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UNIVERSAL DIESEL
SERVICE MANUAL
This copy of the Universal Motors Service Manual has been re-created using images
computer scanned from a manual rather than original artwork. Note that where the page
breaks appear to be out of place, this has been done to retain the page breaks and
numbering of the original manual.
Model 20 & 30
(5416, 5424)
Universal Motors
Universal Motors
Universal Motors
Universal Motors
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Table of Contents
Related Manuals for Universal Motors Universal diesel 5416
Summary of Contents for Universal Motors Universal diesel 5416
- Page 1 Universal Motors Universal Motors This copy of the Universal Motors Service Manual has been re-created using images computer scanned from a manual rather than original artwork. Note that where the page breaks appear to be out of place, this has been done to retain the page breaks and...
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Page 2: Table Of Contents
MODEL 20 & 30 INDEX Specifications 1 – 2 Fuel System 3 – 4 Lubrication System 5 – 6 Oil Filter Combustion System Valve Timing Compression Release Cylinder Liner Cylinder Head Piston & Rings Crankshaft Connecting Rod Gear Train Camshaft Bearings Main Bearings Injection Pump Water Pump... -
Page 3: Specifications
Specifications MODELS 15 (5411) 20 (5416) 30 (5424) 40 (5432) 50 (5444) Horsepower No of Cylinders 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.) Maximum RPM 3000 2800 2800 2800... - Page 4 MODELS 15 (5411) 20 (5416) 30 (5424) 40 (5432) 50 (5444) Operating Temperature to 150 to 190 Maximum Operating Angle Engine Rotation Clockwise when viewed from V-belt end Propeller Rotation Right Hand (Both Standard & V-Drive) Engine Weight (Pounds) Length (Overall) 25.6”...
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Page 5: Fuel System
Construction and Handling ♦ Fuel-filter 2.1 Fuel System The fuel filter is of the cartridge type shown schematically in Fig. 2. Under normal conditions it should only have to be ♦ Fuel system replaced every 400 hours. To install, apply a small amount of The fuel system schematic is shown in Fig. - Page 6 ♦ ♦ ♦ ♦ Fuel injection pump ♦ Handling the injection pump The fuel injection pump is the Bosch “Mine K-type”. It is a Use care in handling and using the injection pump. As men- precision piece of equipment machined to close tolerances tioned before, the injection pump is a precision piece of and its performance directly affects the performance of the equipment and care should be taken not to drop it or clamp it...
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Page 7: Lubrication System
♦ ♦ ♦ ♦ Fuel injection nozzle ♦ ♦ ♦ ♦ Spray pattern The fuel injection nozzle, like the fuel injection pump, is also The nozzle cracking pressure and fuel spray pattern are most a precision piece of equipment and should be treated with the accurately checked by using a nozzle “pop test”... -
Page 8: Oil Filter
[[ Probable cause of low oil pressure ]] (1) Clearance on one of the bearings is too 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.) Faulty pressure regulating valve;... -
Page 9: Combustion System
♦ ♦ ♦ ♦ 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 re- moved. 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. -
Page 10: Valve Timing
♦ ♦ ♦ ♦ Valve timing When the valve clearance has been adjusted as shown in Fig. 17, the standard valve timing shown in the chart can be attained. Intake valve opens B TDC A TDC Intake valve closes B TDC Exhaust valve opens A TDC Exhaust valve closes... -
Page 11: Compression Release
♦ ♦ ♦ ♦ Compression release (Release wire is optional parts) Assemble the 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. -
Page 12: Cylinder Liner
Boring and replacing the cylinder liner ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ Tightening Cylinder Head Capscrews (Fig. 23) (1) The tightening torque of the cylinder head Referring to Fig. 22, the inside diameter of the liner capscrews is 54 to 58 ft.lbs. (7.5 to 8.0 kg.m). should be checked at points 1, 2, and 3 and in the Numbers 7, 8, 11 and 13 ( directions (a) and (b). -
Page 13: Piston & Rings
