Piston ring stuck I I Piston ring worn Lubricant rises through piston gap I 1 Excessive gap between cylinder liner and piston Too much oil Injection delayed r I Compression pressure insufficient r l Injection too early Injection mistimed J 1 I I Injection delayed Plunger does not return completely because Fuel pumps injecting capacity spring is stuck or broken varies Plunger worn Needle valve stuck I Nozzle does not inject fuel Nozzle spring broken 1 properly Too much carbon sticks to nozzle tip Injection pressure too low 1 Y Not enough air Excessive gap between piston and liner Piston ring stuck Piston ring worn Excessive gap between intakeexhaust valve and valve stem Valve stem seal broken Oil leaks from defective packings r Injection pump plunger leaks much fuel Fuel mixed with oil rf Fuel pump leaks much fuel 1 1 Head gasket packing faulty Water mixed with oil r 1 I I Crankcase cracked Gear oil mixed with oil Hydraulic pumps oil seal broken 157 c White or blue exhaust fumes I COLOR OF EXHAUST FUMES NOT NORMAL Black or dark gray exhaust fumes CONSUMPTION LUBRICANT INCREASING 156 I Fuel filter clogged I Fuel pipes broken or loose Air in pump Pump capacity noi constant Injection pump wrong fTappet roller and pin worn Delivery valve not completely oiltight H Fuel leaks from nozzle tip Injection nozzle faulty Fuel not spraying properly Governor spring deformed L Valve clearance incorrect Injection pump or nozzle not functioning normally Compression pressure is different among cylinders Governor sleeve not sliding properly Governor not functioning f Fork lever not functioning normally normally Start spring deformed Control rack not sliding properly LrIdling regulator maladjusted Idling maladjusted Accelerator rod maladjusted Main moving parts have almost seized up r Engine overheated Injection mistimed Governor not functioning normally Filter clogged Fuel supply insufficient 1 Fuel pipe broken or loose Injection pumps capacity not enough L Nozzle needle valve worn I Compression pressure not Air leaking I enough L Air cleaner clogged 155 AdobeUCS ENGINE DOES NOT TURN NORMALLY ENGINE OUTPUT INSUFFICIENT Revolution irregular Slow engine revolutions 154 Revolution is not smooth at high speeds Idling not smooth Crankshaft and camshaft have seized up Piston and cylinder liner have seized up Frictional resistance of moving parts is too much Bearings are oilstuck Lubrication system not working properly I Starter faulty Battery capacity is low or terminal loose r Fuel pipe broken rl Fuel supply to injection pump rr Air erlters fuel pipe through connection is insufficient 1 Fuel filter clogged Fuel pump faulty r Plunger has worn or seized up Injection pump does not send Delivery valve spring broken on fuel Delivery valve not cQmpletely oiltight Needle valve stuck i Fuel does not inject through Nozzle spring broken injection nozzle IInjection pressure maladjusted Injection pipe mounting nut loose rl I Injection mistimed I Injection timing maladjusted I I Contact between intakeexhaust valve and seat r not tight r Intakeexhaust valve spring broken Intakeexhaust valve stuck Gasket faulty I I Compressed air leaks Tightness torque of cylinder head not enough I I Piston riR stCk Piston ring worn Cylinder liner worn Tightness torque of injection nozzle and glow plug not enough y I Valve action timing improper I Valve clearance excessive I 153 Crankshaft does not turn Crankshaft turns 152 No or small fuel injection sounds Fuel injection sounds Battery not sufficiently charged r1 Faulty battery Terminal contact poor Poor grounding Over267running clutch slips Poor contact of contact plate Faulty starter Poor contact between brush and commutator Armature and field coil shorted Bearing worn Pinion and ring gear worn H Pinion and ring gear do not mesh Plunger and shaft distorted r1 Clutch slips I Overrunning clutch worn Main switch or starter switch faulty I Faulty magnet switch Pinion does not pop out by the I attractive force of magnet switch Screw spline rusted Battery not sufficiently charged r1 Faulty battery l Poor terminal contact I Grounded poorly r1 L Faulty magnet switch J Holding coil broken I I Battery not charged sufficiently Faulty battery Poor terminal contact Poorly grounded Incorrect wiring between battery and glow plug Glow plug indicator disconnected Incorrect wiring r Glow plug disconnected Main switch or starter switch faulty Shorted between glow plug indicator and glow plug Circuit shorted Glow plug indicator shorted Glow plug shorted Glow plug cable shorted 151 AdobeUCSr STARTER DOES NOT DRIVE ENGINE PROPERLY I GIOWPLUG INDICATOR meS NOT TURN RED PROPERt y Slow engine speed Starter runs but engine does not No meshing sound from pinion and ring gear Pinion shifts repeatedly r Does not turn red at all Turns red too quickly 150 225225 Faulty battery r Faulty regulator AC dynamos noload Conductivity between voltage is equal or superior regulator connector Faulty wiring between regulator and to the reference value AClead wires main sw AC dynamo sidecheck 2check 3Faulty wiring between dynamo and L not conductive regulator No reference value 1 Faulty dynamo 1 Fan belt slips 149 AdobeUCS1 Checking Bearing Reduction type1 Apply torque to the inner ring with your finger tips and check to see if it turns smoothly 2 Check to see if there are any strange noises when driven quickly 147 Checking and Adjusting Pinion Gap Magnet Switch Type1 Disconnect the connecting lead from C terminal 2 Energize the magnet switch and measure the gap between the pinion tip and the stop collar 3 To adjust the gap change the length of the magnet switch jOint to the specified one Adjustment of pinion gap laPinion gap Reference value 01 to 04 mm 00039 to 00157 in L Pinion juts out to this position IdTurning the joint alters its length Checking Gap between Shaft and Bush Magnet Switch Type1 Measure the inside diameters of the bearing bushings on the side of the drive and commutator 2 Measure the driveside and commutatorside shaft diameters and calculate the gap 3 If the gap exceeds the allowable limit use an undersize bush Model M30 Model M30 Drive shaft dia 125 mm 04921 in Reference value Commutator shaft dia 125 mm 04921 in Commutator side 006 mm 00024 in Drive bushing ID 1254 mm 04937 in Drive 004 mm 0Q16 in Commutator bushing ID 1256 mm 04945 in 146 Allowable limit 02 mm 00079 in Grounding of Brush Holder 1 Check the insulation of the positive brush holder 2 If the insulation is defective replace Reference value Checking Clutch 1 Check to see if the clutch gear is worn or damaged Should not be conducted 2 Check to see if the gear locks in the driving direction and rotates smoothly in reverse 145 Checking Brush Wear 1 Check to see if the brush has worn to more than 23 below the standard dimensions 2 If wear exceeds the allowable limit replace Reference value Allowable limit Longer than 127 mm Model M30 M40 M50 Checking Brush Spring Tension Length 19 mm 07480 in 19 mm 07480 in I I Width 12 mm 04724 in 25 mm 09843 in I I 1 1 I I I J l J Thickness 7mm 02756 in 8mm 03150 in 1 Measure the tension with a new brush in place 2 Replace if the tension is under the reference value Model M30 M40 M50 Reference value Spring tension Commutator diameter 118 N 327 mm 1200 g 12874 in 264lb 175 to 237 N 1785 to 2415 g 300 mm 394 to 553 Ib 17 IeBrush 11811 in laSpring hanger IbAttach the brush spring in this method 144 Field Coil Breakage 1 To check conduction place the tester probes onto the lead and brush 2 If either are not conducting replace I Reference value Should be conducted I Grounding of Field Coil 1 To check the conduction Place the tester probes onto the field coil and yoke 2 If either are conducting replace Reference value Should not be conducted 143 Checking Armature Checking Armature the mica STARTER Staining or Burning of Commutator 1 Check to see if the commutator surface is stained or burnt 2 If it is burnt grind off with finegrain sand paper Checking Commutator Wear 1 Check to see if the contact face of the brush is scored 2 If scored grind off with sand paper or on a lathe 3 If the commutator diameter must be ground to below the allowable limit replace it Commutator diameter Model Reference value Allowable limit M30 327 mm 325 mm 12874 in 12795 in M40 300 mm 290 mm M50 11811 in 11417 in 140 end frame TYPE STARTER Removing Motor 1 Disconnect the connecting lead 2 Remove the through bolts 3 Remove the motor unit Removing Brush Holder 1 Release the spring and draw the brush out from the holder 2 Remove the brush holder Remove Armature 1 Draw the armature out 138 Remove Yoke 1 Draw out the yoke from the drive end frame NOTE FOR REASSEMBLING Take care for yoke knock pin Removing Armature 1 Remove the set bolt from the drive lever 2 Draw out the armature from the drive end frame 3 Detach the drive lever IMPORTANT When reassembling be sure not to mistake the installing direction of the drive lever 137 Removing Armature Brake 1 Remove the end frame cap 2 Remove the washers 3 Remove the packing Removing End Frame 1 Remove the through bolts 2 Remove the end frame Removing Brush Holder 1 Draw out the brush from the holder while holding the spring up 2 Take off the brush holder NOTE FOR REASSEMBLING Be sure not to mistake the direction and position of the spring Do not contact the body with the positive brushs lead 136 Holding Coil Retention Test1 Apply 12 the rated voltage approx 6Vacross the S terminal and the body push the plunger in by hand and then release it 2 If the plunger stays attracted the holding coil is good if not it is defective Reference value The plunger remains attracted DISASSEMBLY AND REASSEMBLY OF MAGNET SWITCH TYPE STARTER Removing Magnet Switch 1 Remove the connecting lead 2 Remove the set screws 3 Detach the magnet switch by lifting it up while taking care that it does not contact the drive lever 135 Motor Test 1 Remove the connecting leads from the starters C terminal and connect them directly to the batterys positive terminal Then connect the batterys negative terminal to the starter body 2 If the starter runs normally the magnet switch is defective if not the motor is defective Electrical connections for motor test Magnet Switch PullIn Coil Attraction TestbC terminal o 1 Apply 12 the rated voltage approx 6Vacross the S terminal and C terminal 2 If the plunger is attracted strongly the pullin coil is good if not it is defective Reference value The plunger should be attracted strongly 134 T I Checking Battery Charging Current 1 After starting the engine disconnect lead of the battery and connect an amperemeter 2 Measure charging current with full electric load with lights etcNOTES ON CHECKING Connect the amperemeter only after