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Universal Diesel 5411 Technical Manual



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UNIVERSAL DIESEL


 MODEL           15 & 25
 (EARLY MODELS 5411 & 5421)




SERVICE MANUAL



          PUBLICATION
            #200151
                         PAGE
Specifications . .       1-2
Fuel System              3-4
Lubrication 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         18-19
Glow Plugs . .            19
Reference Chart        20-24
                                                              SPECIFICATIONS

          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                     2.67 x 2.75    2.99 x 3.23         2.84 x 2.76        2.99 x 3.23      2.99 x 3.23            3.3 x 3.25
          DISPLACEMENT (CU. IN)                31             45                  52                 68                  91                 115
          MAXIMUM R.P.M.                      3000           2800                3200               2800                2800               3000
          COMPRESSION RATIO                   22:1           21:1                22:1               21:1                21:1               21:1
          TYPE                                  Vertical, water cooled, 4-cycle diesel engine
          ELECTRICAL EQUIPMENT                  12 Volt, 55 AMP Altermator, Electric Starter, and Glow Plu~s
.......                                       Mech.        Fuel Pump      Fuel Pump     Fuel Pump       Mech .                           Fuel Pump
          LUBRICATION (Engine)              2.2 Qts.       3.7 Qts.         4 Qts.       5.6 Qts.      11. 5 Qts     8.5 Qts.
                                                Use SAW 30 HD (CD) or IOVJ40 heavy duty diesel lubricating oil.
          ---------------------------------------------------------------------------------------------------------------------------
          LUBRICATION (Transmission)            Fill to full mark on dipstick. Use automatic transmission fluid Type A, Type F,
           (Std and V-Drive)                    and Dextron II
          ---------------------------------------------------------------------------------------------------------------------------
          TRANSMISSION REDUCTION               2:1            2:1                 2:1                2:1                 2:1                2:1
          ---------------------------------------------------------------------------------------------------------------------------
          COOLING SYSTEM (7 PSI CAP)        Sea-water                 Fresh              Water              Cooling             System
                                             cooled        4.8 Qts.           4.0 Qts.            6 Qts.              8 Qts.             8 Qts.
                                                            14 PSI             14 PSI             14 PSI              14 PSI             14 PSI
          ---------------------------------------------------------------------------------------------------------------------------
          SEA WATER INLET &OUTLET                                             3/8" NPT
          ---------------------------------------------------------------------------------------------------------------------------
          EXHAUST FLANGE                    1-1/4 NPT      1-1/4 NPT          1-1/4 NPT          1-1/4 NPT            1-1/2 NPT          1-1/2 NPT
          ---------------------------------------------------------------------------------------------------------------------------
          FUEL                                                        Diesel fuel number 2-D
          ---------------------------------------------------------------------------------------------------------------------------
    ---------------------------------------------------------------------------------------------------------------------------
    FUEL INLET HOSE                                           5/16" I.D.
    ---------------------------------------------------------------------------------------------------------------------------
    FILTERS, FUEL OIL                  298854         298854         298854        298854        298854         298854
    ---------------------------------------------------------------------------------------------------------------------------
    FILTERS, LUBRICATION OIL           299381         298852         300209        298852        299584         299927
    ---------------------------------------------------------------------------------------------------------------------------
    GOVERNOR                                          Centrifugal type - all speeds
    ENGiNE-OPERATiNG-TEMPERATuRE-------1350-~~--------175g-~~--------i750-~~-------1756-~~-------1750-~~--------i75g-~~--------
                                       150 0 F        190 F          190 0 F       190 0 F       190 0 F        190 F
    MAX. OPERATING ANGLE                                         15 0   ALL
    ENGINE ROTATION                              Clockwise when viewed from V-Belt end
    PROPELLER ROTATION                              Right Hand (Both STD. and V-Drive)
    ENGINE WEIGHT (Pounds)               245              365                   285        425      490           545
    LENGTH (Overall)               25.6/27.6 (VD)        28.0           28.5/30.5 (VD)    32.5     36.2          36.0
N
    HEIGHT (Overall)                    21.2             24.1                  22.6       24.6     26.0          26.0
    WIDTH (Overall)                     20.7             20.7                  19.2       20.7     20.7          21.4
    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                                                     · Fuel·filter
· 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 r>acking and tighten seC'lJrely by hancl. For r.!moval,
when 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 injection
pump and vent the system in the same manner as A.
                                                                                                                 :4

       M-15                                                                                                      '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 injectiu(l 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 Cipproxirnately 1.5 degrees in
                                                                    crank anglf~. Tt)eretore, injection will take place 1.5 degrees
                                                                    later when a shim IS added and 1.5 (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   Fi~l.   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




                                                               3
·   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-
                                                                           ing:
                                                                           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 0.00004 in. (1/1000 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 0.2 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.

                                                  '1.1'
                                                  114                (j)
                                                              IS
                                                  (16
                                                          r   17,1

                                                  '18!
                                                  '( g'

                                                  '10 "
                                                          21
                                                  22




       1.   Injection pump ass'y       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 ass'y
     10.    Packing                    23.   Roller
     11.    Tappet guide pin           24.   Roller pin
     12.    Clamp pin
     13.    Bolt

                    Fig. 5. Fuel Injection Pump




                                                                           4
· Fuel injection nozzle                                                        · Spray pattern
 fhe fuel injection nOllie, like the ILJf~1 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                    flCAUTIONll
shims from the top of the nozzle spring. Adding a 0.004 in.                       Hold the nozzles so that the high pressure spray from them
(0.1 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 kgf/cm2)                                                            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
                                       I
                                       I
                                       I
                                                                               (JIlt. I I this sound is not heard or other problems are noted,
                                                                               refer to the "Fuel Injection Pump & Nozzle Maintenance
                                      I                                        Std." in 4.1 in "Engine".
                                      I
                                     d                                         fl Precaution II
                                                                               (1) Assembly and disassembly of the nozzle should be done in
             (21
                                                                                      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 43.5 t8 58 ft·lb (6 to 8 kgf.m)
       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
                                                                               2.2 Lubrication System
                   Good             Bad                                        · Oil pump pick·up screen
                                                                               The nil pump rick-lip IS Il)r<'lted ill the cr;Jn,rilSe as shown in
                                                                               Fig.9 and is fil1f:d with;] mf'\ill screen I f the: screen becomes
                                                                               pluqC)ed, 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
                                                                     ;6'
                                                                               rompletely Iii tered and also the pressure regulating valve in-
                                                               15.'_'
                                                                               stalled in the gear case regulate the oil pressure at 36 - 50 psi
                                                                               (2.5 - 3.5 kgt/c'rn 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 7.1 psi (0.5 kgf /cm 2), t~~t:l~~~~'2.~~am2 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.



