release the four setscrews and remove the fan. If necessary, fit the setscrews to retain the fan extension and the pulley to the hub.

To Fit Clean thoroughly the rear of the fan where it fits onto the fan extension.

Also ensure that all paint is removed form this area.

Put the pulley into position on the hub and the fan extension onto the pulley.

Clean the front face of the fan extension. Fit the fan and tighten the setscrews to 22 N•m (16 lb•ft) 2.2 kg•m.

Engine

133

2.12. Cooling System

To Fill

2.12.4. Cooling System To Drain

21A-04

WARNING WARNING

•If coolant is to be added to the system during service, allow the engine to cool before the dangerous hot coolant could be discharged if the cooling system is still under pressure.

•Do not put too much coolant in the cooling system. There is a relief valve in the filler cap which will open and release hot coolant if too much coolant is added.

•Do not drain the coolant while the engine is still hot and the system is under pressure because dangerous hot coolant can be discharged.

•Discard used coolant in a safe place and in accordance with local regulations.

CAUTIONS : •If coolant is to be added to the system during service, it must be of the same specification as the original that was used to fill the system. See “Coolant specification” in section 5 of the users•‹s handbook.

•Air will remain in the system if coolant is added too quickly, or if coolant is added when the machine is not on a horizontal surface.

•If the engine is operated with air in the system, the temperature of operation will be too high and the engine will be damaged.

PU010

1. Ensure that the machine is on a horizontal surface.

(A) 1. Ensure that the machine is on a horizontal surface.

2. Slowly remove the filler cap of the header tank.

2. Remove the filler cap of the cooling system.

3. Slowly fill the cooling system to the correct level as shown in the manufacturers handbook for the application. Allow time for air bubbles to be released from the system and fit the cap.

3. Remove the drain plug (A1) from the side of the cylinder block in order to drain the engine. Ensure that the drain hole is not restricted.

4. Start the engine. When it has reached its normal temperature of operation, stop the engine and allow it cool.

4. Open the tap or remove the drain plug at the bottom of the radiator in order to drain the radiator.

If the radiator does not have a tap or drain plug, disconnect the hose at the bottom of the radiator.

5. Slowly remove the filler cap of the header tank and if necessary, add coolant to the correct level as shown in the manufacturers handbook for the machine. Fit the filler cap.

5. Flush the system with POWERPART Easy Flush.

6. Fit the drain plug and the filler cap. Close the radiator tap or connect the radiator hose.

Engine

134

2.12. Cooling System

2.12.5. Data and Dimensions Introduction NOTE : This information is given as a guide for personnel engaged on engine overhauls. The dimensions which are shown are those which are mainly used in the factory.

Cooling System Type..............................................................................................................Thermostat controlled- pump assistance Water pump Type..........................................................................................................................................Centrifugal, belt driven Thermostat Type .............................................................................................................................................Single, wax element Nominal temperature stamped

"Start to open"

"Fully open"

Minimum valve lift,

on the base of the by-pass valve

temperature

temperature

fully open

82.0°C (179.6°F)

77/85°C (173.6/185.0°F)

92/98°C (197.6/208.4°F)

9mm (0.35 in)

71.0°C (159.8°F)

67/75°C (152.6/167.0°F)

85/88°C (185.0/190.4°F)

9mm (0.35 in)

Engine

135

2.12. Cooling System

2.13.1. General Description

1. Remove two opposite setscrews from the flywheel and fit temporarily two guide studs to ensure safety when the flywheel is removed and fitted.

The flywheel is fitted with a hardened starter ring.

The flywheel housing is normally made of cast iron.

2. Remove the remainder of the setscrews and washers and remove the flywheel.

2.13. Flywheel and Flywheel Housing

3. Check the flywheel and ring gear for damage and renew, if necessary.

2.13.2. Flywheel To Remove and to Fit

To Fit

22A-01

1. Ensure that the location faces of the crankshaft and the flywheel are clean and free from damage.

Consumable Products: Retainer (oil tolerant)

2. Fit temporarily two guide studs in opposite holes in the crankshaft palm to ensure safety when the flywheel is fitted. Fit the flywheel over the guide studs. Apply retainer (oil tolerant) to the first three threads of the setscrews and fit four setscrews and their washers. Remove the guide studs and fit the remainder of the setscrews and the washers.

Tighten the setscrews to 100 N•m (74 lb•ft) 10.2 kg•m.

WARNING The flywheel is very heavy, use lift equipment or get assistance with the lift operation before removal of the flywheel fasteners.

To Remove

3. Check the flywheel run-out with a dial test indicator (A). This must be less than 0.30 mm (0.012 in) total indicator reading.

4. Check the alignment of the flywheel face (B).

The error in alignment must not be more than 0,03 mm (0.001 in) total indicator reading for every 25mm (1.0 in) of the flywheel radius from the crankshaft axis to the indicator plunger. During this operation, keep the crankshaft pressed toward the front to remove the effect of crankshaft end-float.

PA279

(A)

PA280

(B)

Engine

136

2.13. Flywheel and Flywheel Housing

To Fit

2.13.3. Ring Gear To Remove and to Fit

1. Ensure that the rear face of the cylinder block and the faces of the housing are clean and free from damage. Ensure that the location dowels are fitted correctly.

22A-02

To Remove

2. Fit the housing onto the dowels and tighten the setscrews and the two cap screws to 44 N•m (32 lb•ft) 4.5 kg•m.

WARNING Wear eye protection during this operation.

3. Fit the flywheel, operation 22A-01 and the starter motor, operation 23B-01.

CAUTION : To ensure that the new ring gear is fitted correctly, record the direction of the chamfer of the gear teeth. Fit the new gear with the chamfer in the same direction.

To remove the ring gear, use a hammer and a chisel to break the ring. Ensure that the flywheel is not damaged during this operation.

To Fit The ring gear is heated onto the flywheel. When a new gear is to be fitted, ensure that it is not heated to more than 250°C (480°F). Ensure that the chamfer on the teeth of the gear is in the correct direction.

2.13.4. Flywheel Housing To Remove and to Fit

22A-03

WARNING The flywheel housing is heavy, use lift equipment or get assistance with the lift operation before removal of the flywheel housing fasteners.

To Remove 1. Remove the starter, operation 23B-01, and the flywheel, operation 22A-01.

2. Release the six setscrews and the two cap screws. Carefully hit the housing, with a soft face hammer, to remove it from the dowels.

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137

2.13. Flywheel and Flywheel Housing

2.14. Electrical Equipment 2.14.1. Alternators General Description The alternator is driven from the crankshaft pulley by a single belt.

The Magneti Marelli A127 alternator has a solid state regulator fitted at the rear. The regulator of the Magneti Marelli A 127 alternator includes the brush box as a part of the unit. The regulator is sealed and repair is not possible.

Precautions To prevent damage to the diodes and to the resistors, the precautions given below must be followed: •Do not disconnect the battery while the engine is in operation. This will cause a voltage surge in the alternator charge system which will immediately cause damage to the diodes or to the transistors.

•Do not disconnect an electrical wire before the engine is stopped and all electrical switches are in the "off" position.

•Do not cause a short circuit by the connection of electrical connections to the wrong terminals.

The correct electrical wire must be connected to the correct terminal. A short circuit or wrong connection which gives reverse polarity will immediately cause permanent damage to the diodes and to the transistors.

•Do not connect a battery into the system until it has been checked for correct polarity and voltage.

•Do not check for current flow with a spark contact as damage can be caused to the transistors.

Engine

138

2.14. Electrical Equipment

To Remove and to Fit

Drive Belt To Check

23A-03

1 Loosen the pivot fastener (A3) of the alternator and the adjustment link setscrew (A2).

23A-01

2 Release all of the tension from the belt and remove the belt.

3 Fit the new belt and adjust the tension, operation 23A-02.

PU011

(A) 1. Renew the belt if it is worn or damaged.

2. The condition of the belt should be checked at the intervals shown on page 4.03 in the user's handbook. The belt should be renewed if there are cracks in the belt or if the belt is contaminated by oil or grease.

3. To check the tension, press the belt with the tnumb (A) at the centre of the longest free length pressure 45 N (10 lb) 4.5 kg the correct deflection of the belt is 10 mm(3/8 in).

To Adjust Tension

23A-02

CAUTIONS : •The alternator fitted to the 700 Series engine is driven by a drive belt of a specific design. Use only a Perkins drive belt. If this is not done, an early failure of the belt may occur.

•Do not loosen the setscrew (A1). If this setscrew is loosened, the thermostat housing to cylinder head seal could be broken and result in a leakage of coolant.

1. Loosen the pivot fastener (A3) of the alternator and the setscrew (A2) of the adjustment link.

2. Change the position of the alternator to give the correct tension. Tighten the adjustment link fastener and then the pivot link fastener.

3. Check the belt tension again to ensure that it is still correct.

NOTE : If a new belt is fitted, the belt tension must be checked again after the first 25 hours of operation.

Engine

139

2.14. Electrical Equipment

To Maintain

Alternator To Remove and to Fit

23A-05

1. Ensure that the drive belt is not worn and that the belt tension is correct.

23A-04

2. Keep the alternator clean. to clean the alternator, use a material which is damp with kerosene or a special fluid used for this purpose. Ensure that the fluid does not enter the cover of the alternator.

To Remove

3. Ensure that air can pass easily over the casing to keep it cool.

PU011/1

(A) 1. Disconnect the electrical connection.

2. Loosen the pivot fastener (A3) of the alternator and the setscrew (A2) of the adjustment link.

3. Release all the belt tension and remove the belt.

CAUTION : Do not loosen the setscrew (A1). If this setscrew is loosened, the thermostat housing to cylinder head seal could be broken and result in a leakage of coolant.

4. Remove the setscrew (A2) from the adjustment link and the pivot bolt from the alternator. Make a note of the position of any washers and distance pieces to ensure that they are fitted correctly.

Remove the alternator.

To Fit 1. Put the alternator in position and assemble loosely the pivot bolt (A3) and the screw (A2) in the adjustment link. Ensure that any washers and the distance pieces are fitted in their correct positions and that the alternator pulley is aligned to the crankshaft pulley within +/- 2,4 mm (3/32 in).

2. Fit the drive belt and adjust the drive belt tension, operation, 23A-02. Tighten the fasteners and check the tension again.

3. Connect the electrical connection.

Engine

140

2.14. Electrical Equipment

Any change in the above data can indicate a fault and the procedure that follows should be used before any components are disconnected. This procedure is not suitable for alternators and, if a fault is found, the alternators should be removed for test by a specialist.

Fault Diagnosis The operation of the alternator is correct when a flow of current (indicated by no light at the warning light or a reading shown on an ammeter) shows that the system is in correct operation, no open circuit, voltage, or current output checks need to be done on the installation unless:

The regulator is a sealed unit and a repair is not possible. If there is a regulator fault, the regulator must be renewed.

•The warning light is not illuminated when the alternator is stationary and the switch is in the "on" position, or it is illuminated when the alternator is in operation.

•No charge current is shown on the ammeter.

•The battery is discharged.

•The battery is hotter than normal which is an indication of loss of voltage control.

If the warning light is not illuminated when the switch is in the "on" position: Check the bulb.

If no fault:

If one or more of the above symptoms occur, the procedure indicated below should be applied.

Check all the connections at the regulator, at the alternator and at the battery.

1. Ensure that the battery is fully charged.

If no fault:

2. Connect a moving-coil voltmeter of good quality, with a range of 0-50 volts, across the positive and negative terminals of the alternator. If an ammeter is not fitted in the electrical circuit, fit a moving-coil ammeter of good quality, with a range of 0-100 ampere, in the wire between the alternator and the positive terminal of the battery.

Turn the switch to the "off" position. Disconnect the wire from the "F" terminal on the alternator and connect a wire between the "F" terminal and the negative terminal on the alternator. Turn the switch to the "on" position.

3. Move the warning light switch to the "on" position (main switch on instrument panel); the warning light should be illuminated.

If the warning light continues to show and the ammeter shows no output when the alternator is in operation:

4. Switch on a 10-15 ampere load, for example, lights, fans, etc.

Check all the connections at the regulator, alternator and battery.

5. Start the engine and operate it at a fast idle speed; either the warning light should be extinguished or the ammeter indicates a small change in the current in relationship to the engine speed.

If no fault:

If the warning light shows, the fault is in the regulator.

Turn the switch to the "off" position. Disconnect the wire form the "F" terminal on the alternator and connect a wire between the "F" terminal and the negative terminal on the alternator. Turn the switch to the "on" position and operate the engine at fast idle.

6. Increase the engine speed for a moment to near maximum speed, when the charge current should be approximately equal to the rating for the alternator, as shown in the data and dimensions.

If there is no output, there is a fault in the alternator.

If there is an output, there is a fault in the regulator.

7. Operate the alternator at approximately half speed (engine speed approximately 1500 rev/min) and remove the electrical load. The voltage should go up to 14 volts for a 12 volt system or 28 volts for a 24volt system and then remain constant. At the same time the current reading should show a reduction

Engine

141

2.14. Electrical Equipment

If the warning light continues to show when the alternator is in operation and the ammeter shows a reduced output with maximum output only at maximum engine speed or if the warning light does not show, but there is a reduced output from the alternator with maximum output only at maximum engine speed:

Technical Data Introduction NOTE : This information is given as a guide for personnel engaged on engine overhauls. The dimensions which are shown are those which are mainly used in the factory.

There is a fault in the alternator.

If there is an intermittent light from the warning light and the ammeter needle is not stationary when the battery is charged fully and no load is applied:

Electrical Equipment Alternator

Check for a higher than normal resistance in the negative control wire of the regulator.

Make ....................................Magneti Marelli A 127-65 Rating ............................................................12V/65A

If the resistance is normal, there is a fault in the regulator.

If the battery charge is too high and the ammeter indicates high or maximum output at all times: Check the positive control wire and its connection at the regulator.

If the wire and its connection are correct, there is a fault in the regulator.

Engine

142

2.14. Electrical Equipment

2.14.2. Starter Motors

To test on the Engine

General Description

Ensure that the battery is fully charged.

Turn on the lights and operate the starter switch. if no lights are fitted to the machine, connect a voltmeter across the battery terminals and operate the starter switch.

The Magneti Marelli starter motor is operated by a solenoid and has a six roller clutch.

The solenoid engages the starter drive in two operations to ensure that the motor gets its maximum torque only when the starter motor is engaged fully with the flywheel. The clutch prevents rotation of the armature at high speed if the starter is held in the engaged position.

23B-03

If the starter does not operate but the lights keep their power or there is no voltage drop across the battery, check the switch and all the connections and wires. Slow action of the starter can be caused by faulty connections.

Consumable Products: Hylosil

Failure to engage smoothly between the starter and the flywheel can be caused, on some types of starter motor, by dirt on the helical grooves of the starter motor drive, which can prevent free pinion movement. Clean the shaft thoroughly with gasolene, or a fluid made especially for the purpose, and apply a small quantity of Aero shell 6B or its equal.

To Remove

Technical Data

1. Disconnect the battery.

Introduction

2. Disconnect the starter motor cables.

3. Release the fasteners and remove the starter motor and, if one is fitted, the distance piece.

NOTE : This information is given as a guide for personnel engaged on engine overhauls. The dimensions which are shown are those which are mainly used in the factory.

