SERVICE MANUAL

M-20 + M-30

5416 + 5424

Part Number 200152

Edition 1

October 1990

..

•

•

MODEL 20 & 30 INDEX

Specifications . .

Fuel System . . .

Lubrication System .

Oi- Filter . . . .

Combustion System

Valve Timing . . .

Compression Release

Cylinder Liner . .

Cylinder Head .

Piston and Rings

Crankshaft . . . .

Connecting Rod .

Gear Train . . . .

Camshaft Bearings

Main Bearings

Injection Pump

Water Pump . .

Flywheel ... . .

Starting Motor

Glow Plug . .

Wiring Diagram . .

Reference Charts . . . . . .

· 1-2

· 3-4

. . 5-6

• • • • 6

• • 7

. 8

· . 9

10

10

11

11

12

13

13

14

15

16

· 16

16-17

. . 17-18

• 19

20-24

SPECIFICATIONS

MODEL

15 20 30 40 50

(5411) (5416) (5424) (5432) (5444)

--------------------.----------------------------------------------------------------------------

HORSEPOWER

11 16 24 32 44

------------------------------------------------------------------------------------------------

NO. OF CYLINDERS

2 2 3 4 4

---------------------------------------------------------------------------------.--------------

BORE & STROKE

2.67 x 2.75 2.99 x 3.23 2.99 x 3.23 2.99 x 3.23 3.3 x 3.25

------------------------------------------------------------------------------------------------

DISPLACEMENT (CU. IN.) 31 45 68 91 115

------------------------------------------------------------------------------------------------

MAXIMUM R.P.M.

3000 2800 2800 2800 3000

---------------------------------------------------------------------------------------~------

COMPRESSION RATIO 22:1 21:1 21:1 21:1 21:1

--------------------------------------------------------------------------------------~-----~---

TYPE Vertical, water cooled, 4-cycle diesel engine

------------------------------------------------------------------------------------------------

ELECTRICAL EQUIPMENT

12 Volt, 55 AMP Alternator, Electric Starter,

&

Mech. Fuel P\DIIP Fuel Pump Mech.

Fuel Pump

-----------------------------~------------------------ ------------------------------.-----------

LUBRICATION (Engine) 2.2 Qts. 3.7 Qts. 5.6 Qts. 11.5 Qts. 8.~ Qts.

Use SAE 30 HD (CD) or 10W40 heavy duty diesel lubricating oil

------------------------------------------------------------------------------------------------

LUBRICATION (Transmission) Fill to full mark on dipstick. Use automatic

(Std and V-Drive) transmission fluid Type A.

------------------------------------------------------------------------------------------------

TRANSMISSION REDUCTION 2:1 2:1 2:1 2:1 2:1

------------------------------------------------------------------------------------------------

COOLING SYSTEM (7 PSI CAP) Sea-water Fresh water cooling system cooled 4.8Qts.

14 PSI

6 Qts.

14 PSI

8 Qts.

14 PSI

8 Qts.

14 PSI

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

SEA WATER INLET 6 OUTLET 3/8" NPT

EXHAUST FLANGE 1-1/4" NPT 1-1/2" NPT 1-1/2" NPT

FUEL Diesel fuel number 2-D

FUEL INLET HOSE 5/16" 1.0.

------------------------------------------------------ ------------------------------------~-~--

FILTERS, FUEL OIL 298854 298854 298854 2988~4 298854

----------------------------------------------.-------------------------------------------------

FILTERS, LUBRICATION OIL 299381 298852 298852 299584 299927

----------------------------------------------------------------.----------------

---------------

GOVERNOR Centrifugal type - all speeds

-----------------------------------------------------------------------------------.------------

..

•

•

1

•

MODEL 15

(5411 )

20

(5416)

30

(S424)

40

(S432)

50

(5444)

175

0

to 190

0

r -----------------

DGIN! OPlIATIJIIG

TlJlPEIATUU

MAX.

OPERATING

ANGLE

ENGINE ROTATION

PROPELLER ROTATION

ENGI},,"! WEIGHT (Pounds)

LENGTH (Overall)

HEIGHT (Overall)

WID'11I (Overall)

INJECTION NOZZLE

INJECTION TIMING

245

25.6"

21.2"

20.7"

Clockwise when viewed fro. V-belt end

Rilht Hand

(BOTH STD. AND

V-DRIVE)

365 425

28.0"

24.1"

32.5"

24.6"

20.7" 20.7"

490

36.2"

26.0"

20.7"

25

0

before top dead center - all

.odel.

545

36.0"

26.0"

21.4"

(2)

Construction and Handling

Fuel System

• Fuel system

The fuel systf;)m schematic is shown in Fig. 1 with the fuel flowing in the direction indicated by the arrows. To bleed air from the system, loosen the vent plug "A" on the fuel filter and crank the engine until there are no more air bubbles from the vent. Tighten vent "A" and purge the air from the injection pump at vent "8" using the same procedures.

• Fuel-filter

The fuel filter is of the cartridge type shown schematically in

Fig. 2. Under normal conditions it should only have to be replaced every 400 hours. To install, apply a small amount of fuel to the pack ing and tighten securely by hand. For removal, the use of a filter wrench 15221-86611 is recommended.

(1)

/

(4J

(S)

1.

2.

3.

4.

Fuel filter

Caver

Pipe coupling

Vent plug

5.

6.

7.

"0" ring

"0" ring

Element

\~

I)'

Fig. 2. Fuel Filter

1. Fuel tank

2. Fuel cock

3. Fuel filter

4. Fuel injection pump

5. Injection pipe

6. Nozzle holder

7. Overflow pipe

A: Vent plug, filter

8: Vent plug, pump

Fig. 1. Fuel System

• Fuel injection timing

Fuel in)rction timing is adjusted by changing the number of shims used between the pump and the gear case it fits into. See

Fig. 3. One shim corresponds to approximately 1.5 degrees in crank angle. Therefore. injection will take place 1.5 degrees later when a shim is added and 1.5 degrees earlier when a shim is removed. The timing is correct when the pointer in the peerhole on the side of the flywheel housing lines up with the

"F1" marked on the flywheel. See Fig. 4.

Fuel injection pump Speed control lever

II~-

..

\

Control rack pin Injection timing adjust shims

Fig. 3. Adjustment of

Injection Timing

Fig. 4. Inspection of

Injection Timing

(3)

[Jel injection pump

The Injf'ction pump is the Bosch "Mine K type" It is a preci· sian riPee nf eQlJipment machined to close tolerances and its rerfor l1lance directly affects the performance of the engine.

Therefore, handle it with care.

(I)

.. Handling the injection pump

Use care in handling and using the injection pump. As men· tioned before, the injection pump is a precision piece of equipment and care should be taken not to drop it or clamp it trghtly when working on it. Also, be sure to use only clean fuel that has been filtered. Oil drums left outdoors are always considered to contain water, so always filter this fuel before using.

Clean fuel is a must as the fuel is forced through parts of the pump and nozzel with clearances of 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 correctly placed in the 0.2 in. (5mm) wide groove of the fork lever (,) before tightening the attaching bolts Refer to the diagram. If the bolts are drawn down with the rack pin off the groove, the rack may over travel and stick in this position. This would cause excess fuel flow, allowing the engine to overspeed which would result in engine failure. co

ri0 .....

Ir~

1. Injection pump ass'v

2.

