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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