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Universal Diesel 5432 Technical Manual



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SERVICE MANUAL       Model    5432 5444    Part Number 200153          Edition 1       October 1990                          INDEX                                                                          12Fuel System                              34Lubrication System                           56Combustion System                             7Valve Timing                                8Compression  Liner Cylinder Head                                                9                                               10                                              10Air Cleaner                               10Piston and Rings                               11Crankshaft                                11Connecting Rod                               12Gear Train                              13Camshaft and Bearings                        13Main Bearings                               14Injection Pump                                15Flywheel                                       16Water Pump                                 16Starter                             1617Glow Plugs                                   17Wiring Diagram                            18Reference Charts                           1924Torque Chart                                24                                                              15            20             30            40         50                                  5411        5416         5424        5432     5444 HORSEPOWER                          11            16             24            32         44 NO OF CYLINDERS                    2             2              3              4           4BORE  STROKE                  267 x 275   299 x 323   299 x 323 299 X323 33 x  m IN               31            45            68            91        115MAXIMUM RPM                   3000         2800          2800         2800      RATIO                221         211          211         211       211TYPE                                Vertical water cooled 4cycle diesel  EQUIPMENT                12 Volt 55 AMP Alternator Electric Starter                                    Ii Glow Plugs                                     Mach        Fue 1 Pump    Fuel Pump    Mach            Fuel Pump LUBRICATION Engine              22 Qts      37 Qts      56 Qts     115 Qts          8   Qts                                    Use SAE 30 HD CD or IOW40 heavy duty diesel                                    lubricating oil LUBRICATION Transmission          Fill to full mark on dipstick          Use autOllatic Std and VDrive                  transmission fluid Type ATRANSMISSION REDUCTION            21          21                 21               21      21COOLING SYSTEM 7 PSI CAP        Seawater           Fresh    water     cooling   syst                                    cooled           48Qts            6 Qts       8 Qts   8 Qu                                                     14 PSI            14 PSI       14 PSI    14 PSISEA WATn INLET  OtTlLET                                  38 NPTEXHAUST FLANGE                                           114 NPT                112 NPT 112 NPT                                             Diesel fuel number 2DFUEL                                                     516 IDFUEL INLET HOSE FILTERS FUEL OIL                  298854             298854           298854        298854   298854 FILTERS LUBRICATION OIL           299381             298852           298852        299584   299927 OOVERNOR                                    Centrifugal type  all speeds                                         1MODEL                            15           20                 30         40       50                                5411      5416          5424        5432   5444DGlRE OPIUTIHG TlJlPlIAlUIE                  175 0 to 1900       MAX OPERATING AHGLIENGIIIE ROTATION                Clockv18e when viewed fraa Vbelt  PROPELLEIl IlOTATImf                               Rilbt HaDCl                                           BOTH STD AND VDIlIVEENGllIE WEIGHT Pound         245          365             425           490     545LENGTH Overall                256        280          325          362   360HEIGHT Overall                212        241          246          260   260WIDlB Overall               207        207          207          207   214INJECTlmf  TIMING              25 0 before top dead center  all od18                                                2 Construction and Handling     Fuel System Fuel system                                                       FuelfilterThe fllel system schematic is shown in Fig  with the fuel        The fuel filter is of the cartridge type shown schematically inflowing in the direction indicated by the arrows To bleed air     Fig 2 Under normal conditions it should oly have to befrom the system loosen the vent plug A on the fuel filter       replaced every 400 hours To install apply a small amount ofand crank the engine until there are no more air bubbles from      fuel to the packing anc tightn securely by handthe vent Tighten vent A nd purge the ail from the injection pump at vent S using the same procedure                       Note Vent S is a valve When the valve      is opened air take vent to the fuel tank through the      overflow piP                                                                    7 Fuel filter                                                                    2 Cover                                                                    3 Pipe coupling                                                                    4 Vent plug                                                                    5 0 ring                                                                    6 0 ring                                                                    7 Element                                                                                     Fig 2 Fuel Filter                                                                    Fuel injection timing                                                                                       Fuel injection timing is adjusted by changing the number of                                                                   shims used between the pump and the gear case it fits into See     1    Fuel tank                 6 Nozzle holder              Fig 3 One shim corresponds to approximately 5degrees in     2    Fuel cock                 7 Overflow pipe              crank angle Therefore injection will take place 15 degrees     3    Fuel filter               8 Fuel pump                  later when a shim is added and 15 degrees earlier when a shim     4    Fuel injection pump       A Vent plug filter          is removedThe timing is correct when the pointer in the peep      5   Injection pipe            8 Vent plug pump            hole on the side of the flywheel housing lines up with the                       Fig   t Fuel System                       F marked on the flywheel See Fig 4                                                                       Fuel injection pump Speed control lever                                                                                                                                                           Controllllk pin   Inection timing                                                                                              adjust shims                                                                                Fig 3 Adjustment of        Fig 4 Inspection of                                                                                     Injection Timing             Injection Timing                                                            3   Fuel injection pump                                                   Handling the injection pumpThe inJPctioll pump is the Bos h MiIlP K typ It is a prpi   Use care in handling and using the injection pump As mensinn pit1CC of cqIJinmrnt milChirucJ III rlOSf tolerances and its      tinned before the injection pump is a precision piece ofperformance directly affect the p1rforfllance of the engine           equipment and care should be taken not to drop it or clamp itTherpfore handle it with carl                                         tightly when working on it Also be sure to use only clean                                                                         fuel that has been filtered Oil drums left outdoors are always                                                                         ronsidered to contain water so always filter this fuel before                                                                         using                                                                         Clean fuel is a must as the fuel is forced through parts of the                                                                         pllmp and nozzel with clearances of 00004 in 11000mm                                                                         which may easily be stuck or rusted by even the slightest                                                                         amount of water in the fuel                                                                          Installing the injection pump                                                                         When installing the injection pump make certain that the                                                                         control rack pin is corrertly placed in the 02 in 5mm wide                                                                         groove of the fork lever 1 before tightening the attaching                                                                         bolts Refer to the diagram If the bolts are drawn down with                                                                         the rack pin off the groove the rack may over travel and stick                                                                         in this position This would cause excess fuel flow allowing                                                                         the engine to overspeed which would result in engine failure         1 Injection pump assy             14   Adjusting plate         2 Delivery valve holder            15   Control rack         3 Delivery valve spring            16   Pump housing         4 Delivery valve gasket            17   Control sleeve         5 Delivery valve                   18   Upper spring sheet         6 Cylinder pump element            19   Plunger spring         7 Air bleeder screw                20   Lower spring sheet         8 Packing                          21   Shim         9 HolloIII screw                  22   Tappet assy        10 Packing                          23   Roller        11 Tappet guide pin                 24   Roller bushing        12 Clamp pin                        25   Roller pin        13 Bolt                       Fig 5 Fuel Injection Pump                                                                 4 Fuel injection nozzle                                                       Spray patternThe luel infection nozlle like the lu1 infection pump is also            The nozzle cracking pressure and fuel spray pattern are mosta precision piece 01 eQuipment and should be treated with the                accurately checked by using a nozzle pop tesT stand If asame amount 01 care                                                         pop test stand is not available remove the nozzles from the The nozzle cracking pressure                                               engine leaving the pressure lines connectedThe nozzle cracking pressure is adjusted by adding or sub                   shims Irom the top 01 the nozzle spring Adding a                     Hold the nozzles so that the high pressure spray from them0004 in O1mm shim will increase the cracking pressure by                 will not in any way impinge upon unprotected skin Theabout 142 psi 10 kgcm 2  The nozzle crack ing pressure is                  atomized fuel will easily penetrate the skin and cause blood1990 to 2133 psi 140 to 150 kglcm 2                                        poisoning                                                                            Set the speed control lever at W O T and operate the starter                                                                            The needle valve if it is working properly will produce a high                                                                            pitched pulsating sound like that of a flute as fuel is sprayed                                                                            Ollt If this sound is not heard or other problems are noted                                                                            reler to the Fuel Injection Pump  Nozzle Maintenance                                                                            Std  in 41 in Engine                                                                            UPrecaution D                                                                            1 Assembly and disassembly of the nozzle should be done in                                                                                fresh clean fuel                                                                            2 The nozzle should always be installed as an assembly       7 Delivery nipple 7            7 Nozzle spring                                                                                never by component parts       2 Delivery nipple 2            8 Push rod                                                                            3 Remember never to let the nozzle spray contact unpro       3 Nut                          9 Pressure pin holder                                                                                tected flesh       4 Washer                      70 Nozzle nut                                                                            4 Tighten the retaining nut to 435 to 58 ftlb 6 to 8 kgfm       5 Nozzle holder body          77 Nozzle piece                                                                                