starting the engine In the event of a lower electric load or fully charged battery the stipulated value may not be given Reference value 14 to 15A with dynamo turning at 5200 rpm Checking AC Dynamos NoLoad Voltage 1 Disconnect lead wire from the dynamo 1 Battery Lead 2 Start the engine and measure the voltage generated by the single dynamo Reference value AC 20V or more with the dynamo turning at 5200 rpm 132 Idle gear and bushing as assembled ATool for replacing idle gear bushing 160 6 3010 10 1401551 O39IO39 REPLACING SMALL END BUSHINGS 1 Prepare the necessary tool as shown in Fig A2 Press out the used bushing and press a new bushing in taking due care to see that the con255necting rod hole matches the bushing hole Connecting rod and bushing as assembled 1331524 0 23 D39 D9100 394 e cofD LJ iCJLlCO3 1QOasQOB PkJ NO 23 1 Material S43C Heat treatment Quenching tempering 2 Connecting rod hole 3 Bushing hole 129 I the When the OIL CLEARANCE BETWEEN CRANK PINS AND CRANK PIN BEARINGS 1 Paste a press gauge onto the crank pin bearing with grease 2 Tighten the connecting rod onto the crank pin to the specified torque 265 to 304 Nm 27 to 31 kgfOm 1952 to 2242 ftIbs3 Remove the connecting rod gently and measure the depression of the press gauge with a sheet of gauge paper4 If the measurement exceeds the allowable limit replace the crankpin bearing NOTE FOR MEASURING Fasten the crankshaft so that it does not turn Do not insert the press gauge into the crank pin hole Crankpin bearing measuring pOints are shown below See engine specifications Crank pin measuring points CHECKING END PLAY OF CRANKSHAFT 1 Move the crankshaft to the crank gear side 2 Set a dial gauge to the crankshaft 3 Push the crankshaft toward the flywheel and measure the clearance 4 If the measurement exceeds the allowable limit replace the side bearing IMPORTANT When replacing the side bearing face the oil grooves of side bearing outward See engine specifications 125 of the a sheet CHECKING CONNECTING ROD ALIGNMENT 1 Remove the connecting rod crank pin bearing and tighten the rod bolts 2 Set the connecting rod to a connecting rod aligner 3 Place the gauge on the piston pin Measure the gap between the pin of the gauge and the flat surface of the aligner 4 If the measurement exceeds the allowable limit replace IMPORTANT Because the 10 of the connecting rod small end bushing is used as the basis for this check check it is not worn beforehand See engine specifications CRANKSHAFT CHECKING CRANKSHAFT ALIGNMENT 1 Place V blocks on the surface plate and support the journals at both ends of the crankshaft on the V blocks 2 Set a dial gauge to the central journal 3 Read the dial gauge while rotating the crankshaft slowly Crankshaft flexure is half of the reading 4 If the reading exceeds the allowable limit replace See engine specifications 123 CHECKING PISTON RING CLEARANCE 1 Put the piston ring in the cylinder 2 Turn the piston upside down and push the ring into the cylinder with the piston head 3 Insert a feeler gauge into the piston ring gap 4 If the clearance exceeds the allowable limit replace IMPORTANT Measure the piston ring gap at the point of the minimum inside diameter of the cylinder liner See engine specifications CHECKING SIDE CLEARANCE OF RING IN GROOVE 1 Remove the piston ring from the piston 2 Place the ring in its groove as it shown at left and measure the clearance 3 If the clearance is not within the reference valve replace the ring NOTE As the top ring is a keystone type it cannot be measured by this method See engine specifications 122 PISTON CONNECTING ROD CHECKING INSIDE DIAMETER OF PISTON BOSSES 1 Measure the piston bosses with a cylinder gauge Set the cylinder gauges reference measurement to 23 mm and carry out zero pOint adjustment with an outside micrometer 2 If the measurement exceeds the allowable limit replace See engine specifications CHECKING CLEARANCE BETWEEN PISTON PIN AND SMALL END BUSHING 1 Measure the piston pin with an outside micrometer 2 Measure the ID of connecting rod small end bushing with an inside micrometer Calculate the clearance 3 If the clearance exceeds the allowable limit replace See engine specifications 121 Checking Radial Clearance Between Outer Rotor and Pump Body 1 Insert a feeling gauge into the gap between the oil pump body and the outer rotor and measure the clearance 2 If the measurement exceeds the allowable limit replace See engine specifications Checking end Clearance Between Rotor and Cover 1 Paste a press gauge to the surface of the gear with grease 2 Attach the cover 3 Gently remove the cover Measure the clearance by plaCing the gauge paperon the press gauge where it is crushed 4 If the measurement is not within the reference value replace Reference value 120 008 to 013 mm 00031 to 00051 in WBRICATION SYSTEM TESTING OIL PRESSURE 1 Remove the oil switch and set a pressure gauge 2 Start the engine Measure the oil pressure both at idling and at the rated speed 3 If the measurement is not within the reference value check the oil pump oilways oil clearances and pressure regulating valve NOTE FOR MEASURING Supply the specified amount of recommended oil The oil filter must not be clogged or broken See engine specifications OIL PUMP ROTOR TYPEChecking Rotor Lobe Clearance 1 Insert a feeler gauge into the gap between the inner and outer rotors and measure the clearance 2 If the clearance exceeds the allowable limit replace See engine specifications 119 CHECKING CAM HEIGHTS OF INTAKE AND EXHAUST 1 Measure the height of the cam at its highest point with a micrometer 2 If the measurement exceeds the allowable limit replace the camshaft See engine specifications 1 Cam Height CHECKING GEAR BACKLASH 1 Install a levertype indicator between the gear teeth 2 Clamp one gear rotate the other and measure the backlash 3 If the backlash exceeds the allowable limit replace See engine specifications 118 Cam height measuring points TIMING GEARS CAMSHAFT CHECKING OIL CLEARANCE OF CAMSHAFT 1 Measure the camshaft bearing in the crankcase with an inside micrometer 2 Measure the camshaft journal with an outside micrometer Calculate the clearance 3 If the clearance exceeds the allowable limit replace the camshaft See engine specifications CHECKING CAMSHAFT ALIGNMENT 1 Gently put the camshaft on V blocks 2 Set a dial gauge to the journal 3 While slowly rotating the camshaft read the dial gauge The camshaft flexure is half of the reading 4 If the measurement exceeds the allowable limit replace the camshaft I Allowable limit 117 008 mm 00031 in CHOKING AND ADJUSTING INJECTION TIMING 1 Disconnect the injection pipe from the fuel injection pump 2 Set the acceleration lever for maximum fuel discharge 3 Turn the flywheel until fuel jets out from the delivery valve holder of the fuel injection pump 4 Continue to turn the flywheel slowly and stop it as soon as the fuel level at the tip of the valve holder begins to increase 5 Check to see if the F1 mark on the flywheel is aligned with the dot mark 6 If the timing is out of adjustment readjust with shims IMPORTANT Adding or removing one shim 015 mm 00059 invaries the crank angle by approx 15260 After adjustment apply a thin film of nonclrying adhesive to both sides of the shims See engine specifications Adjustment of injection timing 1 F1 Mark 2 Mark 3 Injection Timing Adjusting Shim 116 267 CHECKING FUEL TIGHTNESS OF DELIVERY VALVE OF FUEL INJECTION PUMP 1 Set a pressure gauge to the pump 2 Rotate the flywheel to increase the pressure to 98 MPa 100 kgfcm2 1422 psi3 Align the plunger with the bottom dead center 4 Measure the time needed to decrease the initial pressure 5 If the measurement is less than allowable limit replace the delivery valve See engine specifications Reference value 10 seconds or more Allowable limit 5 seconds 1 Connector 2 Pressure Sensor Pressure gauge construction 147 MPa 150 kgfcm2 2133 psiand 686 MPa 700 kgfcm2 9954 psi3 Nondrying Adhesive 4 Weld Entire Circumference 5 Copper Packing 6 S45C Steel Tube 7 S45C Hexagonal Steel Tube 8 Injection Pipe 115 Unit mm inCHECKING SHAPE OF FUMES ACROSS NOZZLE TIP 1 Set the nozzle to a nozzle tester and shoot it in the air Check the shape of the fumes 2 If the shape is defective replace the nozzle piece 1 Good 2 Bad 1CHECKING FUEL TIGHTNESS OF FUEL INJECTION PUMP PLUNGER 1 Set a pressure gauge to the pump 2 Rotate the flywheel to increase the pressure to 588 MPa 600 kgfcm2 8532 psi3 Align the plunger with the top dead center 4 Measure the time needed to decrease the initial pressure 5 If the measurement is less than allowable limit replace the pump element In this case ask a repair shop to do the replacement Be sure to give them adjustment reference data on the fuel injection pump Shown belowSee engine specifications Reference valve 8 seconds or more Allowable limit 4 seconds Adjustment of Injection Control rack Speed Amount of injection Allowance mm3position 1rpmmm3st39 1400 225 to 235 26115 or less 8 1400 112 to 262 26138 or less 7 1400 60 to 210 26138 or less o to 35 1550 021 Travel distance from noninjecting point of control rack 2 Zero opening pressure and no injection 3 Allowance on the basis of standard cylinder Profile of fuel pump cam 1 Base Circle 114 FUEL SYSTEM TESTING OPENING PRESSURE OF NOZZLE 1 Move the tester hanctle up and down to prime fuel Measure the pressure of fuel jetting from the nozzle tip 2 If the measurement is not within the reference value adjust with the adjustment washer inside the nozzle holder Each extra 01 mm 00039 inof washer thickness causes an approximate 9806 kPa 10 kgfcm2 1422 psiincrease in fuel injection pressure DANGER Be careful not to come into direct contact with the injected fumes The fumes destroy any cells they may touch They may also cause blood poisoning See engine specifications CHECKING FUEL TIGHTNESS OF NOZZLE VALVE SEAT 1 Apply a pressure 2 After keeping the nozzle under this pressure for 10 seconds check to see if fuel leaks from the nozzle valve seat 3 If fuel should leak replace the nozzle piece See engine specifications 113 the top CHECKING OIL CLEARANCE BETWEEN ROCKER ARM SHAFT AND BUSHING 1 Measure the rocker arm 10 2 Measure the rocker arm 00 3 If the clearance exceeds the allowable limit replace See engine specifications CHECKING TOP CLEARANCE 1 Remove the nozzle holder 2 Lower the piston in the cylinder to be measured 3 Insert a highquality fuse from the nozzle holder hole Be careful not to let the fuse touch the valve surface 4 Rotate the engine with your hand 5 Take the fuse out carefully 6 Measure the place where the fuse was crushed with vernier calipers 7 If the clearance is not within the reference value adjust by inserting a shim between the cylinder head and