To Fit

Electrical Equipment

1. If one is fitted, put the distance piece in position with its location lip to the flywheel housing. Fit the starter motor and tighten the fasteners.

Starter Motor

Starter Motor To Remove and to Fit

23B-01

Make .......................................Magneti Marelli 2M113 Voltage...................................................................12V Number of teeth on pinion .......................................10 Maximum starter cable resistance at 20°C (68°F)...........................................0.0012 ohm

2. Connect the starter motor cables.

3. Connect the battery.

To Maintain the Brush Gear and the Commutator

23B-02

Starter motor Repair of this starter motor is difficult. If necessary, remove the starter motor for specialist repair.

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143

2.14. Electrical Equipment

2.14.3. Starting Aid

1. Disconnect the battery.

General Description

2. Remove the pipe work to the induction manifold.

Remove the engine breather pipe. Release the setscrews for the induction manifold and remove the manifold and the gasket. Discard the gasket.

The starting aid for these engines consists of a set of glow plugs, one for each cylinder. The glow plugs used on UA and UB engines are different.

The glow plugs are fitted in the cylinder head neat to the atomisers.

The tip of the glow plugs reaches into the combustion chamber in the piston crown of UA engines or the pre-combustion chamber of UB engines.

The glow plugs are operated electrically, usually through the start switch. When the glow plugs are energised, their tip become very hot and improve the combustion process during cold start conditions.

3. Remove the nut (A1) from the terminal on the glow plug. Remove the electrical connections(A2) from the glow plug.

4. Release and remove the glow (B1).

To Fit

Glow Plugs To remove and to fit a glow plug 23C-01 NOTE : In order to remove the glow on the UA engine, some types of induction manifold will have to be removed first. The induction manifolds fitted to UB engines need not be removed.

To Remove PU035

(C) CAUTIONS : •Ensure that the cables for the glow plug does not contact the high-pressure fuel pipes. On early engines, bend the connections (A2) away from the high-pressure pipes after the cables have been fitted. If this is not done, it is possible for a short circuit to occur between the connection and the high-pressure pipe.

•Later engines are fitted with a cable (C) which has a terminal (C1) that is already bent to the correct shape.

PU082

(A)

1. Fit the glow plug (B2): sealant is not necessary.

Tighten it to 17 N•m (12.5 lb•ft) 1.7 kg•m.

2. Put the electrical connections (A2) in position, ensure that there is no contact with other components.

PU083

(B) Engine

144

2.14. Electrical Equipment

4. Connect the test lamp between the terminal of the glow plug, which is furthest away from the power supply, and earth. Operate the control switch and the test lamp should be illuminated if the power supply is correct.

For UA engines: fit the cable with the straight connection (A1) toward the front of the engine .

For UB engines: fit the cable with the straight connection (A1) toward the rear of engine 3. Fit and tighten the nuts for the terminals to 1.2 N•m (10.2 lb•in) 11.7 kg•cm.

5. Disconnect the cable at each glow plug.

6. Connect the test lamp to the positive terminal of the battery and to the terminal of a glow plug. The lamp will be illuminated if the continuity is correct.

If the test lamp is not illuminated, renew the glow plug.

4. To ensure correct alignment of the induction manifold, fit two guide studs. Fit a new gasket without jointing compound: the gasket may be fitted either way around. Put the manifold in position on the guide studs. Fit the inner setscrews and remove the guide studs. Fit the outer setscrews. Tighten the setscrews to 22 N•m (16 lb•ft) 2.2 kg•m.

7. When all of the glow plugs have been checked, connect the cables to the glow plugs.

5. Fit the engine breather pipe between the rocker cover and the induction manifold.

Fit the pipe work between the induction manifold and the air filter.

To Check the Operation of Glow Plugs

1. Disconnect the power supply cable and the connection cable from the terminals of the glow plugs.

6. Connect the battery.

To check Power Supply and Continuity

23C-03

2. Connect a 50-0-50 ammeter between the power supply cable and the terminal of a glow plug.

Connect a voltmeter between the glow plug terminal and earth.

23C-02

1. Disconnect the glow plug connection.

3. Engage the control switch and check the readings of the ammeter and the voltmeter. With a 12 volt supply, there should be an initial current of approximately 12.5 amperes, which should reduce to approximately 7 L 1 amperes after 30 seconds for UA engines. For UB engines, the initial current should be approximately 12.5 amperes, which should reduce to approximately 6.5 L 1 amperes after 30 seconds.

If the ammeter reading is low or there is no reading, renew the glow plug. If there is no voltmeter reading, check the switch and the power cable.

2. Apply one probe of a multi, which can check continuity, to the terminal of the glow plug and apply the other probe to a suitable earth. If the continuity is correct the multi-meter will give an audible signal. If there is no audible signal, renew the glow plug. Repeat this check for all of the glow plugs.

4. When all of the flow plugs have been checked, remove the ammeter and the voltmeter and connect the power supply cable. Check that the glow plugs have been connected correctly.

PU035

(A) 3. If a multi-meter is not available, connect a 12V test lamp between the positive of the battery and earth to check that the lamp will light.

Engine

145

2.14. Electrical Equipment

Technical Data

2.14.4. Electrical Stop Solenoid

Introduction

General Description

NOTE : This information is given as a guide for personnel engaged on engine overhauls. The dimensions which are shown are those which are mainly used in the factory.

The electrical stop solenoid is fitted to the cylinder block at the rear of the fuel injection pump. The plunger of the solenoid operates on the rack of the fuel pump. When energised, the stop solenoid allows the rack to move to the excess fuel position for starting.

Electrical Equipment Starting aid Type............................................................Glow plugs Current: -UA ...............................7.0 amperes after 30 seconds -UB ...............................6.5 amperes after 30 seconds

PU102

(A) To Remove and to Fit the Electrical Stop Solenoid

23D-01

To Remove 1. Disconnect the electrical connections (A1).

2. Release the two setscrews (A4)and remove the stop solenoid (A2). Discard the joint (A3).

To Fit 1. Put a new joint (A3) in position on the flange of the stop solenoid.

2. Fit the solenoid (A2) to the cylinder block (A5).

3. Fit the two setscrews (A4) and tighten them to 9 N•m (6.6 lb•ft) 0.92 kg•m.

4. Connect the electrical connections.

Engine

146

2.14. Electrical Equipment

Technical Data

2.15. Auxiliary Equipment

Introduction

2.15.1. General Description

NOTE : This information is given as a guide for personnel engaged on engine overhauls. The dimensions which are shown are those which are mainly used in the factory.

Power take-off is provided from the left hand side of the timing case through an auxiliary drive assembly.

The power take-off assembly is driven by the camshaft gear. The assembly consists of a drive shaft with an integral helical gear and an internal spline to drive the auxiliary equipment. Shaft assemblies are supplied with either nine, ten or eleven tooth splines. A ball bearing is fitted to the front of the drive shaft, a roller bearing is fitted to the rear of the shaft.

Electrical Equipment Electrical Stop Solenoid Current: -Pull in ....................................................36.5 amperes -Hold............................................................1 amperes Voltage.............................................................12 Volts Cable Identification (colour) -Pull in ................................................................White -Hold ......................................................................Red -Earth...................................................................Black

Engine

147

2.15. Auxiliary Equipment

To Fit

2.15.2. Power Take-off Assembly To remove and to Fit

24A-01

Consumable Products: Gasket eliminator

To Remove

PU086

(C)

PU084

(A)

PU087

(B) 1. Clean the recess (C2) in the timing case for the ball bearing and clean the outer race of the ball bearing (C1).

2. Lubricate the recess in the timing case for the ball bearing with clean engine oil. Fit the ball bearing and shaft assembly into the timing case.

PU085

3. Clean the backplate of the timing case and the front face of the fear housing.

Fit a new "O" ring (B3) to the rear housing.

Lubricate the "O" ring with clean engine oil.

(B) 1. Remove the two setscrews (A1) and the two nuts (A5) from the bolts (A4). Support the rear housing (A3) and remove the front cover (A2) together with the two bolts (A4).

4. Apply a 2 mm bead of gasket eliminator to the flange face (D1) of the front cover plate.

5. Fit the front cover plate together with the two bolts (A4). Put the tear housing complete with roller bearing and "O"fing onto the bolts. Move the housing into position against the backplate of the timing case and fit the two setscrews through the front cover. Tighten the setscrews finger tight only.

2. Remove the rear housing complete with its roller bearing (B2), the "O" ring (B3) and the cover.

3. Push the shaft (B1), together with the ball bearing on the front of the shaft, out through the front of the timing case.

6 Fit the rear cover to the housing complete with a new gasket. Fit and tighten the two nuts to 44 N•m (32 lb•ft) 4.4 kg•m.

7. Tighten the setscrews gradually and evenly to 22 N•m to (16 lb•ft) 2.2 kg•m.

Engine

148

2.15. Auxiliary Equipment

To Dismantle and to Assemble

To Assemble

24A-02

1. Press the cup (A3) fully into the drive shaft.

To Dismantle

2. Support the spline end of the drive shaft (A4) and press the ball bearing (a5) fully onto the shoulder of the shaft. Fit the spacer (A2). Fit the circlip (A1).

3. Clean the recess in the front of the rear housing (B3) and the outer race of the roller bearing (B2).

Lightly lubricate the recess and press in the roller bearing onto the shoulder of the recess.

PU088

(A)

PU089

(B) 1. Remove the circlip (A1) that retains the ball bearing (A5). Remove the spacer (A2).

Support the ball bearing and press the shaft (A4) out of the ball bearing.

2. Remove the "O" ring (B1). Support the front face of the rear housing (B3) and press the roller bearing (B2) out of the housing.

3. Press the cup(A3) out of the front of the drive shaft.

Engine

149

2.15. Auxiliary Equipment

2.15.3. Technical Data Introduction NOTE : This information is given as a guide for personnel engaged on engine overhauls. The dimensions which are shown are those which are mainly used in the factory.

Auxiliary Drive Power Take-off Number of teeth on helical gear...............................................................................................................................24 Number of splines in drive shaft ..................................................................................................................9.10 or 11 Outside diameter of shaft for ball bearing ......................................................35.002/35.013 mm (1.3780/1.3785 in) Outside diameter of shaft for roller bearing .........................................................31.96/31.99 mm (1.2583/1.2594 in) Nominal inside diameter of ball bearing ..............................................................................................35 mm (1.378) Nominal inside diameter of roller bearing ............................................................................................32 mm (1.260) Bore of recess in timing case for ball bearing .....................................................80.00/80.03 mm (3.1496/3.1508 in) Bore of recess in rear housing for roller bearing ........................................................52.00/52.03 (2.0472/2.0484 in) Nominal outside diameter of ball bearing ............................................................................................80 mm (3.149) Nominal outside diameter of roller bearing ......................................................................................52 mm (2.047 in)

Engine

150

2.15. Auxiliary Equipment

2.16. List of Special Tools Tool number

Part number

Description

PD.1D

21825478

Remover/replacer for valve guides

PD.1D/2

21825480

Spacer used with main tool PD.1D

PD.1D-13

27610019

Adaptor for use with PD.1D

PD.41D

21825496

Gauge for piston height and valve depth

PD.170

21825577

Replacer tool for front oil seal (main tool)

PD.184

21825589

Slide hammer

PD.208

21825617

Dial gauge for use with PD.41D

PD.243

27610013

Rubber plug replacer tool

PD.244

27610016

Adapter for PD.6118B

PD.249

27610017

Adaptor for valve guide depth, used with PD1D.13

PD.254

27610018

Kit, governor arm lock consists of tools to measure rack movement

PD.255

27610021

Replacer tool for rear oil seal, use with MS.550

PD.256

27610022

Replacer tool for idler gear hub, use with MS.550

PD.258

27610025

Adaptor/remover Idler hub for use with PD.184

PD.259

27610026

Adaptor, main tool to crankshaft nose, for use with PD.170

PD.260

27610027

Adaptor for front seal, for use with PD.170

PD.6118B

21825666

Valve spring compressor

MS.76A

211825938

Set of adjustable cutters for valve seats

MS.550

21825639

Universal drive handle

MS.1519A

27610020

Valve spring compressor

NO.8

21825491

Piston ring compressor

Engine

151

2.16. List of Special Tools

3. VEHICLE 3.1. Specifications 3.1.1. Dimensional & Performance Specifications

• Dimensional Specifications Q

R

T G

S

F

O

K

M

A B

L

C I

N U

J H

P

E D

IGAT001I

Item • Overall Height A. Fully Raised B. To Hinge Pin C. To Canopy • Overall Length D. With Bucket E. Less Bucket • Overall Width F. With Bucket G. Less Bucket • Others H. Wheel Base I. Height of S.I.P. J. Ground Clearance T. Tread U. Departure Angle

Vehicle

Unit

Spec.

in(mm) in(mm) in(mm)

152.8 (3880) 119.1 (3026) 79.3 (2015)

in(mm) in(mm)

125.1 (3177) 98.7 (2508)

in(mm) in(mm)

67.5 (1714) 65.4 (1662)

in(mm) in(mm) in(mm) in(mm) deg

42.0 (1066.5) 40.9 (1040) 8.6 (218) 53.1 (1350) 28°

Item • Dumping K. Dump Angle L. To Hinge Pin • Reach M. Fully Raised • Rollback N. Max. at Ground O. Max. Fully Raised • Digging P. Digging Depth • Clearance (Circle) Q. Front, Less Bucket R. Front, With Bucket S. Rear

153

Unit

Spec.

deg in(mm)

40° 91.5 (2323)

in(mm)

22.5 (572)

deg deg

26° 98°

in(mm)

0.4 (10)

in(mm) in(mm) in(mm)

45.1 (1146) 74.1 (1883) 62.7 (1593)

3.1. Specifications

Maximum Rollback (O) - Fully Raised - The angle in degrees from the bucket cutting edge level position to the maximum rollback position.

Definitions : (Daewoo Skid Steer Loader) Refer to sketches on previous page.

Digging Depth (P) - The vertical distance in inches (millimeters) from the ground to the bottom of the bucket cutting edge at the lowest position with the bucket cutting edge horizontal.

Overall Operating Height (A) - Fully Raised - The vertical distance in inches (millimeters) from the ground to the highest point attainable.

Height to Hinge Pin (B) - Fully Raised - The vertical distance in inches (millimeters) from the ground to the centerline of the bucket hinge pin.

Loader Clearance Circle (Q) - Front No Attachment - The smallest diameter measured in inches (millimeters) that the outermost front point on the machine will describe measured from a point located at 1/2 the wheelbase (H) and 1/2 the overall width (G) of the machine.

Overall Height (C) - The vertical distance in inches (millimeters) from the ground to the highest point on the unit with the bucket on the ground.

Overall Length (D) - The horizontal distance in inches (millimeters) with the bucket on the ground and level, measured from the foremost point of the bucket cutting edge to the rear most point of the machine.

Loader Clearance Circle (R) - Front with Standard Attachment - The smallest diameter measured in inches (millimeters) that the outermost front point on the machine will describe measured from a point located at 1/2 the wheelbase (H) and 1/2 the overall width (G) of the machine.

