61

GROUP 61 SPECIAL EQUIPMENT

SPECIFICATIONS.................................................................................... 61-2

STRUCTURE AND OPERATION.............................................................. 61-3

Air Compressor .......................................................................................................... 61-3

AIR COMPRESSOR ................................................................................ 61-8

<AIR-COOLED (Oldhams Coupling Type)> .............................................................. 61-8
<AIR-COOLED (Laminated Coupling Type)> ............................................................ 61-16

AIR PRESSURE GOVERNOR.................................................................. 61-23

61-1
SPECIFICATIONS
Item Specifications
Air compressor Type Air-cooled, single-cylinder
Cylinder bore stroke 80 40
mm (in.) (3.15 1.57)
Cylinder displacement 201 (0.0531)
L (U.S.gal.)
Manufacturer SANWA SEIKI MFG. CO., LTD

61-2
STRUCTURE AND OPERATION 61

Air Compressor
<Air-cooled type>
<Oldhams coupling type> <Laminated coupling type>

P 18392 P 47000

1 Delivery valve 11 Bearing holder <Laminated coupling type>

2 Cylinder head 12 Coupling <Oldhams coupling type>
3 Unloader valve 13 Connecting rod
4 Unloader valve spring 14 Piston
5 Suction valve 15 Delivery valve spring
6 Suction valve spring
7 Cylinder liner A: From air cleaner
8 Compressor gear B: To air tank
9 Crankshaft C: From air pressure governor
10 Crankcase

The air compressor is driven by compressor gear 8 which is in mesh with the timing gear of the engine.
Cylinder head 2 is provided with fins that prevent it from being overheated by the compression heat generated by
the air compressor.

When air is taken in

When compressor gear 8 is turned, crankshaft 9 in mesh with the
compressor gear lowers piston 14.
The vacuum generated at this time opens suction valve 5, allowing
air A from the air cleaner to be drawn into cylinder liner 7.

12791

61-3
STRUCTURE AND OPERATION
When air is sent under pressure
When piston 14 goes up on the compression stroke, suction valve
spring 6 closes suction valve 5.
The compressed-air pressure overcomes the force of delivery valve
spring 15, pushing to open delivery valve 1, which results in the air
B being sent under pressure to the air tank.

12792

When the unloader valve operates

When the pressure of the air in the air tank builds up to exceed the
predetermined level, the air pressure governor operates and
compressed air C is sent to unloader valve 3, pushing down the
unloader valve. At the same time, the air keeps suction valve 5
open, which means that the air in cylinder liner 7 is not compressed
and the air compressor runs under no load.
As the air pressure of the air tank drops below the predetermined
12793 level, the air pressure governor is operated again to discharge
compressed air C above unloader valve 3. As a result, the unloader
valve is returned to its original position by unloader valve spring 4.

<Water-cooled type (Oldhams coupling type)>

1 Delivery valve
2 Cylinder head
3 Unloader valve
4 Unloader valve spring
5 Suction valve
6 Suction valve spring
7 Piston
8 Cylinder liner
9 Crankcase
10 Compressor gear
11 Bearing
12 Crankshaft
13 Coupling
14 Connecting rod
15 Delivery valve spring

A: From air cleaner

B: To air tank
C: From air pressure governor
P18393

The air compressor is driven by compressor gear 10 which is in mesh with the timing gear of the engine.
To prevent cylinder head 2 from being overheated by the compression heat generated by the air compressor,
coolant is introduced from the oil cooler to cool down each valve of the cylinder head. It is then returned to the
rear end of the engine cylinder head.

61-4
 61

When air is taken in

When compressor gear 10 is turned, crankshaft 12 in mesh with the
compressor gear lowers piston 7.
The vacuum generated at this time opens suction valve 5, allowing
air A from the air cleaner to be drawn into cylinder liner 8.

18394

When air is sent under pressure

When piston 7 goes up on the compression stroke, suction valve
spring 6 closes suction valve 5.
The compressed-air pressure overcomes the force of delivery valve
spring 15, pushing to open delivery valve 1, which results in the air
B being sent under pressure to the air tank.

18395

When the unloader valve operates

When the pressure of the air in the air tank builds up to exceed the
predetermined level, the air pressure governor operates and
compressed air C is sent to unloader valve 3, pushing down the
unloader valve. At the same time, the air keeps suction valve 5 open,
which means that the air in cylinder liner 8 is not compressed and the
air compressor runs under no load. As the air pressure of the air tank
drops below the predetermined level, the air pressure governor is
18396 operated again to discharge compressed air C above unloader valve 3.
As a result, the unloader valve is returned to its original position by
unloader valve spring 4.

