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Generac Power Systems MC User's Manual

1. to Paragraph B Pump tests bads Replace pump C Set VOM to 0 and to 50V scale Disconnect Wire No 14 at the Fuel Pump Connect POSITIVE meter test probe to terminal end of Wire No 14 Connect COMMON test probe to frame ground Crank the engine meter needle should deflect upscale and read approximately 12 Volts DC battery voltage RESULT Meter needle dees NOT swing upscale Go to Paragraph Meter indicated approximately 12 Volts Replace Fuel Pump 2 2 10 Check Wire No 14 between Fuel Pump and terminal strip for open or shorted condition RESULT Wire 14 checks Diagnostic tests Wire No 14 checks 14 UNITS WITH MECHANICAL FUEL PUMP Pressure Gauge en Inlet Disconnect Pump Outlet Line at the carburetor inlet Connect a press ure gauge to the line Disconnect Pump Inlet Line at the fuel lock Mechanical off solenoid and immerse line in Fuel Pump clean gasoline Crank engine The clean Min pressure gauge should indicate 1 S aevi i w Fuel Lock Off 3 P 51 Solenoid RESULT Pressure gauge read 1 3 psi Continue Diagnostic Tests Pressure gauge does not read 1 3 Pump TEST 22 CHECK INSTALLATION Check alternato
2. 77318 16 x 3 4 Bolts Vibration Dampeners 2 3 2 3 18 1 a small amount of Loc 3 2 3 19 Install alternator supp Tite to rotor bearing outer diameter ort onto vibration dampeners Re Install new bearing carrier Retain tain with two 3 8 16 x 3 4 bolts carrier to stator can with four 10 lockwashers Install the low 32 x 3 8 Taptite screws er stator bolt bar Install two lower stator bolts with lockwash ers Tighten all 4 stator bolts Make sure stator can is flush ag ainst adapter casting then tighten all 4 stator bolts to 80 100 inch pounds 5 3 2 3 20 2 red wires No 4 to brush that will be nearest che rotor bearing Retain with a No 6 232 Sims screw and 2 exter nal lockwashers Connect 2 ground wires No 10 to remaining brush with Sims screw and 2 lockwashers 3 2 3 22 Retain brush ground wire No 10 to heat sink with heat sink retaining screw 3 2 10 3 2 3 21 5114 brush holder 1 ing grooves over bearing carrier locking tangs Make sure brushes contact slip rings properly Bend bearing carrier locking tangs to retain brush holder 3 2 3 23 Install end panel Ret ain to stator can with two No 10 32 x 3 8 Taptite screws A small grounding lug is also retained by one of these screws 3 2 3 24 5 11 rear panel with voltage regulator Connect read and white conne
3. ALTERNATOR DIAGNOSTIC REPAIR MANUAL ISSUED JANUARY 1979 P 0 BOX 8 WAUKESHA WISCONSIN 53186 51834 PRINTED IN U S A This Manual is provided to aid the technician in the analysis and repair of malfunctions that might occur in the MC alternator or its engine Keep the Manual in a safe place and refer to it whenever necessary All information illustrations and specifications contained in this Manual are based on the latest product information available at the time of publication Generac reserves the right to make changes in any product at any time without no tice x GENERAC P 0 80X 8 WAUKESHA WISCONSIN 53186 PART GENERAL Section 1 1 SPECIFICATIONS 1 1 Model Numbers 1 2 Fuels and Oils 1 3 Torgue Specifications General 1 4 Torgue Specifications Special 1 5 Sectional View 1 6 Engine Specifications Section 1 2 WIRING DIAGRAMS Section 1 3 SPECIAL TOOLS SECTION 1 1 SPECIFICATIONS 1 1 1 MODEL NUMBERS MC 40 35 mc 35 MC 38 40 3500 3500 3800 3800 4000 4000 Voltage 120x 120 120 120 120 120 Maximum Amperes 29 2 at 120 31 7 at 120 V 33 3 at 120 V 60 Hertz at 3600 rpm Voltage Solid state voltage regulator maintains 120 Volts AC Regulation 2 at 60 Hertz Battery Charge Gross Weight wet Engine Part 48078 48078 48078 48078 48078 48078 Stroke Displacement Governed
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5. TEST 11 BAD GOOD BAD GOOD TEST 13 Ignition Stator BAD Mechanicall_ Movement POUD 6897 4 Replace Choke Pulse Module See Section 2 4 FILL TANK rest 19 page Fuel 2 2 9 GOOD Filter aan GOOD BAD GOOD TEST 23 Page REPLACE Carburetor 2 2 11 ADJUST JETS BAD REPLACE CARBURETOR VALVE BAD REPLACE SEAT BAD CHECK FLOAT LEVEL ADJUST FLOAT GOOD TEST 22 Check Installation 222 11 TEST 24 Page TEST 25 Page Compression 2 2 13 Head Gasket2 2 13 BAD GOOD V REPLACE ITEST 27 Page Rings 2 2 14 GOOD Fuel Fuel Lock Off 5 40 TEST 21 Page Fuel Pump 2 2 10 TEST 32 Governor 2 2 17 BAD Valves 2 2 14XZG00D TEST 28 Cylinder 2 2 14 BAD BAD SWITCH SET TO STOP ENGINE KEEPS RUNNING TEST 3 Replace Switch A C VOLTAGE LOW REPLACE Governor STATOR BAD TEST ADJUST TEST 32 Page 2 1 6 4 A C VOLTAGE HIGH TEST 36 Page Check TEST 37 Page Check 2 2 17 Sensing Output 2 2 19 BAD Frequency 0003 gt Transformer 2 2 19 Correct to 62 Hertz Replace Transformer CHECK CUSTOMER WIRING GOOD NO A C VOLTAGE TEST 38 Main Circuit Breaker Check Output 2 2 19 Voltage
6. to Paragraph Engine will not 5 TO Paragraph D B Set VOM to 250V scale and to Connect the meter test leads to a convenient AC outlet powered by the alternator Hold the Carburet or Throttle Lever against its Idle Speed Stop Screw Adjust Idle Speed Stop Screw until meter indicates 60 Volts a c When a 60 Volt reading is obtained turn Idle Mixture Adjusting Screw until voltage starts to drop off Then turn the screw in the opposite direction until voltage reading again starts to decrease Finally reverse direction again and turn the screw until the highest voltage reading is obtained Release Throttle Lever and let engine accelerate and stabilize C With engine running at governed speed apply normal load to the alternator Connect an accurate frequency meter to the unit s a c out put Turn the High Speed Jet Adjusting screw slowly clockwise then counterclockwise until the highest frequency is obtained When the Jet is set for the highest possible frequency turn adjusting screw count erclockwise 1 8 turn RESULTS Engine starts and runs normallY 0 Discontinue Tests Engine will not start or starts and runs es sd R9 99259 eee deae o s to Paragraph D D Remove Fuel Bowl from Carbur etor Body Inspect Float Valve Seat and Gasket for damage dirt or wear Replace defective compon ents Also check for
7. Inspect closely for damage Use insulation breakdown tester to test for breakdown under load Follow the tester manufacturer s instructions carefully See 1 1 3 ELECTRICAL TEST SPECIFICATIONS 3 2 3 1 During reassembly torque fasteners as specified in Section 1 1 4 TORQUE SPECIFICATIONS GENERAL or 1 1 5 TORQUE SPECIFICATIONS SPECIAL as applicable Do not attempt to re use worn defective or damaged parts The bearing carrier should not be re used once it has been removed 3 2 5 3 2 3 2 Ignition stator mounting holes are offset to make improper installation difficult Install the ignition stator and retain with No 10 32 x 3 8 inch screws 3 2 3 4 Pull both ignition stator wires through the hole provided in the engine gear cover Retain wires flush against gear cover with RTV 1093 3 2 3 6 Install rotor Make sure key and keyway are engaged In stall rotor bolt lockwasher and 2 flatwashers Tighten rotor bolt making sure rotor pulls in as the bolt tightened When rotor is tight and will pull in no further loosen rotor bolt Then tighten bolt to 15 17 foot pounds 2 6 hr 3 2 3 J3 Ignition stator wires No 8 and 25 were cut during disassem bly If wires are too short for pr oper splicing after unit is assemb led additional wiring lengths must be added at this time Above knife edge connectors were used to add the additional wire length Heat shrink tubing was the
8. AD GOOD BAD V Check Customer REPLACE REPLACE Wirin TEST TEST 40 Page TEST 41 Check Field CHECK VOLTAGE Check Stator 2 2 22 Boost 2 2 21 ROTOR J f Ni BAD Check Wire ganiem Check No 4 Wire No 14 for 12 Volts GOOD Replace Printed Circuit Board SECTION 2 2 DIAGNOSTIC TESTS TEST 1 15 AMP FUSE Remove and visually inspect the 15 Amp Fuse Replace if Fuse element has melted A more thorough check may be made with a Volt Ohm Milli ammeter as follows 1 Set VOM to 0 and to Rx1 scale 2 Connect meter test probes and Zero the meter 3 Connect meter test probes to Fuse ends Meter needle should swing upscale to ohms continu ity If meter needle does not move upscale replace the Fuse RESULTS Fuse tests InStall new 15 Amp Fuse Fuse tests 2 tests TEST 2 BATTERY Check Battery condition as well as the condition cleanliness and sec urity of battery cables and connec tions RESULTS Battery cables or connections Recharge or replace de check bad fective Battery Repair clean or replace defect ive cables or connection Battery cables or 5 tests check good TEST 3 STOP START SWITCH 17 10 Ground i Remove 15 Amp Fuse to dis
9. Meter needle swings upscale Continue checks and indicates approximately 7 Ohms resistance To DC Control Board B Charge Coil Set VOM to DC and to Rx10 scale then zero the meter Insert one meter test probe into Pin No 2 of the Ignition Mod ule receptacle Connect the remaining test probe to frame ground The meter needle should swing upscale and indicate approximately 250 Ohms resistance 2 2 6 RESULTS Meter needle does not move Check Wire 8 between Ignition Module receptacle and Ignition Stator Charge Coil for an open condit ion If Wire No 8 checks good replace Ignition Sta tor S indicates approximately 250 Continue checks Ohms REINSTALL CONNECTOR PLUG INTO DC CONTROL BOARD RECEPTACLE AND IGNITION MODULE INTO ITS RECEPTACLE BEFORE CONTINUING TEST 14 IGNITION COIL Primary Winding Set VOM to Rx1 scale and to 0 Zero the meter Connect the positive 4 test probe into Pin 4 of the Igni tion Module receptacle Connect the negative common test probe to frame ground Meter needle should swing upscale to nearly 0 Ignition Coil Ground RESULT Meter needle does not move e Replace Ignition Coil Meter indicates nearly 0 4 2 test B Secondary winding Set VOM to Rx1K and to Zero the met er Install spark plug lead into Ignition Coil Connect one meter test probe to spark p
