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M-14P OVERHAUL MANUAL

TABLE OF CONTENTS SECTION PAGE

1. Engine disassembly 2 2. Parts inspection 5

2.1.-The parts that are mandatory replaced 5 2.2.-Magnetic particle inspection 8 2.3.-LPF inspection 10 2.4.-Roentgen (X-ray) inspection 10 2.5.-Pressure tests 11 2.6.-Part measurements 11

3. Assembly of primary ensemble 77

3.1.-Assembly of the gearbox 77 3.2.-Assembly of the distribution cover 84 3.3.-Assembly of the crankcase 89 3.4.-Assembly of the oil drain sump 92 3.5.-Assembly of the pistons 94 3.6.-Assembly of the master-rod and connecting-rods mechanism 95 3.7.-Assembly of the crankshaft 97 3.8.-Assembly of the valve rockers 106 3.9.-Assembly of the cylinders 107 3.10.-Assembly of the supercharger 112 3.11.-Assembly of the air distributor and start valves 119 3.12.-Assembly of the accessories case 121 3.13.-Assembly of the ignition harness 135

4. General assembly of the engine 139 5. Engine test on test cell 161 6. Table of limits 164

7. Special torque requirements 186

8. Engine chart 187

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1. ENGINE DISASSEMBLY Install the lifting device on the propeller shaft flange of the engine. Disconnect

the transport legs and lift de engine. Attach the three legs of the stand (the general assembling stand) to the transport brackets (the three pieces painted in red, on the engine motoring). Install the engine on the stand.

Remove three screws from the metal covers of the magnetos and four screws from end hoses of the ignition harness. Remove from the magnetos the internal cover (distributor cover). Install back the metal covers of the magnetos. Remove three nuts that hold the magnetos to the accessories case. Remove the magnetos the gasket and the rubber couplings from the engine.

Remove the four nuts that hold the generator adapter to the accessories case. Remove the generator GSR3000M (with the adapter), the gasket and the splined coupling of the generator from the engine.

Remove the four nuts that hold the propeller governor to the gearbox case. Remove the propeller governor R2-04, the gasket and the splined coupling of the propeller governor. (Warning! It is mandatory to remove the splined coupling from the bevel gear of the governor transmission. In contrary case it is not possible to disassemble the gearbox from the engine.)

Unscrew the nut that hold the intake pipe to the cylinder number 1. Unscrew the nut that hold the pipe to the supercharger. Remove the intake pipe from the engine. Repeat these operations to all the engine cylinders.

Remove the four nuts that hold the metal ring of the ignition harness to the engine. Unscrew the nut on the middle of the metal ring of the ignition harness. Release all the ignition hoses from clamps. Remove from the engine the ignition harness.

Remove the four nuts that hold the carburetor AK-14P to the supercharger. Remove from the engine the carburetor and the gasket.

Remove the nuts that hold the air baffles on the top of the cylinder heads. Remove the air baffles (compressing the springs from the intermediate baffles) from the engine.

Unscrew the lock nuts part number 119-RD-2 and the nuts part number 11-08-37 from the plates part number 14-736-104 that hold the intermediate baffles to the cylinders. Remove the washers, the springs, the plates and the intermediate baffles from the engine.

The next step is the disassembling of the start pipes from the engine. Warning! It is mandatory to disassemble the start pipes on the following sequence 6,3,4,2,5,7,9,1,8 only. Unscrew and remove the cover of start valve and the aluminum gasket from the cylinder number 6. Unscrew and remove the cover and the aluminum gasket of the fitting number 6 from the compressed air distributor. Release the pipe from all the clamps and remove from the engine. Repeat these operations for all the start pipes but on the above sequence only. Unscrew and remove from the engine the start valves and the aluminum gaskets.

Remove the nuts that hold the air baffles on the top of the cylinder heads. Remove the air baffles (compressing the springs from the intermediate baffles) from the engine.

Turn the engine with the propeller shaft in vertical position. Remove the nuts part number 26-11-17 that holds the crankcase to the supercharger. Lift the front side of the engine (the gearbox with the crankcase and the cylinders). Install the front assemblies on the stand used for crankcase assembling.

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Remove the nuts of the gearbox lateral cover (on the two series engines only) and remove this cover. Remove the nuts that hold the gearbox to the crankcase, the safeties and the washers. Remove eight screws from the elastic hose between gearbox case and the oil drain sump. Lift the gearbox from the crankcase.

Remove from the hub part number 14-010-394 the ring 14-10-09. Remove the crown gear from the crankshaft.

Adjust the device of the stand by screwing the central part until contacts the rear side of the crankshaft. Remove the covers of the cylinders heads part number 14-04-37 and the rubber gaskets part number 14-04-513.

Turn the crankshaft until the piston of the cylinder number 1 is on the TDC at the end of the compression stroke. Unscrew the lock nuts 14-07-04 and remove the screws 14-307-03. Remove from the engine the push rods 14-307-104. Repeat this operation to the all cylinders turning the crankshaft for each cylinder.

Unscrew the nuts that hold the push rod tubes to the cylinder heads. Warning! It is mandatory to keep in position the fittings from the cylinder heads with a wrench in order to prevent the rotating of the fittings. Unscrew the bolts of the clamps from the rubber hoses and remove from the engine the push rod tubes. Remove from the tappets the end parts 14-309-01-01 and the springs 14-309-09.

Remove four nuts part number 21-11-17 that holds the oil drain sump to the crankcase. Remove the oil drain sump and the gaskets from the engine.

Turn the crankshaft until the cylinder number 5 is on the TDC. Unscrew 8 nuts that hold the cylinder number 5 to the crankcase. Remove the nuts the tab-washers and the cylinder from the engine. Remove the aluminum plugs of the piston, the pin piston and the piston from the engine. Repeat this operation for the next cylinder. Warning! The cylinder number 4 has to be the last cylinder that will be removed from the engine (here it is the master rod).

Remove the split pin from the central nut of the crankshaft, part number 14-703-11. Remove the nut and the hub 14-010-394 from the crankshaft. Remove 6 nuts and 6 safeties from the central plate of the distribution cover. Remove the central plate of the distribution cover (that holds the ball bearing). Install the device on the 6 studs of the distribution cover and lift the distribution cover from the crankcase. Remove from the crankshaft the spacer the distribution drive gear the cam disc with the bushing 14-08-16 and the second spacer. Remove 18 tappets (by inside of the crankcase, unscrew the nuts that hold the bushings of the tappets and remove the bushings and the gaskets.

Remove 9 split pins, 9 nuts and 9 bolts that hold the crankcase. Lift the front half of the crankcase. The roller of the front roller bearing has to remain on the crankshaft. Remove 22 rollers from the front roller bearing. Lift the crankshaft with the master rod and the connecting rods. Remove 22 rollers from the rear roller bearing. Remove from the stand the rear half of the crankcase.

1.1. Gearbox disassembly Unscrew the nuts of the gearbox breather. Remove the safeties, the breather,

gaskets and the screen from inside. Remove the oil filter from the oil channel between propeller governor and the front boss.

Remove the screw 3151A-4-8 that holds the safety 14-010-218 of the central nut 14-010-217 from propeller shaft. Remove the safety and the nut 14-010-217. Remove the spider body with the satellites. Remove the screws 14-10-19 that hold the plate of the pinion sun to the gearbox case and remove the pinion sun with this plate. Remove the ring 14-710-29 that hold the pinion sun to the plate and remove the pinion sun.