Overall Length (E) - Without Bucket - The horizontal distance in inches (millimeters) from the furthest rearward to the furthest point forward.

Loader Clearance Circle (S) - Rear - The smallest diameter measured in inches (millimeters) that the outermost rear point on the machine will describe measured from a point located at 1/2 the wheelbase (H) and 1/2 the overall width (G) of the machine.

Bucket Width (F) - The maximum outside width in inches (millimeters) of the bucket specified.

Overall Width (G) - The maximum outside width in inches (millimeters) of the machine specified exclusive of bucket.

Tread or Track Gauge (T) - The transverse distance in inches (millimeters) between the centerlines of the tires or sprockets. If the front and rear are different, both must be specified.

Wheelbase (H) - The vertical distance in inches (millimeters) from the center of the front wheel or idler to the center of the rear wheel or sprocket.

Angle of Departure (U) - The angle in degrees taken from a line drawn from the lowest and rear most portion of the rear overhang to the rear bottom face of the rear tire to the ground.

Height to S.I.P. (I) - The vertical distance in inches (millimeters) from the ground to the Seat Index Point.

Ground Clearance (J) - The minimum vertical distance in inches (millimeters) from the ground to the lowest point on the machine between the tires or tracks with the lift arm raised.

Dump Angle (K) - The maximum angle in degrees that the longest flat section of the inside bottom of the bucket will rotate below horizontal with the bucket hinge pin at maximum height.

Dump Height (L) - The vertical distance in inches (millimeters) from the ground to the lowest point of the cutting edge with the bucket hinge pin at maximum height and the bucket at a 45° dump angle. The angle is less than 45°, specify angle.

Reach (M) at Maximum Height - The horizontal distance in inches (millimeters) from the foremost point on the machine (including tires, tracks, or loader frame) to the front most point on the bucket cutting edge at a 45° angle with the bucket hinge pin at maximum height. Specify angles less than 45°.

Maximum Rollback (N) - at Ground - Maximum rollback angle in degrees without movement of the lift arm.

Vehicle

154

3.1. Specifications

Specification • Performance (Per SAE J732 Feb 80)

Final Drive Components

Performance

Item • Chain

Item • Rated Capacity • Bucket Capacity (Dirt-60”) • Operating Weight • Tipping Load • Hydraulic Lifting Capacity • Break Out Force -Bucket -Boom

• Boom

• Raising Time-W/O Load -W/ Load • Lower Time -W/O Load -W/ Load • Dump Time -W/O Load -W/ Load • Rollback Time-W/O Load -W/ Load • Drawbar Pull -W/O Load -W/ Load

• Travel Speed • Forward • Reverse

Unit

Spec.

lb(kg) ft3(m3) lb(kg) lb(kg) lb(kg) lb(kg) lb(kg)

1700 (771) 13.5 (0.38) 6636 (3010) 3444 (1562) 5302 (2405) 2910 (1320) 4222 (1915)

sec sec sec sec sec sec sec sec lb(kg) lb(kg)

3.65 3.85 3.94 3.54 2.62 2.57 1.95 2.27 5399 (2449) 6300 (2858)

mph(km.h) mph(km/h)

6.8 (11.0) 6.8 (11.0)

• No. of Teeth • Drive Sprocket (Motor) • Counter Sprocket • Drive Sprocket (Axle) • Ratio • Tire • Type • Size • Pressure • Wheel • Size • Hole x Pitch Circle Diameter

• • • • • • • • • • • •

Make Model Type of Fuel Cooling Method No. of Cylinders Displacement Bore Size Stroke Horsepower Net High Idle Low Idle Torque

• Torque Rise • Lubrication

Vehicle

Spec.

-

3 Chain with Super #80 & #100

each

14

each each

35 & 11 27 6.14

-

Floatation-Tubeless

psi (kg/cm2)

12-16.5, 8PR 40(2.8)

-

9.75 x 16.5 8 x 8”

Hydrostatic Transmission Pump

Power Unit

Item

Unit

Unit

Item

Spec.

• Type

Perkins 704-30 Diesel Water each 4 3 in (cc) 180.3 (2955) 3.82 (97.0) in(mm) 3.94 (100.0) in(mm) hp(ps)/rpm 62.4(63.2)/2500 rpm 2715 ± 30 rpm 800 ± 30 ft•lb(kg.m)/rpm 154.9 (21.4)

% -

• • • • • • •

17.9 Full Flow

155

Unit

Spec.

Piston, Variable Displacement Max. Displacement 2.68 (44) in3(cc)/rev Relief Setting Pressure psi 4000 Charge Pump None Rotation clockwise Swash Plate Operating Angle deg ±16 Mounting SAE 2 Bolt B Mount ANSI B92.1-1970 Shaft Class No.5 30 15 16 32 -

• Standard Pump Pressure and Flow • Flow (Max) • Max. System Pressure LPM(GPM) psiat charge pump bar

77.7 (20.5) 3000±35 (207±2.4bar)

• High Flow Option Pump Pressure and Flow • Flow LPM(GPM) • Max. System Pressure psiat charge pump bar

131.5(34.8) 3000±35 (207±2.4bar)

3.1. Specifications

Hydraulic System

Item • Motor • Type • Displacement • Mounting • Pump • Type • Capacity • Max. Pressure • Max. Speed • Mounting • Shaft • Rotation • Control Valve • No. of Spool • Relief Setting Pressure (set by valve supplier) • Circuit

• Boom Cylinder • Type • Number • Cylinder Bore • Cylinder Rod • Stroke • Mounting • Plating on Rod

• Bucket Cylinder • Type • Number • Cylinder Bore • Cylinder Rod • Stoke • Mounting • Plating on Rod

Vehicle

Item Unit

• Hydraulic Filter • Type • Filter Rating

Spec.

Orbit, Fixed Displacement Bi-rotational 15.03 (246.3) in3(cc)/rev SAE 4 Bolt B Mount Spline Shaft -

in3(cc)/rev psi rpm -

psi -

each in(mm) in(mm) in(mm) -

each in(mm) in(mm) in(mm) -

• Rated Flow • By-Pass Valve

Unit

SAE 2 Bolt A Mount SAE Spline Shaft Clockwise 3 2816 (+70) (194(+5) bar) •Series on Lift Float Function with Detent •Series on Tilt •Series on Auxiliary With Detent

-

Full Flow Spin-On 10 Micron Beta Rating of 1.5 I(gal)/min 132.5 (35) Closing PR13-17 (Normally Open Type)

• Hydraulic Lines and Fittings • Type

Gear 1.92(31.5) 3200 3000

Spec.

-

• Thread

-

• Medium Pressure Line

-

• Hydraulic High Pressure Line • HST High Pressure Line

-

O-Ring Face Seal Fitting (SAEJ1453) Unified Thread is Standard SAE 100R1 Hose (SAE J517) SAE 100R2 Hose (SAEJ517) SAE 100R12 Hose (SAE J517)

Electrical Components

Item

Single Rod, Double Acting 2 2.48 (63) 1.50 (38) 33.1 (840.4) •Single Crest Crevice •Hard Chrome w/15-50 Micron Thickness

Unit

Spec.

• Alternator • Battery

-

• Starter

-

12V - 65A 12V-100AH, 625CCA 12.5 X 6.75 X 8.0” 12V - 3.0KW

each each

2 1

• Lighting • Head Lamps • Rear Lamps

Single Rod, Double Acting 2 2.36 (60.0) 1.5 (38.0) 20.0 (507) •Single Crest Crevice •Hard Chrome w/15-50 Micron Thickness HRC 52-60 Hardness

156

3.1. Specifications

Instrument Features

Seat

Item

Unit

• Instrument Panel (A) -Buzzer alarm -Stop (Red) Warning (Yellow) Warning -Engine Oil Pressure -Engine Water Temperature -Battery Voltage -HST Charge Pressure -HST Oil Temperature -HST Filter • Instrument Panel (B) -Fuel Meter -Hour Meter -Park Brake Monitor -Pre-Heater Monitor • Key Switch • Light Switch • Fuses

-

Item

Spec.

• Cover Material • Cushion Material • Fore/Aft Adjustment • Density -Cushion -Backrest

Standard

each each

Unit

Spec.

in(mm)

Vinyl, Black Urethane Foam ±3 (76)

lb/ft3(kg/m3) lb/ft3(kg/m3)

833 (52) 609 (38)

Standard

Fluid Capacities & Specifications

Item • Engine Lubrication -W/ Filter

• Hydraulic Tank • Hydraulic System

• Chain Case • Fuel Tank

• Cooling Fluid • Grease

Vehicle

Unit

Q’ty

gal(liter)

2.1 (8)

SAE 10W20CD; Taxaco TDH; Mobil Fluid 423; Chevron Tractor Hydraulic Fluid; G Automatic Fluids meeting Caterpillar TO-2 or Allison C3 standards

gal(liter) gal(liter)

9.2 (35) 12.7 (48)

Specifications API CC or CD SAE 10W30 for Ambient Temp above 4 deg. F API CC or CD SAE 5W30 for Ambient Temp below 4 deg. F

API CC or CD SAE 10W30

gal(liter)

7.9 (30)

#2 Diesel recommended for Ambient Temp above 40 deg. F #1 Diesel recommended for Ambient Temp below 40 deg. F

gal(liter)

21.1 (80)

Recommended mixture is 50/50 ethylene glycol and water

gal(liter)

1.8 (6.9)

Recommended is a mineral based grease with a lithium thickener and rust, corrosion and extreme pressure additives. Viscosity conforms to NOGI grade 2.

157

3.1. Specifications

3.1.2. Service Schedule can lead to premature wear and component failure.

Adverse conditions (e.g., excessive dust or corrosive vapors, etc.) may require more frequent service.

This maintenance schedule was designed for you to receive optimum performance and reliability from your SKID STEER LOADER under typical working conditions.

Failure to follow a scheduled maintenance program

SERVICE SCHEDULE ITEM

HOURS

SERVICE REQUIRED

every every every every every every day 50 100 250 500 1000

Check the oil level and fill oil as needed.

Engine Oil

Replace the oil.

(First time)

Replace the oil filter.

(First time)

Clean and replace fuel filter element.

Fuel System Engine Cooling System

Drain water from the water separator Check cooling level and add as needed.

Check for leaks

(First time) (First time)

Check and adjust the tension of fan belt Check the indicator.

(Clean or replace the outer element when the red ring shows.)

Air Cleaner

Clean the dust cover.

Replace the outer element.

(Replace the inner element every third time the outer element is replaced).

Tires

Check air pressure and for damage to tires.

Wheel Nuts

Tighten to correct torque if loose.

Seat Belt

Check the condition of seat belt.

Seat Bar

Check the seat bar for correct operation.

Safety Signs

Check for damaged signs and replace if needed.

Pivots

Grease pivots as needed.

Battery

Check the water level and battery cables for corrosion.

Check whether battery cables are tightly clamped.

Check covers.

Hydraulic Fluid

Check the oil level and add as needed.

Replace the fluid

Hydraulic Tubes and Hoses Chain Case Oil Hydraulic Filter Hydraulic Oil Tank Spark Arrestor for Muffler Suction filter in tank

Check for damage and leaks and replace as needed.

Air breather cap

Inspect and clean or change

Vehicle

(First time)

Replace the oil.

(First time)

Replace the filter.

Replace the hydraulic oil.

Clean the spark chamber

(First time)

Inspect and clean or change

158

3.1. Specifications

3.1.3. Special Torque etc

• Mounting gp-E/G

160 30 N. m (loctite 271)

240

55

40 N . m

1 N .m 100 20 N . m (loctite 271)

55 1 N . m

160 30 N . m (loctite 271) 55 10 N . m

55 1 N . m

105 20 N . m (loctite 271)

Fill MOS 2 Grease

240

40 N . m

100 20 N . m (loctite 271)

55 10 N . m

28 7 N . m

IGAT002I

Vehicle

159

3.1. Specifications

• Canopy gp

.

54 ~ 68 N m

Apply Three Bond 1781

IGAT003I

Vehicle

160

3.1. Specifications

• Mount gp Covers

.

15 ~ 25 N m

.

15 ~ 25 N m (loctite 243)

.

15 ~ 25 N m (loctite 243)

* Apply sealant on all gasket

IGAT004I

Vehicle

161

3.1. Specifications

3.2. Disassembly & Assembly

Disassembly & Assemble Quick-Tach

3.2.1. Quick - Tach

Start By :

Remove & Install Quick-Tach

a. Remove the bucket.

Start By :

b. Remove the Quick-Tach.

a. Remove the bucket.

1

2

1

4

IGAT007P 5

2

3

3

IGAT005P 6

5

1. Position the Quick-Tach (1) so that unexpected movement does not occur when disassembling.

2. Remove the bolts and washers (2) and boom pin assemblies (3).

3. Support Quick-Tach (1) with a hoist and remove the bolts and washers (4), pin assemblies (5).

4

IGAT008P

1. Remove cotter pins (1), nuts (2) and washers (3), levers (4).

2. Remove bolts (5) and covers (6).

IGAT006P

4. Hoist the Quick-Tach and remove it.

NOTE : Install the Quick-Tach in reverse order of removal.

End By : a. Install the bucket.

Vehicle

162

3.2. Disassembly & Assembly

3.2.2. Bucket Cylinder Remove & Install Bucket Cylinder Start By :

8

a. Remove the bucket.

7

b. Remove the Quick-Tach.

IGAT009P

3. Remove pins (7) and snap-ring (8).

4. Remove whole parts.

NOTE : Assembly is the reverse order of disassembly.

1

NOTE : When tightening bolts (5), apply Loctite No.272.

IGAT010P

End By :

1. Hoist the boom (1) so that bucket cylinder hidden end can be easily accessed from behind of the boom.

a. Install the Quick-Tach. b. Install the bucket.

2

IGAT011P

2. Hoist the bucket cylinder (2) or hold the bucket cylinder (2) by another person for the bucket cylinder not to be dropped freely.

Vehicle

163

3.2. Disassembly & Assembly

3 4 7

IGAT012P

IGAT015P

3. Remove the bolts and cover (4).

6 8 5

IGAT016P IGAT013P

5. Disassemble the hose-RH (7) and the hose-LH (8). Remove the bucket cylinder (2).

NOTE : The following steps are for installation of the bucket cylinder.

6

IGAT014P

1

4. Remove bolts and washer (5), pin assembly (6).

IGAT010P

6. Hoist the boom (1) so that bucket cylinder hidden end can be easily accessed from behind of the boom.

Vehicle

164

3.2. Disassembly & Assembly

6 5

2

IGAT011P

IGAT013P

9. Install the pin assembly (6) and bolt and washer (5).

7. Hoist the bucket cylinder (2) and put the bucket cylinder (2) in position on inside of the boom.

3 4 7

IGAT012P

IGAT015P

10. Install cover (4) and bolts (3).

End By : a. Install the Quick-Tach.

8

b. Install the bucket.