                                                                                NOTE
                                                                                *Oil warning lamp and dash panel are oPtlondl P<'lrts




                                                                           5
[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
                                 /
                      ___ rl.f __
                     rjjr ,'~ ~;~              ~       Safety
                                                       valve
                                                                                           Drain plug
                                                                                                                           Pick-up screen

                            H!
               ~ ,-~i [1-:1 _
               [II   "fL~JlrF    n         0                                                   Fig. 9. Detail of Oil Pump Pick-up



                     _~I
                      ('lV-~\ L~-
                                                       O;/{;/t.,


             _1_.    I                             I                               Construction of Oil Filter
           1           ~ ij 1           passage
            L0fr.- 1 ~/"                       I         ~~~:f
Oil pump~W          ~~.~-'~~~::::::::::=-J
                 --'1 ~
     Oil pump         \    ---F _ \Y   ---,-
pick-up screen            ---=---




                          Rocker arm
                          Rocker arm shaft




                                                                Relief valve                              Fig. 10. Oil Filter




                                                                                   Construction of Relief Valve




screen
                     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.




                                                                               6
· Replacing engine oil                                                    ·    Valve
(1) Drilin iJnd rerlaee tlw ei1(jine oil after the first 35 hrs of        Cornbustion air, o.f 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 diff(~rent 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~ pre·combustion chamber
                      (Fig. 12). Furl and air are mixed in this
                                                                                       (l)__

                                                                                       0)-----
                                                                                                 --.-------------
                                                                                                      ----------_     '-,



                                                                                       (1;)--
chamber resllltinfJ in mon' efficient combustion. A gloW1)llIg
is employed to preheat the fuel for easy starts down to 5° F
(_150 C).

                                                                                       (j)---_ ..




                                                                                   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 0.276 to 0.277 in. (7.01 to
                                                                          7.025mm) after installation. The valve head must be recessed
                                       5                                  0.035 to 0.043 in. (0.9 to 1.1 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                                                         Jt1Z:2!63~9.~~~._ ~.
                                                                                                                                 (7. 02-7. 05mm)
          3. Glow plug                                                                                                          0.274-0,2746 in.
                    Fig. 12. Combustion Chamber
                                                                              A:   Finished ID of gUide--            1J (6n'9:~~6n'9751mm)0
                                                                                                                            I




                                                                                   installed in cylinder                i   I       Iil                  .          II
                                                                                                                                        !I"
                                                                                   h
                                                                                       ead.       -:r- J ~ J            i'                     A



                                                                                   r/£f:;rJJ;~:)----lt-lL                                                           ~j,
                                                                                                                     H
                                                                                                            -,---J]~ . -___~~-..-
                                                                                                                                 .r--    --.-r45'1
                                                                                                                                                     l

                                                                                                                                                     -          n
                                                                                                                                                             ....




                                                                                                                    0.921-0.929 in.                1.059-1.067 in.
                                                                                                      M-15          123.4-23.6mm)                  126.9-27.1 mm)
                                                                                                    t - - - - - f - - - --------.----
                                                                                                                1.078-1.086 in.                    1.216-1.224in.
                                                                                                    ~
                                                                                                      M-25
                                                                                                      _ _ _ _ _L127.4-27.6mm)
                                                                                                                 -_ _ _ _ _ _              ~_
                                                                                                                                                   130.9-31.1mm)

                                                                                                            Fig. 14. Standard Dimensions
                                                                                                                     of Valves, Valve Guides,
                                                                                                                     Valve Gap



                                                                                       0.035-0.043in. (0.9-1.1mm)

                                                                         Fig. 15. Sinking of Valve


                                                                     7
·   Valve timing
                                                                                                 Adjust bolt (2)



                                                                                                                           14
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)                   ~~.                   0.0057-0.0072 in.
attained:
                                                                                                              .V                       (O.I45-0.185mm)




                                                                                                                  ,- J
                                                                                        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: 0.0057 to 0.0072 in. (0.145 to O. 185 mm) with
                                                                             engine cold.
·   Rocker Arms

                                                                  10.4325-0.433 in.
                                        r---         ---------
                                        I                         1(10.987-11.008mm)

                                        I
                                        I



                                       1t9!                       I WtN! I                               l~j
                                                                                                          I
                                                                                                                                    II
                                                            I
                                                         J __    0.433""'0.435 in.
                                                                  (10.997-11.038mm)
                                                                                                          1__ ________ _

                                                                 0.432-0.4324 in.
                                                                 (10.973-10.984mm)



                                                      ,-,,--I~
                                                             - - -
                                                                          t
                                                                          t-----~.-JU
                                                                 0.4325-0.433 in.
                                                                 (10.987-11.008mm)




                         III   0   ~l            0    IWWI1          0



                            10          10                          0

                            l ________ J___________.

                                            II                                                                         II
                                            Fig. 17. Standard Relative Position of Rocker Arms


                                                                         8
· Compression release (Release wire is optional parts)                                                             Compression released
Assemble the parts as shown in Fig. 18. Pull the lever out as                                                      position


                                                                                                            r/-!/~
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


glow·plug 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, I'elease the lever and
the engine will start.
(NOTE)
  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
                                            I!4'~                             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 clearance
~CAUTION]
                                                                         Top clearance should be 0.0236 to 0.0314 in. (0.6 to 0.8 mm).
Do not pull the compression release lever when the engine is
                                                                         To adjust, use cylinder gasket shims, 0.0078 in. (0.20 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 piEx:e of fuse on the
speed to idle before doing so.
                                                                         piston top and fiX the cylindler head securf,ly 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 decornpression adjustment window cover from                   The gasket shims Ciln be reused, so do n()t lose thelli.
    cylinder head cover.
                                                                                             Head
(3) Make valve clearance as "0" with use of decompression
    adjust bolt. From this position, turn the bolt further by                                 I
                                                                                                    - Top clearance
    1 to 1.5 turns. Decompression clearance will then be set                                                          0.0236-0.0314 in.
    at 0.030 to 0.044 in. (0.75 to 1 125mm), which is the                                                             (0. 6-0. Bmmj
    designed clearance.
(4) 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 Clearance




                                                                     9
2.4 Main Moving Parts                                                                                                             · Crankshaft and connecting rod
· Pi$tons and piston rings                                                                                                        (1) The crankshaft is a heat treated steel alloy forging. The
The pistons and piston rings are shown in Fig.25. If the                                                                              crank pins are induction hardened for additional wear
cylinder liners have been bored oversize, oversize pistons                                                                            resistance. Crankshaft end play is 0.006 to 0.012 in. (0.15
and rings must be used. The piston is made of high silicon                                                                            to 0.31 mm).
AI·Alloy and is cam ground. The top compression ring is a                                                                         (2) The crankpin bearings are aluminum.
chrome plated keystone type, the second compression ring is                                                                           When instill ling the connecting rods:
discontinuous and undercut and the oi I control ring is of the                                                                        a) Clean both surfaces thoroughly.
standard 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 19.5 to
                I : Diameter of piston skirt thru t of piston pin bore
                                                                                                                                         22.4 ft-Ibs. (2.7 to 3.1 kg-m)_
                E: Diameter of piston skirt perpendicular to piston pin
                                                                                                                                         The bearing caps are matched to each connecting rod
                                                         0.0791", 12mm}
                                                                                                                                         and should not be interchanged. Also, since there are


