Wednesday, March29, 2017

Universal Diesel 5424 Technical Manual

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M20 M30
5416 5424
Part Number 200152
Edition 1
October 1990
Fuel System 34
Lubrication System 56
Oi Filter 6
Combustion System 7
Valve Timing 8
Compression Release 9
Cylinder Liner 10
Cylinder Head 10
Piston and Rings 11
Crankshaft 11
Connecting Rod 12
Gear Train 13
Camshaft Bearings 13
Main Bearings 14
Injection Pump 15
Water Pump 16
Flywheel 16
Starting Motor 1617
Glow Plug 1718
Wiring Diagram 19
Reference Charts 15 20 30
40 50
5411 5416 5424 5432 11 16 24 32 OF CYLINDERS
2 2 3 4 STROKE 267 x 275 299 x 323 299 x 323 299 x 323 33 x
CU IN 31 45 68 91
MAXIMUM RPM 3000 2800 2800 2800 RATIO 221 211
211 211 Vertical water cooled 4cycle diesel EQUIPMENT 12 Volt 55 AMP Alternator
Electric Starter
Glow Plugs
Mech Fuel PDIIP Fuel Pump Mech Fuel Engine 22 Qts 37 Qts 56 Qts 115 Qts 8 Qts
Use SAE 30 HD CD or 10W40 heavy duty diesel
lubricating Fill to full mark on dipstick Use automatic
Std and VDrive transmission fluid Type REDUCTION 21 21 21 21 SYSTEM 7 PSI CAP
Seawater Fresh water cooling system
cooled 48Qts 6 Qts 8 Qts 8 Qts
FUEL Diesel fuel number 2D
FUEL INLET HOSE 516 FUEL OIL 298854 298854 298854 29884
LUBRICATION OIL 299381 298852 298852 299584 Centrifugal type all
MODEL 15 20 30 40 50
5411 5416 S424 S432 5444
ENGINE ROTATION Clockwise when viewed fro Vbelt end
ENGI WEIGHT Pounds 245 365 425 490 545
LENGTH Overall 256 280 325 362 360
HEIGHT Overall 212 241 246 260 260
WID11I Overall 207 207 207 207 214
INJECTION TIMING 250 before top dead center all and Handling
Fuel System Fuelfilter
Fuel system The fuel filter is of the cartridge type shown schematically in
The fuel systfm schematic is shown in Fig 1 with the fuel Fig 2 Under normal conditions it should only have to be
flowing in the direction indicated by the arrows To bleed air replaced every 400 hours To install apply a small amount of
from the system loosen the vent plug A on the fuel filter fuel to the pack ing and tighten securely by hand For removal
and crank the engine until there are no more air bubbles from the use of a filter wrench 1522186611 is vent Tighten vent A and purge the air from
the injec 1
tion pump at vent 8 using the same procedures
1 Fuel filter
2 Caver
3 Pipe coupling
4 Vent plug
5 0 ring
6 0 ring I
7 Element
Fig 2 Fuel Filter
Fuel injection timing
Fuel inrction timing is adjusted by changing the number of
shims used between the pump and the gear case it fits into See
Fig 3 One shim corresponds to approximately 15 degrees in
crank angle Therefore injection will take place 15 degrees
later when a shim is added and 15 degrees earlier when a shim
6 Nozzle holder is removed The timing is correct when the pointer in the peer
1 Fuel tank
7 Overflow pipe hole on the side of the flywheel housing lines up with the
2 Fuel cock
3 Fuel filter A Vent plug filter F1 marked on the flywheel See Fig 4
4 Fuel injection pump 8 Vent plug pump
Fuel injection pump Speed control lever
5 Injection pipe
Fig 1 Fuel System II
Control rack pin Injection timing
adjust shims
Fig 3 Adjustment of Fig 4 Inspection of
Injection Timing Injection Timing
Jel injection pump Handling the injection pump
The Injfction pump is the Bosch Mine K type It is a preci Use care in handling and using the injection pump As men
sian riPee nf eQlJipment machined to close tolerances and its tioned before the injection pump is a precision piece of
rerfor l1lance directly affects the performance of the engine equipment and care should be taken not to drop it or clamp it
Therefore handle it with care trghtly when working on it Also be sure to use only clean
fuel that has been filtered Oil drums left outdoors are always
considered to contain water so always filter this fuel before
Clean fuel is a must as the fuel is forced through parts of the
pump and nozzel with clearances of 00004 in 11000mm
which may easily be stuck or rusted by even the slightest
amount of water in the fuel
Installing the injection pump
When installing the injection pump make certain that the
I control rack pin is correctly placed in the 02 in 5mm wide
groove of the fork lever before tightening the attaching
bolts Refer to the diagram If the bolts are drawn down with
the rack pin off the groove the rack may over travel and stick
in this position This would cause excess fuel flow allowing
the engine to overspeed which would result in engine failure