10. 2 Set the VOM DC and to Rx1 scale Zero the meter Connect the positive 4 test probe to Wire No 78 from the Diode D 2 Connect the common test probe to frame ground Meter needle should not move Set meter to DC or reverse the meter test probes Meter needle should swing upscale to some mid scale reading approximately 7 12 Ohms Circuit Breaker CB 2 RESULT Diode D 2 tests good Reconnect Wire 78 go to Paragraph B Diode D 2 tests Replace Diode D 2 B Set VOM to and to Rx1 scale then zero the meter Connect the positive test probe to the Diode D 1 terminal end Connect the common test probe to frame ground Meter needle should not move Set meter to DC or reverse the test probes Meter needle should move upscale RESULT Diode D 1 tests POO ej cess Continue tests Diode D 1 tests 4 Replace Diode D 1 STATOR BATTERY CHARGE WINDINGS Disconnect Wire 77 from Circuit Break er CB 2 Unplug the red connector plug from its receptacle on the stator can Set VOM to 0 and to Rx1 scale then zero the meter Connect one meter test probe to Wire 55 at the Diode D 1 terminal Connect second test probe to Pin 6 of the red receptacle Meter needle should swing upscale approxim ately 08 Ohm Repeat test with meter test probe connected to red recept
11. Starter tests Meter indicates 12 Volts DC Starter does not 4 Starter Meter does not indieate 12 Volts Check Starter cable 2 2 3 TEST 6 STARTER DRIVE GEAR of Starter Drive Cover Caver Screws 2 14 Stop Start switch at its START position and listen for the starter motor If motor runs free ly without load remove Starter drive cover Pinion Spring Spring Retainer Lock Nut 2 90 110 in Ibs B Visually check Starter pinion for damage if damaged replace pinion C To replace Starter pinion assembly remove lock nut spring retain er and pinion Install a new pinion spring spring retainer and lock nut Tighten lock nut to 90 110 inch pounds DO NOT LUBRICATE PINION SPLINES RESULTS Starter drive checks 4 tests Starter drive is 4 1 1 TEST 7 STARTER RING GEAR Inspect Starter Ring Gear for dam age Ring Gear and Flywheel are heat shrunk onto Rotor assembly If replacement is necessary ent ire assembly must be replaced TEST 8 CHECK SPARK Disconnect spark plug lead from engine spark plug and connect to Spark Tester Part No 41503 Connect Tester clamp to engine spark plug Crank engine spark tester
12. This completes the 12 Volt DC circuit through Wire No 14 the Fuel Lockoff Solenoid FS Fuel Pump FP and the Choke Heater to frame ground The Fuel Lockoff Solenoid is energized open and the Fuel Pump operates 2 4 2 2 4 2 2 CRANKING Push Button Fuel Pump gt Rotor Field De 15 Ohm UL 10 Watt m a o amp 5 Spark Plug Battery power is available to the Stop Start Switch via Wire No 13 the 15 Amp Fuse Wire No 15 the Starter Contactor SC and Wire No 17 When the Stop Start Switch is set to START position the cir cuit is completed through Wire No 10 to frame ground The Starter Contactor SC energizes and its contacts close With the SC contacts closed several events occur as follows 1 2 3 4 5 Battery power is supplied through Wire No 91 to the Starter Mo tor and to frame ground The engine cranks Battery power is supplied through Wire No 91 through the Choke Solenoid CS Wire No 90 and to Pin No 1 of the Choke Pulse Module CM Solid state components within the CM open and close this circuit through CM Pin No 2 and Wire No 10 to ground at a rate dependent upon ambient temperature The Choke Solenoid CS is thus pulsed and the automatic choke operates at a rate dependent on ambient temperature gt Battery power is supplied across the closed SC contacts through Wire No 91 to Pin No 5 of the Choke Pulse Module CM The
13. to 18 22 foot pounds Bend ends of lock tab over bolt heads 3 3 3 10 11 tappets 3 3 3 11 Install cam shaft careful not damage bearing and oil seal Timing mark on valley of crankshaft gear must align with timing mark on tooth o shaft gear 3 3 i2 Instail thrust washer 3 3 3 13 the engine gear cover can be installed crank shaft must be turned to place its keyway at 12 00 position top dead center of piston over end of camshaft 3 3 3 14 11 one of the long er bolts that retained the engine gear cover into the counterbalan ce alignment hole in gear cover Rotate counterbalance while thre ading bolt into alignment hole When bolt engages hole in count erbalance and counterbalance will not rotate tighten bolt no furth a Cle 10 Ww 3 3 3 15 Install new gear cover 3 3 3 16 1 dowel pin on cyl gasket inder block with dowel pin hole on engine gear cover Install gear cover When cover is flush against cylinder block remove bolt from counterbalance align ment hole B gasket 3 3 3 18 Retain engine gear cover to cylinder block with bolts and Lockwashers Tighten all bolts to 90 110 inch pounds 3 3 23 17 Install the correct bolt and flat washer into count erbalance alignment hole USE THE CORRECT BOLT if bolt is too long damage counterbalance will res
14. C With engine running adjust hex nuts at end of Governor Adjust ing Screw to obtain 62 Hertz at no load One hex nut serves as jam nut make sure this nut is tight when 62 Hertz is obtained RESULT Engine runs normal eeeeoeeoocscoceccececcecece lGSt completed Engine hunts eco eece cec s Set Carburetor for richer mixture NOTE All mechanical governors have a normal offspeed fluctuation This is the reaction time of the governor TEST 33 CHECK FREQUENCY Use an accurate Frequency Meter to check alternator output frequency Frequency should be 62 Hertz at no load With a normal electrical load applied frequency should be 59 62 Hertz and stable disregarding the normal offspeed fluctuation 2 2 17 TEST 34 EXCITATION WINDINGS Remove the alternator front panel assembly Stator Can viewed from top Disconnect the white connector plug from its receptacle on the stator can On the receptacle locate Pin No 2 and 6 to which Wires No 2 and 6 attach Set VOM to 0 and to scale then zero the meter Connect one meter test probe to re ceptacle Pin No 2 Connect the re maining test probe to receptacle Pin No 6 Meter needle should swing up scale and read approximately 1 1 Ohms This is the resistance of the excitation winding RESULT Meter needle does not stator Windings check 4 diagnostic t
15. Lock Off Solenoid and terminal strip Disconnect the wire at its Terminal gt Strip terminal strip connection Crank en gine While cranking touch Wire No 14 to its terminal Strip connection Fuel solenoid should actuate the unit has electric fuel pump noticeable change in fuel pump sound will be detected RESULT Solenoid did not 4 to Paragraph Solenoid actuates Continue tests in DIAGNOSTIC FLOW CHARTS B Disconnect Fuel Lock Off Solenoid Wire No 14 at the terminal st rip Set VOM to 0 and to Rx1 scale Zero the meter Connect one meter test probe to the terminal end of Wire No 14 Connect the rem aining test probe to frame ground Meter needle should swing upscale to indicate resistance of solenoid windings RESULT Meter did not swing upscale Check Wire No 14 between sol enoid and terminal strip for open condition Also check the solenoid ground wire and conn ection Meter needle swung upscale Replace Fuel Lock Off Solenoid and solenoid did not actuate in Paragraph A TEST 21 FUEL PUMP UNITS WITH ELECTRIC FUEL PUMP A Disconnect Wire No 14 at the Fuel Pump Set VOM to and to Rx1 scale Zero the meter Connect one meter test probe to the Fuel Pump Wire No 14 Connect the remaining test probe to frame ground Meter needle should swing upscale and indicate approximately 50 Ohms RESULT Pump tests
16. Replace all damaged strips 4 Inspect blower fan for cracks or other damage Replace if damaged 5 Inspect blower fan hub Replace if cracked or damaged or if key way is worn Also check key and keyway on engine taper shaft 3 1 3 RFASSEMBLY 3 1 3 1 Retain blower shroud an 3 1 3 2 Retain blower shroud at blower scroll to cylinder block both sides of cylinder block with two M5 x 10 mm capscrews and With M6 x 15 mm long capscrews lockwashers Tighten capscrews to l9ckwashers and flatwashers 90 110 inch pounds 3e1 3 3 With exhaust pipe u bolt and housing and exhaust pipe sup port loosely retained by 2 hex nuts lockwashers and flatwashers retain housing and exhaust pipe support to engine base and vibrat ion damper 2 3 1 3 4 Loosely retain blower hou 3 12 3 5 blower housing sing support to opposite vibration scroll to blower housing d damper with capscrew lockwasher installed previous with and flatwasher t 20 x 5 inch long bolt and flat washer and a hex nut flatwasher and lockwasher Tighten the hex nut Finally tighten all bolts that thread into the vibration dampers 3 1 3 6 Slide exhaust pipe down 3 1 3 7 Tighten exhaust pipe u bolt through blower housing and through hex nuts exhaust pipe u bolt Install exha ust flange gasket Retain exhaust pipe to exhaust flange with an M8 50 mm long and an M8 x 20 mm long socket head capscrew and lock
