UNIVERSAL DIESEL MODEL 15 25 SERVICE MANUAL
UNIVERSAL DIESELMODEL15 & 25(EARLY MODELS 5411 & 5421)SERVICE MANUALPUBLICATION#200151
Specifications . .Fuel SystemLubrication SystemOi 1 Fi 1ter . . . .Combustion SystemValve Timing . . .Compression ReleasePistons and RingsCrankshaft . .Connecting RodCyl i nder LinerCylinder HeadGear Train . .Cam Bearings .Main BearingsInjection PumpFlywheel . . .Wiring DiagramStarting MotorGlow Plugs . .Reference 0-24
SPECIFICATIONSMODEL15(5411 2442233442.67 x 2.752.99 x 3.232.84 x 2.762.99 x 3.232.99 x 3.233.3 x 3.253145526891115MAXIMUM R.P.M.300028003200280028003000COMPRESSION RATIO22:121:122:121:121:121:1HORSEPOWERNO. OF CYLINDERSBORE &STROKEDISPLACEMENT (CU. IN)TYPEELECTRICAL EQUIPMENT.Vertical, water cooled, 4-cycle diesel engine12 Volt, 55 AMP Altermator, Electric Starter, and Glow Plu sMech.Fuel PumpFuel PumpFuel PumpMech .Fuel Pump2.2 Qts.3.7 Qts.4 Qts.5.6 Qts.11. 5 Qts8.5 Qts.Use SAW 30 HD (CD) or IOVJ40 heavy duty diesel lubricating --------------------------Fill to full mark on dipstick. Use automatic transmission fluid Type A, Type F,LUBRICATION (Transmission)and Dextron II(Std and V-Drive)LUBRICATION -------------------------------TRANSMISSION OOLING SYSTEM (7 PSI CAP)Sea-watercooledFresh4.8 Qts.14 PSI4.0 Qts.14 PSICoolingWater6 Qts.14 PSISystem8 Qts.14 PSI8 Qts.14 --------------------------SEA WATER INLET &OUTLET3/8" --------------------------EXHAUST FLANGE1-1/4 NPT1-1/4 NPT1-1/4 NPT1-1/4 NPT1-1/2 NPT1-1/2 --------------------------FUELDiesel fuel number --------------------------
----------------------FUEL INLET HOSE5/16" --------------------------FILTERS, FUEL -----------FILTERS, LUBRICATION ------------GOVERNORCentrifugal type - all speedsENGiNE-OPERATiNG-TEMPERATuRE-------1350- --------175g- --------i750- -------1756- -------1750- --------i75g- -------150 0 F190 F190 0 F190 0 F190 0 F190 FMAX. OPERATING ANGLE15 0ENGINE ROTATIONClockwise when viewed from V-Belt endPROPELLER ROTATIONENGINE WEIGHT (Pounds)NALLRight Hand (Both STD. and V-Drive)245365285425490545LENGTH (Overall)25.6/27.6 (VD)28.028.5/30.5 (VD)32.536.236.0HEIGHT (Overall)21.224.122.624.626.026.0WIDTH 7299517299517299517INJECTION NOZZLEINJECTION TIMING25 0 before top dead center - all models
12. Construction and Handling.1 Fuel System Fuel systemFuel system is as shown in Fig. 1. The fuel flows in the direc·tion shown by arrow marks. To bleed air trapped in the fuel.first loosen the vent plug A of the fuel filter. Tighten the plugwhen no more air bubbles are in the fuel which flows out fromthe vent. Then proceed to the plug B of the fuel injectionpump and vent the system in the same manner as A. Fuel·filterThe fuel filter is of the cartridge type shown schematically inFig. 2. Under normal conditions it should only have to bereplaced every 400 hours. To install. apply a small amount offuel to the r acking and tighten seC'lJrely by hancl. For r.!moval,ttlC use of a filter wrench.:4M-15'5,1. Fuel filter2. Cover3. Pipe coupling4. Vent plug5. "0" ring6. "0" ring7. Element((;:7,Fig. 2. Fuel Filter1.2.3.4.5.Fuel tankFuel cockFuel filterFuel injection pumpInjection pipe Fuel injection timingFuel injectiu(l timing is adjusted by changing the number ofshims used between the pump arid the gear case it fits into. SeeFig. 3. One shim corresponds to Cipproxirnately 1.5 degrees incrank anglf . Tt)eretore, injection will take place 1.5 degreeslater when a shim IS added and 1.5 (jegrees earlier when a shimis removed. The timing is correct when the mark punched onthe rear end jJlate lines up with the "F 1" marked on the fly·6. Nozzle holder7. Overflow pipeA: Vent plug, filter8. Fuel pumpwheel. SeeFi l.4.Speed control leverFig. 1. Fuel System\Control rack pinInjection timingadjust shimsFig. 3. Adjustment ofInjection TimingFig. 4. Inspection ofInjection Timing3
