SERVICE MANUAL M-20 5416 + + M-30 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 · .
SPECIFICATIONS MODEL 15 (5411) 20 (5416) 30 (5424) 40 (5432) 50 (5444) --------------------.---------------------------------------------------------------------------11 16 44 24 32 -----------------------------------------------------------------------------------------------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.
MODEL 15 (5411 ) 20 (5416) DGIN! OPlIATIJIIG TlJlPEIATUU 30 40 (S424) (S432) 50 (5444) 1750 to 1900 r ----------------- MAX. OPERATING ANGLE ENGINE ROTATION Clockwise when viewed fro. V-belt end PROPELLER ROTATION Rilht Hand (BOTH STD. AND V-DRIVE) ENGI},,"! 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" WID'11I (Overall) 20.7" 20.7" 20.7" 20.7" 21.
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.
[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) co ri0 ..... Ir~ 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
• 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.
nProbable 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 ., :,' -T-·--·.~ ~ffiY l'===~~" -_ ~ .I Rocker arm Rocker arm shaft ~- . -l. Jr t\ \ 011 pump Oil pan pIck-up screen ttJ.--Drain plug Fig. 9. Detail of Oil Pump Pick-up ' ..,.... -.~ Relief valve 24 H.P.
- .--Lj~\ :~~. I .1 n1J • 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. r ---~'~_ J j , __./_ L ___ 1 -, ~ 1, Safety valve body 2. SafetY valve spring 3. "0" ring Valve 4. Oil filter base 5.
• Valve timing I Adjust bolt (2) 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: L k oc nut (1) I ,Valve clearance I ~0.007-0.009 in. ., ._t (0.18-0.22 ~~ . / mm) ~ I(~ .~~ ~.~ (r - - - _~~ I~ Ul'~ ~------------ ~ ~ ~ ~~ -.;. ::.. i:i: Fig. 17. Adjustment of Valve Clearance Intake valve opens I ntake valve closes Exhaust valve opens 20° B TDC - .- 45° A BDC --t-----.----50° B BDC ._----_.
• Compression release (Release wire is optional parts) Assemblp thp parts as shown in Fig. 19. Pull the lever out as Compression released position far as it will go. check to see that the 60° angle is attained and that compression is released. The compression release Operation position ~~ ~ \ 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 II/cr; ® ". \ / C%l .
• 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 Models 5416 and 5424.' 76519mrn). An oversi zed piston ann rings must then he usen with this liner. Once this ()VerSiled liner has excepned its wear limit.
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.
n13n-Ol46m f3]- 31mml Radius 004-0.06!". 0 - 1,5mm/ , 1307-·, I'!313m (43.959 - 43 975mml {, ~l -1 J! 1_ o 130-0. 146m (3.3-3.7mm) 2.044 2.045111 (5'.921 51940mmJ "" "."Tj~ " u 1r-. (52064' 1/9,B7-:X; 13mm} 52131mm) Fig. 28. Crankpin for Undersize Bearing o 74'?-·-O,15Jm 0 782 -~ O. 793m. 2.050 - ) 052m (1887 - '9.1.1mmJ "'W lOT ~1 ~. . r '~q 1 ..;l'1'!.!!.::.2000mm)It 0.078,·0,079"1 '0236 I (26 non OJ I '02"m 16,021",m) ! ! 09065 ·0 90lJIIl '- (23 025 - 23040mml , H.
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) • 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 :{ :H~ 1 II 1 t 1~l..r t~ l' Inq1 f I { --------I.571-I.5731ft. (J9 9:U-19.95Omml 1.575-1.576... (.0.OOO--40.025mml '1 I ]d''''t''.+ru'j ~~r ~-,-, ~L:. :=~ .•.-,...
• 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.
• 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.
• 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 (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.
• Starter specifications ------,- 16 H.P. ------ 24 H.P. • 298783 Code No. 298876 f-. Nominal voltage 12V Nominal output 0.8 kW Direction of rotation • (1) Precautions in care and handling of starter motor 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.
• Glow plug specifications ._J 16 H.P. 24 H.P. 298795 Code No. .r Number I 3 ::> j Vol tilfJP & rw refl t ArprOXIPlately 6.5 amp (l') 10.5 V '---- • Glow plug controller specifications Code No. Current • (1) 16 H.P. 24 H.P. 299839 299839 13A . -- 20A Precautions in handling the glow plug USf' the glow plugs only with Universal glow plug controller.
