Westerbeke M-50, M-40, M-30 Operator's Manual

SERVICE

MODELS

MANUAL

M -

30

M -

40

200154

M -

50

CONTENTS

NOTE: Refer to the beginning of the individual sections for a cqrnplete table

SECTION I - SPECIFICATIONS SECTION SECTION III - CONSTRUCTION AND FUNCTION SECTION IV SECTION V - ELECTRICAL SYSTEM SECTION VI - DISASSEMBLY AND REASSEMBLY SECTION VII - DYNAMO AND REGULATOR TROUBLESHOOTING

II

- PREVENTIVE MAINTENANCE

- LUBRICATION, COOLING, AND FUEL

.........................................................

....................................................

........................................

....................................

SySTEMS

..............................................

.................................

......................................

.......................

of

contents for that section.

83-130 132-147 148-157

1-18 19-24 25-30 31-49 51-82

NOTES

I

a

I

ii

~

SECTION 1-SPECIFICATIONS

Model M-30 Model M-40 Model .M-50

Parts Specifications . Bolt Torques .

......................................................................

.....................................................................

..................................................

.................................................................

.............................................................

,

..................

2,3 4,5

, .

6,7

8-15

. 16-18

1

Horsepower No.

of Cylinders

UNIVERSAL MODEL M-30 SPECIFICATIONS

2800

24 @

3

Bore x Stroke Cubic Inch Maximum Cruising Range (Approx.) Compression Ratio Electrical Equipment Lubrication (Eng. Approx. Qts)

(SAE 30

Lubrication (Trans.) FILL

(Type Transmission Reduction Coolant FWC (50/50 Solution Approx.) Exhaust

R.P.M.

HD.

AFT.

Flange

(CD) or 10W40) CAUTION: FILL ONLY

"/1\'

or GM-DEXRON -

II

Do not mix different oils)

3.00 x 3.23

68

2800

2000-2400

21:1

12

Volt -

51

Amp W/Glow Plugs

5.0

to

TO

FULL MARK ON DIPSTICK

TO

FULL RING ON DIPSTICK

2:1

6 qts.

1 V4"

N.P.T.

R.P.M.

5.5

Fuel

Type Fuel Filter Oil Filter Eng. Operating Propeller Rotation We.ight Injection Nozzle

Engine is governor the need arise: V-Belt, Sea Water Pump Impeller, Fuel & Lube Oil Filters, 1 and 1 Gal. 50/50 Coolant.

All pictorial

(Ibs.)

Temp.

views and specifications subject to change without notice.

Degrees

controlled to prevent overspeed. It is recommended to carry the following extra parts should

F.

#2

Diesel

298854

300209

Right Hand

4251bs.

298787 & 298788

Qt.

of Trans. Oil, 2 Qts. Lub. Oil

2

UNIVERSAL MODEL M-30

FUEL LINES

AIR BREATHER

GLOW

PLUG~-

____

SEA WATER OVERBOARD

HEAT

EX.

DRAIN &

ZINC_

TRANS. DIP STICK

OIL FILL HOLE

---

SHIFT LEVER

ENGINE COUPLIN

COOLANT AIR BLEED VALVE

THERMOSTAT HSG.

__

TIMING PORT

COOLANT FILL CAP

MANIFOLD

FUEL AIR

LEED VALVE

c---_

STOP LEVER

'----OIL

FILTER

BLOCK COOLANT DRAIN

F.W. CIRCULATING

PUMP

---,

ALTERNATOR

SEA WATER PUMP

V·BELT

DIP STICK

OIL PAN

AUST FLANGE

MANIFOLD DRAIN

HEAT EXCHANGER

HEAT

EX.

CLEAN·OUT

COVERS

----DRAIN

AND ZINC

TRANSMISSION

n_'I"~_

DRAIN PLUG

"3

UNIVERSAL MODEL M-40 SPECIFICATIONS

Horsepower No.

of

Cylinders Bore x Stroke Cubic Inch Maximum Cruising Range (Approx.) Compression Ratio Electrical Equipment Lubrication (Eng. Approx. ats.)

(SAE 30

Lubrication (Trans.)

(Type

Transmission Reduction

R.P.M.

HD.

(CD) or 10W40) CAUTION: FILL ONLY

AFT.

"1\' or GM-DEXRON -

12 Volt -

TO

FILL

TO

FULL RING ON DIPSTICK

II

Do not mix different oils)

2800

32 @

4

3.00 x 3.23 91

2800

2000/2500

51

8.0

FULL MARK ON DIPSTICK

.

R.

P.M.

21:1

Amp WIGlow Plugs

to

8.5

2:1

Coolant FWC (50/50 Solution Approx.)

Type

Filter

(Ibs.)

Flange

Temp.

views and specifications subject to change without notice.

Degrees

(Prior to (After

Ser.

controlled to prevent overspeed. It is recommended to carry the following extra parts should

Ser.

#315023)

F.

Exhaust Fuel Fuel Filter Oil Eng. Operating Propeller Rotation Weight Injection Nozzle

Engine is governor the need arise: V-belt, Sea Water Pump Impeller, Fuel & Lube Oil Filters, 1 and 1 Gal. 50/50 Coolant.

All pictorial

8 qts.

1

V4"

#2

Diesel

298854

299927

Right Hand

5451bs.

299517 & 299518

299567

N.P.T.

at.

of Trans. Oil, 2 Ots. Lub. Oil

4

FUEL RETURN

UNIVERSAL MODEL M-40

FUEL LINES

AIR BREATHER

GLOW

SEA WATER OVERBOARD HEAT TRANS. DIP STICK

OIL FILL HOLE

ENGINE

THERMOSTAT HSG

PLUGS-

EX.

DRAIN & ZIN

COUPLING/

COOLANT AIR BLEED VALVE

____

---

_

TIMING PORT

COOLANT FILL CAP

---THROTTLE

MANIFOLD

FUEL AIR

BLEED VALVE

--

BLOCK COOLANT DRAIN

EX

STOP LEVER

--OIL

MOUNTS

FILTER

F.W. CIRCULATING

SEA WATER PUMP

PUMP

ALTERNATOR

---'

V·BELT

DIP STICK

OIL PAN

5

MANIFOLD DRAIN

HEAT EXCHANGER

HEAT

----

EX.

CLEAN·OUT

COVERS

DRAIN AND ZINC

TRANSMISSION

RANS. DRAIN PLUG

UNIVERSAL MODEL M-50 SPECIFICATIONS

Horsepower 44 @ 3000 No.

of Cylinders 4 Bore x Cubic Inch Maximum

Stroke

R.P.M.

3.35 x 3.23 115

3000 Cruising Range (Approx.) 2000/2500 Compression Ratio Electrical Equipment Lubrication (Eng. Approx.

(SAE

30

HD.

(CD)

or

Lubrication

(Trans.)

Transmission Reduction

Coolant Exhaust Fuel

FWC

(50/50 Solution Approx.) 8 qts.

Flange 1

Type

Ots.)

10W40)

CAUTION: FILL

ONLY

FILL

TO

12

Volt -51

TO

FULL MARK

FULL

21:1

Amp WIGlow Plugs

8.5

RING

ON

1.9:1

1/4"

#2

Diesel

R.P.M.

ON

DIPSTICK

N.P.T.

Fuel Filter

Oil Filter

Eng. Operating

Temp.

Degrees

F.

298854

299927

1650 to

195

Propeller Rotation Right Hand

Weight

Injection Nozzle

Engine the need arise: V-Belt, Sea Water Pump Impeller, Fuel & Lube Oil Filters, 1

(Ibs.)

is

governor controlled

to

prevent overspeed. It

is

recommended

545

Ibs.

299567

to

carry the following extra parts should

at.

and 1 Gal. of 50/50 Coolant. All pictorial

views and specifications subject

to

change without notice.

0

of

Trans.

Oil, 2

Ots.

Lub.

Oil

6

UNIVERSAL MODEL M-50

FUEL LINES

AIR BREATHER

FUEL RETURN

GLOW

PLUGS-

____

SEA WATER OVERBOARD

HEAT

EX.

DRAIN &

ZINC_

TRANS. DIP STICK

OIL FILL HOLE

--

SHIFT LEVER

ENGINE

COUPLING/

COOLANT AIR BLEED VALVE

_

TIMING PORT

COOLANT FILL CAP

INJECTOR PUMP

FUEL AIR

--,

... , EED

-----,..---

~-OIL

TH

ROTTLE

STOP LEVER

FILTER

BLOCK COOLANT DRAIN

LEX MOUNTS

VALVE

THERMOSTAT HSG.

F.W. CIRCULATING

PUMP

---

ALTERNATOR

SEA WATER PUMP

V·BELT

DIP STICK

OIL PAN

MANIFOLD

STARTER

EXHAUST FLANGE

/ LD DRAIN

HEAT

EX.

CLEAN·OUT

COVERS

. DRAIN AND ZINC

NS. DRAIN PLUG

7

ENGINE BODY

Cylinder Head

ENGINE SPECIFICATIONS

Item M-30

Cylinder head surface 0.05 mm flatness

Top

clearance

Gasket thickness

Free

Tightened

Gasket shim thickness

Compression pressure

Variance among

cylinders

(0.002

to

0.9

0.7

(0.028 to 0.035 in.) (0.028 to 0.035 in.)

1.30

to 1.60 mm 1.30 to

(0.051

to 0.063 in.)

1.05 to

1.15

(0.041

to 0.045 in.)

0.2 mm 0.2 mm

(0.008 in.) (0.008 in.)

448 psi 448 psi

- -

Valves (IN., EX.)

0.18

Valve clearance (cold)

Valve seat width

Valve seat angle

Valve face angle

Valve recessing Clearance between valve 0.04 to

stem and guide

Valve stem

Valve guide

O.

1.0.

D.

to 0.22 mm

(0.007 to 0.008 in.) (0.007 to 0.008 in.)

2.1

(0.083 in.) (0.083 in.)

45

1.1

to

1.3

(0.043 to

0.07

(0.001

to 0.003 in.)

7.960 to (0.313

8.015 (0.315

7.975

to

to 8.030 mm

to

Valve Timing

M-40

in.) (0.002 in.)

mm

0

mm

0.051

in.)

mm

0.314

in.)

0.316

in.)

0.05 mm

0.7 to

(0.051

to 0.063 in.)

1.05

to

(0.041

to 0.045 in.)

0.18

to 0.22 mm

2.1

1.1

to

(0.043 to

0.04 to

(0.001

to 0.003 in.)

7.960 to (0.313

to

8.015

to 8.030 mm

(0.315

to

0.9

1.60

1.15

45

1.3

0.07

7.975

mm

0

mm

0.051

0.314

0.316

mm

in.)

mm

in.)

Inlet valve

Exhaust valve

Valve Springs

Free length

Tilt

Tension

Open

Close

Open

Close

0.35 rad.

0

before TDC

(20

0.79

rad.

(450 after TDC

0.87

rad.

(500 before TDC

0.26 rad.

(150 after TDC

41.7

to 42.2 mm

(1.642 to

1.0

1.661 mm

(0.039 in.)

1.117

kgf,

N.

26.5

Ibs.)

(12

in.)

0.35 rad.

0

before TDC)

(20

0.79 rad.

0

after TDC

(45

0.87

rad.

0

before TDC

(50

0.26 rad.

(150 after TDC)

41.7

to 42.2 mm

1.661

(1.642 to

1.0

in.

mm

(0.039 in.)

1.117

N

(12

kgf, 26.5 Ibs.)

8

ENGINE SPECIFICATIONS

M-50

0.05

mm

(0.002 in.)

0.7 to

0.9

(0.028 to 0.035 in.)

1.30 to 1.60

(0.051

1.05 to

(0.041

(0.008 in.)

mm

to 0.063 in.

1.15

mm

to 0.045 in.)

0.2

mm

448 psi

-

0.18

to 0.22 mm

(0.007 to 0.008 in.)

2.1

mm

(0.083 in.

0

45

0

45

Allowable

Limit

-

350 psi

10%

-

1.1

to

1.3

(0.043 to

0.04 to

(0.001

7.960 to (0.313

8.015 (0.315

(200 before TDC)

(450 after TDC)

(500 before

0.26 rad.

(150 After TDC

41.7

(1.642 to

(0.039 in.

(12

kgf,

mm

0.051

0.07

mm

to 0.003 in.)

7.975

to

0.314

to 8.030

to

0.316

0.35 rad

rad.

0.79

0.87

rad.

TDC

to 42.2

1.661

1.0

mm

1.117

N

26.5

Ibs.)

mm

1.6

mm

in.) (0.063 in.)

0.1

mm

(0.004 in.

in.)

-

41.2

mm

in. (1.622 in.)

1.00 N

(10.2

kgf, 22.5 Ibs.)

-

9

Rocker Arm

ENGINE SPECIFICATIONS

Item

Clearance between rocker arm and bushing

Rocker arm shaft

Rocker arm bushing

0.0.

1.0.

Camshaft

Camshaft alignment

Cam height

Oil clearance of camshaft

Camshaft

Camshaft bearing

(IN., EX.)

journal

0.0.

1.0.

Timing Gear

Timing gear backlash

Idle gear side clearance Clearance between idle gear

shaft and

Idle gear shaft

Idle gear bushing

idle gear bushing (0.0006 to

0.0.

1.0.

M-30

0.Q18

to

0.070

(0.0007 to 0.003 in.)

13.973

to 13.984 mm

(0.550 to

14.002 to 14.043 mm (0.551

to 0.553 in.)

0.05

(0.002 in.) (0.002 in.)

33.36 mm (1.313

0.050 to (0.002 to 0.004 in.)

39.934 to 39.950 mm (1.572

to 1.573 in.)

40.000 to 40.025 mm 40.000 to 40.025 mm (1.575

to 1.576 in.)

to

0.042

(0.002 to 0.005 il).) (0.002 to 0.005 in.)

to

0.20

(0.008 to 0.020 in.)

0.Q16

to 0.045 mm

15.973

to 15.984 mm

(0.628 to 0.629 in.) (0.628 to 0.629 in.)

16.000 to (0.621

to 0.630 in.)

mm

0.551

in.)

mm

in.)

0.091

mm

0.115

mm

0.51

mm

0.001

in.)

16.018

mm 16.000 to

14.002 to 14.043 mm

39.934 to

M-40

0.Q18

to

0.070

mm

(0.0007 to 0.003 in.)

13.973

to 13.984 mm

(0.550 to

(0.551

0.050 to (0.002 to 0.004 in.)

(1.572

(1.575 to 1.576 in.)

0.042 to

0.20 to

(0.008 to 0.020 in.)

0.Q16

(0.0006 to

15.973

(0.621

0.551

to 0.553 in.)

0.05 mm

33.36 mm (1.313

in.)