Main Moving Parts ♦ ♦ ♦ ♦ Crankshaft and connecting rod (1) The crankshaft is a heat treated steel alloy forging. The crank pins are induction hardened for additional wear ♦ ♦ ♦ ♦ Pistons and piston rings resistance. Crankshaft endplay is 0.006 to 0.012 in. The pistons and piston rings are shown in Fig. - Page 14 Metal Running Clearance Size Part No Bearing Crankpin Diameter Mark in. (mm) 1.7228 to 1.7234 in. 0.20 mm undersize 020 US (43.759 to 43.775 mm) 0.001379 to 0.003819 in. (0.035 to 0.097 mm) 1.7149 to 1.7156 in. 0.40 mm undersize 040 US (43.559 to 43.575 mm) (12)
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Page 15: Gear Train
Main Components Standard dimensions are shown in Fig. 32. Camshaft running ♦ ♦ ♦ ♦ Gear train clearance is: 0.002 to 0.004 in. (0.05 to 0.091 mm) Be sure to assemble the gears by matching the mating marks as shown in Fig 30. The backlash of each gear is 0.002 to 0.005in. -
Page 16: Main Bearings
♦ ♦ ♦ ♦ Main bearing ass’y ♦ ♦ ♦ ♦ Main bearing housing Insert the bearings in the main bearing housing halves as Installation of crankshaft with main bearings in engine block. indicated in Figs. 33 & 34, using the thrust washers only on Slide the crankshaft assembly into the engine block, being the journal nearest the flywheel. -
Page 17: Injection Pump
♦ ♦ ♦ ♦ Idler gear ♦ ♦ ♦ ♦ Injection pump camshaft Secure the idler gear shaft to the engine block with 3 Injection pump camshaft, Fig. 37. Install the bearings and capscrews, torque to 17 to 20 ft-lbs (2.4 to 2.8 kg-m) and governor unit on the camshaft and install in the engine block bend tabs of tab washer. -
Page 18: Water Pump
♦ ♦ ♦ ♦ Attaching flywheel to crankshaft Cooling water pump ♦ ♦ ♦ ♦ Clean the entire contact surface carefully coat the contact To install the cooling fan pulley on the pump securely surface with engine oi1, wash all the oil oft with gasoline and tighten the nut (4) to 50.6 to 57.9 ft-lbs. -
Page 19: Glow Plug
♦ ♦ ♦ ♦ Starter Specifications ♦ ♦ ♦ ♦ Precautions in care and handling of starter motor (1) The starting motor must be installed properly for the 16 H.P. 24 H.P. starter pinion to mesh with the engine ring gear as should. - Page 20 ♦ ♦ ♦ ♦ Glow Plug Specification 16 H.P. 24 H.P. Code No 298795 Number Voltage & current Approx 6.5 amp @ 10.5 V ♦ ♦ ♦ ♦ Glow Plug Controller Specification 16 H.P. 24 H.P. Code No 299839 Current ♦...
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Page 22: Reference Charts
Reference Chart Maximum Parts Items Specifications Standard Value Remarks Limit Cylinder head tightness M10 x 1. 25 54.2 ~ 57.9 ft. lbs When installing apply a (7.5 ~ 8 kg.m) generous coat of engine oil onto Cylinder head surface distortion 0.002 in below the entire surface of each bolt. - Page 23 Maximum Parts Items Specifications Standard Value Remarks Limit ID (with metal) 1.7327 ~ 1.7345 in (44.01 ~ 44.056 mm) Width 0.7429 ~ 0.7531 in Center thickness (18.87 ~ 19.13 mm) 1.85 in (47 mm) 0.0583 ~ 0.0589 in Running Clearance 0.0014 ~ 0.0038 in 0.0079 in (1.482 ~ 1.495 mm)
- Page 24 Maximum Parts Items Specifications Standard Value Remarks Limit Number of teeth, crank gear Number of teeth, idle gear Number of teeth, cam gear Number of teeth, injection pump gear Number of teeth, oil pump drive gear Backlash 0.00163 ~ 0.00454in 0.0118 in (0.0415 ~ 0.1154 mm) (0.3 mm)
- Page 25 Maximum Parts Items Specifications Standard Value Remarks Limit Intake valve opened At 20 BTDC Intake valve closed At 45 ABDC Exhaust valve opened At 50 BBDC Exhaust valve closed At 55 ATDC Ignition process 5416 5424 1-2-3 Injection timing ~ 26 BTDC Trochoid tooth width Use engine oil CD(DS)
- Page 26 Maximum Parts Items Specifications Standard Value Remarks Limit Cooling system 5416 Natural Circulation With pressurized radiator 5424 Forced Circulation (corrugated) Water Pump (Z751-BW and Centrifugal pump with DH1101-B) thermostat (impeller) Gear case to impeller clearance 0.0232 ~ 0.437 in Water temperature 80 (0.59 ~ 1.11 mm) Total lift 19.34 psi (1mAg) (Packing thickness)
- Page 27 Maximum Parts Items Specifications Standard Value Remarks Limit Number of teeth, pinion Number of teeth, ring gear Insulation resistance No failure at 500MV Check interval Every 1000 hours Insulation resistance Output Nominal value 5416 0.8kW 5424 1.0kW Head set bolt and nut M10 x 1.25 54.2 ~ 57.9 ft.lbs Apply a generous coat of engine...
- Page 28 Bolt material grades are shown by numbers punched on the bolt heads. Prior to tightening, be sure to check out the numbers as shown below. Punched Number Bolt Material Grade None Standard Bolts SS41, S20C Special Bolts S43C, S48C (Refined) Special Bolts SCM 3, SCR 3 (Refined) (26)
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