Thursday, March23, 2017

Universal Diesel 5444 Technical Manual

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5432 5444
Part Number 200153
Edition 1
October 1990
Fuel System System System 7
Valve Timing 8
Compression Liner
Cylinder Head
Air Cleaner 10
Piston and Rings 11
Crankshaft Rod 12
Gear Train 13
Camshaft and Bearings 13
Main Bearings 14
Injection Pump 15
Flywheel 16
Water Pump 16
Starter 1617
Glow Plugs 17
Wiring Diagram 18
Reference Charts 1924
Torque Chart 24
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 X323 33 x m IN
31 45 68 91 RPM 3000 2800 2800 2800 RATIO
221 211 211 211 Vertical water cooled 4cycle diesel EQUIPMENT 12
Volt 55 AMP Alternator Electric Starter
Ii Glow Plugs
Mach Fue 1 Pump Fuel Pump Mach Fuel Engine 22 Qts 37 Qts 56 Qts 115 Qts 8 Qts
Use SAE 30 HD CD or IOW40 heavy duty diesel
lubricating Fill to full mark on dipstick Use autOllatic
Std and VDrive transmission fluid Type REDUCTION 21 21 21 21 21
COOLING SYSTEM 7 PSI CAP Seawater Fresh water cooling syst
cooled 48Qts 6 Qts 8 Qts 8 Qu
14 PSI 14 PSI 14 PSI 14 PSI
EXHAUST FLANGE 114 NPT 112 NPT 112 Diesel fuel
number 516 ID
FUEL INLET FUEL OIL 298854 298854 298854 298854 LUBRICATION OIL 299381
298852 298852 299584 Centrifugal type all 1
MODEL 15 20 30 40 50
5411 5416 5424 5432 OPIUTIHG 175 0 to 1900 OPERATING ROTATION Clockv18e when viewed
fraa Vbelt IlOTATImf Rilbt HaDCl
BOTH STD AND WEIGHT Pound 245 365 425 490 545
LENGTH Overall 256 280 325 362 360
HEIGHT Overall 212 241 246 260 Overall 207 207 207 207 TIMING
25 0 before top dead center all od18
Construction and Handling
Fuel System
Fuel system fllel system schematic is shown in Fig with the fuel The fuel filter is of
the cartridge type shown schematically in
flowing in the direction indicated by the arrows To bleed air Fig 2 Under normal conditions it should oly have to be
from the system loosen the vent plug A on the fuel filter replaced every 400 hours To install apply a small amount of
and crank the engine until there are no more air bubbles from fuel to the packing anc tightn securely by hand
the vent Tighten vent A nd purge the ail from the injec
tion pump at vent S using the same procedure
Note Vent S is a valve When the valve
is opened air take vent to the fuel tank through the
overflow piP
7 Fuel filter
2 Cover
3 Pipe coupling
4 Vent plug
5 0 ring
6 0 ring
7 Element
Fig 2 Fuel Filter
Fuel injection timing
Fuel injection timing is adjusted by changing the number of
shims used between the pump and the gear case it fits into See
1 Fuel tank 6 Nozzle holder Fig 3 One shim corresponds to approximately 5degrees in
2 Fuel cock 7 Overflow pipe crank angle Therefore injection will take place 15 degrees
3 Fuel filter 8 Fuel pump later when a shim is added and 15 degrees earlier when a shim
4 Fuel injection pump A Vent plug filter is removedThe timing is correct when the pointer in the peep
5 Injection pipe 8 Vent plug pump hole on the side of the flywheel housing lines up with the
Fig t Fuel System F marked on the flywheel See Fig 4
Fuel injection pump Speed control lever
Controllllk pin Inection timing
adjust shims
Fig 3 Adjustment of Fig 4 Inspection of
Injection Timing Injection Timing
Fuel injection pump Handling the injection pump
The inJPctioll pump is the Bos h MiIlP K typ It is a prpi Use care in handling and using the injection pump As men
sinn pit1CC of cqIJinmrnt milChirucJ III rlOSf tolerances and its tinned before the injection pump is a precision piece directly affect the of
the engine equipment and care should be taken not to drop it or clamp it
Therpfore handle it with carl tightly when working on it Also be sure to use only clean
fuel that has been filtered Oil drums left outdoors are always
ronsidered to contain water so always filter this fuel before
Clean fuel is a must as the fuel is forced through parts of the
pllmp 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
control rack pin is corrertly placed in the 02 in 5mm wide
groove of the fork lever 1 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 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 HolloIII screw 22 Tappet assy