0.091

mm

39.950 mm

to 1.573 in.)

0.115

mm

0.51

mm

to 0.045 mm

0.001

to 15.984 mm

16.018

to 0.630 in.)

in.)

mm

Cylinder (Liner)

Oversize of

1.0.

cylinder liner

Piston/Piston Ring

Piston pin hole

Piston ring clearance

Ring gap

Oversize of piston rings

1.0.

Compression 0.093 to ring 2 (0.004 to 0.005 in.) (0.004 to 0.005 in.)

Oil ring Compression 0.30 to 0.45 mm 0.30 to 0.45 mm

ring Oil ring

1,

76.000 to (2.992 to 2.993 in.) (2.992 to 2.993 in.)

23.000 to

(2.905 to 0.906 in.) (0.905 to 0.906 in.)

0.020

(0.0008 to 0.002 in.) (0.0008 to 0.002 in.)

2

(0.012

0.25 to 0.45 mm 0.25 to 0.45 mm

(0.010

76.019

mm

+0.5

mm +0.5 mm

(+0.020 in.)

23.013

mm 23.000 to

0.120

mm 0.093 to

to 0.052 mm 0.020 to 0.052 mm

to

0.Q18

in.)

to

0.Q18

in.)

+0.5 mm +0.5 mm

(+0.020 in.) (+0.020 in.)

76.000 to

(0.012

(0.010

76.019

(+0.020 in.)

23.013

0.120

to

0.Q18

to

0.Q18

mm

in.)

10

ENGINE SPECIFICATIONS

M-50

0.Q18

to

0.070

mm

(0.0007 to 0.003 in.)

13.973

to 13.984

(0.550 to

14.002 to 14.043 (0.551

to 0.553 in.

0.05

(0.002 in.)

33.36 (1.313

0.050 to (0.002 to 0.004 in.)

39.934 to 39.950 (1.572 to 1.573 in.)

40.000 to 40.025 (1.575 to 1.576 in.)

0.042 to

(0.002 to 0.005 in.)

0.20 to

(0.008

to 0.020 in.)

0.Q16

to 0.045

(0.0006

15.973 to 15.984

16.000 to

to

(0.628 to 0.629 in.)

(0.621

to 0.630 in.)

0.551

mm

in.)

0.091

0.115

0.51

0.001

16.018

mm

in.)

mm

in.)

mm

Allowable

Limit

0.15

mm

(0.006 in.)

-

33.31

mm

(1.315

in.)

0.15

(0.006 in.)

-

0.15

mm

(0.006 in.)

0.6mm

(0.024 in.)

0.10mm

(0.004 in.)

-

85.000 to 85.022 (3.346 to 3.347 in.)

+0.5

(+0.020 in.)

23.000 to 23.013 (0.905 to 0.906 in.)

0.093 to 0.120 (0.004 to 0.005 in.)

0.020 to 0.052

(0.0008 to 0.002 in.)

0.30 to 0.45

(0.012

to

0.25 to 0.45

(0.010

to

+0.5

(+0.020 in.)

mm

0.Q18

mm

in)

mm

in.)

11

-

+0.15

mm

(+0.006 in.)

-

23.053

mm

(0.907 in.)

-

1.25

mm

(0.049 in.)

1.25

mm

(0.049 in.)

-

ENGINE SPECIFICATIONS

Item

Crankshaft alignment Oil clearance between crank-

shaft journal and bearing

Front and intermediate

Journal

Bearing

Oil clearance between crank pin and bearing

Crank pin

Crank pin bearing

Crank shaft side clearance Under sizes of crankshaft

bearing and crank pin bearing Oversizes of thrust bearing

0.0.

1.0.

0.0.

Rear Front and

intermediate Rear

1.0.

Connecting Rod

Connecting rod alignment Oil clearance between piston

pin and small end bushing

Piston

0.0.

Small end bushing (fitting)

1.0.

WBRICATING SYSTEM

At idle

Oil pressure

speed At rated

speed

M-30

0.02

mm

(0.0008 in.)

0.040 to

(0.002 to 0.004 in.)

51.921 (2.044 to 2.045 in.)

51.980 to 52.039 mm (2.046 to 2.049 in.)

51.980 to 52.025 mm

(2.046 to 2.048 in.)

0.035 to 0.093 mm (0.002 to 0.004 in.)

43.959 to

(1.731

44.010

(1.733

0.15

(0.006 to

-0.02

(-0.008 in., -0.016 in.)

+0.2mm,

(+0.008 in., +0.016 in.)

0.014

(0.0006 to

23.002 to (0.905 to 0.906 in.)

23.000 to (0.905 to 0.906 in.)

3.0

0.118

mm

to 51.940 mm

43.975

to 1.732 in.)

to 44.052 mm

to 1.734 in.)

to

0.31

mm

0.012

mm,

-0.04

+0.4 mm

0.02

mm

(0.0008 in.)

to 0.038 mm

0.001

23.011

23.013

kgf/cm

Dsi)

4.5

2

kgf/cm

1.0 (14.2

to

(43 to 64 psi)

mm

in.)

mm

in.) mm

mm

2

M-40

0.02

mm

(0.0008 in.)

0.040 to

(0.002 to 0.004 in.)

51.921 (2.044 to 2.045 in.)

51.980 to 52.039 mm (2.046 to 2.049 in.)

51.980 to 52.025 mm (2.046 to 2.048 in.)

0.035 to 0.093 mm (0.002 to 0.004 in.)

43.959 to

(1.731

44.010

(1.733

0.15

(0.006 to

-0.02

(-0.008 in, -0.Q16 in.)

+0.02 mm, +0.04 mm

(+0.008 in., +0.016 in.)

0.014

(0.0006 to

23.002 to (0.905 to 0.906 in.)

23.000 to (0.905 to 0.906 in.)

3.0

0.118

mm

to 51.940 mm

43.975

to 1.732 in.)

to 44.052 mm

to 1.734 in.)

to

0.31

mm

0.012

mm,

-0.04

0.02

mm

(0.0008 in.,

to 0.038 mm

0.001

23.011

23.013

kgf/cm

DSi)

4.5

2

kgf/cm

1.0 (14.2

to

(43 to 64 psi)

mm

in.)

mm

in.)

mm

2

Oil Pump

Rotor lobe clearance Radial clearance between

outer rotor and pump body End clearance between rotor

and cover

Oil Filter

Opening pressure of bypass valve

0.10

to

0.16

to

0.19

0.007)

0.150

mm

(0.004 to 0.006 in.)

0.11

to

(0.004 to

0.105

(0.004 to 0.006 in.)

98 KPa

1.0

kgf/cm2 (14.2

psi)

12

0.04

to

0.13

0.19

0.007

0.150

mm

(0.002 to 0.005 in.)

0.11

to

(0.004 to

0.105

to

(0.004 to 0.006 in.)

98 KPa

1.0

kgf/cm2 (14.2

in.)

psi)

ENGINE SPECIFICATIONS

M-50

0.02 mm

(0.0008 in.)

0.040 to (0.002 to 0.004 in.)

51.921 (2.044 to 2.045 in.)

51.980 to 52.039 mm (2.046 to 2.049 in.)

51,980 to 52,025 mm

(2,046 to 2.048 in.)

0.035 to 0.093 mm

(0.002 to 0.004 in)

43.959 to 43.975 mm

(1.731

44.010 to 44.052 mm

(1.733

0.15

(0.006

-0.02

(-0.008 mm, -0.016 mm

+0.02 mm, +0.04 mm

(+0.008 in., +0.016 in.)

0.118

mm

to 51.940 mm

to 1.732 in.)

to 1.734 in.)

to

0.31

mm

in. to

0.012

mm,

-0.04

in.)

mm

Allowable

Limit

0.08 mm

(0.003 in.)

0.20 mm

(0.008 in.)

-

0.20 mm

(0.008 in.)

-

0.5mm

(0.020 in.

-

0.02 mm

(0.0008 in.)

0.014

to 0.038 mm

(0.0006 to

23.002 to (0.905 to 0.906 in.)

23.000 to (0.905 to 0.906 in.)

3.0

0.04 to

(0.002 to 0.005 in.)

0.11

(0.004 to 0.007 in.)

0.105

(0.004 to 0.006 in.)

1.0

kgf/cm2 (14.2 psi)

1.0 (14.2

to

4.5

(43 to

to

98 KPa

0.001

23.011

23.013

kgf/cm

psi)

kgf/cm2

64 psi)

0.13

0.19

0.150

2

mm

in.)

mm

0.05 mm

(0.002 in.)

0.15

mm

(0.006 in.)

-

23.053 mm (0.907

in.)

or more

2.5 kgf/cm

(35 psi)

0.20 mm

(0.008 in.)

0.25 mm

(0.010

in.)

0.2 mm

(0.008 in.)

2

13

COOLING SYSTEM

Fan Belt

ENGINE SPECIFICATIONS

Item

Belt deflection under load of

98 N (10

kgf,

21

Ibs.)

Heat Exchanger

Exchanger water tightness Radiator cap opening

pressure

Thermostat

Thermostat's valve opening temperature

Temperature at which thermostat

completely opens

FUEL SYSTEM Injection Pump

Injection timing (static) Fuel tightness of pump

element

tightness of delivery

Fuel

valve

Injection Nozzle

Fuel injection pressure Fuel tightness of nozzle valve

seat

ELECTRICAL SYSTEM Starter

Commutator

0.0.

M-30

7 to 9 mm

(0.275 to 0.355 in.)

to 9 psi)

60

C

500

kgf/cm2

7110

71.1

1991

2

Ibs.)

1.2 kgf/cm

(14

to 15 psi)

0.9 to 0.6 kgf/cm

(15

(140°) F

73.9 C

(165°) F

23° to 25° before TOC

600 to

(8532 to

100 to 5 kgf/cm2

(1422 to

140 to 150 kgf/cm2 (1990 to 2133 Ibs.)

130 to 140 kgf/cm2 (1848 to

32.7 mm

(1.287 in.)

M-40

7 to 9 mm

(0.275 to 0.355 in.)

15

psi)

to 9 psi)

60

C

F

500

kgf/cm2

7110

71.1

1991

in.)

2

Ibs.)

2

Ibs.)

1.2 kgf/cm

(14

to

0.9 to 0.6 kgf/cm

(15

(140°) F

73.9 C

(1650)

23° to 25° before TOC

600 to

(8532 to

100 to 5 kgf/cm2

(1422 to

140 to 150 kgf/cm2 (1990 to 2133 Ibs.)

130 to 140 kgf/cm (1848 to

30.0 mm

(1.181

Variance

Mica undercut

Brush

length

Glow Plug

I Resistance

AC

dynamo

I No-load output

Regulator

I Regulating voltage

45 A or

0.5 to 0.8 mm

(0.092 to 0.032 in.)

Approx.

AC

20

volts or more

13.8 to 14.8 volts

less

19 mm

(0.748 in.)

1.5 ohm

5200

14

RPM

90

0.5 to 0.9 mm

(0.020 to 0.035 in.)

Approx.

AC

20

volts or more

13.8 to 14.8 volts

A or less

19

mm

(0.748 in.)

1.5 ohm

5200

RPM

ENGINE SPECIFICATIONS

M-50

7 to 9 mm

(0.275 to

0.9

23° to 25° before TOC

600

(8532 to

100

(1422 to

0.355 in.)

1.2 kgf/cm2

(14

to

15

psi)

to

0.6

kgf/cm2

(15

to 9 psi)

73.9

C

(165<»

F

to 500 kgf/cm2

7110

Ibs.)

to 5 kgf/cm2

71.1

Ibs.)

Allowable

Limit

-

140

to 150 kgf/cm2

(1990 to 2133 Ibs.) 130 to 140 kgf/cm2

1991

mm

0.9

mm

1.5

Ibs.)

in.)

mm

in.)

ohm

(1848 to

30.0

(1.181

90 A or less

0.5

to

(0.020 to 0.035 in.)

19

(0.748

Approx.

I AC 20 bolts or more 5200 RPM

13.8

to

14.8

volts

-

0.2 mm

(0.008 in.)

-

12.7 mm

(0.500 in.

. 15

BOLT TORQUES

As

a lot of bolts and nuts in the engine are of special shape, be careful to tighten them correctly using a torque wrench.

When tightening,

TIGHTENING BOLTS OF IMPORTANT PARTS

Marked bolts must be tightened after applying oil.

follow this method: First tighten all the bolts 50% of the regular torque, then tighten them fully.

MODEL M-30

Head bolts and nuts Bearing case bolts 1 Bearing case bolts 2 Flywheel bolts Connecting rod bolts Rocker arm bracket studs Idle

gear shaft bolts

Glow plugs

(No neea to apply oil)

Drain plugs Nozzle holders

Oil Switch

Fuel limit lock Fuel limit Injection Crankshaft nut

Air vent screw (on injection pump)

Bis Taper screw

nut

cap nut

pipes

7.5

to

8.0

kgf/m

(54.2 to (21.7

(21.7

(72.3 to

(26.8 to 30.4 ftllbs.)

(12.3

1.0

(7.23 to

(14.5 (28.9

(21.7

0.14

(10.1

(10.8

(20.3

(18.1

(10.8

(101

(10.1

57.9

ftllbs.) (54.2 to

3.0

to

3.5

kgf/m

to

25.3

ftllbs.)

3.0

to

3.5

kgf/m

to

25.3

ftllbs.)

10

to

11

kgf/m

79.6

ft.llbs.)

3.7 to 4.2 kgflm

1.7

to

2.1

kgf/m

to

15.2

ftllbs.)

to

1.15

kgf/m

8.31

ftllbs.)

2.0

to 2.5 kgflm

to

18.1

ftllbs.)

4.0

to

4.5

kgf/m

to 36.2 ftllbs.)

3 to 5 kgf/m

to 36.2 ftllbs.)

to 0.2

kgf/m

to

14.5

ftllbs.)

1.5

to 2.0

kgf/m

to

14.5

ftllbs.)

2.8 to

3.5

kgf/m

to

25.3

ftllbs.)

2.5 to

3.0

kgf/m

to

21.7

ftllbs.)

1.5

to 2.6 kgf/m to

18.8

ftllbs.)

14

to

16

kgf/m

to

116

ftllbs.)

1.4

to

1.8

kgf/m

to

13.0

ftllbs.)

M-40

7.5

to

3.0

to

(21.7

to

3.0

to

(21.7

to

10

to

(72.3 to

3.7 to 4.2

(26.8

to 30.4 ftllbs.)

1.7

to

(12.3

to

1.0

to

(7.23 to

2.0 to 2.5

(14.5

to

4.0

to

(28.9

to 36.2 ftllbs.)

3 to 5

(21.7

to 36.2 ftllbs.)