the gasket Reference value 06 to 08 mm 00236 to 000315 in Thickness of gasket 105 to 115 mm when tightened 00413 to 00453 in Thickness of gasket shim 020 mm 00079 in 111 CHECKING VALVE SPRING SQUARENESS 1 Put the spring on a surface plate place a square on the side of the spring and check to see if the entire side is in contact with the square 2 Rotate the spring and measure the maximum B See illustration below3 If the measurement exceeds the allowable limit replace The flat surface at the end of the spring coil must exceed the full circumference by twothirds Check the entire surface of the spring for scratches Allowable limit CHECKING VALVE SPRING TENSION 13 mm 0051 in How to measure squarenass of valve spring 1 Place the spring on a tester and compress it to the same degree that it is actually compressed in the engine 31 mm 12 in2 Read the compression load on the gauge 3 If the measurement exceeds the allowable limit replace See engine specifications 110 CHECKING GUIDE CLEARANCE 1 Remove carbon from the valve guide 2 After making sure that the valve stem is straight insert the valve into the valve guide 3 Measure the stem guide clearance with a dial gauge 4 If the measurement exceeds the allowable limit replace the stem guide and the valve IMPORTANT When changing the valve guide be sure to ream as the figure indicates after inserting the valve guide See engine specifications Finishing size of inlet valve guide 63S VVV Finishing size of exhaust valve guide CHECKING VALVE SPRING FREE LENGTH 1 Measure the spring with a set of vernier calipers 2 If the measurement exceeds the allowable limit replace See engine specifications 109 REPAIRING THE VALVE SEAT 1 Clean the valve seat surface 2 Use a 45260 cutter suitable for the valve guide and the valve seat 3 Grind the upper surface of valve seat with 15260 cutter so that the valve seat fits to the valve center so as to ensure a b as shown in the figureNOTE After correcting the valve seat check for valve recessing B 15260 cutter A 45260 cutter 1Valve 2Corrected surface of valve seat CHECKING VALVE RECESSING 1 Clean the face of the valve 2 Measure the recessing with a depth gauge 3 See engine specifications 108 How to repair the valve seat B 2How to check cylinder head surface CHECKING FLAW OF CYLINDER HEAD SURFACE 1 Clean the surface of the cylinder head 2 Spray the cylinder head surfacewith the red permeative liquid 3 Wash away the red permeative liquid on the cylinder head surface with the detergent 4 Spray the cylinder head surface with the developer If flawed it can be identified as red marks Reference Should be no flaw AA Air spray red check 1 Detergent 2 Red Permeative Liquid 3 White Developer 2107 REMOVING WATER PUMP 1 Remove the water pump from gear case cover 2 Remove the fan and fan pulley IMPORTANT If changing the water pump change the whole pump If disassembling the water pump check to see the clearance between the water pump impeller and body Water pump assembly 1 Water Pump Impeller 2 Seal Set 3 Water Pump Body 4 Bearing CHECKING FLATNESS OF CYLINDER HEAD SURFACE See illustration on page 1071 Clean the surface of the cylinder head 2 Place a straight edge on each of the cylinder headss four sides and two diagonally as shown at the left to check the straightness of the surface 3 Insert a feeler gauge between the straight edge and the cylinder head surface 4 The maximum thickness that can be inserted is the amount of flatness 5 If the measurement exceeds the allowable limit correct with a surface grinder IMPORTANT Do not place the straight edge on the combustion chamber Allowable limit 005 mm 0002 inper 100 mm 4 inof cylinder head surface length 106 Dry Liner u R 2 u R the bearing the bearing the crankshaft the crankshaft REMOVING FLYWHEEL 1 Flatter the flywheel washers 2 Remove the flywheel bolts except for two which must be loosened and left as they are 3 Set a flywheel puller and remove the flywheel NOTE FOR REASSEMBLING Apply a thin film of grease to the bearing and oil seal at the back of the crankshaft Check the ring gear for any uneven wear lack or crack of teeth Check to see that there are no metal particles left on the flywheel mounting surface To ease alignment of the crankshaft and the flywheel bring the crank of one of the cylinders to TC top dead centerMake sure of the flywheel TC align it with the punch mark of the rear end plate and set the flywheel Tighten the flywheel bolts to 54 to 59 Nm 55 to 60 kgfOm 40 to 43 ftIbsin diagonal order Bend the tangs of the flywheel washer against the bolts 1 Flywheel Puller 2 Crankshaft REMOVING BEARING CASE COVER 1 Remove the bearings case cover mounting bolts First unscrew the eight bolts inside and then work on the nine outside 2 Screw the two bolts removed above into the two right and left holes for the bearing case cover and pull off the cover by jacking it up NOTE FOR REASSEMBLING When installing the main bearing case cover check to see that there are no scratches on the oil seal lip Then apply a thin film of engine oil and install Tighten the mounting bolts in diagonal order to 10 to 12 Nm 10 to 12 kgfOm 72 to 87 ftIbs1 Lift Bolt 2 Bearing Case Cover 102 the top PISTON CRANKSHAFT REMOVING OIL PAN 1 Lay the engine on the engine cradle on its side 2 Remove the eighteen oil pan mounting bolts 3 Detach the oil pan by lightly tapping the grove of the pan with a wooden hammer NOTE FOR REASSEMBLING Wipe off oil on the oil pan mounting surface apply a nondrying adhesive and install the oil pan To avoid uneven tightening tighten mounting bolts in diagonal order from the center Check to see that the drain plug is tight t 1 Oil Pan REMOVING OIL FILTER 1 1 Remove the mounting bolt of oil filter 1 2 Detach oil filter 1 being careful of the Oring NOTE FOR cleaning the oil filter check to see that the filter mesh is clean and install it Visually check the Oring apply engine oil and install it After checking to see that the Oring is securely installed attach the oil filter Jl 1 Oil Filter 1 100 REMOVING OIL PUMP 1 Remove the four pump mounting bolts Detach the oil pump NOTE FOR REASSEMBLING Tighten the bolts 10 to 12 Nm 10 to 12 kgfm 72 to 87 ftIbs1 Oil Pump Assembly REMOVING CRANK GEAR 1 Set a special puller on the crank gear 2 Screw in the center bolt of the puller and draw out the crank gear NOTE FOR REASSEMBLING Check to see that the key is on the crankshaft Heat the crank gear to about 990C 1200Fand fit on the crankshaft If there is fear of the shaft being damaged heat the gear more and fit 1 13T Gear Crank Gear99 REMOVING FUEL CAMSHAFT 1 Remove the fuel camshaft stopper 2 Draw out the fuel camshaft and the injection pump gear NOTE FOR REASSEMBLING Apply a thin film of engine oil to each part and reassemble so that the drive groove at the end of the camshaft engages with the drive shaft of the hydraulic gear pump The balls to be contained in the governor ball case are thirty 397 mm 01563 indiameter ones and eight 13 46 mm 05300 indiameter ones 1 Fuel Camshaft Assembly 2 Fuel Camshaft Stopper REMOVING OIL PUMP DRIVE GEAR 1 Straighten the claw of the claw washer of the oil pan and remove the nut NOTE FOR REASSEMBLING Check to see if there is a feather key Be sure to bend the claw of the claw washer 1 Crank Gear 2 Oil Pump Drive Gear 98 REMOVING GEAR AND CAMSHAFT 1 Draw the camshaft and the cam gear NOTE FOR REASSEMBLING Apply a thin film of engine oil to the camshaft before installation 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 Install the fork lever so that it will not hit the governor sleeve and so that equal space is allowed on either side of the lever After installation check to see that the fork lever 1is fixed to the fork lever shaft and that it can turn smoothly in the holder 1 Fork Lever Assembly 97 REMOVING IDLE GEAR 1 Remove the external circlip 2 Detach the idle gear collar 2 3 Detach the idle gear 4 Detach the idle gear collar 1 NOTE FOR REASEMBLlNG Check to see each gear is aligned with its aligning mark 1 Idle gear and crank gear 2 Idle gear and camshaft gear 3 Idle gear and injection pump gear Tighten the idle gear shaft mounting bolt 7Tto 10 to 12 Nm 10 to 12 kgf8m 72 to 87 ftIbs2 1 00 2 1 Idler Gear 2 Alignment Mark REMOVING CAMSHAFT STOPPER 1 Align the round hole on the cam gear with the camshaft stopper mounting bolt position 2 Remove the camshaft stopper mounting bolt 3 Detach the camshaft stopper 1 Camshaft Stopper 96 noting the DETACHING START SPRING 1 Remove the start spring from the gear case How to remove start spring J U U 1 Detach Start Spring on the Side of Gear Case 2 Gear Case REMOVING FAN DRIVE PULLEY 1 Flatten the crankshaft washer 2 Loosen and remove the crankshaft nut 3 Draw out the pulley with a puller NOTE FOR REASSEMBLING Bend the crankshaft washer against one side of the nut Tighten the nut to 1373 to 1569 Nm 140 to 160 kgfm 1013 to 1157 ftIbsDo not tighten the nut excessively it may damage the oil slinger causing oil leakage 1 Fan Drive Pulley 94 AdobeUCSGEAR CASE TIMING GEAR CAMSHAFT OIL PUMP DETACHING GOVERNOR SPRING 1 Detach the governor springs 1 and 2 from governor fork lever 2 NOTE FOR REASSEMBLING Fix the governor spring to the speed control lever and pull the spring or wire through the window of the injection pump and spring will be able to be hooked on the governor fork with ease Bend the end of the governor spring to prevent it from falling off How to remove governor spring 1 Detach Governor Spring on the Side of Fork Lever 2 Gear Case 3 Fork Lever 2 REMOVING SPEED CONTROL PLATE 1 Remove the speed control plate and governor spring NOTE FOR REASSEMBLING Be careful not to drop the governor spring in the gear case 93 PUMP REMOVING INJECTION PUMP COVER 1 Remove the injection pump cover NOTE FOR REASSEMBLING Before installing the pump cover gasket apply a nondrying adhesive to it REMOVING INJECTION PUMP 1 Remove the injection pump mounting bolts and nuts 2 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 on the gear case and remove the injection pump 4 In principle the injection pump should not be disassembled NOTE FOR REASSEMBLING Install the injection pump by aligning the control rack with the indicated positon Addition or reduction of one shim delays or advances the injection timing by 00262 rad 150Install the injection pump shims after applying thinly a nondrying adhesive 1 Injection Pump 2 Control Rack 3 Removal Groove I 92 4 7 8 ORING 1 Remove the Oring from the periphery of the oil pipe on the crankcase 1 Oring 2 Pipe Pin REMOVING TAPPETS 1 Remove the six tappets from the crankcase NOTE FOR REASSEMBLING Visually check the contact between tappets and cams for proper rotation If a defect is found replace tappets Before installing the tappets apply