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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
                                             PAGE
Specification . . .                          1-2
Fuel System . . . .                          3-4
Lubrication System                           5-6
Combustion System .                            7
Valve Timing . . .                             8
Compression Release
Cylinder Liner .
Cylinder Head . .
                          ..                    9
                                               10
                                             · 10
Air Cleaner . . .                          · · 10
Piston and Rings                               11
Crankshaft . . .                             .11
Connecting Rod .                             · 12
Gear Train . . . .                     . . .   13
Camshaft and Bearings .                    ·   13
Main Bearings .                          · .   14
Injection Pump                             ·   15
Flywheel                                       16
Water Pump . .                             · · 16
Starter . . . .                   . . ..    16-17
Glow Plugs                                 · · 17
Wiring Diagram                         · · · 18
Reference Charts                           19-24
Torque Chart. .                               24
                               SPECIFICATIOtfS
MODEL                               15            20             30            40         50
                                  (5411)        (5416)         (5424)        (5432)     (5444)
-------------------~---------------------------------- ------------------------------------------
HORSEPOWER                          11            16             24            32         44
------------------------------------------------------ ---~----------------------------------------
NO. OF CYLINDERS                    2             2              3              4           4
--------------------~---------------------------------------------------------------------------
BORE , STROKE                  2.67 x 2.75   2.99 x 3.23   2.99 x 3.23 2.99 X3.23 3.3 x 3.25
------------------------------------------------------------------------------------------------
DISPLACEMENT (m. IN.)               31            45            68            91'        115
------------------------------------------------------------------------------------------------
MAXIMUM R.P.M.                   3000         2800          2800         2800 :    3000
------------------------------------------------------------------------------~---~-~------
COMPRESSION RATIO                22:1         21:1          21:1         21:1       21:1
--------------------.-----------------~---------------------------------~---------------~~~----.---
TYPE                                Vertical, water cooled, 4-cycle diesel engin~
------------------------------------------------------------------------------------------------
ELECTRICAL EQUIPMENT                12 Volt, 55 AMP Alternator. Electric Starter,
                                    Ii Glow Plugs
                                     Mach.        Fue 1 Pump    Fuel Pump    Mach.            Fuel Pump
--------------------------~--------------------------- ------------------------------.-----------
LUBRICATION (Engine)              2.2 Qts.      3.7 Qts.      5.6 Qts.     11.5 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 V-Drive)                  transmission fluid Type A.
TRANSMISSION REDUCTION            2:1          2:1                 2:1               2:1      2:1
COOLING SYSTEM (7 PSI CAP)        Sea-water           Fresh    water     cooling   syst_
                                    cooled           4.8Qts.            6 Qts.       8 Qts.   8 Qu.
                                                     14 PSI            14 PSI       14 PSI    14 PSI
SEA WATn INLET , OtTl'LET                                  3/8" NPT
EXHAUST FLANGE                                           1-1/4" NPT                1-1/2" NPT 1-1/2" NPT
----------------------------------------------------------------"--------------------------------
                                             Diesel fuel number 2-D
FUEL
------------------------------------------------------------------------------------------------
                                                     5(16" I.D.
FUEL INLET HOSE
------------------------------------------------------ ------------------------------------~~--
FILTERS. FUEL OIL                  298854             298854           298854        298854   298854
------------------------------------------------------ ------------------------------..~------------
FILTERS, LUBRICATION OIL           299381             298852           298852        299584   299927
------------------------------------------------------ --------------------------.-~----------
OOVERNOR                                    Centrifugal type - all speeds
------------------------------------------------------ ----------------------------~------------




                                        1
MODEL                            15           20                 30         40       50
                                (5411)      (5416)          (5424)        (5432)   (5444)


DGlRE OPIUTIHG TlJlPlIA'l'UIE                 ------ 175 0 to 1900    ,   -----------


MAX. OPERATING AHGLI


ENGIIIE ROTATION                Clockv18e when viewed fraa V-belt . .


PROPELLEIl IlOTATImf                               Rilbt HaDCl
                                           (BOTH STD. AND V-DIlIVE)

ENGllIE WEIGHT (Pound.)         245          365             425           490     545


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

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

WID'l'B (Overall)               20.7"        20.7"          20.7"          20.7"   21.4"

INJECTlmf NOZZLE


IIIJECTICIf TIMING              25 0 before top dead center - all .od.18




                                                (2)
 Construction and Handling
     Fuel System
· Fuel system                                                      · Fuel·filter
The fllel system schematic is shown in Fig. , with the fuel        The fuel filter is of the cartridge type shown schematically in
flowing in the direction indicated by the arrows. To bleed air     Fig. 2. Under normal conditions it should o"ly have to be
from the system, loosen the vent plug "A" on the fuel filter       replaced every 400 hours. To install, apply a small amount of
and crank the engine until there are no more air bubbles from      fuel to the packing anc! tight!'!n securely by hand.
the vent. Tighten vent "A" ~nd purge the ail' from the injec·
tion 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 '.5·degrees in
     2.    Fuel cock                 7. Overflow pipe              crank angle. Therefore, injection will take place 1.5 degrees
     3.    Fuel filter               8. Fuel pump                  later when a shim is added and 1.5 degrees earlier when a shim
     4.    Fuel injection pump       A: Vent plug, filter          is removed.The 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
                                                                                 \




                                                                          Controll'll~k pin   In/ection timing
                                                                                              adjust shims

