Universal Diesel 5421 Technical Manual

UNIVERSAL DIESEL MODEL 15 25 EARLY MODELS 5411 5421SERVICE MANUAL PUBLICATION 200151 12Fuel System 34Lubrication System 5Oi 1 Fi 1ter 6Combustion System 7Valve Timing 8Compression Release 9Pistons and Rings 10Crankshaft 10Connecting Rod 11Cyl i nder Liner 12Cylinder Head 12Gear Train 13Cam Bearings 13Main Bearings 14Injection Pump 15Flywheel 16Wiring Diagram 17Starting Motor 1819Glow Plugs 19Reference Chart 2024 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 267 x 275 299 x 323 284 x 276 299 x 323 299 x 323 33 x 325 DISPLACEMENT CU IN 31 45 52 68 91 115 MAXIMUM RPM 3000 2800 3200 2800 2800 3000 COMPRESSION RATIO 221 211 221 211 211 211 TYPE Vertical water cooled 4cycle diesel engine ELECTRICAL EQUIPMENT 12 Volt 55 AMP Altermator Electric Starter and Glow Plus Mech Fuel Pump Fuel Pump Fuel Pump Mech Fuel Pump LUBRICATION Engine 22 Qts 37 Qts 4 Qts 56 Qts 11 5 Qts 85 Qts Use SAW 30 HD CD or IOVJ40 heavy duty diesel lubricating oil LUBRICATION Transmission Fill to full mark on dipstick Use automatic transmission fluid Type A Type F Std and VDrive and Dextron II TRANSMISSION REDUCTION 21 21 21 21 21 21 COOLING SYSTEM 7 PSI CAP Seawater Fresh Water Cooling System cooled 48 Qts 40 Qts 6 Qts 8 Qts 8 Qts 14 PSI 14 PSI 14 PSI 14 PSI 14 PSI SEA WATER INLET OUTLET 38 NPT EXHAUST FLANGE 114 NPT 114 NPT 114 NPT 114 NPT 112 NPT 112 NPT FUEL Diesel fuel number 2D FUEL INLET HOSE 516 ID FILTERS FUEL OIL 298854 298854 298854 298854 298854 298854 FILTERS LUBRICATION OIL 299381 298852 300209 298852 299584 299927 GOVERNOR Centrifugal type all speeds 150 0 F 190 F 190 0 F 190 0 F 190 0 F 190 F MAX OPERATING ANGLE 15 0 ALL ENGINE ROTATION Clockwise when viewed from VBelt end PROPELLER ROTATION Right Hand Both STD and VDrive ENGINE WEIGHT Pounds 245 365 285 425 490 545 LENGTH Overall 256276 VD 280 285305 VD 325 362 360N HEIGHT Overall 212 241 226 246 260 260 WIDTH Overall 207 207 192 207 207 214 INJECTION NOZZLE 299517 299517 299517 299517 299517 299517 INJECTION TIMING 25 0 before top dead center all models12 Construction and Handling 1 Fuel System Fuelfilter Fuel system The fuel filter is of the cartridge type shown schematically inFuel system is as shown in Fig 1 The fuel flows in the direc Fig 2 Under normal conditions it should only have to betion shown by arrow marks To bleed air trapped in the fuel replaced every 400 hours To install apply a small amount offirst loosen the vent plug A of the fuel filter Tighten the plug fuel to the racking and tighten seClJrely by hancl For rmovalwhen no more air bubbles are in the fuel which flows out from ttlC use of a filter wrenchthe vent Then proceed to the plug B of the fuel injectionpump and vent the system in the same manner as A 4 M15 5 1 Fuel filter 2 Cover 3 Pipe coupling 4 Vent plug 5 0 ring 6 0 ring 7 7 Element Fig 2 Fuel Filter Fuel injection timing Fuel injectiul timing is adjusted by changing the number of shims used between the pump arid the gear case it fits into See Fig 3 One shim corresponds to 15 degrees in crank anglf Tteretore injection will take place 15 degrees later when a shim IS added and 15 jegrees earlier when a shim 6 Nozzle holder is removed The timing is correct when the mark punched on 1 Fuel tank 2 Fuel cock 7 Overflow pipe the rear end jJlate lines up with the F 1 marked on the fly 3 Fuel filter A Vent plug filter wheel See Fil 4 4 Fuel injection pump 8 Fuel pump 5 Injection pipe Speed control lever Fig 1 Fuel System Control rack pin Injection timing adjust shims Fig 3 Adjustment of Injection Timing Fig 4 Inspection of Injection Timing 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 000004 in 11000 mm that they may easily be obstructed or rusted by even a slight amount of water if in the fuel Installing the injection pump When installing the injection pump make certain that the control rack pin is correctly placed in the 02 in 5mm wide groovp of the fork lever 1 before tightening the attaching bolts Refer to the diilqrilm If the bolts are draw Iown with the rack pin off the groove the rack may over travel and stick in this