engine oil thinly around them 1 Tappets 90 REMOVING CYLINDER HEADS 1 Remove the twelve cylinder head set bolts and two nuts 2 Lift up the cylinder head to detach NOTE FOR REASSEMBLING Tighten the bolts and nuts after applying sufficient oil Tighten the bolts and nuts in diagonal sequence starting from the center Tighten them uniformly or the head may deform in the long run IMPORTANT When overhauling the engine replace the gasket with a new one without confusing its front and back Retighten the cylinder head after running the engine for 30 minutes Tighten the cylinder head bolts and nuts to engine specifications REMOVING CYLINDER HEAD GASKET Cylinder head tightening sequence 10 2 7 8 10 0 0 0 21 Gear Case Side 2 Flywheel Side 13 0 5 0 4 0 12 918 1 Detach the cylinder head gasket being careful not to scratch it NOTE FOR REASSEMBLING Before installing the gasket check to see there is no foreign matter on the cylinder head and the cylinder 1 Cylinder Head Gasket 89 ROCKER ARM 1 Remove the set nuts for the rocker arm brackets 2 Detach the whole rocker arm NOTE FOR REASSEMBLING Always adjust the valve clearance Before installing the rocker arm bracket check to see if there are any metallic particles on the surface on which the assembly is mounted Tighten the bolts to 17 to 21 Nm 17 to 21 kgfm 12 to 15 ftIbs1 Rocker Arm REMOVING PUSHRODS 1 Remove the pushrods NOTE FOR REASSEMBLING Before inserting the push rods into the tappets check to see if their ends are properly engaged with the grooves If a push rod is roughly inserted it may hit the shoulder of the tappet and be damaged 1 Pushrod 88 inwhen ATTENTION When reassembling replace all the Orings 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 to see if the head cover gasket is not defective To prevent valve stem seizure apply enough engine oil to the valve guide and valve stem 1 Head Cover REMOVING INJECTION PIPES 12 and 3 1 Loosen the screws on the pipe clamps 2 Detach the injection pipes in the order of 1 2 and 3 NOTE FOR REASSEMBLING Send compressed air into the pipes to blowout dust Then reassemble the pipes in the reverse order Tighten the retaining nuts to 15 to 25 Nm 15 to 25 kgf255m 11 to 18 ft Ibs4 1 Injection Pipe 1 2 Injection Pipe 2 3 Injection Pipe 3 4 Pipe Clamp 5 Retaining Nuts 86 Checking Connecting SECTION VI CONTENTS AND CRANKSHAFT Bearing Case Cover 102 Removing Bearing Case Bolt 2 103 Removing Crankshaft 103 Removing Main Bearing Case 104 Removing Cylinder Liner 104 THERMOSTAT WATER PUMP Removing Thermostat 105 Removing Water Pump 106 CYLINDER HEAD AND VALVES Checking Flatness of Cylinder Head Surface 106107 Checking Flaw of Cylinder Head Surface 107 Reparing Valve Seat 108 Checking Valve Recessing 108 Checking Guide Clearance 109 Checking Valve Spring Free Length 109 Checking Valve Spring Squareness 110 Checking Valve Spring Tension 110 Checking Oil Clearance Between Rocker Arm Shaft and Bushing 111 Checking Top Clearance 111 Adjusting Valve Clearance 113 Adjusting Compression Release 112 FUEL SYSTEM Testing Opening Pressure of Nozzle 113 Checking Fuel Tightness of Nozzle Valve Seat 113 Checking Shape of Fumes Across Nozzle Tip 114 Checking Fuel Tightness of Fuel Injection Pump Plunger 114 Checking Fuel Tightness of Delivery Valve of Fuel Injection Pump 115 Choking and Adjusting Injection Timing 116 TIMING GEARS CAMSHAFT Checking Oil Clearance of Camshaft 117 Checking Camshaft Alignment 117 Checking Cam Heights of Intake and Exhaust 118 Checking Gear Backlash 118 LUBRICATION SYSTEM Testing Oil Pressure 119 Oil Pump Rotor Type 119120 84 SECTION VI DISASSEMBLY AND REASSEMBLY CYLINDER Removing Head Cover 86 Removing Injection Pipes 1 2 and 3 86 Removing Nozzle Holder Assemblies 87 Removing AC Dynamo and Fan Belt 87 Removing Rocker Arm 88 Removing Push Rods 88 Removing Cylinder Heads 89 Removing Cylinder Head Gasket 89 Removing Oring 90 Removing Tappets 90 Removing Valves 91 NOZZLE HOLDER Disassembling Nozzle Holder 91 INJECTION PUMP Removing Injection Pump Cover 92 Removing Injection Pump 92 GEAR CASE TIMING GEAR CAMSHAFT OIL PUMP Detaching Governor Spring 93 Removing Speed Control Plate 93 Detaching Start Spring 94 Removing Fan Drive Pulley 94 Removing Gear Case 95 Removing Crankshaft Oil Slinger 95 Removing Idle Gear 96 Camshaft Stopper 96 Removing Gear and Camshaft 97 Removing Fork Lever Assembly 97 Removing Fuel Camshaft 98 Removing Oil Pump Drive Gear 98 Removing Oil Pump 99 Removing Crank Gear 99 PISTON AND CRANKSHAFT Removing Oil Pan 100 Removing Oil Filter 1 100 Removing Connecting Rod Cap 101 Removing Pistons 101 Removing Flywheel 102 83 AdobeUCSof the AdobeUCS12 Install Brush Assembly Insert brush holder into grooves in hub of rear housing Place D strap or male terminal where applicableon stud and secure brush holder with locknuts two placesSecure other end of D strap Install Rear Cover Be sure felt gasket is in place see illustration belowPosition rear cover on rear housing and secure with two screws INSTALLING REAR COVER ALTERNATOR PERFORMANCE TESTS FELT GASKET The following tests will determine the current producing capability of the repaired alternator Mount the alternator in a test fixture capable of providing 5000 alternator RPM Select required battery voltage and circuit polarity A For remote regulator model connect fixture circuit leads and instruments to the alternator terminals as shown in Diagram A on page 100 Place field rheostat in maximum resistance position Turn drive motor on adjust to obtain 5000 alternator RPM Slowly reduce field rheostat resistance alternator should develop a charge Continue to reduce resistance until alternator reaches rated current output in amperes CAUTION Limit output voltage to 15V maximum DO NOT operate the alternator for more than a few minutes in the manner due to the lack of voltage control If the alternator will deliver its rated output terminate the test B For integral regulator model connect fixture leads and instruments to alternator terminals as shown in Diagram B on page 100 The Carbon pile or resistive load bank and ammeter must be capable of handling the alternator rated output alternaotr RPM CAUTION Make sure connections are well secured and tight to avoid possible damage to instrument alternator or wiring due to short circuits Starting with carbon pile off slowly increase load while observing ammeter and maintaining 5000 RPM Increase load until a minimum output voltage of approximately 137 volts is obtained Record the output current at this point and refer to the chart for minimum acceptable ratings 79 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 FRONT HOUSING ASSEMBLING FRONT HOUSING TO ROTOR Assembly Spacer Fan and Pulley Place pulley spacer over shaft Install Woodruff Key Install fan Install pulley lock washer and nut Mount pulley as shown in left hand illustration on page 92 Tighten to 35 to 50 foot pounds 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 exten255ding through openings at top of rear housing Install through bolts and tighten evenly to between 50 to 60 inch pounds Spin rotor by hand to test freedom of bearings NOTE New front housings contain thrubolt holes that are not tapped Therefore a socket wrench rather than a nut driver will be required to supply sufficient torque to drive the thread forming thrubolts 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 area on rear housing Install assembly to rear housing four screwsPlace strap AC tapin position and connect stator leads three screwsInstall capacitor where Integral Regulator Install brush mounting screws twothrough openings in regulator body Secure regulator to rear housing two screws 78 Slip Ring Assembly Guide rotor leads through one of the oval passages in the slip ring assembly Be sure oval passages is in line with groove in rotor shaft Place rotor on a press as shown in illustration below Choose a driver sleeve with a diameter that clears leads Press slip ring assembly on shaft Solder rotor leads to leads on slip ring Trim excess slip ring leads extending above solder connections Install Front Bearing SLIP RING PRESS DRIVER SLEEVE INSTALLING SLIP RING ASSEMBLY Place front bearing and housing in an arbor press as in illustration below Select a drive tool to contact the outer race only and press bearing into housing bore Bearing replacement is recommended whenever bearing is removed during alternator repair procedures of if bearing is rough dry or noisy Install three bearing retainer screws Torque to 2530 pounds PRESS INSTALLING FRONT BEARING 77 DRIVER TOOL CONTACTS OUTER BEARING RACE ONLY FRONT BEARING FRONT HOUSING REASSEMBLY General DRESS ROTOR LEADS AWAY FROM PULLER REMOVING REAR BEARING The general reassembly instructions are reverse order to the procedures given for disassembly Therefore only information pertaining to special reassembly requirements will be covered in this section Install Rear Bearing Place rotor on a press as shown in illustration below Choose a driver sleeve that exerts pressure on inner race only and press bearing on rotor shaft until it contact shoulder New replacement bearings should be used whenever bearing is removed during repair procedures or when bearing is rough dry or noisy BLOCK REAR BEARING PRESS DRIVER SLEEVE INSTALLING REAR BEARING 76 AdobeUCSthe ends condition AdobeUCSRemove 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 See illustrations below 3BEARING RETAINIER SCREW REMOVING RETAINER SCREWS Inspect Front Housing BEARING INNER RACE PRESSING OUT BEARING 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 INSPECTION AND ELECTRICAL TESTING Check the rotor assembly for the following electrical properties See illustration on page 89 A Current Draw or Resistance of the Winding CAUTION Turn off DC power source before removing test leads to avoid avc damage to slip ring surfaces 1 CURRENT DRAW IN AMPERES AT 70260 TO 80260F 12 VOLT MODELS RATED AT 51 AMPERES CORRECT CURRENT DRAW 150 V 32 to 36 AMPERES 2 RESISTANCE OF WINDING IN OHMS AT 70260 TO 80260 F 12 VOLT MODELS RATED AT 51 AMPERES CORRECT WINDING RESISTANCE 41 to 47 OHM 73 Remove Pulley Fan and Spacer The pulley is a slipfit on the rotor shaft positioned with a Woodruff Key Remove the nut and lockwasher from the shaft using an impact wrench or other suitable tool After nut and lockwasher are removed the alternator can be separated from the pulley The fan will slide over the key The key may be removed with diagonal pliers or with a screwdriver Inspect the fan for cracked or broken fins note the condition of the mounting hole If worn from running loose replace the fan to insure balance Inspect pulley for possible faults as listed in illustration below PULLEY REMOVAL Separate Rotor from