Universal Diesel 5424 Technical Manual
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Bolt material grades are shown by numbers punched on the bolt heads Prior to tlghtenong be sure to check out the numbers as shown below Punched Number Bolt Material Grade None Standard Bolts 5541 520C f7 Special Bolts 543C S48C Refined1 9 Special Bolts SCM 3 seR 3 Refinedl 26 I Maximum Par Items I Specifications Standard Value Remarks 1 limit Number of teeth pinion Number of teeth 89 rIng gear Insulation resistance No failure at 500MV Check interval Every 1000 Insulation resistance tn service hours Output n 16 HP Nominal value 08kW n267 24HP D 10kW Hpad set bolt and nut Ml0x 125 542579ft Ibs Apply a generous coat of 75 8 kgfmengme oil onto the entire surfaces of all important Flywheel set bolts set bolts QJ 723 796 fUbs M12 x 125 10 11 kgfmcr ICrankshaft main bearing Ml0 x 125 470506 fUbs 0 set cap bolts 65 7 kgf267mco C Crankshaft cap bolts M8 125 217 253 fUbs 0 a 30 35 kgf267mE Rocker bracket set studs M8 125 174 203 ftlbs 24 28 kgfmRod bolts M8 1 268 304 fUbs 37 42 kgf267m Gpneral set bolts M12 571 665 ftlbs All these torques are applied to and studs 79 92 kgfmthose S45C bolts and studs which have relief number 7 or QJ MlO 354412 ftlbs punch marks 49 57 kgfmcr 0 0 IM8 174 203 ftlbs 5 24 28 kgf267mCD M6 72 83 fUbs 10115 kgf267mBolt Torques fUbs kgfm Grade Standard Bolt Special Bolt Special Bolt i 225 l Nominal SS41 S20C S43C S48C RefinedSCR3 M6 5869 10 BO 0957283 100 1 1590105 125145 225 M8 130152 180210174203 1240280217 253 300 350Ml0 289333 400460354412 4905701 448521 620720 M12 463 535 640740571665 790920759868 10501200 225 M14 796 926 17002000 225 225 M16 1230 1410 1700 19501 1447 166 4 2000 23001917 2242 2650 3100 225 r M18 18082098 25 00 29002025 1 2800 32502532 2965 3500 4100 225 2712 3182 3750 44003616 4195 5000 58001 M20 ur p225225225225 2459 289 3 3400 Spec if ications Standard Value Maimum Remarks Items Limit Cooling system With pressurized radiator Natural circulation corrugated I 16 24 HP torceo circulation Water pump Z751BW Centrifugal pump and DHll0lBI with thermostat impelled Gear case to impeller 002320437 in Water temperature BOoC clearance 059 111 mml Total lift flow rate Z751BW Packing thicknessE and DHll0lB264 Gallonmin 100Qminor more C Impeller dia iO Z751BW and DHll01BI 26342642 in C 669671mml Pump speed 34503550 rpm SO 0 0 1796203260F w Thermostat actuation No pump for Z751B and ZB51B temperature B2260C 95260CI Z751BWand cap pressure 12B psi 09kgcm2 Fan belt length HM 4055in 1030mml n perimeter 16 24 HP HM 4150in 1054mml in perimeter Model 16 HP NS70 dry 16 HP D 12V70AH 24 HP 24 HP N70Z dry 12VBOAH Electrolyte specific 2i gravity discharge 1 120 iii CD Electrolyte specific 12BO gravity charge 6BoF specific 130 gravity overdischarge Voltage 12V Alternator Current 20A 0 Check interval Every 1000 service Insulation resistance E hours c 0 Brush spring pressure 12B pSi09kgcm2261 15 I nsulation resistance No failure at 500MV 0 Constant voltage 13B 14BV iii C Current lOA II 01 Cutin voltage 125135V 9 0 24AdobeUCS 16 HP 24 HP CI E CI 6 Trochoid tooth width Outer rotor OD clearance side clearance Oil pressure Pump caparity U 16 H P 05866 05874in 1490 1492mm24 HP 08622 08630in 49965000mml o 0035 0063 in 009 016 mmo 0039 0059 in 010015 mm6471 psi 45 5 kgfcml 16 HpD 42 Galonmin 16243imin253 24 HP 58 Gallonmin 22243iminl Use Engine Oil CD oSAbove 77260F 25260CSAE30 260 260 260 Between 32 F 77 F 0 C25260CBelow 32260F OoCI SAElOW 10W26730 16 HP B At pump 2116 rpm I 24 H P At pump 2000 rpm 267267111 i a E Cl c o u C Model I nleC ion pressure Pump plunger dia Pump stroke Pump discharge 1990 psi 140kgcm102165 in55mm AdobeUCSParts Items Specifications Standard Maximum limit Remarks Number of teeth