17. Speed 3720 rpm at no load Ignition System Solid State Starting System 12 Volt DC electric Ring Gear Approximately 90 Amperes Gonsumption Approximately 0 70 Gallons per Hour Pump Factory connected for 120 Volt AC output only Unit is reconnectable to provide dual voltage output AUL S Approximately 127 pounds gt D a D Average Fuel td O D 1 1 2 FUELS AND 0115 RECOMMENDED FUEL Use NON LEADED gasoline Leaded REGULAR grade gasoline is an acceptab le substitute Do not use any highly leaded premium gasoline RECOMMENDED OIL USE OIL CLASSIFIED FOR SERVICE SC SD or SE USE SAE 30 OIL USE SAE 20W Use oil classified For Service SC USE SAE 10 W or 10W 30 OIL SD or SE as shown in the CHART at 10 W 30 10 10 F x oc 23 C 12 2 C TEMPERATURE RANGE ANTICIPATED BEFORE NEXT OIL CHANGE 1 1 3 TORQUE SPECIFICATIONS GENERAL STANDARD TORQUE VALUES 1 4 20 1 4 28 5 16 18 5 16 24 41 8 13 10 GRADE BOLT HEAD SYMBOL 1 1 4 TORQUE SPECIFICATIONS SPECIAL Spark Plug Cylinder Head Bolts Connecting Rod Cap Bolts Engine Gear Cover Bolts Blower Fan Special M14 Hex Nut Rotor Bolt Mechanical Fuel Pump Bolts All Values in FOOT POUNDS TORQUE VALUES 5 PER CENT rade Grade s ze cer 5 4 8 6 6 5 7 Grade 8 DRY LUB Grade DRY
18. cylinder head indicates loose head nuts or a leaking head gasket Tighten loose spark plug re place broken spark plug using a new plug gasket If cylinder head leaks check for warped cylinder head and for a defective head gasket Refer to engine section of manual and to TORQ Ut SPECIFICATIONS SPECIAL TEST 26 VALVES Remove valves Clean all parts in non flammable solvent Remove all carbon Replace damaged or distor ted valves valves are useable them outlined in engine Roller Vaive spring Retainer ction Check for correct tappet Valve Spring clearance as outlined in engine Oluva Spina Reli section of manual i Tappet TEST 27 RINGS 1ST COMPRESSION RING Check for broken or worn rings Check ring clearance in piston grooves and ring gap Refer to engine section of manual OIL CONTROL RING 2ND COMPRESSION RING TEST 28 CYLINDER Inspect cylinder walls for burning scoring or scratching Check cylin der inner diameter Refer to engine section of manual for inspection requirements TEST 29 TIMING The ignition magnet is retained to the fan with a special adhesive which is cured at 300 F for 1 hour or 265 F for 15 hours after ins tallation The ring gear is heated and pressed over the fan and magnet assembly The entire assembly is then balanced as a unit and finall y heated and epoxied into place over the rotor shaft Any damage
19. of electrical components n circuits that pass through the red and white stator can receptacles or through the Ignition Module receptacle Use the Test Plug in any diagnostic test that calls for connection of the VOM test probes to pins in these receptacles Order Part No 27069 INSULATION BREAKDOWN TESTER Resistance testing of alternator compon ents with an Ohmmeter is generally valid Such resistance tests will nearly always indicate the presence of an open or shor ted condition However some malfunctions do not become evident until an electrical load is applied across the defective com ponent The insulation breakdown tester permits a component to be tested under a simulated load condition by applying a selected voltage to the component Follow the tester manufacturer s instructions strictly when using the tester SPARK TESTER The Spark Tester is used to check for pro per ignition spark with the engine cranking Order Part No 41503 ROTOR REMOVAL KIT The Rotor Removal Kit consists of a 3 8 24 gt TAP 3 8 24 BOLT and threaded studs of varying lengths The kit is used for remo e val of the rotor Order Part 41079 T P LOAD BANK The Load Bank is used to apply an electrical load to alternators The unit is eguipped with a Volt meter Ammeter and Freguency Me ter as well as the necessary switches for selecting the desir ed load Specify Model No 5515 P
20. open or shorted wire Volts DC or loose connection between Battery and Starter Solenoid C Connect POSITIVE meter test probe to starter cable connection on solenoid Connect NEGATIVE COMMON probe to ground Hold Stop Start Switch at START meter should indicate approximately 12 Volts DC RESULTS Meter does not read 12 Volts 15 new Starter Solenoid Meter reads 12 Volts and Continue tests in DIAGNOSTIC Solenoid checks good FLOW CHARTS D Set VOM to and to a scale greater than 12 Volts Connect the meter POSITIVE test probe to one of the small terminals on the sol enoid Connect the remaining probe to ground Meter needle should read approximately 12 Volts DC With one probe still connected to ground connect the remaining terminal to the other small terminal on the solen oid meter should indicate approximately 12 Volts DC RESULTS Meter indicates 12 Volts Continue tests Meter does NOT read 12 Volts Repeat Tests 1 2 and 3 When sure that these tests are good and 12 Volts is not indicated in Test 4 D replace solenoid TEST 5 STARTER MOTOR Set VOM to DC and to a scale greater than 12 Volts DC Conn ect VOM positive test probe to the Starter terminal lug and COMMON test probe to frame ground Hold Stop Start switch at START Meter should indicate approximately 12 Volts DC and starter motor should run RESULTS Meter indicates 12 Volts DC
21. plug against the engine block and crank engine Spark plug should emit a sharp snappy blue spark RESULTS Spark Plug tests 4 4 Spark Plug Spark Plug checks BOOS 4653 ca ee vs aa GODU tests 2 2 5 TEST 12 IGNITION MODULE Ignition Unplug the Ignition Module from 2 Module its receptacle on the side of the stator Carefully inspect dule receptacle pins for dam age bending or pushing out from their retainers Plug in a ignition Module known good shop module and Receptacle check for normal sparking at the spark plug RESULTS Ignition Module tests tests Ignition Module tests 4 94 TEST 13 IGNITION STATOR A Irigger Coil Set VOM to DC and to scale Zero the meter On the DC Control Board unplug the connector plug from its receptacle t Stator to prevent interaction Also unplug I the Ignition Module from its recep tacle Insert one meter test probe into Pin No 3 of the Ignition Mod ule Receptacle Connect the remain ing test probe to frame ground The meter needle should swing upscale and read Trigger Coil resistance a bout 7 Ohms RESULTS Meter needle does not move Check Wire No 25 between Ignition Module receptacle and Ignition Stator for an open condition If Wire No 25 is good replace Ignition Stator
22. proper Float setting of Float should be 0 070 0 110 inch below Carburet Vei or Body mounting Flange See illu Te stration at right 2 2 12 RESULT Float Valve Seat Gasket and Float level are 0004 Continue Diagnostic Tests Float Valve Seat Gasket or Float level check bad Replace or adjust then test TEST 24 COMPRESSION COMPRESSION GAUGE A Insert a standard compression gauge into engine spark plug hole SPARK PLUG Open throttle wide open and crank REMOVED engine Compression should be app roximately 75 85 psi cold or 95 105 psi hot RESULT Compression reading gOOQdesssseseeceoseeeeosoeeeaseGO to Test 29 Compression reading s s CONTINUE tests B Squirt a few drops of clean engine oil into spark plug hole on en gine cylinder head Repeat compression test If compression reading is higher than was obtained in Paragraph A ring or cylinder wear is indi cated If little or no difference in compression was noted trouble may be due to head gasket leakage worn valves etc RESULT Noticeable increase in compression obtainediessvss ess e ora to Test 27 Little or no increase in 0 to Test 25 TEST 25 HEAD GASKET Crank the engine A hissing sound at the spark plug indicates the plug is loose or broken Likewise hiss ing at the
23. set Intake valve is identified by the letter I on falve retainers 33 1 10 engine oil Remove all bolts that retain engine bear ing covere Rotate crankshaft to place its keyway at 12 00 position top dead center of piston stroke Install screws into ignition stator screw holes Use these screws and a puller to remove bearing cover 1242 ra re c k R a shaft and valve 3 1 12 governor slider from 3 3 1 13 Remove cam shaft and valv end of cam shaft tappets 3 3 1 14 lock tab ends away from connecting rod bolt heads Remove the connecting rod bolts lock tab oil splasher and connecting rod lower half Push piston and connecting rod up through cylinder and remove Remove crankshaft 3 3 1 16 is not necessary to remove bearings unless replace ment is necessary Bearings must be pressed out of cylinder block 2 3 1 18 oil stopper from ngine bearing cover 3 3 1 17 governor shaft Je retaining clip and governor e Ce shaft i s 3 3 1 19 bolts that ret 3 3 1 20 Install a bolt into the ain counterbalance cover threaded hole at top of counter balance cover Tighten bolt aga inst counterbalance shaft until cover is free of shaft then re move cover 3 3 1 21 Remove counterbalance 3 3 1 22 Shim washers are used at assembly bearing cover end of crankshaft t
