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Universal Diesel M 30 Technical Manual



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SERVICE MANUAL


  M-20     +      M-30
  5416     +      5424




    Part Number 200152
          Edition 1
       October 1990
                          MODEL 20 & 30 INDEX


     Specifications ..                              · 1-2
     Fuel System . . .                              · 3-4
     Lubrication System .                         . . 5-6
     Oi- Filter . . . .                         · ··· 6
     Combustion System                             · · 7
     Valve Timing . . .                               . 8
     Compression Release                            · . 9
     Cylinder Liner . .                                10
·    Cylinder Head .                                   10
     Piston and Rings                                  11
     Crankshaft . . . .                                11
     Connecting Rod .                                  12
     Gear Train . . ..                                 13
     Camshaft Bearings                                 13
     Main Bearings                                     14
     Injection Pump                                    15
     Water Pump ..                                     16
     Flywheel ... . .                               ·  16
     Starting Motor                                 16-17
     Glow Plug . .                              . . 17-18
     Wiring Diagram . .                             · 19
     Reference Charts . . . . . .                  20-24




·

..
                              SPECIFICATIONS
MODEL                               15              20                 30               40         50
                                  (5411)          (5416)             (5424)           (5432)     (5444)
--------------------.----------------------------------------------------------------------------
HORSEPOWER                          11            16             24            32         44
------------------------------------------------------------------------------------------------
NO. OF CYLINDERS                    2             2              3             4          4
---------------------------------------------------------------------------------.--------------
BORE & STROKE                  2.67 x 2.75   2.99 x 3.23    2.99 x 3.23   2.99 x 3.23 3.3 x 3.25
------------------------------------------------------------------------------------------------
DISPLACEMENT (CU. IN.)              31            45             68            91         115
------------------------------------------------------------------------------------------------             ·
MAXIMUM R.P.M.                     3000            2800               2800             2800       3000
---------------------------------------------------------------------------------------~------
COMPRESSION RATIO                  22:1            21:1               21:1             21:1          21:1
--------------------------------------------------------------------------------------~-----~---
TYPE                               Vertical, water cooled, 4-cycle diesel engine
------------------------------------------------------------------------------------------------
ELECTRICAL EQUIPMENT               12 Volt, 55 AMP Alternator, Electric Starter,
                                   &Glow Plugs
                                   Mech.       Fuel P\DIIP     Fuel Pump    Mech.              Fuel Pump
-----------------------------~------------------------ ------------------------------.-----------
LUBRICATION (Engine)             2.2 Qts.      3.7 Qts.      5.6 Qts.     11.5 Qts.            8.~   Qts.
                                   Use SAE 30 HD (CD) or 10W40 heavy duty diesel
                                   lubricating oil
------------------------------------------------------------------------------------------------
LUBRICATION (Transmission)         Fill to full mark on dipstick.            Use automatic
 (Std and V-Drive)                 transmission fluid Type A.
------------------------------------------------------------------------------------------------
TRANSMISSION REDUCTION           2:1        2:1              2:1            2:1       2:1
------------------------------------------------------------------------------------------------
COOLING SYSTEM (7 PSI CAP)       Sea-water       Fresh      water      cooling      system
                                   cooled       4.8Qts.               6 Qts.          8 Qts.    8 Qts.
                                                14 PSI               14 PSI          14 PSI    14 PSI
--------------------~--------------------------------- -----_._-.---------------------------------
SEA WATER INLET 6 OUTLET                                  3/8" NPT
                                                                                                            ·
EXHAUST FLANGE                                       1-1/4" NPT                     1-1/2" NPT 1-1/2" NPT

FUEL                                          Diesel fuel number 2-D
                                                                                                            ..
FUEL INLET HOSE                                       5/16" 1.0.
------------------------------------------------------ ------------------------------------~-~--
FILTERS, FUEL OIL                 298854          298854             298854           2988~4   298854
----------------------------------------------.-------------------------------------------------
FILTERS, LUBRICATION OIL          299381        298852        298852         299584   299927
----------------------------------------------------------------.---------------- ---------------
GOVERNOR                                   Centrifugal type - all speeds
-----------------------------------------------------------------------------------.------------



                                       1
    MODEL                             15           20                30         40        50
                                    (5411 )      (5416)         (S424)      (S432)      (5444)

    DGIN! OPlIATIJIIG TlJlPEIATUU                            1750 to 1900 r -----------------

    MAX. OPERATING ANGLE


    ENGINE ROTATION                 Clockwise when viewed fro. V-belt end


    PROPELLER ROTATION                                  Rilht Hand
                                                (BOTH STD. AND V-DRIVE)

    ENGI},,"! WEIGHT (Pounds)       245          365             425        490          545


    LENGTH (Overall)                25.6"        28.0"           32.5"         36.2"     36.0"


    HEIGHT (Overall)                21.2"        24.1"           24.6"      26.0"        26.0"

    WID'11I (Overall)                20.7"       20.7"           20.7"      20.7"        21.4"


    INJECTION NOZZLE


    INJECTION TIMING                 250 before top dead center - all .odel.




·




                                                       (2)
Construction and Handling
      Fuel System                                                ·    Fuel-filter
·   Fuel system                                                  The fuel filter is of the cartridge type shown schematically in
The fuel systf;)m schematic is shown in Fig. 1 with the fuel     Fig. 2. Under normal conditions it should only have to be
flowing in the direction indicated by the arrows. To bleed air   replaced every 400 hours. To install, apply a small amount of
from the system, loosen the vent plug "A" on the fuel filter     fuel to the pack ing and tighten securely by hand. For removal,
and crank the engine until there are no more air bubbles from    the use of a filter wrench 15221-86611 is recommended.
the vent. Tighten vent "A" and purge the air from the injec-                                                           (1)
tion pump at vent "8" using the same procedures.                                                                       /
                                                                                                         (4J
                                                                                                         (S)
                                                                     1. Fuel filter
                                                                     2. Caver
                                                                     3. Pipe coupling
                                                                     4. Vent plug                   \~

                                                                     5. "0" ring
                                                                     6. "0" ring                    I)'
                                                                     7. Element


                                                                                    Fig. 2. Fuel Filter




                                                                 · Fuel injection timing
                                                                 Fuel in)rction timing is adjusted by changing the number of
                                                                 shims used between the pump and the gear case it fits into. See
                                                                 Fig. 3. One shim corresponds to approximately 1.5 degrees in
                                                                 crank angle. Therefore. injection will take place 1.5 degrees
                                                                 later when a shim is added and 1.5 degrees earlier when a shim
                                    6. Nozzle holder             is removed. The timing is correct when the pointer in the peer-
       1.   Fuel tank
                                    7. Overflow pipe             hole on the side of the flywheel housing lines up with the
       2.   Fuel cock
       3.   Fuel filter             A: Vent plug, filter         "F1" marked on the flywheel. See Fig. 4.
       4.   Fuel injection pump     8: Vent plug, pump
                                                                       Fuel injection pump Speed control lever
       5.   Injection pipe
                                                                                                                                       .
                        Fig. 1. Fuel System                                                  II~-




                                                                                                \
                                                                          Control rack pin   Injection timing
                                                                                             adjust shims