Fuel injection pump Fuel injection pumpThe injection pump is the Bosch "Mini K type". Precautionsin handling fuel injection pump. Many parts in fuel injectionpump are finished precisely. Consequently, even a sl ight carelesshandling will very likely result in a serious drop in engineperformance. Always bear this in mind and observe the following:Be very careful of fuel to use, ensure that it is entirely freefrom water, dirt, and other foreign matters.Oi Idrums left outdoors are always considered to containwater, so be sure to have the fuel filtered before using. Thewater will settle at the bottom of the drum, so refrain fromusing the fuel to the last drop in the drum.Clean fuel is a must because the fuel is forced to pass throughvarious important elements of the pump and nozzles and thenenter the cylinders, all these parts being so precisely assembledwith clearance of 0.00004 in. (1/1000 mm) that they mayeasily be obstructed or rusted by even a slight amount ofwater if in the fuel . Installing the injection pumpWhen installing the injection pump, make certain that thecontrol rack pin is correctly placed in the 0.2 in. (5mm) widegroovp, of the fork lever (1) before tightening the attachingbolts. Refer to the diilqrilm. If the bolts are draw" :Iown withthe rack pin off the groove, the rack may over travel and stickin this position This would cause excess fuel flow, allowlrlgthe engine to overspeed which would result in engine failure.'1.1'(j)114IS(16r17,1'18!'( g''10 "21221.2.3.4.5.6.7.8.9.10.11.12.13.Injection pump ass'yDelivery valve holderDelivery valve springDelivery valve gasketDelivery valveCylinder pump elementAir bleeder screwPackingHollow screwPackingTappet guide pinClamp pinBolt14.15.16.17.18.19.Adjusting plateControl rackPump housingControl sleeveUpper spring sheetPlunger spring20. Lower spring sheet21.22.23.24.ShimTappet ass'yRollerRoller pinFig. 5. Fuel Injection Pump4
Fuel injection nozzlefhe fuel injection nOllie, like the ILJf 1 injection pump, is 'llsoa precision piece of equipment 'lnd should be treated with the Spray patternThe injerlion pressure and fuel spray pattern are most accurately checked by using a nozzle pressure tester. If a nozzlepressure tester is not 'lvailable, remove the nozzles from theengine, leaving the pressure lines connected.same amount 01 care. The injection pressureThe injection pressure is adjusted by adding or subtractingshims from the top of the nozzle spring. Adding a 0.004 in.(0.1 mm) shim will increase the injection pressure by about147 psi (10 kglkm21. The injection iJressure is 1990 to 2133flCAUTIONllHold the nozzles so that the high pressure spray from themwill not in any way impinge upon unprotected skin. Theatomized fuel will easily penetrate the skin and cause bloodpoisoning.psi. (140 to 150 kgf/cm2)(6 115\I7'18'19iSet the speed control Irver 'It W. O. T. and oppra1f the starter.The nepclle valve, if it is working properly, will produce a highpitched pulsating sound likr: that of 'l Ilute ilS fuel is sprayed(JIlt. I I this sound is not heard or other problems are noted,refer to the "Fuel Injection Pump & Nozzle MaintenanceStd." in 4.1 in "Engine".(IIIIIIIdfl Precaution II(1) Assembly and disassembly of the nozzle should be done in(21fresh clean fuel.,.Delivery nipple 12. Delivery nipple 23. Nut4. Washer5. Nozzle holder body6. Adjusting washer(2) The nozzle should always be installed as an assembly,7. Nozzle spring8. Pressure pin9. Pressure pin holder10. Nozzle nut11. Nozzle piecenever by component parts.(3)Remember never to let the nozzle spray contact unprotected flesh.