Clutch cable 4. Starter cable 5. Oil outlet hose. Remove: — upper engine support bolt no. Remove pinion cover no. Set the first gear. Unlock retaining ring then, unscrew the retaining nut. NOTE: Discard the retaining ring. Remove engine pinion and drive chain together.
Install a new retaining ring each time the pinion is removed. For the installation, reverse the removal procedure. Paying attention to the following details. Install pinion with lips on the engine side. Remove exhaust pipe nuts no. Unscrew exhaust clamp no. Pull exhaust pipe forward. Remove pipe gasket no. Remove springs no. Use a new exhaust pipe gasket and make sure that it is properly installed. Tighten flange nuts, making sure RH exhaust pipe is properly aligned inside LH exhaust pipe.
Install retaining ring then retaining nut. Adjust drive chain. LH Exhaust Pipe For installation, reverse the removal procedure, paying attention to the following details. Install flange nuts, making sure exhaust pipe is properly aligned inside muffler ball socket then install retaining springs after pushing muffler forward in exhaust pipe. Do not torque yet.
Install RH exhaust pipe. Torque all flange nuts. Remove screw no. Under rear fender, remove screw no. Remove muffler. Muffler Installation For installation, reverse the removal procedure. NOTE: Check rubber bushings nos. Refer to BODY. Remove head light. Drain engine oil.
Remove: — oil inlet hose no. Unscrew bolts retaining oil tank and fuel tank cover to the frame. Unscrew bolt no. Pull oil tank. Installation For installation, reverse the removal procedure. Install rubber washer no. Do not forget spacers no. Bleed engine if necessary. Pressurize all system through coolant reservoir to kPa 15 PSI.
To drain cooling system, unscrew cooling plug no. Refilling Procedure With vehicle on a flat surface, engine cold, remove the temperature sensor no. Fill radiator no.
Install the temperature sensor and continue the cooling system filling by the radiator. Fill coolant tank no. Install radiator pressure cap. Run engine for brief period then stop engine. Refill up to mark, if necessary. When engine has completely cooled down, recheck coolant level in radiator no.
Check coolant concentration freezing point with proper tester. If not, install a new kPa 16 PSI cap do not exceed this pressure. Do not reinstall pressure cap.
Pure antifreeze without water freezes. Always use ethylene-glycol antifreeze containing corrosion inhibitors specifically recommended for aluminum engines. Drain off coolant. Remove cover no. Drive out spring pin no. Remove left engine housing cover.
Remove shaft no. Remove thrust washer no. Press out sealing rings no. NOTE: Do not drive spring pin into impeller until engine housing cover has been installed. Drive internal sealing ring no. Fill cavity between sealing rings with Molykote paste. Drive external sealing ring no. Refill radiator.
NOTE: Do not forget rubber bushings no. Drain cooling system. Remove: — front facia refer to BODY — inlet no. Inspection Check protector air passage for damage. Remove insects, mud or other obstructions with compressed air or low pressure water. Removal The thermostat is located on the RH side of engine. Unfasten cover no. Pull radiator out of frame by the RH side. Inspection Check radiator air passage for clogging or damage. Check for any coolant leakage from radiator and hoses. To check thermostat, put in water and heat water.
If the limiting system working pressure cap is reached kPa 16 PSI , the pressure relief valve in the pressure cap is lifted from its seat and allows coolant to flow through the overflow hose into the overflow coolant tank. Removal Remove overflow hose no. Unfasten the hose anchor no. Empty coolant tank. Heat Shield Installation The installation is the reverse of the removal procedure.
Test Using a multimeter, measure the resistance between both temperature sender connectors. The multimeter should indicate an infinite resistance O. If the resistance is infinite O. The resistance should be 0. If not, change the temperature sender. Installation The installation is the reverse of the removal procedure, paying attention to the following detail. Check gasket no. Test Using a multimeter, measure the resistance between connector on the top of temperature sensor and threads.