24. should emit a blue snappy spark RESULTS Spark tests good ececcceceeccceGO to Test 15 Spark tests tests 2 2 4 Starter Ring Gear Keyway Magnet TEST 9 011 MAKE UP TANK Oit Filler Cap Check oil level in 011 Make Up Tank If oil level is below OTL CHANGE LEVEL arrows fill tank with recommended engine 011 and recheck for proper start Oil Change Level TEST 10 LOW OIL SWITCH Remove Low Oil Switch Cover and slide it down the Switch wires to expose the Switch terminals Set VOM to and to Rx1 scale then zero the meter Con METER nect one meter test probe to the READS lower terminal on side of switch Connect remaining test probe to RAS ground terminal on bottom of the switch Move switch actuating 1 ver DOWN simulated low oil ition meter needle should TEST PROBES swing upscale to 0 Raise the switch actuating lever FULL con dition meter needle should drop downscale to infinity RESULTS Switch tests 4 switch Switch tests 04 4 4 644 tests Axcaution 4 den de gau ssembling Switch cover make sure float arm is in p dU EOD E switch actuating lever or switch will not function TEST 11 SPARK PLUG Remove engine spark plug With spark plug lead connected to plug ground the spark
25. swing all the way upscale to zero RESULT Meter indicated zero e Replace printed circuit board Meter did not swing upscale Repair replace Wire No 4 or defective connector plug 2 2 21 TEST 41 CHECK STATOR Set VOM to and to 1 Viewed From Top scale then zero the meter Connect 3 meter test probes to Pins 1 and 2 of red receptacle on stator can Me ter needle should swing upscale and indicate approximately 0 42 Ohms RESULT Meter needle did not stator Checks Paragraph B With VOM still set to and to Rx1 scale connect meter test probes to red receptacle Pins 3 and 4 Meter needle should swing scale and indicate approximately 0 42 Ohms RESULT Meter needle did not stator Checks good ecco socecoccccecccccec e cecesGO to Paragraph C Set VOM to and to Rx10 000 scale then zero the meter Connect one meter test probe to red receptacle Pin 1 and the second test probe to frame ground Meter needle should not move Repeat test with one test probe connected to red receptacle Pin 3 and the second probe to frame ground Meter needle should not move RESULT Meter needle moved 1 stator Checks ee eeeeooooooosocccccsCOntinue diagnostic tests 2 2 2
26. to the Rotor Fan Magnet or Ring Gear is cause for replacement of the entire Location estabilsnes ass emb 1 y Timing At 21 This Pole Must Attract The North Seeking Pole Of A Magnetic Compass Ring Gear 2e 2 14 Timing is established at 21 BTDC by the physical location of the magnet on the fan Thus any damage that results a physical change in the TEST 30 CHOKE A Crank the engine The Choke Solenoid should pulse from Choke OPEN to Choke CLOSED position at a rate dependent on ambient tem perature RESULTS Choke movement is to D Choke does not 0 B Check the Choke assembly for binding or sticking caused by im proper alignment dirt Choke back and forth with finger there should be no evidence of binding or sticking magnet s location will cause an out of time condition Check for da maged key or keyway that might have caused slippage of the fan on the rotor shaft Bi Metal Screws 2 Choke Bi Metai 12 Choke Link e 77b Carburetor Choke Lever NR COVER SHOWN REMOVED est 31 PRE CHOKE Go to Paragraph B Solenoid Plunger Choke Link Carburetor Choke Plate RESULTS Choke binding e Adjust or clean choke linkage Choke moves 4 to Paragraph
27. voltage This is the pulsing Wire end Printed Circuit Board voltage from the Ignition Stator Connector Plug Receptacie trigger coil which energizes circ F uit board components NOTE For Model 6897 4 refer to Section 2 4 RESULTS Meter indicates pulsing 1 6 6 tests No pulsing voltage indicated Check Wire No 20 between connector plug and terminal strip and Wire No 25 betw een terminal strip and Igni tion module for open or shor ted condition See illustration above Locate the Wire No 14 connection at terminal strip Plug the Printed Circuit Board connector plug into its recept acle Set VOM to and to 50V scale Connect positive meter test probe to terminal strip Wire No 14 connection Connect remain ing test probe to frame ground Crank the engine Meter should swing upscale and indicate 9 12 Volts DC RESULTS Meter indicated 9 12 Volts Continue tests in Diagnostic Flow Charts Meter did NOT read 9 12 Volts Check Wire No 14 between PCB and terminal strip for open or short If wire is good replace Circuit Board TEST 19 FUEL FILTER To CD s Solenoid Operated Remove and replace fuel filter Fuel Shutoff Valve Make sure arrow on filter body points toward the solenoid ated Fuel Shutoff Valve Repeat Test 16 NO FUEL FLOW TEST 20 FUEL LOCK OFF SOLENOID A Locate Wire No 14 between the Fuel
28. 2 SECTION 2 3 BATTERY CHARGE CIRCUIT TESTS CHARRING CURRENT Wire No 15 Wire No 13 Fuse Holder SIMPSON 260 METER 1 Plug the black test lead 2 Locate the 15 Amp Fuse inside into the 10A jack on the VOM the alternator control panel Co Plug the red test lead into nnect the red meter test probe to the 10A jack on the meter Set the Wire 15 terminal on the Fuse the meter range switch to 10 Amps Holder Connect the black test dual position with 10 MA probe to the Wire 13 terminal on the Fuse Holder 3 Start the alternator With the engine running the 15 Amp Fuse from its holder With the Fuse removed the alternator should indicate a current output dependent on battery condition RESULT Ammeter indicates a current output Discontinue tests No current output indicated Continue tests CIRCUIT BRFAKER CB 2 White Receptacie Red Receptacle Disconnect Wires No 77 and 78 from the battery charge circuit breaker CB 2 Set VOM to and to Rx1 scale then zero the meter Connect the meter test probes to the circuit breaker terminal studs Meter needle should swing upscale to zero If it does not swing upscale replace the circuit breaker Heat Sink Diode D 2 Battery Charge Circuit Breaker Bearing Carrier DIODES D1 ANDD2 A Disconnect Wire No 78 at the circuit breaker
29. 2312 MO A M21 BOLUS BIOQOW GIONS OS 194406 21412879 Vans 30010 1115243 O OMW OS gt JILVN3HOS 9015 501 sp NAS NK o tn ec un 08 NOILS3NNOJ lt ask 4 uii 25 e K sa E x u g D 325 9 DHe ne 4 abi lt lt 11 4 og ad lt lt tw V gt gt 41 5 wt 3 95 11V8 71 1 2 1 0 6 69 0 8 69 6 1 1689 1 9689 1 9689 1 689 S1300 50267 ONISIM NOI193NNO9 43NO1SN9 ann 7 MILIMS 19 89016 5 2 1112412 OBLINA WILIME GOT AND BOWS NONI BINMGOW NOIUNJI 8434 gt OMAAN 41 201 2973 3000 amvaa 0242 82 2 QN32731 1102815 SILVW3H2S 55 1 13NVd 3100439 801 1093 39V110A 84 fo vi 0 310838 J 7 ti 4 02 HOLIMS n 10 MO1 de 32 18715 MS 3015 Zi 01 02
30. ART TROUBLE DIAGNOSIS Section 2 1 DIAGNOSTIC FLOW CHARTS 2 1 1 Introduction Engine won t Crank Engine Cranks won t Start Engine starts hard Runs Rough Switch set to STOP Engine Keeps Running AC Voltage Low AC Power Low AC Voltage High No AC Voltage Section 2 2 Diagnostic Tests Section 2 3 Battery Charge Circuit Tests SECTION 2 1 DIAGNOSTIC FLOW CHARTS 2 1 1 INTRODUCTION The DIAGNOSTIC FLOW CHARTS that follow are intended for use with the DIAGNOSTIC TESTS in Section 2 2 Test numbers assigned in the FLOW CHART are identical to the numbers assigned to specific tests in Sec tion 2 2 ENGINE WON T CRANK Replace Switch TEST 6 Starter Drive Gear 2 2 4 BAD Starter Solenoid 2 2 2 COOP 2 2 47 600D D BAD m Replace ENGINE CRANKS WON T START Ignition Ignition Module Stator Ignition FILL TANK TEST 18 Printed Circuit 2 2 9 Board V REPLACE GO TOJ TEST 19 gt TEST 19 Pa Fuel Filter e TEST 20 Fuel Lock Off 2 2 10ZG00D Solenoid GOOD TEST 24 REPLACE CARBURETOR TO TEST 27 COMPRESSION IS GOOD GO TO TEST 29 TEST 27 Page TEST 28 Rings 2 2 14ZZG00D Cylinder 2 2 14 BAD Timing 2 2 14 ENGINE STARTS HARD RUNS ROUGH TEST 14 Page Check Ignition Ignition WEAK WEAK Module ire
31. C Loosen the two Solenoid Adjusting screws Adjust axial movement of solenoid plunger so that with carburetor choke plate closed the choke solenoid plunger is bottomed Tighten the two adjusting screws and check again for correct choke action RESULTS Choke solenoid pulls in 11 to Test 31 Solenoid does not pull to Paragraph D 2 2 15 D Set VOM to and to 50 Wire No 91 scale Connect the positive Wire No 90 meter test probe to the Wire No 91 terminal on the choke solenoid and the remaining test probe to frame ground Crank the engine meter needle should swing upscale and in dicate a steady 12 Volts DC RESULTS Meter does not indicate 12 Volts Check Wire No 91 for an open or shorted condition Meter indicates 12 Volts Paragraph E Set VOM to and to 50V scale Connect the positive me ter test probe to the Wire No 90 terminal on the choke solenoid and the common test probe to frame ground Crank the engine meter nee die should indicate a puising voltage as choke pulses open and closed RESULTS No meter needle movement Replace Printed Circuit Board Model 6897 4 Replace Choke Pulse Module CM See Sect 2 4 Meter test is good but choke does not Choke assembly TEST 31 PRE CHOKE Bi Metal Adjusting Screws B
