Westerbeke Universal M-30 Operator'S Manual Download Page 134

Page: 134 / 162

Summary of Contents for Universal M-30

Page 1: ...SERVICE MANUAL M 30 MODELS M 40 PIN 200154 M 50 ...

Page 2: ...on SECTION I SPECIFICATIONS 1 18 SECTION II PREVENTIVE MAINTENANCE 19 24 SECTION III CONSTRUCTION AND FUNCTION 25 30 SECTION IV LUBRICATION COOLING AND FUEL SySTEMS 31 49 SECTION V ELECTRICAL SYSTEM 51 82 SECTION VI DISASSEMBLY AND REASSEMBLY 83 130 SECTION VII DYNAMO AND REGULATOR 132 147 TROUBLESHOOTING 148 157 ...

Page 3: ...NOTES ii I a I _i J ...

Page 4: ...SECTION 1 SPECIFICATIONS Model M 30 2 3 Model M 40 4 5 Model M 50 6 7 Parts Specifications 8 15 Bolt Torques 16 18 1 ...

Page 5: ...EXRON II Do not mix different oils Transmission Reduction Coolant FWC 50 50 Solution Approx Exhaust Flange Fuel Type Fuel Filter Oil Filter Eng Operating Temp Degrees F Propeller Rotation We ight Ibs Injection Nozzle 2 1 6 qts 1 V4 N P T 2 Diesel PIN 298854 PIN 300209 Right Hand 4251bs PIN 298787 298788 Engine is governor controlled to prevent overspeed It is recommended to carry the following ext...

Page 6: ...ES TIMING PORT AIR BREATHER FUEL AIR LEED VALVE c _ STOP LEVER OIL FILTER BLOCK COOLANT DRAIN COOLANT AIR BLEED VALVE COOLANT FILL CAP THERMOSTAT HSG F W CIRCULATING PUMP ALTERNATOR SEA WATER PUMP V BELT DIP STICK OIL PAN 3 MANIFOLD AUST FLANGE MANIFOLD DRAIN HEAT EXCHANGER HEAT EX CLEAN OUT COVERS DRAIN AND ZINC TRANSMISSION n_ I _ DRAIN PLUG ...

Page 7: ...erent oils Transmission Reduction Coolant FWC 50 50 Solution Approx Exhaust Flange Fuel Type Fuel Filter Oil Filter Eng Operating Temp Degrees F Propeller Rotation Weight Ibs Injection Nozzle Prior to Ser 315023 After Ser 315023 2 1 8 qts 1 V4 N P T 2 Diesel PIN 298854 PIN 299927 Right Hand 5451bs PIN 299517 299518 PIN 299567 Engine is governor controlled to prevent overspeed It is recommended to ...

Page 8: ... TIMING PORT AIR BREATHER FUEL AIR BLEED VALVE THROTTLE STOP LEVER OIL FILTER BLOCK COOLANT DRAIN EX MOUNTS COOLANT AIR BLEED VALVE COOLANT FILL CAP THERMOSTAT HSG F W CIRCULATING PUMP ALTERNATOR SEA WATER PUMP V BELT DIP STICK OIL PAN 5 MANIFOLD MANIFOLD DRAIN HEAT EXCHANGER HEAT EX CLEAN OUT COVERS DRAIN AND ZINC TRANSMISSION RANS DRAIN PLUG ...

Page 9: ...ransmission Reduction 1 9 1 Coolant FWC 50 50 Solution Approx 8 qts Exhaust Flange 1 1 4 N P T Fuel Type 2 Diesel Fuel Filter PIN 298854 Oil Filter PIN 299927 Eng Operating Temp Degrees F 1650 to 1950 Propeller Rotation Right Hand Weight Ibs 545 Ibs Injection Nozzle PIN 299567 Engine is governor controlled to prevent overspeed It is recommended to carry the following extra parts should the need ar...

Page 10: ...OUPLING TIMING PORT COOLANT AIR BLEED VALVE THERMOSTAT HSG F W CIRCULATING PUMP ALTERNATOR SEA WATER PUMP V BELT DIP STICK AIR BREATHER INJECTOR PUMP FUEL AIR EED VALVE TH ROTTLE STOP LEVER OIL FILTER BLOCK COOLANT DRAIN LEX MOUNTS COOLANT FILL CAP MANIFOLD EXHAUST FLANGE LD DRAIN HEAT EX CLEAN OUT COVERS DRAIN AND ZINC NS DRAIN PLUG STARTER OIL PAN 7 ...

Page 11: ...ve seat angle 450 450 Valve face angle 450 450 Valve recessing 1 1 to 1 3 mm 1 1 to 1 3 mm 0 043 to 0 051 in 0 043 to 0 051 in Clearance between valve 0 04 to 0 07 mm 0 04 to 0 07 mm stem and guide 0 001 to 0 003 in 0 001 to 0 003 in Valve stem O D 7 960 to 7 975 mm 7 960 to 7 975 mm 0 313 to 0 314 in 0 313 to 0 314 in Valve guide 1 0 8 015 to 8 030 mm 8 015 to 8 030 mm 0 315 to 0 316 in 0 315 to ...

Page 12: ... to 0 008 in 2 1 mm 0 083 in 450 450 1 1 to 1 3 mm 1 6 mm 0 043 to 0 051 in 0 063 in 0 04 to 0 07 mm 0 1 mm 0 001 to 0 003 in 0 004 in 7 960 to 7 975 mm 0 313 to 0 314 in 8 015 to 8 030 mm 0 315 to 0 316 in 0 35 rad 200 before TDC 0 79 rad 450 after TDC 0 87 rad 500 before TDC 0 26 rad 150 After TDC 41 7 to 42 2 mm 41 2 mm 1 642 to 1 661 in 1 622 in 1 0 mm 1 00 N 0 039 in 10 2 kgf 22 5 Ibs 1 117 N...

Page 13: ... to 0 51 mm 0 20 to 0 51 mm 0 008 to 0 020 in 0 008 to 0 020 in Clearance between idle gear 0 Q16 to 0 045 mm 0 Q16 to 0 045 mm shaft and idle gear bushing 0 0006 to 0 001 in 0 0006 to 0 001 in Idle gear shaft 0 0 15 973 to 15 984 mm 15 973 to 15 984 mm 0 628 to 0 629 in 0 628 to 0 629 in Idle gear bushing 1 0 16 000 to 16 018 mm 16 000 to 16 018 mm 0 621 to 0 630 in 0 621 to 0 630 in Cylinder Lin...

Page 14: ... 0 042 to 0 115 mm 0 15 mm 0 002 to 0 005 in 0 006 in 0 20 to 0 51 mm 0 6mm 0 008 to 0 020 in 0 024 in 0 Q16 to 0 045 mm 0 10mm 0 0006 to 0 001 in 0 004 in 15 973 to 15 984 mm 0 628 to 0 629 in 16 000 to 16 018 mm 0 621 to 0 630 in 85 000 to 85 022 mm 0 15 mm 3 346 to 3 347 in 0 006 in 0 5 mm 0 020 in 23 000 to 23 013 mm 23 053 mm 0 905 to 0 906 in 0 907 in 0 093 to 0 120 mm 0 004 to 0 005 in 0 02...

Page 15: ... to 1 732 in 44 010 to 44 052 mm 1 733 to 1 734 in 0 15 to 0 31 mm 0 006 to 0 012 in 0 02 mm 0 04 mm 0 008 in 0 016 in 0 2mm 0 4 mm 0 008 in 0 016 in 0 02 mm 0 0008 in 0 014 to 0 038 mm 0 0006 to 0 001 in 23 002 to 23 011 mm 0 905 to 0 906 in 23 000 to 23 013 mm 0 905 to 0 906 in 1 0 kgf cm2 14 2 Dsi 3 0 to 4 5 kgf cm2 43 to 64 psi 0 10 to 0 16 mm 0 004 to 0 006 in 0 11 to 0 19 mm 0 004 to 0 007 0...