crank gear 34 Number of teeth Idel gear 79 Number of teeth cam gear 68 Nllmber of teeth Inwction pump gear 68 Number of teeth at pump drive gear 45 Backlash o 0016300454 in 00118 in to OJ Ci Ul Q iii ShlOkage Face angle I ntake bore Exhaust bore Stem dia Valveguide IQ Stem guide clearance clearance Free length Spring pressure Spring pressure loss when installed 00433 00551 in in t329 33 1 mm1059110669 in 269 271 mm03134in t7 9607 975mm031563161 in in 417 422 mm00016in 004 mmQ00710087 in t018 022 mm2646 Ibsl 3839in 12kg35 15 mm3 15 Valve gUide bore s1ouJd be reamed after inserted into cylinder head When cold Load and length when installed Overall length Dia A 5984 in 152 mmB 5818958346 in 14781482 mm02323in 5961 Specifications Standard Value Maximum Lomit Remarks ID 17327 17345 in OJ 2 c a c U 1 0 C c VJ E u Width 00 Runnmg clearance Axial clearance 4401 44056mml with metal07429 07531 in 18871913mml 1 85 in 47 mml 00014 00038 in 0035 0097 mml 00157 00236in 04 06 mml 00079in 02 mml Center thickness 00583 00589 in 1482 1495 mml Crank arm267 to267 large end clearance 1 jurnal dia Main berlng ID Crankshaft metal 21 Width 20441 2 0449 in 519215194mml 20465 20483 in metal07429 07531 in 1887 1913 mml I Running clearance 0001600041 in 004 0104mml 00079 in 02 mml 1 Crankshaft jurnal da GearSlde main bearing ID CrankShaft metal 1 I Width Crankshaft metal 11 OD 20449 20449 in 51921 5194mm20465 20488 in 5198 52039mmwith metal07823 07925 in 22474 in 57111 57084mml I Running clearance jo 0016 00046 in 004 0118 mml 00079 in 02 mml fCrankpln jurnal dia 17307 17313 in 43959 43975mml Crankshaft Side clearance hearing cap bolt 11 torque Crank bearing car holt 21 torque M 8 x 125 M 10 x 125 00059 00122 in 015031 mml 21 7 283 tUbs 3 35 kgml 470 506ft Ibs 65 7 kgrn00047in When installing apply a generous 0 12 mml coat of engine oil onto the entire su rface of each bolt 1 1 Cam bearing I D Cam shaft dia Ax ial clearance Cam 11ft height 1 574815758 in 40 00040 025mm157221 5728 inl 3993439 950mm02165 In 55mm1 3134 in 3336 mm1 Running clearance 00020 00036 in 10050091 mml 0002800087 in 007 022 mm2107677 in 95 f I 13134 in I 3336 mm05457ik I 1386 Chart Engine Parts Specifications Standard Value Maximum Remarks Items limit Cylinder head tightness Ml0 x 125 542 579 fUbs When installing apply a generous i 75 8 kg267mcoat of engine oil onto the entire II J Cylinder head surface distort inn 0002 in below surface of each bolt 005mm below I 0 45260 0059 in 15mm Intakeehaust valve seat thickness 00276 00354 in U Y4S Top clearance 07 09 mmO059in 15mm15416 050 oversize liner 10 Standard 10 5424 29921 29929 in 29980 in i Piston clearance 15416 0002626700041 in E side 0 5424 c At piston skert00056 00071 in Q141 O 180mmI side U Height above block surface Type Dry 261 000098 in 261 0025 mmStandard 00 15416 5424 29921 in 76mmOversize 0020 in 05 mmc Piston267pin boss 10 o 9U55 09060 in 09071 in B 23000 23013 mm2304 mm a interference Clearance Piston267pin clearance 00004 in 00004 in OOllmm0011 mm Ring gap toP 2nd00118 00178in 00492 in 05 oversize top ring surface should oil ring 125mmbe 00079 in 02 mmbelow 00098 00158in piston side surface Top ring width Keystone type 025 045mmc a c 2nd ring width 00768 00772in Ring groove clearance 0 195 1962mm00037 00047 in above 00079 in J a 0093 0120mml Oil ring 01960 0 1965in O2mmJ 4978 499 mm00008 00020 in 002 0052 mmc 00 09056 09059in a 2300223011mmc 0 0000600015 in 00059 in clearance a 0014 0038 mm015mmSmall end 10 10236 10244 in Pin 2600026021 mm without bushSmall end width 1 0236 in 26 mm0 t Conino 0 18504 18512 in a Large end 10 J rod 4in 100mm247 u without bush II c OOOO79m 261O02mmc Large end width 10079 10118 in a 261O02mmu 256 257 mmRod torsion 00008 in 0002in When installing apply a generous