10 Packing 23 Roller
11 Tappet guide pin 24 Roller bushing
12 Clamp pin 25 Roller pin
13 Bolt
Fig 5 Fuel Injection Pump
Fuel injection nozzle Spray pattern
The luel infection nozlle like the lu1 infection pump is also The nozzle cracking pressure and fuel spray pattern are most
a precision piece 01 eQuipment and should be treated with the accurately checked by using a nozzle pop tesT stand If a
same amount 01 care pop test stand is not available remove the nozzles from the
The nozzle cracking pressure engine leaving the pressure lines nozzle cracking pressure is adjusted by
adding or sub shims Irom the top 01 the nozzle spring Adding a Hold the nozzles so that the high pressure spray
from them
0004 in O1mm shim will increase the cracking pressure by will not in any way impinge upon unprotected skin The
about 142 psi 10 kgcm 2 The nozzle crack ing pressure is atomized fuel will easily penetrate the skin and cause blood
1990 to 2133 psi 140 to 150 kglcm 2 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
Ollt If this sound is not heard or other problems are noted
reler to the Fuel Injection Pump Nozzle Maintenance
Std in 41 in Engine
UPrecaution 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
7 Delivery nipple 7 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 70 Nozzle nut
4 Tighten the retaining nut to 435 to 58 ftlb 6 to 8 kgfm
5 Nozzle holder body 77 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 pllmp pickup is located in the crankcase as shown in
Fig 9 and is fitted with a metal screen If the screen becomec
plugged wash it off with diesel fuel or kerosene
pftAZI Lubrication system
The entire lubrication system is illustrated in Fiq 8 Oil from
the pump is forced through the replaciable parer element
4 filter The filter is equipred with a pressure regulated valve to
6 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 prfSsure switch is located in the passage from the filter
and controls the oil pressure If the oil pressure falls below
14 psi 10 kgf cm 2 the oil warning lamp will light on the
7 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 kgf Icm 2
Probable cause of low oil pressure n
1 Clearance on one of the hearings is to great
2 One of the rocker arms is too loose
I I I j SJ t
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
1 I Jr W
v tl
J j
rTo I llItJ
i pump
Ij djl Oil pan
Drain plug
Fig 9 Detail of Oil Pump Pickup
Rocker arm
Rocker arm shaft
Relief Cover
Fig 8 Lubrication System Safety valve assy
4 Safety tlalve
5 Plug
Oil filter
6 Spring
1 Rlplace the nil lilttr 111 Ivmy other oil change evmy 150
7 Oring
8 Relief tlalve
2 Undm normal condition it is only nrpssary to change
9 Oring
th nil liltpr ilt the 511ilild intprvals If howevpr thp
70 Plug
pn9ine is used in EXTREME L Y dirty conditions the
77 Oring
rrSur I 1ulati111 Vii IVI lnd Sillety valvp should also be
12 Oil filter cartridge assy
rmllrwci and rlpilnld
13 Oil filter cartridge
3 Whfllver the oil liltrr I placed rom the Ponin under
Fig 70 Oil Filter 74 Label
no loan lor il fpw nrirnllp until tltn filtEr has hppn fillPtl
ann thfl1 arid nil to rllar lip 1m what i5 contained in the
7 Relief valtle compo 4 Ball valve
2 0 ring 5 Valve sheet
3 Spring
Fig 11 Pressure Regulating Valve
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 reo
moved If the stem seal are replaced coat the stem liberally
with oil before inserting in the valve guide to prevent burning
thf valve stem seal
1 Safety valve body
2 Safety valve spring
3 0 ring
4 Oil filter base
5 Safety valve
Fig 12 Safety Vallie Complete
Replacing engine oil
1 Dr lin and replace the engine oil after the first 35 hrs of
operation and every 75 hrs thereaftpr
2 The oil is easier to change if the enfjine is warm
3 Do not mix different brands of 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
brand Also do not mi x oils of different viscosities 2 Valve spring retainer 6 Valve guide
3 Vallie spring collet 7 Valve
4 Valve spring
3 Combustion System
Combustion chamber Fig 14 Structure of Valves