                                                                                Fig. 3. Adjustment of          Fig. 4. Inspection of
                                                                                    Injection Timing                Injection Timing




                                                           (3)
    [Jel injection pump                                                 .. Handling the injection pump
The Injf'ction pump is the Bosch "Mine K type" It is a preci·           Use care in handling and using the injection pump. As men·
sian riPee nf eQlJipment machined to close tolerances and its           tioned before, the injection pump is a precision piece of
rerfor l1lance directly affects the performance of the engine.          equipment and care should be taken not to drop it or clamp it
Therefore, handle it with care.                                         trghtly when working on it. Also, be sure to use only clean
                                                                        fuel that has been filtered. Oil drums left outdoors are always
                                                                        considered to contain water, so always filter this fuel before
                                                                        using.
                                                                        Clean fuel is a must as the fuel is forced through parts of the
                                                                        pump and nozzel with clearances of 0.0004 in. (1/1000mm)
                                                                        which may easily be stuck or rusted by even the slightest
                                                                        amount of water in the fuel.
                                                                        .. Installing the injection pump
                                                                        When installing the injection pump, make certain that the
                                                           (I)          control rack pin is correctly placed in the 0.2 in. (5mm) wide
                                                                        groove of the fork lever (,) before tightening the attaching
                                                                        bolts Refer to the diagram. If the bolts are drawn down with
                                                                        the rack pin off the groove, the rack may over travel and stick
                                                                         in this position. This would cause excess fuel flow, allowing
                                                                        the engine to overspeed which would result in engine failure.




                                                           co



                     ri0 .....
                     Ir~



       1.   Injection pump ass'v         14.   Adjusting plate
      2.    Deliverv valve holder        15.   Control rack
      3.    Deliverv valve spring        16.   Pump housing
      4.    Deliverv valve gasket        17.   Control sleeve
      5.    Deliverv valve               18.   Upper spring sheet
      6.    Cvlinder pump element        19.   Plunger spring
      7.    Air bleeder screw            20.   Lower spring sheet
      8.    Packing                      21.   Shim
      9.    Hollow screw                 22.   Tappet ass'v
     10.    Packing                      23.   Roller
     11.    Tappet guide pin             24.   Roller bushing
     12.    Clamp pin                    25.   Roller pin
     13.    Bolt

                    Fig. 5. Fuel Injection Puf'(lP



                                                                 (4 )
· Fuel injection'nozzle                                                   · Spray pattern
The fuel injection nozzle, like the fuel injection pump, is also          The nozzle cracking pressure and fuel spray pattern are most
a precision piece of equipment and should be treated with the             accurately checked by USing a nozzle "pop test" stand. If a
same amount of care.                                                      "pop test" stand is not available, remove the nozzles from the
                                                                          engine, leaving the pressure lines connected.
· The nozzle cracking pressure
The nozzle cracking pressure is adjusted by adding or sub-               ICAUTIOND
tracting shi'ms from the top of the nozzle spring. Adding a                Hold the nozzles so that the high pressure spray from them
0.004 in. (0.1 mm) shim will increase the cracking pressure by             will 'not in any way impinge upon unprotected skin. The
about 142 psi. (10 kg/cm2 ). The nozzle crack ing pressure is              atomized fuel will easily penetrate the skin and cause blood
1990 to 2133 psi. (140 to 150kgf/cm 1 )                                    poisoning.
                                                                         Set the speed control lever at W. O. T. and operate the starter.
                                                                         The needle valve, if it is working properly, will produce a high
                                                                         pitched pulsating sound like that of a flute as fuel is sprayed
                                                                         out. I f this sound is not heard or other problems are noted,
                                                                         refer to the "Fuel Injection Pump & Nozzle Maintenance
                                                                         Std." in 4.1 in "Engine".



                                                                          oPrecaution D
                                                                          (1) Assembly and disassembly of the nozzle should be done in
                                                                              fresh clean fuel.
                                                                          (2) The nozzle should always be installed as an assembly.
       1. Delivery nipple 1            7. Nozzle spring                       never by component parts.
       2. Delivery nipple 2            8_ Push rod
                                                                          (3) Remember never to let the nozzle spray contact unpro·
       3. Nut                          9. Pressure pin holder
                                                                              tected flesh.
       4. Washer                      10. Nozzle nut
                                                                          (4) Tighten the retaining nut to 43.5 to 58 ft-Ib (6 to 8 kgf. ml
       5. Nozzle holder body          11. Nozzle piece                        Any torque higher than this will cause slow action of the
       6. Adjusting washer                                                    needle valve and poor injection.
                    Fig. 6. Fuel Injection Nozzle
                                                                      2.2 Lubrication System
             Good             Bad                                     · Oil pump pick·up screen
                                                                      The oil pump pick-up 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,
                                       vr.~A::;-CZ:)                  · lubrication system
                                                    (j)               The entire lubrication system is illustrated in Fig. 8, Oil from
                                                                      the pump is forced through the replaciable paper element
                                                                      filter. The. filter is equipped with a pressure regulated valve to
                                                                      keep the pressure through the filter at 64-71 psi. (4.5-5
                                                                       kgf/cm 2 ). From the filter part of the oil goes to the crankshaft
                                                                      to lubricate the c;rankpins 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. (1.0 kgf/cm2) the oil warning lamp" will light on the
           1. Pressure spring           4. Nozzle body                dash panel." If the oil pressure lamp stays on after the engine
           2. Pressure pin              5. Needle valve               is running at normal speed, shut the engine off immediately.
           3. Pressure pin holder       6. Nozzle piece               Find and correct the cause of the low oil pressure before
                                                                      operating again.
                              Fig. 7. Nozzle                          If the pressure regulating valve in the filter fails and the
                                                                      pressure rises, a safety valve will limit the pressure to 140 psi.
                                                                      (10 kgf/cm2)




                                                                (5)
nProbable cause of low oil pressure n
(1) Clearance on one of the bearings is to great.
(2) One of the rocker arms is too loose.
(3) Faulty pressure regulating valve; pressure lower than                                       -T-·--·.~
    normal (replace the oil filter or clean the valve on the old
    one with kerosene or diesel fuel.)
                                                                                       :,'        ~ffiY


  16 H.P .,
                                                                                         ~
                               Rocker arm                                                       .I
                                                                                                   ~-
                                                                                         l'===~~" -_
                               Rocker arm shaft                                                                                      \

                                                                                                                   011 pump      Oil pan
                                                                                          .        -l.             pIck-up screen
                                                                                                  Jr     t\
                                                                                                  ttJ.--Drain plug


                                                                                                Fig. 9. Detail of Oil Pump Pick-up



                                                       ' ..,....
                                                     -.~
                                                      Relief
                                                      valve




   24 H.P.
                                                                                                                      7.    Filter cover assy
                      Rocker arm
                      Rocker arm shaft                                                                                2.    Cover
                                                                                                                      3.    Safety valve assy
                                                                                                              I       4.    Safety valve
                                                                                                     '.". ___2__
                                                                                                         ,            5.    Plug
                                                                        Relief valve                                  6.    Spring
                                                                   ...--7
                                                                                                                       7.   O-ring
                                                                                                                       8.   Relief valve
                                                                                                                       9.   O-ring
                                                                                                                      70.   Plug
                                                                                                                      77.   O-ring
                                                                                                                      72.   Oil filter cartridge assy
                                                                                                                      73.   Oil filter cartridge
Oil pump pick·up                                                                       Fig. 70. Oil Filter            74.   Label
screen      .
                Fig. 8. Lubrication System


· Oil filter
(1) Rf'plilC~ the nil filter 
          _r-                                                                                ·   Air cleaner
  :I:     ";1
           lot                   I                .
          N~
          _0>
                                 JI-        l
                                                      ..
                             L-.
          'r-
          M_


                  ,

        ...