                                                               F_c5~~
                                                                                                                                         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.
                         ~---.+-1
                                     I
                                                               .   ~_.
                                                         JJ.O§ 1::-00062 ~n"--
                                                                                                I                                 (3) In the event that the crankpiflS become worn and are no
                                                                                                                                      longer serviceable, undersized bearings may be used.
                                    l
                                     I                 11.555-1.570mm}
                                                      0.158-0.159 in.
                                                      14. 0 10--4. 030mm)
                                                                                                                                      When installing the undersize bearings observe the fol-
                                                     0.1874-0.7879 in.                                                                lowing precautions:
                                             --    -7ijj.ooiF-20~OI3;:;'-mT
                                                                                                                                      a) Machine the crankpin diameter and radii to within
                             OJJJq:-_2Jl.~B.!n: _...,... 8
                              10.25-0.45mm} i.                                                                                           a few thousandths of the correct dimensions and
                 0.078m. (1.99mm)        i.l ,---
                                              i.              '''1 '                  --~
                                                                                        _l,,:~·:·J
                0.0574-0.0e79moJ       "      ,I                                                                                         finish grind to the exact dimensions.
                11.458-1.470mm}              :,! I                                :   _-r:;:-:]
                0.1566-0.1571 in.            r--
                                         - - - 8 ' ::                                  .L·'~r                                         b) After finish grinding the bearing diameter and the radii,
                13.978-3. 990mm}       ii'                                            _~.'
                                                                                                                                         chamfer the diameter of the oil hole with an oilstone.
                     O.CXJ8-0.016m.          J ---{Ai              -     L                  O.~,
                                                                                  ":-,,_:. __
                      10.20--0. 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 super-finished to
r-----
              Standard   9--
                      and Piston Rings
                                                           Over si ze
                                                                                                                                         0.000016 in. (0.0004 mm) or less_
                                                                                                                                      d) Select the bearing from the chart that necessitates the
                                                                                                                                         removal of the least amount of metal from the crank-
                ----                     I-                                            --
                                                                                                                                         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-
 ®               2.677 in.               I
                                      2.6968 in.
                                                                                                     --
                                                                                                                                         necting rod, bearing cap and bearing as described in
                 168rnm)      I       168.5m m)
                                             ------
          2.6718-2.6726 in.     2. 6915-2.69 23 in.                                                                                      section 2 and measure the diameter anywhere within
  I
          (67.865-67.885mm)                                                                                  MODEL                       the 1200 angle indicated in Fig. 27 and subtract the
             ------.----- - 8.365-68. 385rnm)
                                (6
                                                                              -~--,---


  E       2.6742-2.6750 in.
          (67.925-67.945mm)
                                2. 6938-2.69 46 in.
                                (6 8.425-68. 445mm)
                                                                                                              15                         crankpin diameter from this figure.
               2.8346 in.             2.8543 in.
                                                                                                                                      f) The piston pin bushings are of lead bronze.
 ®              (72mrn)               (72.5m m)                                                                                          The inSide diameter of the bushinq should be finished
                              ~- --------- - , -
  I
          2.8293-2.830 in. - - 2. 8490-2.84 98 in.
          (71.865-71.885mm)
                                                                                                             MODEL                       to 0.7884 to 0.7890 in. (20.025 to 20.040 mm).
                                17 2.365-72. 385m'T1)
  E       2.8317-2.8325 in.     2. 8514-2.85 22                                                               25
          (71.925-71.945mm)     (7 2.425-72. 445mm)
                         ------- - - -                                            ------~-.

                                                                              ,                             ----


                                                                                                                   =i-or':s
                                                                                                                        I            --------,
         O~er size
                                                                                                                                               ~-----I
                            [Name of Part                                                                 Part No.
t----------------..--                                                         ---------
                                 Piston 05
  0.02 in. (0.5mm)
                                 Piston ring 05                                                                                   05 OS                        I
                      . - ---------
                                                                                                                     ----                                      I

  0.02 in. (0.5mm)
                                 Cylinder !iner

                                 Piston 05
                                 Piston ring 05
                                                                         --       ----------
                                                                                      2.6968-2.697
                                                                                                                      =r----d-
                                                                                                                   6iO.'68.;;o!k~~9mml'             M-15
                                                                                                                                                               !

                                 Cylinder liner
                                                    --
                                                                                      (1.2J.LR max to 2J.LR max) by honing                      I
                                 Piston 05                                                                                        05 OS
  0.02 in. (0.5mm)
                                 Piston ring 05                                                                                   05 OS
                                                     ----- c----
                                                                                      2.854-2.855 i n. (72.5000-72.519mm)                           M-25
                                 Cylinder liner
                                                                                      (1.2J.LR max to 2J.LR max) by honing

                                                                                                                            If)
                                                                                                                 0.110-0.126 in.
                                                                                                                 (2.8-3.2mml
           M-l.5
                                           1.4551-1.4557 in.
                                           (36.959-·36.975mml




                                                              I [1'-
     u···rQ
                                                             .~ ~
                                                                                                                      O. 110'-0. 126m.
                                                                                                                      (2.B -3.2mmJ




                                                        ,       ...

                                            1.7297-1.7303 in.
                                            (43.934-43.950mml                                                      Fig_ 27. Crankpin for Undersize Bearing




                                                                      r"
   1.7342-1.1368 m.                                     0.104-0.714 in.
   (44.050-44. I 15mml                                  (17.87-18.13mml




                                                     r
  1.8924 -1.8933 m.




                                                             L~tJ
  (48.066-48.09Imml

                                                                                                                                t
                                                                                                                                                           0]
                                                                                                                  c· .. ·


                                                                                                                  (AI
                                                                                                                 -~.-..
                                                                                                                        t       ~
                                                                                                                                -t                                 0.8680-0.8690 m.




