Ford 134 | 144 | 172 | 192 Engine Service Manual
Service Manual
Ford
Service Manual
134 Gas, 144 Diesel 172 & 192 Gas & Diesel
4 Cylinder Engines
THIS IS A MANUAL PRODUCED BY JENSALES INC. WITHOUT THE AUTHORIZATION OF FORD OR IT'S SUCCESSORS. FORD AND IT'S SUCCESSORS
ARE NOT RESPONSIBLE FOR THE QUALITY OR ACCURACY OF THIS MANUAL.
TRADE MARKS AND TRADE NAMES CONTAINED AND USED HEREIN ARE THOSE OF OTHERS, AND ARE USED HERE IN A DESCRIPTIVE SENSE TO REFER TO THE PRODUCTS OF OTHERS.
FO-S-ENG134+
FORD
Power Products
INDUSTRIAL ENGINE
SHOP MANUAL
~R 74 194 -114
ii
TABLE OF CONTENTS
PART I - DESCRIPTION OF ENGINE PART II - OPERATION PART III - MAINTENANCE PART IV - SPECIFICATIONS AND
RESTRICTIONS PART V - REPAIRS
PAGE 1 3 4 7
13
CHAPTER 1 - ENGINE
13
Section:
1. Cylinder Head and Valves
14
2. Oil Pan, Oil Pump and Oil Filter
20
3. Connecting Rod, Bearings,
Pistons, Rings and Cylinder Block 24
4. Main Bearings, Balancer, Flywheel
and Crankshaft
29
5. Engine Governor - Industrial
Models
34
6. Engine Governor - Forklift Models 36
7. Camshaft and Camshaft Gear
37
8. Front Cover - Power Take-Off
39
9. Troubleshooting
40
10. Special Tools
49
CHAPTER 2 - ELECTRICAL SYSTEM 49 Section:
1. Battery
49
2. Generator
54
3. Alternator
56
4. Starting Motor, Solenoid and
Starting Circuit
58
5. Troubleshooting
62
6. Special Tools
67
CHAPTER 3 - IGNITION SYSTEM
68
Section:
1. Spark Plugs and Ignition Wires
68
2. Coil
69
3. Distributor
69
4. Troubleshooting
72
CHAPTER 4 - FUel AND EXHAUST SYSTEM - GASOLINE Section:
1. Con structi on 2_ Fuel Tank 3. Fuel Pump 4. Air Cleaner 5. Carburetor {Marvel Scheblerl 6. Manifold 7. Troubleshooting
PAGE
77
77 77 77 79 79 83 84
CHAPTER 5 - FUel AND EXHAUST
SYSTEM - DIESEL
85
1. Construction
85
2. Fuel Tank
85
3. Primary Fuel Pump
85
4. Air Cleaner
87
5. Bleeding and Flushing the
Fuel System
87
6. Injection Pump
87
7. Idle and High Speed Adjustment 88
8. Variable Speed Droop Device
Adjustment
89
9. Fuel Injectors
90
10. Fuel Injection Pump Drive
92
11. Manifold
93
12. Troubleshooting
94
13. Engine Applications
96
14. Special Tools
98
CHAPTER 6 - FUel SYSTEM -
LPG (ZENITH)
98
Section:
1. Construction
99
2. Principles of Operation
100
3. Carburetor
101
4. Vaporizer
104
5. Troubleshooting
104
CHAPTER 7 - COOLING SYSTEM
106
Section:
1. Construction and Operation
106
2. Care of the Cooling System
107
3. Radiator, Hose and Pressure Cap 107
4. Water Pump (Industrial Series)
107
5. Thermostat
108
6. Fan Drive Belt
108
7. Troubelshooting
109
2
PART I - DESCRIPTION OF ENGINE
All spark plug terminals and lead wires are integrally sealed in molded rubber, and the distributor is tightly sealed against dust and dampness.
On diesel models, an injection pump meters fuel to the injectors. A built-in governor regulates flow of fuel to maintain desired engine speed, and an automatic advance properly times injections with engine speed and load. Each
diesel engine has 4?hole injectors with each precIsionmade injector dispersing fuel evenly into the cylinder for efficient combustion, more power, and better fuel economy. The excess fuel bleeds back to the tank.
Specifications for the models of both, the gasoline and diesel engines, are in Part IV of this manual.
FIGURE 2 - Typical- 4-CylinderGasoline Industrial Engine (Left Front View)
FIGURE 3 - Typical - Diesel Industrial Engine
PART V, CHAPTER 1 - ENGINES
15
c. Remove the two attaching bolts from each injector. Attach Injector Lifting Bar, EIADDN17098 to the injectors as shown in FIGURE 6. Make sure the legs of the tool bear against the cylinder head rather than the rubber injector seal. Remove the fuel injectors and the injector seat washers from the cylinder head.
FIGURE 6 - Removing Fuel Injectors.
d. Remove the two bolts and lockwashers that attach the fuel filter to the cylinder head.
8. Remove the bolts that attach the cylinder head to cylinder block. Carefully lift the cylinder head from the block.
NOTE: If available, use Cylinder Head Overhaul Fixtures, 6085-F.
9. Place the cylinder on its side or in fixture 6049.
B. Cylinder Head Disassembly
1. Prior to removing the valves, clean all carbon deposits from the combustion chambers. Position valve spring Compressor 6513?EE over the valve and spring as shown in FIGURE 7 and compress the valve spring. Remove the two valve spring retainer locks, sleeve, retainer, spring and spacer from each valve. Lift the valves from the head and place them ina numbered rack so that they can be installed in their respective guides.
NOTE: Exhaust valves are provided with a cap and do not have a sleeve. Spacers are used originally only under the exhaust valve springs on diesel engines.
FIGURE 7 - Removing Valve Spring Retainer Locks.
C. Cleaning
GASOLINE ENGINES:
Remove all grit, dirt and grease from the cylinder head with a scraper. Clean the valve gu ides with a valve guide cleaning tool. Scrape all gasket surfaces clean.
DIESEL ENGINES:
Remove any injector washers that remained in the bores with a screwdriver that has approximately the same width blade as the I.D. of the washer. Tap the screwdriver so that the blade bites into the washer, then twist the screwdriver to free the washer. Clean all carbon and dirt from the injec? tor bores.
Carefully scrape the gasket and carbon from the head.
D. Inspection
NOTE: Refer to Part IV Specifications & Restrictions for tolerance and dimensions.
1. Inspect the cylinder head for being cracked, nicked or burred on the gasket surfaces. Replace the head if it is cracked. Remove small burrs or nicks with an oil stone. With a straight edge and thickness gauge, check the flatness of the cylinder head as shown in FIGURE 8. Specifications for flatness are 0.006 inch maximum overall or 0.003 inch in any 6 inches. Check the exhaust valve seat inserts for cracks, looseness or excessive wear. Replace the inserts if any of these conditions exist. Check the width and concen? tricity of the valve seat (FIGURES 9 and 10). Replace the seats if they are pitted or if they are wider than 0.130 inch. Measure the inside dia? meter of the valve guides with a telescope gauge
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