1 Injection pump assv 14 Adjusting plate
2 Deliverv valve holder 15 Control rack
3 Deliverv valve spring 16 Pump housing
4 Deliverv valve gasket 17 Control sleeve
5 Deliverv valve 18 Upper spring sheet
6 Cvlinder pump element 19 Plunger spring
7 Air bleeder screw 20 Lower spring sheet
8 Packing 21 Shim
9 Hollow screw 22 Tappet assv
10 Packing 23 Roller
11 Tappet guide pin 24 Roller bushing
12 Clamp pin 25 Roller pin
13 Bolt
Fig 5 Fuel Injection PuflP
Fuel Spray pattern
The fuel injection nozzle like the fuel injection pump is also The nozzle cracking pressure and fuel spray pattern are most
a precision piece of equipment and should be treated with the accurately checked by USing a nozzle pop test stand If a
same amount of care pop test stand is not available remove the nozzles from the
engine leaving the pressure lines connected
The nozzle cracking pressure
The nozzle cracking pressure is adjusted by adding or sub shims from the top of the nozzle spring Adding a Hold the
nozzles so that the high pressure spray from them
0004 in 01 mm shim will increase the cracking pressure by will not in any way impinge upon unprotected skin The
about 142 psi 10 kgcm2 The nozzle crack ing pressure is atomized fuel will easily penetrate the skin and cause blood
1990 to 2133 psi 140 to 150kgfcm 1 poisoning
Set the speed control lever at W O T and operate the starter
The needle valve if it is working properly will produce a high
pitched pulsating sound like that of a flute as fuel is sprayed
out I f this sound is not heard or other problems are noted
refer to the Fuel Injection Pump Nozzle Maintenance
Std in 41 in Engine
oPrecaution D
1 Assembly and disassembly of the nozzle should be done in
fresh clean fuel
2 The nozzle should always be installed as an assembly
1 Delivery nipple 1 7 Nozzle spring never by component parts
2 Delivery nipple 2 8 Push rod
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 to 58 ftIb 6 to 8 kgf ml
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 oil pump pickup is located in the crankcase as shown in
Fig 9 and is fitted with a metal screen If the screen becomes
plugged wash it off with diesel fuel or kerosene
vrACZ lubrication system
j The entire lubrication system is illustrated in Fig 8 Oil from
the pump is forced through the replaciable paper element
filter The filter is equipped with a pressure regulated valve to
keep the pressure through the filter at 6471 psi 455
kgfcm 2 From the filter part of the oil goes to the crankshaft
to lubricate the crankpins and the remainder goes to lubricate
the rocker arms
An oil pressure switch is located in the passage from the filter
and controls the oil pressure If the oil pressure falls below
14 psi 10 kgfcm2 the oil warning lamp will light on the
1 Pressure spring 4 Nozzle body dash panel If the oil pressure lamp stays on after the engine
2 Pressure pin 5 Needle valve is running at normal speed shut the engine off immediately
3 Pressure pin holder 6 Nozzle piece Find and correct the cause of the low oil pressure before
operating again
Fig 7 Nozzle If the pressure regulating valve in the filter fails and the
pressure rises a safety valve will limit the pressure to 140 psi
10 kgfcm2
cause of low oil pressure n
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 T
normal replace the oil filter or clean the valve on the old
one with kerosene or diesel fuel
16 HP
Rocker arm I
Rocker arm shaft
011 pump Oil pan
l pIckup screen
Jr t
ttJDrain plug
Fig 9 Detail of Oil Pump Pickup
24 HP
7 Filter cover assy
Rocker arm
Rocker arm shaft 2 Cover
3 Safety valve assy
I 4 Safety valve
5 Plug
Relief valve 6 Spring
7 Oring
8 Relief valve
9 Oring
70 Plug
77 Oring
72 Oil filter cartridge assy
73 Oil filter cartridge
Oil pump pickup Fig 70 Oil Filter 74 Label
Fig 8 Lubrication System
Oil filter
1 RfplilC the nil filter It 0vmy nthpr oil change fvery 150
2 Undpr normal camiltiol1 it is only necessarv to changE
the nil filter at the specifipri intervills If however thE
engine is used in EXTREME LY dirty conditions the
prpSSIJrp requlat 1r11 valV and silfptv villve should also be 1 Relief valve compo 4 Ball valve
rflnoved ilIHi cleanpd 2 0 ring 5 Valve sheet
3 WhpJlfvr thl oil filter is rpplacmJ rtm the enqine under 3 Spring
flO IOild fnr il few fllinlltrs lmtil the filter has been filled
Fig 17 Pressure Regulating Valve
ilnri then add oil to milk up tor what is contained in the