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Unscrew the nuts 66RD-2 that hold the front cover of the gearbox. Push the propeller shaft out. Depress from the propeller shaft the bearing and remove the bushing 14-010-211, the spacer 14-010-214, the oil deflectors and the front cover. Remove from the front cover the seal.

By the hole of the breather unscrew the bolt that holds the bushing with the seal rings to the case. Remove this bolt and the safety and remove the bushing 14-010-378 with the seal rings 14-010-216.

Remove the bolts 14-10-13 that hold the plates 14-10-12 to the spider body. Depress the pins of the satellites and remove the satellites with the washers 14-910-011.

1.2. Distribution cover disassembly Remove the nut 14-608-135 and the safety 14-608-142. Remove the nuts

66RD-1 that hold the cover 14-980-180-01 to the distribution cover. Remove this cover with the gear 14-608-134 in the same time with the bevel gear 14-08-607 and the spacer 14-08-25. Remove the second bevel gear 14-08-21. Remove the wedge 26-60-73 and the intermediate gear 14-008-003.Push the 14-608-134 out from the cover and depress the ball bearings.

1.3. Supercharged disassembly Remove the nuts that hold the accessories case to the supercharger. Remove

the washers the accessories case and the gasket. Remove the split pins and the nuts from the studs that hold the motoring to the

supercharger case. Remove the motoring with dampers, washers and studs from the supercharger case.

Remove the elastic ring 14-318-20, the coupling 14-618-100 and the spacer. Remove the nuts 00-03-58, the tab-washers 14-617-119 the dowel 14-317-14 and the gasket 14-318-17. Extract the axle 14-518-102 (assembled with the gear 14-518-101). Remove the four nuts 51003 and the tab-washers 00-12-600. Remove the aluminum cover and the double gear 14-618-125.

Remove the central nut 10-18-13 from the axle of the impeller. Remove the diffuser, the axle of the impeller, the bushing with seal rings, the spacers and the impeller.

Unscrew the nut 14-618-134 and remove from the axle 14-518-102 the safety 14-518-110, the cover 14-518-108, the springs 14-518-109 and the plate springs 14-518-104. Turn the gear 14-518-101 with 30 degrees and remove it from the axle 14-518-102.

1.4. Accessories case disassembly Unscrew the nut that hold the oil pump MN-14A to the accessories case.

Remove the oil pump with the fuel pump 702ML and the gasket. Unscrew the nuts that hold the air compressor to the to the accessories case. Remove the air compressor, the gasket, the coupling 14-611-80-01, the transmission with the bevel gear 14-614-110 and the gasket 14-11-545.

Extract the axles 14-612-110 that drive the magnetos. Remove the nuts 00-03-58, the safeties 00-05-54 the transmission cases 14-612-152 with the bevel gears 14-612-151 and the gasket.

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Remove four nuts 14-204-15 that hold the alternator transmission to the accessories case. Remove the alternator transmission with the bevel gear 14-013-250 and the gasket 14-11-547.

Remove four nuts that hold the cover of the tachometer transmission. Remove the cover with the gear 14-6111-03 and the gasket 15-11-120. Remove the transmission case 14-311-12 with two bevel gears and the gasket 14-311-14. Extract from the bevel gear 14-611-242 the bevel gear 14-611-103 and the spacer 10-11-16.

Remove two nuts that hold the bushing 14-411-13 to the accessories case by inside of the boss of the oil pump. Remove the safety the bushing and the vertical axle 14-611-234. Remove the bevel gear 14-611-235 and the spacer14-611-236. Remove the air distributor. Remove the bevel gear 14-27-714 of the air distributor by inside of the accessories case.

Remove the nuts 00-03-58 that hold the rear cover to the accessories case. Remove the bolt 14-11-714 and extract the plug 14-611-201and the bevel gear 14-311-32. Remove the nut 14-311-26 and disassembly the friction coupling of the bevel gear 14-411-05 that drives the alternator.

2. PARTS INSPECTION 2.1. During the engine overhaul the parts from the next table are mandatory replaced and are not subject of the parts inspection. Table 2.1. No. Nomenclature part number PC's per engine

1 Safety 108365 6 2 Safety 00-05-51 15 3 Safety 00-05-54 46 4 Safety 00-05-55 8 5 Safety 00-05-57 9 6 Safety 00-05-58 12 7 Spring washer 00-07-53 52 8 Split pin 00-12-07 9 9 Safety 00-12-504 6

10 Safety 00-12-600 4 11 Safety 00-12-601 6 12 Safety 00-711-05 18 13 Split pin 00-711-08 4 14 Split pin 00-711-09 3 15 Split pin 00-711-10 2 16 Split pin 00-711-12 9 17 Safety 10-01-25 2 18 Gasket 10-04-26 9 19 Gasket 10-04-46 27 20 Gasket 10-11-31 2 21 Gasket 10-11-50 2 22 Gasket 10-11-65 2 23 Supercharger ring 10-18-11 8 24 Nut 119-RD-2 8 25 Gasket 12-27-26 22

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26 Gasket 14-002-206 1 27 Ring 14-010-216 6 28 Seal 14-010-350 1 29 Gasket 14-010-221 2 30 Gasket 14-01-527 4 31 Ball bearing A212U1 14-03-23 1 32 Gasket 14-04-507 9 33 Gasket 14-04-513 18 34 Piston ring 14-05-514 9 35 Piston ring 14-05-517 9 36 Washer 14-07-511 36 37 "O" ring 14-09-502 36 38 Gasket 14-10-21 2 39 Gasket 14-10-541 4 40 Gasket 14-11-522 2 41 Gasket 14-11-545 2 42 Gasket 14-11-546 2 43 Gasket 14-11-547 4 44 Safety 14-11-715 2 45 Safety 14-17-03 4 46 Safety 14-17-512 1 47 Gasket 14-17-530 1 48 Safety 14-18-515 2 49 Safety 14-204-16 45 50 Gasket 14-211-34 3 51 Gasket 14-211-46 2 52 Gasket 14-212-02 12 53 Gasket 14-217-21 2 54 Gasket 14-27-531 36 55 Gasket 14-27-537 3 56 Gasket 14-27-706 18 57 "O" ring 14-27-711 2 58 "O" ring 14-301-04 4 59 Gasket 14-311-10 2 60 Gasket 14-311-14 2 61 Safety 14-311-28 2 62 Gasket 14-317-03 2 63 Safety 14-317-26 2 64 Gasket 14-318-17 6 65 Gasket 14-327-15 2 66 Hose 14-327-16 12 67 Gasket 14-36-500 18 68 Gasket 14-411-10 2 69 Safety 14-518-110 2 70 Gasket 14-601-114 2 71 Gasket 14-602-104 1 72 Gasket 14-602-106 4 73 Gasket 14-602-107 2 74 Gasket 14-602-108 2 75 Gasket 14-602-112 4 76 Contact 14-602-31 1

