Universal M-12, Service Manual

Page 1: ...MANUAL NO 1 89 UNIVERSAL AMERICAN LEADER IN MARINE POWER SlNCE 1898 SERVICE MANUAL MODELS M 12 M2 t2 M3 20 M4 30 M 18 M 25 M 25XP M 35 IDID o I ...

Page 2: ...MANUAL NO 1 89 UNIVERSAL AMERICAN LEADER IN MARINE POWER SlNCE 1898 SERVICE MANUAL MODELS M 12 M2 t2 M3 20 M4 30 M 18 M 25 M 25XP M 35 IDID o I ...

Page 3: ......

Page 4: ... SECTION I SPECIFICATIONS 1 38 SECTION II PREVENTIVE MAINTENANCE 39 44 SECTION III CONSTRUCTION AND FUNCTION 45 50 SECTION IV LUBRICATION COOLING AND FUEL SYSTEMS 51 69 SECTION V ELECTRICAL SYSTEM 71 102 SECTION VI DISASSEMBLY AND REASSEMBLy 103 150 SECTION VII DYNAMO AND REGULATOR 151 165 TROUBLESHOOTING 166 175 ...

Page 5: ...NOTES ii ...

Page 6: ...CTION I SPECIFICATIONS Model M 12 2 3 Model M2 12 4 5 Model M3 20 6 7 Model M4 30 8 9 Model M 18 10 11 Model M 25 12 13 Model M 25XP 14 15 Model M 35 16 17 Parts Specifications 18 33 Bolt Torques 34 38 1 ...

Page 7: ...EXRON II Do not mix different oils Transmission Reduction Coolant FWC 50 50 Solution Approx Exhaust Flange Fuel Type Fuel Filter Oil Filter Eng Operating Temp Degrees F Propeller Rotation Weight Ibs Injection Nozzle 2 1 2 3 Qts 1 V4 N P T 2 Diesel PIN 298854 PIN 300209 Right Hand 1751bs PIN 301302 Engine is governor controlled to prevent overspeed It is recommended to carry the following extra par...

Page 8: ...OLE ENGINE COUPLI TRANS DRAIN OPPOSITE SIDE BELL HSG COOLANT BLEED VALVE TEMP SENDER F W CIRCULATING PUMP SEA WATER PUMP V BELT THERMOSTAT HSG AIR BREATHER FUEL AIR BLEED VALVE STOP LEVER THROTTLE DIP STICK BLOCK COOLANT DRAIN OILPAN TIMING PORT OIL DRAIN COOLANT FILL CAP EXHAUST FLANGE MANIFOLD DRAIN _ HEAT EXCHANGER DRAIN ZINC PANEL PWG FLEX MOUNTS STARTER 3 ...

Page 9: ...EXRON Do not mix different oils Transmission Reduction Coolant FWC 50 50 Solution Approx Exhaust Flange Fuel Type Fuel Filter Oil Filter Eng Operating Temp Degrees F Propeller Rotation Weight Ibs Injection Nozzle 2 1 2 3 ats 1 Y4 N P T 2 Diesel PIN 298854 PIN 300209 Right Hand 1751bs PIN 302735 Engine is governor controlled to prevent overspeed It is recommended to carry the following extra parts ...

Page 10: ...NS DRAIN OPPOSITE SIDE BELL HSG COOLANT BLEED VALVE TEMP SENDER A8 F W CIRCULATING PUMP SEA WATER PUMP GLOW PWGS INJECTORS THERMOSTAT HSG R BREATHER FUEL AIR BLEED VALVE G STOP LEVER THROTTLE DIP STICK I n COOLANT DRAIN OILPAN TIMING PORT OIL DRAIN COOLANT FILL CAP MANIFOLD EXHAUST FLANGE _ HEAT EXCHANGER DRAIN ZINC PANEL PWG FLEX MOUNTS STARTER SOLENOID STARTER 5 ...

Page 11: ... not mix different oils Transmission Reduction 2 1 Coolant FWC SO 50 Solution Approx Exhaust Flange Fuel Type Fuel Filter Oil Filter Engine Operating Temp Degrees F Propeller Rotation Weight Ibs Injection Nozzles 3 ats 1 V4 N P T 2 Diesel PIN 298854 PIN 300209 Right Hand 2351bs PIN 302735 Engine is governor controlled to prevent overspeed It is recommended to carry the following extra parts should...

Page 12: ...ANS DRAIN OIL FILL CAP GLOW PWGS THERMOSTAT HSG AIR BREATHER FUEL AIR BLEED VALVE S PLEVER DIP STICK CK COOLANT DRAIN OPPOSITE SIDE BELL HSG TIMING PORT COOLANT BLEED VALVE TEMP SENDER F W CIRCULATING PUMP SEA WATER PUMP V BELT OIL FILTER COOLANT FILL CAP MANIFOLD EXHAUST FLANGE MANIFOLD DRAIN PANEL PWG __ HEAT EXCHANGER DRAIN ZINC FLEX MOUNTS STARTER SOLENOID STARTER 7 ...

Page 13: ...not mix different oils Transmission Reduction 2 1 Coolant FWC 50 50 Solution Approx Exhaust Flange Fuel Type Fuel Filter 011 Filter Engine Operating Temp Degrees F Propeller Rotation Weight Ibs Injection Nozzles 31 2 ats 1 V4 N P T 2 Diesel PIN 298854 PIN 300209 Right Hand 270 PIN 302735 Engine is governor controlled to prevent overspeed It is recommended to carry the following extra parts should ...

Page 14: ...ANS DIP STICK ___ OIL FILL HOLE TRANSMISSION ENGINE COUPLING TRANS N OPPOSITE SIDE F W CIRCULATING PUMP SEA WATER PUMP V BELT BELL HSG COOLANT FILL CAP THERMOSTAT HSG EL AIR BLEED VALVE STOP LEVER THROTTLE DIP STICK BLOCK COOLANT DRAIN HAUST FLANGE MANIFOLD DRAIN PANEL PWG HEAT EXCHANGER DRAIN ZINC FLEX MOUNTS STARTER SOLENOID STARTER 9 ...

Page 15: ...o not mix different oils Transmission Reduction Coolant FWC 50 50 Solution Approx Exhaust Flange Fuel Type Fuel Filter Oil Filter Eng Operating Temp Degrees F Propeller Rotation Weight Ibs Injection Nozzle 2 1 3 0 qts 1 V4 N P T 2 Diesel PIN 298854 PIN 300209 Right Hand 2551bs PIN 299517 299518 Engine is governor controlled to prevent overspeed It is recommended to carry the following extra parts ...

Page 16: ...ATER PUMP ALTERNATOR V BELT UNIVERSAL MODEL M 18 OIL FILL CAP GLOW PLUGS THERMOSTAT HSG FUEL AIR BLEED VALVE P LEVER THROTTLE BLOCK COOLANT DRAIN TIMING PORT DECOMPRESSION LEVER OIL PAN EXHAUST FLANGE EXHAUST DRAIN HEAT EXCHANGER PANEL PLUG DRAIN ZINC TRANS DIP STICK OIL FILL HOLE o GINE COUPLING 11 TRANS DRAIN OIL DRAIN HOSE 11 ...

Page 17: ... not mix different oils Transmission Reduction Coolant FWC 50 50 Solution Approx Exhaust Flange Fuel Type Fuel Filter Oil Filter Eng Operating Temp Degrees F Propeller Rotation Weight Ibs Injection Nozzle 2 1 5 qts 1 Y4 N P T 2 Diesel PIN 298854 PIN 300209 Right Hand 285Ibs PIN 299517 299518 Engine is governor controlled to prevent overspeed It is recommended to carry the following extra parts sho...

Page 18: ...NJECTOR PUMP INJ PUMP BLEED THROTTLE STOP LEVER rr DIP STICK BLOCK COOLANT DRAIN BELL HOUSING OIL DRAIN HOSE COOLANT AIR BLEED __ TEMP SENDER F W CIRCULATING PUMP SEA WATER PUMP ALTERNATOR OIL FILTER REGULATOR FUEL FILTER AIR BLEED ON TOP OF FILTER 13 MANIFOLD DRAIN HEAT EXCHANGER PANEL PLUG DRAIN ZINC STARTER SOLENOID TRANSMISSION TRANS DRAIN PLUG ...

Page 19: ...II Do not mix different oils Transmission Reduction Coolant FWC 50 50 Solution Approx Exhaust Flange Fuel Type Fuel Filter Oil Filter Eng Operating Temp Degrees F Propeller Rotation Weight Ibs Injection Nozzle 2 1 5 qts 1 Y4 N P T 2 Diesel PIN 298854 PIN 300209 Right Hand 2851bs PIN 299517 299518 Engine is governor controlled to prevent overspeed It is recommended to carry the following extra part...

Page 20: ... SIDE COOLANT BLEED VALVE TEMP SENDER ____ BY PASS HOSE F W CIRCULATING PUMP SEA WATER PUMP ALTERNA UNIVERSAL MODEL M 25XP OIL FILL CAP THERMOSTAT HSG AIR BREATHER FUEL AIR BLEED VALVE _ STOP LEVER THROTTLE DIP STICK n_ n COOLANT DRAIN MANIFOLD MANIFOLD DRAIN PANEL PWG HEAT EXCHANGER DRAIN ZINC MOUNTS STARTER SOLENOID STARTER 15 ...