Page 16: ...2 mm 1 733 to 1 734 in 0 15 to 0 31 mm 0 5mm 0 006 in to 0 012 in 0 020 in 0 02 mm 0 04 mm 0 008 mm 0 016 mm 0 02 mm 0 04 mm 0 008 in 0 016 in 0 02 mm 0 05 mm 0 0008 in 0 002 in 0 014 to 0 038 mm 0 15 mm 0 0006 to 0 001 in 0 006 in 23 002 to 23 011 mm 0 905 to 0 906 in 23 000 to 23 013 mm 23 053 mm 0 905 to 0 906 in 0 907 in 1 0 kgf cm2 or more 14 2 psi 3 0 to 4 5 kgf cm2 2 5 kgf cm2 43 to 64 psi ...

Page 17: ... to 9 mm 0 275 to 0 355 in 1 2 kgf cm2 14 to 15 psi 0 9 to 0 6 kgf cm2 15 to 9 psi 60 C 140 F 73 9 C 165 F 23 to 25 before TOC 600 to 500 kgf cm2 8532 to 7110 Ibs 100 to 5 kgf cm2 1422 to 71 1 Ibs 140 to 150 kgf cm2 1990 to 2133 Ibs 130 to 140 kgf cm2 1848 to 1991 Ibs 32 7 mm 1 287 in 45 A or less 0 5 to 0 8 mm 0 092 to 0 032 in 19 mm 0 748 in Approx 1 5 ohm AC 20 volts or more 5200 RPM 13 8 to 14...

Page 18: ...2 8532 to 7110 Ibs 100 to 5 kgf cm2 1422 to 71 1 Ibs 140 to 150 kgf cm2 1990 to 2133 Ibs 130 to 140 kgf cm2 1848 to 1991 Ibs 30 0 mm 1 181 in 90 A or less 0 5 to 0 9 mm 0 020 to 0 035 in 19 mm 0 748 in Approx 1 5 ohm I AC 20 bolts or more 5200 RPM 13 8 to 14 8 volts ENGINE SPECIFICATIONS Allowable Limit 0 2 mm 0 008 in 12 7 mm 0 500 in 15 ...

Page 19: ... 1 kgf m 12 3 to 15 2 ftllbs 12 3 to 15 2 ftllbs Idle gear shaft bolts 1 0 to 1 15 kgf m 1 0 to 1 15 kgf m 7 23 to 8 31 ftllbs 7 23 to 8 31 ftllbs Glow plugs 2 0 to 2 5 kgflm 2 0 to 2 5 kgf m No neea to apply oil 14 5 to 18 1 ftllbs 14 5 to 18 1 ftllbs Drain plugs 4 0 to 4 5 kgf m 4 0 to 4 5 kgf m 28 9 to 36 2 ftllbs 28 9 to 36 2 ftllbs Nozzle holders 3 to 5 kgf m 3 to 5 kgf m 21 7 to 36 2 ftllbs ...

Page 20: ... 15 2 ftllbs 1 0 to 1 15 kgf m 7 23 to 8 31 ftllbs 2 0 to 2 5 kgf m 14 5 to 18 1 ftllbs 4 0 to 4 5 kgf m 28 9 to 36 2 ftllbs 3 to 5 kgf m 21 7 to 36 2 ftllbs 0 14 to 0 2 kgf m 10 1 to 14 5 ftllbs 1 5 to 2 0 kgf m 10 8 to 14 5 ftllbs 2 8 3 5 kgf m 20 3 to 25 3 ftllbs 2 5 to 3 0 kgf m 18 1 to 21 7 ftllbs 1 5 to 2 6 kgf m 10 8 to 18 8 ftllbs 14 to 16 kgf m 101 to 116 ftllbs 1 4 to 1 8 kgf m 10 1 to 1...

Page 21: ... 86 8 Ibslft M 14 79 6 92 6 Ibs ft 91 1 108 5 Ibslft 123 0 144 7 Ibs ft M 16 123 0 141 0 Ibslft 144 7 166 4 Ibs ft 191 7 224 2 Ibs ft M 18 180 0 209 8 Ibs ft 202 5 235 1 Ibs ft 253 2 296 5 Ibslft M 20 245 9 289 3 Ibs ft 271 2 318 2 Ibs ft 361 6 419 5 Ibs ft Bolt material grades are shown by numbers punched on the bolt heads Prior to tightening be sure to check out the numbers as shown below Punche...

Page 22: ...nings 20 Maintenance Check List 21 POINTS OF INSPECTION AND CHANGING Engine Lubricating Oil 22 Changing Engine Oil Level 22 Changing Engine Oil 22 Changing Engine Oil Filter Cartridge 23 Inspection of Fuel Filter 23 Venting the Fuel System 24 _ 19 ...

Page 23: ...ssembling When exchanging parts use Universal genuine parts to maintain engine performance and safety To prevent oil and water leakage apply non drying adhesive to the gasket according to this manual before reassembling When hoisting the engine use the hook provided on the cylinder head When installing external circlips or internal circlips direct corner end to the non loosening direction Applying...

Page 24: ...ng fuel pipes and clamps Changing engine oil Cleaning air filter element Cleaning fuel fiilter Checking battery electrolyte level Checking fan belt tension and damage Checking oil or water leakage Checking water pipes and clamps Changing oil filter cartridge Changing fuel filter element Cleaning heat exchanger Recharging battery Changing coolant Changing air filter element or every 6 cleanings Che...

Page 25: ...e oil level is below the lower mark on the dip stick add sufficient oil to the full mark DO NOT OVERFILL 1 Dip Stick 2 Oil Filler Plug CHANGING ENGINE OIL Drain the oil while the engine is still warm by removing the drain plug on the oil pan and oil filler plug or through the oil drain hose so that the oil may completely drain Do not mix different brands of oil If a different brand of oil should b...

Page 26: ...to the prescribed level 1 Oil filter cartridge INSPECTION OF FUEL FILTER The fuel filter is installed in the fuel line from the fuel tank to the injection pump between the tank and feed pump in the basic model As the fuel from the inlet of the cock body moves through the filter element the dirt and impurities in the fuel are filtered allowing only clean fuel to enter the inside of the filter eleme...

Page 27: ...air vent screw at the top of the filter by turning it twice 3 When bubbles disappear from fuel coming out of the plug twist it back on 4 Open the air vent plug on the fuel injection pump 5 Pull the engine stop lever back completely to stop the engine and run the starter for about 10 seconds 6 Close the air vent plug when air bubbles disappear from the fuel flowing out Models 12 2 12 3 20 and 4 30 ...

Page 28: ...ONSTRUCTION AND FUNCTION Cylinder Block 26 Cylinder Head 26 Crankshaft 27 Piston and Piston Rings 28 Connecting Rods 28 Camshaft and Fuel Camshaft 29 Rocker Arm Assembly 29 Inlet and Exhaust Valves 30 Flywheel 30 25 ...

Page 29: ...air can be protected from being heated and expanded by heated exhaust air The cool high density suction air has a higher voluminous efficiency and raises the power of the engine Furthermore distortion of the cylinder head by heated exhaust air is reduced because suction ports are arranged alternately The combustion chamber is exclusive spherical combustion chamber type Suction air is whirled to be...

Page 30: ...to raise wear resistance quality Crankshaft journals are supported by the main bearing cases in which bearing is used Crankshaft bearing 1 at the front end is a wind type bushing and the three bearings 2 behind are split type bushings Side bearings 1 2 of split type are mounted on both sides of the main bearing case 1 at the flywheel side Crankshaft bearings and side bearings are plated with speci...

Page 31: ...ective to prevent oil rising Oil ring is effective to scrape oil because it is closely fitted to the cylinder wall by coil expander and the upper and lower ends of its sliding surface are cut diagonally to raise fare pressure to the cylinder walls A part of scraped oil is forced into the inside of piston through oil escape holes of rings and piston The oil ring is plated with hard chrome to increa...

Page 32: ...se 8 Circlip 9 Circlip 10 Fuel camshaft 11 Ball 12 Ball bearing ROCKER ARM ASSEMBLY The rocker arm assembly includes the rocker arms rocker arm brackets and rocker arm shaft and converts the reciprocating movement of the push rods to an open close movement of the inlet and exhaust valves Valve control timing must be adjusted with screws on the rocker arms Lubrication oil is pressurized through the...

Page 33: ... Inlet valve 8 Exhaust valve FLYWHEEL 7 Intake and exhaust valve 4 _ 5 6 8 Flywheel is connected with the crankshaft Storing explosive force by each cylinder as the force of inertia the flywheel functions to rotate the crankshaft smoothly On the circumference of the flywheel are stamped marks for fuel injection timing and top dead center The flywheel and crankshaft can be fixed to each other at a ...