3.

4.

5.

Deliverv valve holder

Deliverv valve spring

Deliverv valve gasket

Deliverv valve

6.

7.

Cvlinder pump element

Air bleeder screw

8.

9.

10.

11.

Packing

Hollow screw

Packing

Tappet guide pin

12.

13.

Clamp pin

Bolt

Fig. 5. Fuel Injection Puf'(lP

14. Adjusting plate

15.

16.

17.

Control rack

Pump housing

Control sleeve

18. Upper spring sheet

19. Plunger spring

20. Lower spring sheet

21.

22.

Shim

Tappet ass'v

Roller 23.

24.

25.

Roller bushing

Roller pin

(4 )

• Fuel injection'nozzle

The fuel injection nozzle, like the fuel injection pump, is also a precision piece of equipment and should be treated with the same amount of care.

• The nozzle cracking pressure

The nozzle cracking pressure is adjusted by adding or subtracting shi'ms from the top of the nozzle spring. Adding a

0.004 in. (0.1 mm) shim will increase the cracking pressure by about 142 psi. (10 kg/cm2 ). The nozzle crack ing pressure is

1990 to 2133 psi. (140 to 150kgf/cm 1 )

• Spray pattern

The nozzle cracking pressure and fuel spray pattern are most accurately checked by USing a nozzle "pop test" stand. If a

"pop test" stand is not available, remove the nozzles from the engine, leaving the pressure lines connected.

ICAUTIOND

Hold the nozzles so that the high pressure spray from them will 'not in any way impinge upon unprotected skin. The atomized fuel will easily penetrate the skin and cause blood poisoning.

Set the speed control lever at W. O. T. and operate the starter.

The needle valve, if it is working properly, will produce a high pitched pulsating sound like that of a flute as fuel is sprayed out. I f this sound is not heard or other problems are noted, refer to the "Fuel Injection Pump & Nozzle Maintenance

Std." in 4.1 in "Engine".

1. Delivery nipple 1

2. Delivery nipple 2

3. Nut

4. Washer

5. Nozzle holder body

6. Adjusting washer

7. Nozzle spring

8_ Push rod

9. Pressure pin holder

10. Nozzle nut

11.

Nozzle piece

Fig. 6. Fuel Injection Nozzle

Good Bad vr.~A::;-CZ:)

(j)

1. Pressure spring

2. Pressure pin

3. Pressure pin holder

4. Nozzle body

5. Needle valve

6. Nozzle piece

Fig. 7. Nozzle

(1) Assembly and disassembly of the nozzle should be done in fresh clean fuel.

(2) The nozzle should always be installed as an assembly. never by component parts.

(3) Remember never to let the nozzle spray contact unpro· tected flesh.

(4) Tighten the retaining nut to 43.5 to 58 ft-Ib (6 to 8 kgf. ml

Any torque higher than this will cause slow action of the needle valve and poor injection.

2.2 Lubrication System

• Oil pump pick·up screen

The oil pump pick-up is located in the crankcase as shown in

Fig. 9 and is fitted with a metal screen. If the screen becomes plugged, wash it off with diesel fuel or kerosene,

• lubrication system

The entire lubrication system is illustrated in Fig. 8, Oil from the pump is forced through the replaciable paper element filter. The. filter is equipped with a pressure regulated valve to keep the pressure through the filter at 64-71 psi. (4.5-5 kgf/cm 2 ). From the filter part of the oil goes to the crankshaft to lubricate the c;rankpins and the remainder goes to lubricate the rocker arms.

An oil pressure switch is located in the passage from 'the filter and controls the oil pressure. If the oil pressure falls below

14 psi. (1.0 kgf/cm2) the oil warning lamp" will light on the dash panel." If the oil pressure lamp stays on after the engine is running at normal speed, shut the engine off immediately.

Find and correct the cause of the low oil pressure before operating again.

If the pressure regulating valve in the filter fails and the pressure rises, a safety valve will limit the pressure to 140 psi.

(10 kgf/cm2)

..

(5)

Probable cause of low oil pressure n

(1) Clearance on one of the bearings is to great.

(2) One of the rocker arms is too loose.

(3) Faulty pressure regulating valve; pressure lower than normal (replace the oil filter or clean the valve on the old one with kerosene or diesel fuel.)

16 H.P .,

Rocker arm

Rocker arm shaft

-T-·--·.~

:,' ~ffiY

.

~

.I

~l'===~~"

Jr

-l.

t\

\ -_

011 pump Oil pan pIck-up screen ttJ.--Drain plug

Fig. 9. Detail of Oil Pump Pick-up

' ..

, ....

-.~

Relief valve

24 H.P.

Rocker arm

Rocker arm shaft

...--7

Relief valve

,

I

Fig. 70. Oil Filter

7. Filter cover assy

2. Cover

3. Safety valve assy

4. Safety valve

5. Plug

6 . Spring

7. O-ring

8. Relief valve

9. O-ring

70. Plug

77. O-ring

72. Oil filter cartridge assy

73. Oil filter cartridge

74. Label Oil pump pick·up screen .

Fig. 8. Lubrication System

• Oil filter

(1) Rf'plilC~ the nil filter <It 0vmy nthpr oil change (f!very 150 hours)

(2) Undpr normal camiltiol1, it is only necessarv to changE'! the nil filter at the specifipri intervills. If, however, thE'! engine is used in EXTREME L Y dirty conditions, the prpSSIJrp. requlat 1r11 valV!' and silfptv villve should also be

(3) rf'!lnoved ilIHi cleanp.d

Whp.Jlf'v!)r thl' oil filter is rpplacmJ, rtm the enqine under flO

IOild fnr il few fllinlltr~s lmtil the filter has been filled ilnri then add oil to milk ... up tor what is contained in the fdtp-r.

(6)

1. Relief valve compo 4. Ball valve

2. "0" ring

5. Valve sheet

3. Spring

Fig. 17. Pressure Regulating Valve

-- .

--Lj~\

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:~~.

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1 ---~'~_

1J

J j - ,

, __ ./_ L ___

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• Valve

Combustion air. of course. is brought in through the intake valve when the descending piston creates a partial vacuum in the cylinder.

Valve stem seals should be replaced whenever they are removed. If the stem seal are replaced. coat the stem liberally with oil before inserting in the valve guide to prevent burning the valve stem seal.

1, Safety valve body

2. SafetY valve spring

3. "0" ring

4. Oil filter base

5. Safety valve

Fig. 12. Safety Valve, Complete

• Replacing engine oil

(1) Drain and replace the engine oil after the first 35 hrs of orrriltion and every 75 hrs themafter.

(2) The t,il is easier to change il the engine is warm.

(3) Do not mix different brands 01 oil. If a different brand of oil must be used. drain the oil and replace with all one bl and. Also. do not mi x oils of different viscosities.

Combustion System

• Combustion chamber

The engine utilizes a swirl type pm-combustion chamber

See

(Fiq. 13). Fuel and air are mixed in this chamber resulting in more efficient combustion. A glow-plug is employed to preheat the fuel for easy starts down to 5° F

(-15°C).

(.5)

1. Nozzle holder 4. Cylinder head

2. Nozzle piece packing 5. Combustion chamber

3. Glowplug

Fig. 13. Combustion Chamber

( ] ) - - - - - _ . _ - - -

~--

(1)-__ _

1. Valve cap

2. Valve spring retainer

5.