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77 Ring 14-604-165 18 78 Bushing 14-604-178 3 79 Plug 14-604-192 12 80 Piston ring 14-605-122 27 81 Safety 14-608-132 4 82 Safety 14-608-142 2 83 Gasket 14-611-157 1 84 Safety 14-611-173 1 85 Safety 14-611-245 2 86 Spring 14-611-279 2 87 Spring 14-611-279-02 2 88 Spring 14-611-279-03 1 89 Seal 14-611-71 2 90 Seal 14-612-15 2 91 "O" ring 14-612-150 2 92 Seal 14-613-22 1 93 Gasket 14-617-05 1 94 Safety 14-617-119 4 95 Gasket 14-617-121 2 96 Ring 14-627-123 1 97 Roller bearing 14-703-109 1 98 Roller bearing 14-703-110 1 99 Gasket 14-704-04 18

100 Hose 14-707-04 18 101 Safety 14-709-11 36 102 Hose 14-904-033 3 103 Gasket 14-909-011 36 104 Safety 15-04-22 9 105 Gasket 15-11-120 2 106 Washer 15-11-125 1 107 Gasket 1734A-1,5-12,5-16 1 108 Gasket 1734A-1,5-27-38 2 109 Ball bearing 20-304 K 1 110 "O" ring 2262A-104-2 1 111 Safety 26-06-12 36 112 Gasket 26-115-01 4 113 Safety 26-28-23 23 114 Gasket 33M51-18-14,2-2 1 115 Gasket 33M51-22-14,2-1 1 116 Ball bearing 5-204 1 117 Split pin 69-RD-6 18 118 Split pin 70-RD-1 1 119 Gasket AK-05001 21 120 Gasket AK-05003 1 121 Ball bearing 6-214 D1T1 ETU 100/1 1 122 Roller 2,5x9,8-III ETU 100/7-V 396 123 Roller ac 2x7,8 III ETU 100/7-V 1008 124 Spring washer 8.65G05 GOST 6402-70 14 125 Spring washer 6.65G05 GOST 6402-70 28 126 Spring washer 5.65G05 GOST 6402-70 3 127 Spring washer 3.65G019 GOST 6402-70 4

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128 Cable shoe 14-21-67 18 129 Cable shoe 14-21-68 18 130 Cone 14-21-804 18 131 Cone 14-21-805 18 132 Ignition wire PVS5 18

2.2. Magnetic particle inspection The parts from the next table will be inspected by the magnetic particle method. The parts with cracks will be rejected.

Table 2.2. No. Nomenclature part number PC's per engine

Gearbox 1. Propeller shaft 14-010-690 1 2. Hub 14-010-372 1 3. Spider case 14-010-373 1 4. Gear 14-710-30 1 5. Gear 14-710-31 1 6. Satellite 14-910-009 6 7. Satellite pin 14-610-957 6

8. Hub 14-010-394 (14-003-001) 1

Distribution cover 1. Gear 14-008-002 1

2. Bushing 14-08-16 1 3. Gear 14-08-21 1 4. Gear 14-08-507 1 5. Gear 14-008-003 1 6. Axle 14-608-134 1 7. Cam disc 14-708-107 1

Crankcase 1. Bolt 14-01-04 8 2. Bolt 14-601-103 1 3. Push-rod 14-307-104 18 4. Bushing 14-609-125 9 5. Bushing 14-609-126 9 6. Tappet roller 14-709-02 18 7. Tappet cap 14-309-03-01 18 8. Tappet 14-709-04-01 18

Master-rod and connecting-rods mechanism 1. Master-rod 14-606-27 1 2. Connecting-rod 14-606-03 8 3. Pin 14-606-04 8

Crankshaft

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1. Pin 14-603-101 2 2. Bolt 14-703-07 1 3. Counterweight 14-203-82 1 4. Nut 14-703-11 1 5. Bolt 14-03-54 2 6. Front crankshaft 14-703-13 1 7. Rear crankshaft 14-703-108 1

Pistons 1. Piston pin 14-605-120 9

Valve rockers 1. Intake valve rocker 14-407-102-01 9 2. Exhaust valve rocker 14-407-103-01 9

Cylinders 1. Cylinder 14-004-120 9 2. Exhaust valve 14-004-150 9 3. Exhaust valve 14-604-197 9 4. Outer spring 14-004-015 18 5. Inner spring 14-004-016 18 6. Plate 14-604-179 9 7. Plate 14-04-511 9 8. Rocker pin 14-207-02 18

Supercharger 1. Dowel 14-317-14 1 2. Bushing 14-318-04 1 3. Gear 14-518-101 1 4. Impeller axle 14-318-100 1 5. Coupling 14-618-100 1 6. Double gear 14-618-125 1 7. Spring 14-518-109 5 8. Main shaft 14-518-102 1

Air distributor 1. Gear 14-27-714 1 2. Slide valve 14-727-02 1 3. Axial bearing 14-327-106 1

Accessories case 1. Gear 14-611-242 1 2. Spring plate 14-311-24 1 3. Gear 14-311-32 1 4. Disc 14-411-02 1 5. Driver 14-411-04 1 6. Gear 14-411-05 1 7. Gear 14-611-03 1 8. Gear 14-611-103 1

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9. Gear 14-611-235 1 10. Plug 14-611-201

(14-611-210) 1

11. Vertical shaft 14-611-234 1 12. Gear 14-612-151 2 13. Gear 14-013-250 1 14. Gear 14-614-110 1 15. Air compressor coupling 14-611-80-01 1

2.3. LPF inspection The parts from aluminum alloy and magnesium alloy will be inspected by flaw detection with penetrating liquids, florescent method or color method. The parts with cracks will be rejected. On the next table are the parts that are inspected by this method. Table 2.3.

No. Nomenclature part number PC's per engine 1. Accessories case 14-611-32-01 1 2. Supercharger case 14-317-104 1 3. Supercharger diffuser 14-417-103-01 1 4. Impeller 14-318-02 1 5. Piston 14-605-103 9 6. Front half crankcase 14-901-270 1 7. Rear half crankcase 14-901-280 1 8. Oil drain sump 14-602-53 1 9. Tap body 14-602-208 1 10. Distribution cover 14-901-180-01 1 11. Cover 14-608-20 1 12. Gearbox case 14-010-680 1

2.4. Roentgen (X-ray) inspection The parts from the next table will be inspected for internal defects by Roentgen (X-ray) inspection method. The parts with internal defects will be rejected. Table 2.4.

No. Nomenclature part number PC's per engine 1. Accessories case 14-611-32-01 1 2. Supercharger case 14-317-104 1 3. Supercharger diffuser 14-417-103-01 1 4. Intake valve 14-004-150 9 5. Front half crankcase 14-901-270 1 6. Rear half crankcase 14-901-280 1 7. Oil drain sump 14-602-53 1

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8. Distribution cover 14-901-180-01 1 9. Gearbox case 14-010-680 1

2.5. Pressure tests The parts from the next table will be checked id order to detect porosities on the walls and oil channels. The test pressure for case walls will be 2 kilograms force per square centimeter and for oil channels the test pressure 6 kilograms force per square centimeter. Table 2.5.

No. Nomenclature part number PC's per engine 1. Accessories case 14-611-32-01 1 2. Supercharger case 14-317-104 1 3. Oil drain sump 14-602-53 1 4. Gearbox case 14-010-680 1

2.5. Part measurements During the overhaul process the parts from the next cards will be mandatory measured. All the dimensions are in millimeters. The adjustment matching with the postfix “L” is for clearance fit and with the postfix “T” are for interference fit. The dimensions between brackets “[ ]“are the serviceable limits. The dimensions noted with “R” are the oversize dimensions. The part measurements will be done according to the sketches from the cards, on the indicated zone, on two perpendicular directions. The recommendation of the genuine overhaul documentation is to include the next cards on the overhaul file of the engine. The cards are for the followings subassemblies:

- Cards 1 till 8 for gearbox; - Cards 9 till 16 for distribution cover; - Cards 17 till 28 for crankcase; - Carts 29 till 34 for master rod and connecting rods mechanism ; - Cards 35 till 39 for crankshaft; - Cards 40 till 41 for pistons; - Cards 42 till 49 for cylinders; - Cards 50 till 55 for supercharger; - Cards 56 till 57 for air distributor; - Cards 58 till 65 for accessories case.