Combustion air of course is brought in through the intake
valve when the descending piston creates a partial vacuum in
the cylinder
Valve stem seals should be replaced whenever they are re
I moved If the stem seal are replaced coat the stem liberally
with oil before inserting in the valve guide to prevent burning
the valve stem seal
1 Safety valve body 4 Oil filter base
2 SafetY valve spring 5 Safety valve 3 0 ring
Fig 12 Safety Valve Complete
Replacing engine oil
1 Drain and replace the engine oil after the first 35 hrs of
orrriltion and every 75 hrs The til is easier to change il the engine is warm
3 Do not mix different brands 01 oil If a different brand of
oil must be used drain the oil and replace with all one 1 Valve cap 5 Valve stem seal
bl and Also do not mi x oils of different viscosities 2 Valve spring retainer 6 Valve guide
3 Valve spring collet 7 Valve
4 Valve spring
Combustion System
Combustion chamber Fig 14 Structure of Valves
The engine utilizes a swirl type pmcombustion chamber The dimensions of the replacement valves and valve guides are
See Fiq 13 Fuel and air are mixed in this shown in Fig 15 When new villve guides are installed the
chamber resulting in more efficient combustion A glowplug bores should be reamed to 0316 to 0315 in S030 to
is employed to preheat the fuel for easy starts down to 5 F S015mm after installation The valve head must be
0043 to 0055 in 11 to l4mm from der
head to prevent it from hitting the top of the piston
Uf nr
7960 7975mm
A Finished ID of guide
installed in cylinder
I iU
j AI
T c
1059 1067in 1295 1303in
1329 331mmJ
1 Nozzle holder 4 Cylinder head Fig 15 Standard Dimensions
2 Nozzle piece packing 5 Combustion chamber of Valves Valve Guides
3 Glowplug Valve Gap
Fig 13 Combustion Chamber
Fig 16 Sinking of Valve
Valve timing
When the valve clearance has hcpn arlusted as shown in
Adjust bolt 2 I
Fig 17 the standard valve timinq shown in the chart can be L
k I
Valve clearance
00070009 in
nut 1 t 018022
r I
Fig 17 Adjustment of Valve Clearance
Intake valve opens 20 B TDC
I ntake valve closes 45 A BDC
Exhaust valve opens 50 B BDC
Exhaust valve closes 15 A TDC
Valve clearance 0007 to 0009 in 018 to 022mm with
engine cold
Rocker Arms
0551 16 H P
I 14000 j WMI Itj II
0551 055311 1
0550 0551n
24 HP
I 0551 0552in
14002 14043mm
0550 0551in
iig 73 I
Fig 18 Standard Relative Position of Rocker Arms
Compression release Release wire is optional parts Compression thp parts as shown in Fig 19
Pull the lever out as position
far as it will go check to see that the 60 angle is attained
Operation position
and that compression is released The compression release
is to be used when the battery is low or when starting in
cold weather Tn use the compression release preheat the
glow pluq ls IJsual pull the compression release knob out as
far as pOSSible and holrl it there while cranking the engine
This flartially releases the enQine comflression enabling it to
turn faster in cold weather or when the battery is low Once
the engi ne IS turninq fast enough to start release 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
1 elfD 2 Oil filler cap 6 Compression release bolt
Operating released 3 Compression rease lever 7 Shaft
4 Adjustment access cover 8 Valve
Fig 20 Adjustment of Compression Released
Fig 19 Compression Released
Top clearance
Top clearance should be 0028 to 0035 in 07 to 09 mrn
Do not pull the compression release lever when the engine is
To adjust usecyl inder gasket shims 0006 in 015 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 place a piece of fuse on the
speed to idle before doing so
piston top and fix the cylinder head securely on the cylinder
Adjustment of compression release head flanqe The measurement is taken by the fuse The liner is
level with the cylinder frarne at top surface
1 Set exhaust valve in totally closed position
The gasket shirns can be reused so do not lose them
2 Remove decompression adjustment window cover from
cy I i nrler head cover
3 Make valve clearance as 0 with use of adjust bolt From this position turn the holt further by Top clearance
1 to 15 turns Decompression clearance will then be set at 0030 to 0044 in 075 to 1125rnrn which is the
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 hy hand and make certain
valve disk does not contact With pistion top
Fig 21 Top 9
Boring and replacing the cylinder to Fig 22 tht insirif diametPf of the linm sholiid
