SEZIONE 2.pdf

7/27/2019 SEZIONE 2.pdf

1/8

I VAI

Page.2-1.2-1.2-2.2-3.2-4.2-5

.

2-52-52-62-82-92.9

2 . C OOLIN G S EM-1 Generalescriti n- 2 S r v i i g o fw te r p u mp-3 Srvi ig ofthermostat- 4 Sr v i i g o fr a di to r-5 Troublshootj g

1. LUBRICATING SYSTEM1-1 Generai description

MAIN OIL GALLERY

I ~A~ ,~

"'AINBAC

The lubricating system is of the full-flow filtertype and is arranged as illustrated in Fig. 2-1.The engine oil pumped out from the oil pump @s primarily filtered through the full-flow type OILoil filter before it is fed into the oil gallery for PUMPlubricating the vitaJ engine parts. On modelequipped with the oil cooler. the engine oilfed. past the oil filter and oil cooler. into the Ioil gallery .

.ve I


2/8

2-2 LUBRICATING SYSTEM ANO COOLING SYSTEM

(1) Main data and specifications

Pressurized circulation typeTrochoid typeLubricating systemOil pump typeDelivery(Pump speed 1000 r.p.m.,Pressure cf delivery: 4 kg/cm2,Oil temperature; 50C,

Engine oil; SAE 30) :13.0 ill/min. or more

Oil filter type IRelief valve opening 'pressure

-Overflow valve opening pressure- kg/cm2_kg/cm2Paper element type full-tlow tilter5.7- 6.3 (C240)0.8 -1.2 (Pressure of difference at which Overflow valve opens)

Oil cooler typeRelief valve opening pressure kg/cm2External type. water-cooled oil cooler1.3- 1.7 (Pressure of difference at which Relief valve opens)

O.il pressure unit actuating pressure kg/Cm2 0.3 -0.5

1-2 Servicing of oil pump assembly3 -t::::> ~ Z

(2) Inspectjon and correction1) Inspection of vane, rotor and pinion gear.Check these parts for wear or damage andreplace with new ones as necessary.

2) Check the clearance between the vane, rotorand cover. If the measured value is beyondthe value indicating need for servicing, re-piace the rotor and vane.1. SHAFT2. PINION3. PIN4. ROTOR5. PIN6. VANE7. COVER8. BOL T

9. BOL T10. WASHER13. BOL T14. WASHER15. OIL PIPE16. SPACER17. STRAINER18. BOL T

17

FIG.2-2

3) Check the clearance between the rotor andvane. 11 the measured value is beyond thevalue indicating need far servicing, replacethe rotor using a kit.

Measuring tools: Feeler gauge square(1) Disassembly and reassembly

1) .Disconnect the oil pipe.2) Remove the gauze filter case and pump

cover, then remove the vane.3) Pull out the pin retajning the pinion and re-move the pinion from the rotor shaft.4) Remove the pin and rotor.

5) Remove the rotor shaft.6) To reassembfe, reverse the disassemblyprocedure.7) When reassembfy operation is completed,check that the rotor shaft turns smoothly.


3/8

LUBRICATING SYSTEM ANO COOLING SYSTEM 2.3

Servicing of oil filter-3

1. OILFILTERCARTRIDGE2. NUT3. OIL COOLER4. STUD5. PACKING6. PACKING7. BODY8. PIN9. PACKING10. PLUG11. VALVE

12. SPRING13. WASHER14. PLUG15. BOL T

FIG.2-44) Check the clearance between the vane and

pump body. If the clearance is excessive. re-piace the entire pump assembly.

3

4

I5--06--075) Check the clearance between the ratar shaftand pump body. If the measured value is

beyond the value indicating need far servic-ing, replace the entire pump assembly.