                                   CD      -"';
                                                            c1


                                                                    3.130 ·3.131in.
                                                                    (79.505 79.535mml

                                                                 16 &24 H.P.
                                           © Standard size           ©Over size
              !
                                           2.992 - 2.993in.        3.012 3.013in.
              ..                         (76.000 -·76.019mml     (76.500" 76.519mml

                                                           16 & 24 H.P.

              Fig. 22. Standard Dimensions of Cylinder Liner
                       and Liner Bore in Block

· Tightening cylinder head capscrews (Fig. 23)
(1 I Tit" liflhtr~nlilfl tmQue of thp. cylincJAr head caf)screws is
     ~'>4 to f)8 II Ills. !7.fl to 8.0 kq·m) Numbers 7,8 and 11,
      13 (.) ill tllf~ dii:lqrarn ale studs. The nuts on these studs
     shouln ---------                                       ------     --_ ... _ - -                          --




                                                                                ( 11)
                                                                                                                                         n13n-Ol46m
                                                                                                                                         f3]- 31mml
                                                                                                                                                                    Radius 004-0.06!". 0 - 1,5mm/


                                                   , 1307-·, I'!313m
                                                   (43.959 - 43 975mml




                    - {, ~l
                      J!
                  1
                 1_
                                                                                                                                          o 130-0. 146m
                                                                                                                                           (3.3-3.7mm)




                                                   2.044 2.045111




"" "."Tj~
     " u1
                                                   (5'.921 51940mmJ
                                                                                                                                         Fig. 28. Crankpin for Undersize Bearing
2.050 - ) 052m                 0 782 -~ O. 793m.                       o 74'?-·-O,15Jm
                         1/9,B7-:X; 13mm}
          r-.
(52064'     52131mm)                                                   (1887 - '9.1.1mmJ


                                                                                      lOT

                                                                                         ~1
                                                                   .         ~.                         r
"'W

                                                                  1 ..;l'1'!.!!.::.2000mm)I                                              '~q                                      OJ
                                                                                          t
                                                                                  0.078,·0,079"1                                              '0236       '02"m
                                                                                                                                                                                               I    0255
                                                                                                                                                                                               (26 048
                                                                                                                                                                                                            , 0267",
                                                                                                                                                                                                            16 078mm}




                                                                                                                                                                            ~,-'"
                                                                                                                                            I (26 non     16,021",m)

                                                                                                                                            !
                                                                                                                                            ! 09065 ·0 90lJIIl
                                                                                                                                            '- (23 025 - 23040mml

                                                                                                                                                                                        - -    (23001,·     23[1"mrn}




    l 24       H. p ·1
                                                          17307
                                                      143959
                                                                       1.l313m
                                                                       43.975mml
                                                                                                                                           ,                                                   o NJ--O 153m
                                                                                                                                                                                               (18870-'19. f]Omml




                                                      ·.;.f1U~-.11.f-llrr;.1-l
                                                                                                                                                1.850.    '.851m
                                                                                                                                            f
                                                                                                                                            I
                                                                                                                                                (47.000    47.02mrn)


                                                                                                                                        - j
  r=1J[]--r.  rl.ufu-·-
                                                                                                                                                                                               0.0.58 -·O.059In
                                                                                                                                                                                               r,
          ~ --1l                                                                         ~.
                                                                                                                                                                                                  482 - 1 495mml
                                                          ,-.:!(         j _ .t                    l        J
                                        i -  ..    . L-!                         t       i.'       '.                          c.A':   Diameter of piston pin bushing after installation
                                                     __
                                        L.~~_~ -L ____                       .L_____._._!
                                                      2.044·- 2045m                                                            Fig. 29. Standard Dimensions of Connecting Rod
                                                      (51.921- 1j1 .Q40mm)
                                                                                                                                        Bearing and Bushing
  2.050     2.052m             0 782~O.J93111                      0.143- 0.753m
  (52.064
2.247--2.248,"
              52. ,31mm}

                   ,
157 084-57." 'm",1 1
                           !



                           I.
                               (1987-20. 13mm)
                                    ':
                                    I   '
                                                      ---+--.------,------T"' .
                                                                   (18.81-- ,g. 13mm)




                       LUIJ                           rn                     m                  rn
                                                                                        0018 ·0..079;,1.
                                                                                        (1970. - 2000mmJ



   Fig. 27. Standard Dimensions of Crankshaft and Bearings



                                                                                                                                                                                              Runninq Clpilrancp
    Sill"                           Pi] rt I'Jo                                      Bpar ing                                                                           Metal
                                                                                                                         Crankrin Diarn.                                                             in.
                                                                                                                                                                        Mark
                                                                                                                                                                                                           ('nm)


                                                                                                                     1. 7228   '0 , 72"-i~'~~--I
    020                                                                0.20 mrn undersi7P                        I                                             ,.      020US
                     I                                        I                                                      (43.759 to 43.775 rnrn)                   !
                                                                                                                                                                                         0.001379


---:~:-1-________~-]
                  --~o 40                                                                 Od:"",- -t ~;;4~ '0·'7·';"~-I
                                                                                                                                                                                         to 0.003819in.
                                                                                                                                                                                         (0.035 to 0.097rnrn)
                                                                                  mm o                                                                                 040US
                                                                                                                     (43559 to 435"15 rnlll)
                                                                                                ----'------                            ---------'-------'------------
                                                                                                                (12)
       Main Components
                                                                        · Camshaft and camshaft bearings
·    Gear train
                                                                        Standard dimensions are shown in Fig. 32. Camshaft running
Be sure to assemble thp. gears by matchinq the mating marks             clearance is: 0.002 to 0.004 in. (0.05 to 0.091 mm)
as shown in Fig 30. The backlash of each gear is 0.002 to
0.005 in. (00415toO.1154mm)

          "                                                                      16 H. P.    ~      rll ~ 1 II 1 t 1~l..r t~ l' In
                                                                                                    :{ :H                  I {   q
                                                                                                                                 f
                                                                                                                                   1
                                                                                                           ------          ----
                                                                                                              I.571-I.5731ft.
                                                                                                                    (J9 9:U-19.95Omml
                                                                                                                    1.575-1.576...
                                                                                                                    (.0.OOO--40.025mml
                                                                                                                                 '1

                                                                                                     I   ]d''''t''.+ru'j
                                                                                                          ~~r ~-,-, ~L:. :=~
                                                                                                              .·.-,.....   ···               .