61-5
STRUCTURE AND OPERATION
<Water-cooled type (Laminated coupling type)>
1 Delivery valve
2 Suction valve
3 Compressor gear
4 Crankshaft
5 Crankcase
6 Bearing holder
7 Connecting rod
8 Piston
9 Cylinder liner
10 Valve seat assembly
11 Cylinder head assembly

A: From air cleaner

B: To air tank

P 47001

When air is taken in

As compressor gear 3 is driven, crankshaft 4 which is meshed with
the compressor gear is also driven. As a result, piston 8 moves
down.
This creates vacuum which then opens suction valve 2. As a result,
air A is sucked from the air cleaner and flows into cylinder liner 9.

22282

When air is sent out under pressure

As piston 8 moves up in the compression stroke, suction valve 2 is
closed by compressed air B.
Air B compressed by piston 8 opens delivery valve 1 and flows to
the air tank.

22283

61-6
 61

MEMO

61-7
AIR COMPRESSOR <AIR-COOLED (OLDHAMS COUPLING TYPE)>
Removal sequence
1 Unloader pipe
2 Connector
3 Eyebolt
4 Air outlet pipe
5 Eyebolt
6 Air inlet pipe
7 Air compressor assembly P.61-10
8 O-ring

*a: Injection pump assembly Gr 13

*b: Oil pipe Gr 13
*c: Flywheel housing Gr 11

: Non-reusable part

Installation sequence
P 46992 Reverse the order of removal.

Tightening torques Unit: Nm (kgfm) [lbfft]

Location Parts to be tightened Tightening torque Remarks
1 Unloader pipe 20 to 25 (2.0 to 2.5) [14.8 to 18.4]
2 Connector 14.7 to 21.5 (1.5 to 2.2) [10.8 to 15.9]
3 Eyebolt (for air outlet pipe installation) 130 (13) [96.0]
5 Eyebolt (for air inlet pipe installation) 110 (11) [81.1]

Lubricant
Location Points of application Specified lubricant Quantity
8 O-ring Engine oil As required

61-8
 61

Service procedure
7 Installation of air compressor assembly
Set cylinder No. 1 of the engine at TDC in the compression stroke.
Gr 11
After aligning inscribed lines A with each other, install air
compressor assembly 7 to flywheel housing *c.

35653

Remove inspection plug B and check if inscribed line A is aligned

with pointer C.
If not aligned, remove and refit air compressor assembly 7.

35654

61-9
AIR COMPRESSOR <AIR-COOLED (OLDHAMS COUPLING TYPE)>
Air Compressor Assembly

P 46993

61-10
 61

Disassembly sequence
1 Nut 18 Suction valve gasket 35 Piston pin
2 Lock washer 19 Nut 36 Piston
3 Compressor gear 20 Delivery valve holder 37 Nut
4 Spacer 21 Suction valve gasket 38 Lock washer
5 Bolt 22 Delivery valve 39 Connecting rod
6 Coupling 23 Delivery valve spring 40 Bearing
7 Bolt 24 Spring holder 41 Bolt
8 Connector 25 Gasket 42 Connecting-rod cap
9 Gasket 26 Cylinder head 43 Crankshaft
10 Snap ring 27 Bolt 44 Bolt
11 Unloader valve 28 Cylinder liner 45 Plate
12 Unloader valve spring 29 O-ring 46 Bearing
13 Unloader valve guide 30 1st compression ring 47 Crankcase
14 Suction valve holder 31 2nd compression ring
15 Suction valve spring 32 3rd compression ring : Non-reusable parts
16 Suction valve 33 Oil ring P: Locating pin
17 Suction valve seat 34 Snap ring

Reassembly sequence
Reverse the order of disassembly.

Service standards Unit: mm (in.)