IGAT016P

8. Assemble the hose-RH (7) and the hose-LH (8).

Vehicle

165

3.2. Disassembly & Assembly

3.2.3. Boom Lock & Boom Cylinder

3.2.4. Boom Assembly & Boom Stopper Remove & Install Boom Assembly

3

4

Start By : a. Remove the bucket. b. Remove the quick-Tach. c. Remove the bucket cylinders.

1 2

d. Remove the boom cylinders.

IGAT017P

1. Remove the bolt and washer (1), pin assembly (2).

2. Remove knob (3) and lock assembly (4) (L.H. only).

1 5

7

IGAT010P

1. Hoist the boom assembly.

6

IGAT018P

8

3

2

3. Remove the hoses (5).

4. Remove bolt and washer (6), pin assembly (7).

5. Remove boom cylinder (8) with a hoist.

NOTE : Install is the reverse order of removal.

IGAT019P

2. Remove the bolts and washers (2), boom hinge pin assemblies (3) at both sides.

Vehicle

166

3.2. Disassembly & Assembly

Adjustment of Boom Stopper 4

Spacer (2.3t)

Plate-stopper (6t)

Boom

Rubber

IGAT020P

3. Remove the attach line hoses (4).

4. Remove the boom assembly with a hoist.

Contacting surface of Frame

NOTE : The weight of boom assembly is about 306 kg.

IGAT022I

NOTE : Install is the reverse order of removal.

1. Put each 1 plate-stopper (1) with rubber (3) on both sides when boom is raised.

2. Pull down the boom fully.

DANGER : When working on a machine with the boom up, always engage the boom lock.

5

3. Check the gap between the plate - stopper (1) and contacting surface of frame 4. Raise the boom.

5. Put spacer (2) as required on the side of occuring the gap in order to have even contacting surface of frame in both sides (L.H., R.H.) when boom is down fully.

IGAT021P

NOTE : If needed, add or remove shims (5), to adjust boom seating balance as following procedure.

End By : a. Install the boom cylinders. b. Install the bucket cylinders. c. Install the Quick-Tach. d. Install the bucket.

Vehicle

167

3.2. Disassembly & Assembly

3.2.5. Canopy

IGAT026P

4. Disconnect the wiring connector at the rear canopy (R.H.).

IGAT023P

1. Loosen both mounting bolts at the front corners of the canopy.

3

2

1 5 4

IGAT027P

5. Remove ring - retaining (2) and link (3), nuts (4), then dis connect parking cable assembly (5).

IGAT024P

2. Remove the stopper-plastic (1) from the canopy hinge mtg. bracket.

7

6

IGAT028P

6. Remove three bolts (6) and floor plate (7).

IGAT025P

3. Suspend the canopy from a hoist with a sling and then lift slowly all the way up until canopy is stopped.

Vehicle

168

3.2. Disassembly & Assembly

10

9

8

IGAT029P

7. Remove the cotter pin (8) and pin, then loosen the nut (9) and disconnect the cable assembly (10).

IGAT032I

NOTE : Install is the reverse order of the removal.

10. Adjust the Canopy Stops The canopy tilt should be adjusted at the stops so that the maximum lifting angle is approximately 65˚.

This can be measured with a protractor held along the bottom surface of the canopy when it is tilted back against the adjusted stops. Adjust the stop on each side as follows :

13

11

12

IGAT030P

8. Remove the cotter pin (11) and pin (12) from the gas spring (13) where it attaches to the frame.

IGAT033P

1) Loosen the jam nut.

2) Turn the stop in or out until the it measures 6264mm from the surface of the cross member.

14

3) Tighten the jam nut.

IGAT031P

4) Check the canopy lock. It should hold the canopy with out excessive play.

9. Remove the bolt (14) and nut from the rear hinges.

The canopy can be removed with the hoist.

Vehicle

169

3.2. Disassembly & Assembly

3.2.6. Drive Control System

UPPER PLATE

(3) (2)

APPLY LOCTITE 271

(1) USE EXISTING HARDWARE TORQUE TO 18-22 ft.lb.

USE EXISTING HARDWARE TORQUE TO 18-22 ft.lb.

IGAT034I

Neutral Adjusting of Linkage 1) Set drive lever (1) should have a perpendicular on the upper plate with related assemble parts.

2) Adjust the neutral s/w (2) in order to get proper function.

3) To get the straight travel, adjust the length of bolts (3) as to contact with the uppler plate.

Vehicle

170

3.2. Disassembly & Assembly

3.2.7. Hydraulic Control System

(1) (4)

(2) A

A

(3) VIEW A-A

IGAT035I

Adjustment Procedure 1) Raise the seatbar (1).

2) Adjust cable (2) location by nuts (3) in order to get the pedals should be locked.

3) Assemble the cable (3) on the seat bar (1) using the yoke (4).

4) Check whether pedals can be movable when the seatbar is down.

Vehicle

171

3.2. Disassembly & Assembly

3.2.8. Parking Lock Assembly

NOTE : Install is the reverse order of removal.

Remove & Install Parking Lock Assembly

5. Final adjusting procedure.

Refer to next page.

Start By: End By : a. Raise and securely lock the canopy a. Refill oil to the chain case. See Chain Case Drain and Refill section in the Operation & Maintenance Manual.

b. Drain the oil from the chain case. See Chain Case Drain and Refill section in the Operation & Mainternace Manual.

b. Unlock and lower the canopy.

1

2

IGAT036P

1. Remove the front chain case upper cover and gasket (1).

2. Disconnect the spring (2).

3

4

IGAT037P

3. Remove octagonal cover and gasket on the out side frame.

4. Remove the bolts (3) and parking lock assembly (4).

NOTE : When installing, tighten the bolts (3) to a torque of 100 L 10 N•m (73 L 7 lb•ft).

Vehicle

172

3.2. Disassembly & Assembly

Final adjusting Procedure

Seatbar Lock Position

Unlock Position

S/W S/W Lover

pring

20

56 (S

th)

Leng

Plate

76

IGAT038P

1) Pull down seatbar.

2) Set parking lever to the lock position.

3) Put washers as 20mm thickness on the spring mtg.

4) Adjust plate by nuts until the dimension between plate and cable mtg plate to 76mm.

5) Set the parking lever to the unlock position.

6) Adjust S/W location until S/W lever should contact with the plate.

Vehicle

173

3.2. Disassembly & Assembly

3.2.9 Throttle Control Adjustment of Throttle lever

IGAT039P

1) Mount cable as (1) to E/G throttle support bracket.

2) Install pirot (2) to cable end and adjust to align with throttle lever hole in full off position.

3) Adjust throttle lever (3) to position “A” (16˚) using rear lever stop bolt (4) and lock with nut (5).

4) Move throttle lever (3) to position “B” to get full on throttle movement by E/G regulator plate (6) and adjust lever stop bolt (4) and lock with nut (5).

NOTE : Tighten nut-lock (7) in order to get proper friction on throttle lever movemet by hand.

Vehicle

174

3.2. Disassembly & Assembly

3.2.10. Chain Drive System

Counter Sprocket

Chain

Remove & Install Counter Sprocket

Remove & Install Chain

Start By:

Start By:

a. Raise and securely lock the canopy.

a. Raise and securely lock the canopy.

b. Drain the oil from the chain case sec chain Case Drain and Refill section ia the operation & Maintenance Manual.

b. Drain the oil from the chain case. See Chain Case Drain and Refill section in the Operation & Maintenance Manual.

1. Remove the octagonal cover and gasket on the outside frame.

1. Remove the octagonal cover and gasket on the out side frame.

2. Remove chain.

2. Remove chain case upper cover and needed side covers to access chain easily.

IGAT041P

3 2

1

3. Remove the 4 bolts from the round chain case cover on the outside frame. Remove the cover and gasket.

IGAT040P

3. Turn the axle shaft until the chain connection link (1) is accessible from the outside chain case opening.

1

2

4. Pull out the cotter pins (2), remove the connecting link and remove the chain (3) from the case.

NOTE : The following steps are for installation of the chain.

3

5. Through the chain case opening, fit the chain over the sprockets.

IGAT042P

6. Install the connecting link (1) and cotter pins (2).

4. Remove the 4 bolts (1) from the chain case cover on the inside frame. Remove the countershaft and gasket (2).

7. Install all the chain case covers.

End By :

5. Remove the counter sprocket assembly (3), shims and spacers.

a. Refill oil to the chain case. Sec Chain Case Drain and Refill section in the Operation & Maintenance Manual. b. Unlock and lower the canopy.

Vehicle

175

3.2. Disassembly & Assembly

NOTE : Be sure the shims and spacers are installed as they were before disassembly. This is required for proper operation.

NOTICE Mark the shims, spacers, and needle bearings on the inside and outside. For proper chain alignment at reassembly, these components must be assembled in their original locations.

NOTE: Check the each chain slack as follow.

Chain Slack NOTE : Install is the reverse order of removal.

Be careful of following Axle shaft installation.

Install the Axle Shaft

S

A

A

A

A

IGAT044I

The each chain slack(s) is as follows.

A – B : 23~35 mm C – D : 18~27 mm E – F : 11~17 mm

IGAT043I

End By: 1. Install the axle shaft with outside bearing cone in place.

a. Refill oil to the chain case. See Chain Case Drain and Refill section in the Operation & Maintenance Manual.

2.Install the inside bearing cone, spacer, driven sprocket with punched markeing (“A”) facing away from vehicle center line.

b. Unlock and lower the canopy.

3. Initially, tighten the castle nut to 200 L 20 N•m (147 L 15 f•lb).

4. Rotate the axle 1-2 times to be sure there is no binding.

5. Back off the axle nut until it will turn by hand.

6. Retighten the axle nut to 20 N•m(15 ft•lb).

7. Install the axle nut cotter pin.

NOTE : When installing, tighten bolts (1) to a torque of 60 L 10 N•m (44 L 7 lb•ft).

Vehicle

176

3.2. Disassembly & Assembly

3.2.11. Hydrostatic Pump Remove & Install Hydrostatic Pump 6

Start By: a. Raise and securely lock the canopy 5

b. Remove floor plate GP. c. Remove bottom plate.

IGAT046P

d. Disconnect all linkge connected to hydrostatic pump.

4. Fasten hydrostatic pump (5) to the hoist and maintain tension on the hoist to protect hydrostatic pump from free dropping.

5. Remove two bolts and washers (6).

6. Pull the hydrostatic pump (5) out to the front carefully.

7. Remove hydrostatic pump.

1

IGAT045P

4

NOTE : The following steps are for installation of the hydrostatic pump.

3

2

8. Fasten hydrostatic pump to the hoist 1. Disconnect all hydraulic lines (1).

2. Remove two bolts (2).

6

3. Remove four bolts (3) and support bracket (4).

5

IGAT046P

9. Push hydrostatic pump (5) for the shaft of pump to be put into the internal spline of the coupling.

10. Install the bolts (6) and washer.

11. Apply Loctite 271 on the threads and torque the bolts (6) to 105 L 20 N•m (77 L 15 lb•ft).

Vehicle

177

3.2. Disassembly & Assembly

3.2.12. Control Valve Remove & Install Hydraulic Control Valve

1

IGAT048P

2

4

3

2 1

12. Install support bracket (4).

3

13. Install four bolts and washers (3).

IGAT049P

14. Tighten bolts to a torque of 55 L 10 N•m (40 L 7 lb•ft).

1. Disconnect all tubes (1) and hoses (2).

2. Disconnect linkages (3).

15. Install two bolts and washers (2).

16. Tighten the bolts to a torque of 28 L 7 N•m (21 L 5 lb•ft).

17. Connect all hydraulic lines (1).

End By :

5

a. Connect all the linkage connected to hydrostatic pump.

4

b. Install the bottom plate.

IGAT050P

c. Install the floor plate GP. 3. Remove three bolts (4). d. Unlock and lower the canopy.

4. Remove control valve (5).

Vehicle

178

3.2. Disassembly & Assembly

3.2.13. Oil Filter

3.2.14. Hydraulic Motor

Remove & Install Oil Filter

Remove & Install Hydraulic Motor Start By:

4

a. Raise and securely lock the canopy.

2 3

b. Drain the oil from the chain case. See Chain Case Drain and Refill section in the Operation & Maintenance Manual.

1 2

5

IGAT051P

1

1. Disconnect hoses (1) and wire (2).

2. Remove pressure switch (3).

3. Remove bolts (4) and oil filter assembly (5).

IGAT052P

NOTE : Install is the reverse order of removal.

1. Remove the bolts (1), cover(2) and gasket.

5 6

3

4

IGAT053P

2. Remove the octagonal cover and gasket on the out side frame.

3. Remove bolt (3), washer (4), retainer (5) and disk (6), chain, motor sprocket.

WARNING Do not attempt to disconnect hydraulic lines and hoses when they are hot. Allow the system to cool before disconnecting lines and hoses.

Vehicle

179

3.2. Disassembly & Assembly

3.2.15. Muffler Remove & Install Muffler 9

8 10

IGAT054P

7 1

4. Disconnect hoses (7) and tubes (8) from the hydraulic motor.

IGAT055P

5. Remove bolts (9) and hydraulic motor (10).

1. Remove bolts and washers (1).

NOTE : When installing, tighten the bolts (9) to a torque of 125 L 15 N•m (92 L 10 lb•ft) NOTE : Install is the reverse order of removal.

NOTE : When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tube lines and ports to keep dirt out. Dirt can quickly damage the system.

2

3

End By: IGAT056P

a. Refill oil to the chain case See Chain Case Drain and Refill section in the Operation & Maintenance Manual.

2. Remove nuts (2) and bolts (3).

b. Unlock and lower the canopy.

IGAT057P

6

4

5

3. Remove nuts and clamp (4), tail tube (5).

4. Remove muffler (6).

NOTE : Install is the reverse order of removal.

Vehicle

180

3.2. Disassembly & Assembly

3.2.16. Radiator & Oil Cooler Remove And Install Radiator & Oil Cooler

5

1. Drain oil and cooling water.

6

IGAT061P 1

5. Pull out radiator and oil cooler assembly (5) by two persons, disconnect radiator-out hose(6).

6. Completely pull out radiator and oil cooler assembly (5) by two persons.

IGAT058P

NOTE : Install is the reverse order of removal.

2. Remove bolts and nuts, washers at both sides.

9.6 1.0

3 2

9.6 1.0 9.6 1.0

9.6 1.0

IGAT059P

3. Remove nuts (2) and washers, shims and rubbers (3) at both sides.

(7)

IGAT062I 4

Shim spacer (7) to adjust the even clearence between the fan and shroud.

IGAT060P

4. Disconnect oil and cooling lines (4).

Vehicle

181

3.2. Disassembly & Assembly

3.2.17 Flexible Coupling Assembly Assembly Procedure

IGAT063I

STEP 5 : Assemble hub and rubber element on fly wheel with 3 hex socket bolt (tightening w/specified torque).

STEP 1 : Make each items and assembling face of fly wheel clear.

STEP 2 : Assemble the spring pins(6ea) on the hubspline. (projection height of spring pin : MAX.4mm).

*ATTENTION : Hex socket bolt assembly 1) Apply very little grease on bolt seat face(never let the thread contaminanted with grease. erf. fig.1).

STEP 3 : Assembling the hub into the rubber element, make sure the spline direction correct, and tighten 3 hex socket bolt with specified torque aligning spring pin locations.