see diagram002 mm005 mmcoat of engine oil onto the entire Rod bolt torque M8 1 26763038 surface of each bolt ftlbs 37 42 Q en 255Jco I255 Qw ENGINE CONNECTIONS 3 ClL 0 ttr 2 CYl 1 I Diesel PANEL CONNECTIONS I Connect to ACC term on switch i 225 GLOW I PLUGS FUEL PUMP I 225 L L I Blue OIL TEMP FEMALEl SENDER SENDER Z zz Z Z Z Z Z Z Z Z Z ZZ Z ZZ ZZ zz 11 01 AdobeUCS225 Glow plug specifications Code No Number Vol tilfJP rw refl t 16 HP 298795 ArprOXIPlately 65 amp l105 V 225 Glow plug controller specifications 16 HP Code No 299839 Current 13A 225 Precautions in handling the glow plug J 24 HP r I 3 j 24 HP 299839 20A 1USf the glow plugs only with Universal glow plug controller If any other type is used the heating time will not match that of the glow plugs and cause hard starting and various other problems 2As the glow plugs are ill rarallel thlcontroller heating element will tllrn red even if one of the rlugs is bad However the time it for the controller heating etement to get hot is less which will cause the element to bllrn out 3Rerlilcinq a faulty glow plug may not solve all the system prohlems Should thf failed rlug indicate problems in other areas beside the pili they should be checked out iilvThe fl10st probablf are improper fuel inJcction tilTllflq bad nOllie wrong fuel incorrect circuit con255nection gas Ifak etc 18AdobeUCS225 Starter specifications 16 HP 24 HP Code No 298783 298876 Type Solenoid ilctuilted with overruning clutch f Nominal 12V voltage Nominal 08 kW 10 kW output Direction of Clockwise viewed from rotation pinion end 225 Trouble shooting If the battery turns extremely slow or not at all the cause may lie in the battery wiring or the starter The Ilqhts are a very convenient tool for tracing the cause of thetrouble Lllht nlPlhocJ The lise of thiS method of course assumes that the lights are fllnctioning normally 1Liljh15 ar 11 Probable rallse Low hilttery faulty contact at one of the connections faulty wiring If the bilttery remains discharged hecause of a malefaction in the charging it should be correrted before charging the battery to prevent the rroblem from reoccuring 2With battery fully charged aSymptom Lights do not light Probable cause Battery terminal not properly connected bSymptom Lights hPlnmeextpmely dim when crank255inq the enqine and starter slows down or stops Probable cause 225 Bad engine rotatIOnal resistance too great225 Starter does not turn satisfactorily ArrTshaft bent Worn bushing Pole core screw loose Field coil grounded or insulator short circuited Armature coil grounded or insulator shortcircuited cSymptom Lights are brirjht but starter does not turn or turns very slowly Probable causes 225 Starter terminal not ronnected rroperly Solenoid switch not making contact Solenoid not workinq coil grounded or insulator short circuited Faulty starter SWitch contact 17 Insufficient brush contact 225 Dirty or worn commutator 225 Precautions in care and handling of starter motor 1The starting motor must be installed properly for the starter pinion to mesh with the engine ring gear as it should If the ring gear and pinion do not mesh properly the pinion and starter housing may be damaged and in extreme cases the starter may not even turn 2If the starter switch is turned on and the engine turns but will not start the cause is probably in the fuel system Check the fuel I ines and correct as necessary 3In attempting to start an engine never use the startinq motor for more than 30 seconds at a time without a pause to let is cool down The starting motor heats up very rapidly when used and if it is used continously for more than 30 deconds the solder may melt from the armature or the coil or lead wires may melt Also the battery will be iischarged tn such a iegree and wont