Page 34: ...agram 33 Relief Valve 34 By pass Valve 34 Oil Switch 35 Oil Pump 35 COOLING SYSTEM Water Pump 36 Thermostat 36 Oberdorfer Water Pump 37 Sherwood Water Pump 38 Johnson Water Pump 39 New Style Sherwood Water Pump 40 FUEL SYSTEM Fuel Filter 41 Fuel Pump 42 Fuel Injection Pump 42 45 Injection Nozzle 46 Governor 47 49 31 ...

Page 35: ...LUBRICATION SYSTEM Crankpin Bearing Piston Oil Filter 1 32 Oil Filter Cartridge and Relief Valve 1 To rocker arm shaft and camshaft 2 To crankshaft ...

Page 36: ...il filter 1 strainer oil pump relief valve oil filter cartridge and oil switch The oil pump suctions lubrication oil from the oil pan through oil filter 1 and the oil flows down to the filter cartridge where it is further filtered Then the oil is forced to crankshaft connecting rods idle gear camshaft and rocker arm shaft to lubricate each part Some part of oil splashed by the crankshaft or leakin...

Page 37: ...SS VALVE Oil filter cartridge has a by pass valve inside to prevent the lack of lubrication oil in the engine if the oil filter element is clogged When the pressure difference before filtering and after is more than 98 1 kPa 14 2 psi the by pass valve opens and lets the oil pass to each part of engine without passing through the filter Relief valve and by pass valve 1 Relief valve 2 By pass valve ...

Page 38: ...t 11 Contact 12 Lamp 13 Battery The oil pump is of rotor type and works smoothly and noiselessly An inner and outer rotor turn inside a housing In operation the inner rotor is driven inside the outer rotor The inner rotor has one less lobe than the outer rotor so that only one lobe is in full engagement with the outer rotor at anyone time This allows the other lobes to slide over the outer lobes m...

Page 39: ... 2 Mechanical Seal 3 Water Pump Body 4 Bearing Unit THERMOSTAT The thermostat maintains the cooling water at correct temperature and uses wax pellet type thermostat Wax is enclosed in the pallet The wax is solid at low temperatures but turns liquid at high temperatures expands and opens the valve Flow of cooling water r Temperature sensor of wax pellet type thermostat 1 a b 1 Leak hole 7 To radiat...

Page 40: ...57 Item Unit Description 1 4 Cover Screws 2 1 Pump Cover 3 1 Cover Gasket 4 1 Impeller Snap Ring 5 1 Impeller 6 1 PUmp Shaft Old Style 6A 1 1 pc Shaft New Style 7 1 Cam 8 1 Carbon Bushing 9 1 Cam Locking Screw 10 2 Oil Seal 11 1 Drain Plug 37 ...

Page 41: ...1 10 1 11 1 12 2 13 1 SHERWOOD WATER PUMp PUMP ASSEMBLY 300986 Description Cover Screws Pump Cover Cover Gasket Impeller Snap Ring Impeller Key Pump Shaft Old Style 1 pc Shaft New Style Water Seal Cam Pump Body Cam Locking Screw Oil Seal Drain Plug 38 ...

Page 42: ... Description 1 6 Cover Screws 2 1 Pump Cover 3 1 Cover Gasket 4 1 Impeller 5 1 Pump Shaft 6 1 Caqm 7 1 Wear Plate 8 1 Pin 9 1 Cam Locking Screw 10 1 PUmp Body 11 1 Lip Seal 12 1 O Ring 13 1 Washer 14 2 Ball Bearing 15 1 Guide Ring 16 1 Service Kit 39 ...

Page 43: ... H O Housing Ring Cam Screw Cam Impeller Cir Clip Flat Washer Seal Seat Not Available 0 Cir Cr rder 13 Ip Internal Clr cr Ip External Ball Bearing Seal Seat A Cir Cr ssembly K ip External ey Shaft End Plate Gasket Pump Body Lock Washer Bolt 40 ...

Page 44: ...ain into the tank 1 2 3 1 Fuel Tank 2 Fuel Overflow Pipe 3 Injection Pipe 4 Injection Nozzle 5 Injection Pump 6 Fuel Filter Water Separator 7 Fuel Feed Pump Elec 8 Fuel Filter FUEL FILTER A fuel filter is used to prevent dirty fuel from reaching the injection pump and injection nozzles The filter element will require occasional replacement to maintain an adequate flow of fuel to the injection pump...

Page 45: ...JECTION PUMP Inlet stroke Discharge stroke 6 t 1 From Fuel Filter 2 Inlet Valve 3 Outlet Valve 4 Diaphragm 5 Fuel Camshaft 6 To Injection Pump The K type mini pump is provided it features high injection quality even at low engine speed The fuel injection pump plunger is reciprocated by the fuel camshaft which is driven by the crankshaft through a system of timing gears Fuel camshaft rpm is 1 2 of ...

Page 46: ...ves up pressure increases and delivery valve is opened Then fuel is pressure fed through the injection pipe and nozzle into the combustion chamber 4 Completion of pressure feed When plunger moves further up the control groove and feed hole meet Pressurized fuel in the delivery chamber is returned through the plunger s center hole control groove and feed hole to the fuel chamber Then pressure falls...

Page 47: ...ger is rotated a certain amount in the direction of the arrow by the control rack stroke A is effective until the feed hole meets the control groove and fuel is injected as the stroke amount 3 Injection maximum When the plunger is rotated by the control rack to the maximum amount in the direction of the arrow effective stroke reaches maximum and maximum injection is provided Injection Control t 1 ...

Page 48: ...alve lowers preventing fuel dribbling from the nozzle Pump Element The pump element is composed of a cylinder and a plunger Their contact surfaces are precision finished to provide a high injection pressure even at low speeds The cylindrical surface of the plunger has slanted grooves which are called control grooves and a connecting hole for plunger head Control Rack This is connected directly to ...

Page 49: ...he fuel tank Injection pressure can be controlled by inserting shims between nozzle holder body and adjusting washers The pressure increases when a O 1mm shim is inserted Injection nozzle is also precision finished as is the injection pump treat it carefully and protect from water and dust Injection nozzle 1 4 5 o tt tt 6 o flt1l f H tt 7 8 i 1 Nozzle Holder Body 2 Adjusting Washer 3 Nozzle Spring...

Page 50: ...is set at idling position after the engine is started high speed governor spring 1 does not work at all and also low speed governor spring 2 does only a little action Therefore governor sleeve is pushed leftward by a centrifugal force of ball weights Fork lever 1 and control rack are moved leftward by the sleeve and then idling limit spring is compressed by control rack As a result the control rac...

Page 51: ...force of ball weights becomes smaller than the tension of governor springs 1 and 2 As a result the control rack is moved rightward and fuel injection amount is increased to produce an engine torque required for the load a c At middle high speed running 1 Speed Control Lever 2 Governor Spring 1 3 Governor Spring 2 4 Ball Weights When load is increased 1 3 2 t 5 4 __ 1 Engine Torque Curve 2 Small Lo...

Page 52: ...r that when the force of spring becomes larger than the centrifugal force of ball weights fork lever 1 moves rightward to increase fuel injection driving the engine continuously with a high torque At high speed running with overload 1 Ball Weight 2 Fork Lever 2 3 Governor Spring 1 4 Governor Spring 2 5 Maximum Output Limit Bolt 6 Spring 7 Fork Lever 1 To stop engine When stop lever is moved to STO...

Page 53: ...NOTES 50 ...

Page 54: ... 58 Ammeter 58 Alternator Regulator Test Procedure 59 Test Procedure Integral Regulator Systems 60 63 Troubleshooting Guide Integral Regulator Systems 60 61 Test Procedure Remote Regulator Systems 64 66 Troubleshooting Guide Remote Regulator Systems 64 Alternato Repair Procedure 67 73 Rotor Inspection and Electrical Testing 73 76 Alternator Reassembly 76 79 Alternator Performance Tests 79 80 Crank...

Page 55: ... 9 10 11 Glow Pktp 1 per cyl COLOR Black Grey Yellow Red Orange Red Purple Lt Blue Tan Open Grey Orange Red WIRE SIZE 10 10 16 10 10 16 16 16 14 16 14 WIRING DIAGRAM r 10 r 23 1 5 l l _ _ 1H 2 3 __ _ _ _ _ _ _ _ _ _ _ I __ 52 ...

