Universal Motors Universal diesel 5416, Universal diesel 5424 Service Manual
UNIVERSAL DIESEL
Model 20 & 30
SERVICE MANUAL
(5416, 5424)
Universal Motors
Universal Motors
Universal MotorsUniversal 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
numbering of the original manual.
MODEL 20 & 30 INDEX
Specifications 1 – 2
Fuel System 3 – 4
Lubrication System 5 – 6
Oil Filter 6
Combustion System 7
Valve Timing 8
Compression Release 9
Cylinder Liner 10
Cylinder Head 10
Piston & Rings 11
Crankshaft 11
Connecting Rod 12
Gear Train 13
Camshaft Bearings 13
Main Bearings 14
Injection Pump 15
Water Pump 16
Flywheel 16
Starting Motor 16 – 17
Glow Plug 17 – 18
Wiring Diagram 19
Reference Charts 20 – 2
Specifications
MODELS 15 (5411) 20 (5416) 30 (5424) 40 (5432) 50 (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 RPM 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 & Glowplugs
Fuel Pump Mechanical Electric Electric Mechanical Electric
2.2 Qts 3.7 Qts 5.6 Qts 11.5 Qts 8.5 Qts Lubrication (Engine)
Use SAE 30 HD (CD) or 10W40 heavy duty diesel lubricating oil
Lubrication (Transm’n) Fill to mark on dipstick with automatic transmission fluid Type A
Transmission Reduction 2:1
Fresh water cooling system Cooling System (7 psi cap)
Sea water
cooled
Sea Water Inlet & Outlet ⅜” NPT
Exhaust Flange 1¼” NPT 1½” NPT
4.8 Qts
14psi
6 Qts
14psi
8 Qts
14 psi
8 Qts
14 psi
Fuel Diesel fuel number 2-D
Fuel Inlet Hose
Filter, Fuel Oil 298854 298854 298854 298854 298854
Filters, Lubrication Oil 299381 298852 298852 299584 299927
Governor Centrifugal type - all speeds
(1)
5
/16” I.D.
MODELS 15 (5411) 20 (5416) 30 (5424) 40 (5432) 50 (5444)
Operating Temperature 135o to 150o 175o to 190o F
Maximum Operating
15
o
Angle
Engine Rotation Clockwise when viewed from V-belt end
Propeller Rotation Right Hand (Both Standard & V-Drive)
Engine Weight (Pounds) 245 365 425 490 545
Length (Overall) 25.6” 28.0” 32.5” 36.2” 36.0”
Height (Overall) 21.2” 24.1” 24.6” 26.0” 26.0”
Width (Overall) 20.7” 20.7” 20.7” 20.7” 21.4”
Injection Nozzle
Injection Timing 25o before top dead center – all models
(2)
Construction and Handling
2.1 Fuel System
♦ Fuel system
The fuel system 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 “B” 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 packing and tighten securely by hand. For
removal, the use of a filter wrench 15221—86611 is
recommended.
1. Fuel Filter
2. Cover
3. Pipe coupling
4. Vent plug
5. “O” ring
6. “O” ring
7. Element
♦ 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 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 peephole on the side of the flywheel
housing lines up with the “F 1” marked on the flywheel. See
Fig. 4.
Fig. 2. Fuel Filter
a) Fuel tank
b) Fuel cock
c) Fuel filter
d) Fuel injection pump
e) Injection pipe
f) Nozzle holder
g) Overflow pipe
A. Vent plug, filter
B. Vent plug, pump
Fig 1. Fuel System
Fig. 3. Adjustment of Fig. 4. Inspection of
Injection Timing Injection Timing
(3)
♦♦♦♦ Fuel injection pump
The fuel injection pump is the Bosch “Mine K-type”. It is a
precision piece of equipment machined to close tolerances
and its performance directly affects the performance of the
engine. Therefore, handle it with care.
♦ 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
tightly when working on it. Also, he 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 nozzle with clearances of 0.0004 in. (1/1000mm)
which may easily he 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 ever (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.
(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 shims from the top of the nozzle spring. Adding a
0.004in. (0.1mm) shim will increase the cracking pressure by
about 142 psi. (10 kg/cm
1990 to 2133 psi. (140 to 150 kgf/cm
2
). The nozzle cracking pressure is
2
)
♦♦♦♦ 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.
[[ CAUT ION ]]
Hold 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. 0. 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. If this sound is not heard or other
problems are noted, refer to the “Fuel Injection Pump &
Nozzle Maintenance Std.” in 4.1 in “Engine”.
[[ Precaution ]]
(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
unprotected flesh
(4) Tighten the retaining nut to 43.5 to 58 ft-lb (6 to 8
kgf.m) 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
2
kgf/cm
). 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 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/cm
2
) 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/cm
2
)
(5)
r
[[ 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; pressure lower than normal (
♦♦♦♦ Oil Filter
(1) Replace the oil filter at every other oil change (every 150
hours)
(2) Under normal conditions it is only necessary to change
the oil filter at specified intervals. If, however, the engine
is used in EXTREMELY dirty conditions, the pressure
regulating valve and safety valve should also be removed
and cleaned.
(3) Whenever the oil filter is replaced, run the engine under
no load for a few minutes until the filter has been filled
and then add oil to make up for what is contained in the
filter.
(6)
♦♦♦♦ Replacing engine oil
(1) Drain and replace the engine oil after the first 35 hrs of
operation and every 75 hrs thereafter.
(2) The oil is easier to change if the engine 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
brand. Also, do not mix oils of different viscosities.
2.3 Combustion System
♦♦♦♦ Combustion chamber
The engine utilizes a swirl type pre-combustion chamber.
See (Fig. 13). Fuel and air are mixed in this chamber
resulting in more efficient combustion. A glow-plug s
employed to preheat the fuel for easy starts down to 5
0
(-15
C).
0
F
♦♦♦♦ 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.
The dimensions of the replacement valves and valve guides
are shown in Fig 16. When new valve guides are installed,
the bores should be reamed to 0.316 to 0.315 in. (8.030 to
8.015mm) after installation. The valve head must be
recessed 0.043 to 0.055 in. (1.1 to 1.4mm) from the face of
the cylinder head to prevent it from hitting the top of the
piston.
(7)
Loading...