rhe engine utilizes a swirl type chamber The dimensions of the replacement valves and valve guides are
See Fig 13 Fuel and air are mixed in this shown in Fig 15 When new valve guides are installed the
harnber resulting in more efficient combustion A glowplug bores should be reamed to 0316 to 0315 in 8030 to
s employed to preheat the fuel for easy starts down to 5 F 8015mm after installation The valve head must be recessed
15C 0043 to 0055 in 11 to 14mml from the face of the cylin
der head to prevent it from hitting the top of the piston
0313 0314in
A Finished ID of guide
installed in cylinder O head
8015 8030mmJ r1ID
1059 7067in 1295 1303in
269 27 TmmJ 7329 33 7miiiT
1 Nozzle holder 4 Cylinder head Fig 75 Standard Dimensions
2 Nozle piece packing 5 Combustion chamber of Valves Vallie Guides
3 Glowplug Valve Gap
Fig 13 Combustion Chamber
0043 0055in 77 74mmJ
Fig 16 Sinking of Valve
Valve timing
When the vtlvp cleartncr hilS Deen tdrusrl ilS shown in
Fig 17 the sttndard valVf timing shown in thp chart can L
Valve clearance
OCl 00070009 in
nut 1 t 018022
T I mm
Fig 17 Adjustment of Valve Clearance
Intake valve orens 20 B TOC
I ntakf valvp closes 45 A BOC
E xhalls t valve orens 50 B BOC
E xhaus
t closps 15
Valve clearance 0007 to 0009 in 018 to 022 mm with
engine cold
Rocker Arms
0550 0553in
0550 0551 in
j lIJ11
Fig 18 Standard Relative Position of Rocker Arms
Compression release Release wire is optional parts
Compression 11 part a showlI in Fiq lr Pilil I IPVN 11I11 ilS a II wi q dlf to fP Ihat till rn
all111 is th1I is Iaflj rll I nlnrssinll rllnase
IS til Ill liSX wllpn thl battery is Inw IH whell starling in
enid wrlt1111 Tn IIS Ihl 1flpS prltlfilt th
Operation position
as IISlIill pli ttll rlIils IIIh oul ilS
Iill il possiblE illld hold it thlII whi uOlllkinq tlw pHllall rilSlS thP fnqim OIllPSSIOn enahlillq il tr
turn laster in enid wpalhr r whtI the hillpry is low Once
thl cnginl is turning lasl fmouqh to start rrlrlSf the lever and
thp r1Qilw will Make sure the compression release has returned to the
operating position by pushing the knob all the way in
1 Rocker arm 5 Compression release nut
2 Oil filler cap 6 Compression release bolt
3 Compression rese lever 7 Shaft
4 Adjustment access cover 8 Valve
Fig 20 Adjustment of Compression Released
Fig 19 Compression Released
Top Top clearance should be 0028 0035 in 07 to 09 mml
Do not pull the compression release lever when the engine is
Tn adjust ue cylindpr Qaset shims 0006 in 015 mm thick
running at high speed or under load If it is necessary to use
each onto the hpad side
the compression release while the engine is running reduce the
For chfCking the melSumment place 11 piece of luse on the
speed to idle before doing so
ristol1 top and fix th cylinder head sfCurely on the cylinder
Adjustment of compression release head flange The is taken hy the fuse The liner is
I Set exhaust valve in totally rinsed position ICVf1 with thp cylinder frame at top urface
2 Remove adjustlllent window cover from Thf gasket shims can be reused so do not lose them
cylinrler heild cover
3 Milke valve clearanr as 0 with lise 01 adJlJst holl From this position turn thp bolt furthr by
1 to 15 turns clealancp will then be sct
at 0030 to0044 in 075 to 1125mm which is the
designed After adjusting be sure tn lock adjust bolt securely so
that it will not unWrn while engine is in service
5 Make certain that the cleanrance is nnt too wide To
chprk this turn crankshaft hy hand and makp certain
valve rlisk dos not contact with pistion toP
Fig 21 Top 9
Boring and replacing the cylmder tn Fig 22 the insidf diaewl 1 the liner should
be checd at points 12 and anr in thp rlirfrtinns a and
bL The Imer on which the wer has pxcperlpcJ thp Strvice limit
eiln tw bOHn ilun honpd In OoO in 0 Omm finishpj dimensions are 3 248 249 in
82500 and 101 013 in
7GSno 76519
mlll1 An oversiled piston and I inqs must Ihell be lIsed
with thIS IrnpI OnCt this WISild linr has exclPJpd its wear
limit it should be replacfd Wllh A nnw om Tl install il nfW
liner coat the olJtirjp liwrJlly with oil push into II blork
with a press and finish to til standArd ril When Ihis is done