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13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

36

37

38

39

40

41

42

43

44

45

46

47

48

49

50

51

52

53

54

55

56

57

58

59

60

61

62

63

64

65

66

67

68

69

70

71

72

73

74

75

76

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3. Assembly of primary ensembles 3.1. Assembly of the gearbox In order to assemble the gearbox it is necessary the parts from the next table.

TABLE 3.1. No Nomenclature Part number PC’s per engine.

1. Safety 12-01-39 1 2. Oil filter 12-01-92 1 3. Bushing 14-010-206 1 4. Bushing 14-010-211 1 5. Deflector 14-010-212 1 6. Ring 14-010-214 1 7. Nut 14-010-217 1 8. Safety 14-010-218 1 9. Breather 14-010-300 1 10. Plate 14-010-372 1 11. Spider body 14-010-373 1 12. Bushing 14-010-378 1 13. Hub 14-010-394 1 14. Deflector 14-010-452 1 15. Cover 14-010-457 1 16. Gearbox case 14-010-680 1 17. Propeller shaft 14-010-690 1 18. Ring 14-10-09 2 19. Plate 14-10-12 6 20. Screw 14-10-13 12 21. Screw 14-10-19 15 22. Bolt 14-10-24 1 23. Flange 14-610-193 1 24. Ring 14-610-492 6 25. Satellite pin 14-610-957 6 26. Ring 14-710-29 1 27. Pinion sun 14-710-30 1 28. Crown 14-710-31 1 29. Satellite 14-910-009 6 30. Washer 14-910-011 12 31. Screw 3151A-4-8 1 32. Nut 00-03-58 2 33. Screw 3001A-14-36 3 34. Nut 3320A-14 6 35. Washer 3406A-1,5-14-25 6 36. Nut 66-RD-2 9 37. Gasket AK-05001 1 38. Safety 00-05-51 2 39. Safety 00-05-54 15 40. Safety 00-711-05 9 41. Safety 10-01-25 1 42. Seal ring 14-010-216 6 43. Gasket 14-010-221 1

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44. Seal 14-010-350 1 45. Gasket 14-10-541 2 46. Roller 2,5x9,8III ETU 100/7-V 396 47. Safety 26-28-23 1 48. Ball bearing 6-214 D1T1 ETU 100/1 1 49. Safety wire Ø0.8 millimeters

Prior to assemble the gearbox it is necessary to check up the adjustments matching of the parts.

- Check the interference fit between the propeller shaft p/n 14-010-690 and the ball bearing p/n 6-214D1T1 which has to be 0.018 till 0.038 millimeters.

- Check the clearance between the ball bearing p/n 6-214D1T1 and the front bushing of the gearbox case. The clearance has to be 0.000 - 0.042 millimeters.

- Check the interference fit between the front cover of the gearbox p/n 14-010-457 and the adjacent parts according to the sketch 3.1.1 which has to be 0.05 till 0.08 millimeters. The dimension of the front cover L = (A+B)-(C+D) +0.05…0.08. The interference is established by selecting the gasket p/n 14-010-221 or by grinding the front cover.

- Check the gap of the seal rings p/n 14-010-216 on the central bushing of the gearbox case. The gap has to be 0.05 – 0.06 millimeters.

- Check the interference fit between the satellite pins and the spider body holes. The interference fit hast to be 0.005-0.042 millimeters (sketch 3.1.2.).

- Check if all the six satellites are from the same dimension group (I or II). - Check the radial clearance of the roller bearings of the satellites (ID of the satellite minus

the OD diameter of the satellite pin and 2xOD diameter of roller). The radial clearance has to be 0.020 – 0.060 millimeters. The difference of this clearance on a set of six satellites has to be maximum 0.025 millimeters.

- Check the clearance between the satellite pins p/n 14-610-957 and the ring p/n 14-610-492. The clearance has to be 0.180 – 0.230 millimeters.

After the adjustments checking the gearbox assembling starts with the spider body and the satellites ensemble. In each satellite has to be installed 33 rollers the ring p/n 14-610-492 and the next 33 rollers. On each frontal side of the satellites will be installed the washer p/n 14-910-011.

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SKETCH 3.1.1. The spider body will be heat up about 15 minutes at 85 – 95 Celsius degrees. Insert the satellites on the spider body and press the satellite pins from the side with the big holes. Check the clearance between the washers p/n 14-910-011 and the spider body that has to be 0.16 – 0.41 millimeters (sketch 3.1.2). Check the smooth rotation of the satellites. Install the plates 14-10-12 with the chamfer on the surface of the spider body and two screws p/n 14-10-13 on each plate. Safety the screws with safety wire (0.8 on dia.) like on the sketch 3.1.3. Install the pinion sun 14-710-30 on the fixture and the spider body and the satellites ensemble. Check the clearance on the teeth of the pinion sun and satellites. The clearance has to be 0.062 – 0.163 millimeters. Remove from the fixture the pinion sun and the spider body.

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SKETCH 3.1.2.

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SKETCH 3.1.3

Install the pinion sun p/n 14-710-30 on the plate 14-010-372 and the ring p/n 14-710-29 like on the sketch 3.1.4. Check the clearance between the teeth of the pinion sun p/n 14-710-30 and the plate 14-010-372. The clearance has to be 0.32 – 0.44 millimeters.

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SKETCH 3.1.4

Install on the fixture the spider body and the satellites ensemble. Install the crown p/n 14-710-31 on fixture geared with the satellites. Check the clearance between the teeth of the satellites and crown. The clearance has to be 0.094 – 0.220 millimeters (sketch 3.1.2). Remove the spider body and the crown from the fixture. On the crown p/n 14-710-31 install the ring p/n 14-10-09 the hub p/n 14-010-394 and the second ring. Check the clearance between the teeth of the hub and crown. The clearance has to be 0.29 – 0.50 millimeters (sketch 3.1.4). Install 6 seal rings on the bushing p/n 14-010-378. Rotate the rings with the gaps at 180 degrees in the same grove and at 45 degrees between groves. Install the bushing with the seal rings on the central bushing of the gearbox case with the hole for the bolt p/n 14-10-24 in proper position. Put on the bolt p/n 14-10-24 the safety p/n 10-01-25, screw and safety the bolt like on the sketch 3.1.5.

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SKETCH 3.1.5.