Page 21: ...ot mix different oils Transmission Reduction Coolant FWC 50 50 Solution Approx Exhaust Flange Fuel Type Fuel Filter Oil Filter Eng Operating Temp Degrees F Propeller Rotation Weight Ibs Injection Nozzle 2 1 5 qts 1 Y4 N P T 2 Diesel PIN 298854 PIN 300209 165 to 1950 Right Hand 3351bs PIN 299517 299518 Engine is governor controlled to prevent overspeed It is recommended to carry the following extra...

Page 22: ...LL CAP THERMOSTAT HOUSING BY PASS HOSE FUEL FILTER AIR BLEED ON TOP FUEL AIR BLEED VALVE THROTTLE LOCK COOLANT DRAIN FLEX MOUNTS BELL HOUSING TEMP SENDERS F W CIRCULATING PUMP SEA WATER PUMP ALTERNATO OIL FILTER COOLANT FILL CAP OIL DRAIN HOSE OIL PAN 17 FUEL LINES REGULATOR EXHAUST FLANGE HEAT EXCHANGER ENGINE COUPLING TRANS DRAIN ...

Page 23: ... angle 0 785 rad 0 785 rad 45 00 45 00 Valve face angle 0 785 rad 0 785 rad 45 00 45 00 Valve recessing 0 75 to 0 95 mm 0 75 to 0 95 mm 0 0295 to 0 0374 in 0 0295 to 0 0374 in Clearance between valve 0 030 to 0 057 mm 0 030 to 0 057 mm stem and guide 0 00118 to 0 00224 in 0 00118 to 0 00224 in Valve stem 0 0 5 968 to 5 980 mm 5 968 to 5 980 mm 0 23496 to 0 23543 in 0 23496 to 0 23543 in Valve guid...

Page 24: ...0 785 rad 45 0 45 0 0 75 to 0 95 mm 0 75 to 0 95 mm 1 2 mm 0 0295 to 0 0374 in 0 0295 to 0 0374 in 0 047 in 0 030 to 0 057 mm 0 030 to 0 057 mm 0 10 mm 0 00118 to 0 00224 in 0 00118 to 0 00224 in 0 0039 in 5 968 to 5 980 mm 5 968 to 5 98 mm 5 93 mm 0 23496 to 0 23543 in 0 23496 to 0 23543 in 0 2335 in 6 Q10 to 6 025 mm 6 010 to 6 025 mm 0 23661 to 0 23721 in 0 23661 to 0 23721 in 0 35 rad 20 0 35 ...

Page 25: ... 0 0 9 to 1 1 mm 0 035 to 0 043 in 0 035 to 0 065 mm 0 0014 to 0 0026 in 6 960 to 6 975 mm 0 274 to 0 2746 in 7 010 to 7 025 mm 0 2759 to 0 2765 in 0 35 rad 20 before TOC 0 79 rad 45 after TOC 0 87 rad 50 before TOC 0 26 rad 15 after TOC 35 1 mm to 35 6 mm 1 382 to 1 402 in 1 3 mm 0 051 in 74 N 31 mm 7 5 kQf 31mm 16 5 Ibs l1 22 in 20 Model 25 0 05 mm 0 0020 in 0 6 to 0 8 mm 0 0236 to 0 0315 in 1 1...

Page 26: ...ad 0 794 rad 45 45 5 0 9 to 1 1 mm 0 9 to 1 1 mm 1 3 mm 0 035 to 0 043 in 0 035 to 0 043 in 0 051 in 0 035 to 0 065 mm 0 035 to 0 065 mm 0 1 mm 0 0014 to 0 0026 in 0 0014 to 0 0026 in 0 004 in 6 960 to 6 975 6 960 to 6 975 mm 0 2740 to 0 2746 in 0 274 to 0 2746 in 7 010 to 7 025 mm 7 010 to 7 025 mm 0 2759 to 0 2765 in 0 2759 to 2 2765 in 0 35 rad 20 0 35 rad 20 before TOe before TOe 0 79 rad 45 0...

Page 27: ...0 to 0 51 mm 0 20 to 0 51 mm 0 0079 to 0 0201 in 0 0079 to 0 0201 in Clearance between idle gear 0 Q16 to 0 045 mm 0 020 to 0 054 mm shaft and idle gear bushiing 0 00063 to 0 00177 in 0 00079 to 0 00213 in Idle gear shaft O D 15 973 to 15 984 mm 19 967 to 19 980 mm 0 62886 to 0 62929 in 0 78610 to 0 78661 in Idle gear bushing I D 16 000 to 16 018 mm 20 000 to 20 021 mm 0 62992 to 0 63063 in 0 7874...

Page 28: ... 0 20 to 0 51 mm 0 20 to 0 51 mm 0 6 mm 0 0079 to 0 021 in 0 0079 to 0 0201 in 0 024 in 0 020 to 0 054 mm 0 020 to 0 054 mm 0 10 mm 0 00079 to 0 00213 in 0 00079 to 0 00213 in 0 0039 in 19 967 to 19 980 mm 19 967 to 19 980 mm 0 78610 to 0 78661 in 0 78610 to 0 78661 in 20 000 to 20 021 mm 20 000 to 20 021 mm 0 78740 to 0 78823 in 0 78740 to 0 78823 in 66 000 to 66 019 mm 66 000 to 66 019 mm 0 15 m...

Page 29: ...0 51 mm 0 20 to 0 51 mm 0 0079 to 0 0201 in 0 0079 to 0 0201 in Clearance between idle gear 0 016 to 0 045 mm 0 016 to 0 045 mm shaft and idle gear bushiing 0 0007 to 0 0017 in 0 0007 to 0 0017 in Idle gear shaft 0 0 17 973 to 17 984 mm 19 973 to 17 984 mm 0 7076 to 0 7080 in 0 7076 to 0 7080 in Idle gear bushing I D 18 000 to 18 01 mm 18 000 to 18 018 mm 0 7087 to 0 7093 in 0 708 to 0 7093 in Cyl...

Page 30: ... 0079 in 0 20 to 0 51 mm 0 20 to 0 51 mm 0 6 mm 0 0079 to 0 0201 in 0 0079 to 0 0201 in 0 024 in 0 Q16 to 0 045 mm 0 Q16 to 0 045 mm 0 15 mm 0 0007 to 0 0017 in 0 0007 to 0 0017 in 0 0059 in 17 973 to 17 984 mm 17 973 to 17 984 mm 0 7076 to 0 7080 in 0 7076 to 0 7080 in 18 000 to 18 018 in 18 000 to 18 051 mm 0 7087 to 0 7093 in 0 7087 to 0 7106 in 75 000 to 75 019 mm 75 000 to 75 019 mm 2 9528 to...

Page 31: ...22 975 mm 1 33697 to 1 33760 in 33 994 to 34 040 mm 1 33835 to 1 34016 in 0 15 to 0 31 mm 0 0059 to 0 0122 in 0 2 mm 0 4 mm 0 008 in 0 Q16 in 0 2 mm 0 4 mm 0 008 in 0 016 in 0 Q16 to 0 039 mm 0 00063 to 0 00154 in 18 001 to 18 009 0 7087 to 0 70902 in 18 025 to 18 040 mm 0 70965 to 0 71024 in 69 KPa 0 7 kgt em2 10 psi 196 to 441 KPa 2 0 to 4 5 kgf em2 28 to 64 psi 0 07 to 0 15 mm 0 0028 to 0 0059 ...

Page 32: ...in 33 994 to 34 040 mm 33 994 to 34 040 mm 1 33835 to 1 34016 in 1 33835 to 1 34016 in 0 15 to 0 31 mm 0 15 to 0 31 mm 0 15 mm 0 0059 to 0 0122 in 0 0059 to 0 0122 in 0 0059 in 0 2 mm 0 4 mm 0 2 mm 0 4 mm 0 008 in 0 016 in 0 0081 in 0 016 in 0 2 mm 0 4 mm 0 2 mm 0 4 mm 0 008 in 0 016 in 0 008 in 0 016 in 0 05 mm 0 002 in 0 016 to 0 039 mm 0 016 to 0 039 mm 0 10 mm 0 00063 to 0 00154 in 0 00063 to ...

Page 33: ...050 mm 1 4569 to 1 4587 in 0 15 to 0 31 mm 0 0059 to 0 0122 in 0 2 mm 0 4 mm 0 008 in 0 Q16 in 0 2 mm 0 4 mm 0 008 in 0 016 in 0 02 mm 0 0008 in 0 014 to 0 038 mm 0 0006 to 0 0015 in 20 002 to 20 011 mm 0 7875 to 0 7878 in 20 025 to 20 040 mm 0 7884 to 0 789 in 60 KPa 0 7 kgf cm2 10 psi 196 to 441 KPa 2 0 to 4 5 kgf cm2 28 to 64 psi 0 11 to 0 15 mm 0 0043 to 0 0059 in 0 07 to 0 15 mm 0 0028 to 0 0...