a standard sin piston must allain hI IIsld
Gj E
NO t
r i
1 Fig 23 Tightening of Cylinder Head Bolts
Air cleaner
Ig 1 Under normal conditions clpan the dust cap one a WPfk
p If the engine is used in a dirty environment clean it more
often Under no circumstances should dust bp allowj to
aCfumulate to more than half the cap capacity If a lilrrw
en I
Il piecc of 1apr or other obstruction gets stuck in th
air intakf
3130 3131in
remove it immediately Always install the cover with the
stamped TOP uppermost If the cover is installfrj ll1side
j2 HP down by mistake the dust and dirt will not enter the rap and
L 7950 795
the filtPr witt plug prematurely
34944 34856 in
44 HP 188505 88535mml Clllan the element every 100 to 200 hours of o1eratinn KpPf
th dust cap in place while cleaning the filter to 1reVfllt
Standard size
j ver size If a
red signal of the dust indicator attached on the air clpaner
2992 2993in 3012 3013in
J2 HP 76500 76519mml
ilppears remove the element and clean or replace with new
76 019m elements After that push down reset button to returning its
33465 33473 in 33661 33670 in signal
44 HP 85000 85022mml 85500 85S22mml
Fig 22 Standard Dimensions of Cylinder Liner
and Liner Bore in Block
Tightening cylinder head capscrews Fig 23
III Th liqhtrninq tHClll of th ylindr 11al CiJpsrrpws is
54 to 58 ftlbs 75 to 80 kg m Nlllnbers 11 13 and 15 1 2
17 in the diagram are studs The nut on these studs 3
2 Body 1
should ill tlP tiqhtenpd 10 this Ill
3 Air cleaner element IIssy 4
2 All tlH Cillsrrpws 1St il tiqhwncj llllitmrnly Tn d 5
4 Wing nut 6
this tilhtfn all lh rilpsrVJ ill til ordN il1licatPi nn
5 Baffle cover 7
the ilaqrart IIntil thrv ill Jtlst SwI T1un tiqht n poch
6 Cover
nn 1 ollrl turn ilt il tim thIS sam seClllncp tach
7 Clamp
tilllp unlil all havp blen lIrlhtnfd 10 lh rtqllirffl tOlqllP
8 Lavel
31 TI1 Lylini hPAd CilliUtW should h rftiqlltpned if
9 Lavel
thl pnqin has not hen Ilpci fr a IOllq til1H The valvr
10 Indicator assy
lash shotllrj also he adillstfrj prh lirnr tl cylinder heild
Fig 24 Air Cleaner
UII5CIwS jt flOrqwd If th rylidr IHiJd qasbt hilS
Ilpn rellaCtd rim tht l fnl lbOJl 30 rtinlltfS and
rptlqhtln til rylindpr 1111 IPSW as 10
Main Moving Parts Crankshaft and connecting rod
Pistons and piston rings 1 The crankshaft is a heat treated steel
alloy forging The
Thr 01S1Ons ilnd piston rinqs H shown In Fig 26 If the crank pins are induction hardened for
additional Ilnrrs have hecn bOIi ovcri oversize pistons resistance Crankshaft endplay is 0006 to
0012 in 015
and rtngs must hr usel The 0iston is marl If high silicon to 031 mm
AIAIIV imel is Cilm ground The tor cmnprPssion ring is a 2 The crankpin bearings are plateej kvstnne
vrf the seronel rompression ring is When installing the connecting lnt undercut anej tllr 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 pilto pin bar
E Diameter of piston skirt perpendicular to piston pin 304 ftJbs 37 to 42 kgm
The bearing caps are matched to each connecting rod
and should not be interchanged Also since there are
var iations in machining from side to side each bearing
cap and connecting rod are marked and should be
assembled so that the marks line up
3 In the ewmt that the crankpins become worn and are no
longer serviceable undersized bearings may be used
When installing the undersize bearings observe the fol
0081 0082in lowing precautions
a Machine the crankpin diameter and radii to within
0197 0198in a few thousandths of the correct dimensions and
5010 5ijjoU7
finish qrind to the exact dimensions
05 0Q6j b After finish grinding the bearing diameter and the radii
23000 23013mm chamfer the diameter of the oil hole with an oilstone
0012 00 l8in 8 If this is not done an oil film will not form and the
010in 249mm 030
l 1
0TJ ill bearing will O
1950 1962mm
II l
c The crankpin should always be to
0000016 in 00004 mm or less
01957 I k
4978 4990mm
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
9J 10 OOlBm
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
SPCtion 2 and measure the diameter anywhere within
the 1200 angle indicated in Fig 28 ald subtract the
