SERVICE DATA

SERVICE DATA
SPECIFICATIONS
Model F9560W12
Type Reciprocating type
Bore x stroke − No. of cylinders mm (in) 95 x 60 − 1 (3.74 x 2.36 − 1)
3
Theoretical discharge cm (cu in)/rev 425 (25.93)
Normal maximum speed rpm 2,400
2
Normal maximum pressure kPa {kgf/cm , psi} 834 {8.5, 121}
Cooling method Water cooled

SERVICE DATA
Unit: mm (in)

Item Maintenance standard Service limit Remarks

400 Tank capacity:
Less than 124 sec. —
Air charging per- Engine rpm 30! (6-5/8 Imp gal)
formance speed 2,000 0 → 785 kPa {0 → 8
Less than 32 sec. —
rpm kgf/cm2, 0 → 114 psi}
0.18 - 0.25
Clearance be- Piston top 0.28 (0.0110)
(0.0071 - 0.0098)
tween piston and
0.08 - 0.15
cylinder Piston skirt 0.18 (0.0071)
(0.0031 - 0.0059)
Compression 0.15 - 0.30
1.00 (0.0394)
Piston ring end ring (0.0059 - 0.0118)
gap 0.20 - 0.70
Oil ring 1.00 (0.0394)
(0.0079 - 0.0276)
Clearance between piston ring 0.010 - 0.045
0.08 (0.0031) Compression ring only
and ring groove (0.0004 - 0.0018)
Clearance between piston pin 0.01 T - 0.02 L T: Tight
0.08 L (0.003 L)
hole and piston pin (0.0004 T - 0.0008 L) L: Loose
Clearance between connecting 0.02 - 0.04
0.07 (0.0028)
rod small end and piston pin (0.0008 - 0.0016)
Clearance between connecting
0.02 - 0.09
rod large end bushing and crank 0.10 (0.0039)
(0.0008 - 0.0035)
pin
0.1 - 0.7
Crankshaft end play 1.0 (0.0039)
(0.004 - 0.028)
Suction valve
11.5 (0.453) —
Free length of spring
valve spring Delivery valve
13.4 (0.528) —
spring
12.26 8.53 When compressed to
Tension of valve Suction valve
{1.25, 2.76} {0.87, 1.92} 7.5 mm (0.295 in)
spring
Delivery valve 10.79 7.85 When compressed to
N {kgf, lbf}
spring {1.10, 2.43} {0.80, 1.76} 10.0 mm (0.394 in)

EA-1-1
 SERVICE DATA

TIGHTENING TORQUE
Unit: Nzm {kgfzm, ftzlbf}

Item Tightening torque

Suction valve holder 137 - 157 {14.0 - 16.0, 101 - 116}
Delivery valve holder 137 - 157 {14.0 - 16.0, 101 - 116}
Unloader valve connector 98 - 118 {10.0 - 12.0, 72 - 87}
Cylinder head mounting bolts and nut 25 - 29 {2.5 - 3.0, 18 - 22}
Bearing holder securing screws 2.5 - 4 {0.25 - 0.40, 1.8 - 2.9}
Cylinder liner mounting bolts 25 - 29 {2.5 - 3.0, 18 - 22}
Connecting rod cap mounting nuts 23 - 25 {2.3 - 2.6, 17 - 19}
Air compressor drive gear mounting nut (Left-hand screw) 186 - 206 {19.0 - 21.0, 137 - 152}
Air compressor mounting bolts 30 - 41 {3.1 - 4.2, 22 - 30}

EA-1-2
 TOOLS

TOOLS
AIR COMPRESSOR

Tool name and number Description Shape

Valve holder tool For removal and installation of suction valve holder
99744 97003