have suffirient power fm another attempt at starting A good rtlle 10 follow is to crank for 10 seconds and pause for 10 se255conds Repeat until the engine starts 4If the starting motor is too far forward the pinion will not mesh properly with the ring gear and cause rapid piston wear Ad jus t for proper mesh 5Do not turn the starter switch while the enqine is running If this is done the pinion gear will contact the Tlng qear which is tlHning with the full force of the enqlOe which may cause a broken pinion bent shaft broken houslOg etc Glow Plugs The glow plugs are the sheath type with the wiring diagram as shown in Fig 44 1 Glow plug 2 Glow plug controller 3 Starter switch 4 Main switch 5 Regulator 6 Alternator 7 Battery 8 Starter Fig 44 Circuit Diagram for Glow Plugs AdobeUCS225 Attaching flywheel to crankshaft Clean the entire contact suriilP carPiully Coat the contact surface with enginp oil all the oil oil with gasoline and dry it throughly Put the flywheel on and torque the CHpscrews to 70 to 77 ft267lbs 10 to 11 kg267ml Bend the locking tabs back on the washers 225 Tensioning of fan belt The fan belt temion IS adJusted by moving the alternator bracket in or Ollt The belt is properly tensioned when the bel t deflection midway between the alternator pulley and the crankshaft pulley is 025 to 035in 7 to 9mmwith a force of 20 Ibs applied Proper belt tension is essential for good engine cooling and belt life See Fig 38 Fan pulley Tension pulley Alternator pulley025 to 035in 7 to 9mmFan drive pulley Fig 38 Fan Belt Tensioning Starting Motor The starting motor is of the standard bendix type drive with actuating solenoid The assembly is shown in Fig 43 2 rl Fig 43 Starter Assembly 13 16 17 L 1Rust inhibitor and antifreeze should be used in accord267 ance with the in the related manuals 2Be sure to remove all debris that may be plugging the fins 3Check the rubber shock mount nuts periodically to be sure they are tight 225 Cooling water pump To install the enolinC fan pulley on the pump securely tighten the nut 4tn 506 to 579 ft267lbs 7 to 8 kgf mtorque 16 24 HP 1 Pulley 2 Bearing 3 Key 4 Nut 5 Body 6 Shaft 7 Rotator 8 Case 9 Seal Fig 39 Water Pump 1 Starter assy 2 Drive end frame 3 Welch plug 4 Bushing 5 Set bolt267 6 Bolt 7 Drive lever 8 Solenoid 9 Over running clutch 10 Armature 11 Snap ring 12 Collar 13 Yoke 14 Set bolt 15 Packing 16 Field coil 17 Brush 18 Brush 19 Brush holder 20 Brush spring 21 Through bolt 22 End frame I I 20 18 I 23 24 25 26 Bushing Packing Return spring Washer rJ 27 End frame cap 19 16AdobeUCS225 Idler gear Secure the idler gear shaft to the engine block with 3 cap255screws torque to 17 to 20 ftlbs 24 to 28 kgmand bend tabs of tab washer Install gear as shown make sure it runs freely has a running clearance of 0001 to 0002 in 0020 to 0054 mmand 0008 to 0020 in 020 to 051 mmend play 1 Idler gear 2 Spacer 3 Retaining ring 4 Shaft 4 5 Bushing 6 Spacer 5 7 Engineblock 8 Capscrew 9 Tab washer 6 71 Fig 36 Idler Gear 15225 Injection pump camshaft Injection pump camshaft Fig 37 Install the bearings and governor unit on the camshaft and install in the engine block Hour Meter Unit Fig 37 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 1 Fuel injection pump 5 Injection pump gear 2 Speed control lever 6 Governor system 3 Fuel control system 7 Injection pump camshaft 4 Hour meter unit267 Fig 37 Injection Pump Camshaft Assy NOTE Hour meter unit is optional parts M 1 AdobeUCSsuch that the qear will not slide easily it may be heatpd to a slightly higher temperature for installation 225 Camshah gear Rpfer to Fig 31 Place the camshaft retainer plate on the camshJft first Shim the camshaft retainer out from the camshaft 0003 to 0009 in 007 to 022 mmwith shims that can be pulled nut after