Page 56: ...blade terminal for connection to the associated remote regulator Serviceable features of previous Motorola Charging System designs have been retained in these units The voltage regulator and brush assembly can be removed without disassembly of the alternator thus allowing for individual testing or inspection 1 2 3 1 Long life silicon diodes 2 Permanently lubricated sealed rear ball bearing 3 Quiet...

Page 57: ...0 pounds TYPICAL ALTERNATOR MODEL The field for the alternator is wound concentrically about the core of the rotor The field structure contains twelve poles six sets of pole pairs and the rotor is dynamically balanced after assembly to minimize vibration The rotor is supported in the alternator by a pair os sealed ball bearings Field current of approximately 2 5 Amperes is supplied to the field th...

Page 58: ... charging system The alternator designs produce a rated output of 51 amperes Rated output is achieved at approx imately 6000 alternator RPM at an ambient temperature of 75 degrees F 23 8 degrees C The alternator is designed to operate in an ambient of 40 degrees to 212 degrees F 40 to 100 degrees C To ensure proper cooling of the rectifier bridge and internal components of the alter nator it must ...

Page 59: ...lated to protect the circuit and the components from possible damage due to handling or vibration and moisture encountered in a vehicle The voltage regulator is also temperature compensated to provide a slightly higher voltage at low temperatures and a lower voltage at higher temperatures to provide for charging requirements of the battery under these conditions Ui w ffi 80 Q E c 60 I Z W a a 40 I...

Page 60: ...ING ROTATION For special installation requirements the alternator rear housing may be rotated to one of four different positions that are spaced 90 apart To rotate the rear housing proceed as follows 1 Detach plastic cover from rear housing 2 Remove the four 4 through bolts using a 1 4 nutdriver or socket See illustration below 3 Rotate the housing clockwise or counter clockwise to the desired loc...

Page 61: ...VE PULLEY MUST BE IN LINE WITH EACH OTHER REAR FRONT HOUSING HOUSING ALTERNATOR BELT ALIGNMENT Ammeter requirements vary with application An original equipment ammeter may be difficult to replace with a higher reading unit due to limited panel space and the vehicle wiring system For an ammeter to show alternator charge and accessory discharge it must be connected as shown in illustration below ALT...

Page 62: ... if necessary A low or discharged battery may cause false or misleading readings on the in vehicle tests Test Equipment Requirements The Alternator and Regulator tests outlined require electrical test equipment to measure voltage only however most commercial test equipment incorporates several testing devices in a single unit DC VOLTMETER 0 20 Volt Scale BATTERY TEST EQUIP Any commercial type Hydr...

Page 63: ...rged 1 Indicator lamp burned out or 1 Check bulb harness indicator lamp off with key defective wire harness on engine stopped Normal condition is lamp on 2 Broken brush 2 Replace brush assy 3 Defective alternator system 3 Refer to Problem Area Determination Section Battery overcharges 1 Defective wire harness 1 Refer to Problem Area excessive use of water 2 Defective alt system Determination Secti...

Page 64: ... Regulator is O K the cause is probably an open field circuit and Alternator must be removed for repair 4 Further Investigation Requires Alternator Removal and Repair diodes B BATTERY OVERCHARGED 1 Regulator Shorted Replace Regulator IGN IND SW LIGHT POS 0 OUTPUT Ivocrs I RED STEP TEST POIN INDICATION 1 1 _A B_ __ M rr ER7Y W A G E t 2 B REG 1 5 TO 3 0 wcrs WITH II ______ IN D LI GH T O N ____ IL ...

Page 65: ...wires from terminals extending through back cover Remove back cover two screws and reconnect all wires With ignition on and engine not running and jumper not attached check for battery voltage at terminal A and terminal B Indicator light will be ott Add jumper JUl between field and ground If 1 5 to 3 0 volts is present at terminal B and the indicator light is on an open defective regulator is indi...

Page 66: ...ernator Ooutput Test BATTERY After voltmeter is connected as shown in Figure below start and run engine at a fast idle of approximately 1 500 RPM Turn on vehicle headlights and blower fan low speed Check for nominal system output voltage of between 13 8 14 8 volts for a properly operating charging system Voltages may vary a few tenths of a volt higher or lower due to ambient temperature variations...

Page 67: ...tive alternator system 3 Battery overcharges 1 Poor ground 1 excessive use of water 2 Defective alt system 2 ammeter if used shows constant excessive charge voltmeter indicates greater than 14 5 volts connected across battery with no load with engine idling Battery charges at idle but 1 Slipping belts 1 discharges under load 2 Alternator defective conditions 2 Indicator lamp glows slightly 1 Defec...

Page 68: ... not running jumped not attached and no electrical load check for battery voltage at terminal A and for 1 5 to 3 0 volts at terminal B Add jumper JU1 between terminals A and B Start engine and run at idle If indicator lamp now goes off and charging voltage is present at terminal A the diode trio is probably open defective and alternator should be removed for repair VOIJAGE REGULATOR IGN IND SW UGH...

Page 69: ...OIJAGE WITH IND LIGHT OFF JUMPER ATTACHED 1 5 TO B 0 3 0 VOLTS IND LIGHT ON JUMPER NOT ATTACHED OPEN REGULATOR TEST Test No 3 Alternator Output Test B BATTERY After voltmeter is connected as shown in Figure below start and run engine at a fast idle of approximately 1 500 RPM Turn on vehicle headlights and blower fan low speed Check for nominal system output voltage of between 13 8 14 8 volts for a...

Page 70: ... order to isolate and correct the problem The following troubleshooting diagram should help identify some of the more common problems to concentrate on during the overhaul repair procedure Disassembly Testing Detach Back Cover NO LOW NOISY ALTERNATOR ALTERNATOR ALTERNATOR OUTPUT OUTPUT DEFECTIVE REGULATOR DEFECTIVE REGULATOR LOOSE DRIVE PULLEY DEFECTIVE BRUSHES WORN BRUSHES CRACKED OR DAMAGED HOUS...

Page 71: ...e illustration below shows the terminals brush arrangement and testing procedure The original brush set may be reused if the brushes are 3 16 or longer and if brushes are not oil soaked cracked or show evidence of grooves on the sides of the brushes caused by vibration TEST CONTINUITY FROM ATO B FROM CTO 0 NO CIRCUIT FROM AOR B TO COR 0 TEST WITH 12 VOLT DC TEST LAMP OR OHMMETER BRUSH TEST 68 ...

Page 72: ...Diode Trio Field Diode and Rectifier Diode Bridge 2 REGULATOR MOUNTING SCREWS The diode trio and rectifier diode bridge are detached as an assembly Remove cone lockout from positive output B terminal Straighten B strap Remove three terminal screws and four diode trio mounting screws Detach assembly from rear housing and separate diode trio assembly from rectifier bridge See illustration below 4 MO...

Page 73: ...E TRIO Test Diode Rectifier Bridge Assembly Using a commercial diode tested check for continuity Check betweenn pOint A and each of three terminals C for negative diodes Continuity should be observed in one direction polarity only and all diodes should check alike Then check between point B B strap and each of the three terminals C for positive diodes Continuity should be observed in one direction...

Page 74: ...EAR HOUSING SEPARATION Inspect the rear housing for a cracked or broken casting stripped threads or evidence of severe wear in the bearing bore due to a worn rear bearing If casting is to be reused clean in solvent dry with compressed air and install a new rear bearing retainer if retainer is damaged Test Stator The stator assembly consists of three individual windings terminated in the delta type...

Page 75: ...ct the fan for cracked or broken fins note the condition of the mounting hole If worn from running loose replace the fan to insure balance Inspect pulley for possible faults as listed in illustration below PULLEY REMOVAL Separate Rotor from Front Housing CHECK FOR WORN DRIVE SURFACES __ CHECK FOR POLISHED SURFACE HERE NOTE CONDITION OF ____ 1 KEY GROOVE I CHECK BORE FOR WEAR PULLEY INSPECTION POIN...

Page 76: ...e in mounting foot Discard housing if bore shows signs of elongation oval or out of roundness ROTOR INSPECTION AND ELECTRICAL TESTING Check the rotor assembly for the following electrical properties See illustration on page 89 A Current Draw or Resistance of the Winding CAUTION Turn off DC power source before removing test leads to avoid avc damage to slip ring surfaces 1 CURRENT DRAW IN AMPERES A...