I Univel~al ENGINE CONNECTIONS _0 2 CYl. .-. --,-- -t- .. --.. ,tr , GLOW I PLUGS . PANEL CONNECTIONS I __ 3 _Cl,,-L _~ 1-----"""----; Diesel Connect to ACC. term. on switch i • FUEL PUMP 0'1 ....... E Q) ......, en -L Blue ~ >(J) -co (.) .I- ......, (.) -w Q) I I • FEHALE~!! -----L.
Reference Chart Engine Parts .-- ----iII> Cylinder head tightness Cylinder head surface distort inn !: Intake/e)(haust valve seat thickness Standard 10 ~ When installing. apply a generous coat of engine oil onto the entire surface of each bolt. Y4S' .--. 2.9980 in. (76:15mm) 15416 & 5424 2.9921 -. 2.9929 in. (76.000- 76.019mm) 15416 & 5424 0.0026·0.0041 in. !0065-·0.1~mml E side 0.0056 - 0.0071 in. (Q.141 - O. 180mm) I side I { 0.0276"'" 0.0354 in. (0.7 ..... 0.
Maximum Remarks Lomit r---.r--.--.-----------------------~.----------.----_+--------------+_----~--------------1 ID 1.7327 - 1.7345 in. (44.01 - 44.056mml (with metal) Items Width 0.7429 -0.7531 in (1887-19.13mml 00 1 85 in. (47 mml OJ'" :2 c a Standard Value Specifications Center thickness 0.0583 - 0.0589 in. (1.482 - 1.495 mml -'" c '" U 1-- -. Runnmg clearance 0.0014 - 0.0038 in. (0.035 - 0.097 mml Axial clearance 0.0157 -0.0236in. (0.4 -0.6 mml 0.0079in (0.
Parts Items Specifications Number of teeth, crank gear 34 Number of teeth, Idel gear 79 Number of teeth, cam gear 68 Nllmber .of teeth, Inwction pump gear 68 Standard V~lue Maximum limit Remarks Number of teeth, at! pump drive gear 45 Backlash r-- o 00163-{) 00454 in, to 0415-{), 1154mm) 0,0118 in, to,3mm) -~~--------~~-~-----"---~---------t---------t-----t----------------1 ShlOkage 0,0433 '0,0551 in, tl.
P"rts 1--- Item5 Maximum Urn It Standard Value Specifications Remarks I-------------------.-+----------+--------{-----+-------------/ I ntake valve opened I ntake valve closed At 45° ABDC Ex hill.jst valve opened At 50° BBDC Exhaust valve closed At 15 ATDC Iqn,t,on process 1-2 1-2-3 0'> c: E t-QJ 2 o >'" [ [ 16 H.P. 24 H.P. Injectectinn tlmlnq ~-4------·-----------11-----------4-----------~r----_+----------------~ Trochoid tooth width Use Engine Oil CD (oS) U16 H. P.
Parts Spec if ications Items . Cooling system Standard Value --- Ma)(imum Limit Remarks With pressurized radiator (corrugated I Natural circulation 16 & 24 H.P. t-orceo circulation Water pump (Z751-BW and DHll0l-BI E ~ Centrifugal pump with thermostat (impelled Gear case to impeller clearance Circulation flow rate (Z751-BW and DHll0l-B) 0.0232-0.437 in. (0.59 - 1.11 mml (Packing thickness) 26.4 Gallon/min (100Q/min) or more '"> Water temperature BOoC. Total lift 19.34Ibs.
,"'-'" Par" I I 1-. Items -'- --------- Number of teeth. pinion Number of teeth. rIng gear Specifications Maximum limit Standard Value Remarks . 89 Insulation resistance No failure at 500MV ~ "' tn Check interval Every 1000 service hours Insulation resistance n 16 H.P. Output .~ Nominal value 0.8kW n·1.0kW24H.P. .... . _"-- .. - -.- --.--------- -_. Hp.ad set bolt and nut D __ _------.. ' - - -.
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 ----------- ---- - ---- -----------None Bolt Material Grade - -- -- - --- --- --------- - - - - - - - - - - - Standard Bolts 5541. 520C Special Bolts SCM 3. seR 3 (Refinedl -----------------f--------- ----------- ----------- -------------7 Special Bolts 543C.
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