2) Loctite is coated on hex socket bolt(colored blue) for anti-loosening.

The loctite can be workable within 3 times of assemble and disassemble.

STEP 4 : Assemble spring pins(3EA) on fly wheel (projection height of spring pin : MAX. 4mm).

Vehicle

182

3.2. Disassembly & Assembly

3.2.18. Wheel & Tire Remove And Install Wheel & Tire

WARNING Be sure the skid steer loader is on a level surface before removing wheel and tire.

1. Put a hydraulic jack in position under the frame.

1

IGAT064P

2. Loosen the nuts (1) that hold the wheel and tire in place.

3. Lift frame until the tire is clear of the ground.

Remove nuts (1). Remove the wheel and tire.

NOTE : The following steps are for installation of the wheel and tire.

4. Put the wheel and tire in position on the axle hub.

5. Install nuts (1) that hold the wheel and tire in place.

Tighten the nuts to a torque of 147 L 7 N•m (108 L 5 lb•ft).

6. Lower the frame and remove the hydraulic jack.

Vehicle

183

3.2. Disassembly & Assembly

4. HYDRAULIC & HYDROSTATIC SYSTEMS 4.1. Systems Operation 4.1.1. Hydraulic System

5 6 4

7

14 15

8 To Valve Block 2 1

16 13

IGAT065I (1) HST Pump. (2) Hydraulic Pump. (4) Control Valve. (5) Boom Cylinder. (6) Bucket Cylinder. (7) Quick Coupling. (8) Quick Coupling.

(13) Suction Strainer. (14) Valve Shuttle. (15) Valve Bleeder. (16) Hydraulic Tank.

cylinders (5, 6) reach the end of the stroke, the fluid pressure reaches the setting pressure of relief valve (3000psi), it will open and let the fluid by-pass the hydraulic circuit internally and go to the valve block.

When the spool goes back to neutral position, there is fluid available for the other sections of the control valve (4). Two sections of the control valve can be used at the same time as long as the main relief valve is not open.

The hydraulic pump (2) is driven by a shaft through the hydrostatic (HST) pump (1). The fluid flows from the hydraulic tank to the hydraulic pump (2), then goes from the hydraulic pump to control valve (4).

The pump draws hydraulic oil from the tank and charges the hydraulic system with hydraulic power converted from engine power.

When all three spools (boom, bucket, attach) of the control valve are in neutral position, the fluid goes through the control valve (4) and the valve block. If one of the spools is activated by pedal (boom, bucket) or electric rocker switch (attach), the fluid goes out respective port and to either the base end or the rod end of cylinders (5, 6), or attachment is operated. As the fluid goes into one end of the cylinders (5, 6), the fluid from the other side of cylinder flows back into the control valve. The control valve (4) has an adjustable relief valve. When the Hydraulic & Hydrostatic Systems

There is a bleeding system which consists of valve shuttle (14) and valve bleeder (15). When the quickcouplers of attachment are connected or disconnected for mating quick couplers (7, 8), the knob of the valve bleeder (15) is pulled several times to release the pressure left in the system after shutting off engine. Their connections could be done easily and safely.

185

4.1. Systems Operation

4.1.2. HST System 12

11 From Control Valve

3 9 2

1

3

10

16

IGAT066I (1) HST Pump. (2) Hydraulic Pump. (3) HST Motors. (9) Valve Block. (10) Drain Relief Valve. (11) Oil Cooler. (12) Hydraulic Filter.

(16) Hydraulic Tank.

the hydrostatic pump for replenishing, lubrication and cooling. The hydrostatic pump does not need the full volume of the fluid flow, so there is extra fluid. The extra fluid goes to the charge relief valve (160psi).

Return oil from actuating devices is sent to the valve block (9) for distribution to HST pump.

HST pump supplies the oil to the left and right HST motors. HST pump drives the motor forward or reverse direction according to the control lever. The oil from the control valve flows to the HST pump through the valve block (9), oil cooler (11) and hydraulic filter (12).

There are two parts of hydrostatic pump (1) and two hydrostatic motors (3). One part of hydrostatic pump and one of hydrostatic motors work together as a pair to drive one side of the loader. The other part of pump andthe other motor work as a pair to drive the opposite side of the loader.

Various hydraulic lines carry hydraulic oil among the control valve, valve block, oil cooler, and filter.

When the driving levers are in neutral, hydrostatic pump (1) and the hydrostatic motors (3) are not working, but have charge pressure. When the driving levers are moved, the swashplates in the hydrostatic pump are angled and the fluid is forced out of the pressure side of hydrostatic pump and goes to hydrostatic motors.

The fluid flows from the oil cooler (11) through the filter to the center section of the hydrostatic pump (1). The fluid is called “charge supply fluid”. In the center section of hydrostatic pump, the fluid works against two high relief (4060psi)/ replenishing (check) valves, replenishing valve (3-position) of motors (3) and charging relief valve (160psi). The replenishing valve of hydrostatic pump and the replenishing valve of motor open and let fluid go into Hydraulic & Hydrostatic Systems

186

4.1. Systems Operation

The fluid is called “drive pressure fluid”. Drive pressure is much higher than charge pressure causing the replenishing valves (check valves) of hydrostatic pump to close, allowing the flow of fluid to go the hydrostatic motors. There are four replenishing valves (check valves), two for each parts of hydrostatic pump (1). One is for forward travel and the other is for reverse travel.

When the loader is driven with bucket into a pile of material, there is resistance causing high pressure in drive loop.

There is relief valve built into the high relief valve/replenishing valve (for forward travel). This relief valve opens at the pressure of 4060 psi (285 bar), the extra fluid goes from the drive loop to the charge loop to be used again.

The hydrostatic motors (3) are “roller-geroler type”. In each hydrostatic motor there are two kinds of fluid ; case drain fluid which is generated in housing of each hydrostatic motor and flushing fluid which is controlled by the orifice and the replenishing valve (3-position) of each hydrostatic motor. These fluids go through drain relief valve (10) and back to the tank.

The filter (12) has a by-pass valve (20psi, check valve) to allow fluid flow when the fluid will not go through the filter element (plugged).

The valve block (9) works as a cooler-by-pass valve and surge valve. The by-pass valve (20 psi, check valve) of valve block will open when the boom arms are lowered quickly with heavy load in the bucket.

When the pressure which works against the oil cooler is higher than 220 psi at the same condition, the relief valve (220 psi) of valve block will open to protect the oil cooler (11) and filter (12). The by-pass valve (20 psi) of oil cooler (11) will also open when the fluid is cold and is thick to go through the cooler and filter.

Hydraulic & Hydrostatic Systems

187

4.1. Systems Operation

4.1.3. Hydraulic Control Valve Configuration

7 INE K L ort N A p T “T”

6 5 4

8

rts

o ”P

“A

ts

or

P B”

“

3

1 RE SSU ort E PR P” p “

2 Monoblock Valve Body

IGAT067I Configuration of Hydraulic Control Valve (1) Spool. (2) Dust Cover Plate. (3) Main Relief Valve. (4) Float Detent Spool Control. (5) Spring Centering Spool Control.

(6) Check Valves. (7) Internal Pilot Electro-Hydraulic Spool Control. (8) Back-Pressure Valve.

Hydraulic & Hydrostatic Systems

188

4.1. Systems Operation

Schematic

P1

A1 B1

A2 B2

A3 B3

T

SC1 SC3 MV

SC2 CV1

CV2

CV2

210 bar 3000 psi

10 bar 145 psi

P S1

S3

S2 SLP2

SLP1

BPV

SLP3

IGAT068I

Legend P P1 A1-B1 A2-B2 A3-B3 T

= = = = = =

BPV CV1,CV2,CV3 MV S1,S2,S3 SC1 SC2 SC3 SLP1,SLP2,SLP3

= Back-pressure valve = Load check valves = Main relief valve = Spools = Float detent spool control kit = Spring centering spool control kit = Internal pilot electro-hydraulic spool control kit = Spool dust cover kit

Inlet line 2nd inlet line (plugged) 1st section ports 2nd section ports 3rd section ports Outlet line

Hydraulic & Hydrostatic Systems

189

4.1. Systems Operation

Neutral

Operations Spool push-in

Load Check Valve

A

A

B

Working Ports

Pressure Line

B

0 Spool

1 0 Tank Passage Free Line 3

1

0

2

Oil return from work port

To Next Section or to Tank

A B 3

1

0

2 A B

To Next Section or to Tank P

P

T

T IGAT070I

IGAT069I

Oil discharged from the pump returns to the valve block and HST pump through the free passage. A and B ports are blocked.

When the free line passage is closed, the oil discharged from the pump flows to port B. The return oil from port A is returned to the other section (series) or go through the free passage. The spool is returned to neutral by the return spring when released.

Hydraulic & Hydrostatic Systems

190

4.1. Systems Operation

Spool pull-out in float position

Spool pull-out

B

A

A

B

0 2 0

3

Oil return from work port

3

1

0

3

2

0

2

A B

A B

P

1

P

T

IGAT071I

IGAT072I

Oil discharged from the pump returns to the valve block through the tank line. A and B are connected.

When the free line passage is closed, the oil discharged from the pump flows to port A. The return oil from port B is returned to the other section (series) or goes through the free passage.

The spool is retuned to neutral by the return spring when released.

Hydraulic & Hydrostatic Systems

T

191

4.1. Systems Operation

Electrical Connections

A1

A2

A3

IN P

OUT ON OFF

B1

B2

ON

B3

Knob with 3 Positions Push-Button

12 VDC Battery

IGAT073I Configuration of Electrical Connections.

Hydraulic & Hydrostatic Systems

192

4.1. Systems Operation

Loader control valve metering and timing are important in maintaining good boom and bucket control in both conventional and self-leveling circuits.

Cavitation of the boom cylinder is possible, in the boom lower mode, if “inlet to workport” metering lags behind “workport to return” metering. If this is allowed to happen, the bucket will hesitate during the next raise cycle while the rod end of the boom cylinder fills with oil. This may be unacceptable to the operator.

4.1.4. Optional Bucket Self-Leveling System Operation

A B

The following schematics and their accompanying explanations explain the operation of the Self-Level valve. Five different operating modes are described : Self-Leveling, Bucket Cylinder Extended, Retracting Boom Cylinder, Extending Bucket Cylinder, and Retracting Bucket Cylinder.

C

D

IGAT074I Hydraulic Circuit of Self-Leveling

The boom and bucket section of the control valve work together to position the bucket as the boom arms of the loader are being raised. When the boom spool of the control valve is engaged to raise the boom arms, the fluid from the rod end of the boom cylinders is directed through the self-leveling valve.

The self-leveling valve has a flow divider of 2position, which directs some of the returning fluid directly back to the boom section of control valve.

The remaining fluid goes through a check poppet valve (between 2-position valve and 3-position valve in self-leveling valve) and to the base end of bucket cylinder. This forces the bucket cylinder rod out and adjusts the position of bucket as the boom arms are raised. Since the fluid is trapped in the base end of bucket cylinder(bucket pedal in neutral), the pressure will increase and push the flow return spool of 3position open and allow fluid from the rod end of the bucket cylinder to return to boom section of the control valve along with the remaining of the returning fluid from the rod end of boom cylinders.

When the bucket cylinders are fully extended and boom arms are still raising, fluid goes over the relief valve and back to the boom section of control valve.

Hydraulic & Hydrostatic Systems

193

4.1. Systems Operation

Self-Leveling

Boom Cylinder Port “A” Adjustable Orifice

Pump Input Port “B” Flow Divider Spool with Fixed Orifice

Control Valve Return

Unloading Spool Port “C”

Boom Spool “Out” Bucket Spool “Neutral”

Port “D”

Bucket Cylinder

IGAT075I

With the bucket spool in “Neutral” and the boom spool pulled “Out”, flow from the control valve enters the head port of the boom cylinder. As the boom cylinder extends, flow from the rod port is directed to port “A” on the self-level valve. Flow entering port “A” is able to pass through the adjustable orifice and fixed orifice in the flow divider spool. The proportion of the flow split is determined by size of the adjustable orifice. The remainder of the flow passes through the fixed orifice, out port “B” back to the control valve. The flow that passes through the adjustable orifice flows out port “D” and goes to the head port of the bucket cylinder. The resistance on the movement of the bucket cylinder creates a pressure high enough to open the unloading spool in the self-level valve. As the bucket cylinder extends the flow from the rod port of the bucket cylinder enters port “C” past the open unloading spool, around the flow divider spool and out port “B” back to the control valve. The purpose of the unloading spool is to prevent the bucket cylinder from dumping during the self-level cycle.

Hydraulic & Hydrostatic Systems

194

4.1. Systems Operation

Bucket Cylinder Extended

Boom Cylinder Port “A”

Pump Input

Port “B”

Control Valve Return

Unloading Spool

Boom Spool “Out” Bucket Spool “Neutral”

Port “D”

Port “C”

Bucket Cylinder Stroked Out

IGAT076I

In case the bucket cylinder strokes out first during the self-level cycle, or the operator moves the bucket spool to dump the bucket, the boom cylinder will continue to raise.

The unloading spool will shift to the left and unload the flow going to the bucket cylinder head port.

The oil flow goes back to control valve, thus preventing the boom cylinder from stopping during the “Raise” function.

Hydraulic & Hydrostatic Systems

195

4.1. Systems Operation

Retracting Boom Cylinder

Boom Cylinder Port “A” Lift Check

Boom Spool “In”

Pump Input Port “B” Control Valve

Bucket Spool “Neutral”

Return

Port “C”

Port “D”

Bucket Cylinder

IGAT077I

Moving boom spool “In”, the oil flow is directed to port “B” on the self-level valve. Flow enters self-level valve, opens lift check and flows out port “A” to the rod port on the boom cylinder. Flow from head port is directed back to the control valve.

Hydraulic & Hydrostatic Systems

196

4.1. Systems Operation

Extending Bucket Cylinder

Boom Cylinder Port “A”

Boom Spool “Neutral”

Pump Input

Port “B”

Control Valve Return

Bucket Spool “Out”

Lift Check Unloading Spool Port “C”

Port “D”

Bucket Cylinder

IGAT078I

With the bucket spool shifted “Out” oil flow is directed from the control valve to the head port of the bucket cylinder. The flow also enters port “D” on the selflevel valve but is blocked by the lift check. Return flow also enters port “C” on the self-level valve and is blocked by the unloading spool.

Flow from the rod port is directed back to the control valve.

Hydraulic & Hydrostatic Systems

197

4.1. Systems Operation

Retracting Bucket Cylinder

Boom Cylinder Port “A”

Boom Spool “Neutral”

Pump Input Port “B” Control Valve Return Lift Check

Unloading Spool Port “C”

Bucket Spool “In”

Port “D”

Bucket Cylinder

IGAT079I

With the bucket spool shifted “In”, oil flow is directed to the rod port of the bucket cylinder. Flow also enters port “C” on the self-level valve through a tee connection but is blocked by the unloading spool. Oil returning from the head port is directed back to the control valve. Oil flow from the head port enters port “D” on the self-level valve through a tee connection but is blocked by the lift check.