Page 77: ...to the rotor body is a correct condition C Condition of Slip Rings 1 Clean brush contacting surfaces with fine crocus cloth wipe dust and residue away 2 If surfaces are worn beyond this restoration replace the entire rotor assembly D Rotor Shaft and Pole Pieces 1 Stripped threads on shaft 2 Worn key slot 3 Worn bearing surface 4 Scuffed pole fingers 5 Worn or dry rear bearing Replace rotor assembl...

Page 78: ... 1 cap screw into opening at center of slip ring assembly Position bearing puller as shown in illustration below and pull slip ring assembly off rotor shaft CAUTION When holding rear end of rotor shaft in vise be sure not to grip bearing area of rotor shaft Remove Rear Bearing from Rotor STRAIGHTEN ROTOR LEADS REMOVING SLIP RING ASSY Dress rotor leads away from the bearing puller contact area Adju...

Page 79: ...equirements will be covered in this section Install Rear Bearing Place rotor on a press as shown in illustration below Choose a driver sleeve that exerts pressure on inner race only and press bearing on rotor shaft until it contact shoulder New replacement bearings should be used whenever bearing is removed during repair procedures or when bearing is rough dry or noisy BLOCK REAR BEARING RaroR PRE...

Page 80: ...e solder connections Install Front Bearing SLIP RING ASSEMBLY ____ PRESS DRIVER __________SLEEVE INSTALLING SLIP RING ASSEMBLY Place front bearing and housing in an arbor press as in illustration below Select a drive tool to contact the outer race only and press bearing into housing bore Bearing replacement is recommended whenever bearing is removed during alternator repair procedures of if bearin...

Page 81: ...lt holds Position rear housing over slip rings with housing bolt holes aligned and stator leads exten ding through openings at top of rear housing Install through bolts and tighten evenly to between 50 to 60 inch pounds Spin rotor by hand to test freedom of bearings NOTE New front housings contain thru bolt holes that are not tapped Therefore a socket wrench rather than a nut driver will be requir...

Page 82: ...000 alternator RPM Slowly reduce field rheostat resistance alternator should develop a charge Continue to reduce resistance until alternator reaches rated current output in amperes CAUTION Limit output voltage to 15V maximum DO NOT operate the alternator for more than a few minutes in the manner due to the lack of voltage control If the alternator will deliver its rated output terminate the test B...

Page 83: ... rotation to turn the engine crankshaft It is composed of the field coil armature brush commutator pinion overrunning clutch etc The second section allows the pinion and flywheel to engage together and current to flow through the motor section It is composed of the pull in coil holding coil pluge drive lever contract plate etc 1 Field Coil 2 Brush Spring 3 Brush Holder 4 Brush 5 Commutator 6 Throu...

Page 84: ...y the drive lever to engage with the ring gear When start button is pushed 1 Battery 2 Starter Switch 3 Ground 4 Return Spring 5 Spline Tube 6 Pinion 7 Ring Gear 8 Operated By Lever When contact plate is closed When the contact plate is closed a large current flows through the motor section to generate a large mechanical power which turns the engine crankshaft At this time the pinion is moved forw...

Page 85: ...turn spring Simultaneously the pinion is disengaged from the ring gear the contact plate is disconnected and the starter is promptly stopped by the armature brake When push button is released Glow Plugs Glow plugs are used for each pre combustion chamber of the cylinder head to make starting easier The glow plugs are quick heating type which make starting easier with short pre heating time Constru...

Page 86: ...njection Pump Cover 92 Removing Injection Pump 92 GEAR CASE TIMING GEAR CAMSHAFT OIL PUMP Detaching Governor Spring 93 Removing Speed Control Plate 93 Detaching Start Spring 94 Removing Fan Drive Pulley 94 Removing Gear Case 95 Removing Crankshaft Oil Slinger 95 Removing Idle Gear 96 Camshaft Stopper 96 Removing Gear and Camshaft 97 Removing Fork Lever Assembly 97 Removing Fuel Camshaft 98 Removin...

Page 87: ... 110 Checking Valve Spring Tension 110 Checking Oil Clearance Between Rocker Arm Shaft and Bushing 111 Checking Top Clearance 111 Adjusting Valve Clearance 113 Adjusting Compression Release 112 FUEL SYSTEM Testing Opening Pressure of Nozzle 113 Checking Fuel Tightness of Nozzle Valve Seat 113 Checking Shape of Fumes Across Nozzle Tip 114 Checking Fuel Tightness of Fuel Injection Pump Plunger 114 C...

Page 88: ...learance Between Crankshaft Journal and Crankshaft Bearing 1 124 Checking Oil Clearance Between Crankshaft Journal and Crankshaft Bearing 2 124 Checking Oil Clearance Between Crank Pins and Crank Pin Bearings 125 Checking End Play of Crankshaft 125 Checking Wear of Cylinder Liner 126 Crankshaft and Bearing Reference 127 REPLACING VALVE GUIDES BUSHINGS AND BEARINGS Replacing Valve Guides 128 Replac...

Page 89: ...enough engine oil to the valve guide and valve stem 1 Head Cover REMOVING INJECTION PIPES 1 2 and 3 1 Loosen the screws on the pipe clamps 2 Detach the injection pipes in the order of 1 2 and 3 NOTE FOR REASSEMBLING Send compressed air into the pipes to blowout dust Then reassemble the pipes in the reverse order Tighten the retaining nuts to 15 to 25 Nm 1 5 to 2 5 kgf m 11 to 18 ft Ibs 4 1 Injecti...

Page 90: ...on the surface on which the nozzles are to be installed Tighten the nozzles to 29 to 49 Nm 3 0 to 5 0 kgf m 22 to 36 ft Ibs 1 Nozzle Holder Socket Wrench 2 Rock Nut REMOVING AC DYNAMO AND FAN BELT 1 Remove the AC dynamo 2 Detach the fan belt NOTE FOR REASSEMBLING Check to see if the V belt is placed in a correct position where letters on the belt can be read from your side and there is no oil or g...

Page 91: ...ny metallic particles on the surface on which the assembly is mounted Tighten the bolts to 17 to 21 Nm 1 7 to 2 1 kgf m 12 to 15 ft Ibs 1 Rocker Arm REMOVING PUSH RODS 1 Remove the push rods NOTE FOR REASSEMBLING Before inserting the push rods into the tappets check to see if their ends are properly engaged with the grooves If a push rod is roughly inserted it may hit the shoulder of the tappet an...

Page 92: ...eplace the gasket with a new one without confusing its front and back Retighten the cylinder head after running the engine for 30 minutes Tighten the cylinder head bolts and nuts to engine specifications REMOVING CYLINDER HEAD GASKET Cylinder head tightening sequence 10 2 7_ oo oo Oo8 1 0 0 0 0 2 1 Gear Case Side 2 Flywheel Side 13 0 5 0 4 0 12 9 1 8 1 Detach the cylinder head gasket being careful...

Page 93: ...1 O ring 2 Pipe Pin REMOVING TAPPETS 1 Remove the six tappets from the crankcase NOTE FOR REASSEMBLING Visually check the contact between tappets and cams for proper rotation If a defect is found replace tappets Before installing the tappets apply engine oil thinly around them 1 Tappets 90 ...

Page 94: ...he retaining nut with a vise 2 Remove the nut the eye joint and the plain washer 3 Remove the nozzle holder body and take out parts inside NOTE FOR REASSEMBLING When disassembling and reassembling the nozzle piece dip it in clean fuel Install the push rod noting its direction upside down Tighten the retaining nut to 58 8 to 78 4 Nm 6 to 8 kgf m to 57 8 ft Ibs Do not tighten it too much or the need...

Page 95: ...t detach the pump along the removal groove 3 Align the control rack pin with the slot on the gear case and remove the injection pump 4 In principle the injection pump should not be disassembled NOTE FOR REASSEMBLING Install the injection pump by aligning the control rack with the indicated positon Addition or reduction of one shim delays or advances the injection timing by 0 0262 rad 1 50 Install ...