(4) Tighten the retaining nut to 43.5 t8 58 ft·lb (6 to 8 kgf.m)Any torque higher than this will cause slow action of theneedle valve and poor injection.Fig. 6. Fuel Injection Nozzle2.2 Lubrication SystemGood Oil pump pick·up screenThe nil pump rick-lip IS Il)r 'lted ill the cr;Jn,rilSe as shown inBadFig.9 and is fil1f:d with;] mf'\ill screen I f the: screen becomespluqC)ed, wash it ofl with diesel fuel or kerosene. Lubrication systemThe trochoid oil pump suck up lubricating oil through oil filterand the oi I flows down to the fil ter cartridge where it is furtherrompletely Iii tered and also the pressure regulating valve in-4,;6'15.' 'stalled in the gear case regulate the oil pressure at 36 - 50 psi(2.5 - 3.5 kgt/c'rn 2). From the filter, one part of the lubricatingoil will be fed through crank shaft passage to uank pin metaland the remAinder of oil will be fed through the frame to therockpr arm shaft An oil pressure switch is provided for onthe way fnl watching the oil pressure. If the oil pressure falls1. Nozzle spring2. Pressure pin3. Pressure pin holderbelow 7.1 psi (0.5 kgf /cm 2), t t:l '2. am2 on the 'dashpanel will be lighted warning the orerator. In case the oilwarning lamp should stay on while engine, being running at4. Nozzle body5. Needle valve6. Nozzle piecenormal revolution, shut the engine off immediately and checkthe causes of the pressure drop.Fig. 7. NozzleNOTE*Oil warning lamp and dash panel are oPtlondl P 'lrts5
[Probable cause of low oil pressurd(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 thannormal (replace the oil filter or clean the valve on the old. one with kerosene or diesel fuel.)Oil panRocker armRocker arm shaft/rl.frjjr ,' ; Safetyvalve ,- i [1-:1 H![IIn I('lV- \ L "fL JlrF1 .I ij 1L0fr.- 1 /"1Oil pump W\---F \Y--- ---Pick-up screenFig. 9. Detail of Oil Pump Pick-up0O;/{;/t.,IpassageI . -' :::::::::: -J--'1 Oil pumppick-up screenDrain plugConstruction of Oil Filter :f---,-Rocker armRocker arm shaftRelief valveFig. 10. Oil FilterConstruction of Relief ValvescreenFig. 8. Lubrication System Oil filter(1) Replace the 011 filter at every other oil change (every 150hours)(2) Under Ilormal conditions it is only necessary to changethe oil filter. at the specified intervals. If, however, the1. Oil Filter Cartridge2. Relief Valve Assy3. a Ring4. Valve Seat5. Ball6. Spring7. Relief Valve Bodyengine is used in EXTREME L Y dirty conditions. thepressure regulating valve should also be removed andcleaned.(3) Whenever the oil filter is replnced, run the engine underno load for a few minutes until the filter has been filledand then add oil to make up lor what is contained in theIi Iter.Fig. 11. Pressure Regulating Valve6
Replacing engine oil(1) Drilin iJnd rerlaee tlw ei1(jine oil after the first 35 hrs oforeration and every 75 hrs thereafWr.(2) The oil is easier to change if the engine is warm.(3) Do not mix diff( rent brands of oil If a different brand ofoil must he used, drain the oil and replace with all onebrand. Also, do not mix oils of different viscosities.ValveCornbustion air, o.f course, is brought in through the intakevalve when the descending piston creates a partial vacuum inthe cylinder.Valve stem seals should be replaced whenever they are reomoved. If the stern seal are replaced, coat the stem liberallywith oil before inserting in the valve guide to prevent burningthe valve stem seal.2 .3 Combustion System(J)- Combustion chamberThe enqinr Iitililes a swirl tyrf pre·combustion chamber(Fig. 12). Furl and air are mixed in thischamber resllltinfJ in mon' efficient combustion. A )--is employed to preheat the fuel for easy starts down to 5 F( 150 C).(j)--- .1.2.3.4.ValveValveValveValve5. Valve stem sealcapspring retainer 6. Valve guidespring collet7. ValvespringFig. 