11 1210~ 13, ~ 14

/~15

FIG. 2-6

(1) Disassembly and reassembly;..1) Drain the oil filter by removing the drain plug.2) Remove the oil filter assembly from the

engine.3) Remove the filter element assembly.4) Remove the relief valve and overf(ow valve.5) To reassemble. follow the disassembly pro-

cedure in reverse order.NOTE: Apply a thin ccat cf engine cii t c thecil filter O ring. Install the filter as-

sembly and tighten it finger tight.FIG.2-5


4/8


(2) Inspection1) Check the relief valve and overflow valve vis-ually for damage paying attention to the join-ing face. then check- for smoothness of oper-ation. Replace the entire valve assembly iffound to be at fault.2) To check relief valvEf opening pressure. pro-.ceed as follows: Co~nect an oil pipe with oil; pressure gauge to a part of t.he oi~ gallerynear theo:( filter and take reading of the

~ gauge when the relief valve ope~s.

FIG.2-8

I l~~,a~,_~" ,"",c",,""","""","""'~'"" ,;I ,,""~-",~7&;~;;;~I ..=,.~~~~~

1-4FIG.2-7

Servicing cf cil cccler FIG. 2 -9cooler. While the safety valve of oil filter isbuilt in the oil filter element. and if the oilfilter element is stopped. oil can flow the oilgallery without passing the element.Oil will flow through the oil pump, the oilcooler fin, after being heat-exchanged withcooling water in the oil cooler. pass throughthe oil filter element and to the oil gallery ofthe cylinder body gallery without passingthrough the element.Cooling water goes through the intake of thecylinder head then go into and circulatethrough the oil cooler and goes to the backof the engine. and join returned water fromthe heater at 3 way connector in going backto the water pump.

Integrai water cooled oil cooler is madestandard equipment. This regulates lubricantoil temperature to normal, thus preventingoil deterioration and increase endurance ofengine. has sufficient power even under se-vere condition. This oil cooler has 5 stagefins at oil filter body. the upper part of whichis installed cartridge type oil filter element.The oil cooler and the oil filter have respec-tive safety valve. thus when the element or finis choked up bypass is opened through thecooler or filter and ensure the engine Iubrica-tion.The safety valve of oil cooler is fit to the filterbody, and if the oil cooler stopped, oil canflow through the filter without passing oil


5/8

LUBRICATING SYSTEM AND COOLING SYSTEM 2-5

NOTE: Cleaner is inflammable. Se sure tause cleaner under adequate ventila-tian and wear a mask and gagglesfar pratectian.

5) When cleaning is campleted, check ttle ele-ment tar cracking or damage. .FilI the ail caale.r with.water and plug ane afthe Q.iJ parts. Apply. campressed air ihta theail caaler trcm ?-nather ail part and check farwater leakage. ---

(2) Cleaning and inspection1) Make the cleaner by diluting 10% of Mobilso(A with 90% of Keros.ene.2) Fili the oil port of cooler with cleaner and

leave it in for approximately 10 hours.3) Remove 113 of cleaner from the element.plying compressed air (2 kglcm2) into theelement from the oil port.

4) Repeat the above steps more than 5 times.(Number of cleaning cycles should be ad-justed according to the condition of theelement.)

1-5 Trouble shootingCORRECTIONOMPLAINT CAUSE

Oil consumption t 00 high Use of wrong oilOil seals or gaskets detectivePiston rings or ring grooves wornPiston rings stickingValve stem oil controllers. valveguides or valve stems wornCylinder liners worn

Drain and refill with specified oilCorrectReplace piston rings or pistonsReplace piston rings or pistonsReplace oil controllers. valves orvalve guidesReplace cylinder liners

Oil pressure t 00 low Use of wrong OilRelief valve stickingDrain and refill with specified oilReplace relief valve or oilpump assemblycrean or replace gauze filterReplace oil pump assemblyCorrect or replaceReplace oil pump assemblyInstall undersize bearings