Page 34: ...5 mm 1 4569 to 1 4587 in 1 4569 to 1 4587 in 0 15 to 0 31 mm 0 15 to 0 31 mm 0 5 mm 0 0059 to 0 0122 in 0 0059 to 0 0122 in 0 0197 in 0 2 mm 0 4 mm 0 2 mm 0 4 mm 0 008 in 0 Q16 in 0 008 in 0 Q16 in 0 2 mm 0 4 mm 0 2 mm 0 4 mm 0 008 in 0 016 in 0 008 in 0 016 in 0 02 mm 0 02 mm 0 0008 in 0 0008 in 0 014 to 0 038 mm 0 014 to 0 038 mm 0 0006 to 0 0015 in 0 0006 to 0 0015 in 20 002 to 20 011 mm 20 002...

Page 35: ... 15 to 9 psi 600 C 1400 F 73 90 C 1650 F 0 375 to 0 410 rad 21 5 to 23 5 before TOC 59 2 5 to 14 52_ Mt a 400 to 350 kgf cm2 J5689 to 4978 Psi 21 57 to 20 59 MPa 220 to 210 kgf cm2 J3129 to 2987 PsiL 13 73 to 14 71 MPa 140 TO 150 kgf cm2 1991 to 2133 Psi 12 75 MPa 190 kgf cm2 1849 Psi 700 to 800 F 46 amps 3 2 to 3 6 amps 4 1 to 4 7 ohm Acceptable 3 16 or longer Approx 0 8 ohm AC 20 volt or more 52...

Page 36: ...Psi 21 57 to 20 59 MPa 21 57 to 20 59 MPa 22 0 to 21 0 kgf cm2 22 0 to 21 0 kgf cm2 3129 to 2987 Psi 3129 to 2987 Psi 13 73 to 14 71 MPa 13 73 to 14 71 MPa 14 0 to 15 0 kgf cm2 1 0 to 15 0 k9f C 2 1991 to 2133 Psi 1991 to 2133 Psi 12 75 MPa 12 75 MPa 13 0 kgf cm2 13 0 kgf cm2 1849 Psi 1849 Psi 70 to BOo F 46 amps 70 to BOo F 46 amps 3 2 to 3 6 amps 3 2 to 3 6 amps 4 1 to 4 7 ohm 4 1 to 4 7 ohm Acc...

Page 37: ...o 15 psi 0 9 to 0 6 kgf cm2 15 to 9 psi 600 C 1400 F 73 90 C 1650 F 0 401 to 0 436 rad 23 to 25 before TDC 58 8 to 49 0 MPa 600 to 500 kgf cm2 8532 to 7110 psi 9 8 to 0 5 MPa 100 to 5 kgf cm2 1442 0 to 71 1 psi 13 7 to 14 7 MPa 140 TO 150 kgf cm2 1990 to 2133 psi 12 7 MPa 130 kgf cm2 1848 6 psi 700 to 800 F 46 amps 3 2 to 3 6 amps 4 1 to 4 7 ohm Acceptable 3A6 or longer Approx 1 6 ohm AC 20 volt 1...

Page 38: ...Pa 58 8 to 49 0 MPa 600 to 500 kgf cm2 600 to 500 kgf cm2 8532 0 to 7110 0 Pslt 8532 to 7110 0 Psi 100 to 5 kgf cm2 100 to 5 kfg cm2 1422 0 to 71 1 psi 1422 to 71 1 psi 13 7 to 14 7 MPa 13 7 to 14 7 MPa 14 0 to 15 0 kgf cm2 14 0 to 15 0 kgf cm2 1990 to 2133 Psi 1990 to 2133 Psi 12 7 MPa 12 7 MPa 13 0 kgf cm2 1848 6 psi 13 0 kgf cm2 1848 6 psi 70 to 80 F 46 amps 70 to 80 F 46 amps 3 2 to 3 6 amps 3...

Page 39: ...15 kgf m 1 0 to 1 15 kgf m studs 7 23 to 8 32 ft lbs 7 23 to 8 32 ft lbs Idle gear shaft bolts 1 0 to 1 15 kgf m 1 0 to 1 15 kgf m 7 23 to 8 32 ft lbs 7 23 to 8 32 ft lbs Glow plugs 2 0 to 2 5 kgf lbs 2 0 to 2 5 kgf m No need to apply oil 14 5 to 18 1 ft lbs 14 5 to 18 1 ft lbs Drain plugs 3 3 to 3 8 kgf m 3 3 to 3 8 kgf m 23 9 to 27 5 ftllbs 23 9 to 27 5 ftllbs Nozzle holders 5 0 to 7 0 kgf m 5 0...

Page 40: ...f m 7 23 to 8 32 ft lbs 7 23 to 8 32 ft lbs 2 0 to 2 5 kgf m 2 0 to 2 5 kgf m 14 5 to 18 1 ft lbs 14 5 to 18 1 ftllbs 3 3 to 3 8 kgf m 3 3 to 3 8 kgf m 23 9 to 27 5 ft lbs 23 9 to 27 5 ftllbs 5 0 to 7 0 kgf m 5 0 to 7 0 kgf m 36 2 to 50 6 ftllbs 36 2 to 50 6 ft lbs 1 5 to 2 0 kgf m 1 5 to 2 0 kgf m 10 8 to 14 5 ft lbs 10 8 to 14 5 ft lbs 1 5 to 2 0 kgf m 1 5 to 2 0 kgf m 10 8 to 14 5 ftllbs 10 8 t...

Page 41: ... studs 12 3 to 15 2 ft lbs 12 3 to 15 2 ftllbs Idle gear shaft bolts 1 0 to 1 15 kgf m 1 0 to 1 15 kgf m 7 23 to 8 32 ft lbs 7 23 to 8 32 ft lbs Glow plugs 2 0 to 2 5 kgf m 2 0 to 2 5 kgf m No need to apply oil 14 5 to 18 1 ft lbs 14 5 to 18 1 ft lbs Drain plugs 4 0 to 4 5 kgf m 4 0 to 4 5 kgf m 28 9 to 36 2 ftllbs 28 9 to 36 2 ft lbs Nozzle holders 3 0 to 5 0 kgf m 3 0 to 5 0 kgf m 21 7 to 36 2 f...

Page 42: ...t lbs 2 0 to 2 5 kgf m 2 0 to 2 5 kgf m 14 5 to 18 1 ftllbs 14 5 to 18 1 ft lbs 4 0 to 4 5 kgtlm 4 0 to 4 5 kgf m 28 9 to 36 2 ft lbs 28 9 to 36 2 ft lbs 3 0 to 5 0 kgf m 4 0 to 5 0 kgf m 21 7 to 36 2 ft lbs 28 9 to 36 2 ft lbs 0 14 to 0 2 kgf m 0 14 to 0 2 kgf m 10 1 to 14 5 ft lbs 10 1 to 14 5 ftllbs 1 5 to 2 0 kgf m 1 5 to 2 0 kgf m 10 8 to 14 5 ft lbs 10 8 to 14 5 ft lbs 2 8 to 3 5 kgf m 2 8 t...

Page 43: ...bs ft M 14 79 6 92 6 Ibs ft 91 1 108 5 Ibs ft 123 0 144 7 Ibs ft M 16 123 0 141 0 Ibs ft 144 7 166 4 Ibs ft 191 7 224 2 Ibs ft M 18 180 0 209 8 Ibs ft 202 5 235 1 Ibs ft 253 2 296 5 Ibs ft M 20 245 9 289 3 Ibslft 271 2 318 2 Ibs ft 361 6 419 5 Ibs ft Bolt material grades are shown by numbers punched on the bolt heads Prior to tightening be sure to check out the numbers as shown below Punched Bolt ...

Page 44: ...rnings 40 Maintenance Check List 41 POINTS OF INSPECTION AND CHANGING Engine Lubricating Oil 42 Changing Engine Oil Level 42 Changing Engine Oil 42 Changing Engine Oil Filter Cartridge 43 Inspection of Fuel Filter 43 Venting the Fuel System 44 39 ...

Page 45: ...assembling 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 Applyin...

Page 46: ...ng fuel pipes and clamps Changing engine oil Cleaning air filter element Cleaning fuel fiilter Checking battery electrolyte level Checking fan belt tension and damage Checking oii or water leakage Checking water pipes and clamps Changing oil filter cartridge Changing fuel filter element Cleaning heat exchanger Recharging battery Changing coolant Changing air filter element or every 6 cleanings Che...

Page 47: ...e oil level is below the lower mark on the dip stick add sufficient oil to the full mark DO NOT OVERFILL 1 Dip Stick 2 Oil Filler Plug CHANGING ENGINE OIL Drain the oil while the engine is still warm by removing the drain plug on the oil pan and oil filler plug or through the oil drain hose so that the oil may completely drain Do not mix different brands of oil If a different brand of oil should b...

Page 48: ...to the prescribed level 1 Oil filter cartridge INSPECTION OF FUEL FILTER The fuel filter is installed in the fuel line from the fuel tank to the injection pump between the tank and feed pump in the basic model As the fuel from the inlet of the cock body moves through the filter element the dirt and impurities in the fuel are filtered allowing only clean fuel to enter the inside of the filter eleme...

Page 49: ...air vent screw at the top of the filter by turning it twice 3 When bubbles disappear from fuel coming out of the plug twist it back on 4 Open the air vent plug on the fuel injection pump 5 Pull the engine stop lever back completely to stop the engine and run the starter for about 10 seconds 6 Close the air vent plug when air bubbles disappear from the fuel flowing out Models 12 2 12 3 20 and 4 30 ...