6.

Valve stem seal

Valve guide

3. Valve spring collet 7. Valve

4. Valve spring

Fig. 14. Structure of Valves

The dimensions of the replacement valves and valve guides are shown in Fig 15. When new villve guides are installed. the bores should be reamed to 0.316 to 0.315 in. (S.030 to

S.015mm) after installation. The valve head must be recessed

0.043 to 0.055 in. (11 to l.4mm) from thefaceofthecylinder head to prevent it from hitting the top of the piston. ff

0.316-0.317in.

~

A:

0.313-0.314in.

Finished ID of guide

. installed in cylinder.

I

;;~=gdll$jr1,-_~tl_

(B.015-B.030mm) c

7.960- 7.975mm) Uf

.. . j i nr

AI T r

-"'" - ,

I

1.059 - 1.067in. 1.295 -1.303in.

(26.9"::V.Tmiii)

132.9

':::"33.1mmJ

Fig. 15. Standard Dimensions of Valves, Valve Guides,

Valve Gap

0.043-0.055in. (1.1-1.4mm)

Fig. 16, Sinking of Valve

(7)

.~

• Valve timing

When the valve clearance has hcp.n arl/usted as shown in

Fig. 17. the standard valve timinq shown in the chart can be attained:

Adjust bolt (2)

I

L oc k I ,Valve clearance

nut (1) . , -

I

0.007-0.009 in.

._t

(0.18-0.22

. r - - ( _~ Ul'~

~------------

~~

/ mm)

~ I(~ .~~

~ I~ ~.~

~

-.;.

::.. i:i:

Fig. 17. Adjustment of Valve Clearance

Intake valve opens 20° B TDC

-

. -

I ntake valve closes 45° A BDC

- - t - - - - - . - - - - -

Exhaust valve opens

._----_.

50° B BDC

-------_._-

Exhaust valve closes 15° A TDC

Valve clearance 0.007 to 0.009 in. (0.18 to 0.22.mm) with engine cold.

• Rocker Arms

I --0.551 - 0.552i""·"'n.-;;:----:-_

---(14.000 14.027mm)

16 H. P. ,

[ 24 H.P.] j~ ~W\MI I ~tj

II

1_. __ . ___ _ 0.551 - 0.553;11.

-·-.,14.002-~T4~043mm)

0.550 -0.551;n. rij§i3:':'1 j~9iJ4miriJ

I

[ +--

~

I . - .

0.551- 0.552in.

7T4.(jtJ{F~i4:02j~mT -

·--l

(14.002 -. 14.043mm)

0.550 - 0.551in.

(iig

- - -

Fig. 18. Standard Relative Position of Rocker Arms

(8)

• Compression release (Release wire is optional parts)

Assemblp thp parts as shown in Fig. 19. Pull the lever out as far as it will go. check to see that the 60° angle is attained and that compression is released. The compression release is to be used when the battery is low or when starting in cold weather. Tn use the compression release. preheat the glow pluq :ls IJsual. pull the compression release knob out as far as pOSSible and holrl it there while cranking the engine

This flartially' releases the enQine comflression enabling it to turn faster in cold weather or when the battery is low. Once the engi ne

IS turninq fast enough to start. release the lever and the engine will start.

(NOTE)

Make sure the compression release has returned to the operating position by pushing the knob all the way in.

Released

1 elf;D

Operating released

Fig. 19. Compression Released

~

CAUTION n

Do not pull the compression release lever when the engine is running at high speed or under load. If it is necessary to use the compression release while the engine is running reduce the speed to idle before doing so.

• Adjustment of compression release

(1)

Set exhaust valve in totally closed position

(2) Remove decompression adjustment window cover from cy I i nrler head cover.

(3) Make valve clearance as "0" with use of decompression adjust bolt From this position. turn the holt further by

1 to 1.5 turns. Decompression clearance will then be set at 0.030 to 0.044 in. (075 to 1.125rnrn), which is the designed clearance.

(4) After adjusting, be sure to lock adjust bolt securely so that it will not unturn while engine is in service.

(5) Make certain that the cleanrance is not too wide. To check this. turn crankshaft hy hand and make certain valve disk does not contact With pistion top

Operation position

~ ~~

®

".

'

\

Compression released position

II/cr;

C%l

/

.~

1. Rocker arm 5. Compression release nut

2. Oil filler cap 6. Compression release bolt

3. Compression re~ase lever 7. Shaft

4. Adjustment access cover 8. Valve

Fig. 20. Adjustment of Compression Released

• Top clearance

Top clearance should be 0.028 to 0.035 in. (0.7 to 0.9 mrn)

To adjust, usecyl inder gasket shims, 0.006 in. (0.15 mm) thick each, onto the head side

For checking the measurr.rnent, place a piece of fuse on the piston top and fix the cylinder head securely on the cylinder· head flanqe The measurement is taken by the fuse. The liner is level with the cylinder frarne at top surface.

The gasket shirns can be reused, so do not lose them.

Head

- Top clearance

--.-....,-- 0.028-0.035in.

(0.7-0.9mmJ

Piston

Fig. 21. Top Clearance

(9)

• Boring and replacing the cylinder liner

Referriml to Fig 22. tht~ insirif~ diametPf of the linm sholiid be checked at points 1.2. and 3 ann in the directions (a) and

(b). The liner on which the wear has excE'eded the service limit can hf! bored and honed to 0.020 in (O.50mm) oversile.

The finished dimensions are 3.012 to 3.D13 in. (76.500 to

76519mrn). Models 5416 and 5424.'

An oversi zed piston ann rings must then he usen with this liner. Once this

()VerSiled liner has excepned its wear limit. it should be reo placed with a new one. To install a new liner. coat the outside liberally with oil, 'push into the block with a press and finish to the standard size. When this is done, a standard size piston must again be used.

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CD

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3.130 ·3.131in.

(79.505 79.535mml

16 & 24 H.P.

!

..

© Standard size ©Over size

2.992 - 2.993in.

(76.000 -·76.019mml

3.012 3.013in.

(76.500" 76.519mml

16 & 24 H.P.

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

• Tightening cylinder head capscrews (Fig. 23)

(1 I Tit" liflhtr~nlilfl tmQue of thp. cylincJAr head caf)screws is

~'>4 to f)8 II Ills. !7.fl to 8.0 kq·m) Numbers 7,8 and 11,

13 (.) ill tllf~ dii:lqrarn ale studs. The nuts on these studs shouln <llsn he liqhtenerl to this torqup..

(2) All the capSCII?WS must be tiCjhtened uniformly. To do this, tiqhtpn all Ihe capscrews in the orclm indicated on thp. diaqram \lIllil thiN are Just snug. Then tighten each one 1 (ond turn at a timp. in this same sequence each time until all have bem tightened to the rp.Quired torque.

(3) The cylinder head capscrews should be re-tightened if the enqine has not been used for a long time. The valve lagh should also be adjusted p.ach limp. the cylinder head capscrews are retorqlled If the cylinder h(~ild gasket has b0.(!n replaced, rUIl the f'nfline lor allfllJl 30 minutes and re'lighten the cylinder llt:ad capsrrcws as decsribed above.