the gear is installed Heat the gear to aprroximately 176260F BO260Cand slide on the shaft until it hlJtts up aqainst the retainer plate Remove sracer shims If thp qeH will not slide on the shaft easily it tno may be heated to a slightlY highpr ternperature as descrrbed above 0003 0009in 007 022mm1 Camshaft gear 4 Cir267clip 2 Camshaft 5 Pin plug 3 Camshaft retainer plate 6 Key Fig 31 Assembly of Camshaft Gear with Camshaft 13225 Camshaft and camshaft bearings Standard dimensions are shown in Fig 32 Camshaft running clearance is 0002 to 0004 in 005 to 0091 mm16 H P 24 HP rll 1 I 1 t t l In 1 H I I f q I571I5731ft J9 9U1995Omml 15751576 0OOO40025mml 1 I AdobeUCSro NJO 153m 1887019 AdobeUCSMain Moving Parts 225 Pistons and piston rings The Istons and piston rings are shown in Fig 26 If the cyl inder Imers have been bored oversi7e oversize pistons anti rings must be used The piston is made of high silicon AI267Alloy and is cam ground The top compression ring is a chrOln243 plated keystone type the second compression ring is discontinuous and undercut and the oil control ring is of the standilrd expansion type s End gap of rings on poston in cylinder I Diameter of piston skirt thru t of piston pin bore E Diameter of piston skirt perpendicular to piston pin I 010il J25mmIII I 1 lJ20Bl 0OB2in 5010 5030m1 0905 0906in 23000 El 030 045Ff1mi 010in 249mm itCC I 19501962mmi i 0195701965inJ rt181 I f491B4990mmi i I Li J 0010 1i25045mmFig 26 Standard Dimensions of Piston and Piston Rings Standard size Over size IA 2992in 3012in 76mml 765mml rI 2986 2987in 3005 3006in 16 75839 75859mml 7633976359mml r2989 2990in 3008 3009n 24 E 75915 75935mml 06415 76435mml Over Sl7e Name of Part O5mrnPiston 05 002in Piston ring 05 fHP HP 225 Crankshaft and connecting rod 1The crankshaft is a heat treated steel alloy forging The crank pins are induction hardened for additional wear resistance Crankshaft endplay is 0006 to 0012 in 015 to 031 mm2The crankpin bearings are aluminum When installing the connecting rods aClean both surfaces thoroughly bApply engine oil to the threads of the connecting rod capscrews before installing and tighten each to 27 to 304 ft267lbs 37 to 42 kgmi The bearing caps are matched to each connecting rod and should not be interchanged Also since there are variations in machining from side to side each bearing cap and connecting rod are marked and should be assembled so that the marks line up 3In the event that the crankpins become worn and are no longer serviceable undersized bearings may be used When installing the undersize bearings observe the fol267 lowing precautions aMachine the crankpin diameter and radii to within a few thousandths of the correct dimensions and finish grind to the exact dimensions bAfter finish grinding the bearing diameter and the radii chamfer the diameter of the oil hole with an oilstone If this IS not done an oil film will not form and the bearing will sieze cThe crankpin should always be superfinished to 0000016 in 00004 mmor less dSelect the bearing from the chart that necessitates the removal of the least amount of metal from the crank255pin Do not deviate from the chart dimensions as the bearing life will be reduced if they are machined eTo determine the running clearance assemble the con255necting rod bearing cap and bearing as described in section 2 and measure the diameter anywhere within the 1200 angle indicated in Fig 28 and subtract the crankpin diameter from this figure f The piston pin bushings are of lead bronze The inside diameter of the bushing should be finished to 0906 to 0907 in 23025 to 23040 mmMark 05 OS 16 HP 05 OS Cylinder liner 3012 to 3013in 76500 to 76519mm24 HP 12f1R max to 2pR maxby honing 11AdobeUCS225 Boring and replacing the cylinder liner Referriml