Restrictions in oil pump gauze filterOil pump driven rotor or driverotor wornOil pipe cracked. broken orloosely connectedOil pump defectiveCrankshaft bearings or connecting-rod bearings worn excessivelyOil pressure gauge defective ReplaceRestrictions in oil filterGases leaking

Oil deteriorates quickly Replace filter cartridgeReplace piston rings or honecylindersDrain and refill with specified oiUse of wrong oilClean or correctil does not reach valve

system Clean or correctClean or correct

Clean or correct

Oil ports in cylinder block andcylinder head cloggedOil ports in rocker arm shaftcloggedOil ports in rocker arm shaftbrackets cloggedOil ports in rocker arms clogged

2. COOLING SYSTEM2-1 Generai description

The cooling system consists basically of theradiator. water pump. cooling fan and ther-mostat. To facilitate quick normalization ofthe engine after cold starting. the coolingsystem incorporates a thermostat. so that thecoolant is bypassed into the water pumpwithout being cooled at the radiator before

the coolant reaches normal operating tem-perature. When the coolant temperaturereaches 82C, the thermostat valve begins toopen (the valve opens wide at 95C), cjrculat-ing the coolant through the radiator for effi-cient engine cooling.


6/8


Thermostat housingWaxpellet thermostat

Cylinder head...o(O

-o(Oa:

ccc-:-01COOU

Cyl. body oil codler chamber

Water pumpFIG.2-10

(1) Main data and specificationsImpeller type60ill/min. or more

Waxpellet type76C

Water pumpWaterpumptype ooooo.oOelivery (pump speed 3000 r.p.m.)

ThermostatThermostattype 000 0..00000..Valve opening temperature. .o. ..

2-2Il\ 1. FAN CENTER2. PUMP BOOV3. SETSCREW. SPRING WASHER

4. SCREW PLUG5. BEARING NUT6. THROWER7. SEALNUT8. IMPELLER9. GASKET

10. COVER11. SCREW

Service tools: Feeler gauge, square, bench press,scale. ";.~'ij~"~.o ~'~;.f~~~.#~ .".i;'~[~;~~~;,

(1) Di5a55embly1) Remove the bolt fixing the rear cover to the

bodyand remove the rear cover, then IOO5enthe bearing unit 5et 5CreW.2) Remove the pulley center.3) Remove the impeller and 5haft from the im-peller sjde of the body using a bench press.NOTE: Avaid the use af a hammer or otherimpact taal far impefler removal as

the impeller is iran cast and liable tabreak. FIG.2-12


7/8

5) Install the rear cover.NOTE: Apply adhesive compound to bothfaces of the gasket.

6) Install the fan center in position.NOTE: Press the fan center into position Sothat the distance between the fan fit-ting face of the fan center and pump

.body face is 111 + 0.3 mm.

FIG.2-177) Rotate the pump with hand and see if it turns

smoothly.NOTE: Discard used water pump gasket andinstall new one.

FIG.2-19NOTE: 1. It is important to allow a sufficient

time for the valve to open whenchecking the valve lift or valveopening temperature becausereaction of the thermostat to vari-ation in temperature is somewhatsluggish (it takes 3-5 minutes forthe thermostat to work in re-sponse to a change intemperature).2. Be sure to position a piece ofwood under the thermostat orhold the thermostat in suspen-sion in water to prevent effect ofdirect heat when checking thethermostat.3. Stir constantly to even out tem-perature of water during thetesti ng.

2-3

{3) InstallationInstall the thermostat so that its. circumferenceis in good contact with the thermostat housingand then. piace the water outlet pipe.NOTE: Discard used gasket and install new

one.{4) Replacement intervalsThe waxpel1et type thermostat contains. as itsname implies. wax to attain smooth controllingof the valve operation but when a leakage hasdeveloped the valve is closed by the action ofthe spring and the entire coolant is bypassed forcirculation within the engine and can cause en-gine overheatjng. It is therefore, recommendedthat the thermostat be replaced with a new oneperiodically according to the conditions underplaced every 50.000-70.000 km). It is also ad-visable to remove the thermostat assembly andcheck for trouble when the engine is runninghot and a thermostat failure is suspected.