13 Structure of ValvesThe dirnensions of the replacement valves and valve guides areshown in Fig. 14. When new valve guides are installed, thebores should be reamed to 0.276 to 0.277 in. (7.01 to7.025mm) after installation. The valve head must be recessed0.035 to 0.043 in. (0.9 to 1.1 mrn) from the face of the cylin-5der head to prevent it from hitting the top of the piston.1. Nozzle holder2. Nozzle piece packing3. Glow plug4. Cylinder head5. Combustion chamberJt1Z:2!63 9. . .(7. 02-7. 05mm)0.274-0,2746 in.Fig. 12. Combustion ChamberA:Finished ID of gUide--1J (6n'9: 6n'9751mm)0Iinstalled in cylinderihi'IilI.-:r- !I"J Jr/ f:;rJJ; :)----lt-lLead.HIIA.r--l--.-r45'1- j,n.-,---J] . - -.M-150.921-0.929 in.123.4-23.6mm)1.059-1.067 in.126.9-27.1 mm)t - - - - - f - - - --------.----1.078-1.086 in.M-25L127.4-27.6mm)- 1.216-1.224in.130.9-31.1mm) Fig. 14. Standard Dimensionsof Valves, Valve Guides,Valve Gap0.035-0.043in. (0.9-1.1mm)Fig. 15. Sinking of Valve7
Valve timingAdjust bolt (2)When the valve clearance has been adjusted as shown inFig. 16, the standard valve timing shown in the chart can beattained:ILocknut (1)114Valve clearance0.0057-0.0072 in. .V(O.I45-0.185mm),- JFig. 16. Adjustment of Valve ClearanceIntake valve opensIntake valve closes--- .--- ----- --. ----20 S TOC. 45 A SOC---------- ---------- .-Exhaust valve opens50 S SOC------ . -- -------------Exhaust valve closes15 A TOC -.- . -. --- ----Valve clearance: 0.0057 to 0.0072 in. (0.145 to O. 185 mm) withengine cold. Rocker Arms10.4325-0.433 in.1(10.987-11.008mm)r------------III1t9!I WtN! Il jIIJ0.433""'0.435 in.(10.997-11.038mm)10.432-0.4324 in.(10.973-10.984mm)t,-,,--I - - -t----- .-JU0.4325-0.433 in.(10.987-11.008mm)III010 l010IWWI1l J .00IIIIFig. 17. Standard Relative Position of Rocker Arms8II
Compression release (Release wire is optional parts)Assemble the parts as shown in Fig. 18. Pull the lever out asfar as it will go, check to see that the 55 angle is attainedand that compression is released. The cornpression releaseis to be used when the battery is low or when starting incold weather. To use the compression release, preheat theglow·plug as usual, pull the compression release knob out asCompression releasedpositionr/-!/ / ;-'Ifar as possible and hold it there while cranking the engine.This partially releases the engine compression enabling it toturn faster in cold weather or when the battery is low. Oncethe engine is turning fast enough to start, I'elease the lever andthe engine will start.(NOTE)Make sure the compression release has returned to theoperating position by pushing the knob all the way in.I!4' .,@Released1. Rocker arm2. Oil filler cap5.6.3. Compression release lever 7.4. Adjustment access cover B.OperatingCompression release nutCompressIOn release boltShaftValveFig. 19. Adjustment of Compression ReleaseaFig. lB. Compression Released CAUTION]Top clearance should be 0.0236 to 0.0314 in. (0.6 to 0.8 mm).To adjust, use cylinder gasket shims, 0.0078 in. (0.20 mm) thickeach, onto the head side.Do not pull the compression release lever when the engine isrunning at high speed or under load. If it is necessary to usethe compression release while the engine is running reduce thespeed to idle before doing so. Top clearanceFor checking the measurement, rlace il piEx:e of fuse on thepiston top and fiX the cylindler head securf,ly on the cylinder·head flange. The medsurernerll is taken bV tile fuse. Tile liner islevel with the cylinder fldme at tvp surface.The gasket shims Ciln be reused, so do n()t lose thelli.Adjustment of compression releaseSet exhaust valve in totally closed position.(2) Remove decornpression adjustment window cover fromcylinder head cover.(3) Make valve clearance as "0" with use of decompressionadjust bolt. From this position, turn the bolt further by1 to 1.5 turns. Decompression clearance will then be setat 0.030 to 0.044 in. (0.75 to 1 125mm), which is thedesigned clearance.(4) After adjusting, be sure to lock adjust bolt securely sothat it will not unturn while engine is in service.(5) Make certain that the cleanrance is not too wide. Tocheck thiS, turn crankshaft by hand and make certainvalve disk does not contact with pistion top.(I)HeadI- Top clearance0.0236-0.0314 in.(0. 6-0. Bmmj·PistonFig. 20. Top Clearance9