(10)

[24 H.P<

Fig. 23. Tightening of Cylinder Head Bolts

• Air cleaner

Main Moving Parts

• Pistons and piston rings

The ['Istons and piston rings are shown in Fig. 26. If the cyl inder Imers have been bored oversi7e. oversize pistons anti rings must be used. The piston is made of high silicon

AI·Alloy and is cam ground. The top compression ring is a chrOln£' plated keystone type. the second compression ring is discontinuous and undercut and the oil control ring is of the standilrd expansion type. s: End gap of rings on poston in cylinder

I Diameter of piston skirt thru t of piston pin bore

E: Diameter of piston skirt perpendicular to piston pin

III

I

0.10i'l . .J.2.5mm) r~

I

L~,

.----1

lJ2.0Bl - 0.OB2in.

(2JjliF-

2.070mm)

0.191- 0.19Bin.

(5.010::: 5.030m"'1

0.905 '- 0.906in.

(23.000 - 23.013mm)

0.012- O.OlB,'!.:..,

(El!

(0.30 -

0.10in. (2,49mm) : i

0,45Ff1m) t --

0.Oj6B_O._t::J!121n·_n

(1.950-1.962mm) i

!

0,1,957- 0.1965in."J f4.91B-4.990mm)

~

I

0.010O.018i~ i

rt.--

-.'=CC.".

I i . . .

L--<i.\

.'

181

J

I i

(1i.'25- 0.45mm)

Fig. 26. Standard Dimensions of Piston and Piston Rings

~

Standard size Over size

IA

I

2.992in.

(76mml

3.012in.

(76.5mml r----

---

2.986 2.987in. 3.005 - 3.006in.

(75839 75.859mml (76.339- 76.359mml r---

2.989 . 2.990in. 3.008 - 3.009;n.

E

(75.915 75.935mml 06.415 - 76.435mml

16 H.P.

24 H.P.

• Crankshaft and connecting rod

(1) The crankshaft is a heat treated steel alloy forging. The crank pins are induction hardened for additional wear resistance. Crankshaft endplay is 0.006 to 0.012 in. (0.15 to 0.31 mm).

(2) The crankpin bearings are aluminum.

When installing the connecting rods: a) Clean both surfaces thoroughly. b) Apply engine oil to the threads of the connecting rod capscrews before installing and tighten each to 27 to

30.4 ft·lbs. (3.7 to 4.2 kg-mi.

The bearing caps are matched to each connecting rod and should not be interchanged. Also. since there are variations in machining from side to side, each bearing cap and connecting rod are marked and should be assembled so that the marks line up.

(3) In the event that the crankpins become worn and are no longer serviceable, undersized bearings may be used.

When installing the undersize bearings observe the fol· lowing precautions a) Machine the crankpin diameter and radii to within a few thousandths of the correct dimensions and finish grind to the exact dimensions. b) After finish grinding the bearing diameter and the radii, chamfer the diameter of the oil hole with an oilstone.

If this IS not done an oil film will not form and the bearing will sieze. c) The crankpin should always be super-finished to

0000016 in. (00004 mm) or less. d) Select the bearing from the chart that necessitates the removal of the least amount of metal from the crankpin. Do not deviate from the chart dimensions as the bearing life will be reduced if they are machined. e) To determine the running clearance, assemble the connecting rod, bearing cap and bearing as described in section 2 and measure the diameter anywhere within the 120 0 angle indicated in Fig. 28 and subtract the crankpin diameter from this figure. f) . The piston pin bushings are of lead bronze.

The inside diameter of the bushing should be finished to 0906 to 0.907 in. (23.025 to 23.040 mm).

Over Sl7e

0.02in. (O.5mrn) f - -

>---------

Name of Part

Piston 05

Piston ring 05

Mark

05 OS

05 OS

Cylinder liner

- - - - - -

3012 to 3.013in. (76.500 to 76.519mm)

(12f.1R max. to 2pR max.) by honing

--_

...

_ - -

- -

16

24

H.P.

H.P.

( 11)

n13n-Ol46m f3]31mml

Radius 004-0.06!". 0 1,5mm/

1--

1 _

, 1307-·, I'!313m

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(43.959 - 43 975mml o

130-0. 146m

(3.3-3.7mm)

Fig. 28. Crankpin for Undersize Bearing

2.050 - ) 052m

"'W

0 782 -~ O. 793m.

"" "." u

"Tj~

2.044 2.045111

(5'.921 51940mmJ

1 o

74'?-·-O,15Jm

(1887 '9.1.1mmJ r-.

1 l' lOT

. ~. r ~1

0.078,·0,079"1

..; 1'!.!!.::.2000mm)

I l

24 H. p

·1

17307 1.l313m

143959 43.975mml r=1J[]--r. r l.ufu-·-

·.;.f1U~-.11.f-llrr;.1-l

, - . : ! ( j _ . i .. . L-! t i . ' ' .

L.~~_~

__

-L ____ t

~.

.L _____ ._. _! l

J

2.044·- 2045m

(51.921- 1j1 .Q40mm)

2.050 2.052m 0 782~O.J93111

(52.064 52. ,31mm} ! (1987-20. 13mm)

2.247--2.248," ,

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

I ..

' :

I '

LUIJ

0.143- 0.753m

(18.81-,g. 13mm)

---+--.------,------T"' ..

rn m rn

0018 ·0..079;,1.

(1970. - 2000mmJ

Fig. 27. Standard Dimensions of Crankshaft and Bearings

'~q

I

'0236 '02"m

(26 non

16,021",m)

!

! 09065 ·0 90lJIIl

'- (23 025 - 23040mml

OJ

I 0255 , 0267",

(26 048 16 078mm} ~,-'"

- (23001,· 23[1"mrn} o

NJ--O 153m

(18870-'19. f]Omml

,

- j

I f

1.850. '.851m

(47.000 47.02mrn)

0.0.58 -·O.059In r,

482 - 1 495mml

c.A':

Diameter of piston pin bushing after installation

Fig. 29. Standard Dimensions of Connecting Rod

Bearing and Bushing

Sill" Pi] rt I'Jo Bpar ing Crankrin Diarn.

Metal

Mark

020

I

I

0.20 mrn undersi7P I

1. 7228

'0 ,

72"-i~' ~~--I

,.

(43.759 to 43.775 rnrn)

!

020US

---:~:-1-

________

~-]

40

mm o

Od:" " , ---

t

~;;4~

'0·'7·';"

~-I

(43559 to 435"15 rnlll)

040US

Runninq Clpilrancp in.

('nm)

0.001379 to 0.003819in.

(0.035 to 0.097rnrn)

- - - - ' - - - - - - - - - - - - - - ' - - - - - - - ' - - - - - - - - - - - -

(12)

Main Components

• Gear train

Be sure to assemble thp. gears by matchinq the mating marks as shown in Fig 30. The backlash of each gear is 0.002 to

0.005 in. (00415toO.1154mm)

"

,. Crankshaft gear

2. Oil pump drive gear

3.

Idle gear

4. Camshaft gear

5. Fuel injection pump drive gear

Fig. 30. Mating Marks of Gear Train

• Crankshaft gear

Heat to about 176°F (BO°C) and slide on crankshaft If the shaft and hore dimensions iJ[P such that the qear will not slide easily. it may

be

heatp.d to a slightly higher temperature for installation.