Page 50: ...ONSTRUCTION AND FUNCTION Cylinder Block 46 Cylinder Head 46 Crankshaft 47 Piston and Piston Rings 48 Connecting Rods 48 Camshaft and Fuel Camshaft 49 Rocker Arm Assembly 49 Inlet and Exhaust Valves 50 Flywheel 50 45 ...

Page 51: ...air can be protected from being heated and expanded by heated exhaust air The cool high density suction air has a higher voluminous efficiency and raises the power of the engine Furthermore distortion of the cylinder head by heated exhaust air is reduced because suction ports are arranged alternately The combustion chamber is exclusive spherical combustion chamber type Suction air is whirled to be...

Page 52: ...o 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 specia...

Page 53: ...ffective 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 incr...

Page 54: ...all 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 open close movement of the inlet and exhaust valves Valve control timing must be adjusted with screws on the rocker arms Lubrication oil is pressurized throu...

Page 55: ...7 Inlet valve 8 Exhaust valve FLYWHEEL 7 Intake and exhaust valve 4 _ 5 6 8 Flywheel is connected with the crankshaft Storing explosive force by each cylinder as the force of inertia the flywheel functions to rotate the crankshaft smoothly On the circumference of the flywheel are stamped marks for fuel injection timing and top dead center The flywheel and crankshaft can be fixed to each other at a...

Page 56: ...agram 53 Relief Valve 54 By pass Valve 54 Oil Switch 55 Oil Pump 55 COOLING SYSTEM Water Pump 56 Thermostat 56 Oberdorfer Water Pump 57 Sherwood Water Pump 58 Johnson Water Pump 59 New Style Sherwood Water Pump 60 FUEL SYSTEM Fuel Filter 61 Fuel Pump 62 Fuel Injection Pump 62 65 Injection Nozzle 66 Governor 67 69 51 ...

Page 57: ...LUBRICATION SYSTEM Crankpin Bearing Piston Oil Filter 1 52 Oil Filter Cartridge and Relief Valve 1 To rocker arm shaft and camshaft 2 To crankshaft ...

Page 58: ...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 g...

Page 59: ...PASS VALVE Oil filter cartridge has a by pass valve inside to prevent the lack of lubrication oil in the engine if the oil filter element is clogged When the pressure difference before filtering and after is more than 98 1 kPa 14 2 psi the by pass valve opens and lets the oil pass to each part of engine without passing through the filter Relief valve and by pass valve 1 Relief valve 2 By pass valv...

Page 60: ...ng retainer OIL PUMP 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 sea...

Page 61: ...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 _ Temperature sensor of wax pellet type thermostat 1 al bl 1 Leak hole 7 To radiato...

Page 62: ...57 Item Unit Description 1 4 Cover Screws 2 1 Pump Cover 3 1 Cover Gasket 4 1 Impeller Snap Ring 5 1 Impeller 6 1 PUmp Shaft Old Style 6A 1 1 pc Shaft New Style 7 1 Cam 8 1 Carbon Bushing 9 1 Cam Locking Screw 10 2 Oil Seal 11 1 Drain Plug 57 ...

Page 63: ...1 10 1 11 1 12 2 13 1 SHERWOOD WATER PUMP PUMP ASSEMBLY 300986 Description Cover Screws Pump Cover Cover Gasket Impeller Snap Ring Impeller Key Pump Shaft Old Style 1 pc Shaft New Style Water Seal Cam Pump Body Cam Locking Screw Oil Seal Drain Plug 58 ...

Page 64: ... Description 1 6 Cover Screws 2 1 Pump Cover 3 1 Cover Gasket 4 1 Impeller 5 1 Pump Shaft 6 1 Caqm 7 1 Wear Plate 8 1 Pin 9 1 Cam Locking Screw 10 1 PUmp Body 11 1 Lip Seal 12 1 O Ring 13 1 Washer 14 2 Ball Bearing 15 1 Guide Ring 16 1 Service Kit 59 ...

Page 65: ..._ LD __e_ scriP t iO n Impeller Housi O Ring ng Cam Screw Cam Impeller Cir Clip Flat Washer Seal Seat Not Available 0 Cir Cr rder 13 Ip Internal Clr Clip External Ball Bearing Seal Seat A Cir Cr ssembly Ip External Key Shaft End Plate Gasket Pump Body Lock Washer Bolt 60 ...

Page 66: ...ain into the tank 1 2 3 1 Fuel Tank 2 Fuel Overflow Pipe 3 Injection Pipe 4 Injection Nozzle 5 Injection Pump 6 Fuel Filter Water Separator 7 Fuel Feed Pump Elec 8 Fuel Filter FUEL FILTER A fuel filter is used to prevent dirty fuel from reaching the injection pump and injection nozzles The filter element will require occasional replacement to maintain an adequate flow 51 fuel to the injection pump...

Page 67: ...ON PUMP Inlet stroke Discharge stroke 6 t 1 From Fuel Filter 2 Inlet Valve 3 Outlet Valve 4 Diaphragm 5 Fuel Camshaft 6 To Injection Pump The K type mini pump is provided it features high injection quality even at low engine speed The fuel injection pump plunger is reciprocated by the fuel camshaft which is driven by the crankshaft through a system of timing gears Fuel camshaft rpm is 1 2 of camsh...

Page 68: ...s up pressure increases and delivery valve is opened Then fuel is pressure fed through the injection pipe and nozzle into the combustion chamber 4 Completion of pressure feed When plunger moves further up the control groove and feed hole meet Pressurized fuel in the delivery chamber is returned through the plunger s center hole control groove and feed hole to the fuel chamber Then pressure falls a...

Page 69: ...nger is rotated a certain amount in the direction of the arrow by the control rack stroke A is effective until the feed hole meets the control groove and fuel is injected as the stroke amount 3 Injection maximum When the plunger is rotated by the control rack to the maximum amount in the direction of the arrow effective stroke reaches maximum and maximum injection is provided Injection Control t 1...

Page 70: ... 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 t...

Page 71: ...fuel tank Injection pressure can be controlled by inserting shims between nozzle holder body and adjusting washers The pressure increases when a O 1mm shim is inserted Injection nozzle is also precision finished as is the injection pump treat it carefully and protect from water and dust Injection nozzle 31 41 51 H tt 161 JH 1 f t tt t 17l 181 1 1 Nozzle Holder Body 2 Adjusting Washer 3 Nozzle Spri...

Page 72: ...is set at idling position after the engine is started high speed governor spring 1 does not work at all and also low speed governor spring 2 does only a little action Therefore governor sleeve is pushed leftward by a centrifugal force of ball weights Fork lever 1 and control rack are moved leftward by the sleeve and then idling limit spring is compressed by control rack As a result the control rac...

Page 73: ...force of ball weights becomes smaller than the tension of governor springs 1 and 2 As a result the control rack is moved rightward and fuel injection amount is increased to produce an engine torque required for the load a c At middle high speed running 1 Speed Control Lever 2 Governor Spring 1 3 Governor Spring 2 4 Ball Weights When load is increased 1 3 2 t 5 4 __ 1 Engine Torque Curve 2 Small Lo...

Page 74: ...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 6 5 When stop lever is moved to STOP position f...

Page 75: ...NOTES 70 ...

Page 76: ...8 Ammeter 78 Alternator Regulator Test Procedure 79 Test Procedure Integral Regulator Systems 80 83 Troubleshooting Guide Integral Regulator Systems 80 81 Test Procedure Remote Regulator Systems 84 86 Troubleshooting Guide Remote Regulator Systems 84 Alternator Repair Procedure 87 93 Rotor Inspection and Electrical Testing 93 96 Alternator Reassembly 96 99 Alternator Performance Tests 99 100 Crank...

Page 77: ... per cyl WIRE NO COLOR 1 Black 2 Grey 3 Yellow Red 4 Orange 5 Red 6 Purple 7 Lt Blue 8 Tan 9 Open 10 Grey 11 Orange Red WIRE SIZE 10 10 16 10 10 16 16 16 14 16 14 WIRING DIAGRAM 1DI _ __ Starter Extenalon Harne 72 ...

Page 78: ...blade terminal for connection to the associated remote regulator Serviceable features of previous Motorola Charging System designs have been retained in these units The voltage regulator and brush assembly can be removed without disassembly of the alternator thus allowing for individual testing or inspection 1 2 3 1 Long life silicon diodes 2 Permanently lubricated sealed rear ball bearing 3 Quiet...

Page 79: ...0 pounds TYPICAL ALTERNATOR MODEL The field for the alternator is wound concentrically about the core of the rotor The field structure contains twelve poles six sets of pole pairs and the rotor is dynamically balanced after assembly to minimize vibration The rotor is supported in the alternator by a pair os sealed ball bearings Field current of approximately 2 5 Amperes is supplied to the field th...

Page 80: ... the charging system The alternator designs produce a rated output of 51 amperes Rated output is achieved at approx imately 6000 alternator RPM at an ambient temperature of 75 degrees F 23 8 degrees C The alternator is designed to operate in an ambient of 40 degrees to 212 degrees F 40 to 100 degrees C To ensure proper cooling of the rectifier bridge and internal components of the alter nator it m...

