JCB TLT 25G, TLT 30G TELETRUK (VARIABLE REACH TRUCK) Service Repair Manual Instant Download

Foreword The Operator's Manual You and others can be killed or seriously injured if you operate or maintain the machine without first studying the Operator's Manual. You must understand and follow the instructions in the Operator's Manual. If you do not understand anything, ask your employer or JCB dealer to explain it. SERVICE MANUAL Do not operate the machine without an Operator's Manual, or if there is anything on the machine you do not understand. Treat the Operator's Manual as part of the machine. Keep it clean and in good condition. Replace the Operator's Manual immediately if it is lost, damaged or becomes unreadable. TELETRUK (VARIABLE REACH TRUCK) TLT 25G, TLT 30G Contents 01 - Machine 03 - Attachments, Couplings and Load Handling 06 - Body and Framework 09 - Operator Station 12 - Heating, Ventilating Conditioning (HVAC) 15 - Engine 18 - Fuel and Exhaust System 21 - Cooling System 24 - Brake System 25 - Steering System 27 - Driveline 30 - Hydraulic System 33 - Electrical System 72 - Fasteners and Fixings 75 - Consumable Products 78 - After Sales and Air- EN - 9813/8800 - ISSUE 2 - 09/2017 This manual contains original instructions, verified by the manufacturer (or their authorized representative). Copyright 2017 JCB SERVICE All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means, electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE. www.jcb.com

15 - Engine 00 - Engine 00 - General 00 - General Introduction Introduction ...................................................... 15-3 Health and Safety ........................................... 15-4 Technical Data ................................................. 15-5 Component Identification ................................. 15-6 Operation ......................................................... 15-7 Fault-Finding .................................................. 15-11 Clean ............................................................. 15-13 Remove and Install ....................................... 15-14 Store and Recommission .............................. 15-15 This section contains information about the complete engine assembly. For specific engine technical information refer to the Technical Data. Refer to (PIL 15-00). For all other engine disassembly and calibration procedures, refer to the engine manual 9806-2150. Make sure that the correct engine service tools, consumables and torque figures are used when you perform service procedures. Replacement of oil seals, gaskets, etc., and any component that show signs of wear or damage, is expected as a matter of course. It is expected that components will be cleaned and lubricated where required, and that any opened hose or pipe connections will be blanked to prevent excessive loss of hydraulic fluid, engine oil and ingress of dirt. Basic Description The LPG (Liquid Petroleum Gas) engine is a 4 cylinder engine in which the fuel is ignited by the spark plugs. The engine operates on a four stroke cycle. The engine is started by an electric starter motor. The starter motor turns the engine via a pinion and teeth on the engine flywheel. When the engine runs the crankshaft drives the camshaft though the gears. The camshaft opens and closes the inlet and exhaust valves and through push rods in time with the four stroke cycle. The engine has 16 valves, 2 inlet and 2 exhaust valves for each cylinder. Air is drawn into the engine through the inlet manifold and exhaust gases exit through the exhaust manifold. A mechanical lubrication oil pump is driven by the crankshaft through gears. The pump pressurises and circulates oil for engine lubrication and cooling purposes. A drive belt again driven by the crankshaft, drives a coolant circulation pump and alternator. 15 - 3 9813/8800-2 15 - 3

15 - Engine 00 - Engine 00 - General Health and Safety accordance with local regulations. Use authorised waste disposal sites. Hot Components Touching hot surfaces can burn skin. The engine and machine components will be hot after the unit has been running. Allow the engine and components to cool before servicing the unit. Turning the Engine Do not try to turn the engine by pulling the fan or fan belt. This could cause injury or premature component failure. Notice: The engine and other components could be damaged by high pressure washing systems. Special precautions must be taken if the machine is to be washed using a high pressure system.Make sure that the alternator, starter motor and any other electrical components are shielded and not directly cleaned by the high pressure cleaning system. Do not aim the water jet directly at bearings, oil seals or the engine air induction system. WARNING! To bleed the injectors you must turn the engine. When the engine is turning, there are parts rotating in the engine compartment.Before starting this job make sure that you have no loose clothing (cuffs, ties etc) which could get caught in rotating parts.When the engine is turning, keep clear of rotating parts. Notice: Clean the engine before you start engine maintenance. Obey the correct procedures. Contamination of the fuel system will cause damage and possible failure of the engine. Notice: Do not exceed the correct level of engine oil in the sump. If there is too much engine oil, the excess must be drained to the correct level. An excess of engine oil could cause the engine speed to increase rapidly without control. WARNING! The engine has exposed rotating parts. Switch off the engine before working in the engine compartment. Do not use the machine with the engine cover open. WARNING! Hot oil and engine components can burn you. Make sure the engine is cool before doing this job.Used engine crankcase lubricants contain harmful contaminants. In laboratory tests it was shown that used engine oils can cause skin cancer. Notice: A drive belt that is loose can cause damage to itself and/or other engine parts. WARNING! Do not open the high pressure fuel system with the engine running. Engine operation causes high fuel pressure. High pressure fuel spray can cause serious injury or death. CAUTION! It is illegal to pollute drains, sewers or the ground. Clean up all spilt fluids and/or lubricants.Used fluids and/or lubricants, filters and contaminated materials must be disposed of in 15 - 4 9813/8800-2 15 - 4