                                                                                                     If
                                                                                                     ~.~


                                                                              24 H.P.

      ,. Crankshaft gear         4. Camshaft gear
                                                                               ( ---{_~lJJJ l~trrnEro=oo
                                                                                       ..--.---- ........- -- . --r-----.                '
      2. Oil pump drive gear     5. Fuel injection pump drive                                            1.572-1.573..
                                                                                                         (J9.9:U-J9.95Omml
      3. Idle gear                  gear
                                                                                                         1.575 -I.516ln.
                                                                                                         (.OOOO-40.025mml
              Fig. 30. Mating Marks of Gear Train




                                                                                   ~
·   Crankshaft gear
Heat to about 176°F (BO°C) and slide on crankshaft If the
shaft and hore dimensions iJ[P such that the qear will not slide
easily. it may be heatp.d to a slightly higher temperature
for installation.
                                                                            Fig. 32. Standard Dimensions of Camshaft
· Camshah gear                                                                       and Bearings
Rp.fer to Fig. 31. Place the camshaft retainer plate on the
camsh;Jft first. Shim the camshaft retainer rlatr~ out from the
camshaft 0.003 to 0.009 in. (0.07 to 0.22 mm) with shims
that can be pulled' nut after the gear is installed. Heat the gear
to aprroximately 176°F (BO°C) and sl'ide on the shaft until it
hlJtts up aqainst the retainer plate. Remove sracer shims. If
thp qe;'H will not slide on the shaft easily it tno may be heated
to a slightlY highp.r ternperature as descrrbed above.


                                                                                                                                                 .-




                                    0.003 -. 0.009in. (0.07 - 0.22mm)

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


      Fig. 31. Assembly of Camshaft Gear with Camshaft

                                                              (13)
· Main bearing ass'y                                                                     · Main bearing housing
Insert the bearings in the main bearinq hnusing halves as in-                            Installation of crankshaft with main bearings in engine block.
dicated in Figs. 33 & 34, using the thrust wilshers only on the                          Slide the crankshaft assembly into the engine block, being
Journal nearest the flywheel. Coat the crankshaft Journals and                           careful not to nick or scrape the crankpins. After the assembly
the bearing surfaces with engine oil, place the hOllsing halves                          is in position make sure the oil passages are correctly lined up
with bearings on the crankshaft, coat the capscrew threads                               Install the main bearing housing to engine block locking
with engine oil and tighten to 21 to 25 ft-Ibs (3 to 3.5 kg-m)                           capscrew and washer from the side to position the housing and
-M8                                                                                      then install capscew (2) from the bottom and torque to 47
                                                                                         to 50 ft-Ibs (6.5 to 7 kg-m) - M 1               a




                                                                                         1. Bearing
                                                                                         2. Cap screw
                                                                                         3. Locking tab
                                                                                         4. Main bearing housing
                                                                                         5. Cap screw
                                                                                         6. Locking tab
                                                                                         7. Locking tab       Fig. 34. Main Bearing Housing 7
      1. Bearing                                                                                                       Main Bearing Housing 2
      2. Thrust washer
      3. Thrust washer
      4. Crankshaft journal
      5. Main bearing
      6. Cap screw
      7. Locking tab        Fig. 33. Main Bearing Housing 3 with
      8. Locking tab                 Thrust Washe~




                                                                    0                          d
                     ------.,_.-.-    - ----------_.   1----_.._._---_ .. _-------- -- 1---._--_._---         --~.   ------~-   .. -   --------_.

                          Main bearing housing 1
                                                           5.156   - 5.157in.
                                                                                                              16 & 24 H.P.
                                                        1130.968 -130.986mm)
                     .-   --_._-- _. __ ._---,--.------ ------ -."- .__ .. _.. _----                         1-- ------

                          Main bearing housing 2          5.1956 - 5. 1963in.            2.2047- 2.2055in.
                                                        1131.968 - 131.986mm)          156.000 - 56.019mm)           24 H.P.
                                                    5.3137 - 5.3144in.
                          Main bearing housing 3 1134.968 --134.986mml                                         16 & 24 H.P.
                                                                            ..




                                                                          (14 )
·   Idler gear                                                          · Injection pump camshaft
Secure the idler gear shaft to the engine block with 3 cap-             Injection pump camshaft. Fig. 37. Install the bearings and
screws. torque to 17 to 20 ft-lbs (2.4 to 2.8 kg-m) and bend            governor unit on the camshaft and install in the engine block.
tabs of tab washer. Install gear as shown make sure it runs             Hour Meter Unit. Fig. 37. Insert the "tang" on the end of
freely. has a running clearance of 0.001 to 0.002 in. (0.020 to         the hour meter drive shaft into the slot on the end of the
0.054 mm) and 0.008 to 0.020 in. (0.20 to 0.51 mm) end                  injection pump camshaft and install as per the illustration.
play.',




     1. Idler gear
     2. Spacer
     3. Retaining ring                        /"
     4. Shaft                    !4'/
     5. Bushing                               /.
                                          ,
     6.. Spacer                   (5.'/
     7. Engine'block
     8. Capscrew
                                                   '.6   (71
     9. Tab washer

                     Fig. 36. Idler Gear



                                                                          1.   Fuel injection pump       5. Injection pump gear
                                                                          2.   Speed control lever       6. Governor system
                                                                          3.   Fuel control system       7. Injection pump camshaft
                                                                          4.   Hour meter unit·

                                                                                 Fig. 37. Injection Pump Camshaft Assy




                                                                        NOTE
                                                                        *Hour meter unit is optional parts .




                                                               . (15)
 · Attaching flywheel to crankshaft
 Clean the entire contact suriil('P carPiully Coat the contact                     (1) Rust inhibitor and antifreeze should be used in accord·
 surface with enginp. oil, wa~h all the oil oil with gasoline and                      ance with the recommendations in the related manuals
 dry it throughly. Put the flywheel on and torque the CHpscrews                    (2) Be sure to remove all debris that may be plugging the fins.
 to 70 to 77 ft·lbs (10 to 11 kg·ml. Bend the locking tabs back                    (3) Check the rubber shock mount nuts periodically to be
 on the washers .                                                                      sure they are tight.
 · Tensioning of fan belt,
                                                                                   · Cooling water pump
 The fan belt temion IS adJusted by moving the alternator
                                                                                   To install the enolinC] fan pulley on the pump, securely tighten
 bracket in or' Ollt. The belt is properly tensioned when the
                                                                                   the nut (4) tn 50.6 to 57.9 ft·lbs. (7 to 8 kgf .m) torque.
 bel t deflection midway between the alternator pulley and the
 crankshaft pulley is 0.25 to 0.35in (7 to 9mm) with a force
 of 20 Ibs applied.' Proper belt tension is essential for good
 engine cooling and belt life. See Fig. 38.
                                                                                           16 & 24 H.P.