Location Maintenance item Standard value Limit Remedy
15 Suction valve spring load 2.3 N 1.3 N Replace
[Installed length: 9 mm (0.354 in.)] (0.23 kgf) (0.13 kgf)
[0.52 lbf] [0.29 lbf]
23 Suction valve spring load 3.2 N 2.4 N Replace
(0.33 kgf) (0.24 kgf)
[0.72 lbf] [0.54 lbf]
29, 36 Clearance between piston and Top 0.27 to 0.33 0.35 Replace
cylinder liner (0.016 to 0.0130) (0.0138) cylinder
Skirt 0.11 to 0.17 0.19 liner
[Basic diameter: 80 mm (3.15 in.)] (0.00433 to 0.00670) (0.00748)
30 to 33 Piston ring gap (as measured inside Compression 1.0 Replace
cylinder liner) ring (0.0394)
Oil ring 1.0
(0.0394)
30 to Clearance between piston ring and Compression 0.08 Replace
33, 36 piston groove ring (0.00315)
Oil ring 0.08
(0.00315)
35, 36 Clearance between piston pin and piston 0.08 Replace
[Basic diameter: 16 mm (0.630 in.)] (0.00315) piston pin
35, 39 Clearance between piston pin and 0.07 Replace
connecting-rod small end (0.00276) connecting
[Basic diameter: 16 mm (0.630 in.)] rod
39 Connecting rod end play 0.5 Replace
(0.0197) connecting
rod
42, 43 Clearance between connecting-rod bearing and 0.1 Replace
crankshaft (0.0394)
[Basic diameter: 34 mm (1.34 in.)]
43 Crankshaft end play 1.0 Replace
(0.0394) crankshaft
43, 47 Clearance between crankshaft and crankcase 0.12 Replace
bushing I.D. (0.00472) crankshaft
[Basic diameter: 76.5 mm (3.01 in.)]
61-11
AIR COMPRESSOR <AIR-COOLED (OLDHAMS COUPLING TYPE)>

Tightening torques Unit: Nm (kgfm) [lbfft]

Location Parts to be tightened Tightening torque Remarks
1 Nut (for compressor gear installation) 165 to 211 (17 to 21.5) [122 to 156]
5 Bolt (for coupling installation) 30 to 36 (3.1 to 3.7) [22.1 to 26.6]
7 Bolt (for cylinder head installation) 25 to 29 (2.5 to 3.0) [18.4 to 21.4]
8 Connector 29 to 34 (3.0 to 3.5) [21.4 to 25.1]
13 Unloader valve guide 98 to 118 (10 to 12) [72.3 to 87.0]
14 Suction valve holder 98 to 118 (10 to 12) [72.3 to 87.0]
19 Nut 44 to 58 (4.5 to 6.0) [32.5 to 42.8]
20 Delivery valve holder 98 to 118 (10 to 12) [72.3 to 87.0]
27 Bolt (for installation of cylinder liner and 25 to 29 (2.5 to 3.0) [18.4 to 21.4]
crankcase)
37 Nut (for installation of connecting rod and 23 to 25 (2.3 to 2.6) [17.0 to 18.4]
connecting-rod cap)
44 Bolt (for plate installation) 14 to 18 (1.4 to 1.8) [10.3 to 13.3]

Special tools Unit: mm (in.)

Location Tool name and shape Part No. Application

Suction Valve For removal and installation of

14 MH062013
Tool suction valve holder

01730

Delivery Valve For removal and installation of

20 MH062014
Tool delivery valve holder

04813

Piston Ring For removal and installation of

30 to 33 MH060014
Tool piston rings

01732

61-12
 61

Service procedure
3 Installation of compressor gear
Install compressor gear 3 to crankshaft 43, ensuring that the 0
mark on the gear is aligned with the 0 mark on the crankshaft.
Insert tab A of lock washer 2 such that the 0 mark on compressor
gear 3 remains exposed.

35656

Tighten nut 1 to the specified torque. Lock the nut by bending

bottom portion B of lock washer 2 over the nut.

04894

14 Suction valve holder

[Removal and Installation]

04814

[Staking]
Stake cylinder head 26 at points not corresponding to O-rings sealing
surface A.

B: Punch

01736

20 Removal and installation of delivery valve holder

04815

61-13
AIR COMPRESSOR <AIR-COOLED (OLDHAMS COUPLING TYPE)>

30 to 33 Piston rings
[Removal and Installation]

: Piston Ring Tool

01738

[Installation positions]
A: Inscription of letters
B: Gap in 2nd compression ring 31
C: Gap in 1st compression ring 30
D: Side rail gap in oil ring 33
E: Spacer gap in oil ring 33
F: Gap in 3rd compression ring 32

P 46994

39 Assembling connecting rod

Assemble connecting rod cap 42 onto connecting rod 39 such that
inscribed numerical figures A are located on the same side.
Install bolts 41 in such a way that the notches in the bolt heads are
directed toward the inside of connecting rod cap 42.
After tightening the nuts, bend lock washers 38.