32. Choke Heat er to maintain engine operation The Ignition System continues to func tion and Field Boost current is still available 2 4 2 4 SHUTDOWN S To Rotor Field fu Laiks m 15 Ohm D3 5 9L 10 Watt Windings Spark Plug 91 Battery When the Stop Start Switch is set to STOP Ignition Stator IS output from Wire No 25 Ignition Module IM Pin No 3 Wire No 25 to the Terminal Block and Wire No 20 is delivered to frame ground Ignition terminates and the engine shuts down The Control Relay de energizes and its contacts open to close the Fuel Lockoff Solenoid FS and ter minate Fuel Pump FP operation 2 4 3 DIAGNOSTIC TESTS 2 4 3 1 CHOKE PULSE MODULE METHOD 1 Install a known good Choke Pulse Module Crank engine RESULT Choke operates normally Replace Choke Pulse Module Engine starts Choke does not function and or Continue Diagnostic Tests no start Section 2 1 METHOD 2 A Unplug Choke Pulse Module Set VOM to 0 and to 50 scale Connect positive meter test probe to Module receptacle Pin No 1 common test probe to frame Choke Pulse ground Crank engine Meter should indicate 9 12 Volts DC This is the input voltage to the Choke Pu 15 Module Choke Pulse B Plug Choke Pulse Module into Module Receptacie its receptacle Set VOM to DC Ignition Moduie Receptacle and to 50V scale From bottom of receptacle connect pos
33. LUB BEI CRM E RT 1 1 5 SECTIONAL VIEW LETT 1 1 6 SPECIFICATIONS 0 039 1 2 mm 0 079 0 0039 0 0078 Crankshaft End Play 0 0039 0 0118 Piston Diameter at skirt 3 067 77 91 3 068 77 93 mm Piston Pin Diameter 0 7080 0 7086 Width of Compression Grooves 0 0797 2 025 mm 0 0805 2 045 mm Width of Oil Ring Groove 0 1584 4 025 mm 0 1593 4 045 mm Width of Compression Rings 0 0775 0 0784 Width of Oil Ring 0 1560 0 1570 Ring End 0 0078 0 0157 Maximum Permissible Out of Roundness 0 002 0 05 mm of Crankpin Connecting Rod to Crankpin Clearance 0 001 0 030 0 002 0 050 mm Valve Spring Force 14 81 kilograms 19 76 lbs 6 72 8 96 Valve Spring Length Valve Spring Compression Length Valve Seat Width Valve Tappet Clearance 3 970 mm 3 990 mm SECTION 1 2 WIRING DIAGRAMS 0 L689 0 9689 0 9689 0 689 514001 8tL8V NVH49VIJO ONIGIM 01123 02 83WO1Sn2 5 6 301911934 39 110 jd 310W39 1in28l2 01 Ll 11 d GiON310S 330H23 801716 912 m HOLIMS 02 WI 52 MS 18715 m MAWBOSTNVAL MILMS 10315 9015 GIONBIOS 63161 esis 10
34. No 14 the longest from the fuel lock solenoid to the terminal strip Refer to appropriate wiring diagram wiring connections 3424 3 13 Install heat shrink tubing over the connectors on Wires 8 and da 3 2 3 12 No 8 and 25 from the ignition stator were cut during disassembly NOTE Some later pro duction units may have a quick dis connect on these wires If wires Were cut strip wire ends and inst all a knife edge connector 3 2 3 14 Install starter bolt The upper starter bolt 5 16 18 x 4 passes through starter engine gear cover and adapter casting Lower starter bolt is a 5 16 18 x 1 socket head capscrew Tighten starter bolts then torque adapter casting bolts in cluding 4 inch long starter bolt to 120 inch pounds Finally install the starter cable and retain with hex nut and lockwasher 3 2 3 15 111 align stator and install over rotor 3 2 3 16 Retain panel divider to sta 3 2 3 17 1 upper stator bolt bar tor can with two taptite screws The Install both upper stator bolts Only ground wire No 10 previously dis the two upper stator bolts have a spac connected from Stop Start switch ter Bolts can be tightened later after minal connects to one of these screws the two lower stator bolts are install ed el Alternator Support r F 4 A ad N d A 7 2 V gt L5 T 4
35. OM to and to Rx1 scale Zero the meter See illustration at right Connect VOM test probes acr oss the Main Breaker test points Meter needle should swing upscale to zero with Main Breaker ON When the Breaker is set to OFF needle should drop all the way downscale infinity Main Breaker Test Points RESULT Main Breaker checks good Continue diagnostic tests Main Breaker tests Breaker TEST 39 CHECK ROTOR A Disconnect the white connect or plug from its receptacle on the stator can Set VOM to and to Rx1 scale then zero the met er Connect the positive meter test probe to white receptacle Pin 4 Connect the common probe to receptacle Pin 1 Meter needle should swing upscale and indicate rotor winding resistance approxi mately 15 6 Ohms Receptacie E Brush Holder Bearing Slip Rings RESULT Rotor checks good to Test 40 Rotor checks su eS Paragraph B 2 2 20 rotor checks bad in Paragraph A check Wires No 1 and 4 for open or shorted condition Inspect brushes replace if cracked chipp ed or less than 5 16 inch long Inspect slip rings and clean with fine sandpaper if necessary Make sure brushes are making good contact with slip rings Finally recheck rotor winding resistance at Pins 1 and 4 of white receptacle a
36. TRY TO STRAIGHTEN A BENT CRANKSHAFT Crankpin is out of round more than 0 002 inch When installing a crankshaft always lubricate bearing surfaces If the camshaft drive gear on crankshaft is replaced replace the mating cam shaft gear as well The crankshaft must be shimmed during assembly to establish an end play of 0 0039 to 0 0118 inch 3 3 5 3 3 2 5 PISTON piston diameter here Piston diameter 3 067 3 068 Dimensions in inches Clean carbon from piston ring gro Check for proper width of compression oves as well as from upper cylinder and oil ring grooves on piston See bore and head Check piston dimensi illustration above ons as shown above Replacement pi stons are available in 3 sizes standard 0 25 mm oversize and 0 50 mm oversize 3 3 2 6 RINGS Replace rings in sets During installation ring gaps must be staggered Before installing new rings deglaze cylinder walls thoroughly with fine emery cloth and clean thoroughly Rings are available in standard size as well as oversize to match the oversize pistons that are avail able COMPRESSION RINGS 0013 0030 Check for proper clearance of a 0013 0030 compression and oil control rings M M in piston grooves See illustration at ri ght OIL CONTROL RING 3 3 6 Check ring gaps rings to After sguaring the ring in bore determine if rings should be re use feeler gauge to chec
37. ULT No voltage 0 to Paragraph C Voltage is indicated but none Repair replace Wire No 4 in Paragraph A between red receptacle and Field Boost Module C Set VOM to 0 and to any scale that will permit 12 Volts DC to be read Connect the positive meter test probe to the Wire No 14 connection at Field Boost Module Connect the common test probe to frame ground Depress the Fuel Pump button Meter needle should im dicate 9 12 Volts DC RESULT Normal DC voltage indicated Replace Field Boost Module but not in Paragraph B No voltage Wire No 14 between the Field Boost Module and the Control Relay CR 2 4 7 DISASSEMBLY 4 REPAIR Section 3 1 BLOWER SHROUD SECTION 3 1 1 Disassembly 3 1 2 Inspection and RepaIr 3 1 3 Reassembly Section 3 2 ALTERNATOR SECTION 3 2 1 Disassembly 3 2 2 Inspection and Repair 3 2 3 Reassembly Section 3 3 ENGINE SECTION 3 3 1 Disassembly 3 3 2 Inspection and Repair 3 3 3 Reassembly SECTION 3 1 BLOWER SHROUD SECTION 3 1 1 DISASSEMSLY 5 16 inch nut driver 3 1 1 2 phillips head screws that retain blower inlet ring Rem ove blower inlet ring 3 1 1 1 Use to remove screws and flat washers that retain blower shroud end pan el Remove end panel 3 1 1 3 a screwdriver into a 3 1 1 4 While preventing ri
38. acle Pin 6 and Wire 77 meter should indi cate approximately 08 Ohm O lt p N 00 RECEPTACLE BATTERY CHARGE WINDING To DIODE D 1 RESULT Both meter readings were approximately 08 sus good Meter needle did not indicate 08 Ohm Replace stator SECTION 2 4 MODEL 6897 4 2 4 1 GENERAL 2 4 1 1 INTRODUCTION The Model 6897 4 MC 40 alternator incorporates several new components in its DC control system The new components replace the printed circu it board used on earlier models They will improve starting and simpli fy component testing removal and replacement New components are 1 Choke Pulse Module 2 Control Relay CR 3 Field Boost Module FB 2 4 1 2 CHOKE PULSE MODULE The Choke Pulse Module performs several important functions rel ated to engine starting These Choke Pulse odule functions are 1 Provides the necessary compo nents for delivery of a pulsing voltage to the automatic choke solenoid during cranking 2 Provides the required circui try for energizing the fuel iock off solenoid and electric fuel pump during cranking before the control relay CR is energized 2 4 1 3 CONTROL RELAY CR The Control Relay CR is equipped with a pushbutton for manually cl osing the CR contact The pushbut ton can be identified by the words FUEL PUMP on t
39. circuit is completed within the CM through Pin No 3 through Wire No 14 the Fuel Lockoff Solenoid FS the Fuel Pump FP Choke Heater and through Wire No 10 to frame ground The Choke Heater energizes the Fuel Lockoff Solenoid FS opens and the Fuel Pump FP operates As the engine cranks the Ignition Stator IS supplies a volt age pulse to the Ignition Module IM The Ignition Module in turn supplies a timed voltage pulse to the Ignition Coil primary winding The buildup and collapse of this voltage pulse induces a voltage into the Ignition Coil secondary winding to fire the spark plug Battery power is supplied through Wire No 14 to the Field Boost FB module A 15 Ohm 10 Watt resistor reduces this voltage and a Diode D3 ensures correct polarity The reduced voltage is delivered to the rotor windings via Wire No 4 2 4 3 2 4 2 3 RUNNING Rotor Field D3 15 Ohm UL 10 Watt m a 2 5 Plug Coil Releasing the Stop Start Switch to NEUTRAL opens the DC circuit from the battery Wire No 13 15 Amp Fuse Wire No 15 Starter Contactor SC and Wire 17 The SC de energizes and its contacts open to terminate cranking and choke operation The Control Relay CR is held energized by AC output from the Battery Charge Windings and the CR contacts close Battery power is delivered through the closed CR cont acts to the Fuel Pump FP Fuel Lockoff Solenoid FS and