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15 - Engine 00 - Engine 00 - General Technical Data Table 7. Description Engine type Data 4 cylinder in-line, spark ignition, naturally aspi- rated Cast iron, dry or water jacketed Push rod actuated over- head valve. 3L 101.6mm 91.44mm 9:25:1 1,3,4,2 1.12mm 165kg Anticlockwise (when viewed from flywheel end) LPG (Liquid Petroleum Gas) 3600RPM Exhaust system Valve configuration (2 per cylinder) Displacement Bore Stroke Compression ratio Firing sequence Spark plug gap Weight Rotation Fuel type Maximum RPM (Revolu- tions Per Minute) at full load (intermittent opera- tion) Maximum RPM at full load (continuous opera- tion) Idle RPM Timing (LPG) 2600RPM 700RPM 12 BTDC (Before Top Dead Centre) 16 BTDC 0.3091KgM Timing (natural gas) Moment of inertia 15 - 5 9813/8800-2 15 - 5

15 - Engine 00 - Engine 00 - General Component Identification Figure 77. B A L C D K E F G H J A Carburettor (PIL 18-60) C Oil filler cap (PIL 15-57) E Spark plug (PIL 15-81) G Engine mount J Starter motor (PIL 15-75) L Overload spring (PIL 09-28) B Vapouriser and valve assembly (PIL 18-60) D Oil filler hose F Oil filter (PIL 15-21) H Oil sump K Flywheel housing (PIL 15-54) 15 - 6 9813/8800-2 15 - 6

15 - Engine 00 - Engine 00 - General Operation The Four Cylinder Cycle Table 8. The Four Stroke Cycle Cylinder num- ber 1 Piston opera- tion The piston is at the top of its Compression stroke and is about to start its Power stroke. The piston is at the bottom of its Power stroke and is about to start its Exhaust stroke. The piston is at the bottom of its Induction stroke and is about to start its Com- pression stroke. The piston is at the top of its Exhaust stroke and is about to start its Induc- tion stroke. Valve opera- tion Inlet and ex- haust valves closed. This section describes the cycle sequence for the 4 cylinder engine. With the crankshaft positioned as shown, the pistons in numbers 1 and 4 cylinders are at top dead centre and pistons in numbers 2 and 3 cylinders are at bottom dead centre. It is important to note that number 1 cylinder is firing and about to start its Power stroke. Rotating the crankshaft a further full rotation would position the pistons as described but the engine would be at a different stage in its four stroke cycle, with number 1 cylinder about to start its Induction stroke. 2 Inlet valves closed, exhaust valves about to open. 3 Exhaust valves closed, inlet valves about to close. Firing Order A cylinder is said to be firing, when the spark plug ignites the fuel/air mixture and the piston is about to start its power stroke. 4 Valve Opera- tion Exhaust valves about to close, inlet valves about to open. From the stages described, it can be seen that number 1 cylinder will be next to fire. Number 3 cylinder is starting its compression stroke and is next in the cycle, followed by cylinders 4 and 2. The firing order is therefore; 1, 3, 4, 2. The stages in the four stroke cycle for each cylinder are as follows: 15 - 7 9813/8800-2 15 - 7

15 - Engine 00 - Engine 00 - General Figure 78. CYL1 CYL2 CYL3 CYL4 1 2 5 A C B C B C B C B G H J K 4 3 F 745620 745620 G H J K C B B C A A A A C B C B CYL1 CYL3 A C 1 3 5 Cylinder number 1 Cylinder number 3 Camshaft Camshaft lobe - Exhaust valve operation Exhaust valves Crankshaft Camshaft drive gear CYL2 CYL4 B F 2 4 Cylinder number 2 Cylinder number 4 Camshaft lobe - Inlet valve operation Front of engine Inlet valves Crankshaft gear 15 - 8 9813/8800-2 15 - 8