               Fan pulley      Tension pulley (Alternator pulley)                                                                  1. Pulley
                                                                                                                                   2. Bearing
                                                                                                                                   3. Key
                                                                                                                                   4. Nut
                                                                                                                                   5.   Body
                                                                                                                                   6.   Shaft
                                    0.25 to 0.35in. (7 to 9mm)                                                                     7.   Rotator
                                                                                                                                   8.   Case
                                                                                                                                   9.   Seal


                            Fan drive pulley
                             Fig. 38. Fan Belt Tensioning
                                                                                                                          Fig. 39. Water Pump

     Starting Motor
The starting motor is of the standard bendix type drive with                                                        1.  Starter ass'y
actuating solenoid. The assembly is shown in Fig. 43.                                                               2.  Drive end frame
           2                                                                                                        3.  Welch plug
   r-.l                                                                                                             4.  Bushing
                                                                                                                    5.  Set bolt·
                                                                                                                    6.  Bolt
                                                                                                                    7.  Drive lever
                                                                                                                    8.  Solenoid
                                                                                                                    9.  Over running clutch
                                                                                                                    10. Armature
                                                                                                                    11. Snap ring
                                                                                                                    12. Collar
                                                                                                                    13.   Yoke
                                                                                                                    14.   Set bolt
                                                                                                                    15.   Packing
                                                                                                                    16.   Field coil
                                                                                                                    17.   Brush
                                                                                                                    18.   Brush
                                                                                                                    19.   Brush holder
                                                                                                                   20.    Brush spring
                                                                                                                   21     Through bolt
                                                                                                                   22.    End frame
                                                                                   I                               23.    Bushing
                                                                                                                   24.    Packing
                                                                                   I
                                                                                                                   25.    Return spring
                                                       16   17      20        18   I                               26.    Washer
                                                     _ _ --'L
                                                                    - r-..J                                        27.    End frame cap
                                               13                        19
               Fig. 43. Starter Assembly
                                                                 (16)
 ·    Starter specifications                                                                         * Insufficient brush contact
                                 ------,-       ------   --             -----                        · Dirty or worn commutator
                     16 H.P.                                      24 H.P.
                                                                                ·     Precautions in care and handling of starter motor
                                                                                (1)    The starting motor must be installed properly for the
 Code No.                298783                                   298876               starter pinion to mesh with the engine ring gear as it
                                                                                    should. If the ring gear and pinion do not mesh properly,
                  Solenoid ilctuilted with                                          the pinion and starter housing may be damaged and in
 Type
                  overruning clutch
f-.
                                                                                    extreme cases, the starter may not even turn.
 Nominal                                                                        (2) If the starter switch is turned on and the engine turns,
                   12V
  voltage                                                                              but will not start, the cause is probably in the fuel system.
                                                                                       Check the fuel I ines and correct as necessary
 Nominal
                   0.8 kW                                     1.0 kW            (3)    In attempting to start an engine, never use the startinq
  output
                                                                                       motor for more than 30 seconds at a time without a pause
 Direction of      Clockwise, viewed from                                              to let is cool down. The starting motor heats up very
  rotation         pinion end                                                          rapidly when used and if it is used continously for more
                                        ---
                                                                                       than 30 deconds the solder may melt from the armature
                                                                                       or the coil or lead wires may melt. Also, the battery will
 ·    Trouble shooting                                                                 be                                I 3
                                                     j
    Vol tilfJP &   ArprOXIPlately 6.5 amp
     rw refl t     (l')   10.5 V
'----




·     Glow plug controller specifications



                             16 H.P.                     24 H.P.
      Code No.
                              299839                     299839     .
                                                                   --
      Current                      13A                      20A




·     Precautions in handling the glow plug
(1)    USf' the glow plugs only with        Universal
       glow plug controller. If any other type is used, the heating
       time will not match that of the glow plugs and cause
       hard starting and various other problems
(2) As the glow plugs are ill rarallel, thl) controller heating
       element will tllrn red even if. one of the rlugs is bad.
       However, the time it takr~s for the controller heating
       etement to get hot is less, which will cause the element to
       bllrn out.
(3)     Rerlilcinq a faulty glow plug may not solve all the system
       prohlems. Should thf' failed rlug indicate problems in
       other areas beside the pili'], they should be checked out
       iilv). The fl10st probablf' a[(~as are: improper fuel inJcction
       tilTllflq, bad nOllie, wrong fuel, incorrect circuit con-
       nection, gas If'ak, etc.




                                   (18)
                                                                       I

                     ENGINE CONNECTIONS
                                               Univel~al                           Diesel      PANEL CONNECTIONS




          __3 _Cl,,-L _~
                       _0




                                          Connect to ACC. term. on switch
                                                                               I
                     2 CYl.               i                                ·
                  1-----"""----;
                    .
                    -     -.
          --,--



                            .
          -t-

           .. --..
          ,tr
           ,
          GLOW I PLUGS              FUEL PUMP




                                                                                                                   0'1
                                                                                                                   .......




E
                                                                               I
Q)
......,                                                                        I
 en                                                ·  -L   -----L.
 >-
(J)
                                                 Blue ~
                                                       OIL
                                                               -;-
                                                              TEMP                      FEMALE-l CDI~'j141
                                                       SENDER SENDER

-co
 (.)
.-                  FEHALE~!!                 Z zz Z Z Z Z Z Z Z Z Z ZZ Z ZZ ZZ zz       :]1,1:]
......,
 I-

  (.)

-
w
  Q)
Reference Chart
        Engine
                                                                                                           Maximum
Parts                      Items                           Specifications             Standard Value                                    Remarks
                                                                                                             limit
                                         -----           .--
         Cylinder head tightness                    Ml0 x 125                      54.2"'" 57.9 fUbs                    When installing. apply a generous
 iII>                                                                              (7.5 --8 kg·m)                       coat of engine oil onto the entire
 J:      Cylinder head surface distort inn                                         0.002 in below                       surface of each bolt.
                                                                                                                                          I
 ~
 "0
  !:     Intake/e)(haust valve seat thickness       45° 0.059 in. (1.5mm)
                                                                                   (0.05mm below)                                  {
  >                                                                                0.0276"'" 0.0354 in.
 U
         Top clearance                                                             (0.7 ..... 0.9 mm)                          Y4S'     O.059in. (1.5mm)
                                                 .--.                                                                   050 oversize liner 10
         Standard 10                                2.9921 -. 2.9929 in.                                   2.9980 in.
                              15416 & 5424                                                                              3.011.!3_- 3"o.l..?~_In.
  ~                                                 (76.000- 76.019mm)                                     (76:15mm)    (76.500- 76.519mm)
  c:
 .:i
  ~
 "0      Piston clearance                           0.0026·0.0041 in. !0065-·0.1~mml E side
  c:
         (At piston skert)
                              15416 & 5424          0.0056 - 0.0071 in. (Q.141 - O. 180mm) I side
  >
 U                                                                                                                      Height above block surface
         Type                                       Dry                                                                 ± 0.00098 in. (± 0.025 mm)
         Standard 00          15416 & 5424          2.9921 in. (76mm)                                                   Oversize 0.020 in. (0.5 mm)


  c:     Piston·pin boss 10                         o 9U55 -09060 in.                                      0.9071 in.
  B                                                 (23000 -23013 mm)                                      (2304 mm)
  '"
 a:
                                                                               interference Clearance
         Piston·pin clearance                                                  0.0004 in. 0.0004 in.
                                                                               (OOllmm) (0.011 mm)
                                                    ._-----_.                                                                                    .. - ._._----
         Ring gap                                   (toP. 2nd)                   0.0118 - 0.0178in. 0.0492 in           0.5 oversize top ring surface should
                                                                               ~.3~0.45mm) _ _
                                                    (oil ring)                                      (1.25mm)            be 0.0079 in. (0.2 mm) below
                                                                                 0.0098 - 0.0158in.                     piston side surface.
         Top ring width                                                        \ (0.25 - 0.45mm)
  '"
  c:                                                Keystone type
 a:
  0

 a:
   c:
  :;;
         2nd ring width


         Oil ring
                                                    0.0768 -0.0772in.
                                                    (1.95 - 1.962mm)