• Camshah gear

Rp.fer to Fig. 31. Place the camshaft retainer plate on the camsh;Jft first. Shim the camshaft retainer rlatr~ out from the camshaft 0.003 to 0.009 in. (0.07 to 0.22 mm) with shims that can be pulled' nut after the gear is installed. Heat the gear to aprroximately 176°F (BO°C) and sl'ide on the shaft until it hlJtts up aqainst the retainer plate. Remove sracer shims. If thp qe;'H will not slide on the shaft easily it tno may be heated to a slightlY highp.r ternperature as descrrbed above.

• Camshaft and camshaft bearings

Standard dimensions are shown in Fig. 32. Camshaft running clearance is: 0.002 to 0.004 in. (0.05 to 0.091 mm)

16 H. P. ~ rll ~

1 I

I

1 t

I {

1~l..r f t l'

------ - - -

I.571-I.5731ft. q

(J9 9:U-19.95Omml

If

~.~

I

1.575-1.576 ...

(.0.OOO--40.025mml

' 1

]d''''t''.+ru'j

••• .

24 H.P.

(

---{_~lJJJ l~trrnEro=oo

.. --.---- ........ - -- .. --r-----.

1.572-1.573 ..

'

(J9.9:U-J9.95Omml

Fig.

1.575 -I.516ln.

(.OOOO-40.025mml ~

32. Standard Dimensions of Camshaft and Bearings

.-

1. Camshaft gear

2. Camshaft

3. Camshaft retainer plate

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

4. Cir·clip

5. Pin plug

6. Key

Fig. 31. Assembly of Camshaft Gear with Camshaft

(13)

• Main bearing ass'y

Insert the bearings in the main bearinq hnusing halves as indicated in Figs. 33 & 34, using the thrust wilshers only on the

Journal nearest the flywheel. Coat the crankshaft Journals and the bearing surfaces with engine oil, place the hOllsing halves with bearings on the crankshaft, coat the capscrew threads with engine oil and tighten to 21 to 25 ft-Ibs (3 to 3.5 kg-m)

-M8

• Main bearing housing

Installation of crankshaft with main bearings in engine block.

Slide the crankshaft assembly into the engine block, being careful not to nick or scrape the crankpins. After the assembly is in position make sure the oil passages are correctly lined up

Install the main bearing housing to engine block locking capscrew and washer from the side to position the housing and then install capscew (2) from the bottom and torque to 47 to 50 ft-Ibs (6.5 to 7 kg-m) - M 1 a

1. Bearing

2. Thrust washer

3. Thrust washer

4. Crankshaft journal

5. Main bearing

6. Cap screw

7. Locking tab

8. Locking tab

Fig. 33. Main Bearing Housing 3 with

Thrust Washe~

1. Bearing

2. Cap screw

3. Locking tab

4. Main bearing housing

5. Cap screw

6. Locking tab

7. Locking tab Fig. 34. Main Bearing Housing 7

Main Bearing Housing 2

.-

------.,_.-.-

0

-

----------_. 1----_ .. _._---_ .. _-------- --

5.156

-

5.157in.

Main bearing housing 1

--_._-_.

__

._---,--.------

1130.968 -130.986mm)

------

-."-

. __ .. ..

_----

Main bearing housing 2

5.1956 - 5. 1963in.

1131.968 - 131.986mm)

2.2047- 2.2055in.

156.000 - 56.019mm)

--~. ------~-

..

- --------_.

16 & 24

1-- ------

H.P.

24 H.P.

Main bearing housing 3

5.3137 - 5.3144in.

1134.968 --134.986mml

..

16 & 24 H.P.

(14 )

• Idler gear

Secure the idler gear shaft to the engine block with 3 capscrews. torque to 17 to 20 ft-lbs (2.4 to 2.8 kg-m) and bend tabs of tab washer. Install gear as shown make sure it runs freely. has a running clearance of 0.001 to 0.002 in. (0.020 to

0.054 mm) and 0.008 to 0.020 in. (0.20 to 0.51 mm) end play.',

• Injection pump camshaft

Injection pump camshaft. Fig. 37. Install the bearings and governor unit on the camshaft and install in the engine block.

Hour Meter Unit. Fig. 37. Insert the "tang" on the end of the hour meter drive shaft into the slot on the end of the injection pump camshaft and install as per the illustration.

1. Idler gear

2. Spacer

3. Retaining ring

4. Shaft

5. Bushing

6 .. Spacer

7. Engine'block

8. Capscrew

9. Tab washer

Fig. 36. Idler Gear

/"

! 4 ' /

/ .

,

(5.'/

'.6 (71

1. Fuel injection pump

2. Speed control lever

3. Fuel control system

4. Hour meter

unit·

5. Injection pump gear

6. Governor system

7. Injection pump camshaft

Fig. 37. Injection Pump Camshaft Assy

NOTE

*Hour meter unit is optional parts .

. (15)

• Attaching flywheel to crankshaft

Clean the entire contact suriil('P carPiully Coat the contact surface with enginp. oil, wa~h all the oil oil with gasoline and dry it throughly. Put the flywheel on and torque the CHpscrews to 70 to 77 ft·lbs (10 to 11 kg·ml. Bend the locking tabs back on the washers .

• Tensioning of fan belt,

The fan belt temion IS adJusted by moving the alternator bracket in or' Ollt. The belt is properly tensioned when the bel t deflection midway between the alternator pulley and the crankshaft pulley is 0.25 to 0.35in (7 to 9mm) with a force of 20 Ibs applied.' Proper belt tension is essential for good engine cooling and belt life. See Fig. 38.

Fan pulley Tension pulley (Alternator pulley)

0.25 to 0.35in. (7 to 9mm)

(1) Rust inhibitor and antifreeze should be used in accord· ance with the recommendations in the related manuals

(2) Be sure to remove all debris that may be plugging the fins.

(3) Check the rubber shock mount nuts periodically to be sure they are tight.

• Cooling water pump

To install the enolinC] fan pulley on the pump, securely tighten the nut (4) tn 50.6 to 57.9 ft·lbs. (7 to 8 kgf .m) torque.

16 & 24 H.P.

1. Pulley

2. Bearing

3. Key

4. Nut

5. Body

6. Shaft

7. Rotator

8. Case

9. Seal

Fan drive pulley

Fig. 38. Fan Belt Tensioning

Starting Motor

The starting motor is of the standard bendix type drive with actuating solenoid. The assembly is shown in Fig. 43.

2 r - . l

Fig. 39. Water Pump

1. Starter ass'y

2. Drive end frame

3. Welch plug

4. Bushing

5. Set bolt·

6. Bolt

7. Drive lever

8. Solenoid

9. Over running clutch

10. Armature

11. Snap ring

12. Collar

13. Yoke

14. Set bolt

15. Packing

16. Field coil

17. Brush

18. Brush

19. Brush holder

20. Brush spring

21 Through bolt

22. End frame

23.

24.

25.

26.

Bushing

Packing

Return spring

Washer

27. End frame cap

Fig. 43. Starter Assembly

13

16 17

_ _ --'L

20 18

- r-..J

I

19

I

I

(16)

• Starter specifications

16

------,-------

H.P.

Code No. 298783

Type f-.

Nominal voltage

Nominal output

Solenoid ilctuilted with overruning clutch

12V

0.8 kW

Direction of Clockwise, viewed from rotation pinion end

- - -

• Trouble shooting

If the battery turns extremely slow or not at all, the cause may lie in the battery, wiring or the starter The Ilqhts are. a very convenient tool for tracing the cause of thetr-ouble.