15 - Engine 00 - Engine 00 - General Four Stroke Cycle in the flywheel forces the piston up the cylinder expelling the exhaust gases. Induction In a running engine, these four phases are continuously repeated. Each stroke is half a revolution of the crankshaft, thus, in one cycle of a four stroke engine, the crankshaft revolves twice. As the piston travels down the cylinder, it draws filtered air at atmospheric pressure and ambient temperature through an air filter and inlet valves into the cylinder. Figure 79. This stroke of the piston begins at TDC (Top Dead Centre) and ends at BDC (Bottom Dead Centre). In this stroke the intake valve must be in open position, while the piston pulls an fuel/air mixture into the cylinder by producing vacuum pressure into the cylinder. 3 2 Compression When the piston reaches the bottom of its stroke (BDC), the inlet valves close. The piston then starts to rise up the cylinder compressing the fuel/air mixture trapped in the cylinder. This causes the temperature and pressure of the fuel/air mixture to rise. C B Power 4 1 The piston continues to rise after the start of fuel injection, causing a further increase in pressure and temperature. When the piston is at TDC the compressed fuel/air mixture is ignited by a spark plug. 746030 1 2 3 4 A B C BDC Bottom dead centre TDC Top dead centre Induction stroke Compression stroke Power stroke Exhaust stroke Camshaft Camshaft lobe - Inlet valve operation Camshaft lobe - Exhaust valve operation This combustion causes a very rapid rise in both temperature and pressure. The high pressure generated propels the piston downwards turning the crankshaft and producing energy. Exhaust Once the piston has reached the bottom of its travel, the exhaust valves open and momentum stored 15 - 9 9813/8800-2 15 - 9

15 - Engine 00 - Engine 00 - General Clean 9. When the pressure washing is complete, move the machine away from the wash area, or alternatively, clean away the material washed from the machine. Notice: Clean the engine before you start engine maintenance. Obey the correct procedures. Contamination of the fuel system will cause damage and possible failure of the engine. Notice: The engine and other components could be damaged by high pressure washing systems. Special precautions must be taken if the machine is to be washed using a high pressure system. Make sure that the alternator, starter motor and any other electrical components are shielded and not directly cleaned by the high pressure cleaning system. Do not aim the water jet directly at bearings, oil seals or the engine air induction system. 10. Before working on specific areas of the engine, use a compressed air jet to dry off any moisture. When the area is dry, use a soft clean brush to remove any sand or grit particles that remain. 11. When removing components, be aware of any dirt or debris that may be exposed. Cover any open ports and clean away the deposits before proceeding. Additional cleaning must be carried out prior to working on the high pressure fuel system. Refer to Fuel System, General, Clean (PIL 18-00). Before carrying out any service procedures that require components to be removed, the engine must be properly cleaned. Cleaning must be carried out either in the area of components to be removed or, in the case of major work, or work on the fuel system, the whole engine and surrounding machine must be cleaned. Stop the engine and allow it to cool for at least one hour. DO NOT attempt to clean any part of the engine while it is running. 1. Make sure that the electrical system is isolated. 2. Make sure that all electrical connectors are correctly connected. If connectors are open install the correct caps or seal with water proof tape. 3. Cover the alternator with a plastic bag to prevent water ingress. 4. Seal the engine air intake, exhaust and breather system. 5. Make sure that the oil filler caps and dipstick are correctly installed. 6. Use a low pressure water jet and brush to soak off mud or dirt. 7. Apply an approved cleaning and degreasing agent with a brush. Obey the manufacturers instructions. 8. Use a pressure washer to remove the soft dirt and oil. Important: DO NOT aim the water jet directly at oil seals or electrical and electronic components such as the engine electronic control unit (ECU), alternator or fuel injectors. DO NOT place the jet nozzle closer than the specified distance to any part of the engine. Distance: 600mm 15 - 13 9813/8800-2 15 - 13