                                                                                                                                                      cz:+::::r""~m'
                                                                                                                                0:8661-0.8670 m.
                                                                                                                                (22.ooo-22.02Imml

                                                                                                                            l   0.1884 -0. 7890 in.
                                                                                                                                (20.025-20.040",ml
                                                                                                                                                           .   .   0.7875-0.7878 m.
                                                                                                                                                                   (20.002-20.01Imml

                                                                                                                                                                   0.625-0.635 m.
                                                                                                                                                                   fl5.87-16.13mml
                                                 1.4551-1.4557 in.
                                                 (36.959 -36.975mml




                                                     =rDfll~
                                                                                                                            '1,.5748-,.5756 in.
                                                                                                                                (40.000-·40.020mml




                                                ~h~lti!lJJO
                                                                                                                            j
                                                                                                                                                                   0.0585-0.0590 in.
                                                                                                                                                                   (I.485-1.498m",1


                                                                                                          lA',: Diameter of piston pin bushing after installation
                                                 i               I     __-.-J
                                                 1.7297-1.7303 in.                                         Fig. 28. Standard Dimensions of Connecting Rod




                                               rrrn
                                                 (43.934 -43.950mml                                                 Bearing and Bushing
      1.7342-1.7368 m.       0.704-0.714 in.
      (44.050-44 115mml    I (17.87-18.13mml


   :=,,:;:::;;;.'U-m
                                                                       i,  ·            I
                                                                      ..t\---.---- ... """-
                                                                      0,078--0.079ill.
                                                                      (1970-2.ooomml


       Fig. 26. Standard Dimensions of Crankshaft and Bearings
r------r-----------                            ~-                                                            --------.----r--------~-------.----___,


                                                                                                                                                               Running Clearance
                                                                                                                                               Metal
    Size                  Part No.                           Bearing                               Crankpin Diam.                                                     in
                                                                                                                                               Mark
                                                                                                                                                                     (mm)
1-----.,---1----------4---------.-.-------- - - - - _ . _ - - - - -
                         0.007874 in.             1.4472-1.4478 in.
  02                                  undersize                                                                                                02     US
                         (0.20mm)                 (36.759-36. 775mm)
                                                                                                                                                               0.0011-0.00358 in.
1-------1----------+----.-----                  ---------------
                                                                                                                                                               (0.029-0.091 mm)
                         0.015748in.              1.4393-1.440 in.
  04                                  undersize                                                                                                04 US
                         (0.40mm)                 (36.559-36.S75mm)
_ _ _ ....... _._. _ _ _ _._. ___- - - . J _ ._ _ . ____ .__ .. _ _ _ ._ _ _ _ _ _ _ _ .....______________ . ___ .. __ . _____ ...




                                                                                              11
· Boring and replacing the cylinder liner
Referrinq to Fig.21. the inside diameter of the liner should
be checked at points 1.2. and 3 and In thp cJirertions (a) and
(b). Thp liner on whieh thcNear has pxcp.cdr:d the sprVICp. limit
can bp iJored ilnd honed to 0020 in. (050mm)                                                    OVp.rsilf~

The finished dimensions are
                                                2.677 to 2.6779 in. (68.000 to
68.019mml.        for Model 15,                         and 2.834 to 2.835 in.
(72.000 to        72.019mm) for Model                               25.              An oversized
piston and rings must then be used with thi5 liner. Once this
oversized 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                                                     ~ O.~·O~,O.~ .·
                                                                                                                     ~        (             \i(              )(           \
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· ----'IJi"




                         ,.   ~c·   s·,.,,>tj.HCj SIIe   -   T-      C Over sizp
                        1-----             ---~~-+-.
                                                             I


                                                                  2.60f)8 ..... 2 ~:m}6 1;""1
             X-1S                                                 168.500-68.51gn1rnl
                                                                  2.854-285:3 in
             M-25                                                 172.500-72.510'nml


           Fig. 21. Standard Dimensions of Cylinder Liner
                    and Liner Bore in Block


·     Tightening cylinder head capscrews (Fig.22)
(1   I The tightening torque of the cylinder head eapscrews is
      31 [0 ::15 ft·liJs. (4.3 to 4.8 kg·ml                        for Model 15,
                     imd 43 to 4 j' ft·lbs. (6.0 to t).5 kg'ITd               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' [di!S( rr,ws 11111:;1 ill' tlyhtl!l1f'd lI!1if(lrl11ly. TI) do
      th,s. tl'lhlC'11 all The cilliscrews In thr: urdr:r il1d,CilTed on
      the cJla~Hillli until thev arc Just snuq. Then tl1hT';11 (!Jeh
      one 1 (one) turn at a time III thiS same snqur,nce pach
      ti~ne ulltll all haliP been tightened to trw II;(lU1rr,cj t()rque,

(3) The rylillder head CiJPscrews shoulej lw rr;·tlghtencd if
    the pnqine hilS n:lt been usp,d for d Innq timE; Thn valvi'!
      lash sholJld als0 be adJuswd each tlmc the cylinder head
      capser ews arE! retorquccJ.               J.f__ .~.2.~_ey~ i noer          head qasket has
      bet:.~_r_f2!?!~rc(L~nJfl ..t..~~ngl ne for.Y~?.~!"]Q...:..;~i!2.t.:~t"s _~~.c:J_
      .':..§.:.l: gtl.l!~~ .t~n~y.l-, f2Q.e.~:gil_~.S:.~!2.~~rew2_~?~.~~_~~1 b~~~~v:~.

                                                                                                             12
2.5 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: 0.002 to 0.0036 in. (0.05 to 0.091 mm).
as shown in Fig. 2Q. The backlash of each gear is 0.00163 to
0.00454 in. (0.0415 to 0.1154 mm).
                                                                                                         nr   ·tf~lj
                                                                                                         Ui .. J:{   ~_._._
                                                                                                                              t'-1'1-fj\rl--l1nl
                                                                                                                          .. _~l r4 1--. "!
                                                                                                                               /.2966-/.2972 in.




                                                                                                                'l
                                                                                                                               132.934-32.95Omml
                                                                                                                               /.2992-/.3002 in.
                                                                                                                               133.000-33.025mml



                                                                                                                     \IDfwf~m"l,"JI
                                                                                                                     ;'.-'7.J7:n.-.,,".z_~lLr7 rTm.
                                                                                                                                             .·


                                                                                                                 J
                                                                                           C][DrrTI[]UJJfilITD~11
    1. Crankshaft gear                           4. Camshaft gear                                 L. _ . _____ J     ____ ~--.______               t
    2. Oil pump drive gear                       5. Fuel injection pump drive                                        /.2966-/.2972 in.
                                                                                                                     132.934-32.950mml
    3. Idle gear                                    gear
                                                                                                                     /.2992-/.3002 in.
                                                                                                                     133.000-33.025mml
              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 gp.ar will not slide
easily, it may be heated to a slightly higher temperature
for installation.
                                                                                         Fig. 31. Standard Dimensions of Camshaft
· Camshaft gear                                                                                   and Bearings
Referring 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 0.003 to 0.009 in. (0.07 to 0.22mm).
When camshaft gear (1) is in place. Then heat the camshaft
gear to about 176°F (BO°C) and push into place. If the inter-
ference 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.
                                                a>
          CD-._.

          ev -. __
          ~   .- -   -- ._.L   r......,.->-->


          ®--_.