Any torque higher than this will cause slow action of the       6 Adjusting washer                                                      needle valve and poor injection                    Fig 6 Fuel Injection Nozzle                                                                         22 Lubrication System             Good             Bad                                          Oil pump pickup screen                                                                           The oil pllmp pickup is located in the crankcase as shown in                                                                           Fig 9 and is fitted with a metal screen If the screen becomec                                                                          plugged wash it off with diesel fuel or kerosene                                       pftAZI                       Lubrication system                                                                      The entire lubrication system is illustrated in Fiq 8 Oil from                                                                         the pump is forced through the replaciable parer element                                                    4                 filter The filter is equipred with a pressure regulated valve to                                                           6           keep the pressure through the filter at 6471 psi 455                                                    5                                                                           kgfcm 2  From the filter part of the oil goes to the crankshaft                                                                          to lubricate the crankpins and the remainder goes to lubricate                                                                           the rocker arms                                                                          An oil prfSsure switch is located in the passage from the filter                                                                         and controls the oil pressure If the oil pressure falls below                                                                          14 psi 10 kgf cm 2  the oil warning lamp will light on the           7 Pressure spring          4 Nozzle body                   dash panel If the oil pressure lamp stays on after the engine           2 Pressure pin              5 Needle valve                   is running at normal speed shut the engine off immediately           3 Pressure pin holder       6 Nozzle piece                   Find and correct the cause of the low oil pressure before                                                                         operating again                              Fig 7 Nozzle                              If the pressure regulating valve in the filter fails and the                                                                         pressure rises a safety valve will limit the pressure to 140 psi                                                                          10 kgf Icm 2                                                                   5 Probable cause of low oil pressure n1 Clearance on one of the hearings is to great2 One of the rocker arms is too loose                                                                                I I              I j    SJ t                                                                                        LtHLli 3 Faulty pressure regulating valve pressure lower than    normal replace the oil filter or clean the valve on the old                                                                                                                 one with kerosene or diesel fuel                                                                                  1  I                                          Jr W                                                                                         v    tl                                                                                                      J  j                                                                                                           rTo I llItJ                                                                                                                i pump                                                                                                                                t                                                                                Ij         djl                Oil pan                                                                                                        Drain plug                                                                                           Fig 9 Detail of Oil Pump Pickup                       Rocker arm                       Rocker arm shaft                                                                 Relief valvescreen                                                                                                                    Cover                   Fig 8 Lubrication System                                                                             Safety valve assy                                                                                                                    4    Safety tlalve                                                                                                                    5    Plug Oil filter                                                                                                                    6    Spring1 Rlplace the nil lilttr 111 Ivmy other oil change evmy 150                                                                                                                    7    Oring    hours                                                                                                                    8    Relief tlalve2 Undm normal condition it is only nrpssary to change                                                                                                                    9    Oring    th nil liltpr ilt the 511ilild intprvals If howevpr thp                                                                                                                   70    Plug    pn9ine is used in EXTREME L Y dirty conditions the                                                                                                                   77    Oring    rrSur I 1ulati111 Vii IVI lnd Sillety valvp should also be                                                                                                                   12    Oil filter cartridge assy    rmllrwci and rlpilnld                                                                                                                   13    Oil filter cartridge3 Whfllver the oil liltrr I placed rom the Ponin under                                                                                Fig 70 Oil Filter                74    Label    no loan lor il fpw nrirnllp until tltn filtEr has hppn fillPtl    ann thfl1 arid nil to rllar lip 1m what i5 contained in the    liltpr                                                                                        7 Relief valtle compo           4 Ball valve                                                                                        2 0 ring                     5 Valve sheet                                                                                        3 Spring                                                                                        Fig 11 Pressure Regulating Valve                                                                    6                                                                     Valve                                                                    Combustion air of course IS brought in through the intake                                                                    valve when the descending piston creates a partial vacuum in                                                                    the cylinder                                                                    Valve stem seals should be replaced whenever they are reo                                                                    moved If the stem seal are replaced coat the stem liberally                                                                    with oil before inserting in the valve guide to prevent burning                                                                    thf valve stem seal                         5                                                                             0          1 Safety valve body          2 Safety valve spring          3 0 ring                                        4 Oil filter base                                        5 Safety valve                                                                             2l                                                                                                                                                                  0                      Fig 12 Safety Vallie Complete Replacing engine oil 1 Dr lin and replace the engine oil after the first 35 hrs of    operation and every 75 hrs thereaftpr 2 The oil is easier to change if the enfjine is warm 3 Do not mix different brands of oil If a different brand of    oil must be used drain the oil and replace with all one                1 Valve cap             5 Valve stem seal    brand Also do not mi x oils of different viscosities                 2 Valve spring retainer 6 Valve guide                                                                            3 Vallie spring collet  7 Valve                                                                            4 Valve spring3 Combustion System Combustion chamber                                                             Fig 14 Structure of Valvesrhe engine utilizes a swirl type precombustion chamber             The dimensions of the replacement valves and valve guides are          See       Fig 13 Fuel and air are mixed in this       shown in Fig 15 When new valve guides are installed theharnber resulting in more efficient combustion A glowplug        bores should be reamed to 0316 to 0315 in 8030 tos employed to preheat the fuel for easy starts down to 5 F         8015mm after installation The valve head must be recessed 15C                                                            0043 to 0055 in 11 to 14mml from the face of the cylin                                                                    der head to prevent it from hitting the top of the piston                                                                                                       rf03160317in                                                                                                        02805mmT                                                                                                          0313  0314in                                                                      A    Finished ID of guide                                                                           installed in cylinder    O       7960An975rmmJ                                                                           head                                                                           0315031m1r                                                                           8015 8030mmJ                 r1ID                                                                                                                                 Jt                                                                                                                              0                                                                                                        r                                                                                                   1059 7067in 1295 1303in                                                                                                                                                                                                                                  269      27 TmmJ 7329 33 7miiiT         1 Nozzle holder            4 Cylinder head                                              Fig 75 Standard Dimensions         2 Nozle piece packing     5 Combustion chamber                                                  of Valves Vallie Guides         3 Glowplug                                                                                        Valve Gap                    Fig 13 Combustion Chamber                                                                                  0043  0055in 77 74mmJ                                                                       Fig 16 Sinking of Valve                                                             7   Valve timingWhen the vtlvp cleartncr hilS Deen tdrusrl ilS shown inFig 17 the sttndard valVf timing shown in thp chart can beattained          L               Adjust                 r                        r 2                        i                                     l                                Valve clearance              OCl             00070009 in          nut 1             t 018022                                      T            I         mm                                      In                              L                                  C                                                                                                                                                                                        II                                                         c                                                        i                                                                                                                                                                             Fig 17 Adjustment of Valve Clearance         Intake valve orens                        20 B TOC         I ntakf valvp closes                    45 A BOC                                                                       E xhalls t valve orens                    50 B BOC        E xhaus               valve                 t  closps                 15                               J      A TOC                                                                Valve clearance 0007 to 0009 in 018 to 022 mm withengine cold    Rocker Arms                                                                          0550  0553in                                                                         74002404jmJ                                                                                                                                               e                                                                          0550  0551 in                                                                         T13j39B4                                                                                                j  lIJ11                                               r                                               Fig 18 Standard Relative Position of Rocker Arms                                                          8    Compression release Release wire is optional parts                                                                                                                           Compression  11 part a showlI in Fiq lr Pilil I IPVN 11I11 ilS                                                     positionfill a II wi q dlf to fP Ihat till rn all111 is  th1I cmprl5siOfl is Iaflj rll I nlnrssinll rllnaseIS til Ill liSX wllpn thl battery is Inw IH whell starling inenid wrlt1111 Tn IIS Ihl fnlllprsinll 1flpS prltlfilt th                                                                                           Operation position                                                                                                  I                                                                                                                                                                                                                                    I                                                                                                                       ll                                                                                                                           QIIlWpIIlQ as IISlIill pli ttll CoIllIHssinn rlIils IIIh oul ilSIill il possiblE illld hold it thlII whi uOlllkinq tlw pnJinThis pHllall rilSlS thP fnqim OIllPSSIOn enahlillq il trturn laster in enid wpalhr r whtI the hillpry is low Oncethl cnginl is turning lasl fmouqh to start rrlrlSf the lever andthp r1Qilw will startNOTE    Make sure the compression release has returned to the    operating position by pushing the knob all the way in                                                                                          1 Rocker arm              5 Compression release nut                                                                                          2 Oil filler cap          6 Compression release bolt                                                                                          3 Compression rese lever 7 Shaft                                                                                          4 Adjustment access cover 8 Valve                                                                                             Fig 20 Adjustment of Compression Released                      Fig 19 Compression Released                                                                                        Top                                                                                      Top clearance should be 0028  0035 in 07 to 09 mmlDo not pull the compression release lever when the engine is                                                                                     Tn adjust ue cylindpr Qaset shims 0006 in 015 mm thickrunning at high speed or under load If it is necessary to use                                                                                     each onto the hpad sidethe compression release while the engine is running reduce the                                                                                     For chfCking the melSumment place 11 piece of luse on thespeed to idle before doing so                                                                                     ristol1 top and fix th cylinder head sfCurely on the cylinder   Adjustment of compression release                                                head flange The meaiurernpnt is taken hy the fuse The liner isI Set exhaust valve in totally rinsed position                                     ICVf1 with thp cylinder frame at top urface2 Remove dlcomrression adjustlllent window cover from                            Thf gasket shims can be reused so do not lose them    cylinrler heild cover                                                                                                      Head3 Milke valve clearanr as 0 with lise 01 dncompression    adJlJst holl From this position turn thp bolt furthr by    1 to 15 turns Opcompression clealancp will then be sct    at 0030 to0044 in 075 to 1125mm which is the    designed clearance4 After adjusting be sure tn lock adjust bolt securely so    that it will not unWrn while engine is in service5 Make certain that the cleanrance is nnt too wide To    chprk this turn crankshaft hy hand and makp certain    valve rlisk dos not contact with pistion toP                                                                                                         Fig 21 Top Clearance                                                                          9         Boring and replacing the cylmder linerReferrinj tn Fig 22 the insidf diaewl 1 the liner shouldbe checd at points 12 and anr in thp rlirfrtinns a andbL The Imer on which the wer has pxcperlpcJ thp Strvice limiteiln tw bOHn ilun honpd In                         OoO in      0 Omm nversizeThp           finishpj         dimensions are 3 248 249 in                                                            82500 R2S21lfT1                          and 101  013 in                                                   7GSno  76519mlll1         An oversiled piston and I inqs must Ihell be lIsedwith thIS IrnpI OnCt this WISild linr has exclPJpd its wearlimit it should be replacfd Wllh A nnw om Tl install il nfWliner coat the olJtirjp liwrJlly with oil push into II blorkwith a press and finish to til standArd ril When Ihis is donea standard sin piston must allain hI IIsld                    i                   1 I                       IGj    E         i                   N                                    c1t                                  co                 NO         t                             r    i                                              1                                                                   Fig 23 Tightening of Cylinder Head Bolts                                                                                                          Air cleaner                                                    Ig         1                                                                                     Under normal conditions clpan the dust cap one a WPfk     I I                                   p                                                                        If the engine is used in a dirty environment clean it more    I    I                              N                 0                 M                      d                            J                                                     j                                                                                                                 L                                                                                                         often Under no circumstances should dust bp allowj to                                                                                                         aCfumulate to more than half the cap capacity If a lilrrw                                 en                  I                                                                                                 Il                                                                                                 piecc of 1apr or other obstruction gets stuck in th air intakf     X     j                                     Il                                                                       c                                                                                                                                                                                                                                         3130    3131in                                                                                                         remove it immediately Always install the cover with the                                                                                                         stamped TOP uppermost If the cover is installfrj ll1side                                                      j2 HP                                              down by mistake the dust and dirt will not enter the rap and                                        L                          7950 795                                                                                                         the filtPr witt plug prematurely                                                                      34944  34856 in                                                      44 HP          188505  88535mml                 Clllan the element every 100 to 200 hours of o1eratinn KpPf                                                                                                     th dust cap in place while cleaning the filter to 1reVfllt                                 r                                         Standard size                                                       j    ver size                          cntamination                                                                                                         If a red signal of the dust indicator attached on the air clpaner                                      2992  2993in             3012 3013in                J2          HP                                   76500 76519mml                                                                                                         ilppears remove the element and clean or replace with new                                   76 019m                                                elements After that push down reset button to returning its                                   33465 33473 in             33661 33670 in                     signal                44 HP             85000  85022mml            85500  85S22mml                  Fig 22 Standard Dimensions of Cylinder Liner                           and Liner Bore in Block         Tightening cylinder head capscrews Fig 23III Th liqhtrninq tHClll of th  ylindr 11al CiJpsrrpws is                                                                                                                            10                       54 to 58 ftlbs 75 to 80 kg m Nlllnbers 11 13 and 15                                   1 Aircleanerassy             2            17  in the diagram are studs The nut on these studs                                                                        3                                                                                                   2 Body                           1     should ill tlP tiqhtenpd 10 this Ill                                                                                                   3 Air cleaner element IIssy              42 All tlH Cillsrrpws 1St il tiqhwncj llllitmrnly Tn d                                                                                  5                                                                                                    4   Wing nut                                          6    this tilhtfn all lh rilpsrVJ ill til ordN il1licatPi nn                                                                                                    5   Baffle cover                                           7    the ilaqrart IIntil thrv ill Jtlst SwI T1un tiqht  n poch                                                                                                                                                                                            6   Cover    nn 1 ollrl turn ilt il tim  thIS sam seClllncp tach                                                                                                    7   Clamp    tilllp unlil all havp blen lIrlhtnfd 10 lh rtqllirffl tOlqllP                                                                                                    8   Lavel31 TI1 Lylini hPAd CilliUtW should h rftiqlltpned if                                                                                                    9   Lavel    thl pnqin has not hen Ilpci fr a IOllq til1H The valvr                                                                                                   10   Indicator assy    lash shotllrj also he adillstfrj prh lirnr tl cylinder heild                                                                                                                                     Fig 24 Air Cleaner    UII5CIwS jt flOrqwd If th rylidr IHiJd qasbt hilS    Ilpn rellaCtd rim tht l fnl lbOJl 30 rtinlltfS and    rptlqhtln til rylindpr 1111 IPSW as                                                                                             10       Main Moving Parts                                                                                     Crankshaft and connecting rod Pistons and piston rings                                                                                  1 The crankshaft is a heat treated steel alloy forging TheThr 01S1Ons ilnd piston rinqs H shown In Fig 26 If the                                                      crank pins are induction hardened for additional wearcvlindr Ilnrrs have hecn bOIi ovcri oversize pistons                                                   resistance Crankshaft endplay is 0006 to 0012 in 015and rtngs must hr usel The 0iston is marl If high silicon                                                to 031 mmAIAIIV imel is Cilm ground The tor cmnprPssion ring is a                                                2 The crankpin bearings are aluminumchrome plateej kvstnne vrf the seronel rompression ring is                                                When installing the connecting  lnt undercut anej tllr oil control ring is of the                                            a Clean both surfaces  expansion type                                                                                     b Apply engine oil to the threads of the connecting rod                   S End gap of rings on poston in cylinder                                                       capscrews before installing and tighten each to 27 to                   I  Diameter of piston skirt thru t of pilto pin bar                   E Diameter of piston skirt perpendicular to piston pin                                         304 ftJbs 37 to 42 kgm                                                                                                                   The bearing caps are matched to each connecting rod                                                                                                                   and should not be interchanged Also since there are                                                                                                                   var iations in machining from side to side each bearing                                                                                                                   cap and connecting rod are marked and should be                                                                                                                   assembled so that the marks line up                                                                                                            3 In the ewmt that the crankpins become worn and are no                                                                                                                longer serviceable undersized bearings may be used                                                                                                                When installing the undersize bearings observe the fol                                           0081 0082in                                                     lowing precautions                                         7205S2iJ70mm                                                    a Machine the crankpin diameter and radii to within                                          0197 0198in                                                          a few thousandths of the correct dimensions and                                           5010 5ijjoU7                                                                                                                   finish qrind to the exact dimensions                                  05  0Q6j                                                    b After finish grinding the bearing diameter and the radii                                      23000  23013mm                                                          chamfer the diameter of the oil hole with an oilstone                                           I                     0012 00 l8in      8                                                                       If this is not done an oil film will not form and the 010in 249mm    030                            l      1                             0TJ                        ill                                                  bearing will siezeoz8  O1950 1962mm                ri                                                                                      II   l                                                                                                                c The crankpin should always be superfinished to                                                                                                                   0000016 in 00004 mm or less 01957 0965inJt                                   I               k 4978  4990mm                                                                  L    A                                                   81                                                          l                                                          J                                                                                                                                                             0                                                                                                                d Select the bearing from the chart that necessitates the                                                                                                                   removal of the least amount of metal from the crank                                                                                                                   pin Do not deviate from the chart dimensions as the            9J 10  OOlBm                                                                                                                                                                       bearing life will be reduced if they are machined            025045mm                                                                                                                                                                       e To determine the running clearance assemble the con                         Fig 26 Standard Dimensions of Piston                                                    necting rod bearing cap and bearing as described in                                  and Piston Rings                                                                                                                   SPCtion 2 and measure the diameter anywhere within                                                                                                           the 1200 angle indicated in Fig 28 ald subtract the                    Standard size        Over size                                                                crankpin dia meter from this figure                        2992in          3012in            A                                       76mm                   2986  2987in                                         765mm                                                                                3005  3006in                                                        1 The piston pin bushings are of lead bronze                                                                                                                   The inside diameter of the bushing should be finished      I       75839 75859mm 76339  76359mm                                          2 HP              to 0906 to 0907 in 23025 to 23040 mm                   2989  2990in  3008  3009in       E       lAo               75915 75935mm E643                       3346 in         3366 in                                                                                                                                44                       185mm            1855mm        I                  3341 3342 in   3360 3361 in                                                  HP               84855  84875mm 185355  85375mm                  3343 3344 in   3363 3364 in                                      t        E      184915 84935mm 185415  85435mm            Over size               Name of Part                             Part No                         Mark                                                                                               Piston 05                                                                05    OS     002in 05mrn                                   Piston ring                                                       05                                                   05    OS                32      HP         Cylinder liner                      301210 3013in 76500 to 76519mm                                                                       1 2JlR ma x to 2JlR max by honingL                                                                                                   i              44 HP               Cylinder liner                                                                       3366 to 3367 in 85500 to 85522mm                                                                       12JlR max to 2pR ax by honing                                                                                                11                                                                                                                    031   nI4                                                                                                                    111   JIm                                                                                                                                         RMfflll 004  0 06   tr  r SntmJ                                                                                                                      o r300 46                                                                                                                      13J  31mm                                                                                                                    Fig 28 Crankpin for Undersize Bearing                                                                                                                   ll                                                   0155     10267                                                                                                                        I   1036 IfRI                                                                                                                            116000 16WI    9B                                160lR                                                                                                                        l09065090                                                                                                                            12301                                                                                                                                                                                   09059                                                                                                                                                                         123002 10 1m                                                                                                                                                                         o 143 0 753m                                                                                                                                                                        rrR 870 9     Jtmt                                                  2nu2tuSm                                                  S   g    5 UnmJ      2050 205200      52064   52 3   0 1RO 193              o 3 0753                                                                 lB 19 13mm1                                f1     2248              1910 13mm1                                                                                                                                                                         o 058  t059m     1510851                1                                            rw                                                                                                                           H 4112  4fflmm                           j    JI         i              iIi               fll      fl1 1I        A  Oieme  01 pitonpin buhing ef instelletion                                                                                 1                                                                                     0018 00                                                                                                             Fig 29 Standard Dimensions of Connecting Rod                                                                                    l9lrJ2                       Bearing and Bushing      Fig 27 Standard Dimensions of Crankshaft and Bearings                                                                                                                                              Metal                       Size            Part No                                Bearing                    Crankpin Diam 0                                           Running Clearance                                                                                                                                              Mark                                                                                                                                                                                                           020       I 1522122971                        020mm undersize                                                                                                        17228 to 17234 in                                                                                                                                             020US32   HP               040           1522122981                      040mm undersize                                                                                                        43759 to 43775mm                                                                                                        17149 to 17156 in                                                                                                        43559 to 43575mm                                                                                                                                             040US                 0001379                                                                                                                                                                   to 0003661 in                                                                                                        17228 to 17234 in                                       0035 to 0093mm                       020           1547122971                      020mm undersize                                                       020US44 HP                      040           1547122981                      040mm undersize                                                                                                        43759 to 43775mm                                                                                                        17149 to 17156 in                                                                                                        43559 to 43575mm                                                                                                                                             040US                                                                                               12     Main Components                                                        Camshaft gear Gear train                                                             Rptlf to Fiq 31 Place the camshaft retainer plate on theB SIIr to asspmblf thl Clears by matchinq thp millinCi marks       cillTlshaft first Shim the camshaft retailer plate out from the115 shown in Fig 30 Thp backlash of each gear is 0002 to              camshaft 0003 to 0009 in 1007 to 022 mml with shims0005 Ill 00415 to 0 54 mrnl                                        that can be pulled Ollt after the gear is installed Heat the gear                                                                         to approximatply 176 F SOoCI and slide on the shaft until it                                                                         blltts liP aqainst thl retairfr plate Remove spacer shims If                                                                         the qnar will not slide on the shaft easily it too may be heated                                                                         tll a sliqhtly higher temperature as described above                                                                                                                                                                              i                                                                              l                                                                                                       0003  OOO9in 007  022mmJ                                                                             1 Camshaft gear                 4 Circlip                                                                             2 Camshaft                      5 Pin plug                                                                             3 Camshaft retainer plate       6 Key                                                                               Fig 31 Assembly of CamshBft Gear with Camshaft                                                                          Camshaft and camshaft bearings                                                                                     Standard dimnnsions are shown in Fig 32 Camshaft running        5                                                                 clearance is 0002 to 0004 in 005 to 0091 mm                                                    Z 40 T                 34T1                 39 T 2      1 Crankshaft gear           4 Camshaft gear      2 Oil pump drive gear       5 Fuel injection pump drive      3 Idle gear                    gear                 Fig 30 Mating Marks of Gear Train  Crankshaft gear  hl to al10llt 170 F 80n CI and sl idn on cranlshaft If the shaft 1111d bore riimrmsiom arp such that the qPu will not slide fl5i1y it may bl heated to a slightly hihrr tnmperature                                                                                 I ill iljtl IlJlIlUI                                                                                                     51Z1513i1t for installation                                                                                   13113111                                                                                                     1515 15                                                                                       f1lrJL                                                                                       F                                                                                               frr                                                                                                 trl  1                                                                                                          JL  f                                                                                Fig 32 Standard Dimensions of Camshaft                                                                                         and Bearings                                                                 13 Main bearing assy                                                                   Main bearing housingInsert the bearings in the main bearill housing halves as in                        Installation of crankshaft with lain bearings in engine blockdicatec1 in Figs 33  34 usill tht thrust washers only on the                     Slide the crankshaft assembly into the engine block beingJournal nearest the flywheel Coat the Crilnkshilft journals and                   careful not to nick or scrape the crankpins After the assemblyth bearing surfaces with enqine oil f1il the housinq hillves                 is in position make sure the oil passages are correctly lined uPwith bearings on the rrankshaft eOill Ihl capSTCW ihreilds                     Install the main bearing housing to engine block lockingwith engine oil and tighten ttl 21 to 25 fUbs 3 to 35 kgIll                       capscrew and washer from the side to position the hOllsing andM8                                                                                    then install cafscew 2 from the bottom and torque to 47                                                                                      tn 50 ItIbs 65 to 7 kgm  Ml0                                                                                          7 Bearing                                                                                      2 Capscrew                                                                                      3 Locking tab                                                                                      4 Main bearing housing                                                                                      5 cpscrew                                                                                      6 Locking tab                                                                                      7 Locking tab        Fig 34 Main Bearing Housing 7 2 3      7   Bearing      2   Thrust washer      3   Thrust washer      4   Crankshaft journal      5   Main bearing      6 Capscrew      7 Locking tab          Fig 33 Main Bearing Housing 4 with      8 Locking tab                   Thrust Washets                                                                  o                                    d                            Main bearing housing 1        51565157 in                                                                                           130968  130986mml                                                                                   Main bearing housing 2    51956  51963 in                                                   131968 131986mml                                                                                                                                        5235  5236 in                                                                           22047  22055 in                                                    1 156000  56019II1I1I1                            Main bearing housing 3 1132968  132986mml                                                                                                                              53137 53144 in                            Main bearing housing 4     1134968  134986nvnl                                                                     14 Idler gear                                                              Injection pump camshaftSecurp he idler gear shaft to the engine hlock with 3 cap              Injection pump camshaft Fig 37 Install the bearings andscrews torque to 17 to 20 ftlbs 24 to 2B kgml lind bend           governor unit on the camshaft and install in the engine blocktabs of tllb washer Install gfar as lhown make sure it runs          Hour Meter Unit Fig 37 Insert the tang on the end offreflv hilS a running clellrance of 0001 to 0002 in 0020 to       the hour meter drive shaft into the slot on the end of the00f4 rnml ami OOOB to 0020 in 020 to 051 mm end                 injection pump camshaft and install as per the                                                          l                                  fi          1 Idler gear     2 Spacer                    13 1       3 Retaining ring     4   Shaft                     thr     5   Bushing                                 6   Spacer     7   Engine block     8     9          Capscrew          Tab washer                                      7                                                                                 Fig 36 Idler Gear                                                                           1   Fuel injection pump     5 Injection pump gear                                                                           2   Speed control lever     6 Governor system                                                                           3   Fuel control system     7 Injection pump CJlmshaft                                                                           4   Hour meter unit        8 Idling apparatus                                                                                  Fig 37 Injection Pump Camshaft Assy                                                                  15    Attaching flywheel to  the entire contact SIJrfilCf rardull CDilt the cnntilCt             1 Rust inhibitor and antifreeze should be used in accordsurface with engine oil wilsh illl the oil off with gasoline ami                ance with the  in the related manualsdry It throughly Put the flywhpf1 on imd tnrqlll the Cilfscrews          2 Be sure to remove all debris that may be plugging thl finsto 70 10 77 ftlbs 1010 11 lrn Bpnd the IrlCking tabs back            3 Chllk the rubber shock mount nuts periodically to beon the washers                                                                   sure they are tight Tensioning of fan belt                                                                               Cooling water pumpThe fan belt tension is ilejUstpri hv rnovinq thp altlrnator                                                                              Tn install the cooling fan pulley on the pump securely tightenbrackeT in Of out The belt is properly tensioned when the                                                                              the nut 4 to 506 to 579 ftlbs 7 to 8 kgf m torquebelt deflection midway between the alter nator Dillie and thecrankshaft pulley is 025 to 035in 7 tl 9 mm with a forceof 20 Ibs applied Proper bplt tension is essential for goodenginp cooling and belt life See Fiq 8                 Fan pulley             Tension pulley Alternator pulley                                                      1 Pulley                         9                                                                                                                         2 Bearing                                                                                                                                3 Key                                                                                                                                4 Nut                                           r                                                                                  5 Body                                         W                                                                                    6 Shaft                                     025 to 035in 7 to 9mm                                   i                                                                                          7 Rotator                                                                                                                                8 Case                                   iI                                                                                          9 Seal                                   I                               Fan drive pulley                                Fig 38 Fan Belt Tensioning                                                                                                                       Fig 39 Water Pump          Starting Motor    The starting motor is of the rerJlJctinn tyre drive    The assembly is shown in Fig 43                                                                                                                                  t   Yoke                                                                                                                2 Armature                                                                                                                3 Packing                                                                                                                4 Brush holder                                                                                                                5 Brush spring                                                                                                                6 Packing                                                                                                                7 Magnetic switch                                                                                                                8 Gear 1                                                                                                                9 Gear2                                                                                                               10 Ball                                                                                                               1 t   Over running clutch                                                                                                               12    Drive end frame                                                                                                               13    Through bolt                                                                                                               t4    Screw                                                   10        II                              14                    Fig 43 Starter Assembly                                                                      16         Starter specifications                                                          Insufficient brush contact                                                                                        Dirty or worn commutator                                                                       Precautions in care and handling of starter motor                                                                      1 I The starting motor must be installed properly for the  Code No                          299574                                           starter pinion to mesh with the engine ring gear as it                                                                           should If the ring gear and pinion do not mesh properly  TyJe                                                                   the pinion and starter housing may be damaged and in                       Reeluction                                                                           extreme cases the starter may not even turnr                                         21 If the startel switch is turned on and the engine turns  Nominal                       12V                                                 but will not start the cause is probably in the fuel system   voltage                                                                           Check the fuel lines and correct as necessary  Nominal                       14kW                                           31 In attempting to start an engine never use the starting   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 moreL                                                                           than 30 deconds the solder may melt from the armature                                                                           or the coil 01 lead wires may melt Also the battery will  Trouble shooting                                                        be discharged to such a degree and wont have sufficient If the battery turns extremely slow or not at all the cause may          power for another attempt at starting A good rule TO lie If1 the battery wiring or the starter The headlights are            follow is to crank for 1Q seconds and pause for lOse a very convenient tool for tracing the cause of the trouble              conds Repflat until the engine starts Headlight method                                                    41 If the starting motor is too far forward the pinion will The use of this method of course assumes that the headlights             not mesh properly with the ring gear and cause rapid are functioning normally                                                  piston wear Adjust for proper mesh 1 Headlights are dim                                               51 Do not turn the starter switch while the engine is running        Probable cause Low battery faulty contact at one of               If this is done the ninion gear will contact the ring                          the connections faulty wiring If the           qear Jhich is turning with the full force of the engine                          battery remains discharged because of a           which may cause a broken pinion bent shaft broken                          malefaction in the charging system it            housing etc                          should be corrected before charging the                          battery           to prevent the problem          Glow Plugs                          from reocGuring                            The glow plugs are the sheath type with the wiring diagram as 2 With battery fully charged                                      shown in Fig 44      a Symptom Lights do not light         Probable cause Battery terminal not properly                            connected      b Symptom Lights become extemely dim when crank                                                            1 Glowplug                     ing the engine and starter slows down or                                                      2 Glowplug                     stops                                                                                            controller         Probable cause                                                                                           3 Starter switch                      Bad engine rotational resistance too                                                                                                                   4 Main switch                        great I                                                                                    5 Regularor                       Starter does not turn satisfactorily                                                                                                                   6 Alrernaror                                 Armature shaft bent                                                                                                                   7 Battery                                 Worn ushing                                                                                                                   8 Starrer                                 Pole core screw loose                       Field coil grounded or insulator short                                                                                 Fig 44 Circuit Diagram for Glow Plugs                         circuited                        Armature coil grounded or insulator                         shortcircui ted      cl Symptom Ughts are bright bllt starter does not turn                     or turns very slowly         Probable causes                      Starter terminal not connected properly                      Solenoid switch not making contact                      Solenoid not working coil grounded or                        insulator short circuitedl                      FaUlty starter switch contact                                                          17                      ENGINE CONNECTIONS                                               Universal Diesel                  PANEL CONNECTIONS  E  Q                                                                         I                                                                                                                                                                                en          3JCll                                                                         I                                           Connect to ACC term on switch  C                      2 CYl                                                                                                                              1co                      1r                                                                                                GlOW PLUG r          GLOW I PLUGS               FUEL PUMP w Q                                                                                                                                                                                                                                                                                                                                                   00  Reference Chart         Engine                                                                                                          MaximumParIS                       Items                       SlPciflcations           Standard Value                                        Remarks                                                                                                            Limit         I                                                                      When installing apply a generous          Cylinder hfoad tightness                 Ml0 x 125                    542  579 ftlbs  i                                                                            75  8 kgm                        coat of engine oil onto the entire  r      Cylinder head surface dstortion                                       0002 in below                        surface of j h btt                                                                                 1005mm below          I ntakeexhaust valve sPat thickness   45 0059 in 115mm                                                           I           i                                                                     00276  0 0354 in          Top clearance                                               107  09 mm          i O059in                                           fl5mm1                             10          Standard 10                                     32 HP         29Q21 29929 in                                                   76000  76019mm                                                                                               I          29980 in 3011Ql1In                                                                                                          7615mml 176500 76519mm                                      44 HP           3400  33473 In          I              I                               185850mm         Pston clearance           t   HP     OOO  00905 10                                    r            10065  OI64mm                                         At piston skert    144HP 00026  00066 In4I  u                                                                                                                    Height above block surface                                100650167mm4          Type                             Dry               000098 in  0025 mm1    Ir          Standard 00                      HP     29921 in 176mm                                                   Oversize 0020 in 05 mm                               r44HP          33465 in 185mmJ   c    Pistonpin boss 10                       09055 09060 in                                      09071 in   o                                               123000 23013 mm                                    12304mm                                                                                    interference Clearance          Pistonpin clearance                                                  00004 in   00004 in                                                                                001 I mm 1001 I mm                       Rong gap                                 toP 2nd                    00118 00178in        00492 in   05 oversize top ring surface should                                                                        9945m 1125mm         be 00079 in 02 mm below                                                                       i 00098  00158in                                                                                                                       piston side surface   g     Top ring WIdth                           Keystone IVpe                 1025045mm  a          2nd ring width          Oil ring                                                   00768 00772in                                                   1 95  1962mm                                                   01960 0 1965in                                                   4978 499 mm                                                                                 Ring groove clearance                                                                                 00037 00047 in                                                                                 10093 0 120mm                                                                                 00008 0 0020 in                                                                                                                       0 00019 in                                                                                                                                          O2mmJ                                                                                                                                                    J                                                                                 1002 0052 mm1                                  t          i i     t           I   c    00                                       09056 09059in  a                                               12300223011 mm   c   o                                                                               00006 00015 in       00059 in            Pintobush clearance                                                                                 0014 0038 mml        0 15mmlt                                               Small end 10                             1 0236  10244 in                                            i           Pin                                                   2600026021 mml                                                                                                                                                OOOO79in                                                   without bush                                                                                                                         l                                                                                                                                                   to02mm    a          Small end width          Large end 10                                                   10236 jn 26 mm                                                   18504  18512 in                                                                                                                                                                                                                                                                                                                                                                                                                                                                 Connecting                                                                                                                                                  rod    5                                               147000  47 02Omm                                                                     4in f100m  g                                                without bush                                                                             toOOO79in   c  c                                                                                                                  OOOO79m                 to 02mm  8       Large end width                          10079  1 0118 in                                                 to02mm                                                                         256  25 7 mm          Rod torsion                                                            00008 in                0002 in                                                                                                                       When installing apply a generous          see diagraml                                                          O02mm                 005mml                                                                                                                       coat of engine oil onto the entire          Roo bolt torQue                           MSx I                        2676 3038                          surface of each bolt                                                                                 fUbs 37 42                                                                                 kgml                                                                        l9 Parts                   Items                                                                            Maximum                                                  Specifications                      Standard Value                                    Remarks                                                                                                            Limitf                      f              111           10                                 17327  17345 in                                              4401  44056mml                                             wIth metal            Width                                          07429 07531 ill                                                           1887  1913 mml                                                                                                                        Center thickness            00                                             185 in 47 mml                                                 0058300589 in                                                                                                                           1482 1495 mml            Running clearance                                                     00014  00038 in     00079in                                                                                  0035  0097 mml     02mml            Axial clearance                                                       00157 00236in                      Crank armtoIarge end clearance                                                                                  0406mml1      Il            Crankshaft jllrnal dia                         20441  20449 III                                                           151921 5194mm            Main bearing 10                               20465  20481 in    1Running clearan    00079 in                                                           5198 52025mml        00016000411n       02mm                                                           with metal            1004 0 104mml            Crankshaft metal 21                           0742907531 in            width                                          1887 1913 nl           fl            Cr  nkshaft jurnal dia                     20449 20449 in                                                           51921 5194mm      IRunning clearance                                                                                                          00079 in                                                                                   00016 00046 in      102mml            GearSide main bearing 10                      20465 20488 in                                                          5198 52 039mml      1004  O 118 mml  CD                                                           with metal   c              Crankshaf1 metal 11                           07823 07925 in            width                                          11987  2013mml            Crankshaft metal  1I 00                       22485  22474 in                                                           157111  57084mml          f 1 1            Crankpm jurnal dia                           17307  1 7313 ill                           00047in     When installing apply a generous                                                           43959 43975mml                              012 mm    coat of engine oil onto thp entire                                                                                                                       surface of each bolt            Crankshaft side clearance                                             00059  00122 in                                                                                  0 15 031 mml            CrJnk bearinq cap                                                    217293fUbs            boll 1 torque                                                           M8 125                                                                                  3 35kgml            Crank bearinl call                            M lOx 125              470506 It Ibs            boll 2 torque                                                       65 7 kgmlf                                       11            Cam bering ID                                 1574815758 in                                                                                  IRunning clearan                                                                                                                               x                                                           4000040025mm                                                           1 57215728 m1                                                           3993439950mml                                                                                  I00020  00036 1M                                                                                   10050 0091 mml                                                                                                                       01611 in                                                                                                                       f795                                                                                                                                m                                                                                                                                    J     f            Axial clParance                                                       0002800087 in                                                 13134 in  iV   r                                                                                                                                          3336mmJ                                                                                  007  022 mml                                                                                                                               ik  J  III  E  u          Carn hft                                       02165 in 55mn                                           05451                                                                                                                       1386mmJ            Cam heillht                                    13134 in                                                           3336 mml                                                                          20                                                                                                      MaximumPrts                       Items                        Specfcatons           Stllndard Vail                             Remarks                                                                                                        Limit                                            gear                                                                        Number of teeth crank                34            Number of teeth idel gear            79            Number of teeth earn Ifar          68    io 0          Number of teeth    c         Inlectlon pump gear                   68    t        Number of teeth oil pump             45            drive gear            Number of teeth oil pump drive gear I 40            Number of teeth oil pump rive gear 2 39                       a 001631oo4s4 in      00118n                                                                             0   041S I   154mml   03mm            Backlash                     Shlnkillf                          00433  0OSS1 in                                                  11 14mm             Facl angle                           4So                                                            Valve guide bore should be                                                                                                                  reamed after inserted into                                                                                                                  cylinder head             Intake bore                          1 29531 3031 in                                                   329  33 I mm             Exhaust bore                          1 OS9110669 n  Ol                                                  269 27 I mm                Stem da                             0313403140 in                                                  7960797Smm             Valve guide 10                       o 31S63161 in                                                   801S8030mm            Stem guide clearance                                             a oo160028 in                                                                             004 007 mm             Valve clearance                                                 o 007100B7 in                     When cold                                                                             0 18 022 mm                                                                                                                                          Free length                           1641716614 in                                                   417 422 m             Sprong pressure                                                 2646 Ibsl 3839in                 Load lind length when installed    s                                                                         12Icg3S1Smm  0 VI  Ol                                                                                     3               Sprong pressurp loss                                                                     IS             when installed                                                                                                                 Overall length                                                                                                                                                                               A 5984 in                                                      IS2 mm                                                    B S8189                                                      58346 in                                                    1478  0                                                   1482 mm  0  CI               Dia                                  023232402 in  Q                                                   S961 mm                                                                     21                                                                                                                  Maximum Pr                                            fn                                                                                                                 Specifi tions             Standard Value                                                                                                                      Limit                                                                                                                                         Remarks          Intake valve opened                                                                                         At 20 BTOC          Intake vaillt closed                                                          At4S0 ABOC   g         E xhau5t valve opened                                                          At SO BBOC  I   0         E xhaut valve cIClSPd                                                       At 15 AToC  ftj            Ignition process                                                                                          1342          Inlertectlon timing                                                           2So26 BTOC                                                                                                   Trochoid tooth wIdth                                                                                                Use Engine Oil CO 10SI                                                                                                                              Above nOF 125D CI SAE30                                                                                                                              Between 32F noF 100C                                                       08622  08630in                                                    2SoCI SAE20                                                       12190  2192mml                                                                                                                              Below 32F 100CI SAEIOW          Outer rolor 00                               19669  19685in                                                   