15 - Engine 00 - Engine 00 - General Remove and Install 8. Disconnect the wiring connections from the alternator. Refer to: PIL 15-72-00. Consumables Description JCB Threadlocker and Sealer (High Strength) Part No. 4101/0550 4101/0552 Size 0.01L 0.2L 9. Disconnect the wiring connections from the engine sensors and actuators. 10. Drain the engine oil. Refer to: PIL 15-21-00. Lifting Equipment You can be injured if you use incorrect or faulty lifting equipment. You must identify the weight of the item to be lifted then choose lifting equipment that is strong enough and suitable for the job. Make sure that lifting equipment is in good condition and complies with all local regulations. WARNING! Before disconnecting any part of the LPG fuel system, close the shut-off valve on the fuel tank. Run the engine until the fuel lines are empty and the engine stops. If the engine will not run, close the shut-off valve on the fuel tank and release the fuel slowly in a non-hazardous area. LPG can cause an explosion even when the tanks are empty. When replacing the tanks, do not weld, cause sparks or permit flammable material on or near the tanks. Do not change tanks whilst the engine is running. Disconnect the negative battery terminal to prevent sparks. Tanks must be filled by authorised personnel only. Follow all the safety rules. Do not remove any parts from the tank. Use gloves or a cloth to protect your hands from cold metal. Frost on the surface of the tank, the valves or fittings and the odour of LPG fuel indicates a leak. Inspect the system and repair a leak immediately. An LPG fuel leak creates an explosion and fire hazard. Do not attempt to start the engine if there is a leak in the LPG system. 11. Remove the cooling pack. Refer to: PIL 21-03-00. 12. Discharge the hydraulic pressure. Refer to: PIL 30-00-00. 13. Drain the hydraulic tank. Disconnect and plug the hydraulic pipes. Label the hoses to help installation. Refer to: PIL 30-03-00. 14. Disconnect the bottom hose from the engine radiator to drain the cooling system. Refer to: PIL 21-00-00. 14.1. Disconnect the radiator top hose. 14.2. Remove the radiator. 15. Disconnect the fuel vapouriser water feed hoses from the engine. Refer to: PIL 18-66-00. 16. Disconnect and plug the hydraulic cooler hoses. Label the hoses to help installation. 17. Ensure that all relevant harnesses and hoses are unclipped from the engine and tied out of the way. Remove 1. Make the machine safe. Refer to: PIL 01-03. 18. Attach slings to the engine lifting bracket. 19. Take the weight of the engine on the hoist and remove the engine mounting bolts. 2. Obey all fuel system health and safety information. 20. Withdraw the engine in a level attitude until it is clear of the chassis. Raise the engine to lift it clear of the machine. 3. Make sure that the engine is safe to work on. If the engine has been running, let it cool before you start the service work. 21. Lower the engine into a suitable stand that is capable of supporting the weight of the engine. 4. Get access to the engine. Refer to: PIL 06-06-06. Install 5. Disconnect and remove the battery. Refer to: PIL 33-03-00. 1. The installation procedure is the opposite of the removal procedure. Additionally do the following steps. 6. Disconnect the exhaust system. Refer to: PIL 18-24-00. 2. Fill the cooling system with the correct mix of coolant fluid. Refer to: PIL 75-00-00. 7. Disconnect the wiring connections from the starter motor. Refer to: PIL 15-75-00. 3. Fill and Check the hydraulic fluid level. 15 - 14 9813/8800-2 15 - 14

15 - Engine 00 - Engine 00 - General Store and Recommission Refer to: PIL 30-00-00. 4. Fill and Check the engine oil level. Refer to: PIL 15-21-00. Consumables Description Cleaner/Degreaser - General purpose solvent based parts cleaner Part No. 4104/1557 Size 0.4L 5. On completion, check the hydraulic and cooling system for leakage and levels. 6. Check the fuel system for leaks. 7. Check the function of the drive and hydraulic services. Engine Storage (up to 6 months) Before you store the engine make sure that: 8. Note that if you have removed mounting bracket from the engine block, you must apply the specified to the mounting bolts before installation. Consumable: JCB Threadlocker and Sealer (High Strength) The environment is not humid or exposed to bad weather. The storage place is not near an electrical panel. Prevent storing the engine in direct contact with the ground. 1. Cover the engine with a proper protective sheet to prevent it from dampness and atmospheric contaminants. Engine Storage (over 6 months) 1. Follows the precautions mentioned in the above procedure. 2. Fill the engine housing with protective oil up to the maximum level. 3. Refuel the machine with fuel additives for long storage. 4. For machines with expansion tank: 4.1. Make sure that the coolant is up to the maximum level. 5. For machines without expansion tank: 5.1. Fill the coolant until the pipes inside the radiator are covered by specified distance. Distance: 5mm 5.2. Do not overfill the radiator, but leave sufficient space for the fuel to expand. 6. Start the engine and run it at idle speed for the specified duration. Duration: 2min 7. Bring the engine to 75% of the maximum rated speed for the specified duration. Duration: 5 10min 8. Turn off the engine. 9. Drain the fuel tank completely. 10. Spray engine oil (SAE 10W40) on the exhaust and intake manifolds. 15 - 15 9813/8800-2 15 - 15