Hydraulic & Hydrostatic Systems

198

4.1. Systems Operation

Basic Closed Circuit

4.1.5. HST Pump General Description HST Pump and motors provide an infinitely variable speed range between zero and maximum, in both forward and reverse modes of operation.

This variable displacement pump is a compact design, using the parallel axial piston/slipper design in conjunction with a tillable swashplate to vary the pump’s displacement. Reversing the direction of tilt of the swashplate reverses the flow of oil from the pump and thus reverses the direction of the motor output rotation.

INPUT

PUMP

MOTOR

FLOW (BI-DIRECTIONAL)

A direct displacement control system is used on this HST tandem pump. The swashplate control shaft is connected directly to the swashplate. Movement of the control shaft causes a proportional swashplate movement and change in pump flow. This control is located on either side of the unit.

OUTPUT

CASE DRAIN LINE

TANK IGAT080I

The main ports of the pump are connected by hydraulic lines to the main ports of the motors. Fluid flows, in either direction, from the pump to the motor then back to the pump in this closed circuit. Either of the hydraulic lines can be under high pressure. The direction and speed of fluid flow (and the motor output shaft rotation) depends on the position of the pump swashplate. The system pressure is determined by the machine load.

A charge relief valve and charge check valves are included in the pump end cap to control the makeup and cooling oil flow for the system. The charge check valves also incorporate the bypass valve function and high pressure relief valve function into their design.

Case Drain The pump and motor require case drain lines to remove hot fluid from the system. The pump case should be drained from its drain port to insure the case remains full of fluid. The motor housing drain port is connected to the tank.

Charge System and Filter The charge pump supplies cool fluid to the system and keeps the closed loop charged to prevent cavitation. The charge pump draws its fluid from the tank. A filter is required to insure that only clean fluid enters the system.

Hydraulic & Hydrostatic Systems

199

4.1. Systems Operation

Since either of the main hydraulic lines can be high pressure, four charge check valves are used to direct the charge supply into the low pressure line. These check valves (located in the pump end cap) also incorporate the high pressure relief valve function.

Any charge flow not being used for the closed circuit is discharged over a direct operating charge relief valve, through the pump and motor housings, and back to the tank.

4.1.6. HST Motor The outer ring of the gear wheel set of HST motor is stationary part of the motor housing. This ring has internal teeth which mesh with teeth on a gear wheel or rotor which rolls inside the ring.

The motion of the rotor is transmitted to the output shaft through a drive. The drive consists of a movable shaft extension with crowned involute splines at either end. These splines match the corresponding tooth system of the output shaft and rotor, resulting in a toothed coupling between rotor and drive and between drive and shaft respectively.

As it rotates, the rotor causes continuous opening and closing of tooth spaces. Four of these spaces are subjected to fluid pressure, and the opposed four are connected to return line.

High Pressure Relief Valves Four combination check /high pressure relief valves are provided in the pump end cap for overload protection. These cartridge type relief valves are factory set, and are not field adjustable.

Direct Displacement Control The direct displacement control (DDC) is located on either side of the pump, and provides a simple method of control. Movement of the swashplate control shaft produces a proportional swashplate movement and change in pump flow and/or motor shaft speed and direction.

The vehicle control system should be designed to return the swashplate to its neutral position.

Outer ring

Rotor

Zero Position

Bypass Valve In some applications it is desirable to bypass fluid around the pump allowing, for example, a vehicle to be moved short distance at low speed without running the engine. This is accomplished by manually operated bypass valves incorporated into the charge check/high pressure relief valves in the pump. When open (unscrewed 4 turns maximum), these valves connect both sides of the pump/motor closed circuit, allowing the motor to turn. Both valves must be opened for bypass operation and must be fully closed for normal operation. The engine should be shut down when opening or closing the bypass valves.

1/18 Shaft Rotation

1/9 Shaft Rotation IGAT081P

Above pictures show three positions of the rotor, the corresponding rotor center movements, and the locations of pressure and return chambers respectively.

Hydraulic & Hydrostatic Systems

200

4.1. Systems Operation

As can be seen, the circular movement of the rotor center will cause the shaft to move in the opposite direction at eight times smaller angular velocity.

Above illustrations show the typical example which has one shaft revolution against 6 rotor center revolution with displacement of 42 chambers.

Hence 1/9 shaft revolution corresponds to 8/9 rotor center revolution causing the oil from 8 fluid chambers to be displaced, i.e. that one shaft revolution gives 8 revolutions of the rotor centre with displacement of 72 chambers.

A simple rotary channel plate guides the fluid so that pressure and suction chambers rotate synchronously with the rotor, thus causing continuous rotation.

When used in this way, the gear wheel set thus constitutes a hydraulic motor with a power which is approximately 8 times greater per revolution, compared with hydraulic motors of conventional design. The torque which is approximately 8 times greater is obtained at a speed which is 8 times lower without using a reductions gear.

Furthermore, the displacement of 72 fluid chambers per shaft revolution offers the special advantage of steady operation due to the “smoothing” effect of the increased number of chambers.

Outer Ring

IGAT083P

Above illustrations show the shaft rotation according to flow directions of two main ports of HST motor.

Disc Valve Channel Plate

Zero Position Rotor

Revolution of Rotor Center 1/14 Shaft Rotation

1/7 Shaft Rotation High Pressure

Low Pressure IGAT082I

Hydraulic & Hydrostatic Systems

201

4.1. Systems Operation

4.2. Specifications 4.2.1. Hydrostatic Systems Hydrostatic Transmission Pump

Charging Pump

Hydrostatic Pump

IGAT084I

Item

Unit

Specification

Type

–

Piston, Variable Displacement

Maximum Displacement

in3(cc)/rev

2.68 (44)

Relief Setting Pressure

Psi (Bar)

4060 (285)

Internal Charge Pump

–

None

Rotation

–

Clockwise

Swash Plate Operating Angle

Deg

L 16

Mounting

–

SAE 2 Bolt B Mount

Shaft

–

ANSI B92.1-1970 Class No.5 30 B 15 B 16/32

Hydraulic & Hydrostatic Systems

202

4.2. Specifications

Final Drive Item

Unit

Specification

Chain

-

3 Chain with Supper 80 &#100

Drive Sprocket (Motor)

Ea

14

Counter Sprocket

Ea

35 & 11

Drive Sprocket (Axle)

Ea

27

-

6.14

Unit

Specification

-

Geroler

in (cc)/rev

15.03 (246.3)

Mounting

-

SAE 4 Bolt B Mount

Shaft

-

Spline Shaft

Unit

Specification

-

Gear

Displacement

in3(cc)/rev

1.92 (31.5)

Maximum Pressure

Psi (Bar)

3200 (225)

Rpm

3000

Mounting

-

SAE 2 Bolt A Mount

Shaft

-

SAE Spline Shaft

Rotation

-

Clockwise

Unit

Specification

Number of spool

Ea

3

Relief Setting Pressure

Psi

2816 (+70)

Number of Teeth

Ratio

Hydraulic Motor Item Type Displacement

3

4.2.2. Hydraulic Systems Hydraulic Pump Item Type

Maximum Speed

Control Valve Item

(set by valve supplier) Circuit

(194(+5) bar) -

- Series on Boom Float Function with Detent - Series on Bucket - Series on Auxiliary with Electric Detent

Hydraulic & Hydrostatic Systems

203

4.2. Specifications

Pressure and Flow of Standard Skid Steer Loader Item Flow (maximum) Maximum System Pressure at

Unit

Specification

LPM (GPM)

77.7 (20.5)

Psi

3000 L 35 (207 L 2.4 bar)

charging pump

Pressure and Flow of High Flow Skid Steer Loader Item Flow (maximum) Maximum System Pressure

Unit

Specification

LPM(GPM)

131.5 (34.8)

Psi

3000 L 35 (207 L 2.4 bar)

at charging pump

Boom Cylinder Item

Unit

Specification

-

Single Rod, Double Acting

Ea

2

Cylinder Bore

in (mm)

2.37 (60.3)

Cylinder Rod

in (mm)

1.50 (38)

Stroke

in (mm)

33.1 (840.4)

Mounting

-

Single Crest Crevice

Plating on Rod

-

Hard chrome w/15-50 Micron Thickness

Unit

Specification

-

Single Rod, Double Acting

Ea

2

Cylinder Bore

in (mm)

2.36 (60.0)

Cylinder Rod

in (mm)

1.5 (38.0)

Stroke

in (mm)

20.0 (507)

Mounting

-

Single Crest Crevice

Plating on Rod

-

Hard chrome w/15-50

Type Number

Bucket Cylinder Item Type Number

Micron Thickness HRC 52-60 Hardness

Hydraulic & Hydrostatic Systems

204

4.2. Specifications

Hydraulic Filter

Item

Unit

Specification

Type

-

Full Flow Spin-On

Filter Rating

-

10 Micron Beta Ratio of 20

Rated Flow

LPM (GPM)

132.5 (35)

By-Pass Valve

Closing PR13-17 (Normally Open Type)

Hydraulic Lines and Fittings Item

Unit

Specification

Type

-

O-ring Face Seal Fitting (SAE J1453)

Thread

-

Unified Thread is Standard

Medium Pressure Line

-

SAE 100R1 Hose (SAE J517)

Hydraulic High Pressure Line

-

SAE 100R2 Hose (SAE J517)

ST High Pressure Line

-

SAE 100R2 Hose (SAE J517)

Unit

Specification

Fuel Tank (Maximum)

gal (liter)

21.1 (80)

Hydraulic Maximum Oil Tank

gal (liter)

9.2 (35)

Hydraulic System Capacity

gal (liter)

12.7 (48)

Chain Case Oil

gal (liter)

7.9 (30)

Cooling Fluid

gal (liter)

1.8 (6.9)

Engine Lubrication - with filter

gal (liter)

2.1 (8.0)

gal (liter)

2.0 (7.6)

Unit

Specification

Fluid Capacity Item

Without filter

Oil Type Item Chain Case

-

SAE 10W-20: Texaco TDH, Total Mp API CC or CD SAE 10W30

Hydraulic Oil

-

API CC or CD SAE 10W30

Engine Oil

-

API CC or CD SAE 5W30

Hydraulic & Hydrostatic Systems

205

4.2. Specifications

4.3. Testing & Adjusting

Visual Checks

4.3.1. Troubleshooting

A visual inspection of the hydraulic and hydrostatic system and its components is the first step when a diagnosis of a problem is made. Lower the bucket to the ground and follow these inspections;

Troubleshooting of hydraulic system can be difficult.

A list of possible problems and remedies are on the pages that follow.

1. Measure the oil level. Look for air bubbles in the oil tank.

This list of problems and remedies will only give an indication of where a problem can be and what repairs are needed. Normally, more or other repair work is needed beyond the recommendations on the list. Remember that a problem is not necessarily caused only by one part, but by the relation of one part with other parts. This list can not give all possible problems and remedies. The serviceman must find the problem and its source, then make the necessary repairs.

2. Remove the filter element and look for particles removed from the oil by the filter element. A magnet will separate ferrous particles from nonferrous particles (piston rings, O-ring seals, etc.).

3. Check all oil lines and connections for damage or leaks.

The pressure Gauge Kit and fittings can be used to make the pressure tests of the hydraulic system.

Before any test is made, visually inspect the complete hydraulic system for leakage of oil and for parts that have damage.

WARNING To prevent personal injury when testing and adjusting the hydraulic system, move the machine to a smooth horizontal location. Move away from machines and personnel that are at work. There must be only one operator. Keep all other personnel away from the machine or where the operator can see the other personnel.

Hydraulic & Hydrostatic Systems

206

4.3. Testing & Adjusting

Hydraulic System Symptom No hydraulic cylinder action.

Possible Cause

Remedy

Hydraulic oil level is low or empty.

Check level in tank. Add oil if necessary. Check for leaks.

Pedals are disconnected.

Check linkage. Repair as needed.

Contaminated/Damaged relief valve.

Clean/Replace the relief valve.

Damaged hydraulic pump.

Check pump. Replace if needed.

Hydraulic oil is too thick.

Let machine warm up before operating.

Rough hydraulic cylinder action.

Hydraulic oil level is low.

Check level in tank. Add oil if necessary. Check for leaks.

Slow hydraulic cylinder action.

Pedal is hitting floor, or there is dirt under pedal.

Check adjustment. Remove dirt.

Internal cylinder leakage.

Check condition of cylinders and repair as needed.

Damaged hydraulic pump.

Check pump. Replace if needed.

Damaged control valve.

Check valve. Replace if needed.

Hydraulic oil is too thick.

Let machine warm up before operating.

Damaged cylinder rods or seals.

Repair cylinders.

Hydraulic cylinders leak oil.

Boom and Bucket Cylinders Symptom

Possible Cause

Remedy

The piston seals are worn and let oil go through.

Replace seals. Or replace cylinder assembly.

Cylinder has damage.

Replace cylinder assembly.

Foreign material behind the wiper rings which causes scratches on the cylinder rod.

The wiper rings show wear and do not remove dirt and foreign material.

Replace wiper rings.

Too much drift.

Defective boom cylinder seals.

Inspect and replace seals.

Defective control valve.

Replace spool. Or replace control valve assmbly (with changing oil).

There is leakage of oil inside the cylinder or loss of boom or bucket power.

Hydraulic & Hydrostatic Systems

207

4.3. Testing & Adjusting

Control Valve Symptom The boom or bucket cylinders do not hold their position with the valve control spools in neutral position.

The control valve spools do not move freely.

Control valve spools have leakage around the seals.

The bucket lowers when the boom spool is moved from neutral position to the boom-up position.

Spools do not return to neutral.

No motion or slow, then too sudden action of the hydraulic system.

Possible Cause The valve neutral spring is week or broken.

Valve spool worn out.

Load check valve in the control valve is defective.

Dirt or foreign particles between check poppet and its seat.

The oil is too thick at low temperature.

There is foreign material in the hydraulic oil.

Bent spool.

Damage to return springs of the spools.

There is foreign material under seal.

The valve spools worn.

The seal plates are loose.

The seals have damage or are badly worn.

Remedy Replace the neutral return spring.

Replace spool.

Replace load check valve.

Clean or replace load check valve.

Warm the oil by running of engine.

Replace the hydraulic oil and control valve.

Replace spool.

Replace return springs.

Clean.

Replace spool.

Tighten seal plates.

Replace seals.

There is foreign material in the check valve area.

Clean.

The load check valve poppet and seat show wear.

Replace load check valve.

Damage to the relief valve which causes low oil pressure.

The spring broken.

The spool is bent.

The system or valve has foreign particles in it.

Replace relief valve.

The fastening bolts of valve have too much torque.

The relief valve is not correctly set, or will not move in base and or is worn.

Tighten with specified torque.

There is air in the system.

Dirt or foreign particles between relief valve control poppet and its seat.

Replace spring.

Replace spool.

Clean and change oil.

The relief valve is correctly set.

Or replace the relief valve.

Remove the air.

Clean.

Valve body has a crack inside.

Spool not moved to a full stroke.

Auxiliary function doesn’t move.

Hydraulic & Hydrostatic Systems

Replace relief valve.

Inspect spool and spring. Change them if needed.

No electric power.