09645

61-14
 61

MEMO

61-15
AIR COMPRESSOR <AIR-COOLED (LAMINATED COUPLING TYPE)>
Removal sequence
1 Unloader pipe
2 Connector
3 Eyebolt
4 Air outlet pipe
5 Eyebolt
6 Air inlet pipe
7 Air compressor assembly P.61-18
8 O-ring

*a: Injection pump assembly Gr 13

*b: Oil pipe Gr 13
*c: Flywheel housing Gr 11

: Non-reusable part

Installation sequence
P 46966 Reverse the order of removal.

Tightening torques Unit: Nm (kgfm) [lbfft]

Location Parts to be tightened Tightening torque Remarks
1 Unloader pipe 20 to 25 (2.0 to 2.5) [14.8 to 18.4]
2 Connector 14.7 to 21.5 (1.5 to 2.2) [10.8 to 15.9]
3 Eyebolt (for air outlet pipe installation) 130 (13) [96.0]
5 Eyebolt (for air inlet pipe installation) 110 (11) [81.1]

Lubricant
Location Points of application Specified lubricant Quantity
8 O-ring Engine oil As required

61-16
 61

Service procedure
7 Installation of air compressor assembly
Set cylinder No. 1 of the engine at TDC in the compression stroke.
Gr 11
After aligning inscribed lines A with each other, install air
compressor assembly 7 to flywheel housing *c.

35653

Remove inspection plug B and check if inscribed line A is aligned

with pointer C.
If not aligned, remove and refit air compressor assembly 7.

35654

61-17
AIR COMPRESSOR <AIR-COOLED (LAMINATED COUPLING TYPE)>
Air Compressor Assembly

P46967

61-18
 61

Disassembly sequence
1 Nut 17 Nut 33 Piston pin
2 Lock washer 18 Delivery valve holder 34 Piston
3 Compressor gear 19 Suction valve gasket 35 Nut
4 Collar 20 Delivery valve 36 Lock washer
5 Bolt 21 Delivery valve spring 37 Connecting rod
6 Connector 22 Spring holder 38 Bolt
7 Gasket 23 Gasket 39 Connecting-rod cap
8 Snap ring 24 Cylinder head 40 Bolt
9 Unloader valve 25 Bolt 41 Oil seal
10 Unloader valve spring 26 Cylinder liner 42 Bearing holder
11 Unloader valve guide 27 O-ring 43 O-ring
12 Suction valve holder 28 1st compression ring 44 Bearing
13 Suction valve spring 29 2nd compression ring 45 Crankshaft
14 Suction valve 30 3rd compression ring 46 Crankcase
15 Suction valve seat 31 Oil ring
16 Suction valve gasket 32 Snap ring : Non-reusable part

Reassembly sequence
Reverse the order of disassembly.

Service standards Unit: mm (in.)

Location Maintenance item Standard value Limit Remedy
13 Suction valve spring load 2.3 N 1.3 N Replace
[Installed length: 9 mm (0.354 in.)] (0.23 kgf) (0.13 kgf)
[0.52 lbf] [0.29 lbf]
21 Suction valve spring load 3.2 N 2.4 N Replace
[Installed length: 5 mm (0.197 in.)] (0.33 kgf) (0.24 kgf)
[0.72 lbf] [0.54 lbf]
26, 34 Clearance between piston and Top 0.27 to 0.33 0.35 Replace
cylinder liner (0.016 to 0.0130) (0.0138) cylinder
Skirt 0.11 to 0.17 0.19 liner
[Basic diameter: 80 mm (3.15 in.)] (0.00433 o 0.00670) (0.00748)
28 to 31 Piston ring gap (as measured inside Compression 1.0 Replace
cylinder liner) ring (0.0394)
Oil ring 1.0
(0.0394)
28 to Piston ring to piston groove Compression 0.08 Replace
30, 34 clearance ring (0.00315)
Piston pin to piston clearance 0.08 Replace
[Basic diameter: 16 mm (0.630 in.)] (0.00315) piston pin
33, 37 Piston pin to connecting rod small end clearance 0.07 Replace
(0.00276) connecting
[Basic diameter: 16 mm (0.630 in.)] rod
37 Connecting rod end play 0.5 Replace
(0.0197) connecting
rod
37, 45 Connecting rod big end to crankshaft clearance 0.1 Replace
(0.0394) connecting
[Basic diameter: 34 mm (1.34 in.)] rod
45 Crankshaft end play 1.0 Replace
(0.0394) bearing
and/or
crankshaft