position This would cause excess fuel flow allowlrlg the engine to overspeed which would result in engine failure 11 114 j IS 16 r 171 18 g 10 21 22 1 Injection pump assy 14 Adjusting plate 2 Delivery valve holder 15 Control rack 3 Delivery valve spring 16 Pump housing 4 Delivery valve gasket 17 Control sleeve 5 Delivery valve 18 Upper spring sheet 6 Cylinder pump element 19 Plunger spring 7 Air bleeder screw 20 Lower spring sheet 8 Packing 21 Shim 9 Hollow screw 22 Tappet assy 10 Packing 23 Roller 11 Tappet guide pin 24 Roller pin 12 Clamp pin 13 Bolt Fig 5 Fuel Injection Pump 4 Fuel injection nozzle Spray pattern fhe fuel injection nOllie like the ILJf1 injection pump is llso The injerlion pressure and fuel spray pattern are most aca precision piece of equipment lnd should be treated with the curately checked by using a nozzle pressure tester If a nozzlesame amount 01 care pressure tester is not lvailable remove the nozzles from the engine leaving the pressure lines connected The injection pressureThe injection pressure is adjusted by adding or subtracting from the top of the nozzle spring Adding a 0004 in Hold the nozzles so that the high pressure spray from them01 mm shim will increase the injection pressure by about will not in any way impinge upon unprotected skin The147 psi 10 kglkm21 The injection iJressure is 1990 to 2133 atomized fuel will easily penetrate the skin and cause bloodpsi 140 to 150 kgfcm2 poisoning Set the speed control Irver It W O T and oppra1f the starter 6 1 19i The nepclle valve if it is working properly will produce a high 15 7 18 III pitched pulsating sound likr that of l Ilute ilS fuel is sprayed 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 41 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 435 t8 58 ftlb 6 to 8 kgfm 5 Nozzle holder body 11 Nozzle piece Any torque higher than this will cause slow action of the 6 Adjusting washer needle valve and poor injection Fig 6 Fuel Injection Nozzle 22 Lubrication System Good Bad Oil pump pickup screen The nil pump ricklip IS Ilrlted ill the crJnrilSe as shown in Fig9 and is fil1fd with mfill screen I f the screen becomes pluqCed wash it ofl with diesel fuel or kerosene Lubrication system The trochoid oil pump suck up lubricating oil through oil filter 4 and the oi I flows down to the fil ter cartridge where it is further 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 25 35 kgtcrn 2 From the filter one part of the lubricating oil will be fed through crank shaft passage to uank pin metal and the remAinder of oil will be fed through the frame to the rockpr arm shaft An oil pressure switch is provided for on the way fnl watching the oil pressure If the oil pressure falls 1 Nozzle spring 4 Nozzle body below 71 psi 05 kgf cm 2 ttl2am2 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 Plrts 5Probable cause of low oil pressurd1 Clearance on one of the bearings is to great2 One of the rocker arms is too loose3 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 rlf rjjr Safety valve Drain plug Pickup screen H i 11 II fLJlrF n 0 Fig 9 Detail of Oil Pump Pickup I lV L Ot 1 I I Construction of Oil Filter 1 ij 1 passage L0fr 1 I fOil pumpW J 1 Oil pump F Y pickup screen Rocker arm Rocker arm shaft Relief valve Fig 10 Oil Filter Construction of Relief Valvescreen Fig 8 Lubrication System Oil filter1 Replace the 011 filter at every other oil change every 150 1 Oil Filter Cartridge hours 2 Relief Valve Assy2 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 Body3 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 Valve1 Drilin iJnd rerlaee tlw ei1jine oil after the first 35 hrs of Cornbustion air of course is brought in through the intake oreration and every 75 hrs thereafWr valve when the descending piston creates a partial vacuum in2 The oil is easier to change if the engine is warm the cylinder3 Do not mix diffrent brands of oil If a different brand of Valve stem seals should be replaced whenever they are reo oil must he used drain the oil and replace with all one moved If the stern seal are replaced coat the stem liberally brand Also