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



                                                            (3)
·   Fuel injection pump                                                  · Handling the injection pump
The inJP.ctioll pump is the Bos... h "MiIlP K. typ~'" It is a prp.<;i-   Use care in handling and using the injection pump. As men-
sinn pit1CC of cqIJinmrnt milChiru:cJ III rlOSf! tolerances and its      tinned before, the injection pump is a precision piece of
performance directly affect~ the p~1rforfllance of the engine.           equipment and care should be taken not to drop it or clamp it
Therpfore. 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
                                                                         r.onsidered 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 0.0004 in. (1/1000mm)
                                                                         which may easily be stuck or rusted by even the slightest
                                                                         amount of water in the fuel.
                                                                         · Installing the injection pump
                                                                         When installing the injection pump. make certain that the
                                                                         control rack pin is correr.tly placed in the 0.2 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 ass'y             14.   Adjusting plate
         2. Delivery valve holder            15.   Control rack
         3. Delivery valve spring            16.   Pump housing
         4. Delivery valve gasket            17.   Control sleeve
         5. Delivery valve                   18.   Upper spring sheet
         6. Cylinder pump element            19.   Plunger spring
         7. Air bleeder screw                20.   Lower spring sheet
         8. Packing                          21.   Shim
         9. HolloIII' screw                  22.   Tappet ass'y
        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 pattern
The luel infection nozlle. like the lu!!1 infection pump. is also            The nozzle cracking pressure and fuel spray pattern are most
a precision piece 01 eQuipment and should be treated with the                accurately checked by using a nozzle "pop tesT" stand. If a
same amount 01 care.                                                         "pop test" stand is not available. remove the nozzles from the
· The nozzle cracking pressure                                               engine. leaving the pressure lines connected.
The nozzle cracking pressure is adjusted by adding or sub·                  geAuTioND
tracting shims Irom the top 01 the nozzle spring. Adding a                     Hold the nozzles so that the high pressure spray from them
0.004 in. (O.1·mm) shim will increase the cracking pressure by                 will not in any way impinge upon unprotected skin. The
about 142 psi. (10 kg/cm 2 ) The nozzle crack ing pressure is                  atomized fuel will easily penetrate the sk.in and cause blood
1990 to 2133 psi. (140 to 150 kgl/cm 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 4.1 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 43.5 to 58 ft·lb (6 to 8 kgf.m)
       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
                                                                         2.2 Lubrication System
             Good             Bad                                         · Oil pump pick·up screen
                                                                           The oil pllmp pick·up 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.
                                       p:ft:~A:;-'ZI                      · 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 64-71 psi. (4.5-5
                                                    (5\..)
                                                                           kgf/cm 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 prf!Ssure switch is located in the passage from the filter
                                                                         and controls the oil pressure. If the oil pressure falls below
                                                                          14 psi. (1.0 kgf /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 n
(1) Clearance on one of the hearings is to great.
(2) One of the rocker arms is too loose.

                                                                                I ;~I              I j ~ ... _:.. _._;S,J t~
                                                                                        LtH.;{Lli ._
(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[-.. .   t.::l.
                                                                                                     . J  j
                                                                                                           ~r·To. I l~lIt;,-,J
                                                                                                                i/ pump
                                                                                                                                t

                                                                                I~j      ,.,'   ":djl( './    PiCk-upscnoeJII11           Oil pan

                                                                                                       '., Drain plug
                                                                                           Fig. 9. Detail of Oil Pump Pick-up
                       Rocker arm
                       Rocker arm shaft




                                                                 Relief valve




screen                                                                                                                    Cover
                   Fig. 8. Lubrication System                                                                             Safety valve assy
                                                                                                                    4.    Safety tlalve
                                                                                                                    5.    Plug
· Oil filter
                                                                                                                    6.    Spring
(1) Rl)place the nil liltt'r 11.1 I)vmy other oil change (evmy 150
                                                                                                                    7.    O-ring
    hours)
                                                                                                                    8.    Relief tlalve
(2) Undm normal condition~ it is only nr~p.ssary to c:hange
                                                                                                                    9.    O-ring
    th'! nil liltp.r ilt the 51'1~:ilil'd intp.rvals. If. howevp.r. thp.
                                                                                                                   70.    Plug
    p.n9ine is used in EXTREME L Y dirty conditions. the
                                                                                                                   77.    O-ring
    rr'~';Sur'~ I "1ulati11'1 Vii IVI'  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 thereaftp.r
 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 spring
!.3 Combustion System
· Combustion chamber                                                             Fig. 14. Structure of Valves
rhe engine utilizes a swirl type pre-combustion 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. the
:harnber resulting in more efficient combustion. A glow·plug        bores should be reamed to 0.316 to 0.315 in. (8.030 to
s employed to preheat the fuel for easy starts down to 5° F         8.015mm) after installation: The valve head must be recessed
 -15°C).                                                            0.043 to 0.055 in. (1.1 to 1.4mml from the face of the cylin·
                                                                    der head to prevent it from hitting the top of the piston.

                                                                                                       rf0.316-0.317in.   ~
                                                                                                     ~·"02-8.05mmT'"'''' .
                                                                                                         0.313 - 0.314in. .


                                                                     A:    Finished ID of guide
                                                                           installed in cylinder    O       7.960-.A'n··975rmmJ


                                                                           head.
                                                                           0.315-0.31§m.___._-+1r--'--,.............
                                                                           (8.015- 8.030mmJ                 r---.---1ID . .
                                                                                                                               Jt
                                                                                                                              '0
                                                                                                        r
                                                                                                   1.059 -7.067in. 1.295 -1.303in.
                                                                                                                                  .\
                                                                                                (26.9      27. TmmJ 732.9 -33. 7miiiT
         1. Nozzle holder            4. Cylinder head                                              Fig. 75. Standard Dimensions
         2. No?zle piece packing     5. Combustion chamber                                                  of Valves, Vallie Guides,
         3. Glowplug                                                                                        Valve Gap

                    Fig. 13. Combustion Chamber

                                                                                  0.043 - 0.055in. (7.7- 7.4mmJ

                                                                       Fig. 16. Sinking of Valve
                                                             (7)
·   Valve timing

When the v
turn laster in enid wp.alh!!r ,)r wh<)t'I the hill\p.ry is low. Once
thl'! cnginl' is turning lasl fmouqh to start. rr:lr!;lSf! the lever and
thp (!r1Qilw will start.
(NOTE)
    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 re~se lever 7. Shaft
                                                                                          4. Adjustment access cover 8. Valve

                                                                                             Fig. 20. Adjustment of Compression Released
                      Fig. 19. Compression Released
                                                                                     ·   Top clearance
~CAUTIOND
                                                                                     Top clearance should be 0.028 \~ 0.035 in. (0.7 to 0.9 mml.
Do not pull the compression release lever when the engine is
                                                                                     Tn adjust. u~e cylindp.r Qas~et shims. 0.006 in. (0.15 mm) thick
running at high speed or under load. If it is necessary to use
                                                                                     each. onto the hp.ad side.
the compression release while the engine is running reduce the
                                                                                     For chf!Cking the me1 the liner should
be chec~~d at points 1.2, and] anr:! in thp rlirf>r:tinns (a) and
(bL The Imer on which the we"r has p.xcp.erlp.cJ thp. St~rvice limit
eiln tw bOH!n ilun honpd In                         O.o:?O in      (0 !)Omm) nversize.
Thp.           finishp(j         dimensions are 3 248- ~.249 in
                                                            (82.500 -
R2S?2'1lfT1)/                          and ::1.01? - ]013 in
                                                   (7GSno - 76519
mlll)1         An oversiled piston and I inqs must Ihell be lIsed
with thIS Irnp.I' OnCt~ this ()WISi/l!d lin.~r has excl!P When Ihis is done.
a standard sin! piston must allain hI' IIsl'd




                   " 'i:; ~~
                 ' 1 I'
                      ~, I
Gj   .: E
     "",
    i~~
                   .N
                 .- .,.
                  c:.1t)
                 _....
                 co·
                 NO>         t
                             r    i
                                              '1                                                                   Fig. 23. Tightening of Cylinder Head Bolts
                                                                                                         · Air cleaner




                                                ~
    I~:g         ";1                                                                                     Under normal conditions clp.an the dust cap on.e a WPf!k
     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 allow(,(j to
                                                                                                         aCf:umulate to more than half the cap capacity_ If a lilrrw




                                 en                  I
                                                                                            ;]
     Il.                                                                                                 piecc! of [1ap!)r or other obstruction gets stuck in th/: air intakf'.
     X

     j
                   =
                  Il.

                   ~
                                                    ·c'
                                                                                     _
                                                                        _ . . . . . . ..
                                                                     3.130    3.131in.
                                                                                                         remove it immediately. Always install the cover with the
                                                                                                         stamped "TOP" uppermost. If the cover is installf!rj ll[1side
                                                      j2 HP                                              down by mistake. the dust and dirt will not enter the r:ap and
                                        L""                          (79.50~. 79:~5~~!_.
                                                                                                         the filtP.r witt plug prematurely.
                                                                      3.4944 - 3.4856 in.
                                                      44 HP          188.505 - 88.535mml                 Clllan the element every 100 to 200 hours of o[1eratinn. KpP.f'

                                  -© .-                                                                  th£' dust cap in place while cleaning the filter to [1reVf!llt


                                 r_.
                                         Standard size
                                       --.         .-       j.. _ - © ?ver size                          c()ntamination.
                                                                                                         If a red signal of the dust indicator attached on the air c:lp.aner
                                      2.992 . 2.993in.             3.012 3.013in.
                J2          HP                                   (76.500 76.519mml
                                                                                                         ilppears. remove the element and clean or replace with new
                                  .(.~~~.~~ ...76 .019~m)                                                elements. After that. push down reset button to returning its
                                   3.3465 -3.3473 in.             3.3661 -3.3670 in.                     signal.
                44 HP             (85.000 - 85.022mml            (85.500 - 85.S22mml


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

·         Tightening cylinder head capscrews (Fig. 23)
III Th~· liqhtr>ninq t(HClll!~ of th ... (ylind.!r 11"at hilS
    Il'~pn rel'laCt!d. rim tht' '~""l"": fnl ------_ .. _._--_ ..            __ ._._--"
                                                                  .


 i              44 HP               Cylinder liner
                                                                       3.366 to 3.367 in. (85.500 to 85.522mm)
                                                                       (1.2JlR max. to 2pR ~ax.) by honing


                                                                                               ( 11)
                                                                                                                    0'3(1   ~nI4',"
                                                                                                                    1.1.1   JIm""
                                                                                                                                         RMfflll 0.04 - 0 06",   tr - r SntmJ




                                                                                                                      o r30-0. ,46,"
                                                                                                                      13J · 31mm/




                                                                                                                    Fig. 28. Crankpin for Undersize Bearing




                                                                                                                   :~ll                                                  , 0:155     1.0267,"

                                                                                                                        I   1.0'36 I.fRI···.
                                                                                                                            1:16.000 :16.WI"""/    ~9B                                :160lR_,


                                                                                                                        l0.9065··0.90"..
                                                                                                                            1230~-'.'_1
                                                                                                                                                   ~                               .. 09059'''
                                                                                                                                                                         123.002·· ·'.1.0' 1m...,'


                                                                                                                                                                         o 143- ·0 753m
                                                                                                                                                                       . rrR 870· '9     ,Jt)m"..t




                                                  2n.u·~2tuSm.
                                                  (S'   g~, ..   5' !Unm'"J
      2.050 205200.
      (52.064   52. '3',",".'   0 1R~-~O 193,".              o '''3·~ 0.753'"
                                                                 /lB."~ 19. 13mm1

                                f1
     2.,.'.-2'48..              /19"'··10 13mm1
                                                                                                                                                                         o 058 " (t.059m
     151.08.-.5'·"'''''''/1··                1
                                            rw                                                                                                                           H 4112· .. '4!fflmm)


                           j    JI         i~)              iIi               fll'      fl1_... ..1.I        'A : Oieme ··, 01 pi.tonpin bu.hing ef'.' instelletion
                                                                                 ,1.. ....
                                                                                    0.018 ··0.0_·.
                                                                                                             Fig. 29. Standard Dimensions of Connecting Rod
                                                                                    /l9lrJ-2._/                       Bearing and Bushing




      Fig. 27. Standard Dimensions of Crankshaft and Bearings



                                                                                                                                              Metal
                       Size            Part No.                                Bearing                    Crankpin Diam. 0                                           Running Clearance
                                                                                                                                              Mark
                                                                                                                                                                                    .-----
                       020       I 15221-22971                        0.20mm undersize
                                                                                                        1.7228 to 1.7234 in.
                                                                                                                                             020US
32   HP   {            040           15221-22981                      0.40mm undersize
                                                                                                        (43.759 to 43.775mm)
                                                                                                        1.7149 to 1.7156 in.
                                                                                                        (43.559 to 43.575mm)
                                                                                                                                             040US                 0.001379
                                                                                                                                                                   to 0.003661 in.
                                                                                                        1.7228 to 1.7234 in.                                       (0.035 to 0.093m·m)
                       020           15471-22971                      0.20mm undersize                                                       020US
44 HP
           {           040           15471-22981                      0.40mm undersize
                                                                                                        (43.759 to 43.775mm)
                                                                                                        1.7149 to 1.7156 in.
                                                                                                        (43.559 to 43.575mm)
                                                                                                                                             040US

                                                                                               (12)
     Main Components                                                     ·   Camshaft gear
· Gear train                                                             Rp.tl'f to Fiq. 31. Place th.e camshaft retainer plate on the
B~ SIIr!! to asspmblf' thl' Clears by matchinq thp. millinCi marks       cillTlshaft first. Shim the camshaft retai~ler plate out from the
115 shown in Fig. 30. Thp backlash of each gear is 0.002 to              camshaft 0.003 to 0.009 in. 10.07 to 0.22 mml with shims
0.005 Ill. /0.0415 to 0." 54 mrnl                                        that can be pulled Ollt after the gear is installed. Heat the gear
                                                                         to approximatply 176° F .(SOo.CI and slide on the shaft until it
                                                                         blltts liP aqainst thl) retair:'f'r 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~ .··.




                                                                                                      0.003 - O.OO9in. (0.07 - 0.22mmJ
                                                                             1. Camshaft gear                 4. Cir-clip
                                                                             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: 0.002 to 0.004 in. (0.05 to 0.091 mm)


                                                   · ,Z·· 40 T
                 34T'1


                 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 cranl4 rnml ami O.OOB to 0.020 in. (0.20 to 0.51 mm) end                 injection pump c.amshaft and install as per the illustration.
rillY

                                                        "') 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 crankshaft
Clean the entire contact SIJrfilCf' rardull,; CDilt the cnntilCt             (1) Rust inhibitor and antifreeze should be used in accord·
surface with engine oil, wilsh illl the oil off with gasoline ami                ance with the recommfmdations in the related manuals.
dry It throughly Put the flywhpf~1 on imd tnrqlll' the Cilf"!screws          (2) Be sure to remove all debris that may be plugging thl' fins.
to 70 10 77 ft·lbs (1010 11 "-'l·rn). Bpnd the IrlCking tabs back            (3) Chl'lk the rubber shock mount nuts periodically to be
on the washers                                                                   sure they are tight.
· Tensioning of fan belt,
                                                                              · Cooling water pump
The fan belt tension is ilej)Ustp.ri hv rnovinq thp altl'rnator
                                                                              Tn install the cooling fan pulley on the pump, securely tighten
brackeT in Of out. The belt is properly tensioned when the
                                                                              the nut (4) to 50.6 to 57.9 ft-lbs. (7 to 8 kgf .m) torque,
belt deflection midway between the alter nator Dillie,,;, and the
crankshaft pulley is 0.25 to 0.35in. (7 tl) 9 mm) with a force
of 20 Ibs applied', Proper bplt tension is essential for good
enginp. 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
                                    ~ 0.25 to 0.35in. (7 to 9mm)
                                   /i!                                                                                          7. Rotator
                                                                                                                                8. Case
                                   i/I                                                                                          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,
  TyJ:)e                                                                   the pinion and starter housing may be damaged and in
                       Reeluction
                                                                           extreme cases, the starter may not even turn.
r---'-- .... _-       -_.. --_._-----_..                               (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
                       1.4kW                                           (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 more
L....-.
                                                                           than 30 deconds the solder may melt from the armature
                                                                           or the coil 01 le.ad wires may melt. Also. the battery will
 · Trouble shooting                                                        be discharged to such a degree and won't 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, f.aulty wiring. If the           qear. J..hich 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
                         short-circui 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
          __3-JCl,--l._~
                                                                         I
                                           Connect to ACC. term. on switch
  >-
C/)
                      2 CYl.
                      ~
                                           ·                         ·
                      -    -
          -1":
-co
 (.)
           ..
          1,r
                --,   ,    .                                                                         GlOW PLUG
--
 r...
          GLOW I PLUGS               FUEL PUMP
......
 (.)

-
w
 Q)


                                                                                                                 -
                                                                                                                 ........
                                                                                                                 00
  Reference Chart
         Engine
                                                                                                          Maximum
ParIS                       Items                       Sl">P.ciflcations           Standard Value                                        Remarks
                                                                                                            Limit
---.-    ---_._._._-----_ ... _-- .-..-.-.----.. ----- -.-.------+--=---I----------~
                                                                      When installing. apply a generous
          Cylinder hfoad tightness                 Ml0 x 1.25                    54.2 - 57.9 ft.lbs.
  i.,                                                                            (7.5 - 8 kg.m)                        coat of engine oil onto the entire
  :r      Cylinder head surface d,stortion                                       0.002 in below                        surface of j h btt.
                                                                                 10.05mm below)
          I ntake/exhaust valve sP..at thickness   45° 0.059 in. 115mm)                                                           I           i
                                                                     0.0276 - 0 0354 in.
          Top clearance                                               10.7 - 0.9 mm)          ~!i. O.059in.                                           fl.5mm)
1--- -        -------,------------                  -- --·-····----+---------+----4T.J50oversizeliner 10
          Standard 10
                                     32 HP         2.9Q21 2.9929 in.
                                                   (76.000 - 76019mm)
                                                                                               I          .2.9980 in. -3~01)~_-1~Ql1~_In.
                                                                                                          (76.15mml 176.500· 76.519mm)

   ~
                                   44 HP           ~:3400 - 3:3473 In.          I              I
                               ~--~.~--~-~18~5.~~~-~8~5~.0~~~m~m~)~--------~--+-----~.----~~----~--__~
  ~       P,ston clearance           -:t?   HP     O.OO~.? - 0.0905 10.
  ~                                  r.            10_065 - O.I64mm) .                           . ..
  >
          'At piston skert)    1----'44~=-=HP=----·· 0.0026 - 0.0066· In'!....-4----~"'----I
  u                                                                                                                    Height above block surface
                               ~ ________~1~0=-0~6~5--~0~.1~6~7~m~m:~)~4_-------------~
          Type                             Dry              ± 0.00098 in. (± 0.025 mm)
1--..    I----------r--~~==~_+-----------~-----------~------+----------------~
          Standard 00          ~            HP     2_9921 in. 176mm)                                                   Oversize 0.020 in. (0.5 mm)
                               r==44""HP _         3.3465 in. 185mmJ
   c::    Piston·pin boss 10                       0.9055 -0.9060 in                                      0.9071 in.
   o                                               123.000 -23.013 mm)                                    123.04mm)
  ;;
  ~
                                                                                interference Clearance
          Piston-pin clearance                                                  0.0004 in.   0.0004 in.
                                                                                (0.01 I mm) 10.01 I mm)
~         ... -.-- -------:-----------+-- --- .--------~.
          Rong gap                                 (toP. 2nd)                    0.0118 -0.0178in.        ·0.0492 in   0.5 oversize top ring surface should
                                                   .!...~~_                     \...!9~.::..9.:.45m~_ 11.25mm)         be 0.0079 in. (0.2 mm) below
                                                                  . - - - - i 0.0098 - 0.0158in.
                                                                                                                       piston side surface
   g'     Top ring WIdth                           Keystone IVpe                \ 10_25-·0.45mm)
  a:
          2nd ring width


          Oil ring
                                                   0.0768 -0.0772in.
                                                   (1 95 - 1.962mm)

                                                   0.1960 -0. 1965in
                                                   (4978 -4.99 mm)
                                                                                 Ring groove clearance
                                                                                 0.0037 -0.0047 in.
                                                                                 10.093 -0. 120mm)
                                                                                 0.0008 -0 0020 in.
                                                                                                                       »0";' 0.0019 in.
                                                                                                                                          (O.2mmJ
                                                                                                                                                    J.
                                                                                 10.02 -0.052 mm)
---1-----------.---------                          .---- - - - - - - - t - - - - - - - - - i i - - - - t - - - - - - - - - - I
   c::    00                                       0.9056 -0.9059in.
  a:                                               123002""'23.011 mm)
   c::
   o
  ;;                                                                             0.0006 -0.0015 in.       0.0059 in:
  ~
          Pin·to·bush clearance
                                                                                 (0.014 -0.038 mml        (0 15mml
t---- - . - - - - - - - - - - - . - - - - -.. -    . - ... -._. - - _ . - - -   --.-.---------+-----+-------.--------------
          Small end 10                             1 .0236 - 1.0244 in_                                            i           Pin
                                                   (26.000""26.021 mml
                                                                                                                                \..                ±O.OOO79in.
                                                   (without bush)



                                                                                                                         .l ~
                                                                                                                                          \        (to.02mm)


  ~
  a:
          Small end width·

          Large end 10
                                                   1.0236 jn. (26 mm)

                                                   1.8504 - 1.8512 in.                                                  \
                                                                                                                            >.- . .
                                                                                                                              -. -.
                                                                                                                                                  Connecting
                                                                                                                                                  rod
  ...
  5:                                               147.000 - 47 .02Omm)                                                 ~                 . . , 4in. f100m,,!)
  g                                                (without bush)                                                      +..            .           to.OOO79in.
   c::
  c::                                                                                                                  _O.OOO79m.                 (to 02mm)
  8       Large end width                          1.0079 - 1 0118 in.                                                 (to.02mm)                      ·
                                                   /25.6 - 25 7 mm)

          Rod torsion                                                            00008 in.                0.002 in.
                                                                                                                       When installing. apply a generous
          (see diagraml                                                          (O.02mm)                 (005mml
                                                                                                                       coat of engine oil onto the entire
          Roo bolt torQue                           MSx I                        26.76- 30.38                          surface of each bolt.
                                                                                 fUbs. (3.7 -4.2
                                                                                 kg-ml


                                                                        (l9)
 Parts                   Items                                                                            Maximum
                                                  Specifications                      Standard Value                                    Remarks
                                                                                                            Limit
f - - . . - - - - - - . - . - . - - - - - - f-.-              ---·-·------1----·---+----1-------___---1
           10                                 1.7327 -- 1.7345 in.
                                              (44.01 .. 44.056mml
                                             (wIth metal)

            Width                                          0.7429 -07531 ill.
                                                           (18.87 - 19.13 mml
                                                                                                                        Center thickness
            00                                             1.85 in (47 mml                                                 0.0583-0.0589 in.
                                                                                                                           (1.482 -1.495 mml
            Running clearance                                                     0.0014 - 0.0038 in.     0.0079in.
                                                                                  (0.035 .. 0.097 mml     (0.2mml

            Axial clearance                                                       0.0157 -0.0236in                      Crank arm-to-Iarge end clearance
                                                                                  (04-0.6mml
1---- -.......-- -------.-.-.-.------.. -- .-.. ------- -.-.-------+----I--------------l
            Crankshaft jllrnal dia                         2.0441 - 20449 III
                                                           151921 -51.94mm)

            Main bearing 1.0                               2.0465 - 2.048:1 in    1Running clearan,,:-    0.0079 in.
                                                           (5198- 52.025mml        0.0016-0.00411n.       (0.2mm)
                                                           (with metal)            10.04 -0. 104mml

            Crankshaft metal (21                           0.7429-0.7531 in.
            width                                          (1887 -19.13 ""nl
          ..-----.---.--.- .-------f--..--.---.--.-.-~-----.--+_---_l_----------~
            Cr ... nkshaft jurnal dia.                     2.0449 -20449 in.
                                                           (51.921 -51.94mm)      IRunning clearance
                                                                                                          0.0079 in.
                                                                                   0.0016 -0.0046 in      10.2mml
            Gear·Side main bearing 10                      2.0465 -2.0488 in.
  .~
   .'"                                                     (51.98 -52 039mml      1(0.04 - O. 118 mml

  CD
                                                           (with metal)
   c:
   ~
  ~         Crankshaf1 metal (11                           0.7823·- 0.7925 in.
            width                                          119.87 - 20.13mml

            Crankshaft metal ( 1I 00                       2.2485 .. 2.2474 in.
                                                           157.111 - 57.084mml
          f---------.------.---- --.------.---.-1---.. -.-.--------+-------1-----------.---
            Crank·pm jurnal dia.                           1.7307 - 1 7313 ill.                           00047in.     When installing. apply a generous
                                                           (43.959 -43975mml                              (0.12 mm)    coat of engine oil onto thp. entire
                                                                                                                       surface of each bolt.
            Crankshaft side clearance                                             0.0059 - 0.0122 in.
                                                                                  (0 15 -0.31 mml

            Cr;Jnk bearinq cap                                                    217-293fUbs.
            boll (1) torque
                                                           M8" 1.25
                                                                                  (3 -3.5kg.ml

            Crank bearinl] call                            M lOx 125              47.0-50.6 It Ibs.
            boll (2) torque                                                       (6.5 -7 kg-ml

f - - - ..... - ... -.....-----. ---------- - .. -.---.-                          ---..-----.. --- 1----._---'--------------1
            Cam be"ring ID                                 1.5748-1.5758 in
                                                                                  IRunning clearan~




                                                                                                                               x
                                                           (40.000-40025mm)

                                                           1 572<'-1.5728 m.1
                                                           (39.934-39.950mml
                                                                                  I0.0020 -- 0.0036 1M.
                                                                                   10.050- 0.09"1 mml
                                                                                                                       0.1611 in.

                                                                                                                       f79'5
                                                                                                                                m
                                                                                                                                    J     ~f
            Axial clParance                                                       0.0028-00087 in.                                                 1.3134 in.
  iV
   .r:.                                                                                                                         ,                 '33.36mmJ
                                                                                  (0.07 - 0.22 mml


                                                                                                                               ik -. J
  III
  E
  u
   ..       Carn hft                                       0.2165 in (5.5mn»                                           0.5451
                                                                                                                       (13.86mmJ
            Cam heillht                                    13134 in.
                                                           (33.36 mml




                                                                          (20)
                                                                                                      Maximum
P"rts                       Items                        Spec,f,cat,ons           Stllndard Vail"!                             Remarks
                                                                                                        Limit
~.      .   _.... _---_._._--_._---------- -_.- -
                                gear
                                                            ._--_._.
            Number of teeth. crank                34

            Number of teeth. idel gear            79

            Number of teeth. earn !If!ar          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 00163-<1.oo4s4 in.      0.0118,n.
                                                                             (0   041S~. I   154mml   (0.3mm)
            Backlash
--- ..-- -.-.. --"--'-'-- .. --.-----.----.- _..---.------ ------ --
             Shlnkil!lf'                          00433 - 0.OSS1 in.
                                                  (1_1- 1.4mm)




             Facl' angle                           4So                                                            Valve guide bore should be
                                                                                                                  reamed after inserted into
                                                                                                                  cylinder head
             Intake' bore                          1 2953-1 3031 in.
                                                   (329 - 33. I mm)

             Exhaust bore                          1 OS91-1.0669 ,n.
  Ol
  >                                                (269 -27. I mm)
  ;;;
 >
             Stem d,a                             0.3134""0.3140 in.
                                                  (7.960-797Smm)

             Valve guide 10                       o 31S6~.3161 in.
                                                   (801S-8.030mm)

            Stem guide clearance                                            . a oo16~.0028 in.
                                                                             (0.04 -0.07 mm'

             Valve clearance                                                 o 0071~.00B7 in.                     When cold.
                                                                             (0 18 -0.22 mm)
                                                                     -.                                                        _..

             Free length                           16417-1.6614 in.
                                                   (41.7 -42.2 ~m)

             Sprong pressure                                                 2646 Ibs./l .3839in.                 Load lind length when installed.
  '"
  s:                                                                         (12Icg/3S.1Smm'
  0.
 VI
  Ol
  >          Perpendicularoty                                                                         3%
 ;;;
 >
             Sprong pressurp loss                                                                     IS%
             when installed
-_. - --------- -._-------"---                   ----------                                                                              -------
             Over-all length



                                                                                                                           ~
                                                    A 5.984 in.
                                                      (IS2 mm)
                                                    B: S.8189-
                                                      5.8346 in.
                                                    (1478-
  '0                                                   148.2 mm)
  0
  CI:
  ~
  '"
  :>         Dia.                                  0.2323"'{).2402 in.
  Q..
                                                   (S.9-61 mm)




                                                                     (21)
                                                                                                               ..   Maximum
 P~r"
~.        _....·.....   __... _---_._--- -_.,
                               "f~n~
                                                ---   -.-.-
                                                              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 xhau~t valve c;IClSP.d                                                       At 15° ATo"C
  ftj
  >
          Ignition process
                                                                                          1-·3-4-2
          Inler:tectlon timing                                                          . 2So-26° BTOC
              -.---- ----_._--------'-                _ _._-------.---
                                                         ..
          Trochoid tooth wIdth                                                                                                Use Engine Oil CO 10SI
                                                                                                                              Above nOF 125D CI. SAE30


                                                                                                                              Between 32°F -noF 100C-
                                                       0.8622 .. 0.8630in.                                                    2SoCI. SAE20
                                                       121.90 . 21.92mml
                                                                                                                              Below 32°F 100CI. SAEIOW.
          Outer rolor 00                               1.9669 -.. 1.9685in.                                                   lOW-30
                                                       (49.96 - 5O.oomml
   Q.
   E      T rClC"hoid . to-body                                                          0OO35~.0063   in.
   "
   Q.     r:lcarance                                                                     (0.09 -0.16 mml
  5
          Trochoid-to·body side                                                          0.00~.0059   in.
          clearance                                                                      (0.10-0.15 mml
                                                                                         64 ·-71 psi.
          Oil pressure                                                                   14.S - 5 kgf/cm21
         .Pump capacIty                                                                                                                       .

                                                                                                                                  At pump 2000 r.p.m.
                                                                                            5.8 Gallon/min.
                                                                                            12211!min.l
f--      -----------_._-----
          Model
                             f---------- 1-----_. _-                                                    .-.- ...
                                                                                                                              Cam speed        1400 r.p.m_
                                                                                                                              Rack position: . 0.354 in 19 mml
   Q.     Injection pressure                                                             1990 psi. (140kg/cm; .
   E
  ~"
   c      Pump plunger dia.                                                              0.2165 in.IS.5mm)
                                                                                                                                                           ..
  .!:1
  U       Pump stroke
   0>                                                                                    0.2756 in 17 mm)
  I
  ii      Pump discharge                                                                 0.0013-
   "
  II..                                                                                     0.0015 inl/rev
                                                                                         123 ± 1 mm 3 /rey)
1-'-.-   e------..-                             -- 1-'--_._-                        -


 c .,     Model                                                                          NO·ONI2S012
 - ...
 0-
 ~ ~.                                                                                    1990-2133 psi.
 £z       1njeclion pressure
                                                                                         I 140-150kgf./cm2 )




                                                                                 (22)
  Parts                                                   Spec if ications                             Maximum
                               Items                                               Standard Value                             Remarks
                                                                                                         Limit
~         -------------_._.
           Cooling system
                            _._--_... .... ------                                                       .

                                                  Forced circulation

            W:ltp.r pump                          Cl!Iltlllu!lal l,"mp
                                                  with thermostat
                                                  (impeller!
            Gear case tn impeller                                               0.0232-0.437 in.                 Water temperature
            c Icarance Circulation                                              (0.59 -1.11 mml
                                                                                                                 Tatallift 19.34lbs /in 2 (lmAg)
            Flow ratr.                                                          (Packing thickness)
    E                                                                           26.4 Gallon/min
    ~                                                                           (1002/minl or more
    >
   CI)

    i»       Impeller dia.
    i;j
   ~                                              2.63-1-2.642 in
    '"
    .~                                            166 9 -67 lmml                                                 Pump speed 3450- 3550 rpm
   0
   0
   u        Thl!rmostat actuatiC'n
           .temperature


             Radiator cap pressure

             Fan belt If>ngth




~.-       _.. --..........   ------ - _._._----   ----
            Model



                                                  12V llOAH
            ElectrOlyte spec.fic
    >
   !        gravity. d.scnarge                    1.120
   ;;;
   II)
            Electrolyte specific                  1280
            gravity. c:harge                      (68°F; 20°C I

            Electrolyte specific                  1.30
            !lravity _ovP.ldischarqP.
              __ _ _ _-----------
I - - - ...... .. ..... ..
             Voltagr.
                                                                 _.
                                                                                               -----         -
                                                                                                                 Alternator
                                                  12V

             Current

    0        Check .nterval
    .,
    E
    c:
    >
   0
             Brush sprlOQ oressure

             11I5ul1Itio" resistancp.                                                                            No failure at SOOMV
--_.- ... ----...-- ...._
   0
                         ..
            Constant voltagt!
                               _ _ -....-------
                                .. _. ...                   --
   i;j
   ""5
   .,
   '"       Current
   .,
   II:

   ~         Cut·in vnltage
   "0
   >
                                                                         (23)
Part'   II
                                   I terns                              Sn<>c:,I,cations                Standard Value             Maximum
                                                                                                                                                                    Remarks
                                                                                                                                       L~~
1---' ···N.;;,~·b;r-nj·tp.!!;i~~'~;;·--·--+-9---··-----·----j---------+-----+-----------------1

        r     Numbp, 01 teeth.                                     89
              FIn!! gear

              Insulat,on rpslstan<:e                                                                                                                  No failure at 500MV

              Check onlt!rval                                      E:Yf!rv 1000                                                                       Insulation resistance
                                                                   service hours

              Outnut                                               1.4kW                                                                              Nominal value



r-----.- .. -.. -             .- .--.....          - ..-.. --.... -.. ----.....- - - . --.. --.--....-.--.f----.f-----:--------~
              Head    srI   bolt and nu'                           Ml0 x 1.25                       54 2 -579ft Ibs.                                 ApplV a generous coat of
                                                                                                    (7.5 -8 kgl.m)                                   engine oil onto the entire
                                                                                                                                                     surfaces of all imporlant
              r: Ivwheel set bolts                                                                                                                   set bolts.