(1) RemovalTake out the 2 nuts fixing the water outtet pipeand remove the outlet pipe. then remove thethermostat from the housing.

(2) Inspection1) Discard the thermostat and install a new oneif the valve is not correctly seated at normalroom temperature.2) Check the valve opening temperature andvalve lift by heating the thermostat gradualtyin water. Replace the thermostat assemblywith a new one if the measured value de-viates from the standard range.


8/8

LUBRICATING SYSTEM ANO COOLING SYSTEM 2-9

check far trauble when the engine is runninghat and a thermastat failure is suspected.Servicing of radiator-4

3} Flashing of cooling system.Formation of rust and scales in the waterpassages of the cooling system will invite aconsiderable reduction in the cooling effi-ciency. and to prevent this. clean the internaipart of the cooling system by using an essen-tial radiator cleaner or other radiator chemi-cals. The rate of r.eduction in the cooling effi-ciency due to fo~ling will be as follows, as-suming that the cooling efficiency of a cleancooling system i$ 100 percent (%}.When layer of scales is about- 0.42 mm inthickness 75%When layer of scales is about 0.65 mm inthickness 50%

4} Inspection of radiator core.Check the cooling fins for bending and dis-tortion as bent or distored cooling fins willprevent smoo1.hcflow of air and cause engineoverheating.If the cooling fins are found to be bent.straighten them out carefully to preventseparating them from the water tubes. Checkthe radiator core for presence of oil. dirt andother foreign matters and clean as necessaryto maintain normal cooling efficiency.

(1) InspectionIf the pressure valve is de.fective and the coolingwater is not pressurized, not only air bubb(eswill be formed within the cooling system andinvite lowering of cooling efficiency but also theboiling point of the cooling water will qe low-ered nearly to 100C. .,1) Inspection of radiator filler cap.Check the rubber gasket and reaf spring of

the filler cap for abnarmal contact andweakening.AIso check the pressure valve and vacuumvalve opening pressure and replace the fillercap as necessary.2) Inspectian of radiator far leaks.Check the radiatar for leaks and replace iffaund to be defective. Ta test far 'eaks pro-ceed as follows:Submerge the radiator into water with theinlet and autlet plugged and apply air pres-sure of 1 kg/cm2 inta the radiatar and see ifair bubbles arise.

2-5 Trouble shootingCAUSE CORRECTIONOMPLAINT

Replenish, check for leakageand correct as necessaryReplace filfer cap assembly

Engine overheating--

Cooling water level t 00 low

Adjust or replace fan beltReplace fan beltReplace thermostat assembly

Radiator cap pressure valvespring weakenedFan belt loosened or brokenFan belt slippingThermostat defective (valve notopening)Water pump defectiveRestrictions in water passagesdue to accumulation of scalesInjection timing incorrectRestrictions in radiatDr coreGases leaking into water jacketdue to broken cylinder head qasket

Engine over-cooling Thermostat detective (valve notclosing completely)Ambient temperature too low

'requent replenishment is needed Correct or replaceRetighten clips or replace hosesRadiatorleakingRadiator hoses loosely connectedor damagedRadiator cap valve spring weakenedWater pump leakingHeater hoses loosely connected or brokenCylinder head gasket leaking

Replace filler cap assemblyReplace water pump assemblyRetighten or replace hosesCheck cylinder head andreplace gasketReplace cylinder head or

~~Cylinder head or cylinderblock cracked

Replace water pump assemblyRetighten or replace fan assemblyReplace fan assembly

B -place fan ?elt- -

Water pump bearing detectveFan loosely titted or bentFan out ot balancedFan belt detective

Cooling system noisy

SEZIONE 2.pdf

Documents

Transcript of SEZIONE 2.pdf