to Fig 22 diametPf of the linm sholiid be checked at points 12 and 3 ann in the directions aand bThe liner on which the wear has excEeded the service limit can hf bored and honed to 0020 in O50mmoversile The finished dimensions are 3012 to 3D13 in 76500 to 76519mrnModels 5416 and 5424 An oversi zed piston ann rings must then he usen with this liner Once this liner has excepned its wear limit it should be reo placed with a new one To install a new liner coat the outside liberally with oil push into the block with a press and finish to the standard size When this is done a standard size piston must again be used c I E E ot 00267 NO r1 lot 0 rM I I f I II2 I JIl L CD c1 251 Standard size 2992 2993in 76000 26776019mml 3130 2673131in 79505 79535mml 16 24 HP 251Over size 3012 3013in 76500 76519mml 16 24 HP Fig 22 Standard Dimensions of Cylinder Liner and Liner Bore in Block 225 Tightening cylinder head capscrews Fig 231 I Tit tmQue of thp cylincJAr head cafis to fII Ills 7fl to 80 kq267mNumbers 78 and 11 13 ill diilqrarn ale studs The nuts on these studs shouln llsn he liqhtenerl to this torqup 2All the capSCIIWS must be tiCjhtened uniformly To do this tiqhtpn all Ihe capscrews in the orclm indicated on thp diaqram lIllil thiN are Just snug Then tighten each one 1 ond turn at a timp in this same sequence each time until all have bem tightened to the rpQuired torque 3The cylinder head capscrews should be retightened if the enqine has not been used for a long time The valve lagh should also be adjusted pach limp the cylinder head capscrews are retorqlled If the cylinder gasket has b0n replaced rUIl the fnfline lor allfllJl 30 minutes and relighten the cylinder lltad capsrrcws as decsribed above 1024 HP Fig 23 Tightening of Cylinder Head Bolts 225 Air cleaner AdobeUCS225 Compression release Release wire is optional partsAssemblp thp parts as shown in Fig 19 Pull the lever out as far as it will go check to see that the 60260 angle is attained and that compression is released The compression release is to be used when the battery is low or when starting in cold weather Tn use the compression release preheat the glow pluq ls IJsual pull the compression release knob out as far as pOSSible and holrl it there while cranking the engine This flartially releases the enQine comflression enabling it to turn faster in cold weather or when the battery is low Once the engi ne IS turninq fast enough to start release the lever and the engine will start NOTEMake sure the compression release has returned to the operating position by pushing the knob all the way in 1 elfD Released Operating released Fig 19 Compression Released CAUTION n Do not pull the compression release lever when the engine is running at high speed or under load If it is necessary to use the compression release while the engine is running reduce the speed to idle before doing so 225 Adjustment of compression release 1Set exhaust valve in totally closed position 2Remove decompression adjustment window cover from cy I i nrler head cover 3Make valve clearance as 0 with use of decompression adjust bolt From this position turn the holt further by 1 to 15 turns Decompression clearance will then be set at 0030 to 0044 in 075 to 1125rnrnwhich is the designed clearance 4After adjusting be sure to lock adjust bolt securely so that it will not unturn while engine is in service 5Make certain that the cleanrance is not too wide To check this turn crankshaft hy hand and make certain valve disk does not contact With pistion top 9Compression released position Operation position IIcr Cl 256 1 Rocker arm 5 Compression release nut 2 Oil filler cap 6 Compression release bolt 3 Compression lever 7 Shaft 4 Adjustment access cover 8 Valve Fig 20 Adjustment of Compression Released 