If not, change the temperature sensor. Installation The installation is the reverse of the removal procedure. Removal Unfasten socket screws on right engine housing cover. Unfasten central screw plug no. Remove ignition cover no. Unscrew nut no. Remove lock washer no. Remove gasket. NOTE: Clean all metal component in a non-ferrous metal cleaner.
Remove all socket screws no. Apply light coat of Loctite to taper on rotor hub no. Oil sparg clutch no. Slide rotor onto crankshaft, woodruff key and groove must be aligned in one line.
Rotate starter double gear counterclockwise to enable the sparg clutch to slide on the collar of sparg clutch gear no. Install lock washer and nut on crankshaft end. Apply Loctite on threads.
Seal rubber grommet no. Screw handle in center bore. Fit magneto housing and screw down. Unfasten handle and install screw plug in cover.
NOTE: Install a new gasket on ignition cover. Unscrew all socket screws no. Remove sparg clutch from sparg clutch housing. Secure trigger coil with taptite screws and fix screws with Loctite Twist rotor no.
Use feeler gauge to measure gap between guide piece and trigger coil. NOTE: Apply engine oil on sparg clutch. Install sparg clutch with the arrow on the top. Unscrew bolts no. Coat rubber grommet no. If necessary, correct gap by bending the retaining plate. Fit gasket. Unfasten center screw plug to right of engine housing cover. Move crankshaft into TDC setting with the Allen key.
Remove the upper section of camshaft carrier no. Remove camshafts no. NOTE: Only unfasten timing gears if they need to be replaced. Secure timing chain no.
Remove front chain rail no. Inspection Check each lobe for scoring, scuffing, cracks, or other sign of wear. Measure camshaft base circle diameter and lobe height, using a micrometer. Measure clearance between camshaft and camshaft carriers, using the plastic feeler gauge. NOTE: The plastic feeler gauge is available at automotive parts retailer. Tighten camshaft carrier to specified torque. Unfasten camshaft carrier and determine clearance using comparative scale. NOTE: Never stretch spring since this alters the defined spring force.
Tighten screws no. Fit upper section of camshaft carrier and tighten down. Check valve clearance. Install chain tensioner and tighten screw no. Install valve cover with gasket. Unscrew and remove crankshaft locking bolt. Install the screw plug with sealing ring. The spring no. Disassembly Remove the exhaust camshaft no. Use an appropriate punch to press shaft no. Assembly Reassemble in the reverse order of disassembly.
Paying attention to the following detail. After assembly, check if the centrifugal weight move smoothly. Remove starter. Remove camshafts. Withdraw the front chain rail no.
Unfasten nuts no. Unfasten socket screws no. Remove cylinder head. Fitting cylinder head gasket. Slide timing chain through chain duct. Tighten cylinder head and cylinder hand tight with collar screws. Screw collar nuts onto stud bolts and tighten crosswise. Tighten collar screws crosswise. Tighten socket screws on cylinder base. Install camshafts. Valve Inspect valve surface, check for abnormal stem wear and bending. If so, replace by a new one.
Valve Stem and Valve Guide Check valve stem and valve guide for wear or friction surfaces, if so, replace parts. Measure valve stem and valve guide in three places, using a micrometer and a small hole gauge.
NOTE: Clean valve guide to remove carbon deposits before measuring. Removal Remove: — cylinder head no. Compress valve spring, use a spring compressor. Remove valve cotters no. Remove spring compressor, valve spring retainer no. Change valve if valve stem is out of specification. Change cylinder head if valve guides are out of specification. Valve Face and Seat Check valve face and seat for burning, pitting and other signs of damage. Apply some lapping compound to valve face and work valve on its seat with a lapping tool.
Measure valve face contact width. NOTE: The location of contact area should be in center of valve face. Measure valve seat width, using a caliper.