EP14-164

Piston insert tool kit For installation of air compressor piston

99750 97001 j1 Piston insert tool

j1 99754 97002 j2 Crankshaft holder

j2 99756 97001

WEA001A

EA-2-1
 AIR COMPRESSOR F9560

DISASSEMBLY

WEA004A

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

j1 O-ring j14 Bearing case 27 Delivery valve
j
j2 Nut j15 O-ring 28 Delivery valve seat
j
j3 Plain washer >j16 Crankshaft 29 Connector
j
.j4 Drive gear >j17 Connecting rod cap 30 Packing
j
j5 Cylinder head j18 Connecting rod metal 31 O-ring
j
>j6 Cylinder liner j19 Connecting rod 32 Unloader valve
>j
j7 O-ring .>j20 Ball bearing 33 Unloader valve spring
j
j8 O-ring .>j21 Ball bearing .> 34 Suction valve holder
j
j9 Clip >j22 Delivery valve holder 35 Suction valve spring
j
10 Piston pin
j j23 O-ring 36 Suction valve
j
11 Piston
j j24 O-ring 37 Suction valve seat
j
12 Compression ring
>j j25 Spring holder 38 Suction valve packing
j
13 Oil ring
>j j26 Delivery valve spring 39 Crankcase
j
Marks ‘‘.’’ and ‘‘>’’ indicate that the key points of operation are explained in the text.

EA-3-2
 AIR COMPRESSOR F9560

Key point of disassembly

4 Drive gear
j
Using a puller, remove the drive gear from the air compressor.

WEA005A

Before disassembling the air compressor, measure the end

play of the crankshaft.

EEA2003B

20 , j
j 21 Ball bearing
Using a puller, remove the ball bearing from the crankshaft.

EEA2-010

j
34 Suction valve holder
Remove the suction valve holder, using the valve holder tool
(99744 97003). Then remove the suction valve spring, suction
valve, suction valve seat and suction valve packing from the
cylinder head.

WEA006A

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 AIR COMPRESSOR F9560

INSPECTION

Clean all disassembled parts in cleaning solvent. Check for

scratches, cracks or damage and replace faulty parts.
If measurement indicates that the service limit has ex-
ceeded, repair or replace faulty parts.

Clearance between piston and cylinder

Unit: mm (in)
Item Maintenance standard Service limit
Piston top 0.18 - 0.25 (0.0071 - 0.0098) 0.28 (0.0110)
Piston skirt 0.08 - 0.15 (0.0031 - 0.0059) 0.18 (0.0071)

WEA017A

Piston ring end gap

Unit: mm (in)
Item Maintenance standard Service limit
Compression ring 0.15 - 0.30 (0.0059 - 0.0118) 1.00 (0.0394)
Oil ring 0.20 - 0.70 (0.0079 - 0.0276) 1.00 (0.0394)

EP11-14

Clearance between piston ring and ring groove

Unit: mm (in)
Maintenance standard Service limit Remarks
0.010 - 0.045
0.08 (0.0031) Compression ring only
(0.0004 - 0.0018)

EP11-13

EA-3-4
 AIR COMPRESSOR F9560

Clearance between piston pin hole and piston pin

Unit: mm (in)
Maintenance standard Service limit Remarks
0.01 T - 0.02 L T: Tight
0.08 L (0.003 L)
(0.0004 T - 0.0008 L) L: Loose

WEA018A

Clearance between connecting rod small end and

piston pin
Unit: mm (in)
Maintenance standard Service limit
0.02 - 0.04 (0.0008 - 0.0016) 0.07 (0.0028)

WEA019A

Clearance between connecting rod large end bush-

ing and crank pin
NOTE
• Before measuring the clearance between the connect-
ing rod large end bushing and crank pin, tighten the nut
to the specified torque.
: 23 - 25 Nzm {2.3 - 2.6 kgfzm, 17 - 19 ftzlbf}
Unit: mm (in)
Maintenance standard Service limit
0.02 - 0.09 (0.0008 - 0.0035) 0.10 (0.0039)

WEA020A

Crankshaft end play

NOTE
• Check the end play of the crankshaft measured while
disassembling.
Unit: mm (in)
Maintenance standard Service limit
0.1 - 0.7 (0.004 - 0.028) 1.0 (0.039)

EEA2003B

EA-3-5
 AIR COMPRESSOR F9560

Free length of valve spring

Unit: mm (in)
Item Maintenance standard Service limit
Suction valve spring 11.5 (0.453) —
Delivery valve spring 13.4 (0.528) —