15 - Engine 00 - Engine 00 - General 11. Seal the exhaust and intake ducts to prevent contamination. 12. Clean the engine. Refer to: PIL 15-00-00. 13. Apply protective paints on non-painted parts. 14. Loosen the alternator belt. 15. Cover the engine with a proper protective sheet to prevent it from dampness and atmospheric contaminants. Engine Starting After Storage 1. Remove the protective sheet. 2. Use a cloth soaked in degreasing fluid to remove the protective treatment from the external parts. Consumable: Cleaner/Degreaser - General purpose solvent based parts cleaner 3. Inject lubricating oil (not more than 2cm ) into the intake ducts. 4. Adjust the alternator belt tension. Refer to: PIL 15-18-00. 5. Refuel the machine. 6. Make sure that the oil and the coolant are up to the maximum level. 7. Start the engine and run it at idle speed for the specified duration. Duration: 2min 8. Bring the engine to 75% of the maximum rated speed for the specified duration. Duration: 5 10min 9. Stop the engine. 10. While the oil is still hot, drain the protective oil in a suitable container. 11. Put new oil up to the maximum level. 12. Replace the filters (air, oil, fuel). 13. Drain the cooling circuit completely and put new coolant up to the maximum level. Important: Over time, lubricants and filters lose their properties, so it is important to consider whether they need replacing, also based on the criteria mentioned in the maintenance schedules. If the engine is not to be used for an extended period, the protective treatment procedure must be repeated within 730d of the previous one. 15 - 16 9813/8800-2 15 - 16

15 - Engine 18 - Engine Belt 03 - Drive Belt Check (Condition) Remove and Install At the recommended service interval, visually inspect the drive belt for damage. Remove 1. Make the machine safe. Refer to (PIL 01-03). 1. Make the machine safe. Refer to: PIL 01-03-27. 2. Stop the engine and let it cool down. 3. Use a 1/2 inch breaker bar with a socket placed on the tensioner pulley axis bolt. 2. Stop the engine and let it cool down. 3. Replace the drive belt if it has cracks or if it is frayed or has pieces of material missing. 3.1. Carefully rotate the tensioner against the spring force to release the belt tension. Do not use excessive force or the tensioner will be damaged. 4. Keep holding the tensioner against the spring force and lift the belt off the tensioner pulley. 5. Slowly release the spring force by rotating the tensioner unit in the opposite direction. Figure 81. B A E C D A Water pump pulley B Belt tensioner C Alternator pulley D Crankshaft pulley E Idler pulley Install 1. The installation procedure is the opposite of the removal procedure. Additionally do the following steps. 15 - 22 9813/8800-2 15 - 22

15 - Engine 18 - Engine Belt 03 - Drive Belt 2. Before you install the new belt, check that the tensioner roller and the fan pulley rotate smoothly and that there is no play in the bearings. 3. Route the belt over all the pulleys except the belt tensioner. 4. Use a 1/2 inch breaker bar with a socket placed on the tensioner pulley axis bolt. 4.1. Rotate the tensioner to the released position. 5. Install the belt over the tensioner pulley. 6. Check the belt for correct W groove tracking around each pulley. 6.1. Make sure that the belt follows the correct routing. 6.2. Make sure that the grooves in the belt matches the grooves in the pulleys. 15 - 23 9813/8800-2 15 - 23

15 - Engine 81 - Spark Plug 00 - General 00 - General Introduction Introduction .................................................... 15-51 Remove and Install ....................................... 15-52 A spark plug is a device for delivering electric current from an ignition system to the combustion chamber of engine to ignite the compressed fuel/air mixture by an electric spark. A spark plug has a metal threaded shell, electrically isolated from a central electrode by a insulator. The central electrode is connected by a heavily insulated wire to the output terminal of an ignition coil or magneto. The spark plug metal shell is screwed into the engine cylinder head. A high voltage supplied by the ignition system generates a spark across the spark plug gap. 15 - 51 9813/8800-2 15 - 51