Page 81: ...psulated 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 Vi w ffi 80 Il E 60 z w a a 40 I...

Page 82: ...EAR HOUSING ROTATION For special installation requirements the alternator rear housing may be rotated to one of four different positions that are spaced 90 apart To rotate the rear housing proceed as follows 1 Detach plastic cover from rear housing 2 Remove the four 4 through bolts using a 1 4 nutdriver or socket See illustration below 3 Rotate the housing clockwise or counter clockwise to the des...

Page 83: ...PULLEY MUST BE IN LINE WITH EACH OTHER REAR FRONT HOUSING HOUSING ALTERNATOR BELT ALIGNMENT Ammeter requirements vary with application An original equipment ammeter may be difficult to replace with a higher reading unit due to limited panel space and the vehicle wiring system For an ammeter to show alternator charge and accessory discharge it must be connected as shown in illustration below ALTERN...

Page 84: ...if necessary A low or discharged battery may cause false or misleading readings on the in vehicle tests Test Equipment Requirements The Alternator and Regulator tests outlined require electrical test equipment to measure voltage only however most commercial test equipment incorporates several testing devices in a single unit DC VOLTMETER 0 20 Volt Scale BATTERY TEST EQUIP Any commercial type Hydro...

Page 85: ...charged 1 Indicator lamp burned out or 1 Check bulb harness indicator lamp off with key defective wire harness on engine stopped Normal condition is lamp on 2 Broken brush 2 Replace brush assy 3 Defective alternator system 3 Refer to Problem Area Determination Section Battery overcharges 1 Defective wire harness 1 Refer to Problem Area excessive use of water 2 Defective alt system Determination Se...

Page 86: ...tor Test Test No 2 b If Regulator is O K the cause is probably an open field circuit and Alternator must be removed for repair 4 Further Investigation Requires Alternator Removal and Repair diodes B BATTERY OVERCHARGED 1 Regulator Shorted Replace Regulator IGN IND SW LIGHT POS J 4 OUTPUT B IVOLTS I TEST POIN INDICATION A B BATTERY VOLTAGE B REG 1 5 TO 3 0 VOLTS WITH IND LIGHT ON BATTERY 13 5 TO 15...

Page 87: ... from terminals extending through back cover Remove back cover two screws and reconnect all wires With ignition on and engine not running and jumper not attached check for battery voltage at terminal A and terminal B Indicator light will be off Add jumper JU1 between field and ground If 1 5 to 3 0 volts is present at terminal B and the indicator light is on an open defective regulator is indicated...

Page 88: ...tor Ooutput Test BATTERY After voltmeter is connected as shown in Figure below start and run engine at a fast idle of approximately 1 500 RPM Turn on vehicle headlights and blower fan low speed Check for nominal system output voltage of between 13 8 14 8 volts for a properly operating charging system Voltages may vary a few tenths of a volt higher or lower due to ambient temperature variations If ...

Page 89: ...tive alternator system 3 Battery overcharges 1 Poor ground 1 excessive use of water 2 Defective alt system 2 ammeter if used shows constant excessive charge voltmeter indicates greater than 14 5 volts connected across battery with no load with engine idling Battery charges at idle but 1 Slipping belts 1 discharges under load 2 Alternator defective conditions 2 Indicator lamp glows slightly 1 Defec...

Page 90: ...gine not running jumped not attached and no electrical load check for battery voltage at terminal A and for 1 5 to 3 0 volts at terminal B Add jumper JU1 between terminals A and B Start engine and run at idle If indicator lamp now goes off and charging voltage is present at terminal A the diode trio is probably open defective and alternator should be removed for repair VOLTAGE REGULATOR IGN IND SW...

Page 91: ... WITH IND LIGHT OFF v JUMPER ATTACHED 1 5 TO 3 B D 3 0 VOLTS IND LIGHT DN JUMPER NOT ATTACHED OPEN REGULATOR TEST Test No 3 Alternator Output Test B BATTERY After voltmeter is connected as shown in Figure below start and run engine at a fast idle of approximately 1 500 RPM Turn on vehicle headlights and blower fan lOW speed Check for nominal system output voltage of between 13 8 14 8 volts for a p...

Page 92: ... order to isolate and correct the problem The following troubleshooting diagram should help identify some of the more common problems to concentrate on during the overhaul repair procedure Disassembly Testing Detach Back Cover NO LOW NOISY ALTERNATOR ALTERNATOR ALTERNATOR OUTPUT OUTPUT DEFECTIVE REGULATOR DEFECTIVE REGULATOR LOOSE DRIVE PULLEY DEFECTIVE BRUSHES WORN BRUSHES CRACKED OR DAMAGED HOUS...

Page 93: ...e illustration below shows the terminals brush arrangement and testing procedure The original brush set may be reused if the brushes are 3 16 or longer and if brushes are not oil soaked cracked or show evidence of grooves on the sides of the brushes caused by vibration TEST CONTINUITY FROM ATO B FROM CTO 0 NO CIRCUIT FROM AOR B TO COR 0 TEST WITH 12 VOLT DC TEST LAMP OR OHMMETER BRUSH TEST 88 ...

Page 94: ...ATOR MOUNTING SCREWS Remove Diode Trio Field Diode and Rectifier Diode Bridge The diode trio and rectifier diode bridge are detached as an assembly Remove cone lockout from positive output B terminal Straighten B strap Remove three terminal screws and four diode trio mounting screws Detach assembly from rear housing and separate diode trio assembly from rectifier bridge See illustration below 4 MO...

Page 95: ...TESTING DIODE TRIO Test Diode Rectifier Bridge Assembly Using a commercial diode tested check for continuity Check betweenn point A and each of three terminals C for negative diodes Continuity should be observed in one direction polarity only and all diodes should check alike Then check between point B B strap and each of the three terminals C for positive diodes Continuity should be observed in o...

Page 96: ...EAR HOUSING SEPARATION Inspect the rear housing for a cracked or broken casting stripped threads or evidence of severe wear in the bearing bore due to a worn rear bearing If casting is to be reused clean in solvent dry with compressed air and install a new rear bearing retainer if retainer is damaged Test Stator The stator assembly consists of three individual windings terminated in the delta type...

Page 97: ... 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 1 KEY GROOVE CHECK BORE FOR WEAR PULLEY INSPECTION POINTS Positio...

Page 98: ...e in mounting foot Discard housing if bore shows signs of elongation oval or out of roundness ROTOR INSPECTION AND ELECTRICAL TESTING Check the rotor assembly for the following electrical properties See illustration on page 89 A Current Draw or Resistance of the Winding CAUTION Turn off DC power source before removing test leads to avoid avc damage to slip ring surfaces 1 CURRENT DRAW IN AMPERES A...

Page 99: ...ip ring to the rotor body is a correct condition C Condition of Slip Rings 1 Clean brush contacting surfaces with fine crocus cloth wipe dust and residue away 2 If surfaces are worn beyond this restoration replace the entire rotor assembly D Rotor Shaft and Pole Pieces 1 Stripped threads on shaft 2 Worn key slot 3 Worn bearing surface 4 Scuffed pole fingers 5 Worn or dry rear bearing Replace rotor...

Page 100: ... cap screw into opening at center of slip ring assembly Position bearing puller as shown in illustration below and pull slip ring assembly off rotor shaft CAUTION When holding rear end of rotor shaft in vise be sure not to grip bearing area of rotor shaft Remove Rear Bearing from Rotor STRAIGHTEN ROTOR LEADS REMOVING SLIP RING ASSY Dress rotor leads away from the bearing puller contact area Adjust...

Page 101: ...equirements will be covered in this section Install Rear Bearing Place rotor on a press as shown in illustration below Choose a driver sleeve that exerts pressure on inner race only and press bearing on rotor shaft until it contact shoulder New replacement bearings should be used whenever bearing is removed during repair procedures or when bearing is rough dry or noisy BLOCK REAR BEARING ROTOR PRE...

Page 102: ...tending above solder connections Install Front Bearing SLIP RING ASSEMBLY ____ PRESS DRIVER SLEEVE INSTALLING SLIP RING ASSEMBLY Place front bearing and housing in an arbor press as in illustration below Select a drive tool to contact the outer race only and press bearing into housing bore Bearing replacement is recommended whenever bearing is removed during alternator repair procedures of if bear...

Page 103: ...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 New front housings contain thru bolt holes that are not tapped Therefore a socket wrench rather than a nut driver will be...

Page 104: ...000 alternator RPM Slowly reduce field rheostat resistance alternator should develop a charge Continue to reduce resistance until alternator reaches rated current output in amperes CAUTION Limit output voltage to 15V maximum DO NOT operate the alternator for more than a few minutes in the manner due to the lack of voltage control If the alternator will deliver its rated output terminate the test B...

Page 105: ...echanical rotation to turn the engine crankshaft It is composed of the field coil armature brush commutator pinion overrunning clutch etc The second section allows the pinion and flywheel to engage together and current to flow through the motor section It is composed of the pull in coil holding coil pluge drive lever contract plate etc 1 Field Coil 2 Brush Spring 3 Brush Holder 4 Brush 5 Commutato...