                                                    01960 -0 1965in
                                                    (4.978 - 4.99 mm)
                                                                                   Ring groove clearance
                                                                                   0.0037 -00047 in.
                                                                                   (0.093 -0.120mml
                                                                                   00008 -0.0020 in.
                                                                                                                        above 0.0079 in.
                                                                                                                                        (O.2mmJ
                                                                                                                                                   J
                                                                                   (0.02 -0.052 mm)
                                                        -----                                                                                        ._---
  c      00                                         0.9056 ";"0.9059in.
 a:                                                 (23.002-23.011mm)
  c
   0
  :;;                                                                              0.0006-00015 in.        0.0059 in.
 a:      Pin·to·bush clearance
                                                                                   (0.014 -0.038 mm)       (0.15mm)
                                   -
         Small end 10                               1,0236 - 1.0244 in.                                                         Pin
                                                    (26000-26.021 mm)
                                                    (without bush)
                                                                                                                            . ~ 7~oogg:!'i
 "0
 0
 a:
  '"
 .§
         Small end width

         Large end 10
                                                    1 0236 in. (26 mm)

                                                    1.8504 - 1.8512 in.
                                                    (47.000-47.020mm)
                                                                                                                         ~
                                                                                                                         ~
                                                                                                                             t TIJ:l.
                                                                                                                              J-
                                                                                                                                 . .
                                                                                                                                   _.         ?
                                                                                                                                                    Con"",,'ino
                                                                                                                                                    rod
                                                                                                                                                  4in. (100mm)
  u
  II>
  c:
                                                    (without bush)                                                      +          l~·±O;OOO79in.
  c                                                                                                                     _O.OOO79m.                (±O.02mm)
  a      Large end width                            1.0079"'" 1.0118 in,                                                (±O.02mm)
 u                                                  (256"'" 25.7 mm)

         Rod torsion                                                               0.0008 in.              0.002in,
                                                                                                                        When installing, apply a generous
         (see diagram)                                                             (0.02 mm)               (005 mm)
                                                                                                                        coat of engine oil onto the entire
         Rod bolt torque                            M8)( 1                         26.76- 30.38                         surface of each bolt.
                                                                                   ftlbs, (3.7 - 4.2
                                                                                   kg·m)



                                                                            (20)
                                                            Maximum
                                 Items              Specifications             Standard Value
                                                                            Remarks
                                                              Lomit
r---.r--.--.-----------------------~.----------.----_+--------------+_----~--------------1
      ID                      1.7327 - 1.7345 in.
                              (44.01 - 44.056mml
                              (with metal)

               Width                            0.7429 -0.7531 in
  '"
  OJ                                            (1887-19.13mml
  :2                                                                                                            Center thickness
   c
   a           00                               1 85 in. (47 mml                                                   0.0583 - 0.0589 in.
  -'"                                                                                                              (1.482 - 1.495 mml
   c
               Runnmg clearance
  '"
  U
                                                                            0.0014 - 0.0038 in.   0.0079in
                                                                            (0.035 - 0.097 mml    (0.2 mml

               Axial clearance                                              0.0157 -0.0236in.                   Crank arm· to· large end clearance
                                                                            (0.4 -0.6 mml
1-- -.    ------.------.---.----+---.---------+---------..,-----+-------------1
               Cr~nkshaft      jurnal dia       20441 - 2 0449 in
                                                (51.921-51.94mml

               Main be"rlng ID                  20465 - 20483 in
                                                (5198- 52.025mm)
                                                                        I   Running clearance
                                                                            0.0016-0.0041 in.
                                                                                                  0.0079 in.
                                                                                                  (02 mml
                                                (with metal)                (004 -0.104mml

               Crankshaft metal (21             07429 -07531 in.
               Width                            (1887 -1913 mml
          .---------.----.-----+------------+------+----+-----'---------1
               Crankshaft jurnal d,a             20449 -2.0449 in.
                                                 (51921 -51.94mm)
                                                                        I   Running clearance
                                                                                                  0.0079 in.
                                                                            o 0016 -0.0046 in.    (0.2 mml
   0>
   C
               Gear'Slde main bearing ID         20465 -2.0488 in       j (004 -0118 mml
                                                 (5198 -52.039mm)
                                                 (with metal)

               CrankShaft metal (1 I             0.7823 - 0.7925 in.
               Width                             (19.87- 20.13mm)

               Crankshaft metal (11 OD          2.2485 - 2.2474 in.
                                                (57.111 - 57.084mml
         f--                          ----- -----.---f------------------1~-------_+----+------------_1
               Crank,pln jurnal dia             1.7307 -1.7313 in                                 0.0047in.    When installing, apply a generous
                                                (43.959 - 43975mml                                (0 12 mml    coat of engine oil onto the entire
                                                                                                               su rface of each bolt
               Crankshaft Side clearance                                    0.0059 - 0.0122 in.
                                                                            (015-0.31 mml

               Cr~nk hearing cap                                            21 7 - 283 tUbs
                                                M 8 x 1.25
               bolt (11 torque                                              (3 -3.5 kg.ml

               Crank bearing car                M 10 x 1.25                 47.0 -506ft Ibs.
               holt (21 torque                                              (6.5 -7 kg.rn)

               . - .-.--- .-.-.--.-.-----------1-..-.- - -.. --.-------+-----------+--..----+--------------1
               Cam bearing I D                   1 5748-15758 in            Running clearance
                                                                        1

                                                                                                                                f\
                                                 (40 000-40 025mm)
                                                                         0.0020 - 0.0036 in.                   0.7677 in.
               Cam shaft dia.                    15722-1 5728 inl
                                                 (39.934-39 .950mm)
                                                                        1(0.05--0.091 mml
                                                                                                               (/9.5   m~)                    I
               Ax ial clearance                                             0.0028-00087 in.                                             1,3134 in.
  ~
  .c.                                                                       (0.07 - 0.22 mm)
                                                                                                                        I                (33.36 mm)
  VJ



                                                                                                                                  ~ I
   E
  '"
  u            Cam 11ft                         0.2165   In   (5.5mm)
                                                                                                               0.5457ik
                                                                                                               (13.86 mm)
               C~rn   height                     1 3134 in
                                                 (3336 mm)




                                                                     (21)
     Parts                                                                                           Maximum
                                   Items              Specifications             Standard V~lue                                Remarks
                                                                                                       limit
                   Number of teeth, crank gear   34

                   Number of teeth, Idel gear    79

                   Number of teeth, cam gear     68

                   Nllmber .of teeth,
                   Inwction pump gear            68

                    Number of teeth, at! pump
                   drive gear                    45

                    Backlash                                                  o 00163-{) 00454 in,   0,0118 in,
                                                                              to 0415-{), 1154mm)    to,3mm)

     r--           -~~--------~~-~-----"---~---------t---------t-----t----------------1

                    ShlOkage                     0,0433 '0,0551 in,
                                                 tl.l-- 14mm)




                    Face angle                                                                                    Valve gUide bore s/:1ouJd be
                                                                                                                  reamed after inserted into
                                                                                                                  cylinder head,
                    I ntake bore                 1,2953-1,3031 in
                                                 t32,9 - 33 1 mm)

                    Exhaust bore                 1,0591-10669 in
         Q)'
         ~:                                      (26,9 -27,1 mm)
         '"
         >
                    Stem dia,                    0,3134-{),3140, in


--                  Valve.guide IQ
                                                 t7 ,960-7 ,975mm)

                                                 0,3156-{) 3161 in,
                                                 t8,015-B030mm)

                    Stem guide clearance                                      0,0016-{),0028 in
                                                                              (004 ~0,07 mm)

                    V~ve   clearance                                          Q,0071-{) 0087 in                   When cold,
                                                                              t018 -0.22 mm)

     -         -                   --   _.
                    Free length                  1,6417-1,6614 in,
                                                 (41,7 -422 mm)

         OJ         Spring pressure                                           26,46 Ibs./l ,3839in                Load and length when installed-
         ~
                                                                              (12kg/35, 15 mm)
         Ci
         Ul
         ,..
         Q)
                    Perpendicularity                                                                 3%
         iii
         >
                    Spring pressure loss                                                             15%
                    when installed
                   ----. -----~---------~-~-     -------~------- r-,--~---- --~--t-----+---------------------                                       -,
                    Over,all length               A 5984 in
                                                    (152 mm)
                                                  B 5,8189-
                                                    5.8346 in
                                                  (1478-
                                                     1482 mm)

                    Dia                          0.2323-{),2402 in,
                                                 (59-6,1 mm)




                                                                       (22)
                                                                                       Maximum
P"rts                      Item5       Specifications            Standard Value                               Remarks
                                                                                         Urn It
1---    I-------------------.-+----------+--------{-----+-------------/
         I ntake valve opened

         I ntake valve closed                                  At 45° ABDC
  0'>
  c:
 E       Ex hill.jst valve opened                              At 50° BBDC
 t--
  QJ                                                                o
 2       Exhaust valve closed                                  At 15 ATDC
 '"
 >                                                                                                [
         Iqn,t,on process
                                                               1-2
                                                               1-2-3                              [
                                                                                                      16 H.P.
                                                                                                      24 H.P.
         Injectectinn tlmlnq
~-4------·-----------11-----------4-----------~r----_+----------------~
        Trochoid tooth width                                                                      Use Engine Oil CD (oS)
                                    U16 H. P.
                                                                                                  Above 77°F (25°C). SAE30
                                    0.5866 -- 0.5874in.
                                    (14.90 . 14.92mm)
                                     24 H.P.                                                      Between 32 ° F - 77 ° F (0 ° C-
                                    0.8622'" 0.8630in.                                            25°C).SAE20
                                    (21.90- 21.92mm)
                                                                                                  Below 32°F (OoCI. SAElOW.
         Outer rotor OD             1.9669- 1,9685in.                                             10W·30
                                    (49.96- 50.00mml
  CI.
  E      Trochoid·tn·body                                      o 0035-{} 0063 in.
  :>
  CI.    clearance                                             (009 -0,16 mm)
 6
         Troc!1oidto·body side                                 o 0039-{} 0059 in,
         clearance                                             (010-0.15 mm)
                                                               64-71 psi.
         Oil pressure                                          (4.5 - 5 kgf/cml)

        . Pump capar.ity                                       [ 16 H.p.D
                                                                  4.2 Gal/on/min.
                                                                  (16£imin)
                                                                                                  [16 H,P .           B
                                                                                                       At pump 2116 r.p.m.
                                                                                                                                      -
                                                               « 24 H.P.                          I 24 H. P.
                                                                                                       At pump 2000 r.p.m.
                                                                  5.8 Gallon/min.
                                                                  (22£imin.l
. - - ·--·-------------------1----------11------ ----. -.                            ---+-----+-------------i
         Model                                                 Np·PFR3K55/2NP2                    Cam speed         1400 r.p,m.
                                                                                                  Rack position:    0.354 in (9 mm)
  a.     I nleC! ion pressure                                  1990 psi (140kg/cm 1)
  E
  :>
 Cl.
  c:     Pump plunger dia                                      02165 in.(5.5mm)
  o                                                             .         .
  u
         Pump stroke                                           0.2756 in (7 mm)
  '"
  C
         Pump discharge                                        0.0013-
                                                                 00015 in 3 /rev
                                                               (23 ± 1 mm 3 'rev)
 --- -------_ ... __.-------- _._----_._------+----------+------+--------------\



                                                               NDDN12SD12
         Modf!1

                                                               1990 - 2133 pSi.
         I njl'ct Ion pressure
                                                               (14D-150kgf./cm 1 )




                                                        (23)
Parts                                                                                               Ma)(imum
                         Items                      Spec if ications          Standard Value                                Remarks
                                                                                                      Limit
        Cooling system                   .      ---
                                                                                                               With pressurized radiator
                                             Natural circulation                                               (corrugated I
                                               16 & 24 H.P.
                                             t-orceo circulation

        Water pump (Z751-BW                  Centrifugal pump
        and DHll0l-BI                        with thermostat
                                             (impelled
        Gear case to impeller                                             0.0232-0.437 in.                     Water temperature BOoC.
        clearance                                                         (0.59 - 1.11 mml                     Total lift 19.34Ibs.!in 2 (lmAg)
        Circulation flow rate (Z751-BW                                    (Packing thickness)
  E     and DHll0l-B)                                                     26.4 Gallon/min
  ~
  '"
  >                                                                       (100Q/min) or more
 C/)
  ;;;
  iO    Impeller dia.
  ~     (Z751-BW and DHll01-BI               2.634"-2642 in.
  C>
  SO                                         (669-67.1mml                                                      Pump speed 3450- 3550 rpm
  0
  0
  w     Thermostat actuation                 179.6"-203°F                                                      . "No pump for Z751-B and ZB51-B
        temperature                          (B2°C -95°CI
        (Z751-BWand DHl101-B)

        Radiator cap pressure                                             12.B psi. (0.9kg/cm 2 ,

        Fan belt length
                                             HM 40.55in. (1030mml
                                             .n perimeter
                                              16 & 24 H.P.
                                             HM 41.50in. (1054mml
                                             in perimeter




                                 ---.
        Model
                                             16 H.P.
                                                 D                                                             16 H.P.      }   NS70. dry
                                             12V70AH
                                              24 H.P.                                                           24 H.P.         N70Z. dry
                                             12VBOAH
        Electrolyte specific
  >
        gravity. discharge
  2i                                         1 120
  iii
  CD
        Electrolyte specific                 1.2BO
        gravity. charge                      (6BoF; 20°C)

        Etectrolyte specific                 1.30
        gravity. overdischarge


        Voltage                              12V                                                               Alternator

        Current                              20A

  0
        Check interval                       Every 1000 service                                                Insulation resistance
  .,
  E
  c                                          hours.
 >
 0
        Brush spring pressure                                             12.B pSi(0.9kg/cm 2 )     ± 15%
        I nsulation resistance                                                                                 No failure at 500MV