15 - Engine 81 - Spark Plug 00 - General Remove and Install Remove 3. Remove the spark plug cap. Refer to Figure 97. 4. Remove the spark plug. 1. Make the machine safe. Refer to (PIL 01-03). 2. Open the engine compartment cover. Refer to (PIL 06-06). Figure 97. A A Spark plug cap (x4) 15 - 52 9813/8800-2 15 - 52

15 - Engine 81 - Spark Plug 00 - General Install 1. The installation procedure is the opposite of the removal procedure. Additionally do the following steps. 2. When you install the new spark plug do the following: 2.1. Tighten to the correct torque value. Torque: 30N m 3. When you reuse the spark plug do the following: 3.1. Tighten to the correct torque value. Torque: 20N m 15 - 53 9813/8800-2 15 - 53

18 - Fuel and Exhaust System 60 - Carburettor 00 - General Adjust 2. Turn the idle speed screw until the RPM (Revolutions Per Minute) of the engine is within the specification. Refer to (PIL 15-00). Idle Mixture Figure 106. 1. Make the machine safe. Refer to (PIL 01-03). 2. Stop the engine. 3. Turn the idle mixture screw in clockwise direction until it stops. Refer to Figure 105. B 3.1. The idle mixture screw prevents the air to enter the tube through the idle air port. 4. Turn the idle mixture screw three and half turns in anticlockwise direction. 4.1. Start the engine. 4.2. Adjust the screw as needed until the idle is smooth. 4.3. Turning the screw anticlockwise increases the ratio of air to fuel. 5. Stop the engine. B Idle speed screw 6. Restart the engine. Power Mixture 7. If the engine does not starts easily do the following: The power mixture valve controls the flow of fuel to the carburettor when the engine is running at near full capacity. 7.1. Turn the idle mixture screw one half turn in anticlockwise direction. 1. Set the power mixture valve one notch rich from the centre. 7.2. Stop and restart the engine. 8. Continue this procedure until the engine starts easily. 1.1. This setting will be satisfactory for most of the conditions. Figure 105. Figure 107. A C C Power mixture valve A Idle mixture screw Idle speed 1. Make the machine safe. Refer to (PIL 01-03). 18 - 28 9813/8800-2 18 - 28

18 - Fuel and Exhaust System 60 - Carburettor 00 - General Remove and Install Figure 108. C Remove A B 1. Make the machine safe. Refer to (PIL 01-03). B 2. Obey all fuel system health and safety information. Refer to (PIL 18-00). 3. Open the engine compartment cover. Refer to (PIL 06-06). H 4. Close the shut-off valve. 5. Run the engine until it stops. G 6. Turn the ignition key to the OFF position. Remove the ignition key. 7. Disconnect the fuel feed and vacuum hoses from the carburettor. F 8. Disconnect the air inlet hose. D 9. Disconnect the throttle cable from the throttle reaction bracket. Refer to (PIL 09-28). E 10. Remove the bolt (x2). 11. Lift the carburettor away from the throttle bracket. 12. Remove the throttle bracket from the governor assembly. A Throttle reaction bracket B Bolt C Carburettor D Gasket 1 E Governor assembly F Throttle bracket G Throttle cable H Gasket 2 13. Remove and discard the gasket 1 and 2. Install 1. The installation procedure is the opposite of the removal procedure. Additionally do the following steps. 2. Install a new gasket 1 between the carburettor and throttle bracket. 3. Install a new gasket 2 between the carburettor and governor assembly. 4. Check the adjustment of the throttle cable. Refer to (PIL 28-06). 5. Adjust the carburettor idle speed screw and idle mixture screw. Refer to Carburettor, General, Adjust (PIL 18-60). 18 - 29 9813/8800-2 18 - 29

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18 - Fuel and Exhaust System 60 - Carburettor 00 - General Disassemble and Assemble Figure 109. Disassembly 1. A service repair kit is available with complete assembly instructions. Do not attempt to disassemble the unit unless the repair kit is available. 1.1. Over a period of time, degradation of some components will occur due to prolonged contact with LPG (Liquid Petroleum Gas) and it will be impossible to reassemble the unit without new parts. 2. Follow the instructions in the repair kit to disassemble the unit. Refer to Figure 109. A 2.1. Refer to applicable parts catalogue to order the parts. B A Item available in service repair kit. B Gasket available separately Assemble 1. The assembly procedure is the opposite of the disassembly procedure. 1.1. Follow the instructions in the repair kit to assemble the unit. 18 - 30 9813/8800-2 18 - 30

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