Front Housing CHECK FOR WORN DRIVE SURFACES CHECK FOR POLISHED SURFACE HERE NOTE CONDITION OF 1 KEY GROOVE ICHECK BORE FOR WEAR PULLEY INSPECTION POINTS Position front housing on support blocks placed on an arbor press Push rotor assembly from housing See illustration below IPRESS FRONT HOUSING SEPARATING ROTOR FROM FRONT HOUSING 72 Separate StatorRear Housing Assy from Front Housing Remove four thrubolts See illustration below Carefully insert two screwdriver blades in opposite openings between the stator and front housing as shown in illustration below Pry units apart CAUTION Do not insert screwdriver blades deeper than 116 to avoid damaging stator winding THRUBOLT REMOVAL Inspect Rear Housing 4THROUGH BOLT BLADE SCREWDRIVERS AT OPPOSITE OPENINGS CAUTION DO NOT INSERT BLADE OF SCREWDRIVER MORE THAN 116 STATORREAR HOUSING SEPARATION Inspect the rear housing for a cracked or broken casting stripped threads or evidence of severe wear in the bearing bore due to a worn rear bearing If casting is to be reused clean in solvent dry with compressed air and install a new rear bearing retainer if retainer is damaged Test Stator The stator assembly consists of three individual windings terminated in the delta type connections Using an ohmmeter or a test lamp check for winding continuity between terminals A Band C There should be no continuity from any terminal to point D stators showing any signs of winding discoloration should be discarded See illustration below o STATOR WINDING TESTS 71 Test Diode Trio Assembly Using a commercial diode tester or 12 volt DC test lamp check for continuity from each terminal separately to the 0 stud continuity should be observed in one direction polarityonly and all diodes should check alike If any diode is defective replace the entire diode trio assembly See illustration below COMMERCIAL DlOOE TESTER STUD IND LIGHT DIODETRIO Test Diode Rectifier Bridge Assembly Using a commercial diode tested check for continuity Check betweenn pOint A and each of three terminals C for negative diodes Continuity should be observed in one direction polarityonly and all diodes should check alike Then check between point B B strapand 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 If any diode is defective replace the entire diode rectifier bridge assembly e Q COMMERCIAL DIODE TESTER TESTING RECTIFIER BRIDGE 70 e 9 to Remove Brush Holder Remove two locknuts securing brush holder Pull out brush holder See illustration below 2BRUSHOLDER MOUNTING LOCKNUT REMOVING BRUSH HOLDER Inspect and Test Brush Assembly The illustration below shows the terminals brush arrangement and testing procedure The original brush set may be reused if the brushes are 316 or longer and if brushes are not oil soaked cracked or show evidence of grooves on the sides of the brushes caused by vibration TEST CONTINUITY FROM A TO B FROM C TO 0 NO CIRCUIT FROM A OR B TO C OR 0 TEST WITH 12 VOLT DC TEST LAMP OR OHMMETER BRUSH TEST 68 of the AdobeUCS AdobeUCS 3 A AdobeUCSA B C D E TEST REGULATOR LIGHT TERM GROUND ACTAP TACHALTERNATOR TERMINAL IDENTIFICATION REMOTE GUIDE REMOTE REGULATOR SYSTEMS PROBLEM PROBABLE CAUSES Battery undercharged 1 Defective cables dirty battery 1 ammeter if usedindicates posts corroded terminals etc constant discharge indicator lamp remains on 2 Loose or broken belt 2 3 Worn or broken brushes 3 4 Defective alternator system 4 Battery undercharged 1 Indicator lamp burned out or 1 indicator lamp off with key defective wire harness on engine stopped Normal condition is lamp on2 Broken brush 2 3 Defective alternator system 3 Battery overcharges 1 Poor ground 1 excessive use of water 2 Defective alt system 2 ammeter if usedshows constant excessive charge voltmeter indicates greater than 145 volts connected across battery with no loadwith engine idling Battery charges at idle but 1 Slipping belts 1 discharges under load 2 Alternator defective conditions 2 Indicator lamp glows slightly 1 Defective diodetrio 1 under moderate load battery appears charged 64 CORRECTIVE ACTION Check clean repair or replace as needed Check belt Replace brush assy Refer to Problem Area Determination Section Check bulb harness Replace brush assy Refer to Problem Area Determination Section Check ground Refer to Problem Area Determination Section Check belts and adjust tension or replace as necessary Disassemble check diodes Remove replace charged battery AdobeUCS 3 A AdobeUCSA B C D E TEST PROCEDURE INTEGRAL REGULATOR SYSTEMSSee Pages 6466 for Remote Regulator SystemsAC TAp267 TACHDINDICATOR LIGHT TERM INTEGRAL REGULATOR BACK COVER ALTERNATOR SENSE ACTAP TACHDINDICATOR LIGHT TERM GROUND INTEGRAL REGULATOR EXCITE BACK COVER SENSE TO BATT REMOTE BATTERY SENSE ALTERNATOR TERMINAL IDENTIFICATION INTEGRAL GUIDE INTEGRAL REGULATOR SYSTEMS PROBLEM PROBABLE CAUSES CORRECTIVE ACTION Battery undercharged 1 Defective cables dirty battery 1 Check clean repair or replace267 ammeter if usedindicates posts corroded terminals etc as needed constant discharge indicator lamp remains on 2 Loose or broken belt 2 Check belt 3 Worn or broken brushes 3 Replace brush assy 4 Defective alternator system 4 Refer to Problem Area Determination Section Battery undercharged 1 Indicator lamp burned out or 1 Check bulb harness indicator lamp off with key defective wire harness on engine stopped Normal condition is lamp on2 Broken brush 2 Replace brush assy 3 Defective alternator system 3 Refer to Problem Area Determination Section Battery overcharges 1 Defective wire harness 1 Refer to Problem Area excessive use of water 2 Defective alt system Determination Section ammeter if usedshows 3 Poor ground 2 Refer to Problem Area constant excessive charge 4 Broken sense lead remote Determination Section voltmeter indicates greater battery sense only3 Check ground than 145 volts connected 4 Check clean repair or replace across battery with no loadas needed with engine idling Battery charges at idle but 1 Slipping belts 1 Check belts and adjust tension discharges under load 2 Alternator defective or replace as necessary conditions 2 Disassemble check diodes Indicator lamp glows slightly 1 Defective diodetrio 1 Remove replace under moderate load battery appears charged 60 AdobeUCSof the of the of the accessory ammeter Excitation 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 TO BATT ING SW ON0 IND LIGHT REGULATOR ALTERNATOR EXCITATION CIRCUIT Alternator Installation TO BATT CHARGE IND LIGHT ING SW ON0 IND LIGHT TERMINALREMOTE REGULATOR ALTERNATOR EXCITATION CIRCUIT Observe vehicle battery polarity prior to connecting output cables to the alternator Reverse battery polarity will destroy the alternator rectifier diodes ALTERNATOR REAR HOUSING ROTATION For special installation requirements the alternator rear housing may be rotated to one of four different positions that are spaced 90260 apart To rotate the rear housing proceed as follows 1 Detach plastic cover from rear housing 2 Remove the four 4throughbolts using a 14 nutdriver or socket See illustration below 3 Rotate the housing clockwise or the desired location The stator assembly must be rotated with the rear housing 4 Replace throughbolts Tighten throughbolts alternately and evenly until tight Check that rotor shaft turns freely after reassembly 5 Reattach plastic cover to rear housing NOTE Be sure felt gasket located on inside of cover is in place THROUGH BOLT 4STATOR ASSY REAR HOUSING THROUGHBOLT REMOVAL 57 ALT FIELD INTEGRAL REGULATOR Integral Voltage Regulator The voltage regulator is an electronic switching device which senses system voltage level and switches the voltage applied to the field in order to maintain proper system voltage The regulator design utilizes all silicon semiconductors and thickfilm assembly techniques After the voltage has been adjusted to the proper regulating valve the entire circuit is encapsulated to protect the circuit and the components from possible damage due to handling or vibration and moisture encountered in a vehicle The voltage regulator is also temperature compensated to provide a slightly higher voltage at low temperatures and a lower voltage at higher temperatures to provide for charging requirements of the battery under these conditions Ui w ffi 80 Q E c 60 IZ W a a 40 I20 I255o 225 I I I 12 VOLT 51 AMP 4 r 3 I 2 1 1000 2000 3000 4000 5000 6000 7000 ALTERNATOR SHAFT RPM TYPICAL PERFORMANCE CURVES AMBIENT TEMPERATURE OF 750 238260CSAE TEST METHOD 56 en to oJ w o a a o a w o Q W Ca o J AdobeUCSThe stator is connected to a threephase fullwave bridge rectifier package which contains six diodes The bridge converts the AC generated in the stator to a DC output for battery charging and accessories such as radio heater lights ignition etc See illustrations below Power to the regulator and the field of the integral regulator alternators is provided by the field diode or diode triopackage contained in the alternator Remote regulator alternators obtain field power via the regulator in the charging system The alternator designs produce a rated output of 51 amperes Rated output is achieved at 6000 alternator RPM at an ambient temperature of 75 degrees F 238 degrees CThe alternator is designed to operate in an ambient of 40 degrees to 212 degrees F 40 to 100 degrees CTo ensure proper cooling of the rectifier bridge and internal components of the alter255nator it must be used with the proper cooling fan D B D B EXCITE SENSE EXCITE REGULATOR ICI GROUND REGULATOR ICI GROUND STATORACTAP TACHALTERNATOR SENSE INTEGRAL REGBATTERY SENSE INTEGRAL REGD B GROUND STATOR255 ROTOR b TACHREMOTE REGULATOR 267ALTERNATOR SCHEMATIC DIAGRAMS 55 AdobeUCSof the ELECTRICAL SYSTEM General Information The 8E series of charging systems were designed for the replacement of many current Motorola models Models are available for 51 amp 12 volt negative ground systems with or without an integral solidstate voltage regulator The integral voltage regulator incorporates an IC all silicon semiconductors and thickfilm construction The remote regulator model alternator is quipped with a blade terminal for connection to the associated remote regulator Serviceable features of previous Motorola Charging System designs have been retained in these units The voltage regulator and brush assembly can be removed without disassembly of the alternator thus allowing for individual testing or inspection 1 2 3 1 Long life silicon diodes 2 Permanently lubricated sealed rear ball bearing 3 Quiet troublefree dynamically balanced rotor 4 Convenient regulator brush replacement 5 Insulated stator prevents shorts 6 Permanently lubricated sealed front ball bearing 7 Standard shaft CUTAWAY VIEW OF TYPICAL ALTERNATOR 53 2 V ELECTRICAL SYSTEM Wiring