be checked at points 12 and 3 ann in the directions a and
b The liner on which the wear has excEeded the service limit
can hf bored and honed to 0020 in O50mm oversile
The finished dimensions are 3012 to 3D13 in 76500 to
76519mrn Models 5416 and 5424
An oversi zed
piston ann rings must then he usen with this liner Once liner has excepned its wear limit it should be reo
placed with a new one To install a new liner coat the with oil push into the block with a press and finish to
24 HP
the standard size When this is done a standard size piston
must again be used
K1f I
E f
I Fig 23 Tightening of Cylinder Head Bolts
II 2
r Air cleaner
I 1
lot I
JI l
3130 3131in
79505 79535mml
16 24 HP
Standard size Over size
2992 2993in 3012 3013in
76000 76019mml 76500 76519mml
16 24 HP
Fig 22 Standard Dimensions of Cylinder Liner
and Liner Bore in Block
Tightening cylinder head capscrews Fig 23
1 I Tit tmQue of thp cylincJAr head cafscrews is
4 to f8 II Ills 7fl to 80 kqm Numbers 78 and 11
13 ill tllf diilqrarn ale studs The nuts on these studs
shouln llsn he liqhtenerl to this torqup
2 All the capSCIIWS must be tiCjhtened uniformly To do
this tiqhtpn all Ihe capscrews in the orclm indicated on
thp diaqram lIllil thiN are Just snug Then tighten each
one 1 ond turn at a timp in this same sequence each
time until all have bem tightened to the rpQuired torque
3 The cylinder head capscrews should be retightened if
the enqine has not been used for a long time The valve
lagh should also be adjusted pach limp the cylinder head
capscrews are retorqlled If the cylinder hild gasket has
b0n replaced rUIl the fnfline lor allfllJl 30 minutes and
relighten the cylinder lltad capsrrcws as decsribed above
Main Moving Parts Crankshaft and connecting rod
Pistons and piston rings 1 The crankshaft is a heat treated steel alloy forging The
The Istons and piston rings are shown in Fig 26 If the crank pins are induction hardened for additional wear
cyl inder Imers have been bored oversi7e oversize pistons resistance Crankshaft endplay is 0006 to 0012 in 015
anti 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 installing the connecting and undercut and the oil control ring is of the
a Clean both surfaces expansion type b Apply engine oil to the threads
of the connecting rod
s End gap of rings on poston in cylinder
capscrews before installing and tighten each to 27 to
I Diameter of piston skirt thru t of piston pin bore
E Diameter of piston skirt perpendicular to piston pin 304 ftlbs 37 to 42 kgmi
The bearing caps are matched to each connecting rod
I 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
III assembled so that the marks line up
3 In the event that the crankpins become worn and are no
lJ20Bl 0OB2in
L 1
longer serviceable undersized bearings may be used
When installing the undersize bearings observe the fol
lowing precautions
2JjliF 2070mm a Machine the crankpin diameter and radii to within
0191 019Bin a few thousandths of the correct dimensions and
5010 5030m1 finish grind to the exact dimensions
0905 0906in b After finish grinding the bearing diameter and the radii
23000 23013mm chamfer the diameter of the oil hole with an oilstone
0012 OOlB El If this IS not done an oil film will not form and the
030 045Ff1m
bearing will sieze
010in 249mm t
c The crankpin should always be i
01957 01965inJ
181 I
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
0010 O018i
I Li
J pin Do not deviate from the chart dimensions as the
1i25 045mm bearing life will be reduced if they are machined
e To determine the running clearance assemble the con
Fig 26 Standard Dimensions of Piston necting rod bearing cap and bearing as described in
and Piston Rings
section 2 and measure the diameter anywhere within
the 1200 angle indicated in Fig 28 and subtract the
Standard size Over size crankpin diameter from this figure
2992in 3012in
IA 76mml 765mml
f The piston pin bushings are of lead bronze
r The inside diameter of the bushing should be finished
2986 2987in 3005 3006in
75839 75859mml 76339 76359mml 16 HP to 0906 to 0907 in 23025 to 23040 mm
2989 2990in
75915 75935mml
3008 3009n
06415 76435mml
24 HP
Over Sl7e Name of Part Mark
Piston 05 05 OS
002in O5mrn
Piston ring 05 05 OS
16 HP
Cylinder liner 3012 to 3013in 76500 to 76519mm
24 HP
12f1R max to 2pR max by
f3 31mml
Radius 004006 0 15mm
1307 I313m
43959 43 975mml
o 1300 146m
2044 Tj
5921 51940mmJ
Fig 28 Crankpin for Undersize Bearing