0.14

to 0.2

(10.1

to

1.5

to 2.0

(10.8

to

2.8 to

(20.3

to

2.5 to

(18.1

to

1.5

to 2.6 kgflm

(10.8

to

14

to

(100

to

1.4

to

(10.1

to

8.0

57.9

3.5

25.3

3.5

25.3 11

79.6

2.1

15.2

1.15

8.31

18.1

4.5

14.5

3.5

25.3

3.0

21.7

18.8 16

116

1.8

13.0

kgf/m

ftllbs.)

kgflm

ftllbs.)

kgflm

ftllbs.)

kgf/m

ftllbs.)

kgf/m kgf/m

ftllbs.)

kgf/m

ftllbs.)

kgf/m

ftllbs.)

kgf/m

ftllbs.)

kgf/m

ftllbs.)

kgf/m

ftllbs.)

kgf/m

ftllbs.)

kgf/m

ftllbs.)

kgflm

ftllbs.)

.

16

M-50

7.5

to

8.0

kgf/m

(54.2

to 57.9 ftllbs.)

3.0

to

3.5

kgf/m

(21.7

to 25.3 ftllbs.)

3.0

to

3.5

kgf/m

(21.7

to 25.3 ftllbs.)

10

to

11

kgf/m

(72.3

to 79.6 ftllbs.)

3.7 to 4.2 kgflm

to 30.4 ftllbs.)

(26.8

1.7 to

2.1

kgf/m

to 15.2 ftllbs.)

(12.3

1.0

to

1.15

kgf/m

to

8.31

(7.23

to 2.5 kgf/m

2.0

(14.5

to to

4.0

to 36.2 ftllbs.)

(28.9

3 to 5 kgf/m

to 36.2 ftllbs.)

(21.7

0.14

(10.1

to

1.5

to 2.0 kgf/m

(10.8

to

2.8

(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

14

to

(101

to

1.4 to

(10.1

to

ftllbs.)

18.1

ftllbs.)

4.5

kgf/m

to 0.2 kgf/m

14.5

ftllbs.)

14.5

ftllbs.)

3.5

kgf/m

18.8

ftllbs.)

16

kgf/m

116

ftllbs.)

1.8

kgf/m

13.0

ftllbs.)

17

Bolt Torques

Nominal

Material Grade

Dia.

M6

M8

M

10

M

12

M

14

M

16

M

18

M 20

Standard

SS41,S20C S43C, S48C (Refined)

5.8 -6.9

13.0

28.9 - 33.3 Ibs/ft. 35.4 - 41.2 Ibs/ft.

46.3 - 53.5 Ibs/ft.

79.6 - 92.6 Ibs/ft.

123.0 -

180.0 - 209.8 Ibs/ft. 202.5 -

245.9 - 289.3 Ibs/ft. 271.2 - 318.2 Ibs/ft. 361.6 -

Bolt Special Bolt Special Bolt

SCR3, SCM3 (Refined)

Ibs/ft.

- 15.2 Ibslft.

141.0

Ibslft. 144.7 - 166.4 Ibs/ft.

7.2 -

8.3

17.4

- 20.3 Ibs/ft.

57.1 -66.5

91.1

- 108.5 Ibslft.

235.1

Ibs/ft.

21.7

44.8 -

Ibs/ft.

Ibs/ft. 253.2 - 296.5 Ibslft.

75.9 - 86.8 Ibslft.

123.0

191.7

9.0 -10.5

Ibs/ft.

- 25.3 Ibs/ft.

52.1

Ibs/ft.

- 144.7 Ibs/ft.

- 224.2 Ibs/ft.

419.5

Ibs/ft.

Bolt material grades are shown by numbers punched to check out the numbers as shown

Punched

Number

None

7

9

Bolt Material Grade Standard

SS41, S20C Special Bolts

S43C, S48C Special Bolts

SCM3, SCR3,

Bolts

(Refined)

below:

on

the bolt heads. Prior

to

tightening, be sure

18

SECTION II - PREVENTIVE MAINTENANCE

General Warnings Maintenance Check List POINTS OF INSPECTION AND CHANGING Engine Lubricating Oil Changing Engine Oil Level Changing Engine Changing Engine Inspection of Fuel Filter Venting the

.................................................................

............................................................

.............................................................

.........................................................

Oil

..............................................................

Oil Filter Cartridge

Fuel System

............................................................

...........................................................

.................................................

20 21

22 22 22 23 23 24

_

19

GENERAL WARNINGS

• When disassembling engine, arrange each part

on

a clean surface. Do not mix them

up.

Replace bolts and nuts in their original positions.

• When servicing voltaged parts or connecting instruments to electrical equipment, first "disconnect negative battery

• Replace

gaskets or O-rings with new ones when disassembling, and apply grease on the

terminal.

ring and the oil seal when reassembling.

•

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 grease

to

oil seal

Direction

of

installing circlips

3

0-

4

2

1

1.

Inside

of

Lip

2. Grease

3.

External Circlip

4.

Internal Circlip

5.

Direct the Corner End

F-

to

the Direction Subject

to

5

Force.

5

20

MAINTENANCE CHECK LIST

To

maintain long-lasting and safe engine performance, make it a rule to carry out regular inspections by following the

table below.

Item

Checking Changing engine oil Cleaning air filter element Cleaning fuel fiilter Checking battery electrolyte level

Checking fan belt tension

and damage

Checking oil or water Checking water pipes and clamps Changing oil filter cartridge Changing fuel filter element Cleaning heat exchanger Recharging battery Changing coolant

Changing air filter element Checking valve clearance

Checking nozzle injection pressure Changing battery Changing water pipes and clamps Changing fuel pipes and clamps

fuel pipes and clamps

leakage

every every every every every every every every every

50 hrs. 100 hrs.

150

hrs.

200 hrs. 400 hrs. 500 hrs. months months

Service Interval

one or

two

three

one

year year

•

or every 6

cleanings

•

every

two

•

21

ENGINE LUBRICATING OIL

POINTS OF INSPECTION AND CHANGING

Brand name oil (for diesel engines) or CC/CD class oils defined according

SAE-30

CHECKING ENGINE OIL LEVEL

Stop for 5 minutes or more and remove the dip stick, wipe off dip stick engine sufficient

to

temperature.

HD

or 10W-40

oil level

oil

to

HD

on

the dip stick. If the oil level is below the lower mark

the full mark.

DO

NOT

OVERFILL.

by

SPI. It should be as follows

and

recheck. Read the

on

the dip stick, add

1. Dip

Stick

2. Oil Filler Plug

CHANGING ENGINE OIL

Drain the oil while the engine is still warm, by removing the drain plug plug, or through the oil drain

Do

not mix different brands of oil. If a different brand of oil should existing different viscosity.

oil

no

matter how new it may be and then replace it.

hose,

so

that the oil may completely drain.

Do

be

the same when using oil of a

on

the oil

employed, drain out the

pan

and oil filler

1.

Oil Drain Plug

22

CHANGING ENGINE OIL

Remove the oil filter cartridge with a filter wrench.

FILTER

CARTRIDGE

Apply a slight coat of oil to the rubber gasket Screw the new cartridge

Over-tightening may cause deformation of rubber gasket. After cartridge

oil does not leak through the seal and be sure the prescribed level.

has

in

by hand.

been replaced, engine oil normally decreases a little. Check that the engine

on

the new cartridge.

to

read

1.

Oil

filter

the oil level. Then, add engine oil

cartridge

up

to

INSPECTION OF FUEL

The fuel filter and

feed pump

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

The cleaned fuel flows out from the outlet of the cock

Before starting or after disassembling and reassembling, loosen the air vent plug to bleed the air in

the fuel line.

is

installed

in

the basic model).

FILTER

in

the fuel line from the fuel tank

to

enter the inside of the filter element.

body.

to

the injection pump (between the tank

2

1

1.

Cock Body Inlet

2. Cock Body Outlet

3.

Air

Vent Plug

23

VENTING THE FUEL

SYSTEM

- Models

18,

25,

25XP and

35

Air must

be

vented

when:,

• The fuel filter and piping are removed.

• The fuel tank becomes completely empty.

• The engine has not been used for

is

Veriting procedure

1.

Fill the fuel tank with fuel, and open the fuel cock.

2.

Twist

off the air vent screw at the top of the filter

3.

When bubbles disappear from fuel coming out of the plug, twist it back on.

4.

Open the air vent plug

5.

Pull the engine stop lever back completely

as follows:

on

the fuel injection pump.

an

extended time,

to

by

turning it twice.

stop the engine, and

run

seconds.

6.

Close the air vent plug when air bubbles disappear from the fuel flowing out. Models

IMPORTANT:

12,

2-12,

Do

3-20 and

not

4-30

have continuous bleed systems.

perform venting when the engine

is

hot.

the starter for about

10

1.

Air

vent screw

24

SECTION III - CONSTRUCTION AND FUNCTION

Cylinder Block Cylinder Head Crankshaft Piston and Piston Rings Connecting Rods Camshaft and Rocker Arm Inlet and Exhaust Valves Flywheel

....................................................................

.......................................................................

.................................................................

Fuel Camshaft

Assembly

........................................................................

.............................................................

............................................................

.......................................................

...........................................................

26 26 27

28 28 29 29 30 30

25

CYLINDER BLOCK

The engine features a high durability tunnel-typed cylinder in which the crank bearing part is

constructed body. Furthermore, dry-type

cylinder liners, being pressure-fitted into cylinders, allow effective cooling, less distortion, higher wear-resistance qualities and each cylinder having its own chamber

helps to minimize noise.

Tunnel

cylinder

block

CYLINDER HEAD

The cross-flow type inlet/exhaust ports

cylinder head. Because overlaps of inlet/exhaust ports are smaller than which have openings one side, the suction air 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 is reduced because suction ports are arranged spherical

combustion chamber type. Suction air

in

this engine have their openings at both sides of the

in

ports of other types

can

be

protected from being heated and expanded

cylinder head by heated exhaust air

alternately. The combustion chamber is exclusive

is

whirled to

be

mixed effectively with fuel,

prompting combustion and reducing fuel consumption.

In

the combustion chamber are installed throttle type injection nozzle and rapid heating sheathed

type

glow plug. This glow plug assures easier than ever engine starts

Cross-flow

type

cylinder

head

even

at

-15°C

Combustion

(6

(15°F).

chamber

(1)

1_

Combustion chamber

2. Suction

3. Exhaust

4. Nozzle assembly

5. Glow plug

6. Cylinder head

26

CRANKSHAFT

The crankshaft is driven by the pistons and connecting rods, and translates its reciprocating

movement into a circular movement. counterweights are integrated into one unit

It also drives the oil pump, camshaft and fuel camshaft. Six

to

minimize bearing wear and lubricating oil temperature rise. Crankshaft journals, crankpins and oil seal sliding section are induction-hardened 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 special

quality.

Crankslyft

(8)

1.

Crankshaft

2. Piston

3.

Connecting rod

4.

Oil passage

5.

Crankshaft bearing 1

6.

Crankshaft bearing 2

7.

Side bearing

8.

Counterweight

alloy

to

raise wear resistance

27

PISTON AND PISTON RINGS

Piston circumference has a special elliptic shape heat. Piston head is flat-formed. Furthermore, ribs are provided between the piston head and top ring to reduce distortion and to help heat radiation.

Piston is made of special aluminum alloy of low thermal expansion and high temperature resistance.

Top

ring is of

cylinder wall is shaped into barrel face which is well fitted to the wall and plated with hard chrome.

Second ring is of under-cut type which is effective to prevent oil rising.

Oil ring is effective to scrape oil because it is closely fitted to the cylinder wall 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 increase wear resistance quality.

key

stone type which can stand against heavy load, and the sliding surface to the

1.

Rib

2. Top ring

3.

Barrel face

4.

Hard chrome plating

5.

Second ring

6.

Coil expander ring

in

consideration of expansion due to explosion

by

coil expander

Pistons

and

piston

rings

(4)

~

(3)

(2)

~

~/~.o§

(1)

i 0

CONNECTING RODS

Connecting rod

has crankpin bearings (split type) and the small end has a bushing (solid type).

rod

is used to connect the piston with the crankshaft. The big end of the connecting

(3)-_A

(1)-----111

1.

Connecting rod

2. Crankpin bearing

3.

Bushing

(6)

I

1

28

CAMSHAFT AND FUEL CAMSHAFT

The camshaft is made of special cast iron and the journal and cam sections are chilled to resist wear.

The journal sections are force-lubricated. The fuel camshaft controls the reciprocating movement of the injection pump, and is equipped with a camshaft is made of carbon steel and cam sections are quenched and tempered to provide greater wear resistance.

ball to control the governor. Fuel

Camshaft

1.

Tappet

2. Push rod

3.

Camshaft

4.

Camshaft gear

5.

Injection

6.

Governor sleeve

7.

Governor ball case

8.

Circlip

9.

Circlip

10.

Fuel camshaft

11.

Ball

12.

Ball bearing

pump

Fuel Camshaft

gear

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 exhaust oil the entire system are lubricated sufficiently.

1.

2. Rocker arm

3.

4.

5.

6.

7.

8.

9.

10.

valves. Valve control timing must

is

pressurized through the bracket to the rocker arm shaft

Rocker arm

shaft Rocker arm bracket Oil

filer

plug Decompression lever Decompression

Decompression

Decompression Decompression

Valve

window

nut

bolt shaft

cover

be

adjusted with screws

an

open/close movement of the inlet and

on

the rocker arms. Lubrication

so

that the rocker arm bearings and

'~y

(8)

~.

'"

(7)"

t=;:!~~;;-r~Y.rl

(8)

(9)---t++~r

r---ft~~

(4) (1)

(3)

29

INLET AND EXHAUST

VALVES

The inlet and exhaust valves and their guides are different from each other. Other parts, such as

valve springs, valve spring retainers, valve spring same for both the inlet and exhaust valves. to resist

wear.

1.

Valve cap

2. Valve spring Retainer

3.

Valve spring Collets

4.

Valve spring

5.

Valve stem seal

6.

Valve guide

7.

Inlet valve

8.

Exhaust valve

collets, valve stem seals, and valve caps are the

All contact or sliding parts are quenched and tempered

Intake and exhaust valve

(4)

~_-(5)

(6)

(7)

(8)

FLYWHEEL

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

be

center. The flywheel and crankshaft can

fixed to each other at a certain point according to the

arrangement of flywheel mounting bolt hole.

2TC

2

Fl......

1.27

(73°)

11TC .....

1/FI

......

12

173~)ra~d'

rad. 1.27 rad.

Mark Mark

1.27 rad.

(73")

1.19 rad.