Diagram 52 General Information 53 Alternator General Information 5457 Alternator Schematic Diagrams 55 Alternator Rear Housing Rotation 57 Belt Installation Alignment and Tightening 58 Ammeter 58 Test Procedure 59 Test Procedure Integral Regulator Systems 6063 Guide Integral Regulator Systems 6061 Test Procedure Remote Regulator Systems 6466 Guide Remote Regulator Systems 64 Repair Procedure 6773 Rotor Inspection and Electrical Testing 7376 Alternator Reassembly 7679 Alternator Performance Tests 7980 Cranking System 8082 51 AdobeUCSNOTES 50 At high speed running with overload When an overload is applied to the engine running at a high speed the centrifugal force of ball weights become small as the speed is reduced and fork lever 2 is pulled rightward by governor springs 1 and 2 increasing fuel injection Fork lever 2 becomes ineffective to increase fuel injection when it is stopped by maximum output limit bolt After that when the force of spring becomes larger than the centrifugal force of ball weights fork lever 1 moves rightward to increase fuel injection driving the engine continuously with a high torque At high speed running with overload 1 Ball Weight 2 Fork Lever 2 3 Governor Spring 1 4 Governor Spring 2 5 Maximum Output Limit Bolt 6 Spring 7 Fork Lever 1 To stop engine When stop lever is moved to STOP position fork lever is moved leftward and then control rack is moved to the noninjection position stopping the engine To stop engine 1 Stop Lever 2 Fork Lever 1 3 Control Rack 49 At middlehigh speed running The engine speed is controlled when the tension of governor springs 1 and 2 which are pulled speed control lever and the centrifugal force of ball weights are balanced When the speed is reduced A 8with load increased a bthe centrifugal force of ball weights becomes smaller than the tension of governor springs 1 and 2 As a result the control rack is moved rightward and fuel injection amount is increased to produce an engine torque required for the load a cAt middlehigh speed running 1 Speed Control Lever 2 Governor Spring 1 3 Governor Spring 2 4 Ball Weights When load is increased 132t 54 1 Engine Torque Curve 2 Small Loan Torque Curve 3 Large Load Torque Curve 4 Engine RPM 5 Torque 48 GOVERNOR With centrifugal ball weight system this mechanical governor works in the whole range of speeds It keeps the engine speed and controls the engine output At Start When the engine is started more fuel is required than in running At starting fork lever 1 is pulled rightward by starter spring because ball weights have no centrifugal force Control rack moves to a position for overlimit discharging of fuel to assure easy starting At start 1 Ball Weights 2 Start Spring 3 Fork Lever 1 4 Control Rack At Idling When speed control lever is set at idling position after the engine is started high speed governor spring 1 does not work at all and also low speed governor spring 2 does only a little action Therefore governor sleeve is pushed leftward by a centrifugal force of ball weights Fork lever 1 and control rack are moved leftward by the sleeve and then idling limit spring is compressed by control rack As a result the control rack is kept at a position where a centrifugal force of ball weights and forces start spring governor spring 2 and idling limit 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 Limit Spring 9 Start Spring 47 INJECTION NOZZLE This nozzle is throttletype 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 pipe to the fuel tank Injection pressure can be controlled by inserting shims between nozzle holder body and adjusting washers The pressure increases when a O1mm 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 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 46 AdobeUCSof the of the Control 1 Injection zero 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 up 2 Injection medium When the plunger is rotated a certain amount in the direction of the arrow by the control rack stroke A is effective until the feed hole meets the control groove and fuel is injected as the stroke amount 3 Injection maximum When the plunger is rotated by the control rack to the maximum amount in the direction of the arroweffective stroke reaches maximum and maximum injection is provided Injection Control t 1 12 131 1 Effective Stroke 44 Fuel Pressurefeed 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 pump2 Pressurefeed start 3 Pressurefeed 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 pressurefed through the injection pipe and nozzle into the combustion chamber 4 Completion of pressurefeed When plunger moves further up the control groove and feed hole meet Pressurized fuel in the delivery chamber is returned through the plungers center hole control groove and feed hole to the fuel chamber Then pressure falls and pressurefeed is completed Pressurefeed Start to Completion 11 2341 Delivery Chamber 2 Delivery Valve 3 Feed Hole 4 Fuel Chamber 5 Plunger 43 and discharge AdobeUCS1 2 PUMP ASS EMBLY 302648 Description ImpellerH267 O Housing Ring Cam Screw Cam Impeller CirClip Flat Washer Seal Seat Not Available 0 CirCr rder 13 Ip Internal Clr cr Ip External Ball Bearing Seal Seat A CirCr ssembly Kip External ey Shaft End Plate Gasket Pump Body Lock Washer Bolt 40 AdobeUCS1 6 2 1 3 1 4 1 6 1 2 1 7 1 1 1 WATER PUMP 35 Imino 77 IMpgalsmin 92 US galsminof 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 cooling water at correct temperature and uses wax pellet type thermostat Wax is enclosed in the pallet The wax is solid at low temperatures but turns liquid at high temperatures expands and opens the valve Flow of cooling water r Temperature sensor of wax pellet type thermostat 1ab1 Leak hole 7 To radiator 2 Water cover 8 To engine 3 Spindle 9 Pellet 4 Pellet 10 Wax liquid5 Valve 11 Wax solid6 Sheet aAt low temperature bAt high temperature OIL SWITCH Oil switch is provided on the way for the oil pressure If the oil pressure is proper it is switched off if oil pressure falls below 490 kPa 71 psithe oil warning lamp etc will light warning the operator In this case stop the engine immediately and check the cause of the pressure drop Oil switch 11 When oil pressure is proper 2 When oil pressure falls 3 Screw 4 Terminal 5 Spring plate 6 Insulator 7 Spring retainer OIL PUMP 1tljj81128 Rubber packing 9 Oil seat 10 Contact rivet 11 Contact 12 Lamp 13 Battery The oil pump is of rotor type and works smoothly and noiselessly An inner and outer rotor turn inside a housing In operation the inner rotor is driven inside the outer rotor The inner rotor has one less lobe than the outer rotor so that only one lobe is in full engagement with the outer rotor at anyone time This allows the other lobes to slide over the outer lobes making a seal to prevent backup of oil As the lobes slide up and over the lobes on the outer rotor oil is drawn in As the lobes fall into the rings cavities oil is squeezed out 1 Draw in 1 Rotortype pump in operation 2 Draw in 2 3 Draw in 3 4 Squeeze out 5 Inlet 6 Outlet 7 Inner rotor 8 Outer rotor 35 RELIEF VALVE Relief valve prevents damage to the lubrication system due to high oil pressure Control range of the relief valve is 196 to 441 KPa 28 to 64 psLWhen oil pressure exceeds the upper limit the ball is pushed back by high pressure oil and the oil escapes BY267PASS VALVE Oil filter cartridge has a bypass valve inside to prevent the lack of lubrication oil in the engine if the oil filter element is clogged When the pressure difference before filtering and after is more than 981 kPa 142 psithe bypass valve opens and lets the oil pass to each part of engine without passing through the filter Relief valve and bypass valve 1 Relief valve 2 Bypass valve 3 From pump 4 To rocker arm shaft and camshaft 15 To crankshaft 34 t 3ENGINE OIL FLOW 181 ROCKER ARM SHAFT 221 SWITCH 1 I I I f I I 1201 1201 1201 DRAIN I DRAIN l DRAIN J I I l 151 I 161 151 CAMSHAFT TAPPETS I I I I 141 I I 1911 SPLPSH TIMING GEAR 1 I I J 61 MAIN OIL GALLERY 151 19SPLASH f f I 121 I I TAETS I I I I I I I 191 SPLASH f I I I I I 1 I I I I 11 OILPAN This engine lubrication system consists of oil filter 1 straineroil 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 SYSTEM Crankpin Bearing Piston Oil Filter 1 32 Oil Filter Cartridge and Relief Valve 1To rocker arm shaft and camshaft 2To crankshaft SECTION IV LUBRICATION COOLING AND FUEL SYSTEMS LUBRICATION SYSTEM Lubrication System Diagram 32 Engine Oil Flow Diagram 33 Relief Valve 34 Bypass Valve 34 Oil Switch 35 Oil Pump 35 COOLING SYSTEM Water Pump 36 Thermostat 36 Oberdorfer Water Pump 37 Sherwood Water Pump 38 Johnson Water Pump 39 New Style Sherwood Water Pump 40 FUEL SYSTEM Fuel Filter 41 Fuel Pump 42 Fuel Injection Pump 4245 Injection Nozzle 46 Governor 4749 31 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 collets valve stem seals and valve caps are the same for both the inlet and exhaust valves All contact or sliding parts are quenched and tempered 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 FLYWHEEL 7Intake and exhaust valve 468Flywheel is connected with the crankshaft Storing explosive force by each cylinder as the force of inertia the flywheel functions to rotate the crankshaft smoothly On the circumference of the flywheel are stamped marks for fuel injection timing and top dead center The flywheel and crankshaft can be fixed to each other at a certain point according to the arrangement of flywheel mounting bolt hole 2TC 2 Fl 1 FI 12 127 rad 731 TC 127 rad 127 rad 7326073119 rad 6826011TC Mark for top dead center of 1st piston 1FI Mark for fuel injection of 1st piston 30 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 The fuel camshaft controls the reciprocating movement of the injection pump and is equipped with a ball to control the governor Fuel camshaft is made of carbon steel and cam sections are quenched and tempered to provide greater wear resistance Camshaft Fuel Camshaft 1 Tappet 2 Push rod 3 Camshaft 4 Camshaft gear 5 Injection pump gear 6 Governor sleeve 7 Governor ball case 8 Circlip 9 Circlip 10 Fuel camshaft 11 Ball 12 Ball bearing ROCKER ARM ASSEMBLY The rocker arm assembly includes the rocker arms rocker arm brackets and rocker arm shaft and converts the reciprocating movement of the push rods to an openclose movement of the inlet and exhaust valves Valve control timing must be adjusted with screws on the rocker arms Lubrication oil is pressurized through the bracket to the rocker arm shaft so that the rocker arm bearings and the entire system are lubricated sufficiently 1 Rocker arm 2 Rocker arm shaft 3 Rocker arm bracket 4 Oil filer plug 5 Decompression lever 6 Decompression window cover 7 Decompression nut 8 Decompression bolt 