Remove: — cylinder head no. Pull cylinder. If valve seat contact width is too wide, too narrow or has spots, the seat must be ground or cylinder head replaced. Inspection Cylinder Check cylinder for cracks, scoring, rust and wear ridges on the top and bottom of the cylinder. Installation Install valve. NOTE: Remove assembly sleeve once again.
Install valve spring and valve plate spring. NOTE: Install valve tappets with a small amount of grease to facilitate assembly. Inspection of valve stem seals is not needed as new seals should always be installed whenever a cylinder head is diassembled. Difference between measurements should not exceed 0. If so, replace cylinder. Slide timing chain through chain duct, then slide cylinder over piston. Remove the ring compressor. Secure cylinder on engine housing with the socket screws.
Fit cylinder head. Tighten cylinder and cylinder hand tight with collar screws. Remove cylinder. Remove both piston pin circlips no. Inspection Check piston pin for crack or other damage. Measure both ends of piston pin with a micrometer. Apply engine oil on the piston pin. Insert piston pin into piston and connecting rod. Secure piston pin with both piston pin circlips. NOTE: Do not align the end gap of the piston pin circlips with the cutout in the piston bore.
Detach piston from connecting rod. NOTE: Mark base of piston on exhaust end. The measured dimension should be as described in the previous table. If not, replace piston. NOTE: Make sure used piston is not worn. Adjust and lock a micrometer to the piston dimension. Inspection Inspect piston for scoring, cracking or other damages.
With the micrometer set to the dimension, adjust a cylinder bore gauge to the micrometer dimension and set the indicator to 0 zero. NOTE: Install piston with removal mark on base of piston in direction of exhaust end. If the clearance is too large, the piston should be replaced. Read the measurement on the cylinder bore gauge.
If clearance exceeds specified tolerance, replace cylinder or rebore. See previous table. NOTE: Make sure the cylinder bore gauge indicator is set exactly at the same position as with the micrometer, otherwise the reading will be false.
NOTE: In order to correctly position the ring in the cylinder, use piston as a pusher. Using a feeler gauge, check ring end gap. Replace ring, if gap exceeds specified tolerance. See above table. Install the oil ring first, then the middle ring with the word TOP facing up, then the top ring with a dot facing up. Oil ring. NOTE: Use a ring expander to prevent breakage during installation.
The oil ring must be installed by hand. Check that rings rotate smoothly after installation. Lift up left side of engine housing, striking alternate gentle blows with plastic hammer on mainshaft, countershaft and balancer shaft to ensure that these remain on magnet side. Remove shims no. Align marks on balancer shaft and crankshaft with marks on housing.
DO NOT align ring gap with piston thrust side axis 2. Inspection Check balancer shaft bearings nos. Installation Install balancer shaft in engine housing, mark must be aligned with mark on housing. Coat thrust washer no. Rotate crankshaft before installing so that mark is aligned with mark on housing. NOTE: Coat bearing points on shafts. Recentre crankshaft and balancer shaft if either housing, crankshaft or balancer shaft were replaced.
The minimum diameter for bearing journal is If the measure exceeds specified tolerance, replace the crankshaft. Measure the interior diameter of the crankshaft bushing.
Subtract bearing journal diameter from inside bushing diameter. The result is the main bearing radial play. Connecting Rod Big End Axial Play Using a feeler gauge, measure distance between thrust washer and crankshaft counterweight. If the distance exceeds specified tolerance, replace the crankshaft.
Compare to inside diameter of connecting rod. Clamp crankshaft in vise with protective jaws. Align mark on punch with mark on housing. Bushing must be inset behind oil holes. The notch on the bushing should always face the balancer shaft. Using a suitable slide hammer, extract ball bearing. NOTE: The sealed ends of the cage must point outwards. On magneto side, the spacer is always 1. Place crankshaft into right engine housing magneto side.
Do not install spacer on clutch side. Using depth gauge, measure distance between crank web and housing joint. Select suitable spacer to ensure the correct end float is obtained.