Check electric circuit.

On/off pressure reducing valve blocked. Remove the rod pressure regulator, clean it carefully and reassemble.

Or replace it.

High spool friction.

Remove the spool, clean it carefully and reassemble.

Too much back pressure in tank line. Check hydraulic circuit and reduce back pressure lower than 20bar.

No enough back pressure on free line. Remove the back pressure valve, clean it and reassemble.

208

4.3. Testing & Adjusting

Hydrostatic Pump Symptom : Difficult or Impossible to find neutral position of HST pump Possible cause and remedy

Check Control Input (Linkage, Pressure, Current)

OK

Check System Pressure Differential

More Than 50 PSI

Defective

Repair or Replace

Adjust Swashplate Neutral OK

Replace Pump

Hydraulic & Hydrostatic Systems

209

4.3. Testing & Adjusting

Symptom : System Operating Hot Possible cause and remedy

Check Oil Level in Tank

OK

Inspect Heat Exchanger

OK

Defective

Low

Check Charge Pressure (No Load and Under Load)

OK

Check System Pressure

OK

High

Low Fill to Proper Level

Inspect Charge Pump

Repair or Replace

OK

Defective

Inspect Charge Relief Valve

OK

Reduce Transmission Load

Inspect Inlet Filter

Defective

Clogged

OK Repair or Replace

Replace

Repair or Replace

Replace Transmission (Pump & Motor)

Symptom : Transmission Operates in one Direction Only Possible cause and remedy

Check Control Linkage

OK

Inspect System Check/Relief Valves or Charge Check Valves

Defective

Defective

Repair or Replace

Repair or Replace

Hydraulic & Hydrostatic Systems

210

OK

Replace Transmission (Pump and Motor)

4.3. Testing & Adjusting

Symptom : System Response is Sluggish Possible cause and remedy

Check Charge Pressure

OK

Low in Neutral

Inspect Control Valve

OK

Inspect Pump By-Pass Valve

Defective

Defective

Repair or Replace

Repair or Replace

OK

Inspect Orifice Control

Defective

Repair or Replace

OK Low in Neutral & Forward or Reverse

Inspect Charge Relief Valve at Pump

Inspect Charge Relief OK Valve at Pump

Inspect Inlet Filter

OK

Inspect Charge Pump

Defective

Defective

Defective

Defective

Repair or Replace

Repair or Replace

Replace

Repair or Replace

Hydraulic & Hydrostatic Systems

211

OK

Replace Transmission (Pump & Motor)

4.3. Testing & Adjusting

Symptom : Loss of power or transmission will not operate in either direction Possible cause and remedy

Check Oil Level In Reservoir

OK

Inspect Heat Exchanger

Low

Check Charge Pressure (No Load and Under Load)

OK

Defective

Fill to Proper Level

Low

OK

Check System Pressure

Low

High

Reduce Transmission Load

Repair or Replace Inspect Check/Relief Valves or Charge Check Valves

Inspect Charge Pump

OK

Inspect Charge Relief Valve

Defective

Inspect Inlet Filter

OK

OK Defective

Defective

OK

Repair or Replace

Repair or Replace

Clogged

Repair or Replace

Replace

Replace Transmission (Pump & Motor)

Hydraulic & Hydrostatic Systems

212

4.3. Testing & Adjusting

Hydrostatic Motor Symptom Motor shaft does not rotate.

Possible Cause

Remedy

Pump does not run or runs in the

Start pump in the correct direction

wrong direction.

of rotation.

Motor spool has seized in housing.

Replace complete shaft and housing.

Cardan shaft or spool broken

Replace cardan shaft or complete

(shaft and communicate valve in two).

shaft and housing. Eliminate external force which caused the fracture.

Sand, steel chips or similar

Clean the motor and flush system

impurities in motor.

thoroughly. Renew defective parts.

Change the filter.

The seals which are incorporated

Inspect and replace them.

into balance plate are damaged.

Motor shaft rotates in wrong

Oil lines are wrongly connected

direction.

to motor ports.

Gear-wheel and rotary valve

Change the connections.

Adjust setting.

incorrectly fitted.

Leakage at motor shaft.

Shaft seal worn out or cut.

Replace shaft seal.

Leak between motor spigot

Spigot is loose.

Tighten screws with specified torque.

and housing.

O-ring defective.

Replace O-ring.

Leaks between housing,

Screws are loose.

Tighten screws with specified torque.

spacer plate , gear wheel set

O-ring defective.

Replace O-ring.

and end cover, respectively.

Steel washer defective.

Replace steel washer.

Hydraulic & Hydrostatic Systems

213

4.3. Testing & Adjusting

a. With the engine off, locate the adjustment screw on the control valve.

4.3.2. Hydraulic System

b. Loosen the lock nut and turn the adjustment screw approximately 1/8 turn. The adjustment screw is very sensitive, do not rotate it over 1/4 turn at a time. To increase the relief pressure tighten the adjustment screw clockwise, to decrease the relief pressure loosen it.

WARNING Hydraulic oil under pressure can remain in the system after the engine has been stopped.

Personal injury can be caused if this pressure is not released from the system before any work is started.

To be sure that the system is not pressurized, lower the boom to the ground with the engine off move the control pedals back and forth several times. This will release any pressure left in the system after shutting off the engine. The procedure must be done before any fitting, hose, or component is loosened.

Perform adjustments on level ground away traffic.

When making adjustments or taking measurements with the engine running, make sure that all personals clear of the machine.

c. Retighten the lock nut and check the relief pressure with above procedure. If the relief pressure still does not fall in the specific range, shut off the engine and adjust again. Repeat until the relief pressure falls into the specific range.

Adjustment Screw

Lock nut

Check & Adjusting Procedure of Relief Pressure of Control Valve A1

A2

A3

1. If attachment is installed on the truck, take it out from truck.

OUT

IN

2. Check the engine speed. It should be 2710 L 50 rpm, if it is not adjusted.

3. Warm the hydraulic oil to the temperature 100120°F (50 L 5°C).

B1

B2

B3

4. With the engine off, install 5000psi (350bar) rated pressure gage into the female coupler of the auxiliary hydraulic line(down side) on the boom.

IGAT085I

5. Start the engine and at high idle push the auxiliary. With keeping depressing the left side of thumb button on right driving control lever after pushing “on” switch of attachment on control panel, read the pressure gage.

6. The pressure gage should read between 3000 L 35 psi (210 L 2.5 bar) 7. If the relief pressure does not fall into the above range, do the steps that follow.

Hydraulic & Hydrostatic Systems

214

4.3. Testing & Adjusting

4.3.3. Hydrostatic System

WARNING Do not start prime mover unless pump is neutral position (0 swashplate angle). Take precautions to prevent machine movement in case pump is actuated during initial start up.

Start-Up Procedure of Hydrostatic System The following start-up procedure should always be followed when starting up a new installation or when restarting an installation in which either the hydrostatic pump or hydrostatic motor had been removed from the system.

Once charge pressure has been established, increase speed to normal operation speed.

Charge pressure should be 160psi minimum. If charge pressure is incorrect, shut down and determine cause for improper pressure.

WARNING The following procedure may require the vehicle to be disabled (wheels raised off the ground, work function disconnected, etc.) while performing the procedure in order to prevent injury to the technician and by-standers.

With motor output shaft disconnected or drive wheels raised off the ground, run system as full input and output speeds in both directions. Operate system for at least 15 minutes.

Shut down prime mover, remove gauge, and plug ports. Check the tank level and add fluid if necessary.

The transmission in now ready for operation.

Prior to installing the hydrostatic pump and/or motor, inspect the units for damage incurred during shipping and handling. Make sure that all system components (tank, hoses, valves, fittings, oil cooler, etc) are clean prior to filling with fluid.

Fill the tank with recommended hydraulic fluid which should be passed through 10 micron filter prior to entering tank.

The inlet line leading from tank to pump must be filled prior to start up. Check inlet line for properly tightened fittings and make sure it is free of restrictions and air leaks.

Be certain to fill the hydrostatic pump and/or motor housing with clean hydraulic fluid prior to start up. Fill the housing by pouring filtered oil into the upper case drain port.

Install a 500psi (35 bar) pressure gauge in the charge pressure gauge port to monitor the charge pressure during start-up.

With the pump swashplate in its neutral (0 angle) position, “jog” or slowly rotate prime mover until charge pressure starts to rise. Start the prime mover and run at the lowest possible RPM until charge pressure has been established. Excess air may be bled from the high pressure lines through the high pressure gages ports.

Hydraulic & Hydrostatic Systems

215

4.3. Testing & Adjusting

Hydrostatic pump

Gauge Information A

Gage Installation It will be necessary to install a high pressure gauge into the system pressure port (or tee into the high pressure line) to check the setting of the system pressure relief valves.

Measuring the charging pump inlet vacuum will help locate restrictions in the inlet lines, filter etc.

Case pressure readings can help locate restrictions in the return lines, oil cooler, and return filter.

B C

System Pressure

10000 psi (690Bar) gauge

Port “A”

9/16-18 O-ring fitting

System Pressure

10000 psi (690Bar) gauge

Port “B”

9/16-18 O-ring fitting

Charge Pressure

500 psi (35Bar) gauge 7/8-14 O-ring fitting

D

Case Pressure

500 psi (35Bar) gauge 1-1/16-12 O-ring fitting

Direct Displacement Control

A

Front

B

C

Rear

Inspect the connection of the control linkage to the swashplate control shaft to insure that the linkage is properly attached. Neutral position of the swashplate is determined by the vehicle control linkage.

(With Charge Pump)

D

D

Check High Pressure Relief Valves When a problem occurs in one direction, interchange the charge check or check/relief valves to see if the problem changes to the other direction. If so, one valve is malfunctioning or the check/relief valve cartridge does not have the proper setting pressure (4060 psi).

C B

Front

A

(Less Charge Pump) Rear

CAUTION : The relief valves are factory set and should not be tampered with except for replacing the entire cartridge. Disassembly may change the setting and cause erratic unit operation or premature failure.

IGAT086I

Gauge Connections (Top View)

Pump Charge Relief Valve If charge pressure is low, the charge relief valve should be inspected. Inspect for foreign material holding the poppet open, and for scoring or wear on the poppet and seat in the housing.

B Rear (Opposite Side)

Adjustment of the charge pressure is accomplished by changing the shim thickness behind the spring.

Bypass Valve

B

Front

The bypass function is accomplished by manually opening the charge check/high pressure relief valves.

If the system is operating hot, check that the valves are fully seated by turning the special plugs clockwise with a 5/16” internal hex wrench. Torque the plugs to 30 to 50 ft•lb (41 to 68 N•m).

IGAT087I

Gauge Connections (Side View)

Hydraulic & Hydrostatic Systems

216

4.3. Testing & Adjusting

4.4. Disassembly & Assembly 4.4.1. HST Pump NOTE : Only trained personnel should disassemble.

When making repairs on hydrostatic systems, clean the work area before disassembly and keep all parts clean. Mark the match points on housing.

1 5

IGAT090P

3. Remove four check and relief valves (5). The valve may be removed from the special plug by pulling straight out.

6

IGAT088P

2

3

1. Remove the screws (1) and hydraulic pump (2) from the HST pump (3).

4 16

IGAT091P

4. Remove the charge relief valve (6) from end cap (16).

1

7

8

9

10 11

IGAT089P

2. Remove the coupling (4) from the hydraulic pump.

IGAT092P

5. Remove plug (7), O-ring (8), shim (9), spring (10) and valve poppet (11) from the charge relief valve.

NOTE : Protect all exposed sealing surfaces and open cavities from damage and foreign material.

It is recommended that all gaskets and O-rings be replaced.

Hydraulic & Hydrostatic Systems

217

4.4. Disassembly & Assembly

17

12

IGAT093P

IGAT096P

9. Remove the valve plate (17) from the end cap (16).

6. Remove screws (12) from the pump.

Separate the front and rear sections of pump.

(Front pump is engine side and rear pump is hydraulic pump side).

19

Followings are disassembly procedure of front pump.

14

13

IGAT097P

18

10. Remove the cylinder block (18) from the housing (19).

IGAT094P 24 22

7. Remove coupling (13) and O-ring (14) from the front pump.

23

21

15

IGAT098P 16

20

11. Remove the slipper retainer and piston assembly (20) from the cylinder block (21). Remove the slipper retainer guide (24), pins (22) and slipper hold down retainer (23) from the cylinder block.

IGAT095P

8. Remove screws (15) and the end cap (16) with the valve plate from the front pump.

Hydraulic & Hydrostatic Systems

218

4.4. Disassembly & Assembly

26 19

25

31 30

IGAT099P

IGAT102P

16. Remove the screws (30) and the trunnion covers (31) (mark the position of cover for re-assembly).

12. Remove the retaining ring (25) from the housing (19) using plier.

13. Remove support washer (26) and lip seal.

27

28 32

IGAT103P IGAT100P

17. Remove both bearings (32).

14. Remove retaining ring (27) and front shaft (28) with bearing from the housing.

33

28

34

29

IGAT104P

18. Remove thrust plate (33).

IGAT101P

19. Do step 14 through 18 to disassemble rear pump.

15. Remove the retaining ring (29) and press the shaft (28) out of the bearing (34).

Hydraulic & Hydrostatic Systems

NOTE : There is no lip seal in the rear pump.

Remove the retaining ring first. Then the shaft and bearing may be removed.

219

4.4. Disassembly & Assembly

20. Assemble HST pump in the reverse order of disassembly. Refer to following torques when installing.

4.4.2. HST Motor CAUTION : Cleanliness is extremely important when repairing a hydraulic motor. Work in a clean area.

Before disconnecting the lines, clean the port area of the motor thoroughly. Before starting the disassembly procedures, drain the oil from inside the motor.

End cap onto the housing..........................47~61 N•m (35~45 lb•ft) Assembly of front and rear pump ..............47~61 N•m (35~45 lb•ft)

1

Charge relief valve ..................................54~125 N•m (40~100 lb•ft) Check and relief valve ...............................41~68 N•m (31~50 lb•ft)

IGAT105P

1. Place the motor in a vise with the output shaft down. Clamp across the mounting flange of the motor not the housing. Excessive clamping pressure will cause distortion.

2. Remove four bolts (1) from motor with socket spanner.

2

IGAT106P

3. Lift the valve housing (2) straight up.

Hydraulic & Hydrostatic Systems

220

4.4. Disassembly & Assembly

3 4

7

2

IGAT107P

IGAT110P

7. Remove valve drive (7).

4. Remove O-ring (3) and channel plate (4) from the valve housing (2).

5

8

2

9

IGAT111P IGAT108P

8. Remove gear wheel set (8) from bearing housing (9).

5. Remove disc valve (5) from the valve housing (2).

6

10

8

IGAT109P

IGAT112P

9. Remove O-ring (10) from gear wheel set (8).

6. Remove balance plate (6) from the valve housing.

Apply some clean oil for removal, if needed.

Hydraulic & Hydrostatic Systems

221

4.4. Disassembly & Assembly

11 16 9

IGAT113P

IGAT116P

14. Remove shaft and bearing assembly (16) from bearing housing.

10. Remove cardan shaft (11) from bearing housing (9).

Followings are procedures for assembly of HST motor.