225 Top clearance Top clearance should be 0028 to 0035 in 07 to 09 mrnTo adjust usecyl inder gasket shims 0006 in 015 mmthick each onto the head side For checking the measurrrnent place a piece of fuse on the piston top and fix the cylinder head securely on the cylinder267 head flanqe The measurement is taken by the fuse The liner is level with the cylinder frarne at top surface The gasket shirns can be reused so do not lose them Head Top clearance 00280035in 0709mmJ Piston Fig 21 Top Clearance AdobeUCS24 AdobeUCS AdobeUCS6 Valve sheet AdobeUCS225 Fuel The fuel injection nozzle like the fuel injection pump is also a precision piece of equipment and should be treated with the same amount of care 225 The nozzle cracking pressure The nozzle cracking pressure is adjusted by adding or sub255tracting shims from the top of the nozzle spring Adding a 0004 in 01 mmshim will increase the cracking pressure by about 142 psi 10 kgcm2 The nozzle crack ing pressure is 1990 to 2133 psi 140 to 150kgfcm11 Delivery nipple 1 7 Nozzle spring 2 Delivery nipple 2 8 Push rod 3 Nut 9 Pressure pin holder 4 Washer 10 Nozzle nut 5 Nozzle holder body 11 Nozzle piece 6 Adjusting washer Fig 6 Fuel Injection Nozzle Good Bad j1 Pressure spring 4 Nozzle body 2 Pressure pin 5 Needle valve 3 Pressure pin holder 6 Nozzle piece Fig 7 Nozzle 5225 Spray pattern The nozzle cracking pressure and fuel spray pattern are most accurately checked by USing a nozzle pop test stand If a pop test stand is not available remove the nozzles from the engine leaving the pressure lines connected ICAUTIOND Hold the nozzles so that the high pressure spray from them will not in any way impinge upon unprotected skin The atomized fuel will easily penetrate the skin and cause blood poisoning Set the speed control lever at W O T and operate the starter The needle valve if it is working properly will produce a high pitched pulsating sound like that of a flute as fuel is sprayed out I f this sound is not heard or other problems are noted refer to the Fuel Injection Pump Nozzle Maintenance Std in 41 in Engine o Precaution D 1Assembly and disassembly of the nozzle should be done in fresh clean fuel 2The nozzle should always be installed as an assembly never by component parts 3Remember never to let the nozzle spray contact unpro267 tected flesh 4Tighten the retaining nut to 435 to 58 ftIb 6 to 8 kgf ml Any torque higher than this will cause slow action of the needle valve and poor injection 22 Lubrication System 225 Oil pump pick267up screen The oil pump pickup is located in the crankcase as shown in Fig 9 and is fitted with a metal screen If the screen becomes plugged wash it off with diesel fuel or kerosene 225 lubrication system The entire lubrication system is illustrated in Fig 8 Oil from the pump is forced through the replaciable paper element filter The filter is equipped with a pressure regulated valve to keep the pressure through the filter at 6471 psi 455 kgfcm2From the filter part of the oil goes to the crankshaft to lubricate the crankpins and the remainder goes to lubricate the rocker arms An oil pressure switch is located in the passage from the filter and controls the oil pressure If the oil pressure falls below 14 psi 10 kgfcm2the oil warning lamp will light on the dash panel If the oil pressure lamp stays on after the engine is running at normal speed shut the engine off immediately Find and correct the cause of the low oil pressure before operating again If the pressure regulating valve in the filter fails and the pressure rises a safety valve will limit the pressure to 140 psi 10 kgfcm2 AdobeUCSJel injection pump The Injfction pump is the Bosch Mine K type It is a preci267 sian riPee nf eQlJipment machined to close tolerances and its rerfor