Page 96: ...he window of the injection pump and spring will be able to be hooked on the governor fork with ease Bend the end of the governor spring to prevent it from falling off How to remove governor spring 1 Detach Governor Spring on the Side of Fork Lever 2 Gear Case 3 Fork Lever 2 REMOVING SPEED CONTROL PLATE 1 Remove the speed control plate and governor spring NOTE FOR REASSEMBLING Be careful not to dro...

Page 97: ...VE PULLEY 1 Flatten the crankshaft washer 2 Loosen and remove the crankshaft nut 3 Draw out the pulley with a puller NOTE FOR REASSEMBLING Bend the crankshaft washer against one side of the nut Tighten the nut to 137 3 to 156 9 Nm 14 0 to 16 0 kgf m 101 3 to 115 7 ft Ibs Do not tighten the nut excessively it may damage the oil slinger causing oil leakage 1 Fan Drive Pulley 94 ...

Page 98: ... thin film of engine to the oil seal and install it noting the lip come off Before installing the gear case gasket apply a non drying adhesive Tighten the oil filter cartridge by hand REMOVING CRANKSHAFT OIL SLINGER 1 Remove the crankshaft collar 2 Remove the O ring 3 Detach the crankshaft oil slinger 1 Crankshaft Oil Slinger 2 O Ring 3 Crankshaft Collar 95 ...

Page 99: ...r and crank gear 2 Idle gear and camshaft gear 3 Idle gear and injection pump gear Tighten the idle gear shaft mounting bolt 7T to 10 to 12 Nm 1 0 to 1 2 kgf8m 7 2 to 8 7 ft Ibs 2 1 00 2 1 Idler Gear 2 Alignment Mark REMOVING CAMSHAFT STOPPER 1 Align the round hole on the cam gear with the camshaft stopper mounting bolt position 2 Remove the camshaft stopper mounting bolt 3 Detach the camshaft sto...

Page 100: ...r mounting bolts 2 Detach the fork lever assembly NOTE FOR REASSEMBLING Install the fork lever holder and crankcase after cleaning their contact surfaces Install the fork lever so that it will not hit the governor sleeve and so that equal space is allowed on either side of the lever After installation check to see that the fork lever 1 is fixed to the fork lever shaft and that it can turn smoothly...

Page 101: ...ive shaft of the hydraulic gear pump The balls to be contained in the governor ball case are thirty 3 97 mm 0 1563 in diameter ones and eight 13 46 mm 0 5300 in diameter ones 1 Fuel Camshaft Assembly 2 Fuel Camshaft Stopper REMOVING OIL PUMP DRIVE GEAR 1 Straighten the claw of the claw washer of the oil pan and remove the nut NOTE FOR REASSEMBLING Check to see if there is a feather key Be sure to ...

Page 102: ...mp Assembly REMOVING CRANK GEAR 1 Set a special puller on the crank gear 2 Screw in the center bolt of the puller and draw out the crank gear NOTE FOR REASSEMBLING Check to see that the key is on the crankshaft Heat the crank gear to about 990C 1200F and fit on the crankshaft If there is fear of the shaft being damaged heat the gear more and fit 1 13T Gear Crank Gear 99 ...

Page 103: ...pan To avoid uneven tightening tighten mounting bolts in diagonal order from the center Check to see that the drain plug is tight t 1 Oil Pan REMOVING OIL FILTER 1 1 Remove the mounting bolt of oil filter 1 2 Detach oil filter 1 being careful of the O ring NOTE FOR REASSEMBLlNG After cleaning the oil filter check to see that the filter mesh is clean and install it Visually check the O ring apply e...

Page 104: ...ammer 3 Draw out the other two pistons in the same method as above NOTE FOR REASSEMBLING Before inserting the pistons into the cylinders apply enough engine oil to the pistons IMPORTANT Install the piston rings with their gaps making an angle of 2 09 rad 1200 or 3 14 rad 1800 to each other Place the top ring with their gaps on the opposite side of the combustion chamber Attach a ring to the piston...

Page 105: ...of the rear end plate and set the flywheel Tighten the flywheel bolts to 54 to 59 Nm 5 5 to 6 0 kgfOm 40 to 43 ft Ibs in diagonal order Bend the tangs of the flywheel washer against the bolts 1 Flywheel Puller 2 Crankshaft REMOVING BEARING CASE COVER 1 Remove the bearings case cover mounting bolts First unscrew the eight bolts inside and then work on the nine outside 2 Screw the two bolts removed ...

Page 106: ...that the crankshaft can be easily installed Tighten the bearing case bolts 2 to 30 to 34 Nm 3 0 to 3 5 kgfOm 22 to 25 ft Ibs Securely bend tangs of the washer 1 Bearing Case Bolt 2 REMOVING CRANKSHAFT 1 Draw out the crankshaft from the back of the crankcase by lightly tapping it with a copper hammer NOTE FOR REASSEMBLING Before installing the crankshaft clean the oil holes in the crankshaft with c...

Page 107: ...n page 105 1 Grind the cylinder head mounting surface with an oil grinding stone 2 Set a dry liner centering base and adaptor on the frame head 3 Set the dry liner centering base 4 Set the bearing cradle to the dry liner centering base with the bearing on top 5 Insert the pulling out adaptor coupling and fix the center bolt 6 Contact the pulling out adaptor with the bottom of the liner from the bo...

Page 108: ...earing Cradle 3 Center Bolt 4 Nut THERMOSTAT WATER PUMP REMOVING THERMOSTAT 1 Remove the thermostat cover 2 Remove the thermostat NOTE FOR REASSEMBLIING Apply a non drying adhesive only at the thermostat cover side of the gasket 105 ...

Page 109: ...tration on page 107 1 Clean the surface of the cylinder head 2 Place a straight edge on each of the cylinder heads s four sides and two diagonally as shown at the left to check the straightness of the surface 3 Insert a feeler gauge between the straight edge and the cylinder head surface 4 The maximum thickness that can be inserted is the amount of flatness 5 If the measurement exceeds the allowab...

Page 110: ...head surface with the red permeative liquid 3 Wash away the red permeative liquid on the cylinder head surface with the detergent 4 Spray the cylinder head surface with the developer If flawed it can be identified as red marks Reference Should be no flaw A A Air spray red check 1 Detergent 2 Red Permeative Liquid 3 White Developer 2 107 ...

Page 111: ... that the valve seat fits to the valve center so as to ensure a b as shown in the figure NOTE After correcting the valve seat check for valve recessing B 15 cutter A 45 cutter 1 Valve 2 Corrected surface of valve seat CHECKING VALVE RECESSING 1 Clean the face of the valve 2 Measure the recessing with a depth gauge 3 See engine specifications 108 How to repair the valve seat B 2 ...

Page 112: ...wable limit replace the stem guide and the valve IMPORTANT When changing the valve guide be sure to ream as the figure indicates after inserting the valve guide See engine specifications Finishing size of inlet valve guide 6 3S V V V Finishing size of exhaust valve guide CHECKING VALVE SPRING FREE LENGTH 1 Measure the spring with a set of vernier calipers 2 If the measurement exceeds the allowable...

Page 113: ...The flat surface at the end of the spring coil must exceed the full circumference by two thirds Check the entire surface of the spring for scratches Allowable limit CHECKING VALVE SPRING TENSION 1 3 mm 0 051 in How to measure squarenass of valve spring 1 Place the spring on a tester and compress it to the same degree that it is actually compressed in the engine 31 mm 12 in 2 Read the compression l...

Page 114: ...uality fuse from the nozzle holder hole Be careful not to let the fuse touch the valve surface 4 Rotate the engine with your hand 5 Take the fuse out carefully 6 Measure the place where the fuse was crushed with vernier calipers 7 If the clearance is not within the reference value adjust by inserting a shim between the cylinder head and the gasket Reference value 0 6 to 0 8 mm 0 0236 to 0 00315 in...

Page 115: ...ull the compression release lever 0 145 0 185 mm T 0 006 to 0 007 in 4 Reduce the valve clearance to zero by the compression release adjustment bolt Reach for the bolt through the window Then screw in the bolt by 1 to 1 5 turns and tighten the lock nut NOTE After adjustment turn the crankshaft by hand and check to see that the valve and the piston should not be in contact with each other Reference...

Page 116: ...uses an approximate 980 6 kPa 10 kgf cm2 142 2 psi increase in fuel injection pressure DANGER Be careful not to come into direct contact with the injected fumes The fumes destroy any cells they may touch They may also cause blood poisoning See engine specifications CHECKING FUEL TIGHTNESS OF NOZZLE VALVE SEAT 1 Apply a pressure 2 After keeping the nozzle under this pressure for 10 seconds check to...