 0      Constant voltage                                                  13.B .... 14.BV
 iii
 :;
 C>
        Current                                                           lOA
 '"
 II:
 .,
 01
 !9     Cut-in voltage                                                    12.5-13.5V
 '0
 >
                                                                       (24)
,"'-'"
                                                                       I
                                                                                                                                                  Maximum


                                                                  1-.
                                                                       I
 Par"                               Items                                        Specifications                         Standard Value                                               Remarks
                                                                                                                                                    limit
 -'- ---------
             Number of teeth. pinion
                                                                                                           .
             Number of teeth.                                              89
             rIng gear

              Insulation resistance                                                                                                                                No failure at 500MV
   ~
              Check interval
   "'
   tn
                                                                           Every 1000
                                                                           service hours
                                                                                                                                                                   Insulation resistance



                                                                                                      .~
              Output                                                       n 16 H.P.                                                                               Nominal value
                                                                           0.8kW
                                                                           n·  24H.P.
                                                                           1.0kW- ....
                                                                                                           D
  . _"--   - -.- --.---------
              Hp.ad set bolt and nut
                                                                  ..   -_.   __ _-------
                                                                                  ..                           ' - - -.

                                                                                                                                                                   Apply a generous coat of
                                                                           Ml0x 1.25                              54.2-57.9ft Ibs.
                                                                                                                  (7.5 -8 kgf.m)                                   engme oil onto the entire
                                                                                                                                                                   surfaces of all important
              Flywheel set bolts                                                                                                                                   set bolts.

   QJ                                                                                                             72.3 - 79.6 fUbs
   =>                                                                                                             (10 - 11 kgf.m)
   cr                                                                      M12 x 1.25
   (;
  I-
             Crankshaft main bearing                                       Ml0 x 1.25                             47.0-50.6 fUbs.
   0
  co         set cap bolts                                                                                        (6.5 -7 kgf·m)
  C
   ~         Crankshaft cap bolts                                          M8)( 125                               21.7 - 25.3 fUbs.
   0
   a.                                                                                                             (3.0 - 3.5 kgf·m)
  E
  -
              Rocker bracket set studs                                     M8)( 1.25                              17.4 -20.3 ftlbs
                                                                                                                  (24 -2.8 kgf.m)

              Rod bolts                                                    M8)( 1                                 26.8 - 304 fUbs.
                                                                                                                  (3.7 - 42 kgf·m)
--         _."

              Gp.neral set bolts                                           M12                                    57.1 -665 ft.lbs.                               All these torques are applied to
              and studs                                                                                           (79 -9.2 kgfm)                                  those S45C bolts and studs
                                                                                                                                                                  which have relief number "7" or
                                                                           MlO                                    35.4-41.2 ft.lbs.                               punch marks.
   QJ
   =>                                                                                                             (4.9 -5.7 kgf.m)
   cr
   (;
  I-
  (5
  CD
                                                                           M8                                     17.4 -20.3 ft.lbs.
                                                                                                                  (2.4 -2.8 kgf·m)                                           0 0 $-
                                                                           M6                                     7.2 -8.3 fUbs.
                                                                                                                  (1.0-1.15 kgf·m)




                    Bolt Torques                                                                                                                                                          fUbs (kgf-m)

            ............~~terial Grade                       Standard Bolt                                                 Special Bolt                                        Special Bolt
                      -........          i----.. -.---...- -.. -.-..         . .... - -...- . - . -   - - - - - . - . -..· - . - ..- - . - - - - . - - . - . - . - . - - - - - - -   ---------l
                 D;;;~"""""
            Nominal                                          SS41. S20C                                           S43C, S48C (Refined)                               SCR3. SCM3lRefined)
           1-------:·"::>--- - -.-                                                              .. -- - - - - - - . - - . - -.. ------- -----.------.------(
                     M6                      5.8-   6.9
                                                         -
                                                  .. ......... _
                                                                    10 BO - 095)
                                                                ·. - .- .. _._---               .-    ~---.---'
                                                                                                               72-8.3
                                                                                                                   ..__ ._..
                                                                                                                             (100 -
                                                                                                                                     _-_ __
                                                                                                                                     1 15)
                                                                                                                               .. .- "'-'--
                                                                                                                                                                9.0-         10.5        1.25- 1.45)

                     M.8                    13.0- 15.2              (1.80- 210)                            17.4- 203         12.40- 280)                       21.7 -     25.3           3.00 -   3.50)
                                         ----------
                     Ml0                    289- 333                         400- 460)                35.4- 41.2
                                                                                                .. _. --_...       _-
                                                                                                                    '-"                      _
                                                                                                                                   ( 4.90- 5.701
                                                                                                                        _. -_._.... ..-- ... ....-
                                                                                                                                                               44.8- 52.1
                                                                                                                                                     ._-- ------_._------              ( 6.20- 7.20)

                  M12
           -------_._-_     .
                       .._.;_ .. -_......._--_ .·... _.
                                   46.3 -     53.5                           6.40- 7.40)   .. -       -_ _-_._
                                                                                                      57.1-
                                                                                                      ..         66.5
                                                                                                           ... _-_ .. - ------_..  (7.90-   _---_.
                                                                                                                                                9.20)
                                                                                                                                                    --    -     75.9-
                                                                                                                                                               ... -- ..- 86.8         (10.50-12.00)

                     M14
                    M16
                                            79.6 -
                                    123.0""'"' 141.0
                                                       92.6                (1100-1280)
                                                                                       ---_
                                                                                    .·. __ ._....
                                                                           (1700 -19.501
                                                                                                       _._-_._
                                                                                                      91.1-1085
                                                                                                    144.7 -166 4
                                                                                                                 ....     __       112.60-15.00)
                                                                                                                          ._--_.-_... _--- ---- -
                                                                                                                                   (20.00 -23.00)
                                                                                                                                                           ._ ---------. (17.00-2000)
                                                                                                                                                              123.0-144.7
                                                                                                                                                              ...·
                                                                                                                                                              191.7 -224.2             (26.50 -31.00)
                          -_
                ...... .·.... " ' -                                                                                                     -.......-- ..- ... -- r--.- -.-.--               ._..- - - -
                    M18
                     M20
                                  -.-.ur- .
                                    1808-2098
                                                p -



                                          245.9 -289 3
                                                      ····   -.
                                                                           (25 00 - 29.00)
                                                                           (34:00 - 4000)
                                                                                                        202.5 - 23~ 1
                                                                                                         .... - - ........
                                                                                                        271.2 -318.2
                                                                                                                          _-_ __
                                                                                                                               ...
                                                                                                                                      (2800 - 32.50)
                                                                                                                                      (37.50 -4400)
                                                                                                                                                                         253.2 - 296.5
                                                                                                                                                                         361.6 -419.5
                                                                                                                                                                                       (35.00 - 41.00)
                                                                                                                                     · . . . . . . . . . -.- ..-.--.. -~-- - - - - - - - - - - - ;
                                                                                                                                                                                       (5000 -58.001


                                                                                                       (25)
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
     -----------------f--------- ----------- ----------- --------------
            7                     Special Bolts      543C. S48C (Refined)
     -------------- --+--- ---------------- --- ---------------------1
              9                             Special Bolts           SCM 3. seR 3 (Refinedl




                                        (26)
.


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