Page 106: ...e drive lever to engage with the ring gear When start button is pushed 1 Battery 2 Starter Switch 3 Ground 4 Return Spring 5 Spline Tube 6 Pinion 7 Ring Gear 8 Operated By Lever When contact plate is closed When the contact plate is closed a large current flows through the motor section to generate a large mechanical power which turns the engine crankshaft At this time the pinion is moved forward ...

Page 107: ...n spring Simultaneously the pinion is disengaged from the ring gear the contact plate is disconnected and the starter is promptly stopped by the armature brake When push button is released Glow Plugs Glow plugs are used for each pre combustion chamber of the cylinder head to make starting easier The glow plugs are quick heating type which make starting easier with short pre heating time Constructi...

Page 108: ...ection Pump Cover 112 Removing Injection Pump 12 GEAR CASE TIMING GEAR CAMSHAFT OIL PUMP Detaching Governor Spring 13 Removing Speed Control Plate 113 Detaching Start Spring 114 Removing Fan Drive Pulley 114 Removing Gear Case 115 Removing Crankshaft Oil Slinger 115 Removing Idle Gear 116 Camshaft Stopper 116 Removing Gear and Camshaft 117 Removing Fork Lever Assembly 117 Removing Fuel Camshaft 11...

Page 109: ... 130 Checking Valve Spring Tension 130 Checking Oil Clearance Between Rocker Arm Shaft and Bushing 131 Checking Top Clearance 131 Adjusting Valve Clearance 133 Adjusting Compression Release 132 FUEL SYSTEM Testing Opening Pressure of Nozzle 133 Checking Fuel Tightness of Nozzle Valve Seat 133 Checking Shape of Fumes Across Nozzle Tip 134 Checking Fuel Tightness of Fuel Injection Pump Plunger 134 C...

Page 110: ...earance Between Crankshaft Journal and Crankshaft Bearing 1 144 Checking Oil Clearance Between Crankshaft Journal and Crankshaft Bearing 2 144 Checking Oil Clearance Between Crank Pins and Crank Pin Bearings 145 Checking End Play of Crankshaft 145 Checking Wear of Cylinder Liner 146 Crankshaft and Bearing Reference 147 REPLACING VALVE GUIDES BUSHINGS AND BEARINGS Replacing Valve Guides 148 Replaci...

Page 111: ...enough engine oil to the valve guide and valve stem 1 Head Cover REMOVING INJECTION PIPES 1 2 and 3 1 Loosen the screws on the pipe clamps 2 Detach the injection pipes in the order of 1 2 and 3 NOTE FOR REASSEMBLING Send compressed air into the pipes to blowout dust Then reassemble the pipes in the reverse order Tighten the retaining nuts to 15 to 25 Nm 1 5 to 2 5 kgf m 11 to 18 ft Ibs 1 Injection...

Page 112: ... on the surface on which the nozzles are to be installed Tighten the nozzles to 29 to 49 Nm 3 0 to 5 0 kgf m 22 to 36 ft Ibs 1 Nozzle Holder Socket Wrench 2 Rock Nut REMOVING AC DYNAMO AND FAN BELT 1 Remove the AC dynamo 2 Detach the fan belt NOTE FOR REASSEMBLING Check to see if the V belt is placed in a correct position where letters on the belt can be read from your side and there is no oil or ...

Page 113: ...y metallic particles on the surface on which the assembly is mounted Tighten the bolts to 17 to 21 Nm 1 7 to 2 1 kgf m 12 to 15 ft Ibs REMOVING PUSH RODS 1 Remove the push rods 1 Rocker Arm 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...

Page 114: ...lace 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 Cylinder head tightening sequence ___10 2 7_ oo oo oog 1 0 0 0 0 2 13 0 5 0 4 0 12 9 1 8 1 Gear Case Side 2 Flywheel Side REMOVING CYLINDER HEAD GASKET 1 Detach the cylinder head gasket being carefu...

Page 115: ... O ring 2 Pipe Pin REMOVING TAPPETS 1 Remove the six tappets from the crankcase NOTE FOR REASSEMBLING Visually check the contact between tappets and cams for proper rotation If a defect is found replace tappets Before installing the tappets apply engine oil thinly around them 1 Tappets 110 ...

Page 116: ...DER 1 Secure the retaining nut with a vise 2 Remove the nut the eye jOint and the plain washer 3 Remove the nozzle holder body and take out parts inside NOTE FOR REASSEMBLING When disassembling and reassembling the nozzle piece dip it in clean fuel Install the push rod noting its direction upside down Tighten the retaining nut to 58 8 to 78 4 Nm 6 to 8 kgf m to 57 8 ft Ibs Do not tighten it too mu...

Page 117: ...t detach the pump along the removal groove 3 Align the control rack pin with the slot on the gear case and remove the injection pump 4 In principle the injection pump should not be disassembled NOTE FOR REASSEMBLING Install the injection pump by aligning the control rack with the indicated positon Addition or reduction of one shim delays or advances the injection timing by 0 0262 rad 1 50 Install ...

Page 118: ...e 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...

Page 119: ...E PULLEY 1 Flatten the crankshaft washer 2 Loosen and remove the crankshaft nut 3 Draw out the pulley with a puller NOTE FOR REASSEMBLING Bend the crankshaft washer against one side of the nut Tighten the nut to 137 3 to 156 9 Nm 14 0 to 16 0 kgf m 101 3 to 115 7 ft Ibs Do not tighten the nut excessively it may damage the oil slinger causing oil leakage 1 Fan Drive Pulley 114 ...

Page 120: ... thin film of engine to the oil seal and install it noting the lip come off Before installing the gear case gasket apply a non drying adhesive Tighten the oil filter cartridge by hand REMOVING CRANKSHAFT OIL SLINGER 1 Remove the crankshaft collar 2 Remove the O ring 3 Detach the crankshaft oil slinger 1 Crankshaft Oil Slinger 2 O Ring 3 Crankshaft Collar 115 ...

Page 121: ... gear and crank gear 2 Idle gear and camshaft gear 3 Idle gear and injection pump gear Tighten the idle gear shaft mounting bolt 7T to 10 to 12 Nm 1 0 to 1 2 kgfSm 7 2 to S 7 ft Ibs 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 ...

Page 122: ... mounting bolts 2 Detach the fork lever assembly NOTE FOR REASSEMBLING Install the fork lever holder and crankcase after cleaning their contact surfaces Install the fork lever so that it will not hit the governor sleeve and so that equal space is allowed on either side of the lever After installation check to see that the fork lever 1 is fixed to the fork lever shaft and that it can turn smoothly ...

Page 123: ...ve shaft of the hydraulic gear pump The balls to be contained in the governor ball case are thirty 3 97 mm 0 1563 in diameter ones and eight 13 46 mm 0 5300 in diameter ones 1 Fuel Camshaft Assembly 2 Fuel Camshaft Stopper REMOVING OIL PUMP DRIVE GEAR 1 Straighten the claw of the claw washer of the oil pan and remove the nut NOTE FOR REASSEMBLING Check to see if there is a feather key Be sure to b...

Page 124: ...mp Assembly REMOVING CRANK GEAR 1 Set a special puller on the crank gear 2 Screw in the center bolt of the puller and draw out the crank gear NOTE FOR REASSEMBLING Check to see that the key is on the crankshaft Heat the crank gear to about 990C 1200F and fit on the crankshaft If there is fear of the shaft being damaged heat the gear more and fit 1 13T Gear Crank Gear 119 ...

Page 125: ...l pan To avoid uneven tightening tighten mounting bolts in diagonal order from the center Check to see that the drain plug is tight 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 a ring NOTE FOR REASSEMBLlNG After cleaning the oil filter check to see that the filter mesh is clean and install it Visually check the a ring apply e...

Page 126: ...hammer 3 Draw out the other two pistons in the same method as above NOTE FOR REASSEMBLING Before inserting the pistons into the cylinders apply enough engine oil to the pistons IMPORTANT Install the piston rings with their gaps making an angle of 2 09 rad 1200 or 3 14 rad 1800 to each other Place the top ring with their gaps on the opposite side of the combustion chamber Attach a ring to the pisto...

Page 127: ...of the rear end plate and set the flywheel Tighten the flywheel bolts to 54 to 59 Nm 5 5 to 6 0 kgfOm 40 to 43 ft Ibs in diagonal order Bend the tangs of the flywheel washer against the bolts 1 Flywheel Puller 2 Crankshaft REMOVING BEARING CASE COVER 1 Remove the bearings case cover mounting bolts First unscrew the eight bolts inside and then work on the nine outside 2 Screw the two bolts removed ...

Page 128: ...that the crankshaft can be easily installed Tighten the bearing case bolts 2 to 30 to 34 Nm 3 0 to 3 5 kgfOm 22 to 25 ft Ibs Securely bend tangs of the washer 1 Bearing Case Bolt 2 REMOVING CRANKSHAFT 1 Draw out the crankshaft from the back of the crankcase by lightly tapping it with a copper hammer NOTE FOR REASSEMBLING Before installing the crankshaft clean the oil holes in the crankshaft with c...