                                                     0,OO3-0.009in. (0.07-0.22mm)

   1. Camshaft gear                                  4. Cir-clip
   2. Camshaft                                       5. Pin plug
   3. Camshaft retainer plate                        6. Key


     Fig. 30. Assembly of Camshaft Gear with Camshaft
· Main bearing ass'y                                                     · Main bearing housing
Insert the bearings in the main bearing housing halves as in-            Installation of crankshaft with main bearings in engine block.
dicated 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 14.5 to 17.5 ft-Ibs (2 to 2.4 kg-m)       capscrew and washer from the side to position the housing and
-M7.                                                                      then install cap~cew (2) from the bC'ttom and torque to 21
                                                                         to 25 ft-Ibs (3 to 3.5 kg-m) - 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
                                                         D

                                                  4.4083-4.4089 in.
                                                  (111.973-111.988mml
                                                                                 d


                                                                                              M-15    &   25
                                                  4.3887-4.3893 in.     1.8897-1.8904 in.
                       Milin bearing housing 2
                                                  (111.473-111.488mml   (48.000-48.016mml     M-25
                      - - - - - - - - - - - f---
                                                  4.3690-4.3696 in.
                       Main beiJring hOllsinq 3
                                                  (110.973-110.988mml                         M-15    &   25
                       _._------------                                               ,._.




                                                                 14
· Hydraulic oil pump drive unit,     NOT AVAILABLE                     · Injection pump camshaft
Assemble 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 illustration.

                                                                        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 7.23 to 8.32 ft·lbs (1 to 1.15 kg·m land bend
tabs of tab washer. Install gear as shown make sure it runs
freely, has a running clearance of 0.0006 to 0.0018 in. (0.016
to 0.045mml and 0.008 to 0.020 in. (0.20 to 0.51mm) end
play.

                                                                                               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




                                                                  15
· Attaching flywheel to crankshaft                                        · Cooling water pump,fresh water
Clean the entire contact surface carefully. Coat the contact              To install the coolinq fan pulley on the pump, securely tighten
surface with engine oil, wash all the oil off with gasoline and           the nut (4) to 506 to 57.9 ft-ibs. (7 to 8 kgf .m).torque.
dry it throughly. Put the flywheel on and torque the capscrews
to 40 to 43.38 ft-Ibs (5.5 to 6 kg-mi. 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. Pulley
bracket in or out. The belt is properly tensioned when the
                                                                                                                          2. Bearing
belt deflection midway between the tension pulley and the
                                                                                                                          3. Key
crankshaft pullev is 0.25 to 0.35 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             //:;    0.25 to 0.35in. (7 to 9mm)
                             II!'


                            Fan drive pulley


                    Fig. 37. Fan Belt Tensioning

· Radiator
(1) Rust inhibitor and antifreeze should be used in accord·
    arlce wierl llw recommendations 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.




                                                                     16
                      ENGINE CONNECTIONS
                                               Universal Diesel                  PANEL CONNECTIONS

                                                                         I
                                                                         I
                                                                             ·
                                                                                                     I




        __3~q,-L_._...,

                      2 CYL.
                                                                         I
                                           Connect to ACC. term. on switch
                ..----J,.."-~
                                           i                         ·
                  .
                  -        .
                           -
        --r--

        :t
         .--.
        1"T       ·        ·

        GLOW I PLUGS                FUEL PUMP


                                     12 V.                                                               r......
                                      BATT.                                                              ..-i

                        Grounded
                           to
                         Engine
 E                              B

.....
 CD
 en
 >-
en                                                 .                     I


                                                                         I
                                                 Blue ':'
-co
 (.)
                                                    OIL    TEMP
                                                    SENDER SENDER
--
.....
 ~

(.)

-
CD
W
 3.3 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
                                                       (i)
               CD

                                                     1 ..
                                                                                               7.   Magnetic Switch      19.   Brush

               I                                                            (i'\ij)
                                                                                               8.
                                                                                               9.
                                                                                              10.
                                                                                                    Armatur
                                                                                                    Insulater Plate
                                                                                                    Insulater Washer
                                                                                                                         20. Brush Spring
                                                                                                                         21. End Frame
                                                                                                                         22. Bush
                                                 (~,               'j   ').1~@                11.
                                                                                              12.
                                                                                                    External Cir·clip
                                                                                                    Collar
                                                                                                                         23. Through Bolt
                                                                                                                         24. Plain Washer
                                                                                                                         25. Packing
                                                                                                                         26. Return Spring
                                                                                                                         27. Spring Holder

                                                 \                               ..       ---                            28. End Frame Cap




                                               JJ)~~J
                                               /~
                                                ~~~·1




                                                                         Fig. 41.




       6000



                    1.36      7.23    10
       5000
                    (7.0)    (9.81)
                              1.0

                     1.09\5.19        8
        4000
                    (0.8) (7.85)
                           0.8

                    0.82      4.34    6
        3000
                    11;:6f   (5:88)
                              0.6

                    0.54      289     4
        2000    70.4)        (3.92)
                              0.4

                    0.27      1.45    2
        1000
                    70.21
                             e· 96
                              0.2 )


                                           0                 100                  200                                   400
                                                                                        amp. fA)
                                                                         Fig. 42.


                                                                             18
·     Specifications 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
                                12volt(12V)
          Voltage                                                                             of coils and lead wires by heating takes place_ Further-
      1----------------- - - - - - - - - - - - - - - - - - - . - - - - - - - - - -
          Nominal Output 0.8 kW                                                               more, the battery will be remarkably dischanged;
      f - - - - - - - - - - - - - ----- ----.
          Direction of                                                                        making the motor doubly difficult in turning vigorous·
                                Clockwise, viewed from pinion side
          Rotation                                                                            Iy. I n this circumstances, it is recommended to crank
                                                                                              the engine for 10 seconds and then pause for 10 sec-
·     Trouble-shooting 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 fly-wheel 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
                                                                                          3.4 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 equip-
lights. 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 schematic.
contact 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 Indicator
tive 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_ Regulator
case 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
                                                  I
          · Engine defective (Excess revolution resistance)

                                              Starting Motor
                                                will not operate
          ·       Pole core screw loosened
          ·       Field coil grounded or layer insulation short cir-
                  cuited.                                                                                                 M-15
          ·     Armature coil grounded or layer insulation short
                circuited.
    (3)       Lights stay bright, but starting motor will not turn or                                               Fig. 43
                                                                                                                                         M-25
              turn slowly.
              ·   Contact of starting motor terminals defective.
                                                                                      ·     Specifications 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      M-15                 M-25
·     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.                                                       10.5 volt)        10.5 volt)
                                                                                                                        (10.5V)           (10.5V)
    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.