Standard size Over size crankpin dia meter from this figure
2992in 3012in
2986 2987in
3005 3006in 1 The piston pin bushings are of lead bronze
The inside diameter of the bushing should be finished
I 75839 75859mm 76339 76359mm 2 HP to 0906 to 0907 in 23025 to 23040 mm
2989 2990in 3008 3009in
75915 75935mm 3346 in 3366 in
185mm 1855mm
3341 3342 in 3360 3361 in HP
84855 84875mm 185355 85375mm
3343 3344 in 3363 3364 in t
E 184915 84935mm 185415 85435mm
Over size Name of Part Part No Mark
Piston 05 05 OS
002in 05mrn
Piston ring
05 05 OS
32 HP Cylinder liner 301210 3013in 76500 to 76519mm
1 2JlR ma x to 2JlR max by honing
i 44 HP Cylinder liner
3366 to 3367 in 85500 to 85522mm
12JlR max to 2pR ax by honing
031 nI4
111 JIm
RMfflll 004 0 06 tr r SntmJ
o r300 46
13J 31mm
Fig 28 Crankpin for Undersize Bearing
ll 0155 10267
I 1036 IfRI
116000 16WI 9B 160lR
123002 10 1m
o 143 0 753m
rrR 870 9 2nu2tuSm
S g 5 UnmJ
2050 205200
52064 52 3 0 1RO 193 o 3 0753
lB 19 13mm1
2248 1910 13mm1
o 058 t059m
rw H 4112 4fflmm
j JI i iIi fll fl1 1I A Oieme 01 pitonpin buhing ef instelletion
0018 00
Fig 29 Standard Dimensions of Connecting Rod
l9lrJ2 Bearing and Bushing
Fig 27 Standard Dimensions of Crankshaft and Bearings
Size Part No Bearing Crankpin Diam 0 Running
020 I 1522122971 020mm undersize
17228 to 17234 in
32 HP 040 1522122981 040mm undersize
43759 to 43775mm
17149 to 17156 in
43559 to 43575mm
040US 0001379
to 0003661 in
17228 to 17234 in 0035 to 0093mm
020 1547122971 020mm undersize 020US
44 HP
040 1547122981 040mm undersize
43759 to 43775mm
17149 to 17156 in
43559 to 43575mm
Main Components Camshaft gear
Gear train Rptlf to Fiq 31 Place the camshaft retainer plate on the
B SIIr to asspmblf thl Clears by matchinq thp millinCi marks cillTlshaft first Shim the camshaft retailer plate out from the
115 shown in Fig 30 Thp backlash of each gear is 0002 to camshaft 0003 to 0009 in 1007 to 022 mml with shims
0005 Ill 00415 to 0 54 mrnl that can be pulled Ollt after the gear is installed Heat the gear
to approximatply 176 F SOoCI and slide on the shaft until it
blltts liP aqainst thl retairfr plate Remove spacer shims If
the qnar will not slide on the shaft easily it too may be heated
tll a sliqhtly higher temperature as described above
0003 OOO9in 007 022mmJ
1 Camshaft gear 4 Circlip
2 Camshaft 5 Pin plug
3 Camshaft retainer plate 6 Key
Fig 31 Assembly of CamshBft Gear with Camshaft
Camshaft and camshaft bearings
Standard dimnnsions are shown in Fig 32 Camshaft running
5 clearance is 0002 to 0004 in 005 to 0091 mm
Z 40 T
39 T 2
1 Crankshaft gear 4 Camshaft gear
2 Oil pump drive gear 5 Fuel injection pump drive
3 Idle gear gear
Fig 30 Mating Marks of Gear Train
Crankshaft gear
hl to al10llt 170 F 80n CI and sl idn on cranlshaft If the
shaft 1111d bore riimrmsiom arp such that the qPu will not slide
fl5i1y it may bl heated to a slightly hihrr tnmperature
I ill iljtl for installation

1515 15
trl 1
JL f
Fig 32 Standard Dimensions of Camshaft
and Bearings
Main bearing assy Main bearing the bearings in the main bearill housing halves as
in Installation of crankshaft with lain bearings in engine in Figs 33 34 usill tht thrust washers only on the
Slide the crankshaft assembly into the engine block being
Journal nearest the flywheel Coat the journals and careful not to nick or scrape the crankpins After the bearing surfaces with
enqine oil f1il the housinq hillves is in position make sure the oil passages are correctly lined uP
with bearings on the rrankshaft eOill Ihl capSTCW ihreilds Install the main bearing housing to engine block locking
with engine oil and tighten ttl 21 to 25 fUbs 3 to 35 kgIll capscrew and washer from the side to position the hOllsing and
M8 then install cafscew 2 from the bottom and torque to 47
tn 50 ItIbs 65 to 7 kgm Ml0
7 Bearing
2 Capscrew
3 Locking tab
4 Main bearing housing
5 cpscrew
6 Locking tab
7 Locking tab Fig 34 Main Bearing Housing 7 2 3
7 Bearing
2 Thrust washer
3 Thrust washer
4 Crankshaft journal
5 Main bearing
6 Capscrew
7 Locking tab Fig 33 Main Bearing Housing 4 with