9 Decompression shaft 10 Valve 29 8 AND PISTON RINGS Piston circumference has a special elliptic shape in consideration of expansion due to explosion heat Piston head is flatformed 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 key stone type which can stand against heavy load and the sliding surface to the cylinder wall is shaped into barrel face which is well fitted to the wall and plated with hard chrome Second ring is of undercut type which is effective to prevent oil rising Oil ring is effective to scrape oil because it is closely fitted to the cylinder wall by coil expander and the upper and lower ends of its sliding surface are cut diagonally to raise fare pressure to the cylinder walls A part of scraped oil is forced into the inside of piston through oil escape holes of rings and piston The oil ring is plated with hard chrome to increase wear resistance quality Pistons and piston rings 41 Rib 2 Top ring 3 Barrel face 4 Hard chrome plating 5 Second ring 6 Coil expander ring 32i 0 16CONNECTING RODS Connecting rod is used to connect the piston with the crankshaft The big end of the connecting rod has crankpin bearings split typeand the small end has a bushing solid type311 Connecting rod 2 Crankpin bearing 3 Bushing I 1 28 The crankshaft is driven by the pistons and connecting rods and translates its reciprocating movement into a circular movement It also drives the oil pump camshaft and fuel camshaft Six counterweights are integrated into one unit to minimize bearing wear and lubricating oil temperature rise Crankshaft journals crankpins and oil seal sliding section are 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 12 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 alloy to raise wear resistance quality Crankslyft 81 Crankshaft 2 Piston 3 Connecting rod 4 Oil passage 5 Crankshaft bearing 1 6 Crankshaft bearing 2 7 Side bearing 8 Counterweight 27 of the SECTION III CONSTRUCTION AND FUNCTION Cylinder Block 26 Cylinder Head 26 Crankshaft 27 Piston and Piston Rings 28 Connecting Rods 28 Camshaft and Fuel Camshaft 29 Rocker Arm Assembly 29 Inlet and Exhaust Valves 30 Flywheel 30 25 the top CHANGING ENGINE OIL FILTER CARTRIDGE Remove the oil filter cartridge with a filter wrench Apply a slight coat of oil to the rubber gasket on the new cartridge Screw the new cartridge in by hand Overtightening may cause deformation of rubber gasket After cartridge has been replaced engine oil normally decreases a little Check that the engine oil does not leak through the seal and be sure to read the oil level Then add engine oil up to the prescribed level 1 Oil filter cartridge INSPECTION OF FUEL FILTER The fuel filter is installed in the fuel line from the fuel tank to the injection pump between the tank and feed pump in the basic modelAs the fuel from the inlet of the cock body moves through the filter element the dirt and impurities in the fuel are filtered allowing only clean fuel to enter the inside of the filter element The cleaned fuel flows out from the outlet of the cock body Before starting or after disassembling and reassembling loosen the air vent plug to bleed the air in the fuel line 2 1 1 Cock Body Inlet 2 Cock Body Outlet 3 Air Vent Plug 23 how new every every every every every every every every months months year year GENERAL WARNINGS 225 When disassembling engine arrange each part on a clean surface Do not mix them up Replace bolts and nuts in their original positions 225 When servicing voltaged parts or connecting instruments to electrical equipment first disconnect negative battery terminal 225 Replace gaskets or Orings with new ones when disassembling and apply grease on the 0ring and the oil seal when reassembling 225 When exchanging parts use Universal genuine parts to maintain engine performance and safety 225 To prevent oil and water leakage apply nondrying adhesive to the gasket according to this manual before reassembling 225 When hoisting the engine use the hook provided on the cylinder head 225 When installing external circlips or internal circlips direct corner end to the nonloosening direction Applying grease to oil seal Direction of installing circlips 3 2 F1 5 1 Inside of Lip 2 Grease 3 External Circlip 4 Internal Circlip 5 Direct the Corner End to the Direction Subject to Force 20 4 5 SECTION II PREVENTIVE MAINTENANCE General Warnings 20 Maintenance Check List 21 POINTS OF INSPECTION AND CHANGING Engine Lubricating Oil 22 Changing Engine Oil Level 22 Changing Engine Oil 22 Changing Engine Oil Filter Cartridge 23 Inspection of Fuel Filter 23 Venting the Fuel System 24 19 Bolt Torques Material Grade Standard Bolt Special Bolt Special Bolt Nominal Dia SS41S20C S43C S48C RefinedSCR3 SCM3 RefinedM6 58 69 Ibsft 72 83 Ibsft 90 105 Ibsft M8 130 152 Ibslft 174 203 Ibsft 217 253 Ibsft M 10 289 333 Ibsft 354 412 Ibsft 448 521 Ibsft M 12 463 535 Ibsft 571 665 Ibsft 759 868 Ibslft M 14 796 926 Ibsft 911 1085 Ibslft 1230 1447 Ibsft M 16 1230 1410 Ibslft 1447 1664 Ibsft 1917 2242 Ibsft M 18 1800 2098 Ibsft 2025 2351 Ibsft 2532 2965 Ibslft M 20 2459 2893 Ibsft 2712 3182 Ibsft 3616 4195 Ibsft Bolt material grades are shown by numbers punched on the bolt heads Prior to tightening be sure to check out the numbers as shown below Punched Bolt Material Grade Number None Standard Bolts SS41 S20C 7 Special Bolts S43C S48C Refined9 Special Bolts SCM3 SCR3 Refined18 M50 75 to 80 kgfm 542 to 579 ftllbs30 to 35 kgfm 217 to 253 ftllbs30 to 35 kgfm 217 to 253 ftllbs10 to 11 kgfm 723 to 796 ftllbs37 to 42 kgflm 268 to 304 ftllbs17 to 21 kgfm 123 to 152 ftllbs10 to 115 kgfm 723 to 831 ftllbs20 to 25 kgfm 145 to 181 ftllbs40 to 45 kgfm 289 to 362 ftllbs3 to 5 kgfm 217 to 362 ftllbs014 to 02 kgfm 101 to 145 ftllbs15 to 20 kgfm 108 to 145 ftllbs28 35 kgfm 203 to 253 ftllbs25 to 30 kgfm 181 to 217 ftllbs15 to 26 kgfm 108 to 188 ftllbs14 to 16 kgfm 101 to 116 ftllbs14 to 18 kgfm 101 to 130 ftllbs17 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 follow this method First tighten all the bolts 50 of the regular torque then tighten them fully TIGHTENING BOLTS OF IMPORTANT PARTS Marked bolts must be tightened after applying oil MODEL M30 M40 Head bolts and nuts 75 to 80 kgfm 75 to 80 kgfm 542 to 579 ftllbs542 to 579 ftllbsBearing case bolts 1 30 to 35 kgfm 30 to 35 kgflm 217 to 253 ftllbs217 to 253 ftllbsBearing case bolts 2 30 to 35 kgfm 30 to 35 kgflm 217 to 253 ftllbs217 to 253 ftllbsFlywheel bolts 10 to 11 kgfm 10 to 11 kgfm 723 to 796 ftllbs723 to 796 rod bolts 37 to 42 kgflm 37 to 42 kgfm 268 to 304 ftllbs268 to 304 ftllbsRocker arm bracket studs 17 to 21 kgfm 17 to 21 kgfm 123 to 152 ftllbs123 to 152 ftllbsIdle gear shaft bolts 10 to 115 kgfm 10 to 115 kgfm 723 to 831 ftllbs723 to 831 ftllbsGlow plugs 20 to 25 kgflm 20 to 25 kgfm No neea to apply oil145 to 181 ftllbs145 to 181 ftllbsDrain plugs 40 to 45 kgfm 40 to 45 kgfm 289 to 362 ftllbs289 to 362 ftllbsNozzle holders 3 to 5 kgfm 3 to 5 kgfm 217 to 362 ftllbs217 to 362 ftllbsBis 014 to 02 kgfm 014 to 02 kgfm Oil 101 to 145 ftllbs101 to 145 ftllbsSwitch Taper screw 15 to 20 kgfm 15 to 20 kgfm 108 to 145 ftllbs108 to 145 ftllbsFuel limit lock nut 28 to 35 kgfm 28 to 35 kgfm 203 to 253 ftllbs203 to 253 ftllbsFuel limit cap nut 25 to 30 kgfm 25 to 30 kgfm 181 to 217 ftllbs181 to 217 pipes 15 to 26 kgfm 15 to 26 kgflm 108 to 188 ftllbs108 to 188 nut 14 to 16 kgfm 14 to 16 kgfm 101 to 116 ftllbs100 to 116 ftllbsAir vent screw 14 to 18 kgfm 14 to 18 kgflm on injection pump101 to 130 ftllbs101 to 130 ftllbs 16 M50 7 to 9 mm 0275 to 0355 in12 kgfcm2 14 to 15 psi09 to 06 kgfcm2 15 to 9 psi739 C 165273 F 23260 to 25260 before TOC 600 to 500 kgfcm2 8532 to 7110 Ibs100 to 5 kgfcm2 1422 to 711 Ibs140 to 150 kgfcm2 1990 to 2133 Ibs130 to 140 kgfcm2 1848 to 1991 Ibs300 mm 1181 in90 A or less 05 to 09 mm 0020 to 0035 in19 mm 0748 inApprox 15 ohm I AC 20 bolts or more 5200 RPM 138 to 148 volts ENGINE SPECIFICATIONS Allowable Limit 02 mm 0008 in127 mm 0500 in 15 COOLING SYSTEM Fan Belt Item Belt deflection under load of 98 N 10 kgf 21 IbsHeat Exchanger Exchanger water tightness Radiator cap opening pressure Thermostat Thermostats valve opening temperature Temperature at which thermostat completely opens FUEL SYSTEM Injection Pump Injection timing staticFuel tightness of pump element Fuel tightness of delivery valve Injection Nozzle Fuel injection pressure Fuel tightness of nozzle valve seat ELECTRICAL SYSTEM Starter Commutator 00 Variance Mica undercut Brush length Glow Plug I Resistance AC dynamo I Noload output Regulator I Regulating voltage ENGINE SPECIFICATIONS M30 7 to 9 mm 0275 to 0355 in12 kgfcm2 14 to 15 psi09 to 06 kgfcm2 15 to 9 psi60 C 140260F 739 C 165260F 23260 to 25260 before TOC 600 to 500 kgfcm2 8532 to 7110 Ibs100 to 5 kgfcm2 1422 to 711 Ibs140 to 150 kgfcm2 1990 to 2133 Ibs130 to 140 kgfcm2 1848 to 1991 Ibs327 mm 1287 in45 A or less 05 to 08 mm 0092 to 0032 in19 mm 0748 inApprox 15 ohm AC 20 volts or more 5200 RPM 138 to 148 volts 14 M40 7 to 9 mm 0275 to 0355 in12 kgfcm2 14 to 15 psi09 to 06 kgfcm2 15 to 9 psi60 C 140260F 739 C 1650F 23260 to 25260 before TOC 600 to 500 kgfcm2 8532 to 7110 Ibs100 to 5 kgfcm2 1422 to 711 Ibs140 to 150 kgfcm2 1990 to 2133 Ibs130 to 140 kgfcm2 1848 to 1991 Ibs300 mm 1181 in90 A or less 05 to 09 mm 0020 to 0035 in19 mm 0748 inApprox 15 ohm AC 20 volts or more 5200 RPM 138 to 148 volts ENGINE SPECIFICATIONS M50 Allowable Limit 002 mm 008 mm 00008 in0003 in0040 to 0118 mm 020 mm 0002 to 0004 in0008 in51921 to 51940 mm 2044 to 2045 in51921 to 51940 mm 2044 to 2045 in51980 to 52039 mm 2046 to 2049 in51980 to 52025 mm 2046 to 2048 in0035 to 0093 mm 020 mm 0002 to 0004 in0008 in43959 to 43975 mm 1731 to 1732 in44010 to 44052 mm 1733 to 1734 in015 to 031 mm 05mm 0006 in to 0012 in0020 in 002 mm 004 mm 0008 mm 0016 mm 002 mm 004 mm 0008 in 0016 in002 mm 005 mm 00008 in0002 in0014 to 0038 mm 015 mm 00006 to 0001 in0006 in23002 to 23011 mm 0905 to 0906 in23000 to 23013 mm 23053 mm 0905 to 0906 in0907 in10 kgfcm2 or more 142 psi30 to 45 kgfcm2 25 kgfcm2 43 to 64 psi35 psi004 to 013 mm 020 mm 0002 to 0005 in0008 in011 to 019 mm 025 mm 0004 to 0007 in0010 in0105 to 0150 mm 02 mm 0004 to 0006 in0008 in98 KPa 10 kgfcm2 142 psi13 Item Crankshaft alignment Oil clearance between crankshaft journal and bearing Front and intermediate Journal 00 Rear Front and Bearing 10 intermediate Rear Oil clearance between crank pin and bearing Crank pin 00 Crank pin bearing 10 Crank shaft side clearance Under sizes of crankshaft bearing and crank pin bearing Oversizes of thrust bearing Connecting Rod Connecting rod alignment Oil clearance between piston pin and small end bushing Piston 00 Small end bushing 10 SYSTEM At idle Oil pressure speed At