Install the ensemble pinion sun p/n 14-710-30 the plate 14-010-372 and the ring p/n 14-710-29 inside of the gearbox case with the mark “O” from the plate near to the mark “O” from the case. The hole from the plate has not to be on the breather direction (like on the sketch 3.1.3). Warning! If it is necessary to replace the plate p/n 14-010-372 with a new one then it is mandatory to check the run-out of the teeth of this plate installed on gearbox case. The maximum allowable of the total run-out of the teeth it is 0.1 millimeters. Install 15 screws p/n 14-10-19 with 15 safeties p/n 00-05-54, screw and safety the screws. Install on the front cover p/n 14-010-457 the seal 14-010-350. Install this cover on the propeller shaft (sketch 3.1.1). Heat up about 15 minutes at 85 – 95 Celsius degrees the bushing p/n 14-010-206 and the ball bearing V214D1. Install the bushing p/n 14-010-206 on the propeller shaft till the contact with the small flange of the shaft. Install on the propeller shaft the oil deflector p/n 14-010-212 with the big shoulder on the side of the ball bearing. Install the oil deflector p/n 14-010-452 on the propeller shaft. Press the ball bearing V214D1 on the propeller shaft. Install the spacer p/n 14-010-214 with the channels on the side of the ball bearing. Install the bushing p/n 14-010-211 on the propeller shaft on proper position with

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the holes for oil in correspondence with the holes from propeller shaft. Install the gasket p/n14-010-221 on the front cover. Heat up about 15 minutes at 85 – 95 Celsius degrees the gearbox case. Install the gearbox case on the propeller shaft. Screw 2 nuts p/n 66-RD-2 on 2 opposite studs in order to attach the front cover to the gearbox case. Install the spider body on the propeller shaft gearing the satellites with the pinion sun. Screw the nut 14-010-217 on the propeller shaft. Check if the gearbox case is cooled. Tighten the nut with the torque 75 Kgfm (Kilogram force-meter). Install on the nut the safety p/n 14-010-218, screw the bolt 3151A-4-8 with the safety 26-28-23. Safety the bolt like on the sketch3.1.2. Turn the gearbox with the flange of the propeller shaft up. Remove the two nuts and install 9 safeties p/n 00-711-01 and 9 nuts p/n 66-RD-2. Install the oil filter p/n 12-01-92 with the gasket AK-05001 like on the sketch 3.1.5 and safety the oil filter with the safety p/n 12-01-39. Install the gasket p/n 14-10-541 and the screen of the breather p/n 14-010-300 with the cut surface on the side of the ball bearing like on the sketch 3.1.5. Install the second gasket p/n 14-10-541 and the plate p/n 14-10-193. Install 2 safeties p/n 00-05-51 and screw 2 nuts p/n 00-03-38. Pump the gearbox by the end of the propeller shaft (which fits on the crankshaft) with oil under pressure (4 – 6 kilograms force per square centimeter). Check if the oil goes out to the all satellites.

3.2. Assembly of the distribution cover In order to assemble the distribution cover it is necessary the parts from the next table.

TABLE 3.2. No Nomenclature Part number PC’s per engine.

1 Distribution cover 14-901-180-01 1 2 Cover 14-608-20 1 3 Gear 14-608-134 1 4 Gear 14-008-003 1 5 Gear 14-08-507 1 6 Gear 14-08-21 1 7 Bushing 14-08-22 1 8 Spacer 14-08-25 1 9 Nut 14-608-135 1 10 Nut 66-RD-1 4 11 Nut 00-03-58 2 12 Key 26-60-73 1 13 Cam disc 14-708-107 1 14 Bushing 14-08-16 1 15 Gear 14-008-002 1 16 Ball bearing 20-304K 1 17 Ball bearing 5-204 1 18 Ball bearing 14-03-23 1 19 Nut 00-03-58 2 20 Nut 66-RD-1 4 21 Safety 14-608-132 2 22 Safety 14-608-142 1

Prior to assemble the distribution cover it is necessary to check up the adjustments matching of the parts.

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- Check the interference fit between the ball bearing 14-03-23 and the central bushing of the distribution cover that has to be 0.015 – 0.035 millimeters. - Check the interference fit between the ball bearing 14-03-23 and the crankshaft that has to be 0.010 – 0.020 millimeters. - Check the clearance between the OD of the bushing p/n 14-08-16 and the ID of the cam disc that has to be 0.060 – 0.090 millimeters. - Check the clearance between the shoulder of the bushing p/n 14-08-16 and the front of the cam disc that has to be 0.210 – 0.284 millimeters (sketch 3.2.1).

SKETCH 3.2.1. - Check the clearance between the ball bearing p/n 5-204 and the bushing p/n 14-08-22 that has to be 0.002 – 0.018 millimeters (sketch 3.2.2). - Check the interference fit between the ball bearing p/n 5-204 and the bushing from distribution cover that has to be 0.005 – 0.020 millimeters (sketch 3.2.2).

- Check the interference fit between the bushing p/n 14-08-22 and the gear p/n 14-608-134 that has to be 0.000 – 0.018 millimeters.

-Check the clearance between the ball bearing p/n 20-304K and the bushing from cover that has to be 0.005 – 0.030 millimeters. - Check the interference fit between the ball bearing p/n 20-304K and the gear p/n 14-608-134 that has to be 0.000 – 0.022 millimeters.

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SKETCH 3.2.2.

The distribution cover will be heat up about 15 minutes at 85 – 95 Celsius degrees. Press

the ball bearing p/n 5-204 in the bushing from distribution cover (sketch 3.2.2). Heat up about 15 minutes at 85 – 95 Celsius degrees the ball bearing p/n 20-304K.

Install the ball bearing on the gear p/n 14-608-134. After the cooling of the parts install the ball bearing and the gear on the cover p/n 14-608-20. Install the gear p/n 14-008-003 on the gear p/n 14-608-134 with the marked spline on the marked slot of the gear p/n 14-608-134. Press the bushing p/n 14-08-22 on the gear p/n 14-608-134 (sketch 3.2.3).

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SKETCH 3.2.3.

Install the key p/n 26-60-73 on the slot of the gear p/n 14-608-134. Install on the bushing of the distribution cover the bevel gear p/n 14-08-21. Attach the spacer p/n 14-08-25 to the bevel gear p/n 14-08-507 and keep the bevel gear geared with the bevel gear p/n 14-08-21. Insert the ensemble from the sketch 3.2.3 on the distribution cover like on the sketch 3.2.2. Install on the studs the safeties p/n 14-608-132, two nuts p/n 00-03-58 and four nuts p/n 66-RD-1 (sketch 3.2.4). Tighten the nuts with the torque 0.8 Kgfm.

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SKETCH 3.2.4.

Install the safety 14-608-142 on the gear p/n 14-608-134 and screw the nut p/n 14-608-135. Check the clearance between the teeth of the bevel gears wish has to be 0.14 – 0.36 millimeters. The measurement has to be performed on 3 points at about 120 degrees. If the clearance it is not on the range then adjust it by replacing the spacer 14-08-25.

Check the total run-out of the teeth of the gear p/n 14-008-003 which has to be maxim 0.06 millimeters.

Check the total run-out of the teeth of the gear p/n 14-608-134 which has to be maxim 0.06 millimeters.

Secure the nuts p/n 00-03-58, the nuts p/n 66-RD-1 and the nut p/n 14-608-135. Check the smooth rotation of the gears.

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3.3. Assembly of the crankcase

In order to assemble the crankcase it is necessary the parts from the next table.

TABLE 3.3. No Nomenclature Part number PC’s per engine.