40. connect starting circuit Remove panel top cover Disconnect wires from switch terminals to prevent int eraction Set VOM to 0 and to Rxi scale then zero the meter Connect meter test probes to the switch center and right hand ter minals as viewed from switch rear Meter needle should not Hald Switch at START meter MAITA A Set Stop Start Switch to START and back to NEUTRAL several times An audible click should be heard as the solenoid actuates 17 10 Ground Connect VOM test probes to Switch center and left terminals as vi ewed from switch rear Hold the Switch at START meter needle should not move to NEUTRAL meter needle should not move Hold the Switch at STOP needle should swing upscale to 0 eseese Install new Stop Start Switch Switch wires install top panel and 15 Amp Fuse Continue tests Terminals Release the Switch RESULTS Solenoid actuates engine does not tests in Paragraph Solenoid does not actuate Continue tests in Paragraph D B Set VOM to 0 and to a scale greater than 12 Volts DC Connect the NEGATIVE COMMON test probe to ground Connect the POSITIVE probe to the battery cable connection on the solenoid Meter should in dicate approximately 12 Volts DC RESULTS Meter reads 12 Volts DC Continue tests in Paragraph C Meter reads less than 12 Check for
41. ctor plugs into their receptacles Install front panel Connect ground wire No 10 to center terminal of stop start switch 3 2 3 25 Install oil make up tank with pump Connect 011 lines to pump and probe retain with clamps Connect Wire No 20 from low 011 level shutdown switch to terminal strip see appropriate wiring dia gram Connect ground wire from low oil level shutdown switch and from fuel lockoff solenoid to the tapped hole on adapter casting a long with fuel lockoff solenoid clamp 7 3 2 11 SECTION 3 3 3 3 1 1 Disconnect governor spring rom governor adjusting screw Loo sen governor arm clamp bolt and re move governor arm from governor shaft 3 3 1 2 Remove spark plug 3 3 1 3 engine from alterna 3 3 1 4 Remove breather assembly tor slide pan 3 1 5 Remove intake manifold elbow 3 3 1 6 engine cowling 3 3 1 7 8 cylinder head nuts Remove cylinder head and head gasket dy gt 3 3 1 9 valve spring compressor to compress valve springs Then re move roller pin from valve stem Remove compressor then remove valve springs spring retainers and valves Je 3e10e11 Remove thrust washer from end of cam shaft 3 3 1 8 and exhaust valves are shown in a sectional view ab ove Valve springs are retained to valve stems by and a roller pin Keep valve parts together as a
42. e ro the meter Connect meter test probes across wires No 11 and 22 from the Sensing Transformer Meter needle should swing upscale and indi cate secondary winding resistance See illustration at right Sensing Transtormer Located inside Paneli Back Resistance 15 Winding Wescoil Coiltran Primary 785 ohms 969 ohms Secondary 1886 ohms 1438 ohms RESULT Secondary winding resistance checks gaod Go to Paragraph B Meter needle does not swing upscale Replace Transformer B Unplug the white connector plug from its receptacle on the stator Set VOM to and to Rx10 000 scale Zero the meter Connect one meter test probe to white connector plug Pin No 3 Connect the re maining probe to white connector plug Pin No 5 Meter needle should swing upscale and indicate PRIMARY winding resistance See illustration above right 2 2 19 RESULT Primary winding resistance checks good Check customer wiring Primary winding resistance is bad Replace Transformer NOTE The Sensing Transformer secondary windings MUST connect to the Voltage Regulator The primary windings must connect to the white connector plug In most cases primary and secondary wi ndings will be identified when replacing a Transformer If the windings are not identified check winding resistance The winding having the HIGHEST resistance is the SECONDARY winding TEST 38 MAIN CIRCUIT BREAKER Set V
43. e crankshaft the slot ted end of the stud will extend approximately inch into the rotor shaft Thread the stud in to the engine crankshaft 3 2 1 22 Remove the ignition stat 3 2 2 INSPECTION AND REPAIR 3 2 2 1 GENERAL 3 2 1 21 the 5 16 24 bolt included with rotor removal kit into the rotor shaft until 1t 18 tirmly seated against the stud Tighten the bolt against the stud and tap the bolt head with a mal let Continue tightening and tap ping until rotor is free Remove the rotor and fan assembly Inspect wiring for pinching obvious damage defective insulation Clean all parts and inspect for obvious damage cracks etc Check connector plugs and receptacles for damage pins pushed out of sockets etc Repair or replace damaged defective parts as requir ed 3 2 4 3 2 2 2 BRUSH HOLDER AND BRUSHES Replace brush holder if cracked otherwise damaged Replace brushes if cracked chipped or less than 5 16 inch long 3 2 2 4 STATOR Inspect closely for damage Use an insulation breakdown tester and test for breakdown under load Follow the tester manufacturer s instructions carefully See 1 1 3 ELECTRICAL TEST SPECIFICATIONS 3 2 3 REASSEMBLY 3 2 2 3 BEARING CARRIER Once removed the bearing carrier should not be re used Replace the bearing carrier during reassembly 4 m UM MEN nnum 3 2 2 5
44. ests TEST 35 CARBON DEPOSITS Excessive carbon buildup in the engine combustion section can serious ly affect engine power Carbon deposits should be removed every 500 operating hours whenever the cylinder head is removed or when prob lems are encountered Refer to the engine section of Manual for cylin der head removal and installation procedures Cylinder head bolts must be properly located and properly torqued RESULT Power output is normdl isseev seescsevasvseceeDiSCOntinue tests Problem is still encountered Continue diagnostic tests TEST 36 CHECK VOLTAGE Disconnect customer wiring from Wires No T1 and T2 in alternator connection box Check a c voltage output at Wire No T1 and junction of Wires T2 Reading should be ap proximately 125 Volts a c at no load and 115 125 Volts a c under load RESULT Voltage output bad eee eee Continue diagnostic tests Voltage checks 04 customer wiring NOTE Alternators are factory connected to provide a 120 Volt a c output only Some units may have been reconnected to supply 120 240 Volts a c See Page 1 2 3 TEST 37 SENSING TRANSFORMER Wire White Connector Plug Nut Pins 3 and 5 To Voltage Regulator 11 Secondary 22 A Remove 2 wire nuts that connect wires No 11 and 22 between Sensing Transformer and Voltage Regulator Disconnect the wires Set VOM to MDC and to Rx100 scale then z
45. fter engine starts then release RESULT Engine starts and runs normally shuts down after button is 1 to Paragraph C eased No change engine starts then Continue Diagnostic Tests shuts down as before Section 2 1 C Set VOM to Connect one CONTROL RELAY RECEPTACLE ter test probe to Pin No 7 of the VIEWED FROM WIRE END CR receptacle Connect remaining test probe to receptacle Pin B then crank engine Meter should indicate approximately 10 12 Volts AC RESULT Checks good Replace CR Checks bad Check wires 15 and 77 If wires check good replace stator assembly 2 4 3 3 FIELD BOOST MODULE A Unplug red receptacle from its receptacle on stator can Set VOM DC and to any scale that will permit 12 Volts to be read Sail cas Connect the positive meter test Viewed From Top probe to red connector plug Pin No 5 Connect the common probe to frame ground Depress the Fuel Pump button meter should indicate app roximately 9 12 Volts DC RESULT 2 Checks bad to Para graph B Checks good Continue tests Section Red Connector Plug 2 1 B Set VOM to DC and to any scale that will permit 12 Volts to be read Connect the positi ve meter test probe to the Wire No 4 connection at Field Boost Module Connect the common test probe to frame ground De press the Fuel Pump button the meter should indicate 9 12 Volts DC RES
46. he unit control pan el To prime the carburetor prior to cranking the engine depress the pushbutton This action will energize the Fuel Lockoff Solenoid open and operate the electric Fuel Pump After a start the CR remains energized to hold the Fuel Lockoff Solenoid open and operate the Fuel Pump While cranking part of the Choke Pulse Module cir cuit performs the latter function 2 4 1 2 4 1 4 FIELD BOOST MODULE Many alternators rely on residual or stored magnetic energy to provide the initial magnetic field around the rotor windings Residu al magnetism can be lost due to aging shock or physical damage The MC alternator is equipped with a Field Boost Module FB which supplies battery current to the rotor windings during each start ES FIELD BOOST MODULE 2 4 2 CIRCUIT OPERATION 2 4 2 1 PRIMING 4 lt gt 10 Rotor fFieid 1 4 D3 m 15 Ohm 9L 10 Watt a gt 5 E Spark Plug LEGEND Rela CS Choke Solenoid m z via SC Starter Contactor HM Hourmeter 5 Starter Motor LOS Low Oil Level Shutdown Switch CM Choke Pulse Module Fg Field Boost Module FP lt Fuel Pump lt 1 FS Fuel Lockotf Solenoid 59 M Ignition Battery power is available through Wire No 13 the 15 Amp Fuse and Wire No 15 to the Control Relay CR contacts When the push button FUEL PUMP is depressed the CR contacts close
47. i Metal With the choke Bi Metal at ambient temperature the carburetor choke plate should be approximately 1 8 inch away from its full open posi tion toward the closed position If necessary loosen the bi metal Y adjusting screws and move the bi Ko metal to obtain this setting This is the position Carburetor Choke Lever 2 2 16 TEST 32 GOVERNOR A Adjust Carburetor as outlined in Test 23 Carburetor must be adjusted BEFORE attempting to adjust the Governor RESULI Problem is corrected wovon tence sees st completed Engine hunts and or a c voltage or frequency is incorrecto eese sss GO to Paragraph Carburetor Throttle Lever ZS B Make sure Governor Spring is connected to Governor Arm and to Governor Adjusting Screw Loosen Engine Governor Shaft Clamp Nut garas and turn Engine Governor Shaft Shaft Clamp counterclockwise as far as it ASE EMI d will go Then tighten Governor Shaft Clamp Nutand torgue to 110 inch pounds Throttle Rod With Governor Arm Tensioning Spring 2 Governor Spring 7 Hex Nuts B JS Engine Governor Shatt RESULT Engine runs normal provides 62 Hertz at 1 4 Test completed Engine hunts and or a c voltage or frequency is to Paragraph
48. itive 4 meter test probe into receptacle Pin No 1 and common test probe to frame ground Crank engine The meter should indicate a pulsing voltage and choke solenoid should pulse C Plug Choke Pulse Module into its receptacle Set VOM to DC and to 50V scale From bottom of Module receptacle connect positive meter test probe to receptacle Pin No 3 Connect common test pr obe to frame ground Crank engine Meter should indicate approximate ly 12 Volts DC RESULTS A11 tests good Continue diagnostic tests Section 2 1 Test A checked bad Check Wire No 90 between receptacle and Choke Solenoid Choke Solenoid Wire No 91 between Choke Solenoid and Starter Solenoid SC Starter Solenoid SC Test B checked bad Replace Choke Pulse Module CM Test C checked bad Replace Choke Pulse Module CM 2 ijas 2 4 3 2 CONTROL RELAY Refer to 2 4 1 3 and 2 4 2 this Section If engine starts and then shuts down the problem may be caused by the Control Relay CR Pro ceed as follows to check the Control Relay A With unit battery properly connected depress Fuel Pump button The Fuel Lockoff Solenoid should open and Fuel Pump should operate RESULT Checks good ee eeeeeeoecoccccceccceccececcce GO tO Paragraph B Checks bad Check 15 Amp Fuse and priming circuit See 2 4 2 1 PRIMING B Crank engine while holding Fuel Pump button depressed Continue to hold button in a
49. k ring placed Check gaps on new rings determine if cylinder should To check ring gap sguare the ring in the cylinder bore as shown above 3 3 2 1 VALVES Intake and exhaust valves are NOT identical intake valves are id entified by the letter I exhaust valves by an E Clean valve parts in non flammable solvent Remove carbon from valves Replace distorted or damaged valves If valves are useable they may be ground to a 45 degree angle When new or re ground valves are to be installed lap them to ensue a gas tight fit Lap valves as follows 1 Coat valve face sparingly with a fine grade of valve grinding comp ound 2 Rotate valve on valve seat Lift valve from seat every 8 10 strokes to keep compound equalized on surface of valve seat 3 Continue lapping until both the valve and seat has a smooth surf ace Clean thoroughly to remove all traces of iapping compound Dry thoroughly To obtain correct valve tappet clearance grind ends of valve stems off squarely Use a V block to hold valve stem square to grinding wheel After grinding check for proper clearance as follows 3 3 7 Rotate crankshaft until piston is at top dead center of its 1 compression stroke 2 Insert valves in their guides and hold them firmly on their seats 3 Check clearance with feeler gauge Use a metric feeler gauge be tween valve stem and tappet Correct clearance is 0 1
50. l aW CL up SW dWNd T3N4 NOLING 1 2 3 MODEL 6897 4 WV39VIO 2NIMY28 HOLLOW 1535010 uSnHB x NOIL23NNO2 33WO1S0n2 19908 ANTE 38166 MILIS 10915 901 O Ow os 9 VOiowiowa MOLINE NO MOT 4 Mon BOLLS MOLINO 37000w 55 9 Om eens VALIDI MTA LINDAI ON3731 SITVW3H2S 13NYd 310W34 801911998 M 3281104 LVIS 4015 310334 T7 AS m 0L HJIIMS v 10 WI 1 Pt i Zt 01 02 52 02 01 S 5 0t 14915 3015 16 1 01 02 _ 63 5 m 2 x08 st tu SI y dNAd 1303 01108 HSfid 11V8 1 2 4 RED CONNECTOR PLUG MAIN CIRCUIT Bea Pa DONNE SN STATOR T1 120 FACTORY WIRING CONNECTIONS CUSTOMERS 120 VOLTS ONLY CONNECTIONS RED CONNECTOR PLUG RED RECEPTACLE MAIN CIRCUIT BREAKER CB 1 STATOR RECONNECTED FOR 120 240 VOLT OUTPUT CUSTOMER CONNECTIONS 1 2 5 SECTION 1 3 SPECIAL TOOLS ELECTRICAL TEST PLUG The Electrical Test Plug facilit ates the testing
51. lug end of spark plug lead and the remaining probe to frame ground Meter needle should swing upscale and indicate approxim ately 5000 Ohms 10 RESULT Meter needle does not move Check spark plug lead for open condition If lead is good replace Ignition Coil Meter reads test 5000 Ohms Acaution To prevent damage to Ignition Coil make sure spark plug lead and spark plug are installed and grounded to engine before cranking 2 2 7 TEST 15 LOW FUEL To Alternator Engine To Vehicl The motor home engine and the alt To Vehicle To Alternator user ernator engine should share the d vehicle fuel tank through a dual fuel pickup tube arrangement See illustration at right To prevent the alternator from depleting the Y Variable d Fuel fuel tank the alternator fuel B Potentiometer e pickup tube is usually several in ches shorter than the vehicle ine tube Thus the alternator may be out of gas while the vehicle engine has sufficient fuel supply Installation Of Second Fuel Pick Up Tube Tank Outlet Anti Siphon Holes B Fuel Pickup Float Assembly Make sure the alternator fuel supply line is NOT connected into the ve hicle engine fuel supply line If the vehicle engine is running the alternator engine may be starved of fuel When the vehicle engine is not running the alternator may drain
52. mm plus 0 05 mm minus 0 3030302 Install counterbalance co 3 3 3 1 11 counterbalance as sembly over its shaft engine ver Retain with 4 bolts and lock gear cover washers Tighten bolts to 90 110 inch pounds 3 4 Install governor shaft as ubi Retain with spring clip Install oil stopper into der block Tighten bolts to 0 inch pounds Je in 1 3 3 3 8 Connecting rod and connect ing rod cap are a matched set and must be replaced as a set Mark on cap see above must align with id entical mark on connecting rod dur ing installation 3 3 3 6 Install crankshaft end play shims Install crankshaft Use care not to damage vil bearing seal and 3 3 3 7 11 rings onto piston Ring end gaps should be staggered See Section 3 3 2 INSPECTION AND REPAIR for proper ring locations in piston grooves Slide connecting rod with piston installed down through cylinder until rings contac top of cylinder block Then use compressor to compress rings into piston grooves With rings compress ed tap piston into cylinder While tapping align connecting rod with crankshaft When rings are engaged by cylinder remove ring compressor rt 4 3 3 3 9 Lubricate bearing surfaces of connecting rod and cap Install connecting rod cap oil splasher and lock tab onto connecting rod Retain with connecting rod bolts Use torque wrench and tighten bolts
53. n installed and shrunk over the connectors Some later production units may be equipped with quick disconnects at these wires for ease of maintenance 3 m Es 3 2 3 5 Woodruff key and keyway on engine taper shaft and rotor Replace key if damaged or worn Install key into keyway on engine taper shaft e 3 2 3 7 Align adapter casting with bolt holes in engine gear cover Install casting making sure the carburetor intake manifold studs are aligned with carburetor At the lower right corner of casting retain with a 5 16 18 x 2 bolt with square nut Also retain with two 5 16 18 x 2 bolts lockwash ers and hex nuts Upper left corn er of casting will be retained by a 5 16 18 x 4 bolt and hex nut which will aslo retain the starter 3 2 3 9 Fuel Pump Only Install fuel pump inlet filter solenoid shutoff valve interconn ecting hoses and clamps Retain the fuel pump with two M6 x 18 mm sock et head capscrews and lockwashers Tighten capscrews to 25 30 inch pounds Je 2e 3e 8 Install a new carburetor to intake manifold gasket Retain carburetor to intake manifold with wo 20 NyLok nutss 3 2 3 10 fuel pump to carburet or fuel line contains a filter screen Install clamps over fuel line Then connect line to carbur etor inlet fitting and fuel pump outlet fitting Retain line with clamps 3 2 3 11 Wire
54. ng gear cooling air slot of engine adapter from turning remove the special M housing to prevent ring gear from 14 hex nut that retains the blower turning fan hub to engine taper shaft 3 1 1 5 Install three 5 16 24 bolts into threaded holes of blower fan hub Install a puller as shown at right and pull blower fan and blow er fan hub free of engine taper shaft 3 1 1 6 10 mm wrench to rem 1 1 7 four M10 bolts and ove blower scroll bolts nearest the four lockwashers that retain the cv engine taper shaft The bolt at low linder head cover Remove cylinder er right corner of blower scroll ex head cover tends through the shrouding and is retained by a lock washer flatwash er and hex nut on shroud exterior Use a 7 16 inch wrench to remove the bolt and nut 3 1 1 9 Remove bolt and washer that retains housing and exhaust pipe support to vibration dampener 3 1 1 8 two M8 socket head capscrews that retain the exhaust pipe to engine Lo M 3 1 1 10 05 a nut driver to remove screws that retain blower housing upper ends to engine Remove blower housing 3 1 2 INSPECTION AND REPAIR Clean and degrease all components including sheet metal Inspect all parts as follows 1 Carefully check all sheet metal for cracks or other damage Repair or replace damaged sheet metal 2 Inspect all weld nuts 3 Check foam rubber gaskets on blower shroud sheet metal