do not mix oils of different viscosities with oil before inserting in the valve guide to prevent burning the valve stem seal2 3 Combustion System J Combustion chamberThe enqinr Iitililes a swirl tyrf precombustion chamber Fig 12 Furl and air are mixed in this l 0 1chamber resllltinfJ in mon efficient combustion A gloW1llIgis employed to preheat the fuel for easy starts down to 5 F150 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 0276 to 0277 in 701 to 7025mm after installation The valve head must be recessed 5 0035 to 0043 in 09 to 11 mrn from the face of the cylin der head to prevent it from hitting the top of the piston 1 Nozzle holder 4 Cylinder head 2 Nozzle piece packing 5 Combustion chamber Jt1Z2639 7 027 05mm 3 Glow plug 027402746 in Fig 12 Combustion Chamber A Finished ID of gUide 1J 6n96n9751mm0 I installed in cylinder i I Iil II I h ead r J J i A rfrJJltlL j H J r r451 l n 09210929 in 10591067 in M15 1234236mm 1269271 mm t f 10781086 in 12161224in M25 L1274276mm 1309311mm Fig 14 Standard Dimensions of Valves Valve Guides Valve Gap 00350043in 0911mm Fig 15 Sinking of Valve 7 Valve timing Adjust bolt 2 14When the valve clearance has been adjusted as shown inFig 16 the standard valve timing shown in the chart can be Lock I 1 Valve clearance nut 1 0005700072 inattained V OI450185mm 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 00057 to 00072 in 0145 to O 185 mm with engine cold Rocker Arms 1043250433 in r I 11098711008mm I I 1t9 I WtN I lj I II I J 04330435 in 1099711038mm 1 043204324 in 1097310984mm I t tJU 043250433 in 1098711008mm 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 the parts as shown in Fig 18 Pull the lever out as position rfar as it will go check to see that the 55 angle is attainedand that compression is released The cornpression releaseis to be used when the battery is low or when starting in cold weather To use the compression release preheat the Iglowplug as usual pull the compression release knob out asfar as possible and hold it there while cranking the engineThis partially releases the engine compression enabling it toturn faster in cold weather or when the battery is low Oncethe engine is turning fast enough to start Ielease the lever andthe engine will startNOTE Make sure the compression release has returned to the operating position by pushing the knob all the way in Released 1 Rocker arm 5 Compression release nut I4 2 Oil filler cap 6 CompressIOn release bolt Operating 3 Compression release lever 7 Shaft 4 Adjustment access cover B Valve Fig 19 Adjustment of Compression Releasea Fig lB Compression Released Top Top clearance should be 00236 to 00314 in 06 to 08 mmDo not pull the compression release lever when the engine is To adjust use cylinder gasket shims 00078 in 020 mm thickrunning at high speed or under load If it is necessary to use each onto the head sidethe compression release while the engine is running reduce the For checking the measurement rlace il piExe of fuse on thespeed to idle before doing so piston top and fiX the cylindler head securfly on the cylinder Adjustment of compression release head flange The medsurernerll is taken bV tile fuse Tile liner isI Set exhaust valve in totally closed position level with the cylinder fldme at tvp surface2 Remove decornpression adjustment window cover from The gasket shims Ciln be reused so do nt lose thelli cylinder head cover Head3 Make valve clearance as 0 with use of decompression adjust bolt From this position turn the bolt further by I Top clearance 1 to 15 turns Decompression clearance will then be set 0023600314 in at 0030 to 0044 in 075 to 1 125mm which is the 0 60 Bmmj designed clearance4 After adjusting be sure to lock adjust bolt securely so that it will not unturn while engine is in service Piston5 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 924 Main Moving Parts Crankshaft and connecting rod Pitons and piston rings 1 The crankshaft is a heat treated steel alloy forging TheThe pistons and piston rings are shown in Fig25 If the crank pins are induction hardened for additional wearcylinder liners