2050 052m 0 782 O 793m o 19B7X 13mm
52064 52131mm 1887 911mmJ
1 q OJ
0236 02m
I 0255
26 048
16 078mm
I 26 non 16021m
09065 0 90lJIIl
23 025 23040mml
23001 l 24 H p 1
o NJO 153m
1887019 fOmml
1850 851m
47000 4702mrn
r1Jr rlufu
0058 O059In
482 1 495mml
j t l J
i L t i cA Diameter of piston pin bushing after installation
2044 2045m Fig 29 Standard Dimensions of Connecting Rod
51921 1j1 Q40mm
Bearing and Bushing
2050 2052m 0 782OJ93111 0143 0753m
52 31mm
157 08457 m1 1
198720 13mm
1881 g 13mm
LUIJ rn m rn
0018 00791
1970 2000mmJ
Fig 27 Standard Dimensions of Crankshaft and Bearings
Runninq Clpilrancp
Sill Pi rt IJo Bpar ing
Crankrin Diarn in
1 7228 0 72iI
020 020 mrn undersi7P I
I I 43759 to 43775 rnrn
o 40 Od t 4 07I
to 0003819in
0035 to 0097rnrn
mm o 040US
43559 to 43515 rnlll
Main Components
Camshaft and camshaft bearings
Gear train
Standard dimensions are shown in Fig 32 Camshaft running
Be sure to assemble thp gears by matchinq the mating marks clearance is 0002 to 0004 in 005 to 0091 mm
as shown in Fig 30 The backlash of each gear is 0002 to
0005 in 16 H P rll 1 II 1 t 1lr t l In
H I q

I r L
24 HP
Crankshaft gear 4 Camshaft gear
lJJJ ltrrnErooo
2 Oil pump drive gear 5 Fuel injection pump drive
3 Idle gear gear
1575 I516ln
Fig 30 Mating Marks of Gear Train
Crankshaft gear
Heat to about 176F BOC and slide on crankshaft If the
shaft and hore dimensions iJP such that the qear will not slide
easily it may be heatpd to a slightly higher Fig 32 Standard Dimensions
of Camshaft
Camshah gear and to Fig 31 Place the camshaft retainer plate on the
camshJft first Shim the camshaft retainer rlatr out from the
camshaft 0003 to 0009 in 007 to 022 mm with shims
that can be pulled nut after the gear is installed Heat the gear
to aprroximately 176F BOC and slide on the shaft until it
hlJtts up aqainst the retainer plate Remove sracer shims If
thp qeH will not slide on the shaft easily it tno may be heated
to a slightlY highpr ternperature as descrrbed above
0003 0009in 007 022mm
1 Camshaft gear 4 Circlip
2 Camshaft 5 Pin plug
3 Camshaft retainer plate 6 Key
Fig 31 Assembly of Camshaft Gear with Camshaft
Main bearing assy Main bearing the bearings in the main bearinq hnusing halves
as in Installation of crankshaft with main bearings in engine in Figs 33 34 using the thrust wilshers only on the
Slide the crankshaft assembly into the engine block being
Journal nearest 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 hOllsing halves is in position make sure the oil passages are correctly lined
with bearings on the crankshaft coat the capscrew threads Install the main bearing housing to engine block locking
with engine oil and tighten to 21 to 25 ftIbs 3 to 35 kgm capscrew and washer from the side to position the housing and
M8 then install capscew 2 from the bottom and torque to 47
to 50 ftIbs 65 to 7 kgm M 1 a
1 Bearing
2 Cap screw
3 Locking tab
4 Main bearing housing
5 Cap screw
6 Locking tab
7 Locking tab Fig 34 Main Bearing Housing 7
1 Bearing Main Bearing Housing 2
2 Thrust washer
3 Thrust washer
4 Crankshaft journal
5 Main bearing
6 Cap screw
7 Locking tab Fig 33 Main Bearing Housing 3 with
8 Locking tab Thrust Washe
0 d
Main bearing housing 1
5156 5157in
16 24 HP
1130968 130986mm
Main bearing housing 2 51956 5 1963in 22047 22055in
1131968 131986mm 156000 56019mm 24 HP
53137 53144in
Main bearing housing 3 1134968 134986mml 16 24 HP
Idler gear Injection pump the idler gear shaft to the engine block with 3 cap
Injection pump camshaft Fig 37 Install the bearings and
screws torque to 17 to 20 ftlbs 24 to 28 kgm and bend governor unit on the camshaft and install in the engine block
tabs of tab washer Install gear as shown make sure it runs Hour Meter Unit Fig 37 Insert the tang on the end of
freely has a running clearance of 0001 to 0002 in 0020 to the hour meter drive shaft into the slot on the end of the
0054 mm and 0008 to 0020 in 020 to 051 mm end injection pump camshaft and install as per the 1 Idler gear
2 Spacer
3 Retaining ring
4 Shaft 4
5 Bushing
6 Spacer 5
7 Engineblock
8 Capscrew
6 71
9 Tab washer
Fig 36 Idler Gear
1 Fuel injection pump 5 Injection pump gear
2 Speed control lever 6 Governor system
3 Fuel control system 7 Injection pump camshaft
4 Hour meter unit
Fig 37 Injection Pump Camshaft Assy
Hour meter unit is optional parts
Attaching flywheel to crankshaft
Clean the entire contact suriilP carPiully Coat the contact 1 Rust inhibitor and antifreeze should be used in accord