8 Locking tab Thrust Washets
o d
Main bearing housing 1 51565157 in
130968 130986mml
Main bearing housing 2 51956 51963 in
131968 131986mml
5235 5236 in
22047 22055 in
1 156000 Main bearing housing 3 1132968 132986mml
53137 53144 in
Main bearing housing 4 1134968 14
Idler gear Injection pump he idler gear shaft to the engine hlock with 3 cap
Injection pump camshaft Fig 37 Install the bearings and
screws torque to 17 to 20 ftlbs 24 to 2B kgml lind bend governor unit on the camshaft and install in the engine block
tabs of tllb washer Install gfar as lhown make sure it runs Hour Meter Unit Fig 37 Insert the tang on the end of
freflv hilS a running clellrance of 0001 to 0002 in 0020 to the hour meter drive shaft into the slot on the end of the
00f4 rnml ami OOOB to 0020 in 020 to 051 mm end injection pump camshaft and install as per the
1 Idler gear
2 Spacer 13 1
3 Retaining ring
4 Shaft 5 Bushing
6 Spacer
7 Engine block
Tab washer 7
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 CJlmshaft
4 Hour meter unit 8 Idling apparatus
Fig 37 Injection Pump Camshaft Assy
Attaching flywheel to the entire contact SIJrfilCf rardull CDilt the cnntilCt 1 Rust inhibitor and antifreeze should be used in with
engine oil wilsh illl the oil off with gasoline ami ance with the in the related manuals
dry It throughly Put the flywhpf1 on imd tnrqlll the Cilfscrews 2 Be sure to remove all debris that may be plugging thl fins
to 70 10 77 ftlbs 1010 11 lrn Bpnd the IrlCking tabs back 3 Chllk 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 tension is ilejUstpri hv rnovinq thp altlrnator
Tn install the cooling fan pulley on the pump securely in Of out The belt is properly tensioned when the
the nut 4 to 506 to 579 ftlbs 7 to 8 kgf m torque
belt deflection midway between the alter nator Dillie and pulley is 025 to 035in 7 tl 9 mm with a force
of 20 Ibs applied Proper bplt tension is essential for good
enginp cooling and belt life See Fiq 8
Fan pulley Tension pulley Alternator pulley 1 Pulley
2 Bearing
3 Key
4 Nut
r 5 Body
W 6 Shaft
025 to 035in 7 to 9mm
i 7 Rotator
8 Case
iI 9 Seal
Fan drive pulley
Fig 38 Fan Belt Tensioning
Fig 39 Water Pump
Starting Motor
The starting motor is of the rerJlJctinn tyre drive
The assembly is shown in Fig 43
t Yoke
2 Armature
3 Packing
4 Brush holder
5 Brush spring
6 Packing
7 Magnetic switch
8 Gear 1
9 Gear2
10 Ball
1 t Over running clutch
12 Drive end frame
13 Through bolt
t4 Screw
10 II 14
Fig 43 Starter Assembly
Starter Insufficient brush contact
Dirty or worn commutator
Precautions in care and handling of starter motor
1 I The starting motor must be installed properly for the
Code No
299574 starter pinion to mesh with the engine ring gear as it
should If the ring gear and pinion do not mesh properly
TyJe the pinion and starter housing may be damaged and in
extreme cases the starter may not even turn
r 21 If the startel switch is turned on and the engine turns
12V but will not start the cause is probably in the fuel system
Check the fuel lines and correct as necessary
14kW 31 In attempting to start an engine never use the starting
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 01 lead wires may melt Also the battery will
Trouble shooting be discharged to such a degree and wont have sufficient
If the battery turns extremely slow or not at all the cause may power for another attempt at starting A good rule TO
lie If1 the battery wiring or the starter The headlights are follow is to crank for 1Q seconds and pause for lOse
a very convenient tool for tracing the cause of the trouble conds Repflat until the engine starts
Headlight method 41 If the starting motor is too far forward the pinion will
The use of this method of course assumes that the headlights not mesh properly with the ring gear and cause rapid
are functioning normally piston wear Adjust for proper mesh
1 Headlights are dim 51 Do not turn the starter switch while the engine is running
Probable cause Low battery faulty contact at one of If this is done the ninion gear will contact the ring
the connections faulty wiring If the qear Jhich is turning with the full force of the engine