(68°)

for

top

dead center

for

fuel injection

1

FI

1 TC

of

1st piston

\~

1st piston

30

SECTION

LUBRICATION SYSTEM

IV -LUBRICATION,

COOLING,

AND

FUEL

SYSTEMS

Lubrication System Diagram Engine Relief Valve By-pass Valve Oil Switch Oil Pump

COOLING SYSTEM Water Thermostat Oberdorfer Water Pump

Sherwood Johnson

New

FUEL

Fuel Filter

Fuel

Fuel Injection Pump

Oil Flow Diagram

......................................................................

....................................................................

.......................................................................

........................................................................

Pump

Style Sherwood Water Pump

SYSTEM

Pump

.....................................................................

......................................................................

Water

.......................................................................

Pump

.......................................................................

...........................................................

............................................................

..............................................................

............................................................

........................................................

...................................................

32 33 34 34 35 35

36 36 37 38 39 40

41 42

42-45

Injection Nozzle Governor

.....................................................................

..................................................................

46

47-49

31

LUBRICATION SYSTEM

Oil Filter Cartridge and Relief Valve

Piston

Crankpin Bearing

Oil Filter 1

(1)

To

rocker arm shaft

and camshaft

To

(2)

crankshaft

32

ENGINE OIL FLOW

(151

(141

TIMING GEAR

(161

CAMSHAFT

~

,.

I

1(201 :

DRAIN

I

l

,

(181 ROCKER

(151

1\,

ARM

SHAFT

1 I 1(201 I

DRAIN I I

,

\

TAPPETS

~

I I

I

(1911

SPLP.SH

(19) SPLASH

I I

__

.J

(151

'\

(221

SWITCH

I

f

1(201

l

DRAIN

f f

,

I

,

(

(121

I

TA;ETS

(191!

SPLASH

)II

_+-_1

I

I I I I

f

I

I I

I

~

I I

,..-_...J

I I

(61

MAIN

OIL

GALLERY

----,

I

~-_-_-_-_-_-_

(11

OILPAN

This engine lubrication system consists of oil 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 leaking and dropping from gaps of each part, lubricates these parts: pistons, cylinders, small ends of connecting rods, tappets, pushrods, inlet and exhaust

valves and timing gears.

33

RELIEF VALVE

Relief valve prevents damage to the lubrication system due the

relief valve is

ball

is

pushed back by high pressure oil and the oil escapes.

BY·PASS VALVE

Oil filter cartridge has a by-pass valve inside, the

oil filter element is clogged. When the pressure difference before filtering and after is more

than

98.1

kPa

without passing through the

196

to

441

KPa,

(28

to

64

psL)

When oil pressure exceeds the upper limit, the

to

prevent the lack of lubrication oil

(14.2

psi). the by-pass valve opens and lets the oil pass

filter.

to

high oil pressure. Control range of

in

the engine, if

to

each part of engine

Relief valve

and

by-pass valve

1.

Relief valve

2. By-pass valve

3.

From pump

4.

To

rocker arm shaft and camshaft

5.

To

crankshaft

(1)

t

(3)

34

OIL

SWITCH

Oil switch

is

provided off, if oil pressure operator.

In

this

case,

1. When

2. When oil pressure falls

3. Screw

4. Terminal

5. Spring plate

6.

Insulator

7.

Spring retainer

on

the way for the oil pressure. If the oil pressure is

falls below

49.0

kPa

(7.1

psi), the oil warning lamp

proper,

etc.

will light, warning the

it

stop the engine immediately and check the cause of the pressure drop.

Oil

switch

(1)

oil

pressure

is

proper

(1)

_'t=l.,jj..-

(11)

(8)

(2)

8. Rubber packing

9.

Oil seat

10. Contact rivet

11. Contact

12. Lamp

13. Battery

is

switched

OIL PUMP

The oil pump inside a housing. one less lobe than the outer at

anyone

back-up of

As the lobes slide up and over the lobes

the ring's cavities, oil

1.

Draw in 1

is

of rotor type and works smoothly and noiselessly.

In

operation, the inner rotor is driven inside the outer

rotor,

so

that only one lobe time. This allows the other lobes oil.

is

squeezed out.

2. Draw in 2

3.

Draw in 3

4.

Squeeze

5.

Inlet

6.

Outlet

7.

Inner rotor

8.

Outer rotor

out

An

inner and outer rotor turn

rotor.

is

in

full engagement with the outer rotor

to

slide over the outer lobes, making a seal

on

the outer

rotor,

oil is drawn in. As the lobes fall into

Rotor-type

The inner rotor

pump

in operation

to

prevent

has

35

WATER

35

Imino

PUMP

(7.7

IMp.gals/min.

9.2

U.S.

gals/min) of water is forced into the crank case and cyliinder head to cool them. The impeller, of backward type, is bent as far as possible from the center, in the opposite direction to rotation. The bearing unit prevents

cooling water from entering by a

special mechanical seal.

1.

Water Pump Impeller

2. Mechanical Seal

3.

Water Pump Body

4.

Bearing Unit

THERMOSTAT

The thermostat maintains the thermostat. Wax is

enclosed in the pallet. The wax is solid at low temperatures, but turns liquid at

cooling water at correct temperature and uses wax pellet type

high temperatures, expands and opens the

Flow

of

cooling

(1)

1.

Leak hole

2. Water cover

3.

Spindle

4.

Pellet

5.

Valve

6.

Sheet

valve.

water

,-.-----r->

10.

11. a)

7.

To

8.

To

9.

Pellet Wax (liquid) Wax (solid)

At low temperature

Temperature

radiator engine

b) At high temperature

sensor

(a)

of

wax

pellet

type

(b)

thermostat

OBERDORFER WATER PUMP

PUMP

Item Unit Description

1 4

ASSEMBLY 301357

Cover

Screws

2 1 Pump Cover

3 1

4 1

5 1

6 6A

1 1 1 pc.

Cover Gasket Impeller Snap Ring Impeller

Shaft

PUmp

Shaft

7 1 Cam

8 1

9

10 11

1 Cam Locking

2

1

Carbon Bushing

Oil Seal

Plug

Drain

Old Style

New

Screw

37

Style

SHERWOOD

WATER

PUMp·

\

@

Item

1 2 1 3

4

5

6 1

7 1 7A

8 1

9 10 11 12 13

PUMP ASSEMBLY 300986

Unit

6

1

1 1

1

1 1 1

2

1

Description

Cover

Screws

Pump Cover

Cover Gasket

Impeller Snap Ring Impeller Key

Shaft

Pump 1 pc.

Shaft

New

Water

Seal

Cam

Pump Body Cam Locking

Oil Seal

Drain Plug

Old Style

Style

Screw

38

JOHNSON

WATER

PUMP

PUMP ASSEMBLY 302259

Item Unit Description

Cover

1 6 2 1 3 1 4 1

5 6 1 Caqm

1 Pump

7 1

8 1 Pin

9

10 11 12 13 14 15 16

1 Cam Locking

1 1 1 1 2

1 Guide Ring

1 Service Kit

Screws Pump Cover Cover Gasket Impeller

Shaft

Wear

Plate

PUmp Body Lip

Seal O-Ring Washer Ball Bearing

Screw

39

PUMP ASS EMBLY 302648

Description

Impeller-H::·

. Housing

O

-Ring Screw

Cam 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

ip External

K

ey Shaft End

Plate Gasket Pump Body Lock Washer Bolt

=-------~-

40

FUEL SYSTEM

While the engine the fuel pump, which feeds fuel to the injection pump. The injection pump then feeds the fuel through the injection pipes, fuel leaking from nozzles is collected

is

running, fuel

is

fed

from the fuel tank (optional part) through the fuel filter

to

the nozzles which inject fuel

in

the fuel overflow pipes which drain into the tank.

1

to

the cylinders for combustion. Any

2 3

to

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 The filter element will require occasional replacement to maintain injection pump. The frequency of this service will vary according and the care

to

prevent dirty fuel

used

in

storage.

1 . Cock Body 2 . Cock Body Outlet

3.

Air

Vent Plug

Inlet

from

reaching the injection pump and injection nozzles.

1

an

adequate flow of fuel

to

the cleanliness of available fuel

to

3

the

41

FUEL PUMP

Filtered fuel is forcibly sucked from the tank by the fuel pump and fed under pressure to the injection pump. diaphragm which is caused by the special cam (for pump) of the fuel camshaft. Fuel is suctioned on the downward stroke, and discharged on the upward stroke. A system of two

to flow in only one direction.

Inlet and discharge pressures are produced by a vertical movement of the

valves allows fuel

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

INJECTION PUMP

FUEL

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 Injection

pump

(2)

(3)

-+-'I::P1P'

~~-(6)

Fuel camshaft rpm is

~-..l~'---

(9)

1.

1/2

of camshaft rpm.

Delivery Valve Holder

(9)

(1)

(5)

(4)

(7)

2. Delivery Valve Spring

3.

Delivery Valve

4.

Plunger

5.

Cylinder Pump Element

6.

Control Rack

7.

Tappet

8.

Plunger Spring

9.

Air

Vent Screw

42

Fuel Pressure-feed

1.

Bottom dead center of plunger:

At bottom dead center, fuel enters the delivery chamber through the fuel chamber and the feed hole. (Fuel chamber is always kept full by the fuel pump.)

2.

Pressure-feed start

3.

Pressure-feed process: Plunger is pushed up by camshaft to close the feed hole, and fuel pressurization starts. As

the plunger moves

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:

up,

When plunger moves further

in

the delivery chamber is returned through the plunger's center hole, control groove, and

the control groove and feed hole meet. Pressurized fuel

feed hole to the fuel chamber. Then pressure falls and pressure-feed is completed.

Pressure-feed

11

Start

to

Completion

2)

3)

1. Delivery

Chamber

2. Delivery Valve

3.

Feed Hole

4. Fuel Chamber

5.

Plunger

43

4)

Injection Control

1.

Injection

The feed hole meets the control groove before it is closed by the plunger top. Therefore, fuel is not pressurized, and is not injected even if the plunger moves

2.

Injection

When the plunger is rotated a certain amount in the direction of the arrow by the control

rack, stroke A is effective as the stroke amount.

3.

Injection

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.

"zero":

up.

"medium":

until the feed hole meets the control groove and fuel is injected

"maximum":

Injection

Control

1)

+

t 1

2)

(1)

31

1.

Effective Stroke

44

Delivery Valve

The delivery valve is composed of the valve and the valve seat. It performs two functions:

1.

Reverse flow prevention: If the circuit between the delivery chamber and the nozzle is always closed, a time lag will

occur between pressure feed start of turn, will prevent injection from stopping

To

eliminate this time lag, the valve lowers on completion of pressure-feed and the relief

valve

contacts the valve seat, and breaks the circuit between the injection pipe and

valve element and start of nozzle injection. This, in

properly until after completion of pressure-feed.

plunger.

2. Fuel dribbling prevention: After the

valve

relief valve contacts delivery valve seat, this valve lowers a little. Since the relief

breaks the circuit pressure int he injection pipe is reduce

as

the valve 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 the governor fork in the engine body. It is connected with the

plunger by pinion to change injection volume.

Tappet

The tappet converts rotating movement of the camshaft into a reCiprocating movement to

drive

plunger. A roller is used where it contacts the cam to reduce friction.

Delivery Valve

(31---~

(5)

(4)

(6)

1.

Relief Valve

Seat

2.

3.

Delivery Valve Seat

4.

Pressure Decrease Because

5.

End

of

Pressure-feed and Start

6.

End

of

Sucking Back

7.

Pump Element

8.

Cylinder

9.

Plunger

10.

Feed Hole

11.

Control Groove

of

Increase in

of

Sucking Back

Pump Element

this

Volume

(7)

12. Driving Face

(10)

(8)

(11)

(9)

(12)

45

INJECTION NOZZLE

This nozzle is throttle-type. Fuel fed from the pump pressurized to push the needle valve up and the

fuel is then injected. The needle valve is pressed by the nozzle spring through the push rod. Fuel overflow is passed from nozzle holder center through the fuel overflow nipple and the fuel overflow nozzle holder body and adjusting washers. The pressure increases when a

pipe to the fuel tank. Injection pressure can be controlled by inserting shims between

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)

(8)--+----<-i

o~"""""?"":::::-tt-tt---

o-flt1l-f--+---+H--tt---(7)

1.

Nozzle Holder Body

2. Adjusting Washer

3.

Nozzle Spring

4. Push Rod

5.

Retaining Nut

6.

Nozzle Body

7.

Needle Valve

8.

Combustion Chamber

9.

Fuel Overflow Nipple

10.

Fuel Overflow Pipe

(6)

46

GOVERNOR

With centrifugal ball weight system this mechanical governor works It keeps the engine speed and controls the engine output.

At

Start

When the engine is started, more fuel is required than pulled rightward by starter spring because ball weights have moves to a position for

1.

Ball Weights

2.

Start Spring

3.

Fork Lever 1

4.

Control Rack

overlimit discharging of fuel

At

start

in

running.

no

centrifugal force. Control rack

to

assure easy starting.

in

the whole range of speeds.

At

starting, fork lever 1

is

At

Idling

When speed control lever governor spring 1 does not work

is

set

at

idling position after the engine is started, high speed

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. spring is compressed by control rack. a

centrifugal force of ball weights and forces start spring, governor spring 2 and idling limit

Fork

lever 1 and control rack are moved leftward by the sleeve and then idling limit

As

a result, the control rack

is

kept at a position where

spring are balanced, providing stable idling.

At

idling

1.

Speed Control Lever

2. Governor Spring 1

3.

Governor Spring 2

4.

Ball Weight

5.

Governor Sleeve

6.

Fork Lever 1

7.

Control Rack

8.

Idling

9.

Start Spring

Limit

Spring

47

At

middle/high

The engine speed pulled speed control speed becomes

is

reduced

smaller than the tension of governor springs 1 and

speed

is

controlled when the tension of governor springs 1 and

lever,

(A

- 8) with load increased

is moved rightward and required for the load.

1.

Speed Control Lever

(a -c)

2. Governor

3.

Governor Spring 2

4.

Ball Weights

running

2,

which are

and the centrifugal force of ball weights are balanced. When the

(a -b),

fuel injection amount is increased

At

middle/high

the centrifugal force of ball weights

2.

As a result, the control rack

to

speed

produce

running

an

engine torque

Spring 1

When load

is

increased

t

(5)

(4)

__

1.

Engine Torque Curve

2.

Small Loan Torque Curve

3.

Large Load Torque Curve

4.

Engine R.P.M.

5.

Torque

(1)

(3)

(2)

48

At

high speed running

When

an

overload is applied to the engine running

with

ball weights become small governor springs 1 and increase

fuel injection when it is stopped by maximum output limit bolt. After that when the force of spring becomes rightward to increase

1.

Ball Weight

2,

larger than the centrifugal force of ball weights, fork lever 1 moves

fuel injection, driving the engine continuously with a high torque.

2. Fork Lever 2

3.