Place balancer shaft into left engine housing clutch side. Using depth gauge, measure distance between the top of balancer gear and housing joint. Determine dimension between compressed gasket in left engine housing clutch side and washer contact face. Determine dimension between compressed gasket in right engine housing magneto side and inner ring of bearing. If the engine pressure is out of specifications, check the points described in Low or No Oil Pressure section above.
Oil change should be done with a warm engine. Clean the reservoir drain plug area. Drain all oil from oil tank by removing drain plug. Wipe out any oil spillage. Unscrew drain plug no. Unscrew oil filter cover no. Remove oil filter and replace by a new.
Change gasket no. Check if the RED indicator lamp stays ON, if yes, stop engine and bleed system by removing oil filter and bleeding screw no.
Refer to Bleeding Engine Oil Circuit below. Install pressure bleeding screw. Removal Ensure vehicle is on a level surface. Drain oil tank.
Remove hose under oil tank. Unscrew and remove oil tank strainer. Cleaning and Inspection Clean oil tank strainer with the parts cleaner then use an air gun to dry it. Remove: — snap ring no. Inspect oil pump for marks or other damages, specially scratches in crankcase between inlet and outlet parts.
Using a feeler gauge, measure the clearance between oil pump rotor and inner rotor. Markings on inner rotor and oil pump rotor must be visible. Coat inner rotor and oil pump rotor with oil. Removal Separate both crankcase housings. Unscrew the bolts no. Cleaning and Inspection Clean engine oil strainer with the parts cleaner then use an air gun to dry it. Check engine oil strainer for damage and change if necessary.
Measure oil pump rotor thickness and oil pump rotor bore depth. If so, replace oil pump rotor. The clutch adjustment is necessary after any works in the clutch system. Removal Drain engine oil and coolant. Detach clutch cable. Remove: — starter — water pump cover no. Unfasten screws no. Pressure plate bearing must have full freedom of movement. If not, change the bearing. Check spline on clutch actuator rack no. Change if necessary. Disassembly Remove the retaining ring no. Assembly For assembly, reverse the disassembly order.
The pressure plate bearing may come out of pressure plate. Remove friction plates no. Unlock the tab washer no. Unscrew the clutch lock nut no. Remove clutch hub no. Inspection Friction Drive Plate Measure the package of friction drive plate thickness. Friction drive plates must be replaced when thickness is The friction drive plate maximum warpage should fall through a slot of 3.
Steel Driven Plate The steel driven maximum warpage should fall through a slot of 1. The wear limit of the whole package is Clutch Basket Check slots of clutch basket for damage or wear caused by friction drive plates. Assembly in the reverse sequence of disassembly. Install the needle bearings.
NOTE: Install small needle bearing underneath. Coat spline on countershaft with Loctite anti-seize. In first, install steel driven plate, then friction drive plate in alternate order. Remove LH engine housing cover. Remove the retaining ring no. Withdraw clutch release shaft from housing. Insert clutch release shaft. Install LH engine housing cover and do not forget gasket.
Removal Remove engine from vehicle. Separate both crankcase housings. Press shift pawl slightly outwards and withdraw shift shaft no. Remove index lever no. Remove shift fork shafts nos. Swivel shift forks outwards and remove. Withdraw shift drum no. Inspection Check for: — worn or scored shifting forks — rounded engagement dogs and slots — bent shift forks — bent shift fork shafts — worn tracks on shift drum.
Measure the shift fork claw thickness. Install index lever no. Attach pawl spring no. Proper strength Loctite 3.
Shaft 1. Clean inner housing diameter and outer gasket diameter. Standard 2. Spray housing and gasket with Loctite Primer N 1. When they are not specified refer to following table. The table also gives the metric conversion. Print page 1 Print document 21 pages. Rename the bookmark. Delete bookmark? Cancel Delete. Delete from my manuals? Sign In OR. It's definitely isn't instant download so beware and they don't answer there customer support.
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