have been bored oversize oversize pistons resistance Crankshaft end play is 0006 to 0012 in 015and rings must be used The piston is made of high silicon to 031 mmAIAlloy and is cam ground The top compression ring is a 2 The crankpin bearings are aluminumchrome plated keystone type the second compression ring is When instill ling the connecting and undercut and the oi I control ring is of the a Clean both surfaces expansion type b Apply engine oil to the threads of the connecting rod B End gap of rings on poston in cvlinder capscrews before installing ahd tighten each to 195 to I Diameter of piston skirt thru t of piston pin bore 224 ftIbs 27 to 31 kgm E Diameter of piston skirt perpendicular to piston pin The bearing caps are matched to each connecting rod 00791 12mm and should not be interchanged Also since there are Fc5 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 JJO 100062 n I 3 In the event that the crankpiflS become worn and are no longer serviceable undersized bearings may be used l I 115551570mm 01580159 in 14 0 104 030mm When installing the undersize bearings observe the fol 0187407879 in lowing precautions a Machine the crankpin diameter and radii to within OJJJq2JlBn 8 1025045mm i a few thousandths of the correct dimensions and 0078m 199mm il i 1 lJ 0057400e79moJ I finish grind to the exact dimensions 114581470mm I r 0156601571 in r 8 Lr b After finish grinding the bearing diameter and the radii 139783 990mm ii chamfer the diameter of the oil hole with an oilstone OCXJ80016m J Ai L O 10200 40mm If this is not done an oil film will not form and the bearing will sieze Fig 25 Standard Dimensions of Piston c The crankpin should always be superfinished tor Standard 9 and Piston Rings Over si ze 0000016 in 00004 mm or less d Select the bearing from the chart that necessitates the removal of the least amount of metal from the crank 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 2677 in I 26968 in necting rod bearing cap and bearing as described in 168rnm I 1685m m 2671826726 in 2 6915269 23 in section 2 and measure the diameter anywhere within I 6786567885mm MODEL the 1200 angle indicated in Fig 27 and subtract the 836568 385rnm 6 E 2674226750 in 6792567945mm 2 6938269 46 in 6 842568 445mm 15 crankpin diameter from this figure 28346 in 28543 in f The piston pin bushings are of lead bronze 72mrn 725m m The inSide diameter of the bushinq should be finished I 282932830 in 2 8490284 98 in 7186571885mm MODEL to 07884 to 07890 in 20025 to 20040 mm 17 236572 385mT1 E 2831728325 in 2 8514285 22 25 7192571945mm 7 242572 445mm iors I Oer size I Name of Part Part Not Piston 05 002 in 05mm Piston ring 05 05 OS I I 002 in 05mm Cylinder iner Piston 05 Piston ring 05 269682697 rd 6iO68ok9mml M15 Cylinder liner 12JLR max to 2JLR max by honing I Piston 05 05 OS 002 in 05mm Piston ring 05 05 OS c 28542855 i n 72500072519mm M25 Cylinder liner 12JLR max to 2JLR max by honing If 01100126 in 2832mml Ml5 1455114557 in 3695936975mml I 1 urQ O 1100 126m 2B 32mmJ 1729717303 in 4393443950mml Fig 27 Crankpin for Undersize Bearing r 1734211368 m 01040714 in 4405044 I 15mml 17871813mml r 18924 18933 m LtJ 480664809Imml t 0 c AI t t 0868008690 m czrm 0866108670 m 22ooo2202Imml l 01884 0 7890 in 2002520040ml 0787507878 m 200022001Imml 06250635 m fl5871613mml 1455114557 in 36959 36975mml rDfll 157485756 in 4000040020mml hltilJJO j 0058500590 in I4851498m1 lA Diameter of piston pin bushing after installation i I J 1729717303 in Fig 28 Standard Dimensions of Connecting Rod rrrn 43934 43950mml Bearing and Bushing 1734217368 m 07040714 in 4405044 115mml I 17871813mml Um i I t 00780079ill 19702ooomml Fig 26 Standard Dimensions of Crankshaft and Bearingsrr r Running Clearance Metal Size Part No Bearing Crankpin Diam in Mark mm114 0007874 in 1447214478 in 02 undersize 02 US 020mm 3675936 775mm 00011000358 in11 00290091 mm 0015748in 143931440 in 04 undersize 04 US 040mm 3655936S75mm J 11 Boring and replacing the cylinder linerReferrinq to Fig21 the inside diameter of the liner shouldbe checked at points 12 and 3 and In thp cJirertions a andb Thp