rated speed 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 ENGINE SPECIFICATIONS M30 002 mm 00008 in0040 to 0118 mm 0002 to 0004 in51921 to 51940 mm 2044 to 2045 in51921 to 51940 mm 2044 to 2045 in51980 to 52039 mm 2046 to 2049 in51980 to 52025 mm 2046 to 2048 in0035 to 0093 mm 0002 to 0004 in43959 to 43975 mm 1731 to 1732 in44010 to 44052 mm 1733 to 1734 in015 to 031 mm 0006 to 0012 in002 mm 004 mm 0008 in 0016 in02mm 04 mm 0008 in 0016 in002 mm 00008 in0014 to 0038 mm 00006 to 0001 in23002 to 23011 mm 0905 to 0906 in23000 to 23013 mm 0905 to 0906 in10 kgfcm2 142 Dsi30 to 45 kgfcm2 43 to 64 psi010 to 016 mm 0004 to 0006 in011 to 019 mm 0004 to 00070105 to 0150 mm 0004 to 0006 in98 KPa 10 kgfcm2 142 psi12 M40 002 mm 00008 in0040 to 0118 mm 0002 to 0004 in51921 to 51940 mm 2044 to 2045 in51921 to 51940 mm 2044 to 2045 in51980 to 52039 mm 2046 to 2049 in51980 to 52025 mm 2046 to 2048 in0035 to 0093 mm 0002 to 0004 in43959 to 43975 mm 1731 to 1732 in44010 to 44052 mm 1733 to 1734 in015 to 031 mm 0006 to 0012 in002 mm 004 mm 0008 in 0Q16 in002 mm 004 mm 0008 in 0016 in002 mm 00008 in 0014 to 0038 mm 00006 to 0001 in23002 to 23011 mm 0905 to 0906 in23000 to 23013 mm 0905 to 0906 in10 kgfcm2 142 DSi30 to 45 kgfcm2 43 to 64 psi004 to 013 mm 0002 to 0005 in011 to 019 mm 0004 to 0007 in0105 to 0150 mm 0004 to 0006 in98 KPa 10 kgfcm2 142 psiENGINE SPECIFICATIONS M50 Allowable Limit 0Q18 to 0070 mm 015 mm 00007 to 0003 in0006 in13973 to 13984 mm 0550 to 0551 in14002 to 14043 mm 0551 to 0553 in 005 mm 0002 in3336 mm 3331 mm 1313 in1315 in0050 to 0091 mm 015 0002 to 0004 in0006 in39934 to 39950 mm 1572 to 1573 in40000 to 40025 mm 1575 to 1576 in0042 to 0115 mm 015 mm 0002 to 0005 in0006 in020 to 051 mm 06mm 0008 to 0020 in0024 in0Q16 to 0045 mm 010mm 00006 to 0001 in0004 in15973 to 15984 mm 0628 to 0629 in16000 to 16018 mm 0621 to 0630 in85000 to 85022 mm 015 mm 3346 to 3347 in0006 in05 mm 0020 in23000 to 23013 mm 23053 mm 0905 to 0906 in0907 in0093 to 0120 mm 0004 to 0005 in0020 to 0052 mm 00008 to 0002 in030 to 045 mm 125 mm 0012 to 0Q18 in0049 in025 to 045 mm 125 mm 0010 to 0Q18 in0049 in05 mm 0020 in11 ENGINE SPECIFICATIONS Rocker Arm Item M30 M40 Clearance between rocker 0Q18 to 0070 mm 0Q18 to 0070 mm arm and bushing 00007 to 0003 in00007 to 0003 inRocker arm shaft 00 13973 to 13984 mm 13973 to 13984 mm 0550 to 0551 in0550 to 0551 inRocker arm bushing 10 14002 to 14043 mm 14002 to 14043 mm 0551 to 0553 in0551 to 0553 inCamshaft Camshaft alignment 005 mm 005 mm 0002 in0002 inCam height IN EX3336 mm 3336 mm 1313 in1313 inOil clearance of camshaft 0050 to 0091 mm 0050 to 0091 mm 0002 to 0004 in0002 to 0004 inCamshaft journal 00 39934 to 39950 mm 39934 to 39950 mm 1572 to 1573 in1572 to 1573 inCamshaft bearing 10 40000 to 40025 mm 40000 to 40025 mm 1575 to 1576 in1575 to 1576 inTiming Gear Timing gear backlash 0042 to 0115 mm 0042 to 0115 mm 0002 to 0005 il0002 to 0005 inIdle gear side clearance 020 to 051 mm 020 to 051 mm 0008 to 0020 in0008 to 0020 inClearance between idle gear 0Q16 to 0045 mm 0Q16 to 0045 mm shaft and idle gear bushing 00006 to 0001 in00006 to 0001 inIdle gear shaft 00 15973 to 15984 mm 15973 to 15984 mm 0628 to 0629 in0628 to 0629 inIdle gear bushing 10 16000 to 16018 mm 16000 to 16018 mm 0621 to 0630 in0621 to 0630 inCylinder LinerCylinder Liner10 76000 to 76019 mm 76000 to 76019 mm 2992 to 2993 in2992 to 2993 inOversize of cylinder liner 05 mm 05 mm 0020 in0020 inPistonPiston Ring Piston pin hole 10 23000 to 23013 mm 23000 to 23013 mm 2905 to 0906 in0905 to 0906 inCompression 0093 to 0120 mm 0093 to 0120 mm Piston ring ring 2 0004 to 0005 in0004 to 0005 inclearance 0020 to 0052 mm 0020 to 0052 mm Oil ring 00008 to 0002 in00008 to 0002 inCompression 030 to 045 mm 030 to 045 mm Ring gap ring 1 2 0012 to 0Q18 in0012 to 0Q18 inOil ring 025 to 045 mm 025 to 045 mm 0010 to 0Q18 in0010 to 0Q18 inOversize of piston rings 05 mm 05 mm 0020 in0020 in10 ENGINE SPECIFICATIONS M50 Allowable Limit 005 mm 0002 in07 to 09 mm 0028 to 0035 in130 to 160 mm 0051 to 0063 in 105 to 115 mm 0041 to 0045 in02 mm 0008 in448 psi 350 psi 10 018 to 022 mm 0007 to 0008 in21 mm 0083 in 450 450 11 to 13 mm 16 mm 0043 to 0051 in0063 in004 to 007 mm 01 mm 0001 to 0003 in0004 in 7960 to 7975 mm 0313 to 0314 in8015 to 8030 mm 0315 to 0316 in035 rad 200 before TDC079 rad 450 after TDC087 rad 500 before TDC 026 rad 150 After TDC 417 to 422 mm 412 mm 1642 to 1661 in 1622 in10 mm 100 N 0039 in 102 kgf 225 Ibs1117 N 12 kgf 265 Ibs9 ENGINE SPECIFICATIONS ENGINE BODY Cylinder Head Item M30 M40 Cylinder head surface 005 mm 005 mm flatness 0002 in0002 inTop clearance 07 to 09 mm 07 to 09 mm 0028 to 0035 in0028 to 0035 inFree 130 to 160 mm 130 to 160 mm Gasket 0051 to 0063 in0051 to 0063 inthickness Tightened 105 to 115 mm 105 to 115 mm 0041 to 0045 in0041 to 0045 inGasket shim thickness 02 mm 02 mm 0008 in0008 inCompression pressure 448 psi 448 psi Variance among cylinders Valves IN EXValve clearance cold018 to 022 mm 018 to 022 mm 0007 to 0008 in0007 to 0008 inValve seat width 21 mm 21 mm 0083 in0083 inValve seat angle 450 450 Valve face angle 450 450 Valve recessing 11 to 13 mm 11 to 13 mm 0043 to 0051 in0043 to 0051 inClearance between valve 004 to 007 mm 004 to 007 mm stem and guide 0001 to 0003 in0001 to 0003 inValve stem O D 7960 to 7975 mm 7960 to 7975 mm 0313 to 0314 in0313 to 0314 inValve guide 10 8015 to 8030 mm 8015 to 8030 mm 0315 to 0316 in0315 to 0316 inValve Timing Open 035 rad 035 rad Inlet valve 200 before TDC 200 before TDCClose 079 rad 079 rad 450 after TDC 450 after TDC Open 087 rad 087 rad 500 before TDC 500 before TDC Exhaust valve Close 026 rad 026 rad 150 after TDC 150 after TDCValve Springs Free length 417 to 422 mm 417 to 422 mm 1642 to 1661 in1642 to 1661 in Tilt 10 mm 10 mm 0039 in0039 inTension 1117 N 1117 N 12 kgf 265 Ibs12 kgf 265 Ibs8 UNIVERSAL MODEL M50 FUEL LINES FUEL RETURN GLOW PLUGS SEA WATER OVERBOARD HEAT EX DRAIN ZINC TRANS DIP STICK OIL FILL HOLE SHIFT LEVER ENGINE COUPLING TIMING PORT COOLANT AIR BLEED VALVE THERMOSTAT HSG FW CIRCULATING PUMP ALTERNATOR SEA WATER PUMP V267BELT DIP STICK AIR BREATHER INJECTOR PUMP FUEL AIR EED VALVE TH ROTTLE STOP LEVER FILTER BLOCK COOLANT DRAIN LEX MOUNTS COOLANT FILL CAP MANIFOLD EXHAUST FLANGE LD DRAIN HEAT EX CLEAN267OUT COVERS DRAIN AND ZINC NS DRAIN PLUG STARTER OIL PAN 7 MODEL M50 SPECIFICATIONS Horsepower 44 3000 No of Cylinders 4 Bore x Stroke 335 x 323 Cubic Inch 115 Maximum RPM 3000 Cruising Range Approx20002500 RPM Compression Ratio 211 Electrical Equipment 12 Volt 51 Amp WIGlow Plugs Lubrication Eng Approx Ots85 SAE 30 HD CDor 10W40CAUTION FILL ONLY TO FULL MARK ON DIPSTICK Lubrication TransFILL TO FULL RING ON DIPSTICK Transmission Reduction 191 Coolant FWC 5050 Solution Approx8 qts Exhaust Flange 1 14 NPT Fuel Type 2 Diesel Fuel Filter PIN 298854 Oil Filter PIN 299927 Eng Operating Temp Degrees F 1650 to 1950 Propeller Rotation Right Hand Weight Ibs545 Ibs Injection Nozzle PIN 299567 Engine is governor controlled to prevent overspeed It is recommended to carry the following extra parts should the need arise VBelt Sea Water Pump Impeller Fuel Lube Oil Filters 1 at of Trans Oil 2 Ots Lub Oil and 1 Gal of 5050 Coolant All pictorial views and specifications subject to change without notice 6 FUEL RETURN GLOW PLUGS SEA WATER OVERBOARD HEAT EX DRAIN ZIN TRANS DIP STICK OIL FILL HOLE ENGINE COUPLING UNIVERSAL MODEL M40 FUEL LINES TIMING PORT AIR BREATHER FUEL AIR BLEED VALVE THROTTLE STOP LEVER OIL FILTER BLOCK COOLANT DRAIN EX MOUNTS COOLANT AIR BLEED VALVE COOLANT FILL CAP THERMOSTAT HSG FW CIRCULATING PUMP ALTERNATOR SEA WATER PUMP V267BELT DIP STICK OIL PAN 5 MANIFOLD MANIFOLD DRAIN HEAT EXCHANGER HEAT EX CLEAN267OUT COVERS DRAIN AND ZINC TRANSMISSION RANS DRAIN PLUG UNIVERSAL MODEL M40 SPECIFICATIONS Horsepower No of Cylinders Bore x Stroke Cubic Inch Maximum RPM Cruising Range Ratio Electrical Equipment Lubrication Eng Approx ats32 2800 4 300 x 323 91 2800 20002500 R PM 211 12 Volt 51 Amp WIGlow Plugs 80 to 85 SAE 30 HD CDor 10W40CAUTION FILL ONLY TO FULL MARK ON DIPSTICK Lubrication TransFILL TO FULL RING ON DIPSTICK Type AFT 1 or GMDEXRON II Do not mix different Reduction Coolant FWC 5050 Solution ApproxExhaust Flange Fuel Type Fuel Filter Oil Filter Eng Operating Temp Degrees F Propeller Rotation Weight IbsInjection Nozzle Prior to Ser 315023After Ser 31502321 8 qts 1 V4 NPT 2 Diesel PIN 298854 PIN 299927 Right Hand 5451bs PIN 299517 299518 PIN 299567 Engine is governor controlled to prevent overspeed It is recommended to carry the following extra parts should the need arise Vbelt Sea Water Pump Impeller Fuel Lube Oil Filters 1 at of Trans Oil 2 Ots Lub Oil and 1 Gal 5050 Coolant All pictorial views and specifications subject to change without notice 4 GLOW SEA WATER OVERBOARD HEAT EX DRAIN ZINC TRANS DIP STICK OIL FILL HOLE SHIFT LEVER ENGINE COUPLIN UNIVERSAL MODEL M30 FUEL LINES TIMING PORT AIR BREATHER FUEL AIR LEED VALVE c STOP LEVER OIL FILTER BLOCK COOLANT DRAIN COOLANT AIR BLEED VALVE COOLANT FILL CAP THERMOSTAT HSG FW CIRCULATING PUMP ALTERNATOR SEA WATER PUMP V267BELT DIP STICK OIL PAN 3 MANIFOLD AUST FLANGE MANIFOLD DRAIN HEAT EXCHANGER HEAT EX CLEAN267OUT COVERS DRAIN AND ZINC TRANSMISSION DRAIN PLUG MODEL M30 SPECIFICATIONS Horsepower No of Cylinders Bore x Stroke Cubic Inch Maximum RPM Cruising Range Ratio Electrical Equipment Lubrication Eng Approx Qts24 2800 3 300 x 323 68 2800 20002400 RPM 211 12 Volt 51 Amp WGlow Plugs 50 to 55 SAE 30 HD CDor 10W40CAUTION FILL ONLY TO FULL MARK ON DIPSTICK Lubrication TransFILL TO FULL RING ON DIPSTICK Type AFT 1 or GMDEXRON II Do not mix different Reduction Coolant FWC 5050 Solution ApproxExhaust Flange Fuel Type Fuel Filter Oil Filter Eng Operating Temp Degrees F Propeller Rotation Weight IbsInjection Nozzle 21 6 qts 1 V4 NPT 2 Diesel PIN 298854 PIN 300209 Right Hand 4251bs PIN 298787 298788 Engine is governor controlled to prevent overspeed It is recommended to carry the following extra parts should the need arise VBelt Sea Water Pump Impeller Fuel Lube Oil Filters 1 Qt of Trans Oil 2 Qts Lub Oil and 1 Gal 5050 Coolant All pictorial views and specifications subject to change without notice 2 SECTION Model M30 23 Model M40 45 Model M50 67 Parts Specifications 815 Bolt Torques 1618 1 NOTES ii I a I NOTE Refer to the beginning of the individual sections for a cqrnplete table of contents for that section SECTION I SPECIFICATIONS 118 SECTION II PREVENTIVE MAINTENANCE 1924 SECTION III CONSTRUCTION AND FUNCTION 2530 SECTION IV LUBRICATION COOLING AND FUEL SySTEMS 3149 SECTION V ELECTRICAL SYSTEM 5182 SECTION VI DISASSEMBLY AND REASSEMBLY 83130 SECTION VII DYNAMO AND REGULATOR 132147 148157 M M M