Page 129: ...n page 125 1 Grind the cylinder head mounting surface with an oil grinding stone 2 Set a dry liner centering base and adaptor on the frame head 3 Set the dry liner centering base 4 Set the bearing cradle to the dry liner centering base with the bearing on top 5 Insert the pulling out adaptor coupling and fix the center bolt 6 Contact the pUlling out adaptor with the bottom of the liner from the bo...

Page 130: ...earing Cradle 3 Center Bolt 4 Nut THERMOSTAT WATER PUMP REMOVING THERMOSTAT 1 Remove the thermostat cover 2 Remove the thermostat NOTE FOR REASSEMBLIING Apply a non drying adhesive only at the thermostat cover side of the gasket 125 ...

Page 131: ...tration on page 127 1 Clean the surface of the cylinder head 2 Place a straight edge on each of the cylinder heads s four sides and two diagonally as shown at the left to check the straightness of the surface 3 Insert a feeler gauge between the straight edge and the cylinder head surface 4 The maximum thickness that can be inserted is the amount of flatness 5 If the measurement exceeds the allowab...

Page 132: ...ead surface with the red permeative liquid 3 Wash away the red permeative liquid on the cylinder head surface with the detergent 4 Spray the cylinder head surface with the developer If flawed it can be identified as red marks Reference Should be no flaw A Air spray red check 1 Detergent 2 Red Permeative Liquid 3 White Developer 1 2 3 127 ...

Page 133: ... that the valve seat fits to the valve center so as to ensure a b as shown in the figure NOTE After correcting the valve seat check for valve recessing B 15 cutter A 45 cutter 1 Valve 2 Corrected surface of valve seat CHECKING VALVE RECESSING 1 Clean the face of the valve 2 Measure the recessing with a depth gauge 3 See engine specifications 128 How to repair the valve seat B 2 ...

Page 134: ... 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 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...

Page 135: ... flat surface at the end of the spring coil must exceed the full circumference by two thirds Check the entire surface of the spring for scratches I Allowable limit CHECKING VALVE SPRING TENSION 1 3 mm 0 051 in How to measure squarenass of valve sprin g 111 1 Place the spring on a tester and compress it to the same degree that it is actually compressed in the engine 31 mm 12 in 2 Read the compressi...

Page 136: ...uality fuse from the nozzle holder hole Be careful not to let the fuse touch the valve surface 4 Rotate the engine with your hand 5 Take the fuse out carefully 6 Measure the place where the fuse was crushed with vernier calipers 7 If the clearance is not within the reference value adjust by inserting a shim between the cylinder head and the gasket 131 Reference value Thickness of gasket when tight...

Page 137: ...ull the compression release lever 0 145 0 185 mm T 0 006 to 0 007 in 4 Reduce the valve clearance to zero by the compression release adjustment bolt Reach for the bolt through the window Then screw in the bolt by 1 to 1 5 turns and tighten the lock nut NOTE After adjustment turn the crankshaft by hand and check to see that the valve and the piston should not be in contact with each other Reference...

Page 138: ...ses an approximate 980 6 kPa 10 kgf cm2 142 2 psi increase in fuel injection pressure DANGER Be careful not to come into direct contact with the injected fumes The fumes destroy any cells they may touch They may arso cause blood poisoning See engine specifications CHECKING FUEL TIGHTNESS OF NOZZLE VALVE SEAT 1 Apply a pressure 2 After keeping the nozzle under this pressure for 10 seconds check to ...

Page 139: ...rement is less than allowable limit replace the pump element In this case ask a repair shop to do the replacement Be sure to give them adjustment reference data on the fuel injection pump Shown below See engine specifications Reference valve 8 seconds or more Allowable limit 4 seconds Adjustment of Injection Control rack Speed Amount of injection Allowance mm3 position 1 rpm mm3 st 3 9 1400 22 5 t...

Page 140: ...he initial pressure 5 If the measurement is less than allowable limit replace the delivery valve See engine specifications Reference value Allowable limit 1 Connector 2 Pressure Sensor 10 seconds or more 5 seconds Pressure gauge construction 14 7 MPa 150 kgflcm2 2133 psi and 68 6 MPa 700 kgflcm2 9954 psi 3 Non drying Adhesive 4 Weld Entire Circumference 5 Copper Packing 6 S45C Steel Tube 7 S45C He...

Page 141: ...p it as soon as the fuel level at the tip of the valve holder begins to increase 5 Check to see if the F1 mark on the flywheel is aligned with the dot mark 6 If the timing is out of adjustment readjust with shims IMPORTANT Adding or removing one shim 0 15 mm 0 0059 in varies the crank angle by approx 1 5 After adjustment apply a thin film of non drying adhesive to both sides of the shims See engin...

Page 142: ...ance 3 If the clearance exceeds the allowable limit replace the camshaft See engine specifications CHECKING CAMSHAFT ALIGNMENT 1 Gently put the camshaft on V blocks 2 Set a dial gauge to the journal 3 While slowly rotating the camshaft read the dial gauge The camshaft flexure is half of the reading 4 If the measurement exceeds the allowable limit replace the camshaft I Allowable limit 137 0 08 mm ...

Page 143: ...exceeds the allowable limit replace the camshaft See engine specifications 1 Cam Height CHECKING GEAR BACKLASH 1 Install a lever type indicator between the gear teeth 2 Clamp one gear rotate the other and measure the backlash 3 If the backlash exceeds the allowable limit replace See engine specifications 138 Cam height measuring points ...

Page 144: ...he oil pump oilways oil clearances and pressure regulating valve NOTE FOR MEASURING Supply the specified amount of recommended oil The oil filter must not be clogged or broken See engine specifications OIL PUMP ROTOR TYPE Checking Rotor Lobe Clearance 1 Insert a feeler gauge into the gap between the inner and outer rotors and measure the clearance 2 If the clearance exceeds the allowable limit rep...

Page 145: ...lowable limit replace See engine specifications Checking end Clearance Between Rotor and Cover 1 Paste a press gauge to the surface of the gear with grease 2 Attach the cover 3 Gently remove the cover Measure the clearance by placing the gauge paper on the press gauge where it is crushed 4 If the measurement is not within the reference value replace Reference value 140 0 08 to 0 13 mm 0 0031 to 0 ...

Page 146: ...ith an outside micrometer 2 If the measurement exceeds the allowable limit replace See engine specifications CHECKING CLEARANCE BETWEEN PISTON PIN AND SMALL END BUSHING 1 Measure the piston pin with an outside micrometer 2 Measure the LD of connecting rod small end bushing with an inside micrometer Calculate the clearance 3 If the clearance exceeds the allowable limit replace See engine specificat...

Page 147: ...PORTANT Measure the piston ring gap at the point of the minimum inside diameter of the cylinder liner See engine specifications CHECKING SIDE CLEARANCE OF RING IN GROOVE 1 Remove the piston ring from the piston 2 Place the ring in its groove as it shown at left and measure the clearance 3 If the clearance is not within the reference valve replace the ring NOTE As the top ring is a keystone type it...

Page 148: ...MPORTANT Because the 1 0 of the connecting rod small end bushing is used as the basis for this check check it is not worn beforehand See engine specifications CRANKSHAFT CHECKING CRANKSHAFT ALIGNMENT 1 Place V blocks on the surface plate and support the journals at both ends of the crankshaft on the V blocks 2 Set a dial gauge to the central journal 3 Read the dial gauge while rotating the cranksh...

Page 149: ...earing 1 See engine specifications CHECKING OIL CLEARANCE BETWEEN CRANKSHAFT JOURNALS AND CRANKSHAFT BEARINGS 2 1 Paste a press gauge with grease on the crankshaft bearing 2 Tighten the crankshaft bearing case onto the crankshaft journal to the specified torque 29 4 to 34 3 Nm 3 0 to 3 5 kgfOm 21 7 to 25 3 ft Ibs 3 Detach the bearing case slowly and measure the depression of the press gauge with a...

Page 150: ...e the crankpin bearing NOTE FOR MEASURING Fasten the crankshaft so that it does not turn Do not insert the press gauge into the crank pin hole Crankpin bearing measuring points are shown below See engine specifications Crank pin measuring points CHECKING END PLAY OF CRANKSHAFT 1 Move the crankshaft to the crank gear side 2 Set a dial gauge to the crankshaft 3 Push the crankshaft toward the flywhee...

Page 151: ...e cylinder liner is worn beyond the allowable limit bore and hone it by 0 5 mm 0 0197 in 1 The cylinder liner which has been oversized by 0 5 mm 0 0197 in should use a piston and ring of the same oversize NOTE When the oversized cylinder liner is worn beyond the allowable limit replace the cylinder liner and bore and hone it See engine specifications Measuring points of cylinder liner 1 1 EO 2 b I...

Page 152: ...to 3 7 mm 0 1300 to 0 1457 in 2 2 8 to 3 2 mm 0 1102 to 0 1260 in 3 Oil hole must be 1 to 1 5 mm 0 0394 to 0 0591 in Be sure to chamfer the oil circumference with an oil stone Undersize and Oversize 4 The crankpin must be fine finished to higher than 1 0 4 5 5 The crank journal must be fine finished to higher than 1 0 4 5 6 The crank journal side surface must be fine finish to higher than 0 4 5 5e...