ES-87

Tension of valve spring

Unit: N {kgf, lbf}
Maintenance
Item Service limit Remarks
standard
Suction valve 12.26 8.53 {0.87, When compressed
spring {1.25, 2.76} 1.92} to 7.5 mm (0.295 in)
When compressed
Delivery valve 10.79 7.85 {0.80,
to 10.0 mm (0.394
spring {1.10, 2.43} 1.76}
in)
WEA007A

REASSEMBLY
Key point of reassembly
j
34 Suction valve holder
1. Install the suction valve packing, suction valve seat, suction
valve and suction valve spring, then, using a valve holder
tool (99744 97003), tighten the suction valve holder into the
cylinder head.
: 137 - 157 Nzm {14.0 - 16.0 kgfzm, 101 - 116 ftzlbf}

WEA006A

2. After tightening the valve holder, push the suction valve with
your fingers or a rod from the unloader valve side. When
doing so, make sure the suction valve and suction valve
spring operate smoothly.

WEA008A

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 AIR COMPRESSOR F9560

3. Using a punch, stake the periphery of the suction valve

holder in three locations so that the suction valve does not
rotate.
NOTE
• Do not stake the same portion that has previously
staked.

WEA022A

j
32 Unloader valve
1. Install the O-ring and unloader valve spring to the unloader
valve. After inserting them into the cylinder head, tighten the
connector with the packing in place.
: 98 - 118 Nzm {10.0 - 12.0 kgfzm, 72 - 87 ftzlbf}
NOTE
• Before installing, be sure to coat the O-ring and O-ring
groove in the valve with grease.
WEA009A

2. After tightening the connector, push the unloader valve with

your fingers or a rod. When doing so, make sure the
unloader valve and unloader valve spring operate smoothly.

WEA010A

j
22 Delivery valve holder
1. Install the O-ring to the delivery valve holder.
2. Insert the delivery valve seat, delivery valve, delivery valve
spring and spring holder into the cylinder head.
3. Tighten the delivery valve holder with the O-ring in place.
: 137 - 157 Nzm {14.0 - 16.0 kgfzm, 101 - 116 ftzlbf}
NOTE
• Apply a coat of 0.2 to 0.3 m! (0.007 to 0.11 Imp fl oz)
LOCTITE No. 271 to three threads of the delivery valve
holder. WEA011A

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 AIR COMPRESSOR F9560

4. After tightening the delivery valve holder, push the spring

holder with your fingers or a rod. When doing so, make sure
the spring holder and delivery valve spring operate
smoothly.

WEA012A

20 , j
j 21 Ball bearing
Install the ball bearings on the crankshaft by press-fitting.

EP11-19

j
17 Connecting rod cap
Fit the metals in the connecting rod and bearing cap, and install
the connecting rod to the crankshaft through the lock washer.
: 23 - 25 Nzm {2.3 - 2.6 kgfzm, 17 - 19 ftzlbf}
NOTE
• Assemble with the matching marks of the connecting
rod and bearing cap on the same side.

WEA021A

j
16 Crankshaft
Press-fit the crankshaft assembly to the crankcase.

WEA015A

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 AIR COMPRESSOR F9560

j
13 Oil ring
j
12 Compression ring
Install the piston rings in the ring grooves, and attach the
connecting rod to the piston.
NOTE
• Install the piston rings so that their joints are neither
parallel nor normal to the piston pin and the
manufacturer’s mark faces up.

WEA023A

6 Cylinder liner
j
Install the O-ring onto the cylinder liner, then, using a piston
insert tool kit (99750 97001), install them into the crankcase with
the O-ring in place.
: 25 - 29 Nzm {2.5 - 3.0 kgfzm, 18 - 22 ftzlbf}
99750 97001 (Piston insert tool kit)
j1 99754 97002 (Piston insert tool)
j2 99756 97001 (Crankshaft holder)

WEA016A

Make sure that the end play of the crankshaft is within the
service limit.
Unit: mm (in)
Maintenance standard Service limit
0.1 - 0.7 (0.004 - 0.028) 1.00 (0.0394)

EEA2003B

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 AIR COMPRESSOR F9560

- MEMO -

EA-3-10