liner on whieh thcNear has pxcpcdrd the sprVICp limitcan bp iJored ilnd honed to 0020 in 050mm OVprsilfThe finished dimensions are 2677 to 26779 in 68000 to68019mml for Model 15 and 2834 to 2835 in72000 to 72019mm for Model 25 An and rings must then be used with thi5 liner Once thisoversized liner has exceeded its wear lifnit it should be reo 106 2 3 0 7 11placed With a new one To install a new liner coat the outside OOO 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 pistonmust again be used 13 0 5 4 0 12 l 9 1 8 li Fig 22 Tightening of Cylinder Head Bolts r IJi c stjHCj SIIe T C Over sizp 1 I 260f8 2 m6 11 X1S 28542853 in M25 17250072510nml Fig 21 Standard Dimensions of Cylinder Liner and Liner Bore in Block Tightening cylinder head capscrews Fig221 I The tightening torque of the cylinder head eapscrews is 31 0 15 ftliJs 43 to 48 kgml for Model 15 imd 43 to 4 j ftlbs 60 to t5 kgITd for Model 25 Numbers 9 10 and 11 13 t in the diagram are studs 1 he nuts on these studs sholdd also be tightened to th is torell Ie2 All thi diS rrws 111111 ill tlyhtll1fd lI1iflrl11ly TI do ths tllhlC11 all The cilliscrews In thr urdrr il1dCilTed on the cJlaHillli until thev arc Just snuq Then tl1hT11 Jeh one 1 one turn at a time III thiS same snqurnce pach tine ulltll all haliP been tightened to trw IIlU1rrcj trque3 The rylillder head CiJPscrews shoulej lw rrtlghtencd if the pnqine hilS nlt been uspd for d Innq timE Thn valvi lash sholJld als0 be adJuswd each tlmc the cylinder head capser ews arE retorquccJ Jf 2ey i noer head qasket has betrf2rcLnJfl tngl ne forYQi2tts cJ l gtll tnyl f2QegilS2rew21 bv 1225 Main Components Camshaft and camshaft bearings Gear train Standard dimensions are shown in Fig 31 Camshaft runningBe sure to assemble the gears by matching the mating marks clearance is 0002 to 00036 in 005 to 0091 mmas shown in Fig 2Q The backlash of each gear is 000163 to000454 in 00415 to 01154 mm nr tflj Ui J t11fjrll1nl l r4 1 29662972 in l 1329343295Omml 29923002 in 13300033025mml IDfwfmlJI 7J7nzlLr7 rTm J 1 Crankshaft gear 4 Camshaft gear L J t 2 Oil pump drive gear 5 Fuel injection pump drive 29662972 in 13293432950mml 3 Idle gear gear 29923002 in 13300033025mml Fig 29 Mating Marks of Gear Train L Crankshaft gearHeat to about 176 F 80 0 C and sl idp on crankshaft I f theshaft and bore dimensions are such that the gpar will not slideeasily it may be heated to a slightly higher temperaturefor installation Fig 31 Standard Dimensions of Camshaft Camshaft gear and to Fig 30 place retainer plate 3 on camshaft 2first Make certain the clearance of the retainer plate to thecamshaft end is made 0003 to 0009 in 007 to 022mmWhen camshaft gear 1 is in place Then heat the camshaftgear to about 176F BOC and push into place If the interference should be excessive and there are fears that the shaftwould be damaged raise the heating temperature further tomake the gear softer allowing an easier fit a CD ev L r 0OO30009in 007022mm 1 Camshaft gear 4 Circlip 2 Camshaft 5 Pin plug 3 Camshaft retainer plate 6 Key Fig 30 Assembly of Camshaft Gear with Camshaft Main bearing assy Main bearing housingInsert the bearings in the main bearing housing halves as in Installation of crankshaft with main bearings in engine blockdicated in Figs 32 33 using the thrust washers only on the Slide the crankshaft assembly into the engine block beingjournal nearpst the flywheel Coat the crankshaft journals and careful not to nick or scrape the crankpins After the assemblythe bearing surfaces with engine oil place the housing halves is in position make sure the oil passages are correctly lined upwith bearings on the cran kshaft coat the capscrew threads Install the main bearing housing to engine block lockingwith engine oil and tighten to 145 to 175 ftIbs 2 to 24 kgm capscrew and washer from the side to position the housing andM7 then install capcew 2 from the bCttom and torque to 21 to 25 ftIbs 3 to 35 kgm M8 1 Bearing 2 Capscrew 3 Locking tab 4 Main bearing housing 5 Cap screw 6 Locking tab 7 Locking tab Fig 33 Main Bearing Housing 2 1 Bearing Main Bearing Housing 3 2 