Page 117: ...urement is less than allowable limit replace the pump element In this case ask a repair shop to do the replacement Be sure to give them adjustment reference data on the fuel injection pump Shown below See engine specifications Reference valve 8 seconds or more Allowable limit 4 seconds Adjustment of Injection Control rack Speed Amount of injection Allowance mm3 position 1 rpm mm3 st 3 9 1400 22 5 ...

Page 118: ...ecrease the initial pressure 5 If the measurement is less than allowable limit replace the delivery valve See engine specifications Reference value 10 seconds or more Allowable limit 5 seconds 1 Connector 2 Pressure Sensor Pressure gauge construction 14 7 MPa 150 kgf cm2 2133 psi and 68 6 MPa 700 kgf cm2 9954 psi 3 Non drying Adhesive 4 Weld Entire Circumference 5 Copper Packing 6 S45C Steel Tube ...

Page 119: ... it as soon as the fuel level at the tip of the valve holder begins to increase 5 Check to see if the F1 mark on the flywheel is aligned with the dot mark 6 If the timing is out of adjustment readjust with shims IMPORTANT Adding or removing one shim 0 15 mm 0 0059 in varies the crank angle by approx 1 5 After adjustment apply a thin film of non clrying adhesive to both sides of the shims See engin...

Page 120: ...ance 3 If the clearance exceeds the allowable limit replace the camshaft See engine specifications CHECKING CAMSHAFT ALIGNMENT 1 Gently put the camshaft on V blocks 2 Set a dial gauge to the journal 3 While slowly rotating the camshaft read the dial gauge The camshaft flexure is half of the reading 4 If the measurement exceeds the allowable limit replace the camshaft I Allowable limit 117 0 08 mm ...

Page 121: ...exceeds the allowable limit replace the camshaft See engine specifications 1 Cam Height CHECKING GEAR BACKLASH 1 Install a lever type indicator between the gear teeth 2 Clamp one gear rotate the other and measure the backlash 3 If the backlash exceeds the allowable limit replace See engine specifications 118 Cam height measuring points ...

Page 122: ...he oil pump oilways oil clearances and pressure regulating valve NOTE FOR MEASURING Supply the specified amount of recommended oil The oil filter must not be clogged or broken See engine specifications OIL PUMP ROTOR TYPE Checking Rotor Lobe Clearance 1 Insert a feeler gauge into the gap between the inner and outer rotors and measure the clearance 2 If the clearance exceeds the allowable limit rep...

Page 123: ...lowable limit replace See engine specifications Checking end Clearance Between Rotor and Cover 1 Paste a press gauge to the surface of the gear with grease 2 Attach the cover 3 Gently remove the cover Measure the clearance by plaCing the gauge paper on the press gauge where it is crushed 4 If the measurement is not within the reference value replace Reference value 120 0 08 to 0 13 mm 0 0031 to 0 ...

Page 124: ...ith an outside micrometer 2 If the measurement exceeds the allowable limit replace See engine specifications CHECKING CLEARANCE BETWEEN PISTON PIN AND SMALL END BUSHING 1 Measure the piston pin with an outside micrometer 2 Measure the I D of connecting rod small end bushing with an inside micrometer Calculate the clearance 3 If the clearance exceeds the allowable limit replace See engine specifica...

Page 125: ...PORTANT Measure the piston ring gap at the point of the minimum inside diameter of the cylinder liner See engine specifications CHECKING SIDE CLEARANCE OF RING IN GROOVE 1 Remove the piston ring from the piston 2 Place the ring in its groove as it shown at left and measure the clearance 3 If the clearance is not within the reference valve replace the ring NOTE As the top ring is a keystone type it...

Page 126: ...MPORTANT Because the 1 0 of the connecting rod small end bushing is used as the basis for this check check it is not worn beforehand See engine specifications CRANKSHAFT CHECKING CRANKSHAFT ALIGNMENT 1 Place V blocks on the surface plate and support the journals at both ends of the crankshaft on the V blocks 2 Set a dial gauge to the central journal 3 Read the dial gauge while rotating the cranksh...

Page 127: ...earing 1 See engine specifications CHECKING OIL CLEARANCE BETWEEN CRANKSHAFT JOURNALS AND CRANKSHAFT BEARINGS 2 1 Paste a press gauge with grease on the crankshaft bearing 2 Tighten the crankshaft bearing case onto the crankshaft journal to the specified torque 29 4 to 34 3 Nm 3 0 to 3 5 kgfOm 21 7 to 25 3 ft Ibs 3 Detach the bearing case slowly and measure the depression of the press gauge with a...

Page 128: ...e the crankpin bearing NOTE FOR MEASURING Fasten the crankshaft so that it does not turn Do not insert the press gauge into the crank pin hole Crankpin bearing measuring pOints are shown below See engine specifications Crank pin measuring points CHECKING END PLAY OF CRANKSHAFT 1 Move the crankshaft to the crank gear side 2 Set a dial gauge to the crankshaft 3 Push the crankshaft toward the flywhee...

Page 129: ...e cylinder liner is worn beyond the allowable limit bore and hone it by 0 5 mm 0 0197 in 1 The cylinder liner which has been oversized by 0 5 mm 0 0197 in should use a piston and ring of the same oversize NOTE When the oversized cylinder liner is worn beyond the allowable limit replace the cylinder liner and bore and hone it See engine specifications Measuring points of cylinder liner 1 Top 2 Midd...

Page 130: ...m 0 1300 to 0 1457 in 2 2 8 to 3 2 mm 0 1102 to 0 1260 in 3 Oil hole must be 1 to 1 5 mm 0 0394 to 0 0591 in Be sure to chamfer the oil circumference with an oil stone Undersize and Oversize 4 The crankpin must be fine finished to higher than 1111111 0 4 5 5 The crank journal must be fine finished to higher than 1111111 0 4 5 6 The crank journal side surface must be fine finish to higher than 1111...

Page 131: ...valve guide by means of reemer machining to dimensions shown in Figs B and C NOTE Be careful not to strike valve guides with a hammer during replacement A Tool for replacing valve guides 8 Finishing size of inlet valve guide e Finishing size of exhaust valve guide REPLACING ROCKER ARM BUSHINGS 1 Prepare the necessary tool as shown in Fig A 2 Press out the used bushing and using this tool press fit...

Page 132: ...USHINGS 1 Prepare the necessary tool as shown in Fig A 2 Press out the used bushing and press a new bushing in taking due care to see that the con necting rod hole matches the bushing hole A Tool for replacing small end bushings B Connecting rod and bushing as assembled 1331524 0 23 D 39 D 9 100 3 94 R D 1 e cofD Fo 07 9 _ L J iC JL l CO 3 L l oc o as 1 Q Oas Q O B PkJ I NO 2 3 i 1 Material S43C H...

Page 133: ...e extracting tool 3 Insert a new bearing 1 using the inserting tool taking due care to see that the contact edge of bearing 1 faces the exhaust manifold side A Tool for extracting crankshaft bearing 1 B Tool for inserting crankshaft bearing 1 13C1tS I2 1 1301512 1 C Crankshaft and crankshaft bearing 1 as assembled 2 130 ...

Page 134: ... s No load Voltage 132 STARTER No load Testing of Starter 133 Motor Test 134 Checking Magnet Switch Pull in Coil Attraction Test 135 Holding Coil Retention Test 135 Disassembly Reassembly of Magnet Switch Type Starter 135 137 Reduction type Starter 138 139 Servicing Starter 140 147 ___________ 131 ...

Page 135: ...emeter only after starting the engine In the event of a lower electric load or fully charged battery the stipulated value may not be given Reference value 14 to 15A with dynamo turning at 5200 rpm Checking AC Dynamo s No Load Voltage 1 Disconnect lead wire from the dynamo 1 Battery Lead 2 Start the engine and measure the voltage generated by the single dynamo Reference value AC 20V or more with th...

Page 136: ...e starter body 3 Connect the voltmeter s positive probe to the starter s B terminal and the negative probe to the starter body 4 Set a tachometer 5 Connect the starter s B terminal to the magnet switch s S terminal 6 Check to see that the magnet switch is operating and that the specified speed current and voltage are obtained NOTE FOR CHECKING Use a fully charged battery Use an ammeter and leads o...