2.4 Main Moving Parts Crankshaft and connecting rod(1) The crankshaft is a heat treated steel alloy forging. Thecrank pins are induction hardened for additional wearresistance. Crankshaft end play is 0.006 to 0.012 in. (0.15to 0.31 mm).(2) The crankpin bearings are aluminum.When instill ling the connecting rods:a) Clean both surfaces thoroughly.b) Apply engine oil to the threads of the connecting rodcapscrews before installing ahd tighten each to 19.5 to22.4 ft-Ibs. (2.7 to 3.1 kg-m)The bearing caps are matched to each connecting rodand should not be interchanged. Also, since there arevariations in machining from side to side, each bearingcap and connecting rod are marked and should beassembled so that the marks line up.(3) In the event that the crankpiflS become worn and are nolonger serviceable, undersized bearings may be used.When installing the undersize bearings observe the following precautions:a) Machine the crankpin diameter and radii to withina few thousandths of the correct dimensions andfinish 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 thebearing will sieze.c) The crankpin should always be super-finished to0.000016 in. (0.0004 mm) or lessd) Select the bearing from the chart that necessitates theremoval of the least amount of metal from the crankpin. Do not deviate from the chart dimensions as thebearing life will be reduced if they are machined.e) To determine the running clearance, assemble the connecting rod, bearing cap and bearing as described insection 2 and measure the diameter anywhere withinthe 1200 angle indicated in Fig. 27 and subtract thecrankpin diameter from this figure.f) The piston pin bushings are of lead bronze.The inSide diameter of the bushinq should be finishedto 0.7884 to 0.7890 in. (20.025 to 20.040 mm). Pi tons and piston ringsThe pistons and piston rings are shown in Fig.25. If thecylinder liners have been bored oversize, oversize pistonsand rings must be used. The piston is made of high siliconAI·Alloy and is cam ground. The top compression ring is achrome plated keystone type, the second compression ring isdiscontinuous and undercut and the oi I control ring is of thestandard expansion type.End gap of rings on poston in cvlinderI : Diameter of piston skirt thru t of piston pin boreE: Diameter of piston skirt perpendicular to piston pinB:0.0791", 12mm}F c5 . ---. -1 .IJJ.O§ 1::-00062 n"--IlI--11.555-1.570mm}0.158-0.159 in.14. 0 10--4. 030mm)0.1874-0.7879 in.-7ijj.ooiF-20 OI3;:;'-mTOJJJq:- 2Jl. B.!n: .,. 810.25-0.45mm} i.0.078m. (1.99mm)i.0.0574-0.0e79moJ",I11.458-1.470mm}:,! I0.1566-0.1571 in.- - - 8 ' ::13.978-3. 990mm}ii'-- '''1 'i.l ,---l,,: ·:·Jr--O.CXJ8-0.016m.J ---{Ai--r:;:-:]:.L·' r .'O. ,L":-,, :.10.20--0. 40mm}. Fig. 25. Standard
SERVICE MANUAL PUBLICATION #200151 . Specifications . Fuel System Lubrication System . LUBRICATION (Engine) 15 (5411 ) 11 2 2.67 x 2.75 31 3000 22:1 SPECIFICATIONS 20 (5416) 16 2 25 (5421) 21 3 30 (5424) 24 3 40 . To install. apply a small amount of
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TEST FUELS Test fuels were CARB ultra low sulf- ur diesel and GTL diesel. CARB diesel was supplied by a local distributor of Chevron Products Company. This fuel was not analyzed but was presumed to meet the fuel specification for CARB diesel. CARB diesel is characterized by a maximum 10% by volume aromatics and minimum cetane number of 48.