Thrust washer 3 Thrust washer 4 Crankshaft journal 5 Main bearing 6 Cap screw 7 Locking tab Fig 32 Main Bearing Housing 1 with B Locking tab Thrust Washers Main bearing housing 1 D 4408344089 in d M15 25 4388743893 in 1889718904 in Milin bearing housing 2 4800048016mml M25 f 4369043696 in Main beiJring hOllsinq 3 M15 25 14 Hydraulic oil pump drive unit NOT AVAILABLE Injection pump as shown in Fig 34 InjACtion pump camshaft Fig 36 Install the bearings and governor unit on the camshaft and install in the engine block Hour Meter Unit Fig 36 Insert the tang on the end of the hour meter drive shaft into the slot on the end of the injection pump camshaft and install as per the illustration Structure of Fuel Cam Shaft1 Oil pump2 Injection pump camshaft3 Engine block Fig 34 Hvdraulic Oil Pump Drive Unit Idler gearSecure the idler gear shaft to the engine hlock with 3 capscrews torque to 723 to 832 ftlbs 1 to 115 kgm land bendtabs of tab washer Install gear as shown make sure it runsfreely has a running clearance of 00006 to 00018 in 0016to 0045mml and 0008 to 0020 in 020 to 051mm endplay 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 pumpfresh waterClean the entire contact surface carefully Coat the contact To install the coolinq fan pulley on the pump securely tightensurface with engine oil wash all the oil off with gasoline and the nut 4 to 506 to 579 ftibs 7 to 8 kgf mtorquedry it throughly Put the flywheel on and torque the capscrewsto 40 to 4338 ftIbs 55 to 6 kgmi Bend the locking tabs Model 25back on the washers Tensioning of fan beltThe fan belt tension is adjusted by moving the tension pulley 1 Pulleybracket in or out The belt is properly tensioned when the 2 Bearingbelt deflection midway between the tension pulley and the 3 Keycrankshaft pullev is 025 to 035 in 7 to 9mm with a force 4 Nutof 20 Ills apIJlied Proper belt tension is essential for good 5 Bodyengine cooling and belt life See Fig 37 6 Shaft 7 Rotator P Jl Fan pulley Tension pulley y 8 Case 9 Seal Fig 38 Water Pump I 025 to 035in 7 to 9mm II Fan drive pulley Fig 37 Fan Belt Tensioning Radiator1 Rust inhibitor and antifreeze should be used in accord arlce wierl llw in the related manuals2 Be sure to remove all debris that may b IJlugging the fins3 Check th rubber shock mount nuts periodically to be sure thIN are tight 16 ENGINE CONNECTIONS Universal Diesel PANEL CONNECTIONS I I I 3qL 2 CYL I Connect to ACC term on switch J i r t 1T 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 CDW 33 Starting MotorThe starting motor employed in this engine is of the roller 1 Drive End Frame 13 Over Running Clutchclutch type starter in which magnetic force operates the 2 End Frame Cap 14 Yokelever thereby pushing the drive pinion in the ring gear This 3 Bush 15 Set Boltis 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 iij 8 9 10 Armatur Insulater Plate Insulater Washer 20 Brush Spring 21 End Frame 22 Bush j 1 11 12 External Circlip Collar 23 Through Bolt 24 Plain Washer 25 Packing 26 Return Spring 27 Spring Holder 28 End Frame Cap JJJ 1 Fig 41 6000 136 723 10 5000 70 981 10 109519 8 4000 08 785 08 082 434 6 3000 116f 588 06 054 289 4 2000 704 392 04 027 145 2 1000 7021 e 96 02 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 12volt12V Voltage of coils and lead wires by heating takes place Further 1 Nominal Output 08 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 for starting motor onds one after the other In case starting motor turns extremely slow or does not 4 In case the pinion gear will not engage with the ring operate at all the causes may be attributed to the follow gear on the flywheel and the motor makes racing ings causing wear out on the tip of pinion gear adjust the Defective battery advance position of the pinion gear Defective wiring Defective starting motor 34 Glow PlugsThe easy method to determine whether the starting motoror some other component is at fault is to turn on the head The glow plug is sheath type one and each cylinder is equiplights That is turn on the headlights while engine is ped with one glow plug in parallel wiring for