Page 137: ...starter runs normally the magnet switch is defective if not the motor is defective Electrical connections for motor test Magnet Switch Pull In Coil Attraction Test b C terminal o 1 Apply 1 2 the rated voltage approx 6V across the S terminal and C terminal 2 If the plunger is attracted strongly the pull in coil is good if not it is defective Reference value The plunger should be attracted strongly ...

Page 138: ...e plunger stays attracted the holding coil is good if not it is defective Reference value The plunger remains attracted DISASSEMBLY AND REASSEMBLY OF MAGNET SWITCH TYPE STARTER Removing Magnet Switch 1 Remove the connecting lead 2 Remove the set screws 3 Detach the magnet switch by lifting it up while taking care that it does not contact the drive lever 135 ...

Page 139: ...e 1 Remove the through bolts 2 Remove the end frame Removing Brush Holder 1 Draw out the brush from the holder while holding the spring up 2 Take off the brush holder NOTE FOR REASSEMBLING Be sure not to mistake the direction and position of the spring Do not contact the body with the positive brush s lead 136 ...

Page 140: ...SEMBLING Take care for yoke knock pin Removing Armature 1 Remove the set bolt from the drive lever 2 Draw out the armature from the drive end frame 3 Detach the drive lever IMPORTANT When reassembling be sure not to mistake the installing direction of the drive lever 137 ...

Page 141: ...r 1 Disconnect the connecting lead 2 Remove the through bolts 3 Remove the motor unit Removing Brush Holder 1 Release the spring and draw the brush out from the holder 2 Remove the brush holder Remove Armature 1 Draw the armature out 138 ...

Page 142: ...End Frame 1 Remove the drive end frame 2 Remove the gears drive pinion idler gear and clutch Remove Plunger 1 Remove the end cover from the magnet switch 2 Draw the plunger out 3 Remove steel balls 139 __ ______ ___ I ...

Page 143: ... Checking Commutator Wear 1 Check to see if the contact face of the brush is scored 2 If scored grind off with sand paper or on a lathe 3 If the commutator diameter must be ground to below the allowable limit replace it Commutator diameter Model Reference value Allowable limit M 30 32 7 mm 32 5 mm 1 2874 in 1 2795 in M 40 30 0 mm 29 0 mm M 50 1 1811 in 1 1417 in 140 ...

Page 144: ...ica depth Model Reference value Allowable limit 01102 B 0 5 to 0 8 mm 01302 B 0 0197 to 0 315 in 0 2 mm 01402 B 0 0079 in V1502 B 0 5 to 0 9 mm V1702 B 0 0197 to 0 0354 in V1902 B al Bad bl Good Good Grounding of Armature Coil 1 Check conduction across the commutator and the armature shaft 2 If conducting replace Reference value Should not be conducted 141 ...

Page 145: ...cking Armature Coil Short Circuited 0 1 mm 0 0039 in 1 Set the armature on the armature tester Rotate the armature while touching it with steel piece 2 If the steel piece starts to vibrate or to be attracted somewhere on the armature this suggests that the coil contains a layer short at the point 3 If faulty replace Reference value The armature should not be short circuited 142 ...

Page 146: ...the lead and brush 2 If either are not conducting replace IReference value Should be conducted I Grounding of Field Coil 1 To check the conduction Place the tester probes onto the field coil and yoke 2 If either are conducting replace Reference value Should not be conducted __ 143 ...

Page 147: ...0 in 19 mm 0 7480 in I I Width 12 mm 0 4724 in 25 mm 09843 in I I 1 1 I I I J lJ Thickness 7mm 0 2756 in 8mm 0 3150 in 1 Measure the tension with a new brush in place 2 Replace if the tension is under the reference value Model M 30 M 40 M 50 Reference value Spring tension Commutator diameter 11 8 N 32 7 mm 1 200 g 1 2874 in 2 64lb 17 5 to 23 7 N 1 785 to 2 415 g 30 0 mm 3 94 to 5 53 Ib 17 Ie Brush...

Page 148: ...tive brush holder 2 If the insulation is defective replace Reference value Checking Clutch 1 Check to see if the clutch gear is worn or damaged Should not be conducted 2 Check to see if the gear locks in the driving direction and rotates smoothly in reverse 145 ...

Page 149: ...rning the joint alters its length Checking Gap between Shaft and Bush Magnet Switch Type 1 Measure the inside diameters of the bearing bushings on the side of the drive and commutator 2 Measure the drive side and commutator side shaft diameters and calculate the gap 3 If the gap exceeds the allowable limit use an undersize bush Model M 30 Model M 30 Drive shaft dia 12 5 mm 0 4921 in Reference valu...

Page 150: ...Checking Bearing Reduction type 1 Apply torque to the inner ring with your finger tips and check to see if it turns smoothly 2 Check to see if there are any strange noises when driven quickly 147 ...

Page 151: ...HOOTING BAl1rgJ l Battery charging current otSeft GaS dynamo runs is equal to or exceeds the QUICK reference value check 1 lower than the reference value dynamo does not run slow running does not run at all 148 ...

Page 152: ...ity between voltage is equal or superior regulator connector Faulty wiring between regulator and to the reference value AC lead wires main s w AC dynamo side check 2 check 3 Faulty wiring between dynamo and L not conductive regulator No reference value j 1 Faulty dynamo 1 Fan belt slips 149 ...

Page 153: ...LY I GI OWPLUG IND ICATOR meS NOT TURN RED PROPERt y TROUBLESHOOTING Slow engine speed Starter runs but engine does not No meshing sound from pinion and ring gear Pinion shifts repeatedly r Does not turn red at all Turns red too quickly 150 ...

Page 154: ...gnet switch Pinion does not pop out by the I attractive force of magnet switch Screw spline rusted Faulty battery Battery not sufficiently charged r 1 Faulty battery l Poor terminal contact I Grounded poorly r 1 L Faulty magnet switch J Holding coil broken I I Battery not charged sufficiently Faulty battery Poor terminal contact Poorly grounded Incorrect wiring between battery and glow plug Glow p...

Page 155: ...TROUBLESHOOTING Crankshaft does not turn Crankshaft turns 152 No or small fuel injection sounds Fuel injection sounds ...

Page 156: ...Delivery valve spring broken_ on fuel Delivery valve not cQmpletely oil tight Needle valve stuck i Fuel does not inject through Nozzle spring broken injection nozzle I Injection pressure maladjusted Injection pipe mounting nut loose rl I Injection mistimed I Injection timing maladjusted I I Contact between intake exhaust valve and seat r not tight r Intake exhaust valve spring broken Intake exhaus...

Page 157: ... ENGINE DOES NOT TURN NORMALLY ENGINE OUTPUT INSUFFICIENT TROUBLESHOOTING Revolution irregular Slow engine revolutions 154 Revolution is not smooth at high speeds Idling not smooth ...

Page 158: ...sure is different among cylinders Governor sleeve not sliding properly Governor not functioning f Fork lever not functioning normally normally Start spring deformed Control rack not sliding properly L r Idling regulator maladjusted Idling maladjusted Accelerator rod maladjusted Main moving parts have almost seized up r Engine overheated Injection mistimed Governor not functioning normally Filter c...

Page 159: ...TROUBLESHOOTING cWhite or blue exhaust fumes I COLOR OF EXHAUST FUMES NOT NORMAL Black or dark gray exhaust fumes M ru TJ ____ _ CONSUMPTION _ LUBRICANT INCREASING 156 ...

Page 160: ...ct fuel Nozzle spring broken 1 properly Too much carbon sticks to nozzle tip Injection pressure too low __________________________________________ c o m p r es s ed a ir l ea_k_s_ ______________________ 1 Y Not enough air Excessive gap between piston and liner Piston ring stuck Piston ring worn Excessive gap between intake exhaust valve and valve stem Valve stem seal broken Oil leaks from defectiv...

Page 161: ......

Page 162: ......

Search results

Summary of Contents for Universal M-30

Reviews:

Related manuals for Universal M-30

Brands by name

Popular brands

Westerbeke Universal M-30, Operator'S Manual

Search results

Summary of Contents for Universal M-30

Reviews:

Related manuals for Universal M-30

Brands by name

Popular brands