Governor Spring 1

4.

Governor Spring 2

5.

Maximum Output

6.

Spring

7.

Fork Lever 1

overload

at

a high speed, the centrifugal force of

as

the speed

is

reduced, and fork lever 2

is

pulled rightward by

increasing fuel injection. Fork lever 2 becomes ineffective to

At

high

speed

running with overload

Limit

Bolt

To

stop

engine

When stop

lever is moved

rack is moved

1.

2. Fork Lever 1

3.

to

"STOP" position, fork lever

to

the non-injection position, stopping the engine.

To

stop

engine

Stop Lever

Control Rack

is

moved leftward and then control

49

NOTES.

50

SECTION V - ELECTRICAL SYSTEM

Wiring Diagram General Information Alternator, General Information Alternator Schematic Diagrams Alternator Rear Housing Rotation

Belt Installation, Alignment and Tightening Ammeter Alternator/Regulator Test Procedure Test Procedure Troubleshooting Guide -

..............

:

....................................................

...............................................................

....................................................

......................................................

....................................................

............................................

........................................................................

..................................................

Integral Regulator Systems

Test Procedure - Remote Regulator Systems

Troubleshooting Guide - Remote

Alternato~

Rotor

Alternator Reassembly

Repair Procedure

Inspection and Electrical Testing

..........................................................

Alternator Performance Tests Cranking System

...............................................................

Regulator Systems

......................................................

.............................................

.....................................................

........................................

..................................

........................................

....................................

52 53

54-57

55 57 58 58

59 60-63 60,61 64-66

64 67-73 73-76 76-79 79,80 80-82

51

WIRING DIAGRAM

Glow

Pktp

(1

per cyl.,

r--------------{10'r---------~

~

~'23.

~1.5

l~l----~_~_~~~~-------

WIRE

10

11

1

2

3

4

5

6

7

8

9

NO.

COLOR

Black Grey Yellow-Red Orange Red Purple

Lt.

Blue Tan Open Grey Orange-Red

WIRE

#10 #10 #16 #10

#10 #16 #16 #16 #14 #16 #14

SIZE

1H

, 2

3~

~

'-

__

-_-_-_-_-_-_-_-_-_-_-...:-=-~~-~~I~~

......

~~~~~~~~~~~~~~~~

__

~

52

ELECTRICAL SYSTEM

General Information

The 8E series of charging systems were designed for the replacement of many current Motorola models. Models integral, solid-state voltage regulator.

are available for

51

amp,

12

volt, negative ground systems with or without

an

The integral voltage regulator incorporates construction.

The remote associated remote

Serviceable units. The alternator thus allowing for individual testing or inspection.

regulator model alternator is quipped with a blade terminal for connection to the

regulator.

features of previous Motorola Charging System designs have been retained in these

voltage regulator and brush assembly can be removed without disassembly of the

1

an

IC,

all silicon semiconductors and thick-film

2

3

1. Long life silicon diodes

2. Permanently lubricated & sealed rear ball bearing

3. Quiet & trouble-free dynamically balanced rotor

4. Convenient regulator & brush replacement

5. Insulated stator prevents shorts

6. Permanently lubricated & sealed front ball bearing

7.

Standard

CUTAWAY

%"

shaft

VIEW

OF

TYPICAL ALTERNATOR

53

ALTERNATOR

These alternators are available in two basic versions. One version includes a solid-state regulator and forms a complete charging system. The other version does not include a regulator. However, it is equipped with a

blade terminal for connection to a remote regulator.

The alternator portions of these charging systems are three-phase, diode rectified machines with die cast

minimum. The weight of a

aluminum housings to provide the necessary strength while keeping the weight to a

typical alternator, excluding pulley, is approximately

10

pounds.

TYPICAL ALTERNATOR MODEL

The field for the alternator is wound concentrically about the core of the 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

Field current of approximately

set of electrographite brushes. The

NOTE: The design is a sealed brush design and therefore is suitable for marine applications. The

2.5

Amperes is supplied to the field through copper slip rings and a

slip rings ar small

in

diameter for extended brush life.

rotor.

The field structure

os

sealed ball bearings.

brusholder is easily removed for either inspection or replacement. Removal does not require the

disassembly of the alternator.

54

The stator is connected to a three-phase, full-wave bridge rectifier package which contains six diodes. The bridge converts the and accessories such as radio,

Power to the regulator and the field of the integral regulator alternators is provided by the field diode (or diode trio) package contained

regulator

in

the charging system.

in

the alternator. Remote regulator alternators obtain field power via the

A.C.

heater,

generated

lights, ignition,

in

the stator to a

etc.

See illustrations below.

D.C.

output for battery charging

The alternator designs produce a rated output of

imately 6000 alternator

alternator is designed to operate

degrees C).

nator,

it must

To

ensure proper cooling of the rectifier bridge and internal components of the alter-

be

used with the proper cooling fan.

D+

EXCITE

REGULATOR

(ICI)

STATOR-

RPM

at

an

ambient temperature of 75 degrees F

in

an

ambient of -40 degrees to

B+

':'

GROUND

ACTAP (TACH.)

51

amperes. Rated output is achieved

(23.8

degrees C). The

$212

degrees F

D+

SENSE EXCITE

REGULATOR

(ICI)

STATOR-

at

approx-

(-40

to

100

B+

':'

GROUND

,*".IJII!ar-~--o

ACTAP (TACH.)

ALTERNATOR SENSE (INTEGRAL REG.)

D+

STATOR-

~ACTAP

+

REMOTE REGULATOR

·ALTERNATOR SCHEMATIC DIAGRAMS

BATTERY SENSE (INTEGRAL REG.)

B+

':'

GROUND

,*,,11111~"""-<>

ROTOR

b (TACH.)

55

INTEGRAL REGULATOR

Integral Voltage Regulator

The voltage regulator is switches the

The regulator design utilizes all silicon semi-conductors and thick-film assembly techniques. After

voltage has been adjusted to the proper regulating valve, the entire circuit is encapsulated to

the

protect the circuit and the components from moisture encountered

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.

voltage applied to the field

an

electronic switching device which senses system voltage level and

in

order to maintain proper system voltage.

possible damage due to handling or vibration and

in

a vehicle.

12

VOLT,

51

Ui

w

ffi

80

Q.

:!E

c:(

--

60

I-

Z

W

a:: a::

40

~

(.)

I-

~

20

I-

~

o

1000 2000 3000 4000 5000 6000 7000

~

.......

•

I

l~

I

~

,,"

r--

I""""""

~

,'"

......

~'

........

-

.....

-

--

AMP

--

en

to

-oJ

~

4

!!:.

w

~

o

3

a::

~

a::

2

o

a::

w

::

1

o

Q.

W

C/)

a::

o

J:

ALTERNATOR SHAFT

TYPICAL PERFORMANCE CURVES @AMBIENT

(23.8°C) SAE TEST METHOD

TEMPERATURE OF 75

56

RPM

0

Alternator

The residual magnetism of an alternator is very low therefore some field current must be supplied

to the rotor to initiate the generation of power by the machine.

Excitation

CHARGE

IND.

LIGHT

ING. SW

(ON)

+

TO

BATT

INTERGRAL REGULATOR ALTERNATOR

EXCITATION CIRCUIT

Alternator

Observe vehicle battery polarity prior to connecting output cables to the alternator. Reverse battery

polarity will destroy the alternator rectifier diodes.

ALTERNATOR REAR HOUSING

For special installation requirements, the alternator rear housing may be rotated to one of four

different positions that are spaced

1.

Detach plastic cover from rear housing.

2. Remove the four (4)

3.

Rotate the housing (clockwise or counter-clockwise) to the desired location. The stator assembly must be rotated with the rear housing.

Installation

0+

(IND. LIGHT

TERMINAL)

ROTATION

90° apart.

through-bolts using a 1/4" nutdriver or socket. See illustration below.

To

rotate the rear housing, proceed as follows:

TO

+

BATT

ING.

SW

(ON)

REMOTE REGULATOR ALTERNATOR

EXCITATION CIRCUIT

0+

(IND. LIGHT

TERMINAL)

'"

ALT

FIELD

4.

Replace through-bolts. Tighten through-bolts alternately and evenly until tight. Check that rotor shaft turns freely after re-assembly.

5.

Reattach plastic cover to rear housing. NOTE: Be sure felt gasket located on inside of cover is

place.

in

STATOR

ASSY

THROUGH BOLT (4)

THROUGH-BOLT REMOVAL

REAR HOUSING

57

BELT

INSTALLATION, ALIGNMENT & TENSIONING

Correct belt alignment is essential for maximum alternator and belt service life. The center line of all pulleys related to the alternator drive must be within 1/32" of the true center line. See illustration below.

Tighten drive belts by applying pressure to the alternator front housing

pressure to the rear housing or stator. Set belt tension to the engine manufacturer's recommendations. fan cannot be turned by hand.

If this information is not available, tighten belts to the point where the alternator

ONLY.

DO NOT apply

CAUTION:

APPLY PRESSURE HERE (TO FRONT HOUSING ONLY) WHEN SETTING BELT TENSION

ALTERNATOR PULLEY AND ENGINE

/

REAR FRONT

HOUSING HOUSING

ALTERNATOR BELT ALIGNMENT

I DRIVE PULLEY MUST BE IN LINE

WITH

EACH OTHER.

AMMETER

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 illustration

below.

alternator charge and accessory discharge, it must be connected as shown in

ALTERNATOR

CHARGE

PATH

1

AMMETER

BATTERY

DISCHARGE

PATH

T~

~

AMMETER CHARGE & DISCHARGE CIRCUIT

An

accessory ammeter may be used available ammeters are not long heavy gauge wiring required. Failure to provide adequate wiring will result in poor system performance.

in

two types: direct reading, and external shunt types. Internal shunt (direct reading)

usually recommended for charging systems of high output capability due to the

if

it provides 75-0-75 scale information. Such meters are

58

ALTERNATOR/REGULATOR TEST PROCEDURE

General

It is desirable to test the charging system (alternator and voltage regulator) in the vehicle using the vehicle wiring harness and electrical loads that are a permanent part of the system. In-vehicle testing will then provide the technician with the .major components of the

electrical system.

an

operational test of the charging system as well as

Preliminary Checks & Tests

Before starting the actual electrical test procedure, the charging system, battery and wiring should be

checked to eliminate possible problem areas. The following procedure is recommended:

1.

Check the condition and adjustment of belts.

A.

If the alternator fan can

should

B.

Replace any worn or glazed belts.

2.

Check to see that all terminals, connectors and plugs are clean and tight.

A.

Loose or corroded connections cause high resistance and this could cause

be adjusted.

be

moved by pushing

on

a fan blade with your finger, the belts

overcharging, undercharging or damage to the charging system.

B.

Badly corroded battery cables could prevent the battery from reaching a fully charged

condition.

3.

Check battery condition and change 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

however, most commercial test equipment incorporates several testing devices in a single

only; unit.

DC VOLTMETER: 0-20 Volt Scale BATTERY

TEST

EQUIP.:

Any commercial type, Hydrometer with temperature correction scale.

Storage Battery

The vehicle storage battery circuit represents a continuous although variable electrical load to the alternator. If the circuit, position or negative, is opened or broken while the alternator is charging, the

loss of the battery will result in the charging voltage rising to unsafe levels.

Battery Inspection

The following table illustrates typical ranges of specific gravity for a cell in various states of charge. THE

BATTERY

MUST BE

AT

LEAST 75% OF FULL CHARGE

FOR

EFFECTIVE

ALTERNATOR

TESTING.

1.260

SP.

GR

BATTERY BATTERY STATE

Sp.

Gr. Gr.

Gr.

1.260 Sp.

1.230 Sp.

1.200 Sp. Gr.

1.170 Sp.

1.140 Sp.

1.110

SP.

1.280

1.280 Sp.

1.250 Sp.

1.220 Sp.

1.190 Sp.

1.160 Sp.

1.130 Sp.

GR. CHARGE

Gr. Gr.

Gr. Gr. Gr. Gr.

100% Charged 75%

Charged

50%

Charged

25%

Charged Very Low Cap. Discharged

After completing these preliminary checks and tests, proceed with the tests as outlined Trouble-Shooting Guide.

59

in

the

TEST PROCEDURE - (INTEGRAL REGULATOR SYSTEMS)

(See Pages 64-66 for Remote Regulator Systems)

BACK

COVER

SENSE

(TO

(D+)

INDICATOR

LIGHT

GROUND-~

INTEGRAL

REGULATOR

TERM.

AC

TAp·

(TACH)

BACK

COVER

ALTERNATOR

SENSE

INDICATOR

(D+)

LIGHT TERM.

GROUND

INTEGRAL

REGULATOR

ACTAP

(TACH)

EXCITE

ALTERNATOR TERMINAL IDENTIFICATION (INTEGRAL REGULATOR)

TROUBLESHOOTING GUIDE

INTEGRAL REGULATOR SYSTEMS

PROBLEM PROBABLE CAUSES CORRECTIVE ACTION

A.

Battery undercharged

- ammeter (if used) indicates constant discharge.

- indicator

lamp remains on.

1.

Defective cables, dirty battery posts, corroded

2.

Loose or broken belt.

3.

Worn or broken brushes.

4.

Defective alternator system.

terminals, etc. as needed.

1.

Check, clean, repair or

2.

Check belt.

3.

Replace brush assy.

4.

Refer to

"Problem

Determination

BATT.

+)

REMOTE

BATTERY

SENSE

Area

Section".

replace·

B.

Battery undercharged

- indicator

lamp off with key defective wire harness. on & engine stopped. condition is lamp on.)

C.

Battery overcharges

- excessive use of water.

- ammeter (if used) shows constant excessive charge.

- voltmeter indicates greater than

14.5

volts (connected across battery with no load) with engine

D.

Battery charges at idle, but

discharges under

idling.

load

conditions.

E.

Indicator lamp glows slightly under moderate load; battery

appears charged.

(Normal

1.

Indicator lamp burned out or

2.

Broken brush.

3. Defective alternator system.

1.

Defective wire harness.

2.

Defective alt. system.

3.

Poor ground.

4.

Broken sense lead (remote Determination Section". battery sense

only.)

1.

Check bulb & harness.

2.

Replace brush assy.

3. Refer to

Determination

1.

Refer to Determination

2.

Refer to "Problem Area

"Problem

Section".

"Problem

Section".

3. Check ground.

4.

Check, clean, repair as needed.

1.

Slipping belts.

2.

Alternator defective or replace as necessary

1.

Defective diode-trio.

1.

Check belts and adjust tension

2.

Disassemble, check diodes.

1.

Remove & replace.

Area

or

replace

60

PROBLEM AREA DETERMINATION

SECTION

CONDITIONS: Engine Idling

A.

BATTERY

1.

Remove Battery sense a.

2.

a.

3.

a.

4.

UNDERCHARGED

Perform Harness Voltage

Indicator Lamp

On

Perform Open Diode-Trio

Indicator Lamp Off (Ignition

Perform Regulator

b.

If Regulator removed for

is

repair.

Further Investigation Requires Alternator Removal and Repair

(diodes).

B.

BATTERY

1.

OVERCHARGED

Regulator Shorted, Replace Regulator.

O.K.,

For

All

only.

Test

on

Test.

(Test

the cause

Tests

(Unless otherwise specified)

(Test

No.3)

(Test

NO.1)

and engine stopped)

NO.2)

is

IGN.

SW

probably

'IND.

LIGHT

an

open field circuit and Alternator must

be

0

...

>+----

I vocrs I

+ -

STEP

TEST

______

(B+)

NOT

POIN

__

~M~rr~ER7Y~W~~~A=G~E==~~

1.5

+-"IN=D:.:..

13.5 LIGHT ATTACHED.

ATTACHED

RED

1~=~:~~1*~_A~(B_+~)

~?:==t>

II

IL...I'.>

---,..

2* B (REG)

~~

3 A

·JUMPER

OPEN

INDICATION

TO

3.0

wcrs

=LI=GH:.:.:T'-'O:.:.;N'-TO

15.0

OFF.

WITH

____

wcrs & IND.

(JUMPER

ENGINE

IDLING)

~

DIODE-TRIO TEST

BATTERY

*·REMOTE

SENSE

ONLY

POS

+

OUTPUT

(B+)

BATT

61

Alternator/Regulator Tests

Test No. 1 Open Diode-Trio With ignition

electrical load), check for battery voltage at terminal A and for

(no Add

jumper

goes

"ott"

(defective) and alternator should Test

No.2

NOTE:

terminals extending through back

on

and engine not running and jumped not attached

JUl

between terminals A and

and charging voltage is present

Open Regulator

Test

requires removal of back cover of alternator.

Test

B.

Start engine and run at idle. If indicator lamp now

at

terminal

be

removed for repair.

cover.

Remove back cover (two screws) and reconnect all wires.

A,

1.5

to

3.0

volts at terminal

the diode-trio is probably

To

remove, disconnect wires from

B.

"open"

With ignition terminal A and terminal

1.5

to

3.0

indicated.

is indicated and

on

and engine not running and jumper not attached, check for battery voltage at

volts is present at terminal B and the indicator light is on,

If lamp is still not "on",

alternator repair is required.

B.

Indicator light will

an

I

voas

I

+ -

·JUMPER

be

ott. Add jumper

open field circuit (brushes, slip-rings, etc.)

TEST A

(B+)

B

(REG)

B (0+)

NOT

POIN

ATTACHED

INDICATION BATTERY BATTERY

IND.

LIGHT

JUMPER

ATTACHED,

3.0

voas

VOIJAGE VOIJAGE

OFF

IND.

WITH

1.5

LIGHT

JUl

between field and ground. If

an

open (defective) regulator is

AC

TAP

(TACH)

BATTERY

TO

ON

··REMOTE SENSE

BATT

ONLY

-

REGULATOR TEST (BACK COVER REMOVED)

62

Test No. 3 Harness Voltage Test (Remove Battery Sense Only) Remove harness sense lead from sense terminal and connect voltmeter leads as shown in Figure

below. Voltmeter should indicate battery voltage (approx. 12.6 volts for a fully charged battery with ignition key off). replaced.

If voltage is zero, the hardness

INTEGRAL

REGULATOR

"sense"

lead is open and should be repaired

or

I

voas

I

+ -

~-f--I

Test No. 4 After voltmeter is connected, as shown in Figure below, start and run engine at a fast idle of

approximately 1,500 RPM.

nominal system output voltage of between

(Voltages may vary a few tenths of a volt (higher or lower) due to ambient temperature variations).

If the alternator output voltage does not fall within the proper range, the alternator should be

disassembled for further inspection and tests.

Alternator Ooutput Test

Turn

on vehicle headlights and blower fan (low speed). Check for

EXCITE

(TO

IGN.

SN.

OIL

PRESS.

BLK

RED

·REMOTE

CABLE HARNESS

SW.)

BATTERY

13.8-14.8

IGN.

SW.

OR

LIGHT

SENSE

ONLY

VOLTAGE

volts for a properly operating charging system.

IND

BATTERY

TEST

I

was

+ -

RED

I

INTEGRAL

REGULATOR

BLK

POS + OUTPUT

13.8

ALTERNATOR OUTPUT TEST

TO

--~

14.BV

...

63

·REMOTE

BATTERY

·SENSE BATT

SENSE

TO

(+)

ONLY

TEST PROCEDURE-(REMOTE REGULATOR SYSTEMS)

ACTAP

(TACH)

(D+)

INDICATOR

LIGHT

TERM.

GROUND

ALTERNATOR

TERMINAL IDENTIFICATION (REMOTE REGULATOR)

TROUBLESHOOTING GUIDE

REMOTE REGULATOR SYSTEMS

PROBLEM

A.

Battery undercharged

- ammeter (if used) indicates posts, corroded terminals, etc. constant discharge.

- indicator

B.

Battery undercharged

- indicator lamp off with key defective wire harness. on condition is lamp on.)

C.

Battery overcharges

- excessive use of water.

- ammeter (if used) shows constant excessive charge.

voltmeter indicates greater than

across battery with no

with engine idling.

lamp remains on.

& engine stopped. (Normal

14.5

volts (connected

load)

PROBABLE CAUSES

1.

Defective cables, dirty battery

2.

Loose or broken belt.

3.

Worn or broken brushes.

4.

Defective alternator system.

1.

Indicator lamp burned out or

2.

Broken brush.

3. Defective alternator system.

1.

Poor ground.

2.

Defective alt. system.

CORRECTIVE ACTION

1.

Check, clean, repair or replace as needed.

2.

Check Replace

3.

4.

Refer to "Problem Area Determination

1.

Check bulb & harness.

2.

Replace brush

3.

Refer to "Problem Area Determination

1.

Check ground.

2.

Refer to Determination

belt.

brush

assy.

Section".

assy.

Section".

"Problem Area

Section".

D.

Battery charges at idle, but discharges under load conditions.

E.

Indicator lamp glows slightly under moderate load; battery appears charged.

1.

Slipping belts.

2.

Alternator defective

1.

Defective diode-trio.

64

1.

Check belts and adjust tension

replace as necessary

or

2.

Disassemble, check diodes.

1.

Remove

& replace.

Problem Area Determination Section A.

BATTERY

1.

2.

3.

B.

BATTERY

1.

a.

UNDERCHARGED

Indicator Lamp On.

Perform Open Diode-Trio

Indicator Lamp Off (Ignition

Perform Regulator

b.

If Regulator removed for

is

O.K.,

repair.

Test

on

Test

(Test

the cause

Further Investigation Requires Alternator Removal and Repair (diodes).

OVERCHARGED

Regulator Shorted, Replace Unit.

Alternator/Regulator Tests Test

No.1

Open Diode-Trio

With ignition

on battery voltage terminals A and voltage

is

present at terminal

be removed for

and

engine not running (jumped not attached and

at

terminal A and for

B.

Start engine and

repair.

Test

1.5 run

A,

the diode-trio is probably "open" (defective) and alternator should

(Test

No.1).

and

engine stopped).

No.2)

is

probably

to

3.0

volts

at

idle. If indicator lamp now goes

an

open field circuit and Alternator must be

at

terminal

B.

no

electrical load), check for

Add

jumper

JU1

"off"

and charging

between

EXCITE

(TO

SW.

OIL

PRESS.

SW.)

VOIJAGE

REGULATOR

IGN.

OR

L....T-=F--i

RED

BLK GRN

I

VOIIS

I

+ -