1. Crankcase 14-901-310 1 2. Oil sump 14-602-53 1 3. Guide bushing of tappet 14-609-125 9 4. Guide bushing of tappet 14-609-126 9 5. Tappet 14-709-04-01 18 6. Roller 14-709-02 18 7. Pin 14-709-01 18 8. Bushing 14-709-03 18 9. Ring 14-01-33 2 10. Nut 00-03-58 36 11. Roller bearing 14-703-109 1 12. Roller bearing 14-703-110 1 13. O-ring 14-09-502 18 14. Gasket 14-909-011 18 15. Safety 14-709-11 36

Prior to assemble the crankcase it is necessary to check up the adjustments matching of

the parts. -Check the clearance between the OD of the roller bearing p/n 14-703-109 and the ID of the central bushing of the front half crankcase that has to be 0.000 – 0.024 millimeters. -Check the clearance between the OD of the roller bearing p/n 14-703-110 and the ID of the central bushing of the rear half crankcase that has to be 0.000 – 0.024 millimeters. -Check the clearance between the OD of the tappets p/n 14-709-04-01 and the ID of the guide bushings p/n 14-609-125 and 14-609-126 that has to be 0.016 – 0.054 millimeters. -Check the clearance between the OD of the bushings p/n 14-709-03 and the ID of the rollers p/n 14-709-02 that has to be 0.030 – 0.074 millimeters. -Check the clearance between the ID of the bushings p/n 14-709-03 and the OD of the pin p/n 14-709-01 that has to be 0.035 – 0.082 millimeters. -Check the paint print of the mating surfaces of the two half crankcases (the surface from middle). The paint print has to be minimum 80%. - Check the paint print of the mating surfaces of the crankcase and the oil sump. The paint print has to be minimum 70%. Install the external ring of the ball bearing p/n 14-703-109 on the central bushing of the

front half crankcase with the mark on front side of the engine. Install the ring p/n 14-01-33 in order to secure the ring of the ball bearing. Install the external ring of the ball bearing p/n 14-703-110 on the central bushing of the rear half crankcase with the mark on rear side of the engine. Install the ring p/n 14-01-33 in order to secure the ring of the ball bearing (sketch 3.3.1).

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SKETCH 3.3.1.

Install the gaskets p/n 14-909-011 on the crankcase. Install the O-rings on the guide bushings p/n 14-609-125 and 14-609-126.

Warning! The bushings p/n 14-609-125 have holes in correspondence with the oil channels of the crankcase. These bushings are designated for the upper cylinders and will be installed to the exhaust tappets of the cylinders numbers 1,2,3,8 and 9 and to the intake tappets of the cylinders numbers 1,2,8 and 9. The flanges of these bushings have a slot on the middle of the lateral surface. In order to install in proper position the bushings (the holes of the bushings in correspondence with the oil channels of the crankcase) the slot has to be in the front side of the engine. If these bushings are not installed in proper position then the oil will not go to the upper rockers resulting serious engine damaging. Install the guide bushings on the front half crankcase. By the inside of the crankcase install the pattern on the slots of three bushing. On the bushing from middle install two safeties p/n 14-709-11 and two nuts p/n 00-03-58. Screw and secure the nuts (sketch 3.3.2). Move the pattern until the next bushing. Repeat the above operation for all the bushing.

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SKETCH 3.3.2.

Install the bushings p/n 14-709-03 on the rollers p/n 14-709-02. Introduce the ensembles roller – bushing in the slot of the tappets p/n 14-709-04-01. Introduce the pins p/n 14-709-01.

Install the tappets on the guide bushings (sketch 3.3.3).

SKETCH 3.3.3.

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Lock the tappets by the inside of the front half crankcase with the transport device (the

ring from aluminum sheet). 3.4. Assembly of the oil drain sump In order to assemble the oil drain sump it is necessary the parts from the next table.

TABLE 3.4. No Nomenclature Part number PC’s per engine. 1 Oil sump case 14-602-53 1 2 Screen chips detector 14-602-55 1 3 Tap 14-602-39 1 4 Cup 14-602-37 1 5 Ring 14-602-161 1 6 Spring 14-602-162 1 7 Washer 54530 5 8 Nut 00-03-58 5 9 Cover 14-902-029 1 10 Screw 14-717-21 2 11 Nut 51003 3 12 Washer 54531 3 13 Gasket 14-602-106 1 14 Washer 6.65.G.05 5 15 Gasket 14-211-34 1 16 Safety 00-05-58 2 17 Gasket 14-602-104 1 18 Split pin 70-RD-1 1 19 Washer 5.65.G.05 3

Prior to assemble the oil drain sump it is necessary to check up the following parts.

-Check the screen chips detector on the electric installation. If it is applied a wire to the contact of the chips detector and the second wire to the small screen then the lamp does not to lighten. If it is applied a short circuit to the end washers of the chips detector then the lamp has to be on.

-Check the tap p/n 14-602-39 with compressed air at the pressure 1 kilogram force per square centimeter. Leak-off is not permitted.

Install on the oil sump case the gasket p/n 14-602-106. Install the cup p/n 14-602-37. Pun on studs 3 washers p/n 54530 and 3 washers p/n 6.65.G.05. Screw 3 nuts p/n 00-03-58.

Install on the inside of the cup the spring p/n 14-602-162 and the ring p/n 14-602-161.

Install on the cup the gasket p/n 14-602-104. Install the cover p/n 14-902-029. Install 2 safeties p/n 00-05-58 and 2 screws p/n 14-717-21.

Insert the screen chips detector p/n 14-602-55 in the cup with the contact in the right side looking from the front side of the engine. Install the tap p/n 14-602-39 with the lever in the left side looking from the front side of the engine. Install three washers p/n 54531 and three nuts p/n 51003.

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SKETCH 3.4.1.

Install the gasket p/n 14-211-34 on the boss of the breather for inverted flight (sketch 3.4.2). Install the cover p/n 14-002-207. Install the two washers p/n 54530, two washers p/n 6.65.G.05. Screw 2 nuts p/n 00-03-58.

SKETCH 3.4.2.

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3.5. Assembly of the pistons In order to assemble the pistons it is necessary the parts from the next table.

TABLE 3.5. No Nomenclature Part number PC’s per engine. 1 Piston 14-605-103 9 2 Piston pin 14-605-120 9 3 Plug 14-605-121 18 4 Compression ring 14-605-122 27 5 Oil ring 14-05-514 9 6 Scraper ring 14-05-517 9

Prior to assemble the pistons it is necessary to check up the adjustments

matching of the parts. -Check the weight of the pistons. The pistons assembled in the same engine

have to be selected in complement with piston weights matched within 6 grams.

-Check the clearance between the OD of the piston pin and ID of the holes of the piston that has to be 0.000 – 0.032 millimeters.

-Check the gap of the compression rings p/n 14-605-122 that has to be 1.1 – 1.4 millimeters.

-Check the gap of the oil rings p/n 14-05-514 that has to be 0.6 – 0.9 millimeters.

-Check the gap of the scraper rings p/n 14-05-517 that has to be 0.3 – 0.6 millimeters.

Install the piston rings according to the sketch 3.5.1. The rings p/n 14-05-514 and 14-05-517 will be installed with the mark “����” on the side of the piston head (the Russian word “����” meaning TOP).

SKETCH 3.5.1.

-Check the clearance of the compression rings p/n 14-605-122 on the piston

groves that has to be 0.07 – 0.155 millimeters. -Check the clearance of the oil rings p/n 14-05-514 on the piston groves that

has to be 0.07 – 0.12 millimeters.

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-Check the clearance of the scraper rings p/n 14-05-517 on the piston groves that has to be 0.05 – 0.1 millimeters.