11. Separate bearing housing from the vise.

16

12

9

13

IGAT114P IGAT116P

12. Remove six screws (12) and front cover (13) from bearing housing.

15. Install shaft and bearing assembly (16) to bearing housing (9).

14 14 15 15

13 13

IGAT115P IGAT115P

13. Remove shaft seal (14) and O-ring (15) from front cover (13).

Hydraulic & Hydrostatic Systems

16. Install shaft seal (14) and O-ring (15) to front cover (13).

222

4.4. Disassembly & Assembly

12 8 13

9

9

IGAT119P

IGAT111P

20. Install gear wheel set (8) to bearing housing (9).

17. Install front cover (13) to bearing housing (9) and tighten six screws (12) with torque of 24 L 2 N•m (210 L 17 lb•in).

7

8 10

8

IGAT110P IGAT112P

21. Install valve drive (7) to gear wheel set (8).

18. Install O-ring (10) to gear wheel set (8).

4 11

9

IGAT124P IGAT113P

22. Install channel plate (4) with O-ring to gear wheel set.

19. Install cardan shaft (11) to bearing housing (9).

Hydraulic & Hydrostatic Systems

223

4.4. Disassembly & Assembly

5 1 4

IGAT125P

IGAT105P

26. Tighten four bolts with the torque of 140 L 5 N•m (100 L 4 lb•ft).

23. Install disc valve (5) to channel plate (4).

4.4.3. Hydraulic Control Valve

16

1 2

IGAT109P 2

24. Install balance plate (6) to valve housing (2).

3

IGAT129P

2

1. Remove four screws (1) and electro-hydraulic kit (2) from the control valve assembly (3).

4

IGAT106P

25. Install valve housing (2) including balance plate to motor.

2

IGAT130P

2. Remove spool assembly (4) from the electrohydraulic kit (2).

Hydraulic & Hydrostatic Systems

224

4.4. Disassembly & Assembly

20 24

6

19

23

22

5

21

IGAT131P

IGAT134P

7. Remove joint (19), piston (21), flange (22), O-ring (23), spool control kit (20) and end cap (24).

3. Remove boot (5) and coil (6).

11

9

16 28 27

25

26 15 IGAT132P

14

13

12

10

8

7

IGAT135P

4. Remove tube (7), O-ring (16), pin (8), open ring (9), ring (10), spring (11), ring (12), rod (13), bushing (14) and spring (15).

8. Remove two screws (25), cover flange (26), ring (27) and O-ring (28) from the control valve.

5. Do steps 3 and 4 to disassemble the other coil assembly.

25

27

18

28

26

IGAT136P

IGAT133P

9. Remove plug (25), spring (26) and piston (27) from back-pressure valve body (28).

17

10. Remove back-pressure valve body from the control valve.

6. Remove flange (17) and O-ring (18).

Hydraulic & Hydrostatic Systems

225

4.4. Disassembly & Assembly

31 30

29

43

IGAT137P

IGAT139P

11. Remove main relief valve (29) from the control valve.

15. Remove load check valve (43) from the control valve.

12. Remove four screws (30) and float detent spool control kit (31).

16. Assemble control valve in the reverse order of disassembly. Refer to following torques when installing.

34

38

33

39

35

40

Main relief valve.........................42 N•m (31 lb•ft).

Back-pressure valve ..................42 N•m (31 lb•ft).

Load check valve .......................24 N•m (18 lb•ft).

41

36 32

42

37

IGAT138P

13. Remove boom spool assembly (32) from control valve.

14. Remove cover (33), O-ring (34), spring (35), thrust ring (36), bushing (37), cover (38), pin (39), bushing (40), spring (41) and bushing (42).

Hydraulic & Hydrostatic Systems

226

4.4. Disassembly & Assembly

4.4.4. Boom Cylinder

IGAT140I

1. Place the boom cylinder in a vice and remove the rod cover (3).

6. Remove the bushing (17) from the knuckle and head cover.

2. Remove rod assembly (2) from the cylinder assembly.

7. Assemble the boom cylinder in the reverse order of disassembly.

3. Remove spring pin (16), hex nut (15), piston (10) and rod cover (3) from the rod assembly.

4. Remove O-ring (11), dust ring (14), slipper seal (12) and wear ring (13) from the piston.

5. Remove dust wiper (4), back up ring (6), U-packing (5), DU-bush (7), O-ring (8) and back up ring (9) from the rod cover.

Hydraulic & Hydrostatic Systems

227

4.4. Disassembly & Assembly

4.4.5. Bucket Cylinder

IGAT141I

1. Place the bucket cylinder in a vice and remove the rod cover (3).

6. Remove the bushing (19) from the knuckle and head cover.

2. Remove rod assembly (2) from the cylinder assembly.

7. Assemble the bucket cylinder in the reverse order of disassembly.

3. Remove spring pin (18), hex nut (17), piston (12) and rod cover (3) from the rod assembly.

4. Remove cushion ring (11), O-ring (13), dust ring (14), slipper seal (15) and wear ring (16) from the piston.

5. Remove dust wiper (4), back up ring (6), U-packing (5), washer (10), DU bush (7), back up ring (9) and O-ring (8) from the rod cover.

Hydraulic & Hydrostatic Systems

228

4.4. Disassembly & Assembly

4.5. Hydraulic Schematic

8

14 15

B3 A3

9

11

7

6

B2 A2

16 5

B1 A1

OPTIONAL SELF LEVELING B2 A2 BUCKET CYL.

12 A1

1

BOOM CYL.

B1

4 ITEM

2

3

17 10 13

COMPONENTS

1

HST PUMP

2

HYDRAULIC PUMP

3

HST MOTOR

4

CONTROL VALVE

5

BOOM CYLINDER

6

BUCKET CYLINDER

7

QUICK COUPLING

8

QUICK COUPLING

9

VALVE BLOCK

10

DRAIN RELIEF VALVE

11

OIL COOLER

12

HYDRAULIC FILTER

13

SUCTION STRAINER

14

SHUTTLE VALVE

15

VALVE BLEEDER

16

ONE DIRECTIONAL RESTRICTOR

17

CONNECTOR WITH SCREEN FILTER

5. ELECTRICAL SYSTEMS 5.1. E/G Starting & Stop System

•12 Volts, 100 AH battery with 750 cold-cranking amps.

•Neutral safety switches on each drive lever centering control to prevent starting with transmission engaged.

•The start motor is rated 2.5 KW.

Electric Systems

231

5.1. E/G Starting & Stop System

5.2. Preheating System

•4 Glow plugs •Glowplug relay (Controller) The glow plug relay controls the operation of the glow plugs to give better starts to a cold engine. The relay senses the temperature around the engine and uses that information to regulate the amount of time the glow plugs are turned on before a start is attempted. The relay also operates a light on the instrument panel to indicate when the glow plugs are heating.

Electric Systems

232

5.2. Preheating System

5.3. Charging System

•65 amp alternator with built in voltage regulator.

Electric Systems

233

5.3. Charging System

5.4. Instrument Panel Layout

9

2

3

10

4

5

8

6

11

7

14

1

A

16

C

B

17

D

18

12

15

19

E

A) On switch B) OFF switch C) Green indicator light D) detent switch “ON” E) Detent switch “OFF”

1) Key Switch 2) Water temperature warning light 3) Engine oil pressure warning light 4) Charge warning light 5) HST oil temperature warning light 6) HST pressure warning light 7) Oil filter warning light 8) Warning light 9) Stop light 10) Buzzer 11) Light switch 12) Pre-heat light 13) Parking brake light 14) Fuel gage 15) Hour meter 16) Fuse-lamp 17) Fuse-instrument panel 18) Fuse-start 19) Fuse-horn

Electric Systems

13

NOTE : The left-hand instrument panel is a sealed unit. Warning lamps cannot be replaced individually.

In the right-hand unit, the pre-heat light (12) and parking brake light (13) can be replaced from the back.

NOTE : Refer to 5.4.1 MONITORING SYSTEM.

234

5.4. Instrument Panel Layout

5.4.1. Monitoring System

Electric Systems

235

5.4. Instrument Panel Layout

Electric Systems

236

Pushing button(C)

Pushing button(A)

Pushing button(C)

Pushing button(A)

forward control

panel

Pushing switch(E)

Pushing switch(D)

Pushing switch(D)

Pushing switch(D)

Either way

Pushing switch(E)

Pushing switch(E)

Pushing switch(E)

NOTE : Refer to 5.5.1. Schematic-Elec for Thumb control.

control

Detent

control

Momentary

switch(D,E) on

forward control

panel

Detent rocker

Button(A,C)on

Thumb button

“D1” relay “D2” relay

-After that releasing button

-

“R2” relay

Either way

“R1” relay

“D2” relay

releasing button

of button,

“D1” relay

-After that

right hand side

“F2” relay

of button,

“ON” relay

“F1” relay

left handside

-Keep depressing

“ON” relay

“D2” relay

“D1” relay

“ON” relay

-Keep depressing

Neutral

-

“R2” relay

of button Either way

“ON” relay “R1” relay

“F2” relay

of button Keep kepressing

“F1” relay

left hand side

right hand side

“ON” relay

“ON” relay

Keep depressing

Neutral

lever

on right control

operation

mode

Operation by operator

Relay

Operation

control valve

activation

-

REV solenoid

FWD solenoid

-

-

REV solenoid

FWD solenoid

-

Spool-in

Spool-out

-

-

Spool-in

Spool-out

-

of hydraulic

solenoid

-

spool motion

Attachment

spool

Attachment

-

Upper side

Down side

-

-

Upper side

Down side

-

boom(left side)

line port on

attachment

Flow out of

5.5. Operation of the related parts in momentary control & detent control-1760XL/DSL802

- Relay, solenoid valve, spool motion of control valve and direction of pump flow to attachment quick coupler port

5.5. Operation of the related parts in momentary control & detent control-1760XL/DSL802

5.5.1. Thumb Control

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5.5. Operation of the related parts in momentary control & detent control-1760XL/DSL802

5.6. LIGHTS and OPTIONS •Dual front and single rear area flood lights for standard.

•Available Options •Strobe light •Horn •Back up Buzzer •Heater •Cigar lighter NOTE : Refer to WIRING SCHEMATIC - ELEC.

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5.6. LIGHTS and OPTIONS

4) Charge warning Light

5.7. Item Descriptions and Functions 1) Key Switch

•The light turns on when trouble occurs in the charging system.

2) Water Temperature Warning Light 5) HST Oil temperature Warning Light

•The light turns on when the temperature of the engine cooling water exceeds 110˚C (230 ˚F).

•The light turns on when the temperaturre of the hydraulic oil to drive HST goes up to 100˚C (212 ˚F).

3) Engine Oil Pressure Warning Light 6) HST Pressure Warning Light

•The light turns on when the engine oil pressure is below 0.5 kg/cm2(15 psi).

Electric Systems

•The light turns on when the pressure of the HST pump oil falls below 6.0 kg/cm2 (85 psi).

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5.7. Item Descriptions and Functions

7) Oil filter warning Light

10) Buzzer

•If the oil filter becomes clogged, the light turns on.

•The buzzer is activated simultaneously with water temperature and engine oil pressurre warning lights.

8) Warning Light 11) Light Switch

•The light turns on simultaneously with Charge HST oil temperature, HST pressure and oil filter warning lights.

•Step 1 : Two front lights turn on.

•Step 2 : Two front lights and one rear light turn on simultaneously.

9) Stop Light 12) Pre-heat Light

•The light turns on simultaneously with water temperature and engine oil pressure warning lights.

Electric Systems

•When the key is turned to the “IGN” position, the glowplug relay turns on this light.

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5.7. Item Descriptions and Functions

13) Parking Brake Light

•Raising the hand lever, the parking brake is engaged and the light turns on.

14) Fuel Gage

•Fuel gage shows the amount of fuel in the fuel tank.

15) Hour meter

•Hour meter indicates the total hours of vehicle operating.

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5.7. Item Descriptions and Functions

5.8. Trouble shooting

5.8.2. Trouble shooting Guide

5.8.1. Test Equipment

NOTE 1 : The DSL has no electrical shutdowns, only visual and auditory indicators.

The following items should be sufficient to allow you to perform most electrical troubleshooting operations on the 1760 XL/DSL802 electrical system.

NOTE 2 : The lighting, instrument panel, and start (key switch) fuses (and horn fuse-optional, if equipped) located in the right-side instrument panel are all 15-amp tube-type fuses.

•Volt/ohmmeter (Multimeter) •Jumper wires (variety of lengths) with alligator clip ends •Needle tips •External 12-volt source •1760XL/DSL802 wiring diagram

Symptom Discharged battery

Engine does not crank

The following troubleshooting guide presents possible causes and actions in a logial order from simplest/most likely to more complex/less likely (more drastic). For any symptom, if a given action does not identify the problem, proceed to the next action.

Possible Cause Loose/damaged alternator belt.

Action Tighten/replace belt.

Loose/dirty connections.

Adjust/clean clamps, posts.

Battery faulty.

Replace battery.

Alternator faulty.

Check or replace.

Battery may be discharged.

Check battery condition.

Start fuse may be blown.

Check fuse in instrument panel.

Problem in neutrl safety

Wiggle drive levers while trying to

mechanisms.

start. If engine starts, adjust neutral switches and/or centering control(s).

Neutral switch(es) may be faulty.

Jumper neutral switch(es) one at a time. If engine starts, replace neutral switch(es).

Start relay may be faulty.

Jumper start relay. If engine starts, replace start relay.

Engine cranks but does not start

Glow plug does not work

Loader is out of fuel.

Check fuel tank.

Engine has starting problem not

Check engine. See section

related to electrical system.

2 Engine in this manual.

Alternator may be faulty.

Check alternator.

Wiring problem.

Check glow plug wiring.

Glow plug relay may be faulty.

Check wiring to relay. Jumper relay.

If glowplug works, replace relay.

Instrument panel indicator lights do

Glow plug elements(s) may be

Check elements. If problems found,

faulty.

replace glow plug.

Fuse may be blown

Check/replace fuse in instrument panel.

not come on or give faulty indications.

Individual panel lights do not

Control unit may be faulty

Replace control unit.

Bulbs may be faulty.

Check/replace bulbs.

come on.

Wiring to light may be faulty.

Check individual wiring.

Repair faulty connections or replace wires.

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5.8. Trouble shooting

Symptom Fuel gage does not work or gigves

Possible Cause Sender wiring may be faulty.

Action Check wiring between meter and

faulty indication (other instrument

instrument panel. Check sender

panel functions are OK)

ground.

Gage may be faulty.

Replace gage.

Meter wiring may be faulty.

Check meter wiring.

are OK).

Rear or front flood lights do not

Meter may be faulty.

Replace meter.

Fuse may be blown in instrument

Check/replace fuse in instrument

turn on.

panel.

panel.

Bulb(s) may be burned out.

Check/replace bulbs.

Wiring may be faulty.

Check connections and wires.

Hour meter does not register hours (other instrument panel functions

Check connections in cab wiring connector.

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5.8. Trouble shooting

2905 Shawnee Industrial Way Suite 100 Suwanee, GA 30024