~~~-

BLK

RED

STEP

I'='~)

..

::==:;>

II II

~=-.:~

l'

2'

3 A (B+)

'JUMPER

TEST

A (B+)

B

(REG)

NOT

OPEN

IGN.

SW.

______________

POIN

ATTACHED

IND.

UGHT

FIELD

INDICATION

BATTERY

1.5 IND.

13.5 UGHT ATTACHED.

TO

3.0

UGHT

TO

OFF.

VOIJAGE

VOIIS

15.0 (JUMPER

ENGINE

ON

VOIIS & IND.

DIODE-TRIO TEST

WITH

IDUNG)

n.+--

POS. + OUTPUT

(B+)

J

BATTERY

65

Test

No.2

Open Regulator

With ignition

on

and engine not running and jumper not attached check for battery voltage at

terminal A and terminal

1.5 to

3.0

volts

is

present indicated. If lamp is indicated and

is

still not "on",

alternator repair is required.

Test

B.

Indicator light will be off. Add jumper JU1 between terminals

at

terminal B and the indicator light is on,

an

open field circuit (brushes, slip-rings, etc.)

an

open (defective) regulator

Band

C.

11

is

EXCITE

(TO

sw.

OIL

PRESS.

sw.)

VOIJAGE

REGULATOR

IGN.

OR

I

VOIJS

I

-

+

REO

STEP

--"

__

">

1-

2-

1'---">

IL

:r--~

~=="v

3

-JUMPER

RED BLK GREEN

BLK

TEST A

(B+)

B

(REG)

B (0+)

NOT

IGN.

sw.

POIN

ATTACHED

IND.

LIGHT

INOICATION

BATTERY BATTERY

IND.

LIGHT

JUMPER

3.0

VOLTS

VOIJAGE VOIJAGE

OFF

ATTACHED,

IND.

LIGHT

OPEN REGULATOR TEST

WITH

1.5 ON

f"\.o~--

TO

POS + OUTPUT

(B+)

BATTERY

Test No. 3 Alternator Output After voltmeter is connected, as shown

approximately 1,500 RPM.

Test

Turn

in

Figure below, start and run engine at a fast idle of

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.)

If the alternator output voltage does not fall within the proper range, the alternator should be disassembled for further inspection and tests.

EXCITE

(TO

sw.

OIL

PRESS

sw.)

IGN.

VOIJAGE

REGULATOR

I

+ -

OR

VOIJS

RED

IGN.

sw.

RED BLK GRN

I

BLK

POS + OUTPUT

13.8

TO

IND.

LIGHT

14.8V

0-*--

POS + OUTPUT

(B+)

BATTERY

-

ALTERNATOR OUTPUT TEST

66

ALTERNATOR REPAIR PROCEDURE

General

The following instructions are presented

of

an

alternator.

a repair is necessary will

However,

it should be

seldom, if

pOinted

ever,

as

a general overall procedure for complete disassembly

out that following the complete procedure whenever

be

required.

In

cases where the causes of the

malfunction are known, it is only necessary to follow that portion of the procedure directly related

to resolving the problem. Similarly, when the reasons for the malfunction are uncertain, it will

be

necessary to follow the procedure in greater depth in 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.

NO

ALTERNATOR

OUTPUT

~

DEFECTIVE

REGULATOR

~

DEFECTIVE

BRUSHES

~

OPEN FIELD

DIODE

~

OPEN

ROTOR

LOW

ALTERNATOR ALTERNATOR

OUTPUT

+

DEFECTIVE

REGULATOR

~

WORN

BRUSHES

~

GROUNDEDI

SHORTED

ROTOR WINDINGS

~

GROUNDEDI

SHORTED

STATOR

WINDINGS

~

SHORTED/OPEN

RECTIFIER DIODE

"NOISY"

~

LOOSE DRIVE

PULLEY

~

CRACKED OR

DAMAGED

HOUSING

WORN

BEARINGS

~

SHORTED

RECTIFIER

DIODE

~

SHORTED OR

GROUNDED

WINDINGS

STATOR

ALTERNATOR TROUBLESHOOTING-DIAGRAM

Disassembly

& Testing

Detach Back Cover: Remove nuts from terminals. Remove two screws securing back cover to rear housing.

REMOVING BACK COVER

67

(2) BACK COVER

MOUNTING SCREWS

Remove Brush Holder: Remove two locknuts securing brush holder. Pull out brush holder. See illustration below.

(2) BRUSHOLDER

MOUNTING LOCKNUT

REMOVING BRUSH HOLDER

Inspect

The 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

cracked or show evidence of grooves

and

Test

Brush Assembly:

if

brushes are not oil soaked,

on

the sides of the brushes caused by vibration.

TEST

CONTINUITY FROM A TO FROM C TO

NO FROM A OR

TO C OR

B

0

CIRCUIT:

B

0

TEST WITH

TEST LAMP

BRUSH TEST

12

VOLT

OR OHMMETER

DC

68

Remove Integral Voltage Regulator: Remove two screws securing integral voltage regulator to rear housing.

NOTE: rear housing instead of the

Remove Diode-Trio (Field Diode) and Rectifier Diode Bridge: The diode-trio and rectifier diode bridge are detached as positive output (B+) trio mounting screws. Detach assembly from rear housing and separate diode-trio assembly from rectifier bridge. See illustration below.

Alternators with remote voltage regulator systems will have a space part mounted to the

integral voltage regulator.

REGULATOR

(2)

MOUNTING SCREWS

REMOVING

terminal. Straighten

B+

VOLTAGE

strap. Remove three terminal screws and four diode-

REGULATOR

an

assembly. Remove cone lockout from

REMOVING DIODE-TRIO

CONE LOCKNUT

AND

AND RECTIFIER DIODE BRIDGE.

(4) MOUNTING

SCREW

B+

STRAP

69

Test

Diode

Trio

Assembly: Using a commercial diode tester or separately to the diodes should check alike. If any diode is defective replace the entire diode trio assembly. See illustration below.

0+

stud; continuity should be observed

12

volt DC test lamp; check for continuity from each terminal

in

one direction (polarity) only, and all

COMMERCIAL

DlOOE

TESTER

L...---t~:r

Test

Diode Rectifier Bridge Assembly:

Using a commercial diode tested, check for continuity. Check betweenn terminals C for negative diodes. Continuity should 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 only, and all diodes should check alike. See illustration below.

any diode is defective, replace the entire diode rectifier bridge assembly.

If

~----D+

(IND.

TESTING DIODE-TRIO

e

Q

LIGHT

be

observed

STUD

TERMINAL)

in

COMMERCIAL

DIODE

TESTER

pOint

A and each of three

one direction (polarity) only, and

e

9

TESTING RECTIFIER BRIDGE

70

Separate Stator/Rear Housing Remove four

thru-bolts. See illustration below.

Assy.

from Front Housing:

Carefully as shown

CAUTION: Do winding.

insert two screwdriver blades in opposite openings between the stator and front housing,

in

illustration below. Pry units apart.

not

insert

screwdriver blades deeper

THROUGH

(4)

BOLT

than

1/16"

to

BLADE SCREWDRIVERS AT

OPENINGS ---::::-----...