                                                                                 19
    4. Reference Chart

4.1 Engine
                                                                                                                                                     Maximum
 Parts                             Items                                   Specifications                           Standard Value                                                       Remarks
                                                                                                                                                      limit

                Cylinder head tightness         M-25               M9 x 1.25                                    43.4-46.99 ft.lbs.                                      When installing. apply a generous
                                              ~    ___._-+-__________ +-,(.::::6.:;:0_-.::::6.:;:5--"k",-g..;..:m:':")_ _-l                                             coat of engine oil onto the entire
                                                                                                                31.09-34.7 ft.lbs.                                      surface of each bolt.
                                                M-15               M8 x 1.25
   TI                                                                                                           (4.3-4.8 kg·m)
       '"
      Q)
   I
    C;;
   "0
    c
                ,:ylinder head surface distortion                                                               0.002 in below
                                                                                                                (O.05mm below)
                                                                                                                                                                                     L
      >         intake/exhaust valve seat thickness                45° 0.059 in. (1.5mm)                                                                                                0.059in. f7.5mm)
   U                                                                                                            0.0236-0.0314 in.
                                                                                                                (0.6-0.8 mm)
                Top clearance
I - - - f--.-----------                    - - - - - -..       --i_--.-----.---                            r----------+.---- r----.---------------l
                                                                                                                                                                       r-.-------.-----,
                                                                                                                                                                        050 oversize liner I D


                                              ~- -r-2.6~-i~1-~2~.:~79-in-.--=·i------------1-2-.-6-8--3--i~.--~6968~2.6976-;-;;-:--
                Standard ID

                                                         ..-
                                                M-15               (68.000-68.019mm),                                                               (68.15mm)           (68.500-68.519mm)
    C;;
    C           Piston clearance                M-25               2.8346-2.8354 in.                       I                                        2.8405 in.          2.8543-2.8550 in.
   ...J         (At piston skert)             ~ ___ f-~7~.00~-72.01!~mm)_L___                                                                       (72. 15mm)          (72.500-72.519mm)
    c;;
   TI
    C
                                                                                          !
                                                                                          I
  u
   >                                          ~-------     - -- --O.002'::O.003iin-.--(O:055-0.094mm) E side-
                                                M-15               0.0045-0.0060 in. (0. 115-0.154mrn) I side
                                              f - - - - - ..- -.-1-- ..... -. - -..-------. - .--------.-.-----.---.-
                                                M-25               0.0021-0.0037 in. (0.055-0.094mm) E side


                _ · Cle
                      ____ .___         _     ~~~_:~,045-00:;~IOTOl=m:' ~';d' __                                                                     _ __
                                                                                                                                                       ..   .. _ . .
                                                                                                                                                                        Height above block surface
                                                                                                                                                                        '0.00098 in. (~0.025mm)
                                                                                                                                                                        --_.__ ._-_.._--_ .... _-   -_ .. _---
                ';~andard     OD                                                                                                                                        Oversize 0.020 in. (O.5mm)
                                              f-------~-.---------

                                                M-15               2.677 in. (68mm)
                                              r----                                                 --.-
   c
            I                                   M-25               2.8346 in. (72mm)
   2
  .!!?
  c..           Piston-pin boss ID                                0.7874-0.7879 in.                                                                 0.7885 in.
                                                                  (20.000-20.013mm)                                                                 (20.03mml
                                                                                                               I nterference Clearance
                Piston·pin clearance                                                                           0.0004 in. 0.0004 in.
                                                                                                               (O.Ollmm) (O.Ollmm)
1 - - + - - - - - - - - _.... _ - - - -- -.-- --. --------.--                                                  ---------_ .. __ .    __. -.                       _. ..... _ ... -   _.__._.._...._- _. . _---
                Ring gap                                           (toP. 2nd)                                  0.0098-0.0158 in.                    0.0492 in.          0.5 oversize top ring surface should
                                                                                                                (0.25-0.40:-"m:,-m~)'--_-I (1.25mm)                     be 0.0079 in. (0.2mm) below
                                                                  (oil ring)                                   0.0078-0.0158 in.                                        piston side surface.
   Cl
   c                                                            I--:c,.-----.--.-. +-(:..::0.:..:.2:..:0c...-...=0c:....4:...:0:;..m"'m=..)_----1
                Top ring width                                     Keystone type
  a:
   c
  ~             2nd ring width                                    0.0574-0.0579 in.
                                                                                                                                                                                                   !~
                                                                                                               Ring groove clearance
  c::                                                             (1.458-1.470mm)                              0.0033-0.0044 in.                                               above 0.0079 in
                                                                                                               (0.085-0.112mm)                                                        (0.2mm) J~

                (~iI   ring                                       0.1565-0.1571 in.                            0.0008-0.0020 in.
                                                                  (3.975-3.99mm)                               (0.02-0.052mm)


  c             OD                                                0.7874-0.7878 in.
 c::
  c                                                               (20.002-20.011mm)
  2
  '"
 c::            Pin·to·bush clearance                                                                          0.0006-0.0015 in.                    0.0059 in.
                                                                                                               (0.014-0.038mm)                      (0.15mm)
                                                                                                        Maximum
 Parts                      I tems                          Specifications              Standard Value                            Remarks
                                                                                                          Limit
f - - - - - - - . - - - - - - - - - - - - - - - - - .. -.. -.----------.-.... -.-- -------.--.----------          -.--------------
          Smail end I D                              0.8661-0.8670 in.
                                                     (22.000-22.021mm)
                                                     (without bush)                                                                          ±0.00079in.
                                                                                                                                             (±0.02mmJ
               Small end width                      0.8582-0.8622 in.                                                         \
                                                    (21.8-21.9mm)
      -0
       o                                                                                                                      L ..... ,-..   Connecting
      a::      Large end I D                        1.5748-1.5756 in.                                                      - .r+,-" ~        rod
       Cl
                                                    (40.000-40.020mm)                                                                 ~4in_ (100m,"-~
       '"
       ~                                            (without bush)
                                                                                                                                         ±O. 00079 in.
       'g
        "      Large end width                      0.8582-0.8622 in.
                                                                                                                  ±0_00079 in.
                                                                                                                  (±0.02mmJ
                                                                                                                                         (±0.02mmJ
     u
                                                    (21.8-21.9mm)

               Rod torsion (see diagram)                                   0.0008 in. (0.02mm)      0.002 in.
                                                                                                                  When installing. apply a generous
                                                                                                    (0.05mm)
                                                                                                                  coat of·el1gine oil onto the entire
               Rod bolt torque                      M7 x 0.75              19.527 - 22.42 ft.lbs.                 surface of each bolt.
                                                                           (2.7-3.1 kg·m)
t---+------------------                           ~-------   ..----.----.--+_------------ ------- .---.-------.. - - - - - - - - 4
               ID                                   1.4568-1.4587 in.
                                                    (37.004-37.050mm)
                                                    (with metal)

     iii      Width                                 0.6248-0.6350 in.
     Q;
     :?:                                            (15.87-16.13mm)                                               Center thickness
                                                                                                                   0.0585-0.0590 in.
      '"
     .0.      OD                                    1.575 in. (40mm)                                                (1.485-1.498mm)
     -"'
    '"
    III
    U          Running clearance                                           0.0011-0.0036 in.        0.0059 in.
                                                                           (0.029-0.091 mm)         (0.15mm)

              Axial clearance                                              0.0078-0.0157 in.                      Crank arm-to-Iarge end clearance
                                                                           (O.2-0.4mm)
t--- --------- -.---------------                  _._-------_.. _------+------------                              ------.-----------l
              Crankshaftjurnal dia                  1.7296-1.730 in.
                                                    (43.934-43.95mm)       Running clearance        0.0059 in.