l1lance directly affects the performance of the engine Therefore handle it with care 1 2 3 4 5 6 7 8 9 10 11 12 13 ri0 Injection pump assv Deliverv valve holder Deliverv valve spring Deliverv valve gasket Deliverv valve Cvlinder pump element Air bleeder screw Packing Hollow screw Packing Tappet guide pin Clamp pin Bolt Ico 14 Adjusting plate 15 Control rack 16 Pump housing 17 Control sleeve 18 Upper spring sheet 19 Plunger spring 20 Lower spring sheet 21 Shim 22 Tappet assv 23 Roller 24 Roller bushing 25 Roller pin Fig 5 Fuel Injection PuflP 4 Handling the injection pump Use care in handling and using the injection pump As men267 tioned before the injection pump is a precision piece of equipment and care should be taken not to drop it or clamp it trghtly when working on it Also be sure to use only clean fuel that has been filtered Oil drums left outdoors are always considered to contain water so always filter this fuel before using Clean fuel is a must as the fuel is forced through parts of the pump and nozzel with clearances of 00004 in 11000mmwhich may easily be stuck or rusted by even the slightest amount of water in the fuel Installing the injection pump When installing the injection pump make certain that the control rack pin is correctly placed in the 02 in 5mmwide groove of the fork lever before tightening the attaching bolts Refer to the diagram If the bolts are drawn down with the rack pin off the groove the rack may over travel and stick in this position This would cause excess fuel flow allowing the engine to overspeed which would result in engine failure and Handling Fuel System 225 Fuel system The fuel systfschematic is shown in Fig 1 with the fuel flowing in the direction indicated by the arrows To bleed air from the system loosen the vent plug A on the fuel filter and crank the engine until there are no more air bubbles from the vent Tighten vent A and purge the air from the injec255tion pump at vent 8 using the same procedures 1 Fuel tank 2 Fuel cock 3 Fuel filter 4 Fuel injection pump 5 Injection pipe 6 Nozzle holder 7 Overflow pipe A Vent plug filter 8 Vent plug pump Fig 1 Fuel System 3225 Fuelfilter The fuel filter is of the cartridge type shown schematically in Fig 2 Under normal conditions it should only have to be replaced every 400 hours To install apply a small amount of fuel to the pack ing and tighten securely by hand For removal the use of a filter wrench 1522186611 is recommended 1 2 3 4 5 6 7 4J SFuel filter Caver Pipe coupling Vent plug 0 ring 0 ring IElement Fig 2 Fuel Filter 1 225 Fuel injection timing Fuel intiming is adjusted by changing the number of shims used between the pump and the gear case it fits into See Fig 3 One shim corresponds to approximately 15 degrees in crank angle Therefore injection will take place 15 degrees later when a shim is added and 15 degrees earlier when a shim is removed The timing is correct when the pointer in the peer255hole on the side of the flywheel housing lines up with the F1 marked on the flywheel See Fig 4 Fuel injection pump Speed control lever Control rack pin Injection timing adjust shims Fig 3 Adjustment of Injection Timing Fig 4 Inspection of Injection Timing AdobeUCSMODEL DGIN OPlIATIJIIG TlJlPEIATUU MAX OPERATING ANGLE ENGINE ROTATION PROPELLER ROTATION ENGI WEIGHT PoundsLENGTH OverallHEIGHT OverallWID11I NOZZLE INJECTION TIMING 225 15 5411 20 541630 S42440 S43250 54441750 to 1900 r Clockwise when viewed fro Vbelt end Rilht Hand BOTH STD AND VDRIVE245 365 425 490 545 256 280 325 362 360 212 241 246 260 260 207 207 207 207 214 250 before top dead center all odel 2275 299 221 211 211 AdobeUCS 8 9 SERVICE MANUAL M20 M30 5416 5424 Part Number 200152 Edition 1 October 1990
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