which isstopped I f the I ights stay dark the battery is defective or shown in the of wiring and terminals is defective Of course onthe condition that headlights air unit is functioning pro 1 Glow Plugperly I n case the battery is barely operative due to defec 2 Glow Plug Indicatortive charging system be sure to cleare up the cause and 3 Key Switch Dremove it otherwise same troubles will not be ceased In 4 Regulatorcase 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 Starter2 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 M15 Armature coil grounded or layer insulation short circuited 3 Lights stay bright but starting motor will not turn or Fig 43 M25 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 M15 M25 Precautions in handling starting motor Quantity 2 31 I n installing starting motor it should be securely fixed 7 amp 7A 7 amp 7A by tightening with close contact other wise pinion gear approx after approx after Voltage Current will not engage with the ring gear properly thereby 30 seconds at 30 seconds at per one plug causing breakage of the pinion gear and rear end plate 105 volt 105 volt 105V 105V Sometimes starting motor will not operate2 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 Chart41 Engine Maximum Parts Items Specifications Standard Value Remarks limit Cylinder head tightness M25 M9 x 125 4344699 ftlbs When installing apply a generous 6065kgm l coat of engine oil onto the entire 3109347 ftlbs surface of each bolt M15 M8 x 125 TI 4348 kgm Q I C 0 c ylinder head surface distortion 0002 in below O05mm below L intakeexhaust valve seat thickness 45 0059 in 15mm 0059in f75mm U 0023600314 in 0608 mm Top clearanceI f i r rl r 050 oversize liner I D Standard ID M15 6800068019mm 6815mm 6850068519mm C C Piston clearance M25 2834628354 in I 28405 in 2854328550 in J At piston skert f7007201mmL 72 15mm 7250072519mm c TI C I u E side M15 0004500060 in 0 1150154mrn I side f 1 M25 0002100037 in 00550094mm E side Cle 04500IOTOlm d Height above block surface 000098 in 0025mm andard OD Oversize 0020 in O5mm f M15 2677 in 68mm r c I M25 28346 in 72mm 2 c Pistonpin boss ID 0787407879 in 07885 in 2000020013mm 2003mml I nterference Clearance Pistonpin clearance 00004 in 00004 in OOllmm OOllmm1 Ring gap toP 2nd 0009800158 in 00492 in 05 oversize top ring surface should 025040mmI 125mm be 00079 in 02mm below oil ring 0007800158 in piston side surface Cl c Ic 020c0c40mm1 Top ring width Keystone type a c 2nd ring width 0057400579 in Ring groove clearance c 14581470mm 0003300044 in above 00079 in 00850112mm 02mm J iI ring 0156501571 in 0000800020 in 3975399mm 0020052mm c OD 0787407878 in c c 2000220011mm 2 c Pintobush clearance 0000600015 in 00059 in 00140038mm 015mm Maximum Parts I tems Specifications Standard Value Remarks Limitf Smail end I D 0866108670 in 2200022021mm without bush 000079in 002mmJ Small end width 0858208622 in 218219mm 0 o L Connecting a Large end I D 1574815756 in r rod Cl 4000040020mm 4in 100m without bush O 00079 in g Large end width 0858208622 in 000079 in 002mmJ 002mmJ u 218219mm Rod torsion see diagram 00008 in 002mm 0002 in When installing apply a generous 005mm coat ofel1gine oil onto the entire Rod bolt torque M7 x 075 19527 2242 ftlbs surface of each bolt 2731 kgmt 4 ID 1456814587 in 3700437050mm with metal iii Width 0624806350 in Q 15871613mm Center thickness 0058500590 in 0 OD 1575 in 40mm 14851498mm III U Running clearance 0001100036 in 00059 in 00290091 mm 015mm Axial clearance 0007800157 in Crank armtoIarge end clearance O204mmt l dia 172961730 in 439344395mm Running clearance 00059 in Main bearing I D 1731617333 in 4398444026mm 10001300036 in 00340092mm O15mm with metal Crankshaft metal 2 width 0703507138 in 17871813mm i Crankshaft jurnal dia 172961730in 439344395mm Running clearance 1 00059 in Cl 00013000417 in III Gearside main bearing I D 1731617338 in 015mm OJ O0340106mm CD 439844404mm 0 with metal III Crankshaft metal 1 width 0703507138 in r 17871813mm u III Crankshaft metal 1 OD 1892318933 in 4806648091 mm t Crankpin jurnal dia 145514557 in 00047 in When installing apply a