CAUTION: DO NOT INSERT SCREWDRIVER MORE THAN 1/16"

BLADE OF

avoid damaging

OPPOSITE

stator

THRU-BOLT REMOVAL

Inspect Inspect wear in the bearing bore due to a worn rear bearing.

If casting is to be reused, clean in solvent, dry with compressed retainer if retainer is damaged.

Test The stator assembly consists of three individual windings terminated in the delta type connections.

Using There should be signs of winding

Rear Housing: the rear housing for a cracked or broken casting, stripped threads or evidence of severe

Stator:

an

ohmmeter or a test lamp, check for winding continuity between terminals

no

continuity from any terminal to point D (laminations). Also, stators showing any

discoloration should be discarded. See illustration below.

STATOR-REAR HOUSING SEPARATION

air,

and install a new rear bearing

A,

Band

C.

o

STATOR

WINDING TESTS

71

Remove Pulley,

The pulley is a slip-fit on the rotor shaft, positioned with a Woodruff

lockwasher from the shaft using

After nut and lockwasher are removed the alternator can be separated from the pulley.

Fan

and Spacer:

an

impact wrench or other suitable tool.

Key.

Remove the nut and

The fan will slide over the

Inspect the fan for cracked or broken fins, note the condition of the mounting hole. If worn from running

Inspect pulley

Separate Rotor from Front Housing: Position front housing on support blocks placed on an arbor press. Push rotor assembly from housing.

loose, replace the fan to insure balance.

for possible faults as listed

PULLEY REMOVAL

See illustration below.

key.

The key may be removed with diagonal pliers, or with a screwdriver.

in

illustration below.

CHECK DRIVE SURFACES

NOTE CONDITION OF KEY GROOVE.

FOR WORN

.

..,.--

__

CHECK FOR POLISHED SURFACE

CHECK BORE FOR

HERE.

WEAR.

PULLEY

____

INSPECTION POINTS

.....

-=:;:::::==1

I-

I--PRESS

FRONT

HOUSING

/

SEPARATING ROTOR FROM FRONT HOUSING

72

Remove Front Bearing from Housing:

Remove three bearing retainer screws. Position housing on support blocks placed on an arbor

press. Using a tool that contacts inner race of bearing, press out front bearing.

BEARING RETAINIER

(3)

See illustrations below.

SCREW

BEARING INNER RACE

REMOVING RETAINER SCREWS

PRESSING

OUT

BEARING

Inspect Front Housing:

Check housing for cracks. Check condition of threads in adjusting

ear.

Check bore 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 A. Current Draw CAUTION: Turn

ring

surfaces.

1.

CURRENT DRAW IN AMPERES,

or

Resistance of the Winding

off

DC

power

source

AT

before

70°

TO

removing

80°F.

test

leads

to

avoid avc

damage

CORRECT

CURRENT DRAW

@ 15.0 V

3.2 to

3.6

AMPERES

AT

70°

TO

80°

F.

CORRECT WINDING

RESISTANCE

4.1

to 4.7 OHM

2.

RESISTANCE

12 VOLT MODELS,

RATED

51

AT:

AMPERES

OF

WINDING IN OHMS,

12 VOLT MODELS,

RATED

51

AT:

AMPERES

89.

to

slip

73

.

REAR

BEARING

TEST CURRENT

DRAW OR RESISTANCE

BEWEEN RINGS

B.

Grounded Slip Ring or Winding Use

12

volt

DC

test

lamp,

body

and

the other

on

correct condition.

C.

Condition of Slip Rings

1.

Clean brush contacting surfaces with fine crocus cloth, wipe dust and residue

2.

If surfaces are worn beyond this restoration, replace the entire rotor assembly.

SLIP \

RING~

ROTOR INSPECTION AND ELECTRICAL TESTING

ohmmeter, or

110V

AC

test lamp. Place one test lead

BEARING

AREA

/ KEY SLOT

SHAFT

NOTE: PLACE TEST LEADS ON EDGES OF SLIP RINGS TO AVOID CREATING ARCS ON BRUSH CONTACT SURFACES.

THREADS

either slip ring. Open circuit from either slip ring

to

the rotor

to

the rotor body

away.

is

a

D.

Rotor Shaft and

1.

Stripped threads

2.

Worn

key

3.

Worn

bearing surface

4. Scuffed pole fingers

5.

Worn

or dry rear bearing

slot

Pole

Pieces

on

shaft

Replace rotor assembly if any of the above faults are noted with the exception of item NOTE: If

New

rotors include a new rear bearing and new slip rings as part of the assembly.

rear bearing requires replacement, follow instructions for this operation.

5.

_

74

Remove Slip Rings from Rotor Assembly Unsolder the rotor leads from the slip ring terminals. Carefully unwind the ends of the rotor coil

leads from the slip ring terminals,

as

shown

in

illustration below.

REMOVE FROM

BETWEEN

SLIP RINGS

UNSOLDER

-"==~-r:J

CAUTION:

UNSOLDER

Straighten rotor leads. Insert a

Position bearing puller

as

No.

shown

in

CAUTION: When holding rear end rotor shaft.

ALL RESIDUE

II

I"T"

DO

NOT

OVERHEAT

10 x 1"

ROTOR

cap screw into opening

LEADS FROM SLIP RINGS

at

center of slip ring assembly.

illustration below and pull slip ring assembly off rotor shaft.

of

rotor

shaft

in

vise, be sure

not

to

grip

bearing area

STRAIGHTEN

ROTOR

LEADS

of

REMOVING SLIP RING

Remove Rear Bearing from Rotor Dress rotor leads away from the bearing puller contact area.

Adjust puller to contact inner bearing

at top of page

76.

race,

carefully remove bearing from the shaft. See illustration

This completes the disassembly of the alternator.

75

ASSY.

DRESS

AWAY

REMOVING REAR BEARING

ROTOR

FROM PULLER

LEADS

ALTERNATOR

General

The general reassembly instructions are reverse order to the procedures given for disassembly. Therefore, only information pertaining to special reassembly requirements will

section.

Install Rear Bearing

Place rotor

on inner race

bearings should is rough, dry or noisy.

REASSEMBLY

on

a press

only and press bearing

as

shown in illustration below. Choose a driver sleeve that exerts pressure

be

used whenever bearing is removed during repair procedures or when bearing

on

REAR

BEARING

be

covered in this

rotor shaft until it contact shoulder. New replacement

--PRESS

DRIVER

-SLEEVE

RaroR~

BLOCK

~

\

INSTALLING REAR BEARING

76

Install Slip Ring Assembly

Guide rotor leads through one of the oval passages passages is

in

line with groove

in

rotor shaft. Place rotor

in

the slip ring assembly.

Choose a driver sleeve with a diameter that clears leads.

on

a press as shown

Be

sure oval

in

illustration

below.

Press slip ring assembly

on

shaft. Solder rotor leads to leads on slip ring.

leads extending above solder connections.

RING

SLIP

ASSEMBLY~

____

__________

PRESS

Trim

DRIVER

SLEEVE

excess slip ring

INSTALLING SLIP RING ASSEMBLY

Install Front Bearing

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 bearing is rough, dry or

noisy.

Install three bearing retainer screws.

Torque

to 25-30 pounds.

_----

PRESS

DRIVER TOOL

OUTER BEARING

HOUSING

CONTACTS

RACE ONLY

FRONT

BEARING

FRONT

INSTALLING FRONT BEARING

77

Assemble Rotor and Front Housing

Place the rotor on the bed of an arbor press, using two steel blocks for support,

as

shown

in illustration below. Place front housing over shaft. Using driver sleeve that contacts inner bearing race

only, press front housing down until inner bearing race contacts shoulder on the shaft.

CAUTION: Be sure rotor leads clear blocks.

.---PRESS

DRIVER

~SLEEVE

FRONT

/HOUSING

ASSEMBLING FRONT HOUSING

Assembly Spacer,

Fan

and Pulley

Place pulley spacer over shaft. Install Woodruff Mount

pulley as shown in left hand illustration

Key.

Install fan. Install pulley, lock washer and nut.

on

page 92. Tighten to 35 to 50 foot pounds.

TO

ROTOR

Spin rotor by hand to test freedom of bearing.

Assembly Front & Rear Housing

Place stator into front housing with stator leads at top and notches in laminations aligned with bolt 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:

rather than a nut driver

New front housings contain thru-bolt holes that are not tapped. Therefore, a socket wrench

will

be

required to supply sufficient torque to drive the "thread forming"

thru-bolts.

Install Diode Rectifier Bridge and Diode

Trio

Insert B + strap through slot in diode trio body. Bend strap over B + terminal and secure with cone

locknut. Apply thin film of heat sink compound to back of diode rectifier bridge and to mating

on

area

rear housing.

Install assembly to rear housing (four screws). Place strap (AC tap) in position and connect stator leads (three screws).

Install capacitor (where applicable).

Install Integral Regulator

Install brush mounting screws (two) through openings in regulator

body.

Secure regulator to rear

housing (two screws).

_

78

Install Insert brush holder into grooves in hub of rear housing. Place D + strap (or male terminal where

applicable) on stud and secure brush holder with locknuts (two places). Secure other end of D +

strap.

Brush

Assembly

Install

Be sure secure with two screws.

ALTERNATOR PERFORMANCE TESTS The following tests will determine the current producing capability of the repaired alternator. Mount

the voltage and circuit polarity.

Rear Cover

felt gasket is in place (see illustration below). Position rear cover on rear housing and

FELT

GASKET

INSTALLING REAR COVER

alternator in a test fixture capable of providing 5000 alternator RPM Select required battery

A.

For remote regulator model, connect fixture circuit leads and instruments to the alternator terminals position.

Turn drive motor on, adjust to obtain alternator should develop a charge. Continue to reduce resistance until alternator reaches rated current output in amperes. alternator for more than a few minutes in the manner, alternator will deliver its rated output, terminate the test.

B.

For integral regulator model, connect fixture leads and instruments to alternator terminals as shown in Diagram B on page

The Carbon pile or resistive load bank and ammeter must be capable of handling the alternator

rated output alternaotr RPM. CAUTION: Make

instrument, Starting with carbon pile off, slowly increase load while observing ammeter and maintaining 5000

RPM. Increase load until a minimum output voltage of approximately Record the output current at this point and refer to the chart for minimum

as shown in Diagram A on page

5000 alternator RPM. Slowly reduce field rheostat resistance,

CAUTION: Limit output voltage to 15V maximum. DO NOT operate the

100.

sure

alternator

connections

or

wiring

are

due

to

well

short

100.

Place field rheostat in maximum resistance

due

to the lack of voltage control. If the

secured

circuits.

and

tight

to

avoid

possible

13.7

volts is obtained.

acceptable ratings.

damage

to

79

MINIMUM ACCEPTABLE OUTPUT

VAWES

RATING OUTPUT 51

AMP 46 AMP

AT

70°

TO

800

I

WLTS

I

FIELD

RHEOSTAT

(TO

OIL

EXCITE

IGN.

SW.

PRESS.

D+

OR

SW.)

AC

+ -

BLK RED

RED

+

BATTERY

DIAGRAM A-REMOTE REGULATOR MODEL

TYPICAL

CRANKING SYSTEM

Starter The magnet-switch type starter is composed of two main sections. The first section converts

battery current into coil,

armature, brush, commutator, pinion, overrunning clutch, pinion and composed of the

flywheel to engage together and current to flow through the motor section. It is

mechanical rotation to turn the engine crankshaft. It is composed of the field

pull-in coil, holding coil pluge drive

ALTERNATOR PERFORMANCE TESTS

DIAGRAM B-INTEGRAL

etc.

lever,

contract plate,

POS + OUTPUT

·REMOTE

The second section allows the

SENSE

etc.

BATT

ONLY

REGULATOR MODEL

TAP

(TACH)

1.

Field Coil

2. Brush Spring

3.

Brush Holder

4.

Brush

5.

Commutator

6.

Through

7.

Pole Core

8.

End Frame

9.

Contact

10.

Contact Plate

11.

Holding Coil

12. Magnet

13.

PUll-in Coil

14.

Moving Core

15.

Drive Lever

16.

Drive Spring

17.

Lever

18.

Bearing

19.

Drive Side Housing

20. Over Running Clutch

21.

Armature

22.

Yoke

Bolt

Switch

Set

Bolt

80

Starter

circuit

1.

2.

PC HC

(3)

:Pull-in Coil :Holding Coil

(1) (2)

3. S :Switch

4. Drive Lever

clutch

5. Screw Spline

6. Armature

7.

Pole Core

8. Commutator

9. Contact Plate

When Start Button is Pushed: When the start button is pushed on, a current flows from the battery through the pull-in coil

magnet switch section to the holding coil, energizing the plunger to pull it in. At this time, the pinion moves

by

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

in

the

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 forward

Since the pull-in coil ends are short-circuited

by

the screw spline for more contact.

by

the contact plate, the plunger is held only

by

force of the holding coil.

When

contact

plate

il

clo'"

the

81

When Push Button

When

the push button is released, a current flows instantaneously through the pull-in coil in

the opposite direction as shown in Figure

pull-in coil are balanced. As a result, the plunger is returned by the return 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.

is

Released:

below. Therefore, the forces of the holding coil and

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 time.

glow plugs are quick-heating type, which make starting easier with short pre-heating

1.

Housing

2.

Metal Tube

3.

Insulating Powder

4.

Heat Coil

Construction

~··"···f.l..·~

(1)

of

bar

glow

(~

plug

(~

(2)

82

CYLINDER

SECTION VI - DISASSEMBLY AND REASSEMBLY

Removing Head Cover Removing Removing

Injection Pipes Nozzle Holder Assemblies

.............................................................

1,

2 and 3

Removing AC Dynamo and Fan Removing Rocker Arm Removing Push Rods Removing Removing

Cylinder Heads

Cylinder Head Gasket Removing O-ring Removing Tappets Removing Valves

.............................................................

..............................................................

..........................................................

..................................................................

...............................................

.................................................................

NOZZLE HOLDER Disassembling Nozzle Holder

.......................................................

INJECTION PUMP Removing Removing GEAR CASE,

Injection Pump Cover Injection Pump

..........................................................

TIMING GEAR, CAMSHAFT, OIL PUMP

.................................................

Belt

.................................................

....................................................

.....................................................

,

.................

86 86 87 87 88 88 89 89 90 90 91

91

92 92

Detaching Governor Spring Removing Speed

Control Plate Detaching Start Spring Removing Fan Drive Removing Gear Case Removing Crankshaft Removing

Idle Gear

Camshaft Stopper

...............................................................

.................................................................

.........................................................

.............................................................

Pulley

.........................................................

..............................................................