Page 153: ...ning to dimensions shown in Figs B and C NOTE Be careful not to strike valve guides with a hammer during replacement A Tool for replacing valve guides 190 7 48 B 80 3 15 1 7 v I I 9 I oo M 1 30 1 18 L 1 0 v J 7 i moo D I 0 m I 0 o REPLACING ROCKER ARM BUSHINGS 1 Prepare the necessary tool as shown in Fig A 8 Finishing size of inlet valve guide e Finishing size of exhaust valve guide 2 Press out th...

Page 154: ...D BUSHINGS 1 Prepare the necessary tool as shown in Fig A B Idle gear and bushing as assembled 2 Press out the used bushing and press a new bushing in taking due care to see that the con necting rod hole matches the bushing hole A Tool for replacing small end bushings B Connecting rod and bushing as assembled 100 13 94 g 9 2 0 079 1 1331524 10 23 O 39 0 91 g g Olg o NO _1 ro J I2 IJ 2 3 Cl CO 3 C ...

Page 155: ... extracting tool 3 Insert a new bearing 1 using the inserting tool taking due care to see that the contact edge of bearing 1 faces the exhaust manifold side A Tool for extracting crankshaft bearing 1 8 Tool for inserting crankshaft bearing 1 130 5 12 130 5 12 039 1 C Crankshaft and crankshaft bearing 1 as assembled 2 150 ...

Page 156: ...STARTER AND GLOW PLUG No load Testing of Starter 153 Motor Test 154 Checking Magnet Switch 154 Checking Magnet Switch Holding Coil Retention Test 155 Checking Magnet Switch Plunger Return 155 Checking for Breakage and Short circuit of Glow Plug 156 DISASSEMBLY Disassembly of Starter 156 159 Servicing Starter 159 165 151 ...

Page 157: ...emeter only after starting the engine In the event of a lower electric load or fully charged battery the stipulated value may not be given Reference value 14 to 15A with dynamo turning at 5200 rpm Checking AC Dynamo s No Load Voltage 1 Disconnect lead wire from the dynamo 1 Battery Lead 2 Start the engine and measure the voltage generated by the single dynamo Reference value AC 20V or more with th...

Page 158: ...minal to the starter body 3 Connect the voltmeter s positive prove to the starter s B terminal and the negative probe to the starter body 4 Set a tachometer 5 Connect the starter s B terminal to the magnet switch s S terminal 6 Check to see that the magnet switch actuation results in the specified speed current and voltage NOTE FOR CHECKING Use a fully charged battery Use an ammeter and lead of mo...

Page 159: ...ulty if not the motor is faulty Reference value The motor is O K if it rotates smoothly A Electrical connections for testing motor 1 Starter Checking Magnet Switch Pull in Coil Attraction Test 1 Apply 1 2 the rated voltage across S terminal and C terminal 2 If the plunger is attracted strongly the pull in coil is normal if not it is faulty Reference value If the plunger is attracted strongly the p...

Page 160: ...if not it is faulty Reference value If the plunger is maintained in the attracted position the holding coil is good if not it is faulty Checking Magnet Switch Plunger Return 1 Apply the rated voltage across C terminal and body push the plunger in by hand and release your hand 2 If the plunger returns immediately it is good if not it is faulty Reference value If the plunger returns immediately it i...

Page 161: ...If the resistance is zero ohms the glow plug is shorted If the resistance is infinite the glow plug coil is broken DISASSEMBLY OF STARTER Removing Magnet Switch 1 Remove the connecting lead 2 Remove the set screws Reference value Approx 1 6 1 Glow Plug DISASSEMBLY 3 Detach the magnet switch by lifting it up while taking care that it does not contact the drive lever 156 ...

Page 162: ...Removing Armature Brake 1 Remove the end frame cap 2 Remove the washers 3 Remove the brake spring 4 Remove the packing Removing End Frame 1 Remove the through bolt 2 Remove the end frame 157 ...

Page 163: ...o not contact the body with the positive brush s lead Removing Yoke 1 Draw out the yoke from the drive end frame NOTE FOR REASSEMBLING Take care yoke does not knock pin Removing Armature 1 Remove the set bolt from the driver 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 ...

Page 164: ...tch 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 Reference value 0 1 to 5 0 mm 0 004 to 0 197 in A Adjustment of pinion gap 2 1 Pinion Gap 2 Pinion Juts Out to this Position 3 Joint 4 Turning the Joint Alters its Length 159 ...

Page 165: ... 0 0020 to 0 0039 in Diameters of shaft and bushing D D of drive shaft 12 50 mm 0 4921 in D D of commutator shaft 12 50 mm 0 4921 in I D of drive bushing 12 55 to 12 60 mm 0 4941 to 0 4961 in I D of commutator bushing 12 53 to 12 60 mm 0 4933 to 0 4961 in Grounding Armature Coil 1 Check conduction across the commutator and core shaft If it is not conducting the coil is good if it is conducting the...

Page 166: ...er or on a lathe 3 When the wear between the maximum and minimum diameters exceeds 0 4 mm correct the wear to within 0 05 mm on the lathe Allowable limit is not less than 2 mm smaller than the reference value of outside diameter Commutator diameter Reference value Allowable limit 28 0 mm 27 0 mm 1 1024 in 1 0630 in 161 ...

Page 167: ...ut 1 Check to see if the mica has sunk below the allowable limit 2 If it is below the allowable limit correct with a saw blade Since the correction produces burrs on the corner of the segment chamfering should be executed Reference value Allowable limit 0 50 to 0 80 mm 0 0197 to 0 0315 in Less than 0 20 mm 0 0079 mm in 1 Bad 2 Good 3 Mica 4 Segment 5 Depth of Mica 162 ...

Page 168: ...ce Reference value If it is conducting the coil is good if it is not the coil is faulty Checking Insulation Between Field Coil and Yoke 1 Place each tester probe on the field coil and yoke 2 If conducting replace Reference value If is is not conducting the insulation is good if it is conducting the insulation is defective 163 ...

Page 169: ...sions of starter brush Length 16 0 mm 0 6299 in Width 12 0 mm 0 4724 in Thickness 7 0 mm 0 2756 in Checking Brush Spring Tension 1 Measure the tension with a new spring in place 2 Replace if the tension is under the reference value Reference value Spring tension Commutator diameter 1 Spring Hanger 9 8N 1 0 kgf 2 21 Ibs 32 70 mm 1 2874 in I 1 i 2 2 Install the Brush and Spring in this Manner 3 Brus...

Page 170: ... of Brush Holder 1 Check the insulation of the positive brush holder 2 Replace if faulty Reference value If it is not conducting the brush holder is acceptable if it is conducting the brush holder is faulty 165 ...

Page 171: ...TROUBLESHOOTING dynamo runs dynamo does not run 166 Battery charging current is equal to or exceeds the reference value check 1 lower than the reference value slow running does not run at all ...

Page 172: ...tage is equal or superior regulator connector Faulty wiring between regulator and to the reference value AC lead wires main s w AC dynamo side check 2 check 3 Faulty wiring between dynamo and L not conductive regulator _ t No reference value I Faulty dynamo I IFaulty dynamo 167 ...

Page 173: ...TROUBLESHOOTING Slow engine speed Starter runs but engine does not No meshing sound from pinion and ring gear Pinion shifts repeatedly Does not turn red at all Turns red too quickly 168 ...

Page 174: ...net switch Pinion does not pop out by the I attractive force of magnet switch Screw spline rusted Faulty battery Battery not sufficiently charged Faulty battery I Poor terminal contact I Grounded poorly I Faulty magnet switch Holding coil broken J I Battery not charged sufficiently Faulty battery Poor terminal contact Poorly grounded r Incorrect wiring between battery and glow plug y r Glow plug i...

Page 175: ...TROUBLESHOOTING Crankshaft does not turn Crankshaft turns 170 No or small fuel injection sounds Fuel injection sounds ...

Page 176: ...elivery valve spring broken on fuel Delivery valve not cQmpletely oil tight_ Needle valve stuck Fuel does not inject through Nozzle spring broken injection nozzle Injection pressure maladjusted Injection pipe mounting nut loose r1 1 Injection mistimed I Injection timing maladjusted J I Contact between intake exhaust valve and seat not tight Intake exhaust valve spring broken r Intake exhaust valve...

Page 177: ...ENGINE DOES NOT TURN N RMALLY f TROUBLESHOOTING Revolution irregular ENGINE OUTPUT Slow engine revolutions INSUFFICIENT 172 Revolution is not smooth at high speeds Idling not smooth ...

Page 178: ...ure is different among cylinders r Governor sleeve not sliding properly Governor not functioning 1 Fork lever not functioning normally normally j Start spring deformed Control rack not sliding properly y Idling maladjusted r Idling regulator maladjusted L Accelerator rod maladjusted Main moving parts have almost seized up f Engine overheated f Injection mistimed Governor not functioning normally F...

Page 179: ...TROUBLESHOOTING White or blue exhaust fumes Black or dark gray exhaust fumes 174 ...

Page 180: ...ozzle spring broken I properly I Too much carbon sticks to nozzle tip Injection pressure too low ____________________________________________ r 1 c o m p r es s ed a ir 1_ea_k_s_ ______________________ i Y Not enough air Excessive gap between piston and liner Piston ring stuck Piston ring worn Excessive gap between intake exhaust valve and valve stem Valve stem seal broken Oil leaks from defective...