generolls 3695936975mm O12mm coat of engine oil onto the entire surface of each bolt Crankshaft side clearance 0005900122in 015031mm Crank bearing cap bolt 1 torque M7 x 10 144617357 ftlbs 224 kgmI Crank bearing cap bolt 2 torque M8 x 125 217253 ftlbs 335 kgm 21Parts Items Specifications Maximurn Standard Value Rtmarks Limit J co r Cam bearing 10 Cam haft diil 1299 130 in 13300033025mm 1296612972 in 13293432950mm IRunning clearance 0002000036 in 0050091 rnrn 10582 in Ul 26 88mm Axi1 clearance 0002800081 in E co 007 022mm u Cam lift 01968 in Iflmm 042831f1 1088mm Corn heig 15 12rn Number of teeth crank gear 25 I Number of teeth idle gear 69 Nurnber of teeth cam gear 50 I I I backlash I 00020005 in 00118 in 10041501154rnm 1O3rnm Shlnkage 0035400433 in O911mrn F Jee angle 45 Valve quide Ire should be rilrneej after inserted into cylinder head I ntake bore IM15 10601067 in 269 27 1mr j t2 1216512244 in 30931 1n1 m Exhaust bore 0921209291 in 1 123423jlTlrn J Ql ro 1078710866 in I i274 21611l1ll Sttrn dia 0274002746 in Ii 16960697lrnm Valve guide 10 027tj902765 in 70107025rnm Stern guide clearance 000137000256 in O0350065rnm Valve clearance 0005700072 in Wien culd 01t150105rnlTl Free length 1381914016 in 351 356mm OJca Spring pressure 1654Ibs12201 inQl 175 kg3099rnm2co Spring pressure loss wilen installed I0 Overall length I OOO ir127mrn 1 o B 4b5434 810 i 1a 11233 123 7mlll Did 019C80204 in 15 52rnrn 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 12 123 Injection timingf Trochoid tooth width 0786607874 in Use Engine Oil CD DS 1998200mm Above 77F 25C SAE 30 Between 32F7TF OC25C SAE2ll Outer rotor OD 1595615968 in Below 32 F 0 C 40534056mm SAE lOW lOW30 Q Trochoidtobody clearance 0002700059 in Q O0700150mm T rochoidtobody side clearance 0003100051 in 00800 130rnrn Oil pressure 64 psi 45 kgfcm Pump capacity 365 galmin levulu lio 01 pump 000 rpm I 138Qmin1 1 t Q E Model Model is NPPFR2KD502NP3 Cam speed 1500 rpm J Q C Model 25 NPPFR3KD502NP4 o I nJection pressure 1990 psi 140kqfcm u OJ C Pump plunger dia 01968 in 5mm li l LL Pump stroke 02756 in 7mm 1 N Model NDDN12SD12 N 9i c z o I njection pressure 19902133 psi 140150kgfcm 1 Cooling system Natural circulation Wi lh pressurized rddidtor C co Radiator cap pressure 128 psi 09kgtcm 3 170 psi 12kUfUll 0 c F dn bel t length FM 30 in 762mm o o in perimeterIu Model 12V 45AH NS60 Electrolyte specific gravity discharge 1120 Electrolyte specific gravity charge ro co Electrolyte specific gravity over 130 discharge t Voltaye 12V o E C1 c Current 85A o Check interval Every 1000 serviceL1 lhours 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 08kW Nominal value 43394701 ftbs Apply a generous cot of engine oil M9 X1 665Qfrn orito the entire surfaces of all im portan t set bol ts 31093471 ItIbs M8 x 125 4348 kgm Il Flywheel fixing bolts Ml0 x 125 404338 ftlbs cr 556 kgml I Crankshaft main bearing set cap M8 x 125 2110 2531 ftl bs 0 bolts OJ 335 kgfm C Crankshaft cap bolts M7 x 1 14471736 ftlbs 0 0 224 kgfm E Rocker bracket set studs M7 x 1 12291518 fUbs 1721 kgfm Rod bolts M7 x 075 19522242 fUbs 2731 kgfm f Glleral st bolts and studs M12 571665 frlbs All these torques are applied to 7992 kglm those S43C bolts and studs which Il have relief number 7 or punch MlO 354412 ftlbs cr marks 495 7 kgfm I o J M8 174203 fLlbs 2428 kglm M6 7283 ftlbs 10115kgfm Bolt TorquesBolt material qrnrips am shown by numbers punched on the bolt headsPrior to tightening bp sure to heck au the numbers as shown below ftlbs kgfm Mlterial Grade StAndard Bolt NoneJ Speciill Bolt 7J Special Bolt 9J Punctwrl No S43C S48C RefinedNominal Dia SSI 1 S20C SCR3 SCM3 Refined M 6 58 69 080 095 72 83 100 115 90 105 125 145 M 8 130 152 180 210 174 203 240 280 217 253 300 350 M10 289 333 400 460 354 412 490 570 448 521 620 720 M12 463 535 640 710 571 66E 790 920 759 868 1050 1200 M14 796 926 1100 1280 9111085 1260 1500 1230 1447 1700 2000 M16 1230 1410 1700 1950 1447 1664 2000 2300 1917 2242 2650 3100 M18 1808 2098 2500 2900 2025 2351 2800 3250 2532 2965 3500 4 100 M20 2459 2893 3400 4000 2712 3182 3750 4400 3616 4195 5000 5800 24