61-19
AIR COMPRESSOR <AIR-COOLED (LAMINATED COUPLING TYPE)>

Tightening torques Unit: Nm (kgfm) [lbfft]

Location Parts to be tightened Tightening torque Remarks
1 Nut (for compressor gear installation) 165 to 211 (17 to 21.5) [122 to 156]
5 Bolt (for cylinder head assembly 29 to 34 (3.0 to 3.5) [21.4 to 25.1]
installation)
6 Connector 29 to 34 (3.0 to 3.5) [21.4 to 25.1]
11 Unloader valve guide 98 to 118 (10 to 12) [72.3 to 87.0]
12 Suction valve holder 98 to 118 (10 to 12) [72.3 to 87.0]
17 Nut 44 to 58 (4.5 to 6.0) [32.5 to 42.8]
18 Delivery valve holder 98 to 118 (10 to 12) [72.3 to 87.0]
25 Bolt (for cylinder liner installation) 25 to 29 (2.5 to 3.0) [18.4 to 21.4]
35 Nut (for installation of connecting rod cap 23 to 26 (2.3 to 2.6) [17.0 to 19.2]
and connecting rod )
40 Bolt (for bearing holder installation) 14 to 18 (1.4 to 1.8) [10.3 to 13.3]

Special tools Unit: mm (in.)

Location Tool name and shape Part No. Application

Suction Valve For removal and installation of

12 MH062013
Tool suction valve holder

01730

Delivery Valve For removal and installation of

18 MH062014
Tool delivery valve holder

04813

Piston Ring For removal and installation of

28 to 31 MH060014
Tool piston rings

01732

61-20
 61

Service procedure
3 Installation of compressor gear
Install compressor gear 3 to crankshaft 45, ensuring that the 0
mark on the gear is aligned with the 0 mark on the crankshaft.
Insert tab A of lock washer 2 such that the 0 mark on compressor
gear 3 remains exposed.

35656

Tighten nut 1 to the specified torque. Lock the nut by bending

bottom portion B of lock washer 2 over the nut.

04894

12 Suction valve holder

[Removal and Installation]

: Suction Valve Tool

04814

[Staking]
Stake cylinder head 24 at points not corresponding to O-rings sealing
surface A.

B: Punch

01736

18 Removal and installation of delivery valve holder

: Delivery Valve Tool

04815

61-21
AIR COMPRESSOR <AIR-COOLED (LAMINATED COUPLING TYPE)>

28 to 31 Piston rings
[Removal and Installation]

: Piston Ring Tool

09643

[Installation positions]
A: Inscription of letters
B: Side rail
C: Spacer
D: Gap in 2nd compression ring 29
E: Gap in 1st compression ring 28
F: Side rail gap in oil ring 31
G: Spacer gap in oil ring 31
H: Gap in 3rd compression ring 30

P 36519

37 Assembling connecting rod

Assemble connecting rod cap 39 onto connecting rod 37 such that
inscribed numerical figures A are located on the same side.
Install bolts 38 in such a way that the notches in the bolt heads are
directed toward the inside of connecting rod cap 39.
After tightening the nuts, bend lock washers 36.

09645

41 Installing oil seal

Face oil seal 41 as shown in the illustration. Then, fit it in bearing
holder 42 by pressing evenly until it is flush with end face A of the
holder.

P 46829

61-22
AIR PRESSURE GOVERNOR 61

Disassembly sequence
1 Cover
2 Nut
3 Adjusting screw
4 Spring
5 Nut
6 Sleeve
7 O-ring
8 Snap ring
9 Filter
10 Screen
11 Cap
12 Diaphragm

: Non-reusable parts

Reassembly sequence
Reverse the order of disassembly.

Adjustment after reassembly

P.61-8

18426

Tightening torque Unit: Nm (kgfm) [lbfft]

Location Parts to be tightened Tightening torque Remarks

2 Nut (for tightening of adjusting screw) 9.8 to 15 (1 to 1.5) [7.2 to 11.1]
5 Nut (for tightening of sleeve) 15 to 20 (1.5 to 2) [11.1 to 14.8]

61-23