3.6. Assembly of the master-rod and connecting-rods mechanism In order to assemble the master-rod and connecting-rods mechanism it is necessary the parts from the next table.

TABLE 3.6. No Nomenclature Part number PC’s per engine. 1 Master-rod 14-606-27 1 2 Connecting-rod 14-606-03 8 3 Pin 14-606-04 8

4 Plate 14-06-11 2 5 Screw 12-06-13 18 6 Safety 26-06-12 18

Prior to assemble the master-rod and connecting-rods mechanism it is necessary to check up the adjustments matching of the parts.

- Check the weight of the connecting-rods. The connecting-rods assembled in the same engine have to be selected in complement with the connecting-rod weights matched within 6 grams. -Check the clearance between the OD of the pins p/n 14-606-04 and ID of the bushings of the connecting-rods that has to be 0.048 – 0.082 millimeters. -Check the interference fit between the OD of the pins p/n 14-606-04 and ID of the holes of the master-rod that has to be 0.020 – 0.042 millimeters. - Check the clearance between the OD of the piston pins p/n 14-605-120 and ID of the bushings of the master-rod and connecting-rods that has to be 0.030 – 0.059 millimeters. - Check the clearance between ID of the big bushing of master-rod and the crankpin that has to be 0.060 – 0.091 millimeters (0.110 max serviceable limits). Install the master-rod on device with the big holes for pins up. Install the connecting-rods

in proper position according to the sketch 3.6.1. Insert the pins p/n 14-606-04 on proper position. The pins are stamped with the number of the connecting-rod. Press the pins until the front surfaces are on the same plan with the front surface of the master-rod. Check the clearance between the front surfaces of the connecting-rods and the inside surface of the master rod. The clearance has to be 0.15 – 0.33 millimeters (sketch 3.6.2).

Install the plates p/n 14-06-11 and four screws p/n 12-06-13 on each. Check the clearance between the shoulders of the pins p/n 14-606-04 and the lateral surfaces of the plates which has to be 0.0 – 0.1 millimeters (adjust the plates if is it necessary). Remove the screws. Install 18 safeties p/n 26-06-12 and 18 screws p/n 12-06-13. Check the gap between the plates p/n 14-06-11 and the frontal surfaces of the master-rod. The maxim allowable gap is 0.050 millimeters. Secure the screws with the safeties p/n 26-06-12.

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SKETCH 3.6.1.

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SKETCH 3.6.2.

3.7. Assembly of the crankshaft In order to assemble the crankshaft it is necessary the parts from the next table.

TABLE 3.7. No Nomenclature Part number PC’s per

engine. 1. Front half of crankshaft 14-703-13 1 2. Rear half of crankshaft 14-703-108 1 3. Pin of counterweight 14-603-101 2 4. Rear counterweight 14-203-82 1

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5. Plate 14-03-53 1 6. Screw 14-03-54 2 7. Nut 14-03-55 2 8. Plug 14-703-10 1 9. Bolt 14-703-07 1 10. Nut 14-03-04 1 11. Injector 14-703-06 1 12. Nut 14-703-11 13. Plug 14-03-518 1 14. Checking pin 14-03-82 1 15. Plug 14-203-09 2 16. Master-rod and connecting-rods

mechanism 14-606-01 1

17. Split pin 00-711-10 1 18. Split pin 00-711-08 2 19. Split pin 00-711-09 1 20. Safety 108365 1 21. Roller bearing 14-703-109 1 22. Roller bearing 14-703-110 1

Prior to assemble the crankshaft it is necessary to check up the adjustments matching of

the parts. -Check the interference fit between the ID of the roller bearing p/n 14-703-109 and the OD of the front half of the crankshaft that has to be 0.010 – 0.030 millimeters. -Check the interference fit between the ID of the roller bearing p/n 14-703-110 and the OD of the rear half of the crankshaft that has to be 0.010 – 0.030 millimeters. -Check the interference fit between the ID of the front half of the crankshaft and the OD of the plug p/n 14-03-518 that has to be 0.020 – 0.050 millimeters.

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SKETCH 3.7.1.

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SKETCH 3.7.2.

Following it is the balancing procedure for the M-14P engine:

a) The reciprocating weight R= P+Mp+Cp-0.03Cc P – sum of weight of pistons with rings, bolts and plugs; Mp – reciprocating weight of master rod (assembled with bolts, plates, screws and safeties); Cp – sum of reciprocating weight of connecting rods; Cc – sum of rotating weight of connecting rods; b) The rotating weight T=Mc+1.03Cc+E Mc -rotating weight of master rod (assembled with bolts, plates, screws and safeties); Cc – sum of rotating weight of connecting rods; E= 50 grams - it is the weight of oil from inside of crankpin during engine running. b) The total weight what has to be balanced is S=T+0.5R

On the next sketch (3.7.3.) it is the front half of the crankshaft. On the position 1 it is the unbalanced weight of the crankshaft, stamped at the end of the manufacturing process on the manufacturing shop to the crankpin. On the position 2 it is stamped the total weight that was calculated at the anterior engine assembling (like above). The weight that has to be compensated it is the difference between the weight S and the weight stamped on manufacturing shop.

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SKETCH 3.7.3.

On the section “a-a” are two plugs p/n 14-203-09 or p/n14-203-10 that are screwed in the fixed counterweight in order to compensate the above difference. These plugs are from aluminum for compensated weight until 100 grams or from steel for compensated weight over 100 grams. In order to determine the length of these plugs it is necessary to use the chart 3.7.4 for plugs from steel and the chart 3.7.5 for plugs from aluminum.

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CHART 3.7.4

The length determined according to the charts is the total length of the two plugs. The length of the each plug will be ½ of the total length.

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CHART 3.7.5 Screw the plugs on the front half of the crankshaft. Secure the plugs using a

chisel according to the sketch 3.7.3. The front half of the crankshaft will be heat up about 15 minutes at 100– 110 Celsius degrees. Press the plug p/n 14-03-518 on crankshaft (sketch 3.7.1). Secure the plug with the checking pin p/n 14-03-82. The internal ring of the roller bearing p/n 14-703-109 will be heat up about 15 minutes at 100– 110 Celsius degrees. Press the ring on the front half of the crankshaft with the chamfer on the side of the crank.

The internal ring of the roller bearing p/n 14-703-110 will be heat up about 15 minutes at 100– 110 Celsius degrees. Press the ring on the rear half of the crankshaft with the chamfer on the side of the crank (sketch 3.7.2.). Screw the nut p/n 14-703-11 with the chamfer on the side of the bearing ring, until the clearance gauge with the dimension 0.02 will not go between the ring of the roller bearing p/n 14-703-110 and the shoulder of the rear half of the crankshaft. Secure the nut p/n 14-703-11 with the split pin p/n 00-711-09 like on the next sketch.

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SKETCH 3.7.6.