Ll<lht nlPlhocJ

The lise of thiS method, of course, assumes that the are fllnctioning normally

(1) lights

Liljh15 ar,

,11-'

Probable rallse Low hilttery, faulty contact at one of the connections, faulty wiring. If the bilttery remains discharged hecause of a malefaction in the charging syw~m, it should be correr:ted before charging the battery from reoccuring to prevent the rroblem

(2) With battery fully charged a) Symptom Lights do not light

Probable cause Battery terminal not properly connected b) Symptom' Lights hP.l.nmeextp.mely dim when crankinq the enqine and starter slows down or stops

Probable cause

• Bad engine (rotatIOnal resistance too great)

• Starter does not turn satisfactorily.

ArrT)ature shaft bent

Worn bushing

Pole core screw loose

* Field coil grounded or insulator short circuited

* Armature coil grounded or insulator short-circuited c) Symptom Lights are brirjht but starter does not turn or turns very slowly.

Probable causes

• Starter terminal not r.onnected rroperly

* Solenoid switch not making contact

* Solenoid not workinq (coil grounded or insulator short circuited)

* Faulty starter SWitch contact

(17)

24

- - - - -

H.P.

298876

1.0 kW

* Insufficient brush contact

• Dirty or worn commutator

• Precautions in care and handling of starter motor

(1) The starting motor must be installed properly for the starter pinion to mesh with the engine ring gear as it should. If the ring gear and pinion do not mesh properly, the pinion and starter housing may be damaged and in extreme cases, the starter may not even turn.

(2) If the starter switch is turned on and the engine turns, but will not start, the cause is probably in the fuel system.

Check the fuel I ines and correct as necessary

(3) In attempting to start an engine, never use the startinq motor for more than 30 seconds at a time without a pause to let is cool down. The starting motor heats up very rapidly when used and if it is used continously for more than 30 deconds the solder may melt from the armature or the coil or lead wires may melt. Also, the battery will be <iischarged tn such a <iegree and won't have suffirient power fm another attempt at starting. A good rtlle 10 follow is to crank. for 10 seconds and pause for 10 se-

(4) conds. Repeat until the engine starts

If the starting motor is too far forward, the pinion will

(5) not mesh properly with the ring gear and cause rapid piston wear. Ad jus t for proper mesh.

Do not turn the starter switch while the enqine is running.

If this is done, the pinion gear will contact the Tlng qear, which is tlHning with the full force of the enqlOe which may cause a broken pinion, bent shaf.t, broken houslOg, etc.

Glow Plugs

The glow plugs are the sheath type with the wiring diagram as shown in Fig_ 44.

/

1. Glow plug

2. Glow plug controller

3. Starter switch

4. Main switch

5, Regulator

6, Alternator

7. Battery

8. Starter

Fig. 44. Circuit Diagram for Glow Plugs

• Glow plug specifications

Code No.

16 H.P.

298795

Number

Vol tilfJP & rw refl t

' - - - -

::>

ArprOXIPlately 6.5 amp

(l') 10.5 V

. _J 24 H.P.

. r

I 3 j

• Glow plug controller specifications

Code No.

Current

16 H.P.

299839

13A

24 H.P.

299839 .

--

20A

• Precautions in handling the glow plug

(1) USf' the glow plugs only with

Universal

glow plug controller. If any other type is used, the heating time will not match that of the glow plugs and cause hard starting and various other problems

(2) As the glow plugs are ill rarallel, thl) controller heating element will tllrn red even if. one of the rlugs is bad.

However, the time it takr~s for the controller heating etement to get hot is less, which will cause the element to bllrn out.

(3) Rerlilcinq a faulty glow plug may not solve all the system prohlems. Should thf' failed rlug indicate problems in other areas beside the pili'], they should be checked out iilv). The fl10st probablf' a[(~as are: improper fuel inJcction tilTllflq, bad nOllie, wrong fuel, incorrect circuit connection, gas If'ak, etc.

(18)

ENGINE CONNECTIONS

I

Univel~al Diesel

PANEL CONNECTIONS

_Cl,,-L

_ 0

_~

2

CYl.

-

.

-

.

--,--

-t-

..

GLOW

--..

I PLUGS

. i

Connect to ACC. term. on switch

•

I

FUEL PUMP

E

......, en

>-

(J)

co

w

(.)

Q)

I

I

• -L

Blue ~

OIL TEMP

FEMALE-l

CDI~'j141

SENDER SENDER FEHALE~!!

Z zz

Z Z Z Z Z Z Z Z Z ZZ Z ZZ ZZ zz

:]1,1:]

0'1

.......

Reference Chart

Engine

Parts i

II>

J:

~

"0

!:

>

U

Items

Cylinder head tightness

Cylinder head surface distort inn

-----

Intake/e)(haust valve seat thickness

Top clearance

Standard 10

.--

Specifications

Ml0 x 125

45° 0.059 in. (1.5mm)

15416 &

.--.

5424 2.9921 -. 2.9929 in.

(76.000- 76.019mm)

.:i

~

"0 c:

>

U

Standard Value

54.2"'" 57.9 fUbs

(7.5 --8 kg·m)

0.002 in below

(0.05mm below)

0.0276"'" 0.0354 in.

(0.7 ..... 0.9 mm)

Piston clearance

(At piston skert)

15416 & 5424

0.0026·0.0041 in. !0065-·0.1~mml E side

0.0056 - 0.0071 in. (Q.141 - O. 180mm) I side

Type

Standard 00

Dry

15416 & 5424 2.9921 in. (76mm) c:

B a:

Piston·pin boss 10

Piston·pin clearance

Ring gap

'" a: c:

0

:;; a:

Top ring width

2nd ring width

Oil ring c a: c

0

:;; a:

00

Pin·to·bush clearance

-

Small end 10

Maximum limit

Remarks

When installing. apply a generous coat of engine oil onto the entire surface of each bolt.

{ I

Y4S'

O.059in. (1.5mm)

050 oversize liner 10

2.9980 in. 3.011.!3_3"o.l..?~_In.

(76:15mm) (76.500- 76.519mm)

Height above block surface

± 0.00098 in. (± 0.025 mm)

Oversize 0.020 in. (0.5 mm) o

9U55 - 09060 in.

(23000 -23013 mm)

._-----_.

(toP. 2nd)

(oil ring)

Keystone type

0.0768 -0.0772in.

(1.95 1.962mm)

01960 -0 1965in

(4.978 - 4.99 mm)

-----

0.9056 ";"0.9059in.

(23.002-23.011mm)

0.9071 in.

(2304 mm) interference Clearance

0.0004 in. 0.0004 in.

(OOllmm) (0.011 mm)

.. ._._----

0.0118 - 0.0178in.

~.3~0.45mm) _ _

0.0492 in 0.5 oversize top ring surface should

(1.25mm) be 0.0079 in. (0.2 mm) below

0.0098 - 0.0158in. piston side surface.

\ (0.25 - 0.45mm)

Ring groove clearance

0.0037 -00047 in.

(0.093 -0.120mml above 0.0079 in.

(O.2mmJ

J

00008 -0.0020 in.

(0.02 -0.052 mm)

._---

0.0006-00015 in.

(0.014 -0.038 mm)

0.0059 in.

(0.15mm)

1,0236 - 1.0244 in.