battery remains discharged because of a which may cause a broken pinion bent shaft broken
malefaction in the charging system it housing etc
should be corrected before charging the
battery to prevent the problem Glow Plugs
from reocGuring 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 become extemely dim when crank 1 Glowplug
ing the engine and starter slows down or 2 Glowplug
stops controller
Probable cause 3 Starter switch
Bad engine rotational resistance too
4 Main switch
great I 5 Regularor
Starter does not turn 6 Alrernaror
Armature shaft bent
7 Battery
Worn ushing
8 Starrer
Pole core screw loose
Field coil grounded or insulator short
Fig 44 Circuit Diagram for Glow Plugs
Armature coil grounded or insulator
shortcircui ted
cl Symptom Ughts are bright bllt starter does not turn
or turns very slowly
Probable causes
Starter terminal not connected properly
Solenoid switch not making contact
Solenoid not working coil grounded or
insulator short circuitedl
FaUlty starter switch contact
Universal Diesel PANEL E
Connect to ACC term on switch
2 CYl
Reference Chart
ParIS Items Standard Value Remarks
When installing apply a generous
Cylinder hfoad tightness Ml0 x 125 542 579 ftlbs
i 75 8 kgm coat of engine oil onto the entire
r Cylinder head surface dstortion 0002 in below surface of j h btt
1005mm below
I ntakeexhaust valve sPat thickness 45 0059 in 115mm I i
00276 0 0354 in
Top clearance 107 09 mm i O059in fl5mm
1 10
Standard 10
32 HP 29Q21 29929 in
76000 76019mm
I 29980 in 7615mml 176500 76519mm
44 HP 3400 33473 In I I
Pston clearance t HP OOO 00905 10
r 10065 OI64mm
At piston skert 00026 00066 u
Height above block surface
Type Dry 000098 in 0025 mm
1 Standard 00 HP 29921 in 176mm Oversize 0020 in 05 mm
r44HP 33465 in 185mmJ
c Pistonpin boss 10 09055 09060 in 09071 in
o 123000 23013 mm 12304mm
interference Clearance
Pistonpin clearance 00004 in 00004 in
001 I mm 1001 I mm
Rong gap toP 2nd 00118 00178in 00492 in 05 oversize top ring surface should
1125mm be 00079 in 02 mm below
i 00098 00158in
piston side surface
g Top ring WIdth Keystone IVpe a
2nd ring width
Oil ring
00768 00772in
1 95 1962mm
01960 0 1965in
4978 499 mm
Ring groove clearance
00037 00047 in
10093 0 120mm
00008 0 0020 in
0 00019 in
1002 0052 t i i t I
c 00 09056 09059in
a mm
00006 00015 in 00059 in
Pintobush clearance
0014 0038 mml 0 15mml
t Small end 10 1 0236 10244 in i
without bush
Small end width
Large end 10
10236 jn 26 mm
18504 18512 in
5 147000 47 02Omm 4in f100m
g without bush toOOO79in
c OOOO79m to 02mm
8 Large end width 10079 1 0118 in to02mm
256 25 7 mm
Rod torsion 00008 in 0002 in
When installing apply a generous
see diagraml O02mm 005mml
coat of engine oil onto the entire
Roo bolt torQue MSx I 2676 3038 surface of each bolt
fUbs 37 42
Parts Items Maximum
Standard Value Remarks
f f 10 17327 17345 in
4401 44056mml
wIth metal
Width 07429 07531 ill
1887 1913 mml
Center thickness
00 185 in 47 mml 0058300589 in
1482 1495 mml
Running clearance 00014 00038 in 00079in
0035 0097 mml 02mml
Axial clearance 00157 00236in Crank armtoIarge end clearance
Crankshaft jllrnal dia 20441 20449 III
151921 5194mm
Main bearing 10 20465 20481 in 1Running clearan 00079 in
5198 52025mml 02mm
with metal 1004 0 104mml
Crankshaft metal 21 0742907531 in
width 1887 1913 nl
Cr nkshaft jurnal dia 20449 20449 in
51921 5194mm IRunning clearance
00079 in
00016 00046 in 102mml
GearSide main bearing 10 20465 20488 in
5198 52 039mml 1004 O 118 mml
with metal
Crankshaf1 metal 11 07823 07925 in
width 11987 2013mml
Crankshaft metal 1I 00 22485 22474 in
157111 57084mml
Crankpm jurnal dia 17307 1 7313 ill 00047in When installing apply a generous
43959 43975mml 012 mm coat of engine oil onto thp entire
surface of each bolt
Crankshaft side clearance 00059 00122 in
0 15 031 mml
CrJnk bearinq cap 217293fUbs
boll 1 torque
M8 125
3 35kgml
Crank bearinl call M lOx 125 470506 It Ibs
boll 2 torque 65 7 kgml
f Cam bering ID 1574815758 in
IRunning clearan
1 57215728 m1
I00020 00036 1M
10050 0091 mml
01611 in
J f
Axial clParance 0002800087 in 13134 in
r 3336mmJ