Attach the mobile counterweight to the rear half of the crankshaft with the big chamfer on the side on the roller bearing. Insert the pins p/n 14-603-101 like on the sketch 3.7.2. Install on position the plate p/n 14-03-53. Insert two screws 14-03-54 with the holes for split pins parallel with the mobile counterweight. Install the nuts p/n 14-03-55. Check the clearance between the plate p/n 14-03-53 and the mobile counterweight that has to be 0.9 – 1.1 millimeters. Secure the nuts with the split pins p/n 00-711-08. Install the 22 rollers of the rear bearing (use grease to keep the rollers on bearing ring) with the mark on the side of the nut p/n 14-703-11. Install the protective ring. Install the 22 rollers of the front bearing with the mark on the side of crank. . Install the protective ring. Install the safety p/n 108365 and the oil injector p/n 14-703-06. Secure the injector with the safety like on the next sketch. Clean the end on the crankpin and the big hole on the rear half of the crankshaft. On these surfaces it is not allowable oil or any kind of grease. Install the master-rod and connecting-rods mechanism on the front half of the crankshaft, like on the next sketch (the big radius of the bushing on the front side). Insert on the ear of the rear half the device and enlarge the ear. Introduce the end of the crankpin on the hole of the rear half.

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Adjust the longitudinal clearance of the master rod on crankpin that has to be 0.1 -0.17 millimeters. Remove the device from ear and install the bolt p/n 14-703-07 and the nut p/n 14-03-04 (use anti-seize compound). Remove the protective rings from the bearings and install the external rings of the bearings.

Install the entire ensemble on the stand. Check by rotating the ensemble the run-out of the surface “D” at 10 millimeter of the end of the spines. The total run-out has to be 0.03

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millimeters maxim. If the total run-out exceeds 0.03 then adjust it by knocking with an aluminum hammer the front counterweight. Tighten progressively the nut p/n 14-03-04 until the length of the bolt p/n 14-703-07 increase with 0.18 -0.2 millimeters. During this process it is necessary to check the total run-out of the surface “D” and the longitudinal clearance of the master rod on crankpin. Secure the nut p/n 14-03-04 with the split pin p/n 00-711-10.

3.8. Assembly of the valve rockers In order to assemble the valve rockers it is necessary the parts from the next table.

TABLE 3.8. No Nomenclature Part number PC’s per engine. Intake valve rocker 14-407-102-01 9 Exhaust valve rocker 14-407-103-01 9 Screw 14-307-03 18

Nut 10-07-04 18 Washer 14-07-03 36 Ring 14-07-08-01 18 Bushing 14-07-04-01 18 Roller 2x7,8 III ETU 100/7-V 1008

Prior to assemble the valve rockers it is necessary to check up the adjustments matching of the parts.

-Check the ID of intake and exhaust valve rockers. The maximum allowable ID is 19.950 millimeters -Check the OD of the bushings p/n 14-07-04-01. The minimum allowable OD is 15.89 millimeters. Install the screws p/n 14-307-03 on valve rockers. Install the nuts p/n 10-07-04 on

screws. Install the rings p/n 14-07-08-01 on the bushings p/n 14-07-04-01. Install the bushings inside of the rocker valves. Attach to each rocker two washers p/n 14-07-03. Check the gap between the lateral surface of the rockers and washers which has to be between 0.229 and 0.330 millimeters. Remove the washers p/n 14-07-03. Install 28 rollers on each side of the valve rockers (use grease if it is necessary). Put the washers back.

SKETCH 3.8.1.

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3.9. Assembly of the cylinders In order to assemble the cylinders it is necessary the parts from the next table.

TABLE 3.9. No Nomenclature Part number PC’s per

engine. Cylinder 14-004-120 9 Intake valve 14-604-197 9 Exhaust valve 14-004-150 9 Plate-intake valve 14-04-511 9 Plate-exhaust valve 14-604-179 9 Lock-intake valve 14-04-529 18 Lock-exhaust valve 14-604-180 18 Spring 14-004-015 18 Spring 14-004-016 18 Washer-intake valve 14-604-183 9 Washer-exhaust valve 14-004-011 9 Intake valve rocker 14-407-104-01 9 Exhaust valve rocker 14-407-105-01 9 Axle 14-207-02 18 Ring 14-604-200 9 Nut 14-04-546 18 Bushing 14-004-014 9 Ring 14-604-201 9 Washer 14-07-513 18 Cover 10-04-37 18 Nut 26-07-16 18 Washer 14-07-512 18 Cable 10-04-38 18 Ring 14-604-165 18 Gasket 10-04-46 27 Gasket 14-04-513 18 Split pin 69 RD 6 18 Gasket 14-07-511 36 Prior to assemble the cylinders it is necessary to check up the adjustments matching of

the parts. -Check the clearance between the OD of the stem of the intake valves and the ID of the intake guide bushings, which has to be 0.033 – 0.069 [0.099] millimeters. -Check the clearance between the OD of the stem of the exhaust valves and the ID of the exhaust guide bushings, which has to be 0.065 – 0.099 [0.120] millimeters. Install the exhaust valves on cylinders and lap the valve with the valve seats.

Remove the exhaust valves from cylinders and check the print that has to be on the entire circumference of the exhaust valves with1.5 millimeters on wide. Repeat the process with the intake valves. Check the print that has to be on the entire circumference of the intake valves with 2 millimeters on wide.

Heat up about 15 minutes at 150 – 200 Celsius degrees the bushing p/n 14-004-014. On each busing install a scraper ring p/n 14-604-165 with the internal chamfer like on the next sketch, the ring p/n 14-604-200, the second scraper ring and press the ring p/n 14-604-201. The ring p/n 14-604-201 has to be pressed on the bushing with the external chamfer on the side of the shoulder of the bushing.

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After cooling the scraper rings will be rotate with the gaps on opposite sides.

SKETCH 3.9.1.

Install three gaskets p/n 10-04-46 to the intake port like on the sketch 3.9.2. The total thickness of the gaskets has to be 5.2 – 6.2 millimeters.

Install the intake valves and the exhaust valves on cylinders in correspondence with the cylinder number inscribed on each cylinder valve. Install the cylinder on a fixture that hold the intake and the exhaust valves on position. Install the washer-intake valve p/n 14-604-183, the spring p/n 14-004-16 and 14-004-15 and the plate-intake valve p/n 14-04-511. Press the springs and install the lock-intake valve p/n 14-04-529 (sketch 3.9.3.). Install the washer-exhaust valve p/n 14-004-011. Press the bushing with scraper rings till the contact with the valve guide bushing. Install the spring p/n 14-004-16 and 14-004-15 and the plate-exhaust valve p/n 14-604-179. Press the springs and install the lock-exhaust valve p/n 14-604-180.

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SKETCH 3.9.2. Remove the cylinder from the fixture. Check the stroke of the valves that has to be 14.5 millimeters. Install the cylinders like on the sketch 3.9.4. Fill up the intake and the exhaust ports with kerosene. After 5 minutes check by the inside of the cylinder for valve leakage. If it is observed leakage then knock with a wooden hammer the end of the valve and repeat the leakage test. If the leakage persist then it is necessary to lap again the valve and the valve seat. Insert on the axles of the valve rocker p/n 14-207-02 a washer p/n 14-04-513 and a gasket p/n 14-04-511. Install the valve rockers in correspondence with the valves and the cylinder number. Press the axle from inside on the valve rockers. Check the clearance (before to tighten the nut of the axle) between the wall of the rocker box from cylinder head and the washer of the rocker, which has to be 0 – 0.044 millimeters. Install the second gasket p/n 14-04-511, the washer p/n 14-04-512 and the nut p/n 26-07-16 on the axle. Tighten the nut. Check the axial clearance of the valve rocker, which has to be 0.1 millimeters minimum (sketch 3.9.5). Secure the nuts with the split pins p/n 69 RD 6.

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SKETCH 3.9.3.