(26000-26.021 mm)

(without bush)

Small end width

"0

0 a: Large end 10

'" u

II> c: a

u

Large end width

Rod torsion

(see diagram)

Rod bolt torque

1 0236 in. (26 mm)

1.8504 - 1.8512 in.

(47.000-47.020mm)

(without bush)

1.0079"'" 1.0118 in,

(256"'" 25.7 mm)

Pin

. ~ t .. .

Con"",,'ino

~ J-

TIJ:l. rod

4in. (100mm)

+ l~·±O;OOO79in.

_O.OOO79m.

(±O.02mm)

(±O.02mm)

M8)( 1

0.0008 in.

(0.02 mm)

26.76- 30.38 ftlbs, (3.7 - 4.2 kg·m)

0.002in,

(005 mm)

When installing, apply a generous coat of engine oil onto the entire surface of each bolt.

(20)

Items Specifications Standard Value

Maximum

Lomit

Remarks r---.r--.--.-----------------------~.----------.----_+--------------+_----~--------------1

ID 1.7327 - 1.7345 in.

(44.01 - 44.056mml

(with metal)

'"

:2 c a

-'" c

'"

Width

00

Runnmg clearance

0.7429 -0.7531 in

(1887-19.13mml

1 85 in. (47 mml

Center thickness

0.0583 - 0.0589 in.

(1.482 1.495 mml

0.0014 - 0.0038 in.

(0.035 - 0.097 mml

0.0079in

(0.2 mml

1-- -.

Axial clearance

20441 - 2 0449 in

(51.921-51.94mml

0.0157 -0.0236in. Crank arm· to· large end clearance

(0.4 -0.6 mml

------.------.---.----+---.---------+---------..,-----+-------------1

Cr~nkshaft jurnal dia

Main be"rlng ID 20465 - 20483 in

(5198- 52.025mm)

(with metal)

I

Running clearance

0.0016-0.0041 in.

(004 -0.104mml

0.0079 in.

(02 mml

0>

C

Crankshaft metal (21 07429 -07531 in.

Width (1887 -1913 mml

.---------.----.-----+------------+------+----+-----'---------1

Crankshaft jurnal d,a 20449 -2.0449 in.

I

Running clearance

(51921 -51.94mm)

0.0079 in. o

0016 -0.0046 in.

Gear'Slde main bearing ID 20465 -2.0488 in j

(0.2 mml

(5198 -52.039mm)

(004 -0118 mml

(with metal)

0.7823 - 0.7925 in.

(19.87- 20.13mm)

CrankShaft metal (1 I

Width

.c.

VJ

E

'" f--

Crankshaft metal (11 OD 2.2485 - 2.2474 in.

(57.111 - 57.084mml

---------.---f------------------1~-------_+----+------------_1

Crank,pln jurnal dia 1.7307 -1.7313 in

(43.959 - 43975mml

0.0047in. When installing, apply a generous

(0 12 mml coat of engine oil onto the entire su rface of each bolt

Crankshaft Side clearance 0.0059 - 0.0122 in.

(015-0.31 mml

Cr~nk hearing cap bolt (11 torque

M 8 x 1.25

21 7 - 283 tUbs

(3 -3.5 kg.ml

Crank bearing car holt (21 torque

M 10 x 1.25 47.0 -506ft Ibs.

(6.5 - 7 kg.rn)

. - .-.--- .-.-.--.-.-----------1-.. -.- - -.. --.-------+-----------+--.. - - - - + - - - - - - - - - - - - - - 1

Cam bearing I D 1 5748-15758 in

(40 000-40 025mm)

1

Running clearance

Cam shaft dia.

Ax ial clearance

15722-1 5728 inl

(39.934-39 .950mm)

0.0020 - 0.0036 in.

1(0.05--0.091 mml

0.0028-00087 in.

(0.07 - 0.22 mm)

0.7677 in.

(/9.5 m~) f\

I

1,3134 in.

I

(33.36 mm)

~

I

Cam 11ft 0.2165

In

(5.5mm)

0 . 5 4 5 7 i k

(13.86 mm)

C~rn height 1 3134 in

(3336 mm)

(21)

--

Parts

Items

Number of teeth, crank gear

Number of teeth, Idel gear

Number of teeth, cam gear

Nllmber .of teeth,

Inwction pump gear

Number of teeth, at! pump drive gear

34

79

68

68

Specifications

Standard V~lue

Maximum limit

Remarks

45

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

0,0118 in, to,3mm) r - -

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

ShlOkage

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

Face angle

I ntake bore

Q)'

~:

Exhaust bore

Stem dia,

Valve.guide IQ

Stem guide clearance

-

Free length

--

_.

Spring pressure

OJ

~

Ci

Ul

,.. iii

>

Perpendicularity

Spring pressure loss when installed

Over,all length

Dia

Valve gUide bore s/:1ouJd be reamed after inserted into cylinder head,

1,2953-1,3031 in t32,9 33 1 mm)

1,0591-10669 in

(26,9 -27,1 mm)

0,3134-{),3140, in t7 ,960-7 ,975mm)

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

0,0016-{),0028 in

(004 ~0,07 mm)

Q,0071-{) 0087 in t018 -0.22 mm)

When cold,

1,6417-1,6614 in,

(41,7 -422 mm)

26,46 Ibs./l ,3839in

(12kg/35, 15 mm)

Load and length when installed-

3%

15%

-------~------- r-,--~---- --~--t-----+---------------------

-,

A 5984 in

(152 mm)

B 5,8189-

5.8346 in

(1478-

1482 mm)

0.2323-{),2402 in,

(59-6,1 mm)

(22)

P"rts

1---

Maximum

Item5 Specifications Standard Value Remarks

Urn It

I - - - - - - - - - - - - - - - - - - - . - + - - - - - - - - - - + - - - - - - - - { - - - - - + - - - - - - - - - - - - - /

I ntake valve opened

I ntake valve closed At 45° ABDC

0'> c:

E t--

QJ

2

'"

Ex hill.jst valve opened

Exhaust valve closed

Iqn,t,on process

At 50° BBDC o

At 15 ATDC

1-2

1 - 2 - 3

[

[

16 H.P.

24 H.P.

Injectectinn tlmlnq

~-4------·-----------11-----------4-----------~r----_+----------------~

Trochoid tooth width U 16 H. P. Use Engine Oil CD (oS)

Above 77°F (25°C). SAE30

0.5866 -- 0.5874in.

(14.90 . 14.92mm)

24 H.P.

0.8622'" 0.8630in.

(21.90- 21.92mm)

° ° °

C-

25°C).SAE20

Outer rotor OD 1.9669- 1,9685in.

(49.96- 50.00mml

Below 32°F (OoCI. SAElOW.

10W·30

CI.

E

:>

CI.

6

Trochoid·tn·body clearance o

0035-{} 0063 in.

(009 -0,16 mm)

Troc!1oidto·body side clearance o

0039-{} 0059 in,

(010-0.15 mm)

Oil pressure

64-71 psi.

(4.5 - 5 kgf/cml)

. Pump capar.ity

[ 16 H.p.D [16 H,P . B

«

4.2 Gal/on/min.

(16£imin)

24 H.P.

5.8 Gallon/min.

I 24

At pump 2116 r.p.m.

H. P.

At pump 2000 r.p.m.

(22£imin.l

. - - ·--·-------------------1----------11------ ----. -.