  Q)
                                                                                                    77.3 - 79.6 fUbs.
  :>                                                                                                110-11 kgf.m)
  e-
  o
                                                                   M12lC 1.25
  I-
              Cranksl.1f1 rnain be.tr in!!                         Ml0 x 1.25                       47.0 -SO 6 It Ibs.
  o
  CD          set cap holts                                                                         (6.5 -7 kgl.m)
  'E
  ~           Cranitshllft can bolts                               M8 x 1.25                        21.7 - 25.3 fUbs.
  (5
  a                                                                                                 (3.0 -3.5 kgl.m)
  E
              Rocker bracket set studs                             M8 xl 25                         17.4 -20.3 fUbs.
                                                                                                    (2.4 -2.8 kgf.m)

              Rod bolts                                            M8 xl                            26.8 - 30.4 IUbs
                                                                                                    (3.7 -4.2 kgf.m)
-.- --.-----.. - -." ------. '-.- --------- -- .---------+-----+--------------t
              General !*!t bolts                                   M12                               57.1 -66.5 IUbs.                                All these torques are applied to
              and studs                                                                              (7.9 -9.2 kgf.m)                                those S45C bolts and studs
                                                                                                                                                     which haVe relief number ''7'' or
  .
  :>
                                                                   Ml0                               35.4- 41.2 fUbs.
                                                                                                     (4.9 -5.7 kgf.m)
                                                                                                                                                     punch marks.

  e-
  o
  I-
  (5
  CD
                                                                   M8                                17.4-20.3f1lbs
                                                                                                     12.4 .... 2.8" kgl·rn)                                  ®O$'
                                                                   M6                                7.2 -8.3 fUbs
                                                                                                     11.0 - I IS kgf.rn)



                 Bolt Torques                                                                                                                                            ft.lbs (kgf-m)

                                ------_.. . .. -_.__.. _-- -_._-_...... _._._·.. -.-.------
         -· ..........
                    Material Grade                      Standard Bolt                                     Special BOlt
                                                                                                                Special Boll
                -- -   ............  ...... -.
         Ilr",,",aIDia-.............   5541. S20C                         S43C, S48C (Refined)             SCR3, SCM3 (Refined)
                 .   -.--.~ ---_.. -_.         .. -- - .-...-
                                                       '-'--"'-"                                 .-4-----------.--.-.-..-
                   M 6         58- 6.9       (080 - 0.95)         7.2- 8.3            (1.00- 1.15)    9.0- 10.5          1.25- 1451
                              130- 152       (180-210)
                                                              --.. -.....
                                                                17.4 - 203
                                                                          ---....     ( 2.40 - 2.801
                                                                                                            ------.----+--.---.:....~~------~
                                                                                                     21.7 - 25.3         3.00-  3.501
                   M 8
        f-----. .
              Ml0
        1---_........ -
                                         28.9 -     33.3       I 400- 4.60).35.;4 .~. 41 ~ _ ........( .~.~O_~._~:~~)._                      _..~:~:_~ _ _ ~20 -                  7 ~~
             ·M12
        1---_._.....--1-' --.-           46.3 -     53.5
                                                  .-.. -- ..   I 640:-:-.. _?~0)..._..!)?.:..~:-:. ~_!)_ ·.. _.J. !_.~.::_~.~!..            ...?5.J..::'.~~             (10.SO-g'Hn!l, he surl! to check aut the numbp.rs as shown below'




        Punched NumbP.r                                                 Bolt Material Grade
        -- .. - .....---.--.- .....- - .-.- .. - ... -                     ._--- - .-.-.. - - - - -
                                                                                .. _.- - _... _----_._-
                 Nnne .                                Standard Bolts             5541, S20C
                     --.--.-.--. - ._--- .-..                         --_ .. _
                                                                               __
                 ...                                                          .·.
                  7                                    Sf'P.Cial BOilS .. -... --   ._.. 548C
                                                                                  5431:,     ._._.-
                                                                                               (Refined)
                  9                              Special Bolts           SCM 3, 5CR 3 (Refined)




                                                (2~)


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The information on this web site has not been checked for accuracy. It is for entertainment purposes only and should be independently verified before using for any other reason. There are five sources. 1) Documents and manuals from a variety of sources. These have not been checked for accuracy and in many cases have not even been read by anyone associated with L-36.com. I have no idea of they are useful or accurate, I leave that to the reader. 2) Articles others have written and submitted. If you have questions on these, please contact the author. 3) Articles that represent my personal opinions. These are intended to promote thought and for entertainment. These are not intended to be fact, they are my opinions. 4) Small programs that generate result presented on a web page. Like any computer program, these may and in some cases do have errors. Almost all of these also make simplifying assumptions so they are not totally accurate even if there are no errors. Please verify all results. 5) Weather information is from numerious of sources and is presented automatically. It is not checked for accuracy either by anyone at L-36.com or by the source which is typically the US Government. See the NOAA web site for their disclaimer. Finally, tide and current data on this site is from 2007 and 2008 data bases, which may contain even older data. Changes in harbors due to building or dredging change tides and currents and for that reason many of the locations presented are no longer supported by newer data bases. For example, there is very little tidal current data in newer data bases so current data is likely wrong to some extent. This data is NOT FOR NAVIGATION. See the XTide disclaimer for details. In addition, tide and current are influenced by storms, river flow, and other factors beyond the ability of any predictive program.