              Main bearing I D                      1.7316-1.7333 in.
                                                    (43.984-44.026mm)
                                                                          10.0013-0.0036 in.
                                                                           (0.034-0.092mm)
                                                                                                    (O.15mm)


                                                    (with metal)

              Crankshaft metal (2) width            0.7035-0.7138 in.
                                                    (17.87-18.13mm)
             i---.------
              Crankshaft jurnal dia.                1.7296-1.730in.
                                                    (43.934-43.95mm)       Running clearance

                                                                          1                         0.0059 in.
     Cl
    .§                                                                     0.0013-0.00417 in .
     III      Gear-side main bearing I D            1.7316-1.7338 in.                               (0.15mm)
     OJ                                                                    (O.034-0.106mm)
    CD                                              (43.984-44.04mm)
     '"
    .;0
    :?:
                                                    (with metal)
     .....
    ....
     III
              Crankshaft metal (1) width            0.7035-0.7138 in .
    .r:
     '"                                             (17.87-18.13mm)
    -'"
    '"
    u
     III
              Crankshaft metal (1) OD               1.8923-1.8933 in.
                                                    (48.066-48.091 mm)
             ~-------------------t---------------                         ----.. --------.-+---.-------- ------- ----.---------
              Crank-pin jurnal dia.                 1.455-1.4557 in.                                0.0047 in.    When installing. apply a generolls
                                                    (36.959-36.975mm)                               (O.12mm)      coat of engine oil onto the entire
                                                                                                                  surface of each bolt.
              Crankshaft side clearance                                    0.0059-0.0122in.
                                                                           (0_15-0.31mm)

              Crank bearing cap bolt (1) torque     M7 x 1.0               14.46-17.357 ft.lbs.
                                                                           (2-2.4 kg·m)



I             Crank bearing cap bolt (2) torque     M8 x 1.25              21.7-25.3 ft.lbs.
                                                                           (3-3.5 kg-m)




                                                                             21
Parts                      Items                             Specifications                                          Maximurn
                                                                                                    Standard Value                               Rt:marks
                                                                                                                       Limit
                                                                                                                                           .,,- .---- . - - - - - J




 -co
 .r::
        Cam bearing 10



        Cam ,haft diil.
                                                      1.299- 1.30 in.
                                                      133.000-33.025mm)

                                                      1.2966-1.2972 in.
                                                      132.934-32.950mm)
                                                                                             IRunning clearance
                                                                                              0.0020'~0.0036  in.
                                                                                              (0.05-0.091 rnrn)

                                                                                                                                                             1.0582 in.
 Ul                                                                                                                                                          (26. 88mm)
        Axi,,1 clearance                                                                      0.0028-0.0081 in.
 E
 co                                                                                           (0.07 --0.22mm)
 u
        Cam lift                                      0.1968 in. Iflmm)                                                           0.42831f1.
                                                                                                                                  (10.88mm)
        Corn   heig~.~ _____ ._. __.__ .. _._ .. _.....1.?5~~.~~ 12~.~~~.rn)+
        Number of teeth, crank gear                   25                                I
        Number of teeth, idle gear                    69

        Nurnber of teeth, cam gear                    50
                                                                                        I
                                                                                        I
 I--    backlash                                                                        I    0.002-0.005 in.         0.0118 in.
                                                                                             10.0415-0.1154rnm)      1O.3rnm)

        Shlnkage                                      0.0354-0.0433 in.
                                                      (O.9-1.1mrn)

        F 
 ro
>                                                     1.0787-1.0866 in.                I
                                                      i27.4 -21.611l1ll)

        Stt.:rn dia.                                  0.2740-0.2746 in.           ..   ~Ii
                                                      16.960-6.97~lrnm)


        Valve guide 10                                0.27tj9-0.2765 in.
                                                      (7.010-7.025rnm)

        Stern guide cl       Perpendicularity

        Spring pressure loss wilen installed     I

'0
        Over·all length                          I ~: ~).OOO ir'-'127mrn)              .1 . . . .
o                                                    B     4.b543~'4  810 i, ,.         1
a:
                                                           1123.3 ~ 123. 7mlll)


        Did.                                         0.19C8-0.204! in.
                                                     15- 5.2rnrn!
                                                                                        I
                                                         _ _ _ _ _ _ _ _ _ .<_ ...
                                                                                        I
                                                                                        l _________--'---____--'__


                                                                               22
    Parts                                  Items                                  Specifications                                                   Maximum
                                                                                                                       Standard Value                                                  Remarks
                                                                                                                                                     Limit
~---+------------------                                          --- ._--._ .. -- ... _.- -             _. - -- ._-.-
                        I ntake valve opened                                                                    At 20" BTDC

          OJ
          c             I ntake valve closed                                                                    At 45° ABDC
          E
         f-
          Q)
                        Exhaust valve opened                                                                    At 50° BBDC                                               Model         15     &   25
         ~
          co            Exhaust valve closed                                                                    At 15° ATDC
         >
                        Ignition process                                                                        1-2
                                                                                                                1--2-3

                        Injection timing
f - - - - - - - - - - - - - - - - . - - - - - - - - - - . - - - - - - - - -.. ----. - - - - - - . - -------
                        Trochoid tooth width                                                                   0.7866-0.7874 in.                                    Use Engine Oil CD (DS)
                                                                                                               ( 19.98-20.0mm)                                      Above 77°F (25"C). SAE 30

                                                                                                                                                                    Between 32°F-7T'F
                                                                                                                                                                    (O°C-25°C), SAE2ll

                        Outer rotor OD                                      1.5956-1.5968 in.                                                                       Below 32" F (0" C),
                                                                            (40.53-40.56mm)                                                                         SAE lOW, lOW·30
         Q.