Oil Slinger

Removing Gear and Camshaft Removing Fork Lever Removing Removing Removing

Fuel Camshaft

Oil Pump Drive Gear

Oil Pump

Removing Crank Gear

Assembly

...........................................................

...............................................................

.............................................................

PISTON AND CRANKSHAFT Removing Removing Oil Filter 1

Oil Pan

.................................................

.............................................................

......................................................

....................................................

......................................................

.....................................................

~

..............

93 93 94 94 95 95 96 96 97 97 98 98 99 99

100

100 Removing Connecting Rod Cap Removing Pistons Removing Flywheel

................................................................

...............................................................

....................................................

83

101

102

SECTION

PISTON AND CRANKSHAFT (Continued)

VI

- CONTENTS (Continued)

Removing Bearing Removing Bearing Case Bolt 2 Removing Crankshaft Removing Main Bearing Case

Removing Cylinder Liner

THERMOSTAT,

Removing Thermostat Removing Water Pump

Case Cover

.....................................................

.............................................................

......................................................

..........................................................

WATER PUMP

............................................................

...........................................................

CYLINDER HEAD AND VALVES Checking Flatness of Cylinder Head Surface Checking Flaw of Cylinder Head Surface Reparing Valve Seat Checking Valve Recessing Checking Guide Clearance

..............................................................

.........................................................

........................................................

Checking Valve Spring Free Length Checking Valve Spring Squareness Checking Valve Spring Tension

.....................................................

.............................................

.................................................

......................................

102 103 103 104

104

105 106

106-107

107 108 108 109 109 110

110 Checking Oil Clearance Between Rocker Arm Shaft and Bushing Checking Top Clearance Adjusting Valve Clearance Adjusting Compression FUEL

SYSTEM

Testing Opening Pressure of Nozzle

Checking

Fuel Tightness of Nozzle Valve Seat Checking Shape of Fumes Across Checking Checking

Fuel Tightness of Fuel Injection Pump Plunger Fuel Tightness of Delivery Valve of Fuel Injection Pump

Choking and Adjusting

..........................................................

.........................................................

Release

....................................................

.................................................

........................................

Nozzle Tip

.........................................

................................

Injection Timing

..............................................

TIMING GEARS, CAMSHAFT

Checking Oil Clearance of Camshaft Checking Camshaft Checking

Cam Checking Gear

Alignment

......................................................

Heights of Intake and Exhaust

Backlash

..........................................................

................................................

.........................................

LUBRICATION SYSTEM

.........................

........................

111 111 113 112

113 113 114 114 115 116

117 117 118 118

Testing Oil Pressure

Oil Pump (Rotor Type)

..............................................................

........................................................

84

119

119-120

PISTON, CONNECTING ROD

SECTION

VI

- CONTENTS (Continued)

Checking Inside Diameter of Piston Bosses

...........................................

Checking Clearance Between Piston Pin and Small End Bushing Checking Piston Ring Clearance Checking Checking Connecting

Side Clearance of Ring

Rod Checking Crankshaft Alignment Checking Checking Checking Checking End Checking Wear of

Oil Clearance Between Crankshaft Journal and Crankshaft Bearing 1 Oil Clearance Between Crankshaft Journal and Crankshaft Bearing 2 Oil Clearance Between Crank Pins and Crank Pin Bearings

Play of Crankshaft

Cylinder Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crankshaft and Bearing Reference

....................................................

in

Alignment

Groove

................................................

..........................................

....................................................

...................................................

..................................................

REPLACING VALVE GUIDES, BUSHINGS AND BEARINGS Replacing Valve Guides Replacing Rocker Arm Bushings Replacing Replacing

Idle Gear Bushings Small End Bushings

...........................................................

....................................................

......................................................

.....................................................

.........................

.............

.....................

..

121 121 122 122 123

123 124 124 125 125

126

127

128 128 129 129

Replacing Crankshaft Bearing 1

....................................................

130

85

ATTENTION: When reassembling, replace all the O-rings and gaskets with new ones.

CYLINDER HEAD

REMOVING HEAD COVER

1.

Remove the head cover nuts.

2.

Remove the head

cover.

NOTE FOR REASSEMBLING: Check

valve stem seizure, apply enough engine oil to the valve guide and valve stem.

REMOVING INJECTION PIPES

1.

Loosen the screws

2.

Detach the injection pipes in the order of

on

the pipe clamps.

1,2

to

see if the head cover gasket is not defective.

1.

Head Cover

and

3.

1,

2 and

3.

To

prevent

NOTE FOR REASSEMBLING: Send compressed air into the pipes to

reassemble the pipes in the reverse order. Tighten the retaining nuts to m,

11

to

18

ft

Ibs).

1.

Injection Pipe 1

blowout

2. Injection Pipe 2

3. Injection Pipe 3

4. Pipe Clamp

5. Retaining Nuts

15

dust. Then,

to

25

Nm

4

(1.5

to

2.5

kgf-

86

REMOVING NOZZLE HOLDER ASSEMBLIES

1.

Remove the pipe clips holding the fuel overflow pipes, and detach the pipes.

2.

Detach the nozzle holders using a 27mm (1-1/16") nozzle holder socket wrench, after loosening the rock nuts.

3.

Detach the copper gaskets on the seats on which the nozzles are to be installed.

NOTE FOR REASSEMBLING: Return the nozzle holders after confirming that there are no metallic particles or foreign matter on the surface on which the nozzles are to be installed. Tighten the nozzles to 29 to 49 Nm

1.

Nozzle

2.

Rock

Holder

Nut

(3.0

Socket

to

5.0

kgf-m, 22 to 36 ft-Ibs.).

Wrench

REMOVING AC DYNAMO AND

1.

Remove the AC dynamo.

2.

Detach the fan belt.

NOTE

letters on the belt can be read from your side), and there is no oil or grease on the belt. tension: The belt should deflect approx. 7 mm (0.28 in.) when the center of the belt is depressed with a finger pressure of

FOR REASSEMBLING: Check to see if the V-belt is placed in a correct position (where

58.8

1.

AC

Dynamo

2. Fan

Belt

FAN

to

68.6 N (6

BELT

to 7 kgf-m, 13.2 to

15.4

Ibs.)

Fan

belt

2

1

87

REMOVING ROCKER

1.

Remove the set nuts for the rocker

2.

Detach the whole rocker arm.

NOTE FOR REASSEMBLING: Always adjust the valve clearance. Before installing the rocker arm

bracket, check

to

mounted. Tighten the bolts to

ARM

arm

brackets.

see if there are any metallic particles

17

to

21

Nm

(1.7

to

2.1

1. Rocker Arm

on

kgf-m,

the surface

12

to

15

on

which the assembly

ft-Ibs.).

is

REMOVING PUSH-RODS

1.

Remove the push-rods.

NOTE FOR REASSEMBLING: Before inserting the push rods into the tappets, check

ends are shoulder of the tappet and

properly engaged with the grooves. If a push

be

damaged.

1.

Push-rod

rod

is

roughly inserted, it may hit the

to

see

if their

88

REMOVING CYLINDER HEADS

1.

2.

Remove Lift

the twelve cylinder head set bolts and two nuts.

up

the cylinder head

to

detach.

NOTE bolts and nuts may deform

IMPORTANT: confusing minutes. Tighten the cylinder head bolts and nuts

FOR

REASSEMBLING: Tighten the bolts and nuts after applying sufficient oil. Tighten the

in

diagonal sequence starting

in

the long run.

When overhauling the engine, replace the gasket

its

front and back. Retighten the cylinder head after running the engine for 30

from

the

1.

Gear Case Side

2.

Flywheel Side

center.

to

Tighten them uniformly, or the head

with

a new one

engine specifications.

Cylinder head tightening sequence

10 2

~oo

(1)

0 0 0 0

13 0 5 0 4 0

without

~oo

918

~Oo

7_--.

8

(2)

12

REMOVING CYLINDER HEAD GASKET

1.

Detach the cylinder head gasket, being careful not

NOTE on

FOR

REASSEMBLING: Before installing the gasket, check to see there

the cylinder head and the cylinder.

1.

Cylinder Head Gasket

to

scratch

it.

is

no

foreign matter

89

REMOVING O-RING

1.

Remove the O-ring from the periphery of the oil pipe

on

1. O-ring

2. Pipe Pin

the crankcase.

REMOVING

1.

Remove the six tappets from the crankcase.

NOTE FOR REASSEMBLING: Visually check the contact between tappets and cams for proper

rotation. around them.

TAPPETS

If a defect is found, replace tappets. Before installing the tappets, apply engine oil thinly

1. Tappets

90

REMOVING

1.

Remove the valve caps.

2.

Remove the valve spring collet, pushing the valve spring retainer

3.

Remove the valve spring retainer, valve spring and valve stem seal.

4.

Remove the

VALVES

valve.

by

valve spring replacer.

IMPORTANT:

DISASSEMBLING NOZZLE HOLDER

1.

Secure the retaining nut with a vise.

Don't

change

1.

Valve Spring Replacer

2. Valve Cap

3.

Valve Spring Collet

4.

Valve Spring Retainer

5.

Valve Spring

6.

Valve Stem Seal

7.

Valve

the

combination

of

valve and valve guide.

NOZZLE HOLDER

2.

Remove the nut, the

3.

Remove the nozzle holder body and take out parts inside

NOTE clean fuel. Install the push to slide easily and the injection performance will

78.4

FOR

REASSEMBLING: When disassembling and reassembling the nozzle piece, dip it

Nm

(6

to 8 kgf-m, to

1.

Retaining

2.

Nozzle Holder Body

3.

Nut

4.

Eye

5.

Plain Washer

6.

Adjusting Washer

7.

Nozzle Spring

8.

Push Rod

9.

Distance Piece

10.

Nozzle Piece

eye

Joint

joint and the plain washer.

rod,

noting its direction (upside down). Tighten the retaining nut to

57.8

ft-Ibs).

Nut

Do

not tighten it too much, or the needle valve will not

be

decreased.

2

;,

I

~Q

t·

"\

\ 4

3

1

t'~

......

.~\\

\ 7 8

6

\

5

in

58.8

/~

\

10

9

91

REMOVING INJECTION PUMP COVER

1.

Remove the injection pump

cover.

INJECTION PUMP

NOTE adhesive

REMOVING INJECTION PUMP

1.

2.

FOR

REASSEMBLING: Before installing the pump cover gasket, apply a non-drying

to

it.

Remove the injection pump mounting bolts and nuts. Detach the injection pump.

To

prevent the pump rack from being caught, detach the pump

along the removal groove.

3.

Align the control rack pin with the slot

4.

In

principle, the injection pump should not

NOTE

FOR

REASSEMBLING: Install the injection pump

on

the gear case and remove the injection pump.

be

disassembled.

by

aligning the control rack with the

indicated positon. Addition or reduction of one shim delays or advances the injection timing

0.0262 rad.

0

(1.5

).

Install the injection pump shims after applying thinly a non-drying adhesive.

1.

Injection Pump

2. Control Rack

3.

Removal Groove

by

I 92

GEAR CASE, TIMING GEAR, CAMSHAFT, OIL PUMP

DETACHING GOVERNOR SPRING

1.

Detach the governor springs 1 and 2 from governor fork lever

2.

NOTE spring or wire through the window of the injection pump, and spring will

FOR

RE,ASSEMBLING: Fix the governor spring to the speed control

be

lever, able to

and pull the

be

hooked

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

2. Gear Case

3.

Fork Lever 2

REMOVING SPEED CONTROL PLATE

the

Side

of

Fork Lever

on

(2)

1.

Remove the speed control plate and governor spring.

NOTE

FOR

REASSEMBLING:

Be

careful not to drop the governor spring

in

the gear

case.

93

DETACHING

1.

Remove the start spring from the gear case.

START

SPRING

1.

Detach Start Spring on the Side of Gear Case

2. Gear Case

How

~

to

,J

remove

start

spring

U U

REMOVING

1.

Flatten the crankshaft washer.

2.

Loosen and remove the crankshaft nut.

3.

Draw out the pulley with a puller.

FAN

DRIVE PULLEY

NOTE FOR REASSEMBLING: Bend the crankshaft washer against one side of the nut. Tighten

the nut to

kgf-m,

101.3

to

115.7

ft-Ibs.).

Do

not tighten the nut

137.3

to

156.9

Nm

(14.0

to

16.0

excessively; it may damage the oil slinger, causing oil leakage.

1.

Fan

Drive Pulley

94

REMOVING GEAR

1.

Remove the gear case cover.

2.

Remove the O-ring.

CASE

NOTE FOR REASSEMBLING: a thin film of engine case gasket,

REMOVING CRANKSHAFT OIL SLINGER

1.

Remove the crankshaft collar.

2.

Remove the O-ring.

apply a non-drying adhesive. Tighten the oil filter cartridge by hand.

to

the oil seal, and install it, noting the lip come off. Before installing the gear

Check to see if there are three O-rings inside the gear case. Apply

3.

Detach the crankshaft oil slinger.

1.

Crankshaft Oil

2. O-Ring

3.

Crankshaft Collar

Slinger

95

REMOVING IDLE GEAR

1.

Remove the external circlip.

2.

Detach the idle gear collar

3.

Detach the idle gear

4.

Detach the idle gear collar

NOTE FOR REASEMBLlNG: Check to see each gear is aligned with its aligning mark: .

1.

Idle

gear

and crank gear

Idle

gear

and and

camshaft injection

2.

3.

Idle

gear

2.

1.

gear

pump

gear

Tighten the idle gear shaft mounting bolt

00

REMOVING CAMSHAFT STOPPER

1.

Align the round hole

on

the cam gear with the camshaft stopper mounting bolt position.

(7T)

1.

2.

to

10

to

12

Idler

Gear

Alignment

Nm

Mark

(1.0

to

1.2

kgf8m,

7.2

to

8.7

----1

==-----2

ft-Ibs).

2

2.

Remove the camshaft stopper mounting bolt.

3.

Detach the camshaft stopper.

1.

Camshaft

Stopper

96

REMOVING GEAR AND CAMSHAFT

1.

Draw the camshaft and the cam

NOTE FOR REASSEMBLING: Apply a thin film of engine oil to the camshaft before installation.

gear.

1

1.

Camshaft Assembly

REMOVING FORK LEVER ASSEMBLY

1.

Remove the two fork lever holder mounting bolts.

2.

Detach the fork lever assembly.

NOTE FOR REASSEMBLING: Install the fork lever holder and crankcase after cleaning their

contact surfaces. space is allowed fixed to the fork

Install the fork lever so that it will not hit the governor sleeve, and so that equal

on

either side of the

lever shaft, and that it can turn smoothly

lever.

After installation, check to see that the fork lever

in

the holder.

1.

Fork Lever Assembly

(1)

is

97

Westerbeke M-50, M-40, M-30 Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual