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Universal Diesel M 25 Technical Manual

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MODEL 15 25
Fuel System System 5
Oi 1 Fi 1ter 6
Combustion System 7
Valve Timing 8
Compression Release 9
Pistons and Rings 10
Crankshaft 10
Connecting Rod 11
Cyl i nder Liner 12
Cylinder Head 12
Gear Train 13
Cam Bearings 13
Main Bearings 14
Injection Pump 15
Flywheel 16
Wiring Diagram 17
Starting Motor 1819
Glow Plugs 19
Reference Chart 2024
MODEL 15 20 25 30 40 50
5411 5416 5421 5424 5432 5444
HORSEPOWER 11 16 21 24 32 44
NO OF CYLINDERS 2 2 3 3 4 4
BORE STROKE 267 x 275 299 x 323 284 x 276 299 x 323 299 x 323 33 x 325
DISPLACEMENT CU IN 31 45 52 68 91 115
MAXIMUM RPM 3000 2800 3200 2800 2800 3000
COMPRESSION RATIO 221 211 221 211 211 211
TYPE Vertical water cooled 4cycle diesel engine
ELECTRICAL EQUIPMENT 12 Volt 55 AMP Altermator Electric Starter and Glow Plus
Mech Fuel Pump Fuel Pump Fuel Pump Mech Fuel Pump
LUBRICATION Engine 22 Qts 37 Qts 4 Qts 56 Qts 11 5 Qts 85 Qts
Use SAW 30 HD CD or IOVJ40 heavy duty diesel lubricating oil
LUBRICATION Fill to full mark on dipstick Use automatic transmission fluid Type A Type F
Std and VDrive and Dextron II
COOLING SYSTEM 7 PSI CAP Seawater Fresh Water Cooling System
cooled 48 Qts 40 Qts 6 Qts 8 Qts 8 Qts
14 PSI 14 PSI 14 PSI 14 PSI 14 PSI
EXHAUST FLANGE 114 NPT 114 NPT 114 NPT 114 NPT 112 NPT 112 NPT
FUEL Diesel fuel number 2D
FILTERS FUEL OIL 298854 298854 298854 298854 298854 298854
FILTERS LUBRICATION OIL 299381 298852 300209 298852 299584 299927
GOVERNOR Centrifugal type all speeds
150 0 F 190 F 190 0 F 190 0 F 190 0 F 190 F
ENGINE ROTATION Clockwise when viewed from VBelt end
ENGINE WEIGHT Pounds 245 365 285 425 490 545
LENGTH Overall 256276 VD 280 285305 VD 325 362 360
HEIGHT Overall 212 241 226 246 260 260
WIDTH Overall 207 207 192 207 207 214
INJECTION NOZZLE 299517 299517 299517 299517 299517 299517
INJECTION TIMING 25 0 before top dead center all models
12 Construction and Handling
1 Fuel System Fuelfilter
Fuel system The fuel filter is of the cartridge type shown schematically in
Fuel system is as shown in Fig 1 The fuel flows in the direc Fig 2 Under normal conditions it should only have to be
tion shown by arrow marks To bleed air trapped in the fuel replaced every 400 hours To install apply a small amount of
first loosen the vent plug A of the fuel filter Tighten the plug fuel to the racking and tighten seClJrely by hancl For no more air bubbles are in
the fuel which flows out from ttlC use of a filter wrench
the vent Then proceed to the plug B of the fuel and vent the system in the same manner as A
M15 5
1 Fuel filter
2 Cover
3 Pipe coupling
4 Vent plug
5 0 ring
6 0 ring 7
7 Element
Fig 2 Fuel Filter
Fuel injection timing
Fuel injectiul timing is adjusted by changing the number of
shims used between the pump arid the gear case it fits into See
Fig 3 One shim corresponds to 15 degrees in
crank anglf Tteretore injection will take place 15 degrees
later when a shim IS added and 15 jegrees earlier when a shim
6 Nozzle holder is removed The timing is correct when the mark punched on
1 Fuel tank
2 Fuel cock 7 Overflow pipe the rear end jJlate lines up with the F 1 marked on the fly
3 Fuel filter A Vent plug filter wheel See Fil 4
4 Fuel injection pump 8 Fuel pump
5 Injection pipe Speed control lever
Fig 1 Fuel System
Control rack pin Injection timing
adjust shims
Fig 3 Adjustment of
Injection Timing
Fig 4 Inspection of
Injection Timing
Fuel injection pump Fuel injection pump
The injection pump is the Bosch Mini K type Precautions
in handling fuel injection pump Many parts in fuel injection
pump are finished precisely Consequently even a sl ight careless
handling will very likely result in a serious drop in engine
performance Always bear this in mind and observe the follow
Be very careful of fuel to use ensure that it is entirely free
from water dirt and other foreign matters
Oi Idrums left outdoors are always considered to contain
water so be sure to have the fuel filtered before using The
water will settle at the bottom of the drum so refrain from
using the fuel to the last drop in the drum
Clean fuel is a must because the fuel is forced to pass through
various important elements of the pump and nozzles and then
enter the cylinders all these parts being so precisely assembled
with clearance of 000004 in 11000 mm that they may
easily be obstructed or rusted by even a slight amount of
water if in the fuel
Installing the injection pump
When installing the injection pump make certain that the
control rack pin is correctly placed in the 02 in 5mm wide
groovp of the fork lever 1 before tightening the attaching
bolts Refer to the diilqrilm If the bolts are draw Iown with
the rack pin off the groove the rack may over travel and stick
in this position This would cause excess fuel flow allowlrlg
the engine to overspeed which would result in engine failure
114 j
r 171
1 Injection pump assy 14 Adjusting plate
2 Delivery valve holder 15 Control rack
3 Delivery valve spring 16 Pump housing
4 Delivery valve gasket 17 Control sleeve
5 Delivery valve 18 Upper spring sheet
6 Cylinder pump element 19 Plunger spring
7 Air bleeder screw 20 Lower spring sheet
8 Packing 21 Shim
9 Hollow screw 22 Tappet assy
10 Packing 23 Roller
11 Tappet guide pin 24 Roller pin
12 Clamp pin
13 Bolt
Fig 5 Fuel Injection Pump
Fuel injection nozzle Spray pattern
fhe fuel injection nOllie like the ILJf1 injection pump is llso The injerlion pressure and fuel spray pattern are most ac
a precision piece of equipment lnd should be treated with the curately checked by using a nozzle pressure tester If a nozzle
same amount 01 care pressure tester is not lvailable remove the nozzles from the
engine leaving the pressure lines connected
The injection pressure
The injection pressure is adjusted by adding or subtracting from the top of the nozzle spring Adding a 0004 in
Hold the nozzles so that the high pressure spray from them
01 mm shim will increase the injection pressure by about will not in any way impinge upon unprotected skin The
147 psi 10 kglkm21 The injection iJressure is 1990 to 2133 atomized fuel will easily penetrate the skin and cause blood
psi 140 to 150 kgfcm2 poisoning
Set the speed control Irver It W O T and oppra1f the starter
6 1 19i The nepclle valve if it is working properly will produce a high
15 7 18 III
pitched pulsating sound likr that of l Ilute ilS fuel is sprayed
JIlt I I this sound is not heard or other problems are noted
refer to the Fuel Injection Pump Nozzle Maintenance
I Std in 41 in Engine
d fl Precaution II
1 Assembly and disassembly of the nozzle should be done in
fresh clean fuel
Delivery nipple 1 7 Nozzle spring
2 The nozzle should always be installed as an assembly
never by component parts
2 Delivery nipple 2 8 Pressure pin
3 Remember never to let the nozzle spray contact unpro
3 Nut 9 Pressure pin holder
tected flesh
4 Washer 10 Nozzle nut
4 Tighten the retaining nut to 435 t8 58 ftlb 6 to 8 kgfm
5 Nozzle holder body 11 Nozzle piece
Any torque higher than this will cause slow action of the
6 Adjusting washer needle valve and poor injection
Fig 6 Fuel Injection Nozzle
22 Lubrication System
Good Bad Oil pump pickup screen
The nil pump ricklip IS Ilrlted ill the crJnrilSe as shown in
Fig9 and is fil1fd with mfill screen I f the screen becomes
pluqCed wash it ofl with diesel fuel or kerosene
Lubrication system
The trochoid oil pump suck up lubricating oil through oil filter
4 and the oi I flows down to the fil ter cartridge where it is further
rompletely Iii tered and also the pressure regulating valve in
stalled in the gear case regulate the oil pressure at 36 50 psi
25 35 kgtcrn 2 From the filter one part of the lubricating
oil will be fed through crank shaft passage to uank pin metal
and the remAinder of oil will be fed through the frame to the
rockpr arm shaft An oil pressure switch is provided for on
the way fnl watching the oil pressure If the oil pressure falls
1 Nozzle spring 4 Nozzle body below 71 psi 05 kgf cm 2 on the dash
2 Pressure pin 5 Needle valve panel will be lighted warning the orerator In case the oil
3 Pressure pin holder 6 Nozzle piece warning lamp should stay on while engine being running at
normal revolution shut the engine off immediately and check
Fig 7 Nozzle
the causes of the pressure drop
Oil warning lamp and dash panel are oPtlondl Plrts
Probable cause of low oil pressurd
1 Clearance on one of the bearings is to great
2 One of the rocker arms is too loose
3 Faulty pressure regulating valve pressure lower than
normal replace the oil filter or clean the valve on the old
one with kerosene or diesel fuel
Oil pan
Rocker arm
Rocker arm shaft
rjjr Safety
Drain plug
Pickup screen
i 11
II fLJlrF n 0 Fig 9 Detail of Oil Pump Pickup
lV L
1 I I Construction of Oil Filter
1 ij 1 passage
L0fr 1 I f
Oil pumpW 1
Oil pump F Y
pickup screen
Rocker arm
Rocker arm shaft
Relief valve Fig 10 Oil Filter
Construction of Relief Fig 8 Lubrication System
Oil filter
1 Replace the 011 filter at every other oil change every 150 1 Oil Filter Cartridge
hours 2 Relief Valve Assy
2 Under Ilormal conditions it is only necessary to change 3 a Ring
the oil filter at the specified intervals If however the 4 Valve Seat
engine is used in EXTREME L Y dirty conditions the 5 Ball
pressure regulating valve should also be removed and 6 Spring
cleaned 7 Relief Valve Body
3 Whenever the oil filter is replnced run the engine under
no load for a few minutes until the filter has been filled
Fig 11 Pressure Regulating Valve
and then add oil to make up lor what is contained in the
Ii Iter
Replacing engine oil Valve
1 Drilin iJnd rerlaee tlw ei1jine oil after the first 35 hrs of Cornbustion air of course is brought in through the intake
oreration and every 75 hrs thereafWr valve when the descending piston creates a partial vacuum in
2 The oil is easier to change if the engine is warm the cylinder
3 Do not mix diffrent brands of oil If a different brand of Valve stem seals should be replaced whenever they are reo
oil must he used drain the oil and replace with all one moved If the stern seal are replaced coat the stem liberally
brand Also do not mix oils of different viscosities with oil before inserting in the valve guide to prevent burning
the valve stem seal
2 3 Combustion System J
Combustion chamber
The enqinr Iitililes a swirl tyrf chamber
Fig 12 Furl and air are mixed in this
resllltinfJ in mon efficient combustion A gloW1llIg
is employed to preheat the fuel for easy starts down to 5 F
150 C
1 Valve cap 5 Valve stem seal
2 Valve spring retainer 6 Valve guide
3 Valve spring collet 7 Valve
4 Valve spring
Fig 13 Structure of Valves
The dirnensions of the replacement valves and valve guides are
shown in Fig 14 When new valve guides are installed the
bores should be reamed to 0276 to 0277 in 701 to
7025mm after installation The valve head must be recessed
5 0035 to 0043 in 09 to 11 mrn from the face of the cylin
der head to prevent it from hitting the top of the piston
1 Nozzle holder 4 Cylinder head
2 Nozzle piece packing 5 Combustion chamber
7 027 05mm
3 Glow plug 027402746 in
Fig 12 Combustion Chamber
A Finished ID of gUide 1J
installed in cylinder i I Iil II
ead r J J i A
r r451
09210929 in 10591067 in
M15 1234236mm 1269271 mm
t f 10781086 in

Fig 14 Standard Dimensions
of Valves Valve Guides
Valve Gap
Fig 15 Sinking of Valve
Valve timing
Adjust bolt 2
When the valve clearance has been adjusted as shown in
Fig 16 the standard valve timing shown in the chart can be Lock I 1 Valve clearance
nut 1 0005700072
Fig 16 Adjustment of Valve Clearance
Intake valve opens 20 S TOC
Intake valve closes 45 A SOC
Exhaust valve opens 50 S SOC
Exhaust valve closes 15 A TOC
Valve clearance 00057 to 00072 in 0145 to O 185 mm with
engine cold
Rocker Arms
1043250433 in
1t9 I WtN I lj
J 04330435 in
043204324 in
043250433 in
III 0 l 0 IWWI1 0
10 10 0
Fig 17 Standard Relative Position of Rocker Arms
Compression release Release wire is optional parts Compression the parts as shown in Fig
18 Pull the lever out as position
far as it will go check to see that the 55 angle is attained
and that compression is released The cornpression release
is to be used when the battery is low or when starting in
cold weather To use the compression release preheat the I
glowplug as usual pull the compression release knob out as
far as possible and hold it there while cranking the engine
This partially releases the engine compression enabling it to
turn faster in cold weather or when the battery is low Once
the engine is turning fast enough to start Ielease the lever and
the engine will Make sure the compression release has returned to the
operating position by pushing the knob all the way in
Released 1 Rocker arm 5 Compression release nut
I4 2 Oil filler cap 6 CompressIOn release bolt
Operating 3 Compression release lever 7 Shaft
4 Adjustment access cover B Valve
Fig 19 Adjustment of Compression Releasea
Fig lB Compression Released
Top Top clearance should be 00236 to 00314 in 06 to 08 mm
Do not pull the compression release lever when the engine is
To adjust use cylinder gasket shims 00078 in 020 mm thick
running at high speed or under load If it is necessary to use
each onto the head side
the compression release while the engine is running reduce the
For checking the measurement rlace il piExe of fuse on the
speed to idle before doing so
piston top and fiX the cylindler head securfly on the cylinder
Adjustment of compression release head flange The medsurernerll is taken bV tile fuse Tile liner is
I Set exhaust valve in totally closed position
level with the cylinder fldme at tvp surface
2 Remove adjustment window cover from The gasket shims Ciln be reused so do nt lose thelli
cylinder head cover
3 Make valve clearance as 0 with use of adjust bolt From this position turn the bolt further by I
Top clearance
1 to 15 turns Decompression clearance will then be set 0023600314 in
at 0030 to 0044 in 075 to 1 125mm which is the 0 60 Bmmj
designed After adjusting be sure to lock adjust bolt securely so
that it will not unturn while engine is in service Piston
5 Make certain that the cleanrance is not too wide To
check thiS turn crankshaft by hand and make certain
valve disk does not contact with pistion top
Fig 20 Top 9
24 Main Moving Parts Crankshaft and
connecting rod
Pitons and piston rings 1 The crankshaft is a
heat treated steel alloy forging The
The pistons and piston rings are shown in Fig25 If the crank pins are
induction hardened for additional wear
cylinder liners have been bored oversize oversize pistons resistance
Crankshaft end play is 0006 to 0012 in 015
and rings must be used The piston is made of high silicon to 031 mm
AIAlloy and is cam ground The top compression ring is a 2 The crankpin
bearings are plated keystone type the second compression ring is When
instill ling the connecting and undercut and the oi I control ring is of the a
Clean both surfaces expansion type b
Apply engine oil to the threads of the connecting rod
B End gap of rings on poston in cvlinder capscrews before installing
ahd tighten each to 195 to
I Diameter of piston skirt thru t of piston pin bore
224 ftIbs 27 to 31 kgm
E Diameter of piston skirt perpendicular to piston pin
The bearing caps are matched to each connecting rod
00791 12mm
and should not be interchanged Also since there are
variations in machining from side to side each bearing
cap and connecting rod are marked and should be
assembled so that the marks line up
JJO 100062 n
I 3 In the event that the crankpiflS become worn and are no
longer serviceable undersized bearings may be used
I 01580159 in
14 0 104 030mm
When installing the undersize bearings observe the fol
0187407879 in lowing precautions
a Machine the crankpin diameter and radii to within
1025045mm i a few thousandths of the correct dimensions and
0078m 199mm il
i 1
I finish grind to the exact dimensions
I r
0156601571 in r
8 Lr b After finish grinding the bearing diameter and the radii
139783 990mm ii
chamfer the diameter of the oil hole with an oilstone
J Ai L O
10200 40mm If this is not done an oil film will not
form and the
bearing will sieze
Fig 25 Standard Dimensions of Piston
c The crankpin should always be to
Standard 9
and Piston Rings
Over si ze
0000016 in 00004 mm or less
d Select the bearing from the chart that necessitates the
removal of the least amount of metal from the crank
pin Do not deviate from the chart dimensions as the
bearing life will be reduced if they are machined
e To determine the running clearance assemble the con
2677 in I
26968 in
necting rod bearing cap and bearing as described in
168rnm I 1685m m
2671826726 in 2 6915269 23 in section 2 and measure the
diameter anywhere within
MODEL the 1200 angle indicated in Fig 27 and subtract the
836568 385rnm
E 2674226750 in
2 6938269 46 in
6 842568 445mm
15 crankpin diameter from this figure
28346 in 28543 in
f The piston pin bushings are of lead bronze
72mrn 725m m The inSide diameter of the bushinq
should be finished
282932830 in 2 8490284 98 in
MODEL to 07884 to 07890 in 20025 to 20040 mm
17 236572 385mT1
E 2831728325 in 2 8514285 22 25
7 242572 445mm
Oer size
Name of Part Part
Piston 05
002 in 05mm
Piston ring 05 05 OS I
002 in 05mm
Cylinder iner
Piston 05
Piston ring 05
Cylinder liner
12JLR max to 2JLR max by honing I
Piston 05 05 OS
002 in 05mm
Piston ring 05 05 OS
28542855 i n M25
Cylinder liner
12JLR max to 2JLR max by honing
01100126 in
1455114557 in
O 1100 126m
2B 32mmJ
1729717303 in
Fig 27 Crankpin for Undersize Bearing
1734211368 m 01040714 in
4405044 I 15mml r
18924 18933 m
t 0868008690 m
0866108670 m
l 01884 0 7890 in
0787507878 m
06250635 m
1455114557 in
36959 rDfll
0058500590 in
lA Diameter of piston pin bushing after installation
i I J
1729717303 in Fig 28 Standard Dimensions of Connecting Rod
43934 43950mml Bearing and Bushing
1734217368 m 07040714 in
4405044 115mml I i I
Fig 26 Standard Dimensions of Crankshaft and
Size Part No Bearing Crankpin Diam
0007874 in 1447214478 in
02 undersize 02 US
020mm 3675936 775mm
00290091 mm
0015748in 143931440 in
04 undersize 04 US
040mm J
Boring and replacing the cylinder to Fig21 the inside diameter of the liner should
be checked at points 12 and 3 and In thp cJirertions a and
b Thp liner on whieh thcNear has pxcpcdrd the sprVICp limit
can bp iJored ilnd honed to 0020 in 050mm finished dimensions are
2677 to 26779 in 68000 to
68019mml for Model 15 and 2834 to 2835 in
72000 to 72019mm for Model 25 An and rings must then be used with thi5 liner Once liner has
exceeded its wear lifnit it should be reo 106 2 3 0 7 11
placed With a new one To install a new liner coat the outside OOO
liberally with oil push into the block with a press and finish to
0 0 0
the stanciJrd Slle When thiS is done a standard size piston
must again be used 13 0 5
4 0 12
l 9 1 8 li
Fig 22 Tightening of Cylinder Head Bolts
r c stjHCj SIIe T C Over sizp
260f8 2 m6 11
X1S 28542853 in
M25 Fig 21 Standard Dimensions of Cylinder Liner
and Liner Bore in Block
Tightening cylinder head capscrews Fig22
1 I The tightening torque of the cylinder head eapscrews is
31 0 15 ftliJs 43 to 48 kgml for Model 15
imd 43 to 4 j ftlbs 60 to t5 kgITd for
Model 25 Numbers 9 10 and 11 13 t in the diagram
are studs 1 he nuts on these studs sholdd also be tightened
to th is torell Ie
2 All thi diS rrws 111111 ill tlyhtll1fd TI do
ths tllhlC11 all The cilliscrews In thr urdrr il1dCilTed on
the cJlaHillli until thev arc Just snuq Then tl1hT11 Jeh
one 1 one turn at a time III thiS same snqurnce pach
tine ulltll all haliP been tightened to trw IIlU1rrcj trque
3 The rylillder head CiJPscrews shoulej lw rrtlghtencd if
the pnqine hilS nlt been uspd for d Innq timE Thn valvi
lash sholJld als0 be adJuswd each tlmc the cylinder head
capser ews arE retorquccJ Jf 2ey i noer head qasket has
tngl ne cJ
l gtll tnyl bv
25 Main Components Camshaft and camshaft bearings
Gear train Standard dimensions are shown in Fig 31 Camshaft running
Be sure to assemble the gears by matching the mating marks clearance is 0002 to 00036 in 005 to 0091 mm
as shown in Fig 2Q The backlash of each gear is 000163 to
000454 in 00415 to 01154 mm
nr tflj
Ui J
l r4 1
29662972 in
29923002 in
1 Crankshaft gear 4 Camshaft gear L J t
2 Oil pump drive gear 5 Fuel injection pump drive 29662972 in
3 Idle gear gear
29923002 in
Fig 29 Mating Marks of Gear Train L
Crankshaft gear
Heat to about 176 F 80 0 C and sl idp on crankshaft I f the
shaft and bore dimensions are such that the gpar will not slide
easily it may be heated to a slightly higher Fig 31 Standard
Dimensions of Camshaft
Camshaft gear and to Fig 30 place retainer plate 3 on camshaft 2
first Make certain the clearance of the retainer plate to the
camshaft end is made 0003 to 0009 in 007 to 022mm
When camshaft gear 1 is in place Then heat the camshaft
gear to about 176F BOC and push into place If the should be excessive and there are fears that the shaft
would be damaged raise the heating temperature further to
make the gear softer allowing an easier fit
1 Camshaft gear 4 Circlip
2 Camshaft 5 Pin plug
3 Camshaft retainer plate 6 Key
Fig 30 Assembly of Camshaft Gear with Camshaft
Main bearing assy Main bearing the bearings in the main bearing housing halves as in
Installation of crankshaft with main bearings in engine in Figs 32 33 using the thrust washers only on the Slide the crankshaft assembly
into the engine block being
journal nearpst the flywheel Coat the crankshaft journals and careful not to nick or scrape the crankpins After the assembly
the bearing surfaces with engine oil place the housing halves is in position make sure the oil passages are correctly lined up
with bearings on the cran kshaft coat the capscrew threads Install the main bearing housing to engine block locking
with engine oil and tighten to 145 to 175 ftIbs 2 to 24 kgm capscrew and washer from the side to position the housing and
M7 then install capcew 2 from the bCttom and torque to 21
to 25 ftIbs 3 to 35 kgm M8
1 Bearing
2 Capscrew
3 Locking tab
4 Main bearing housing
5 Cap screw
6 Locking tab
7 Locking tab Fig 33 Main Bearing Housing 2
1 Bearing Main Bearing Housing 3
2 Thrust washer
3 Thrust washer
4 Crankshaft journal
5 Main bearing
6 Cap screw
7 Locking tab Fig 32 Main Bearing Housing 1 with
B Locking tab Thrust Washers
Main bearing housing 1
4408344089 in
M15 25
4388743893 in 1889718904 in
Milin bearing housing 2
4369043696 in
Main beiJring hOllsinq 3
M15 25
Hydraulic oil pump drive unit NOT AVAILABLE Injection pump as shown in Fig 34
InjACtion pump camshaft Fig 36 Install the bearings and
governor unit on the camshaft and install in the engine block
Hour Meter Unit Fig 36 Insert the tang on the end of
the hour meter drive shaft into the slot on the end of the
injection pump camshaft and install as per the Structure of Fuel Cam Shaft
1 Oil pump
2 Injection pump camshaft
3 Engine block
Fig 34 Hvdraulic Oil Pump Drive Unit
Idler gear
Secure the idler gear shaft to the engine hlock with 3 cap
screws torque to 723 to 832 ftlbs 1 to 115 kgm land bend
tabs of tab washer Install gear as shown make sure it runs
freely has a running clearance of 00006 to 00018 in 0016
to 0045mml and 0008 to 0020 in 020 to 051mm end
1 Injection Pump
2 Speed Adjusting Lever
3 Foel Control Device
5 Injection Pump Gear
1 Idler gear
6 Fuel Cam shaft
2 Spacer
7 Idling Limitting Device
3 Retaining ring
4 Shaft Fig 36 Injection Pump Camshaft AssV
5 Bushing
6 Spacer
7 Engine block
8 Capscrew
9 Tab washer 6
Fig 35 Idler Gear
Attaching flywheel to crankshaft Cooling water pumpfresh water
Clean the entire contact surface carefully Coat the contact To install the coolinq fan pulley on the pump securely with engine oil wash
all the oil off with gasoline and the nut 4 to 506 to 579 ftibs 7 to 8 kgf it throughly Put the flywheel on and torque the capscrews
to 40 to 4338 ftIbs 55 to 6 kgmi Bend the locking tabs Model 25
back on the washers
Tensioning of fan belt
The fan belt tension is adjusted by moving the tension pulley
1 in or out The belt is properly tensioned when the
2 Bearing
belt deflection midway between the tension pulley and the
3 pullev is 025 to 035 in 7 to 9mm with a force
4 Nut
of 20 Ills apIJlied Proper belt tension is essential for good
5 Body
engine cooling and belt life See Fig 37
6 Shaft
7 Rotator
P Jl
Fan pulley Tension pulley
y 8 Case
9 Seal
Fig 38 Water Pump
I 025 to 035in 7 to 9mm
Fan drive pulley
Fig 37 Fan Belt Tensioning
1 Rust inhibitor and antifreeze should be used in accord
arlce wierl llw in the related manuals
2 Be sure to remove all debris that may b IJlugging the fins
3 Check th rubber shock mount nuts periodically to be
sure thIN are tight
Connect to ACC term on switch
12 V r
en I
SENDER 33 Starting Motor
The starting motor employed in this engine is of the roller 1 Drive End Frame 13 Over Running Clutch
clutch type starter in which magnetic force operates the 2 End Frame Cap 14 Yoke
lever thereby pushing the drive pinion in the ring gear This 3 Bush 15 Set Bolt
is the most popular type of starting motor 4 Screw 16 Field Coil
5 Set Bolt 17 Brush
8 6 Drive Lever 18 Brush Holder
7 Magnetic Switch 19 Brush
I iij
Insulater Plate
Insulater Washer
20 Brush Spring
21 End Frame
22 Bush
j 1 11
External Circlip
23 Through Bolt
24 Plain Washer
25 Packing
26 Return Spring
27 Spring Holder
28 End Frame Cap
Fig 41
136 723 10
70 981
109519 8
08 785
082 434 6
116f 588
054 289 4
2000 704 392
027 145 2
e 96
0 100 200 400
amp fA
Fig 42
of Starting Motor 3 In case the engine will not start be sure not to keep
turning the starting motor more than 30 seconds The
Code No starting motor is designed to operate for short time
1 running at rated capacity accordingly long time ope
Type Roller Clutch Type
1 ration of such motor may bring about such troubles
Nominal that soldering on armature coils melts away or sticking
Voltage of coils and lead wires by heating takes place Further
Nominal Output 08 kW more the battery will be remarkably dischanged
Direction of making the motor doubly difficult in turning vigorous
Clockwise viewed from pinion side
Rotation Iy I n this it is recommended to crank
the engine for 10 seconds and then pause for 10 sec
for starting motor onds one after the other
In case starting motor turns extremely slow or does not 4 In case the pinion gear will not engage with the ring
operate at all the causes may be attributed to the follow gear on the flywheel and the motor makes racing
ings causing wear out on the tip of pinion gear adjust the
Defective battery advance position of the pinion gear
Defective wiring
Defective starting motor
34 Glow Plugs
The easy method to determine whether the starting motor
or some other component is at fault is to turn on the head The glow plug is sheath type one and each cylinder is That is
turn on the headlights while engine is ped with one glow plug in parallel wiring for which is
stopped I f the I ights stay dark the battery is defective or shown in the of wiring and terminals is defective Of course on
the condition that headlights air unit is functioning pro 1 Glow Plug
perly I n case the battery is barely operative due to defec 2 Glow Plug charging system be sure to cleare up the cause and
3 Key Switch D
remove it otherwise same troubles will not be ceased In 4 the battery is in the state fully charged
5 Alternator
1 The headlights failed to light contact of battery ter 6 Battery
minals is defective 7 Starter
2 In cranking the engine lights become extremely dim
and revolution of starting motor slows down and stops
Armature shaft bent
Bearing bush worn au t
Engine defective Excess revolution resistance
Starting Motor
will not operate
Pole core screw loosened
Field coil grounded or layer insulation short cir
cuited M15
Armature coil grounded or layer insulation short
3 Lights stay bright but starting motor will not turn or Fig 43
turn slowly
Contact of starting motor terminals defective
of glow plug
Magnet switch defective Coil disconection ground
ed or layer insulation short circuited
Starter switch circuit contact defective
Brush contact pressure defective
Worn commutator
I M15 M25
Precautions in handling starting motor Quantity 2 3
1 I n installing starting motor it should be securely fixed
7 amp 7A 7 amp 7A
by tightening with close contact other wise pinion gear approx after approx after
Voltage Current
will not engage with the ring gear properly thereby 30 seconds at 30 seconds at
per one plug
causing breakage of the pinion gear and rear end plate 105 volt 105 volt
105V 105V
Sometimes starting motor will not operate
2 In case the starting switch is on and the engine is turn
ing but the engine will not start check the fuel system
for its cause
4 Reference Chart
41 Engine
Parts Items Standard Value
Cylinder head tightness M25 M9 x 125 4344699 ftlbs When
installing apply a generous
l coat of engine oil onto the entire
3109347 ftlbs surface of each bolt
M15 M8 x 125
TI 4348 kgm
ylinder head surface distortion 0002 in below
O05mm below
valve seat thickness 45 0059 in 15mm
0059in f75mm
U 0023600314 in
0608 mm
Top clearance

050 oversize liner I D
Standard ID
M15 6815mm C
C Piston clearance M25 2834628354 in I 28405 in
2854328550 in
J At piston skert 72 15mm c
E side
M15 0004500060 in 0 1150154mrn I side
f 1 M25 0002100037 in E side
Height above block surface
000098 in 0025mm
andard OD
Oversize 0020 in O5mm
M15 2677 in 68mm
I M25 28346 in 72mm
c Pistonpin boss ID 0787407879 in 07885 in
I nterference Clearance
Pistonpin clearance 00004 in 00004 in
OOllmm OOllmm
Ring gap toP 2nd 0009800158 in 00492 in 05
oversize top ring surface should
125mm be 00079 in 02mm below
oil ring 0007800158 in piston side surface
c Top ring width Keystone type
2nd ring width 0057400579 in
Ring groove clearance
c 0003300044 in
above 00079 in
02mm J
iI ring 0156501571 in 0000800020 in
c OD 0787407878 in
c 2
c Pintobush clearance 0000600015 in 00059 in
Parts I tems Standard Value Remarks
f Smail end I D 0866108670 in
without bush 000079in
Small end width 0858208622 in
o L Connecting
a Large end I D 1574815756 in r rod
4in 100m
without bush
O 00079 in
Large end width 0858208622 in
000079 in
Rod torsion see diagram 00008 in 002mm 0002 in
When installing apply a generous
coat ofel1gine oil onto the entire
Rod bolt torque M7 x 075 19527 2242 ftlbs surface of each bolt
2731 4
ID 1456814587 in
with metal
iii Width 0624806350 in
Center thickness
0058500590 in
0 OD 1575 in 40mm
U Running clearance 0001100036 in 00059 in
00290091 mm 015mm
Axial clearance 0007800157 in Crank armtoIarge end clearance
dia 172961730 in
Running clearance 00059 in
Main bearing I D 1731617333 in
with metal
Crankshaft metal 2 width 0703507138 in
Crankshaft jurnal dia Running clearance
1 00059 in
III Gearside main bearing I D 1731617338 in 015mm
with metal
Crankshaft metal 1 width 0703507138 in
Crankshaft metal 1 OD 1892318933 in
Crankpin jurnal dia 145514557 in 00047 in When installing apply a generolls
O12mm coat of engine oil onto the entire
surface of each bolt
Crankshaft side clearance
Crank bearing cap bolt 1 torque M7 x 10 144617357 ftlbs
224 kgm
I Crank bearing cap bolt 2 torque M8 x 125 217253 ftlbs
335 kgm
Parts Items Maximurn
Standard Value Rtmarks
Cam bearing 10
Cam haft diil
1299 130 in
1296612972 in
IRunning clearance
0050091 rnrn
10582 in
26 88mm
Axi1 clearance 0002800081 in
co 007 022mm
Cam lift 01968 in Iflmm 042831f1
Corn heig 12rn
Number of teeth crank gear 25 I
Number of teeth idle gear 69
Nurnber of teeth cam gear 50
I backlash I 00020005 in 00118 in
Shlnkage 0035400433 in
F Jee angle 45 Valve quide Ire should be
after inserted into cylinder head
I ntake bore
IM15 10601067 in
269 27 1mr j
t2 1216512244 in
30931 1n1 m
Exhaust bore
0921209291 in 1
1078710866 in I
i274 Sttrn dia 0274002746 in Ii
Valve guide 10 in
Stern guide clearance in
Valve clearance 0005700072 in Wien culd
Free length in
351 356mm
Spring pressure in
175 Spring pressure loss wilen installed I
Overall length I OOO ir127mrn 1
o B 4b5434 810 i 1
11233 123 7mlll
Did 019C80204 in
15 52rnrn
l 22
Parts Items Maximum
Standard Value Remarks
I ntake valve opened At 20 BTDC
c I ntake valve closed At 45 ABDC
Exhaust valve opened At 50 BBDC Model
15 25
co Exhaust valve closed At 15 ATDC
Ignition process 12
Injection timing
Trochoid tooth width 0786607874 in Use Engine Oil
1998200mm Above 77F 25C SAE 30
Between 32F7TF
OC25C SAE2ll
Outer rotor OD 1595615968 in Below 32 F 0 C
clearance 0002700059 in
T side clearance 0003100051 in
00800 130rnrn
Oil pressure 64 psi 45 kgfcm
Pump capacity 365 galmin levulu lio 01
pump 000 rpm
I 1
E Model Model is Cam
speed 1500 rpm
C Model 25 o
I nJection pressure 1990 psi 140kqfcm
C Pump plunger dia 01968 in 5mm
LL Pump stroke 02756 in 7mm
Model NDDN12SD12
o I njection pressure 19902133 psi
Cooling system Natural circulation Wi lh
pressurized rddidtor
Radiator cap pressure 128 psi 09kgtcm
3 170 psi 0
F dn bel t length FM 30 in 762mm
o in

Model 12V 45AH NS60
Electrolyte specific gravity discharge 1120
Electrolyte specific gravity charge
Electrolyte specific gravity over 130
Voltaye 12V
c Current 85A
Check interval Every 1000 L L L J
Parts Items Standard Value
Number of teeth pinion 9
Number of teeth ring gear 98
I nsulation resistance No failure at 500MV
Check interval Every 1000 service hours I nsulation resistance
08kW Nominal value
43394701 ftbs Apply a generous cot of engine oil
M9 X1 orito the entire surfaces of all im
portan t set bol ts
31093471 ItIbs
M8 x 125
4348 kgm
Il Flywheel fixing bolts Ml0 x 125 404338 ftlbs
cr 556 kgml
Crankshaft main bearing set cap M8 x 125 2110 2531 ftl bs
0 bolts
OJ 335 kgfm
Crankshaft cap bolts M7 x 1 14471736 ftlbs
0 224 kgfm
Rocker bracket set studs M7 x 1 12291518 fUbs
1721 kgfm
Rod bolts M7 x 075 19522242 fUbs
2731 kgfm
Glleral st bolts and studs M12 571665 frlbs All these torques are applied to
7992 kglm those S43C bolts and studs which
Il have relief number 7 or
MlO 354412 ftlbs
cr marks
495 7 kgfm
M8 174203 fLlbs
2428 kglm
M6 7283 ftlbs
Bolt material qrnrips am shown by numbers punched on the bolt heads
Prior to tightening bp sure to heck au the numbers as shown below ftlbs kgfm
Mlterial Grade StAndard Bolt NoneJ Speciill Bolt 7J Special Bolt 9J
Punctwrl No S43C S48C Dia SSI 1 S20C
SCR3 SCM3 Refined
M 6 58 69 080 095 72 83 100 115 90 105 125 145
M 8 130 152 180 210 174 203 240 280 217 253 300 350
M10 289 333 400 460 354 412 490 570 448 521 620 720
M12 463 535 640 710 571 66E 790 920 759 868 1050 1200
M14 796 926 1100 1280 9111085 1260 1500 1230 1447 1700 2000
M16 1230 1410 1700 1950 1447 1664 2000 2300 1917 2242 2650 3100
M18 1808 2098 2500 2900 2025 2351 2800 3250 2532 2965 3500 4 100
M20 2459 2893 3400 4000 2712 3182 3750 4400 3616 4195 5000 5800

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