surface with enginp oil wah all the oil oil with gasoline and ance with the in the related manuals
dry it throughly Put the flywheel on and torque the CHpscrews 2 Be sure to remove all debris that may be plugging the fins
to 70 to 77 ftlbs 10 to 11 kgml Bend the locking tabs back 3 Check the rubber shock mount nuts periodically to be
on the washers sure they are tight
Tensioning of fan belt
Cooling water pump
The fan belt temion IS adJusted by moving the alternator
To install the enolinC fan pulley on the pump securely tighten
bracket in or Ollt The belt is properly tensioned when the
the nut 4 tn 506 to 579 ftlbs 7 to 8 kgf m torque
bel t deflection midway between the alternator pulley and the
crankshaft pulley is 025 to 035in 7 to 9mm with a force
of 20 Ibs applied Proper belt tension is essential for good
engine cooling and belt life See Fig 38
16 24 HP
Fan pulley Tension pulley Alternator pulley 1 Pulley
2 Bearing
3 Key
4 Nut
5 Body
6 Shaft
025 to 035in 7 to 9mm 7 Rotator
8 Case
9 Seal
Fan drive pulley
Fig 38 Fan Belt Tensioning
Fig 39 Water Pump
Starting Motor
The starting motor is of the standard bendix type drive with 1 Starter solenoid The assembly
is shown in Fig 43 2 Drive end frame
2 3 Welch plug
rl 4 Bushing
5 Set bolt
6 Bolt
7 Drive lever
8 Solenoid
9 Over running clutch
10 Armature
11 Snap ring
12 Collar
13 Yoke
14 Set bolt
15 Packing
16 Field coil
17 Brush
18 Brush
19 Brush holder
20 Brush spring
21 Through bolt
22 End frame
I 23 Bushing
24 Packing
25 Return spring
16 17 20 18 I 26 Washer
rJ 27 End frame cap
13 19
Fig 43 Starter Assembly
Starter Insufficient brush contact
Dirty or worn commutator
16 HP 24 HP
Precautions in care and handling of starter motor
1 The starting motor must be installed properly for the
Code No 298783 298876 starter pinion to mesh with the engine ring gear as it
should If the ring gear and pinion do not mesh properly
Solenoid ilctuilted with the pinion and starter housing may be damaged and in
overruning clutch
extreme cases the starter may not even turn
Nominal 2 If the starter switch is turned on and the engine turns
voltage but will not start the cause is probably in the fuel system
Check the fuel I ines and correct as necessary
08 kW 10 kW 3 In attempting to start an engine never use the startinq
motor for more than 30 seconds at a time without a pause
Direction of Clockwise viewed from to let is cool down The starting motor heats up very
rotation pinion end rapidly when used and if it is used continously for more
than 30 deconds the solder may melt from the armature
or the coil or lead wires may melt Also the battery will
Trouble shooting be iischarged tn such a iegree and wont have suffirient
If the battery turns extremely slow or not at all the cause may power fm another attempt at starting A good rtlle 10
lie in the battery wiring or the starter The Ilqhts are follow is to crank for 10 seconds and pause for 10 se
a very convenient tool for tracing the cause of thetrouble conds Repeat until the engine starts
Lllht nlPlhocJ 4 If the starting motor is too far forward the pinion will
The lise of thiS method of course assumes that the lights not mesh properly with the ring gear and cause rapid
are fllnctioning normally piston wear Ad jus t for proper mesh
1 Liljh15 ar 11 5 Do not turn the starter switch while the enqine is running
Probable rallse Low hilttery faulty contact at one of If this is done the pinion gear will contact the Tlng
the connections faulty wiring If the qear which is tlHning with the full force of the enqlOe
bilttery remains discharged hecause of a which may cause a broken pinion bent shaft broken
malefaction in the charging sywm it houslOg etc
should be correrted before charging the
battery to prevent the rroblem Glow Plugs
from reoccuring The glow plugs are the sheath type with the wiring diagram as
2 With battery fully charged shown in Fig 44
a Symptom Lights do not light
Probable cause Battery terminal not properly
b Symptom Lights dim when crank
inq the enqine and starter slows down or 1 Glow plug
2 Glow plug
Probable cause
3 Starter switch
Bad engine rotatIOnal resistance too
4 Main switch
5 Regulator
Starter does not turn 6
ArrTature shaft bent
7 Battery
Worn bushing
8 Starter
Pole core screw loose
Field coil grounded or insulator short
Fig 44 Circuit Diagram for Glow Plugs
Armature coil grounded or insulator
