Constant-speed throttle removal and installation

AR01.50-B-1000B

Constant-speed throttle removal and installation

12.02.16



Remove

1

Removing injection nozzles

AR07.03-B-6830B

2

Removing the cylinder head

AR01.30-B-5800D

Place the cylinder head on the fastening device so the constant throttle valve remains supported on a piece of wood or plastic.

This procedure will facilitate removal of the keepers, maintaining the valve pressed in its housing.



*442589046300

3

Remove the plug (8) and the metal sealing ring (9)

4

Remove the piston (12) the sealing ring (10) and the guide ring (11)

The piston (13A) is utilized in current engines.

5

Remove the keepers (6)

For removal, utilize the spring compressor (7) and press it so the keepers (6) become released from the exerted pressure.

If necessary make use of a small hook to release the valve stem keepers.

Remove the compressor from the spring (7) and rotate the cylinder head. Push the valve manually so the keepers can get out.



*442589001400

6

Remove the spring (4) with the top plate (5) and bottom plate (3)

7

Remove the valve (1)



Check

8

Check the throttle valve (1) for condition and dimensions

Replace the valve when presenting wear or rework it if necessary.

Stem diameter (G)

*BE01.50-B-1001-01A

Valve head diameter (E) (cylindrical part)

*BE01.50-B-1002-01A

Total valve length (H) measured from the reference line “A” to the valve's sealing face

*BE01.50-B-1003-01A

Diameter (D)

*BE01.50-B-1004-01A

Out-of-round measured on line “A”

*BE01.50-B-1005-01A

Sealing face width (C) measured from the line “A” to the line “B” (A and B = reference lines)

*BE01.50-B-1006-01A

Inclination angle (I) on the valve's sealing face

*BE01.50-B-1007-01A

Angle (J)

*BE01.50-B-1008-01A

Angle (F)

*BE01.50-B-1009-01A



*001589532100

If necessary, rework it.

Measure and check the housing of the throttle seat, if necessary rework the seat housing in the cylinder head.

The throttle housing does not have seat insert.

Measure the bore diameter of the stem housing in the cylinder head

*BE01.50-B-1005-01A

Seat milling is indicated to correct small irregularities on the valve's seat face.

Carry out the milling observing the indicated angles.

After milling thoroughly clean the valve seat, check with a new or machined valve, if the seating is perfect. To do so, apply a small quantity of oil and Prussian blue mix on the face of the valve seat. Next, put the valve in its seat and turn it a few times to the right and to the left approximately 1/4 of one turn.

Remove the valve and check the contact area with the seat. The seat must present Prussian blue totally and uniformly. Otherwise, make the required corrections.

Clean the seats with an adequate solvent and oil them lightly.

There is no depth to be measured from the cylinder head mating surface to the valve head. The milling is carried out on the same cylinder head material, it has no seat insert.

9

Check the spring pressure

Spring free length.

*BE01.50-B-1010-01A

Spring length with load on the testing scale.

*BE01.50-B-1011-01A

Maximum valve opening with the pneumatic piston at end of stroke.

*BE01.50-B-1012-01A

10

Check the bore diameter of the stem housing in the cylinder head

*BE01.50-B-1016-01A

11

Check the bore diameter of the pneumatic piston housing in the cylinder head

*BE01.50-B-1017-01A

12

Check the outside piston diameter (12)

*BE01.50-B-1018-01A



Installing

13

Install the valve stem

Oil the stem with engine oil.

Install the cylinder head again in the device so the valve remains pressed-in. For this, place a small wooden or plastic block on the valve head.

14

Install the bottom plate (3), the spring (4), and the top plate (5) observing its correct position

Oil the plates and the springs with engine oil, press-in the spring (4) with the manual compressor (7) so the keepers (6) are released. Confirm the actuation of the valve (1) with the spring (4). To do so, press the end of the valve stem with a small hammer handle. The valve should open and close normally.

15

Install a new piston (13A) complete with rings

16

Manually install the guide bushing (14) in the cylinder head

Oil inside the bushing (14) and the piston (13A) with engine oil.



*442589001400

17

Install the piston (13A) through the guide bushing (14) and press it with the assembly drift (15) until resting against the valve stem.



*442589001400

19

Remove the guide bushing (15) from the cylinder head.

19

Install the plug (8) with a new metal sealing ring (9).



*BA01.50-B-1002-01A

20

Installing cylinder heads.

AR01.30-B-5800D

21

Installing injection nozzles

AR07.03-B-6830B

Número

Denominação

Engine 475.9; 476.9

BE01.50-B-1001-01A

Rod diameter (G)

mm

7,995...8,010

BE01.50-B-1002-01A

Valve head diameter (E) (cylindrical part)

mm

16,850...17,150

BE01.50-B-1003-01A

Valve total length (H) measuring from the A reference line up to the rod's end flat face

mm

85,80...86,00

BE01.50-B-1004-01A

Diameter (D)

mm

15,99...16,01

BE01.50-B-1005-01A

Eccentricity measured in the A line”

mm

0,03

BE01.50-B-1006-01A

Sealing face width (C) measured from the A line up to the B line” (A and B = reference lines)

mm

1,5

BE01.50-B-1007-01A

Slant angle (I) on valve seal face

mm

45° +10’

BE01.50-B-1008-01A

Angle (J)

mm

30°

BE01.50-B-1009-01A

Angle (F)

mm

90° +20’

BE01.50-B-1010-01A

Free spring length

mm

40,40

BE01.50-B-1011-01A

Spring length with load

60 - 80 N

mm

20

74 - 94 N

mm

16

BE01.50-B-1012-01A

Maximum valve opening with pneumatic piston at limit switch

mm

4,2

BE01.50-B-1016-01A

Rod housing opening diameter in the cylinder head

mm

8,000...8,015

BE01.50-B-1017-01A

Pneumatic piston housing diameter in the cylinder head

mm

28,500...28,533

BE01.50-B-1018-01A

External diameter of the pneumatic piston

mm

28,240...28,320

Número

Denominação

Engine 475.9; 476.9

BA01.50-B-1002-01A

Piston compartment plug in the cylinder head

Nm

100