Model Np·PFR3K55/2NP2

---+-----+-------------i

Cam speed 1400 r.p,m.

Rack position: 0.354 in (9 mm) a.

E

:>

Cl. c: o

I nleC! ion pressure

Pump plunger dia

1990 psi (140kg/cm 1) u

'"

Pump stroke 0.2756 in (7 mm)

Pump discharge 0.0013-

00015 in

3

/rev

(23 ± 1 mm

3

'rev)

--- -------_ ... __ .-------- _._----_._------+----------+------+--------------\

-

Modf!1

I njl'ct Ion pressure

NDDN12SD12

1990 - 2133 pSi.

(14D-150kgf./cm1 )

(23)

Parts

Items

Cooling system

Water pump (Z751-BW and DHll0l-BI

Gear case to impeller clearance

Circulation flow rate (Z751-BW

E

~

'"

C/)

;;; iO

~ and DHll0l-B)

Impeller dia.

(Z751-BW and DHll01-BI

C>

SO

0

0 w

Thermostat actuation temperature

(Z751-BWand DHl101-B)

.

Spec if ications

---

Natural circulation

16 & 24 H.P. t-orceo circulation

Centrifugal pump with thermostat

(impelled

2.634"-2642 in.

(669-67.1mml

179.6"-203°F

(B2°C -95°CI

Radiator cap pressure

Fan belt length

HM 40.55in. (1030mml

.n perimeter

16 & 24 H.P.

HM 41.50in. (1054mml in perimeter

Standard Value

0.0232-0.437 in.

(0.59 1.11 mml

(Packing thickness)

26.4 Gallon/min

(100Q/min) or more

12.B psi. (0.9kg/cm 2 ,

Ma)(imum

Limit

Remarks

With pressurized radiator

(corrugated I

Water temperature BOoC.

Total lift 19.34Ibs.!in

2 (lmAg)

Pump speed 3450- 3550 rpm

. "No pump for Z751-B and ZB51-B

---.

Model

0 iii

:;

C>

.,

01

!9

'0

>

0

., c

>

0

Electrolyte specific

>

2i gravity. discharge iii

CD

Electrolyte specific gravity. charge

Etectrolyte specific gravity. overdischarge

Voltage

Current

Check interval

Brush spring pressure

I nsulation resistance

Constant voltage

Current

Cut-in voltage

16 H.P.

D

12V70AH

24 H.P.

12VBOAH

1 120

1.2BO

(6BoF; 20°C)

1.30

12V

20A

Every 1000 service hours.

12.B pSi(0.9kg/cm 2 ) ±

15%

13.B .... 14.BV lOA

12.5-13.5V

(24)

16 H.P.

} NS70. dry

24 H.P.

N70Z. dry

Alternator

Insulation resistance

No failure at 500MV

,"'-'"

Par" Items

- ' - - - - - - - - -

Number of teeth. pinion

~

Number of teeth. rIng gear

Insulation resistance

Check interval

Output

. _"-- -.--.---------

Hp.ad set bolt and nut

Flywheel set bolts

QJ

=> cr

(;

I-

0 co

-

C

~

0

E

Crankshaft main bearing set cap bolts

Crankshaft cap bolts

Rocker bracket set studs

Rod bolts

- -

_ . "

Gp.neral set bolts and studs

QJ

=> cr

(;

I-

(5

CD

I

I 1-.

89

Specifications

.

Standard Value

Maximum limit

Every 1000 service hours

.. n

16 H.P. .~

0.8kW n· 24H.P. D

1.0kW- ....

-_.

__

..

_-------

' - - -

.

54.2-57.9ft Ibs. Ml0x 1.25

(7.5 - 8 kgf.m)

Remarks

No failure at 500MV

Insulation resistance

Nominal value

Apply a generous coat of engme oil onto the entire surfaces of all important set bolts.

M12

MlO

M8

M6

M12 x 1.25

Ml0 x 1.25

M8)( 125

M8)( 1.25

M8)( 1

72.3 79.6 fUbs

(10 11 kgf.m)

47.0-50.6 fUbs.

(6.5 - 7 kgf·m)

21.7 - 25.3 fUbs.

(3.0 - 3.5 kgf·m)

17.4 -20.3 ftlbs

(24 -2.8 kgf.m)

26.8 - 304 fUbs.

(3.7 - 42 kgf·m)

57.1 -665 ft.lbs.

(79 -9.2 kgfm)

35.4-41.2 ft.lbs.

(4.9 -5.7 kgf.m)

17.4 -20.3 ft.lbs.

(2.4 -2.8 kgf·m)

7.2 -8.3 fUbs.

(1.0-1.15 kgf·m)

All these torques are applied to those S45C bolts and studs which have relief number "7" or punch marks.

0 0 $-

Bolt Torques

fUbs (kgf-m)

............

~~terial

Grade Standard Bolt

-........

Nominal

D;;;~"""""

i - - - -.. -.---... - -.. -.-.. . .... - -... - . - . -

1-------:·"::>--- - -.-

SS41. S20C

Special Bolt

S43C, S48C (Refined)

Special Bolt

- - - - - . - . -..• - . - .. - - . - - - - . - - . - . - . - . - - - - - - -

- - - - - - - - - l

SCR3. SCM3lRefined)

.. -- - - - - - - . - - . - -.. ------- - - - - - . - - - - - - . - - - - - - (

M6

M.8

Ml0

-------_._-_ ..

.

_.;_

M14

5.8-

..

6.9

......... _ •.

10 BO -

...

_._---

13.015.2

----------

289- 333

.-

(1.80- 210)

7 2 8.3

~---.---'

__

17.4- 203

._

-_

....... _--_

.•... _.

79.6 92.6

_-_

..

__ 1 15)

. - "'-'--

12.40- 280)

9.010.5

21.7 25.3

1.251.45)

3.00 3.50)

400- 460)

.. _.

--_ ...

_-

' - "

_. -_._....

( 4.90- 5.701

..-- ...

-_

..

_-_._

... _-_ .. ------_

_

.... -

._-- - - - - - _ . _ - - - - - -

_---_.

--

... --

..

-

(10.50-12.00)

---_

.•.

__

._ ....

_._-_._

....

__

._--_.-_ ...

_--- ----

._ 123.0-144.7

...•

---------.

144.7 -166 4 191.7 -224.2

(17.00-2000)

(1700 -19.501 123.0""'"' 141.0 M16

......

M18

.•....

" ' -.-.ur- .. p -

245.9 -289 3 M20

• • • • - .

(25 00 - 29.00)

(34:00 - 4000)

202.5 -

.... -

23~

........

_-_

271.2 -318.2

...

__

(2800 - 32.50)

• . . . . . . . . . -... -.-..

(37.50 -4400)

253.2 - 296.5

-~--

361.6 -419.5 (5000 -58.001

(25)

Bolt material grades are shown by numbers punched on the bolt heads_

Prior to tlghtenong. be sure to check out the numbers as shown below:

Punched Number Bolt Material Grade

----------- ---- - ---------------

-

-- --

- --- ---

--------- - - - - - - - - - -

None Standard Bolts 5541. 520C

-----------------f--------- ----------- ----------- --------------

7 Special Bolts

-------------- --+--- ---------------- - --

543C. S48C (Refined)

---------------------1

9 Special Bolts SCM 3. seR 3 (Refinedl

(26)

..