007 022 mml
ik J
Carn hft 02165 in 55mn 05451
Cam heillht 13134 in
3336 mml
Prts Items Stllndard Vail Remarks
Number of teeth crank 34
Number of teeth idel gear 79
Number of teeth earn Ifar 68
0 Number of teeth
c Inlectlon pump gear 68
t Number of teeth oil pump 45
drive gear
Number of teeth oil pump drive gear I 40
Number of teeth oil pump rive gear 2 39 a in 00118n
0 041S I 154mml 03mm
Shlnkillf 00433 0OSS1 in
11 14mm
Facl angle 4So Valve guide bore should be
reamed after inserted into
cylinder head
Intake bore 1 29531 3031 in
329 33 I mm
Exhaust bore 1 OS9110669 n
269 27 I mm
Stem da in
Valve guide 10 o 31S63161 in
Stem guide clearance a oo160028 in
004 007 mm
Valve clearance o 007100B7 in When cold
0 18 022 mm
Free length 1641716614 in
417 422 m
Sprong pressure 2646 Ibsl 3839in Load lind length when installed
s 0
Sprong pressurp loss IS
when installed
Overall length
A 5984 in
IS2 mm
B S8189
58346 in
0 1482 mm
Dia in
S961 mm
Specifi tions Standard Value
Intake valve opened
At 20 BTOC
Intake vaillt closed At4S0 ABOC
E xhau5t valve opened At SO BBOC
E xhaut valve cIClSPd At 15 AToC
Ignition process
Inlertectlon timing 2So26 BTOC
Trochoid tooth wIdth Use Engine Oil CO 10SI
Above nOF 125D CI SAE30
Between 32F noF 100C
08622 08630in 2SoCI SAE20
12190 2192mml
Below 32F 100CI SAEIOW
Outer rolor 00 19669 19685in lOW30
4996 5Ooomml
E T rClChoid tobody 0OO350063 in
Q rlcarance 009 016 mml
side 0000059 in
clearance 010015 mml
64 71 psi
Oil pressure 14S 5 kgfcm21
Pump capacIty
At pump 2000 rpm
58 Gallonmin
f 1
Cam speed 1400 rpm
Rack position 0354 in 19 mml
Q Injection pressure 1990 psi 140kgcm
c Pump plunger dia 02165 inIS5mm
U Pump stroke
0 02756 in 17 mm
ii Pump discharge 00013
II 00015 inlrev
123 1 mm 3 rey
1 e 1
c Model NOONI2S012
19902133 psi
z 1njeclion pressure
Parts Spec if ications Maximum
Items Standard Value Remarks
Cooling system
Forced circulation
Wltpr pump lmp
with thermostat
Gear case tn impeller 002320437 in Water temperature
c Icarance Circulation 059 111 mml
Tatallift 1934lbs in 2 lmAg
Flow ratr Packing thickness
E 264 Gallonmin
1002minl or more
i Impeller dia
26312642 in
166 9 67 lmml Pump speed 3450 3550 rpm
u Thlrmostat actuatiCn
Radiator cap pressure
Fan belt
12V llOAH
ElectrOlyte specfic
gravity dscnarge 1120
Electrolyte specific 1280
gravity charge 68F 20C I
Electrolyte specific 130
0 Check nterval
Brush sprlOQ oressure
11I5ul1Itio resistancp No failure at SOOMV
Constant voltagt
Cutin vnltage
Part II
I terns Standard Value Maximum
1 r Numbp 01 teeth 89
FIn gear
Insulaton rpslstane No failure at
Check onltrval EYfrv 1000 Insulation
service hours
Outnut 14kW Nominal
Head srI bolt and nu Ml0 x 125 54 2 579ft Ibs
ApplV a generous coat of
75 8 kglm engine oil onto the entire
surfaces of all imporlant
r Ivwheel set bolts set bolts
773 796 fUbs
11011 kgfm
M12lC 125
Cranksl1f1 rnain betr in Ml0 x 125 470 SO 6 It Ibs
CD set cap holts 65 7 kglm
Cranitshllft can bolts M8 x 125 217 253 fUbs
a 30 35 kglm
Rocker bracket set studs M8 xl 25 174 203 fUbs
24 28 kgfm
Rod bolts M8 xl 268 304 IUbs
37 42 kgfm
General t bolts M12 571 665 IUbs All these torques are
applied to
and studs 79 92 kgfm those S45C bolts and
which haVe relief number 7 or
Ml0 354 412 fUbs
49 57 kgfm
punch marks
M8 124 28 kglrn
M6 72 83 fUbs
110 I IS kgfrn
Bolt Torques
ftlbs kgfm
Material Grade Standard Bolt Special BOlt
Special Boll
5541 S20C S43C S48C Refined SCR3 SCM3 Refined
M 6 58 69 080 095 72 83 100 115 90 105 125 1451
130 152 180210
174 203
240 2801
217 253 300 3501
289 333 I 400 460354 41 20 7
463 535
I 640 J 10SOgp
M14 196 926 111001280 9111085 12601500
12301447 117002000
12301410 1170019501 447664 120002300 19172242 M16
M18 1808 2098 12500 2900 2025 2351 128003250 2532 2965 3500 4100
M20 2459 2893 13400 4000 2712 3182 3750 4400 36164195 15000 58 00
Bolt matllial 01II15 F hown by numbers punchoo ern the bolt hPads
Prrr to he surl to check aut the numbprs as shown below
Punched NumbPr Bolt Material Grade
Nnne Standard Bolts 5541 S20C
7 SfPCial BOilS 548C
9 Special Bolts SCM 3 5CR 3 2

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