c Symptom Lights are brirjht but starter does not turn
or turns very slowly
Probable causes
Starter terminal not ronnected rroperly
Solenoid switch not making contact
Solenoid not workinq coil grounded or
insulator short circuited
Faulty starter SWitch contact
Glow plug 16 HP J 24 HP
Code No 298795
Number I 3
Vol tilfJP 65 amp
rw refl t l 105 V
Glow plug controller 16 HP 24 HP
Code No
299839 299839
Current 13A 20A
Precautions in handling the glow plug
1 USf the glow plugs only with Universal
glow plug controller If any other type is used the heating
time will not match that of the glow plugs and cause
hard starting and various other problems
2 As the glow plugs are ill rarallel thl controller heating
element will tllrn red even if one of the rlugs is bad
However the time it takrs for the controller heating
etement to get hot is less which will cause the element to
bllrn out
3 Rerlilcinq a faulty glow plug may not solve all the system
prohlems Should thf failed rlug indicate problems in
other areas beside the pili they should be checked out
iilv The fl10st probablf aas are improper fuel inJcction
tilTllflq bad nOllie wrong fuel incorrect circuit con
nection gas Ifak etc
Univelal Diesel PANEL 3 ClL
Connect to ACC term on switch
2 CYl i
en L L
Reference Chart
Parts Items Standard Value Remarks
Cylinder head tightness Ml0 x 125 542 579 fUbs When installing apply a generous
iII 75 8 kgm coat of engine oil onto the entire
J Cylinder head surface distort inn 0002 in below surface of each bolt
valve seat thickness 45 0059 in 15mm
005mm below
00276 00354 in
Top clearance 07 09 mm Y4S O059in 15mm
050 oversize liner 10
Standard 10 29921 29929 in 29980 in
15416 5424 30113
76000 76019mm 7615mm 76500 76519mm
0 Piston clearance 0002600041 in E side
At piston skert
15416 5424 00056 00071 in Q141 O 180mm I side
U Height above block surface
Type Dry 000098 in 0025 mm
Standard 00 15416 5424 29921 in 76mm Oversize 0020 in 05 mm
c Pistonpin boss 10 o 9U55 09060 in 09071 in
B 23000 23013 mm 2304 mm
interference Clearance
Pistonpin clearance 00004 in 00004 in
OOllmm 0011 mm
Ring gap toP 2nd 00118 00178in 00492 in 05 oversize top ring surface should
oil ring 125mm be 00079 in 02 mm below
00098 00158in piston side surface
Top ring width 025 045mm
c Keystone type
2nd ring width
Oil ring
00768 00772in
195 1962mm
01960 0 1965in
4978 499 mm
Ring groove clearance
00037 00047 in
0093 0120mml
00008 00020 in
above 00079 in
002 0052 mm
c 00 09056 09059in
a c
0000600015 in 00059 in
a Pintobush clearance
0014 0038 mm 015mm
Small end 10 10236 10244 in Pin
2600026021 mm
without bush
Small end width
Large end 10
1 0236 in 26 mm
18504 18512 in
t TIJl
4in 100mm
without bush c
OOOO79m O02mm
a Large end width 10079 10118 in O02mm
u 256 257 mm
Rod torsion 00008 in 0002in
When installing apply a generous
see diagram 002 mm 005 mm
coat of engine oil onto the entire
Rod bolt torque M8 1 2676 3038 surface of each bolt
ftlbs 37 42
Items Standard Value
ID 17327 17345 in
4401 44056mml
with metal
Width 07429 07531 in
OJ 2
Center thickness
a 00 1 85 in 47 mml 00583 00589 in
1482 1495 mml
Runnmg clearance
00014 00038 in 00079in
0035 0097 mml 02 mml
Axial clearance 00157 00236in Crank arm to large end clearance
04 06 mml
1 Crnkshaft jurnal dia 20441 2 0449 in
Main berlng ID 20465 20483 in
5198 52025mm
I Running clearance
0001600041 in
00079 in
02 mml
with metal 004 0104mml
Crankshaft metal 21 07429 07531 in
Width 1887 1913 mml
Crankshaft jurnal da 20449 20449 in
51921 5194mm
I Running clearance
00079 in
o 0016 00046 in 02 mml
GearSlde main bearing ID 20465 20488 in j 004 0118 mml
5198 52039mm
with metal
CrankShaft metal 1 I 07823 07925 in
Width 1987 2013mm
Crankshaft metal 11 OD 22485 22474 in
57111 57084mml
f Crankpln jurnal dia 17307 17313 in 00047in When installing
apply a generous
43959 43975mml 0 12 mml coat of engine oil onto the entire
su rface of each bolt
Crankshaft Side clearance 00059 00122 in
015031 mml
Crnk hearing cap 21 7 283 tUbs
M 8 x 125
bolt 11 torque 3 35 kgml
Crank bearing car M 10 x 125 470 506ft Ibs
holt 21 torque 65 7 kgrn
Cam bearing I D 1 574815758 in Running clearance
40 00040 025mm
00020 00036 in 07677 in
Cam shaft dia 157221 5728 inl
3993439 950mm
10050091 mml
95 m I
Ax ial clearance 0002800087 in 13134 in
c 007 022 mm
I 3336 mm
u Cam 11ft 02165 In 55mm
1386 mm
Crn height 1 3134 in
3336 mm
Parts Maximum
Items Standard Vlue Remarks
Number of teeth crank gear 34
Number of teeth Idel gear 79