lOW30                                                       4996  5Ooomml   Q   E      T rClChoid  tobody                                                          0OO350063   in      Q     rlcarance                                                                     009 016 mml  5          Trochoidtobody side                                                          0000059   in          clearance                                                                      010015 mml                                                                                         64 71 psi          Oil pressure                                                                   14S  5 kgfcm21         Pump capacIty                                                                                                                                                                                                                                                         At pump 2000 rpm                                                                                            58 Gallonmin                                                                                            12211minlf                Model                             f 1                                                                                                                                                                                    Cam speed        1400 rpm                                                                                                                              Rack position  0354 in 19 mml   Q     Injection pressure                                                             1990 psi 140kgcm    E     c      Pump plunger dia                                                              02165 inIS5mm                                                                                                                                                             1  U       Pump stroke   0                                                                                    02756 in 17 mm  I  ii      Pump discharge                                                                 00013     II                                                                                     00015 inlrev                                                                                         123  1 mm 3 rey1   e                              1                         c      Model                                                                          NOONI2S012   0                                                                                      19902133 psi z       1njeclion pressure                                                                                         I 140150kgfcm2                                                                                  22  Parts                                                   Spec if ications                             Maximum                               Items                                               Standard Value                             Remarks                                                                                                         Limit                    Cooling system                                                                                                                                       Forced circulation            Wltpr pump                          ClIltlllulal lmp                                                  with thermostat                                                  impeller            Gear case tn impeller                                               002320437 in                 Water temperature            c Icarance Circulation                                              059 111 mml                                                                                                                 Tatallift 1934lbs in 2 lmAg            Flow ratr                                                          Packing thickness    E                                                                           264 Gallonmin                                                                               1002minl or more       CI    i       Impeller dia    ij                                                 26312642 in                                                    166 9 67 lmml                                                 Pump speed 3450 3550 rpm   0   0   u        Thlrmostat actuatiCn           temperature             Radiator cap pressure             Fan belt Ifngth                            Model                                                  12V llOAH            ElectrOlyte specfic               gravity dscnarge                    1120      II            Electrolyte specific                  1280            gravity charge                      68F 20C I            Electrolyte specific                  130            lravity ovPldischarqP                 I                    Voltagr                                                                                                                                                                                                                                                                                          Alternator                                                  12V             Current    0        Check nterval        E    c       0             Brush sprlOQ oressure             11I5ul1Itio resistancp                                                                            No failure at SOOMV      0                                     Constant voltagt                                                                                         ij   5             Current      II            Cutin vnltage   0                                                                            23Part   II                                   I terns                              SncIcations                Standard Value             Maximum                                                                                                                                                                    Remarks                                                                                                                                       L1 Nbrnjtpi9j1        r     Numbp 01 teeth                                     89              FIn gear              Insulaton rpslstane                                                                                                                  No failure at 500MV              Check onltrval                                      EYfrv 1000                                                                       Insulation resistance                                                                   service hours              Outnut                                               14kW                                                                              Nominal valuer                                    ff              Head    srI   bolt and nu                           Ml0 x 125                       54 2 579ft Ibs                                 ApplV a generous coat of                                                                                                    75 8 kglm                                   engine oil onto the entire                                                                                                                                                     surfaces of all imporlant              r Ivwheel set bolts                                                                                                                   set bolts  Q                                                                                                    773  796 fUbs                                                                                                  11011 kgfm  e  o                                                                   M12lC 125  I              Cranksl1f1 rnain betr in                         Ml0 x 125                       470 SO 6 It Ibs  o  CD          set cap holts                                                                         65 7 kglm  E             Cranitshllft can bolts                               M8 x 125                        217  253 fUbs  5  a                                                                                                 30 35 kglm  E              Rocker bracket set studs                             M8 xl 25                         174 203 fUbs                                                                                                    24 28 kgfm              Rod bolts                                            M8 xl                            268  304 IUbs                                                                                                    37 42 kgfm        t              General t bolts                                   M12                               571 665 IUbs                                All these torques are applied to              and studs                                                                              79 92 kgfm                                those S45C bolts and studs                                                                                                                                                     which haVe relief number 7 or                                                                       Ml0                               354 412 fUbs                                                                                                     49 57 kgfm                                                                                                                                                     punch marks  e  o  I  5  CD                                                                   M8                                174203f1lbs                                                                                                     124  28 kglrn                                  O                                                                   M6                                72 83 fUbs                                                                                                     110  I IS kgfrn                 Bolt Torques                                                                                                                                            ftlbs kgfm                                                                     Material Grade                      Standard Bolt                                     Special BOlt                                                                                                                Special Boll                                IlraIDia   5541 S20C                         S43C S48C Refined             SCR3 SCM3 Refined                                                                                                                          4                   M 6         58 69       080  095         72 83            100 115    90 105          125 1451                              130 152       180210                                                                                                                               174  203                                                                                240  2801                                                                                                                                                                                                                 217  253         300  3501                   M 8        f               Ml0        1                                          289      333       I 400 460354  41    O                         20                   7              M12        11            463      535                                                       I 640 0   J             5J             10SOgp                   M14                   196      926        111001280     9111085                      12601500                                                                                           H                                                                                                                                                       12301447                 117002000                                                                                                                                                                                                      12301410              1170019501                 447664            120002300         19172242     265031001                M16        1                                                                                               1                   M18                    1808 2098             12500 2900            2025  2351             128003250                2532 2965           3500 4100                   M20                 2459 2893            13400 4000           2712 3182               3750  4400           36164195             15000 58 00                                                                                                   24Bolt matllial 01II15   F hown by numbers punchoo ern the bolt hPadsPrrr   to lrlhtHnl he surl to check aut the numbprs as shown below        Punched NumbPr                                                 Bolt Material Grade                                                                                                                                                   Nnne                                 Standard Bolts             5541 S20C                                                                                                                                                                                                                               7                                    SfPCial BOilS       548C                                                                                  5431                                                                                                    Refined                  9                              Special Bolts           SCM 3 5CR 3 Refined                                                2

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