          ~             Trochoid-to-body clearance                                                             0.0027-0.0059 in.
         Q.
                                                                                                               (O.070-0.150mm)


                        T rochoid-to-body side clearance                                                       0.0031-0.0051 in.
                                                                                                               (0.080-0. 130rnrn)

                        Oil pressure                                                                           64 psi (4.5 kgf/cm')

                        Pump capacity                                                                          3.65 gal./min.                                       '-levulu lio" 01 pump: :;000 rpm
                                                                      I                                        (13.8Q/min.)
1---                                                                      - - . - - - - - - - - - - - 1 - - . - - - . - - - . - - - - - - - - - - - - - - - - - t------ .-.-.-.   .. - .-.
  Q.
  E  Model                                                                    Model is                         NP-PFR2KD50/2NP3                                     Cam speed. 1500 rpm
         :J
     Q.
         C                                                                    Model 25                         NP-PFR3KD50/2NP4
         o
                        I nJection pressure                                                                    1990 psi. (140kqf/cm')
         u
         OJ
         C          Pump plunger dia.                                                                          0.1968 in. (5mm)
     li
         :l
     LL             Pump stroke                                                                                0.2756 in. (7mm)
---                ------------_._-----------                         - - - - - - - - - - - 1 - - - - - _ . _ - - - - - - - - -.-.. -.                        ---   -_._--- _.. _._- ---     --.- --- - ----
     §~
    .-         N
                    Model                                                                                      ND-DN12SD12
     -         N

    ·9i
     c z
        o           I njection pressure                                                                        1990-2133 psi.

~                  --   - - ------ -------.. ---_ .. _---   ..   _-                      (140-150kgf/cm' )
                                                                      ._-_._--_.-._-----1-----_._---_.  __ ._----
-        ~          Cooling system                                         Natural circulation                                                                      Wi lh pressurized rddidtor
     C/)
         >

         ~
         co
                    Radiator cap pressure                                                                      12.8 psi (0.9kgt/cm')
     3:                                                                                                        17.0 psi (1.2kUf/Ull')
         0;
         c
                    F dn bel t length                                      FM 30 in. (762mm)
     o
     o                                                  in perimeter
I-~u~.+-_.                _________ . _____.______ _ --"-_._---- . ---- --------------                       ----,_ .... - -   ---   - ---- -- -                                        _.-- --_. __ .. _-_._---

                    Model                                                  12V 45AH                                                                                 NS60

                    Electrolyte specific gravity, discharge                1.120
         >
     ~              Electrolyte specific gravity, charge
     ro
     co
                    Electrolyte specific gravity, over-                    1.30
                    discharge
~-_+--------------------                                              ----------- -.----.- - ------------------ -.-- t-.- .. -.- .. -'-'- - ... - ---.---'--' _._._- ------ --- ----.----
                    Voltaye                                                12V
         o
         E
         C1)
         c          Current                                                8.5A
         >
     o
                    Check interval                                         Every 1000 service
L_---1_ _ _ _ _ _ _ _ _ _ _ _ _ _ _......l..-.:.:h:::.o:::.u.:..:rs~_ _ _ _ _ _...L___ ._ _ _ _ _ _ __L_ _ _ _ _..L_ _ _ _ _ _ _ _ _ _ _ _ _..J


                                                                                                                23
                                         Specifications                                                           Maximum
  Parts               Items                                                                Standard Value                                              Remarks
                                                                                                                    Limit
 1----- ------------.--------------- .----- ------.---------                                                     ._-- --. - _._+-- -- - - ---- -- .- -        - ----------
        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

                                                         0_8kW                                                                       Nominal value
                                                                                                                 ---- ---------   --------.-.------------------
                                                                                       43.39-47_01 ft./bs_                           Apply a generous co~t of engine oil
                                                         M9   X_1_.~~_ ___ ____ . ___ (6_--:6.5~Qf.rn)                               orito the entire surfaces of all im-
                                                                                                                                     portan t set bol ts.
                                                                                       31.09-34.71 It-Ibs_
                                                         M8 x 1.25
                                                                                       (4.3-4.8 kg·m)


    
    cr                                                                                 (5.5-6 kg·ml
    (;
    I-
             Crankshaft main bearing set cap             M8 x 1.25                     21.10- 25.31 ft.l bs_
    0        bolts
    OJ                                                                                 (3-3.5 kgf·m)
    C
    ~        Crankshaft cap bolts                        M7 x 1                        14.47-17_36 ft.lbs.
    0
    0-                                                                                 (2-2.4 kgf-m)
    E
    -
             Rocker bracket set studs                    M7 x 1                        12_29-15.18 fUbs_
                                                                                       (1.7-2_1 kgf·m)

             Rod bolts                                   M7 x 0.75                     19.52-22.42 fUbs.
                                                                                       (2.7-3.1 kgf·m)
  ------~-             - ---- --.-------------.---. --.-.---.---.. -------.----f-------- .. -.--.-                                     -------_.-   --------------- - - - - - - -
             G!                                                  MlO                           35.4-41.2 ft.lbs.
     cr                                                                                                                              marks.
     (;                                                                                (4_9-5 7 kgf·m)
    I-

     o
    (J)
                                                         M8                            17.4'-20_3 fLlbs_
                                                                                       (2.4-2.8 kgl·m)

                                                         M6                            7_2-8.3 ft.lbs.
                                                                                       (1.0-1_15kgf·m)




           Bolt Torques


Bolt material qrnrip.s am shown by numbers punched on the bolt heads_
Prior to tightening. bp. sure to ,:heck au! the numbers as shown below:                                                                     ft·lbs. (kgf·m)


 "- M'lterial Grade            StAndard Bolt [NoneJ               Speciill Bolt [7J                            Special Bolt [9J
   , ...· , [Punctwrl                                      ____________ .__ .       _________________________ ._._. _____ .. _____________
           ' ...... No.] --.---------------------------- -       S43C, S48C (Refined)
Nominal Dia_ " ,                  SSI\ 1. S20C                                                             SCR3, SCM3 (Refined)

           M 6             5.8 -       6.9   ( 0.80 _.   0.95)         7.2 -     8.3         1.00 -      1.15)      9.0 -     10.5         ( 1.25-        1.45)

           M 8            13.0 -      15_2   ( 1.80 -    2_10)        17.4-    20.3          2.40-       2.80)    21.7 -      25.3         ( 3.00 -       3.50)

           M10            28.9 -      33.3   ( 4_00 -    4.60)       35.4 -    41.2          4.90 -      5.70)    44.8 -      52.1         ( 6.20 -       7.20)

           M12            46.3 -.     53.5   ( 6.40 -    7.1\0)      57.1 -    66_E;      ( 7.90 -       9.20)     75.9 -     86.8         (10_50 -·12_00)

           M14            79.6-       92.6   (11.00 - 12.80)         91.1-108.5           (12.60 -·1500)         123_0 - 144.7             (17.00"       20_00)

           M16           123.0- 141.0        (17.00 - 19:50)        144_7 - 166.4         (20.00 - 23.00)        191.7 - 224_2             (26.50 - 31.00)

           M18           180.8 - 209_8       (25_00 - 29.00)        202.5 - 235.1         (28.00 - 32.50)        253.2 - 296.5             (35.00 - 4 1.00)

           M20           245.9 - 289.3       (34_00 - 40.00)        271.2 - 318.2         (37.50 - 44.00)        361.6 - 419.5             (50_00 -- 58.00)




                                                                                24


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