Number of teeth cam gear 68
Nllmber of teeth
Inwction pump gear 68
Number of teeth at pump
drive gear 45
Backlash o 00163 00454 in 00118 in
to 0415 1154mm to3mm
r ShlOkage 00433 00551 in
tll 14mm
Face angle Valve gUide bore s1ouJd be
reamed after inserted into
cylinder head
I ntake bore 1295313031 in
t329 33 1 mm
Exhaust bore 1059110669 in
269 271 mm
Stem dia in
Valveguide IQ
t7 9607 975mm
03156 3161 in
Stem guide clearance in
004 007 mm
Vve clearance Q0071 0087 in When cold
t018 022 mm
Free length 1641716614 in
417 422 mm
OJ Spring pressure 2646 Ibsl 3839in Load and length when installed
12kg35 15 mm
Spring pressure loss 15
when installed
Overall length A 5984 in
152 mm
B 58189
58346 in
1482 mm
Dia in
5961 mm
Prts Item5 Standard Value Remarks
Urn It
1 I ntake valve opened
I ntake valve closed At 45 ABDC
E Ex hilljst valve opened At 50 BBDC
QJ o
2 Exhaust valve closed At 15 ATDC
Iqnton process
16 HP
24 HP
Injectectinn Trochoid tooth width Use Engine Oil CD oS
U16 H P
Above 77F 25C SAE30
05866 05874in
1490 1492mm
24 HP Between 32 F 77 F 0 C
08622 08630in 25CSAE20
2190 2192mm
Below 32F OoCI SAElOW
Outer rotor OD 19669 19685in 10W30
4996 5000mml
E o 0035 0063 in
CI clearance 009 016 mm
side o 0039 0059 in
clearance 010015 mm
6471 psi
Oil pressure 45 5 kgfcml
Pump caparity 16 HpD
42 Galonmin
16 HP B
At pump 2116 rpm
24 HP I 24 H P
At pump 2000 rpm
58 Gallonmin
Model Cam speed 1400 rpm
Rack position 0354 in 9 mm
a I nleC ion pressure 1990 psi 140kgcm 1
c Pump plunger dia 02165 in55mm
Pump stroke 02756 in 7 mm
Pump discharge 00013
00015 in 3 rev
23 1 mm 3 rev
1990 2133 pSi
I njlct Ion pressure
Parts Maimum
Items Spec if ications Standard Value Remarks
Cooling system
With pressurized radiator
Natural circulation corrugated I
16 24 HP
torceo circulation
Water pump Z751BW Centrifugal pump
and DHll0lBI with thermostat
Gear case to impeller 002320437 in Water temperature BOoC
clearance 059 111 mml Total lift 1934Ibsin 2 lmAg
Circulation flow rate Z751BW Packing thickness
E and DHll0lB 264 Gallonmin
100Qmin or more
iO Impeller dia
Z751BW and DHll01BI 26342642 in
SO 669671mml Pump speed 3450 3550 rpm
w Thermostat actuation 1796203F No pump for Z751B and ZB51B
temperature B2C 95CI
Z751BWand DHl101B
Radiator cap pressure 12B psi 09kgcm 2
Fan belt length
HM 4055in 1030mml
n perimeter
16 24 HP
HM 4150in 1054mml
16 HP
D 16 HP NS70 dry
24 HP 24 HP N70Z dry
Electrolyte specific
gravity discharge
2i 1 120
Electrolyte specific 12BO
gravity charge 6BoF 20C
Etectrolyte specific 130
gravity Voltage 12V Alternator
Current 20A
Check interval Every 1000 service Insulation resistance
c hours
Brush spring pressure 12B pSi09kgcm 2 15
I nsulation resistance No failure at 500MV
0 Constant voltage 13B 14BV
Current lOA
9 Cutin voltage 125135V
Par Items Standard Value
Number of teeth pinion
Number of teeth 89
rIng gear
Insulation resistance
No failure at 500MV
Check interval
Every 1000
service hours
Output n 16 HP
Nominal value
n 24HP
Hpad set bolt and nut
Apply a generous coat of
Ml0x 125 542579ft Ibs
75 8 kgfm engme oil onto the entire
surfaces of all important
Flywheel set bolts
set bolts
QJ 723 796 fUbs
10 11 kgfm
cr M12 x 125
Crankshaft main bearing Ml0 x 125 470506 fUbs
co set cap bolts 65 7 kgfm
Crankshaft cap bolts M8 125 217 253 fUbs
a 30 35 kgfm
Rocker bracket set studs M8 125 174 203 ftlbs
24 28 kgfm
Rod bolts M8 1 268 304 fUbs
37 42 kgfm
Gpneral set bolts M12 571 665 ftlbs All
these torques are applied to
and studs 79 92 kgfm those
S45C bolts and studs
which have relief number 7 or
MlO 354412 ftlbs punch marks
49 57 kgfm
M8 174 203 ftlbs
24 28 kgfm 0 0
M6 72 83 fUbs
10115 kgfm
Bolt Torques
fUbs kgfm
Grade Standard Bolt Special Bolt Special
i l
Nominal SS41 S20C S43C S48C Refined
SCR3 M6 58 69
10 BO 095
1 15
90 105 125 145
M8 130 152 180 210 174 203 1240 280 217 253
300 350
Ml0 289 333 400 460 354 412
490 5701
448 521
620 720
463 535 640 740
868 M14
1230 1410
926 11001280
1700 19501
1447 166 4
2000 2300
1917 2242 2650 3100
2459 289 3
25 00 2900
3400 4000
2025 23 1
2712 3182
2800 3250
3750 4400
2532 2965
3616 4195
3500 4100
5000 58001
Bolt material grades are shown by numbers punched on the bolt heads
Prior to tlghtenong be sure to check out the numbers as shown below
Punched Number Bolt Material Grade
None Standard Bolts 5541 520C
7 Special Bolts 543C S48C Refined
9 Special Bolts SCM 3 seR 3 26

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