55. o establish crankshaft end play Check number of shims during re assembly the same number of shims must be used 3 3 2 INSPECTION AND REPAIR 3 3 2 1 CYLINDER BLOCK Replace cylinder block if ae Fins are broken or cracked b Head mounting surface is warped c Cylinder inner diameter is greater than 0 5 mm oversize If cylinder is to be rebored first determine whether to bore 0 25 mm or 0 50 mm oversize Use any standard commercial hone of a suitable size Chuck the hone in a drill press having about a 600 rpm speed Use standard boring procedures Valve seats require grinding only if pitted or scored If seats are not pitted or scored lapping will provide a satisfactory valve seat Valves must be lapped to seats when seats are reground 3 3 2 2 ENGINE GEAR COVER Clean and degrease engine gear cover Replace if cracked warped or damaged 3 3 2 3 CAMSHAFT Clean camshaft in non flammable solvent and blow dry Replace a camshaft that shows signs of wear or scoring If a damaged camshaft gear is replaced also replace the mating crankshaft gear If keyways are damaged or worn replace camshaft Inspect keys replace any that are dam aged or worn excessively Repl ace flyweight or governor shaft if damaged 3 3 2 4 CRANK SHAFT Replace crankshaft if Damaged threads can t be dressed b Bearing surfaces are worn scratched or damaged Flat spots have developed d Crankshaft is bent NEVER
56. r Aemove brush holder from carrier Remove brush leads from brushes re and remove brush holder and brus hes 3 2 1 8 alternator support to vibration dampener bolts r 3 2 1 9 two bottom stator TEN to bolts and stator bolt bar 3 2 1 10 4 screws that ret IRTEN A ain bearing carrier to stator Remove bearing carrier using a puller 2 R 2 3 2 1 12 panel divider The 2 541 11 2 upper stator stator can may now be removed as bolts and stator bolt bar well L 13 Remove starter cable at he starter terminal 3 2 1 15 At the terminal strip from the fuel disconnect the wire lockoff solenoid 3 2 1 17 Remove bolts nuts and washers that retain the adapter casting Remove carburetor to intake manifold nuts then rem ove adapter casting 3 2 1 19 Use rotor removal kit See Section to remove rotors 1 3 SPECIAL TOOLS Use the 5 16 24 tap from kit to cut threads totor as shown at right 3 2 1 14 Wires 8 25 that go to the ignition stator 3 2 1 16 fuel line at carb uretor Carburetor to intake fold nuts may also be loosened at this time These nuts will be pletely removed prior to removal of de adapter casting Step 3 2 K ti com 3 2 1 20 Select a stud from the kit that is long enough so that when the stud is threaded into the engin
57. r installation for 1 Any other filter in the fuel supply line from gas tank If other filters are found check for clogging 2 A Shutoff Valve in the fuel supply line Make sure Shutoff Valve is OPEN 3 Anything that might restrict cooling air flow such as air inlet or exhaust openings too small clogged air inlet screening etc If cooling air flow is inadequate interior compartment tempera tures will be high resulting in possible fuel line vapor lock 4 Alternator fuel pump located too high above fuel supply tank Maximum vertical lift for MC units with an electric pump is app roximately 18 inches for mechanical fuel pumps approximately 9 inches TEST 23 CARBURETOR This test covers the procedures for adjustment of the carburetor Idle Speed Stop Screw Idle Mixture Adjusting Screw and High Speed Jet Ad justing Screw In addition to these adjustments the float valve and its seat should be checked as well as the float level 2 2 11 Automatic Choke A Turn High Speed Jet Adjusting Screw clockwise until it just bot toms DO NOT USE EXCESSIVE FORCE Then turn High Speed Jet Adjusting Screw counterclockwise about 15 turns Perform the same initial ad justment on the Idle Mixture Adjust ment Screw This initial adjustment Fri ic HESS should permit the engine to be star ted and warmed up Adjusting Screw RESULTS Engine 5 5
58. s outlined in Paragraph A RESULT Wires slip rings and brushes check good but rotor still Checks rotor Wires slip rings or brushes check Repair clean or replace TEST 40 CHECK FIELD ROOST ee cee on Model 6897 4 Unplug the Ignition Module to pre vent the engine from starting Al Stabe Can so unplug the red connector plug Viewed Fror from its receptacle on the stator Set VOM to 0 and to scale that will permit 12 Volts be read Connect the positive meter test probe to red connector plug Pin 5 Connect the negative test probe to frame ground Crank the engine meter needle should swing upscale and indicate approximately 9 12 Volts 4 Red Connector Plug RESULT No field boost veltage indicated Go to Paragraph Field boost voltage checks good Continue diagnostic tests B Unplug connector plugs from the Printed Circuit Board and from the red receptacle on stator can Wire No 4 Set VOM to 0 and to 1 sca Pin 5 le then zero the meter Connect one meter test probe to Pin No 2 of the printed circuit board conn Red Connector Plug ector plug Connect second test Stator Can probe to Pin No 5 of the red con BOTH CONNECTOR PLUGS VIEWED FROM WIRE END nector plug Meter needle should
59. the vehicle engine fuel line and even the vehicle engine carburetor The latter will result in hard starting of the vehicle engine TEST 16 NO FUEL FLOW Disconnect fuel line at Carburetor inlet fitting Place open end of fuel line into a suitable contain er then crank engine Fuel should pump from open end of fuel line If little or no fuel comes from fuel line check in line filter for clogging Replace fuel line and fi lter if filter is clogged FUEL LINE RESULIS Little or fuel flow observed eee eee Continue tests Fuel flow is FW TEES Aa y ees vau usb to Test 23 TEST 17 4 AMP FUSE The 4 Amp Fuse is equipped with a Fuse Puller Tab for easy removal Remove the Fuse from the Printed Circuit Board and test in same manner 15 Fuse Test 1 d Fuse is defective replace NOTE Model 6897 4 has no 4 Amp Fuse See Section 2 4 4 Amp Fuse 2 2 8 TEST 18 PRINTED CIRCUIT BOARD Depress Printed Circuit Board connector plug locking tangs and NET remove connector plug On the conn pde ector plug locate Pin 4 to which Wire No 20 attaches Set VOM to ignition L 25 gt ignition and to the 2 5 volt scale Connect one meter test probe to connector 20 plug Pin 4 Connect the other test ME TTE probe to frame ground Crank engine Temi X Meter should indicate a small puls mio 1 Connector ing
60. ult 3 3 3 19 Install upper and lower valve spring retainers over ends of valve springs Keep intake and exhaust valve parts together as a set See illustration for correct retainer locations UPPER RETAINER SPRING AOWER RETAINER 34 3 11 3 3 3 20 Install springs and ret ainers over tappets Intake valve is identified by the letter I exhaust valve by an Slide both valves down through valve guides retainers and springs Te 6 san lt lt Indicates Longer Stud Nuts 3 3 3 22 Install new cylinder head gasket Install cylinder head Location of 4 longer stud nuts and torque sequence are shown in illustration 3 3 3 245 Install cowling gt 3 3 3 21 Compress valve springs using a spring compressor Then install roll pin through hole in valve stem Remove compressor and make sure roll pin is locked in place by lower valve spring retainer 3 3 3 23 Tighten head nuts to 22 29 foot pounds in sequence shown in previous illustration 5 3 3 3 26 Install spark plug Cap bow gasket Install intake should be set to 0 035 1nch Tor amp uibow que spark plug to 18 22 foot pounds 3 3 3 28 Install engine onto alter 3 3 3 27 11 breather assembly nator slide pan Tighten bolts to 90 110 inch pounds 9 I I
61. wash ers 3 1 3 8 Retain cylinder head cover with four M10 x 20 mm long bolts and lockwashers Tighten bolts to 12 foot pounds Install all No 10 32 screws that retain head cover to blower housing IN 3 1 3 9 Align keyway in blower fan 3 1 3 10 Install inlet ring as hub with drive key on engine shaft shown Retain with No 6 32 x Install blower fan over engine 3 8 inch long Screws and lock shaft Make sure drive key and key washers way are engaged Install special M 14 hex nut and flatwasher Prevent crankshaft from turning then torq ue hex nut to 50 55 foot pounds 3 1 3 11 11 blower shroud end panel Retain with No 10 32 screvs and flatwashers 1 5 SECTION 3 2 ALTERNATOR SECTION 3 2 1 DISASSEMBLY 3 2 1 2 oil line clamp at oil make up pump Slide clamp down hose then disconnect hose from pump fitting 28 PF XL i 3 2 1 1 the terminal strip dis Wire 20 that comes connect the level shutdown sw from the low oil itch e RSS 3 2 1 4 Unplug the red connector plug from its stator can receptacle Also remove ground wire retained by panel divider screw 3 2 1 3 Remove 4 screws that retain front panel Remove front panel 3 2 1 5 screws that retain rear panel Remove rear panel 3 2 1 6 end panel 3 2 1 7 Straighten brush holder locking tangs on bearing carrie

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