ade-422-423-424-workshop-manual-abby.pdf

ADE 422 , 423 , 424 Workshop Manual

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Workshop Manual for ADE 422, 423,424

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ENGINE REPAIR MANUAL ADE 420 SERIES

ATLANTIS DIESEL ENGINES (PTY) LTD AMENDMENT 7/90

P art No. 80530257 P ublished by h t e P arts and Service Department of Atlantis Diesel Engines (Pty) Ltd.

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Workshop Manual for ADE 422, 423, 424

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FOREWORD T his manual is de signe d to be of as sistan ce to all perso nnel conce rned with the ma intenance and overhaul of the ADE Diesel Engine. It presents a complete and detailed description of the Engine, together with precise instructions on the servicing and overhaul procedure, also a schedule covering technical data and dimensions which should be closely followed when overhauling any part of the E ngine, to the M anufacturers standards. ADE 420 Series Engines have a left hand rotation when viewed from the rear. Throughout this manual, whenever L eft or R ight hand side o f the engine is referred to, it is the s ide of the engine when viewed from the flywheel end. E ffective maint ena nce can on ly be carried o ut if the personnel conce rned are fully conversa nt with the various components of the engine. Before maintenance operations are commenced, therefore, this manual should be carefully studied, and should at all times be kept where it will be needed in the workshop. Certain operations described in this manual require the use of special tools. These tools are ob tainable from G rundyTe chniform, full details are given in Se ction 21. A S chool of I ns truction is maint ained at ADE A tlan tis where s taff empl oyed by Dis tributors and Operators of ADE powered applications are given instructions on diesel engine maintenance, with particular regard to the special characteristics of ADE Engines.

ENGINE PARTS W henever parts are ordered for ADE E ngines it is es se ntial that the fulles t information poss ible is given, always quote the engine number, type of application, part number and where possible the description.

R unning in Procedure It is not necessary to gradually runin a new engine and any prolonged light load running during the early life of the engine can in fact prove harmful to the bedding in of piston rings and liners.

CONTENTS TE CHNICAL DATA

08

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

OPERATING AND MAINTENANCE SCHEDULE FAULT FINDING

10

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

CYLINDER BLOCK AND LINERS CYLINDER HEAD

11

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

12

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

PISTONS AND CONNECTING RODS CRANKSHAFT AND MAIN BEARINGS

13

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

14

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

CAMSHAFT, TIMING CASE AND DRIVETIMING LUBRICATING SYSTEM AND SUMP FUEL SYSTEM

09

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

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

;................ 15 16

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

17

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

ANCILLARY EQUIPMENT: COMPRESSOR, FLYWHEEL, TURBOCHARGER, EXHAUST BRAKE ALTERNATOR AND STARTER MOTOR, FAN BELT, POWER STEERING PUMP ........................... 18 COOLING SYSTEM LUBRICATING OILS

19

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

20

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

APPROVED SERVICE TOOLS

21

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

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Workshop Manual for ADE 422, 423 ,42 4

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SECTION 081

Technical Data 422N

422T

422TI

423N

423T

423TI

424N

424T

424TI

Ratings to SABS 0131977 O utput kW/r/min

Torque N.m/r/min Cubic capacity Bore mm

1022/1200 1402/1200 1550/1200 1278/1200 1687/12002000/1 200 1388/1200 2236/1200 1400 2400/

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

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

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

No. of cylinders

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

Compression ratio

14,62714,627 128

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

S troke mm

202/2300 243/2300276/2300 256/ 2300 300/2300 368/2300 289/2300 412/ 2300 452/2300

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

14,627

18,27718.277

18.277

21,93721,937

21,937

128

128

128

128

128

128

128

128

142 142

142

142

142

142

142

142

142

8

8

10

12

8

10

10

16,9:1 16,25:1 16,25:1

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

C ompression test pressure MP a

2,8

2,6

16,9:1

2,6

16,25:1

2,8

16,25:1

2,6

2,6

12 16,9:1 2,8

12 16,25:1 2,6

16.25:1 2,6

Engine at operating temperature, readings taken at 180200 r/min. Minimum pressure 2,0 MPa. Difference between cylinders should not exceed 0,4 MPa. S tart of delivery Firing order

13°±0.5 15°±0,5 15°±0,5

__________________

1.5.7.2.6.34.8.

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

Engine Mass Kg ........... .............. ......... (approximate figures depending on application) Idling speed

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

815

13°±0,5 15°±0.5

15°±0.5

1.6.5.10.2.7 .3.8.4.9.

865

865

965

1020

13°±0,5

15°±0,5

15°±0,5

1.12.5.8.3.10.6.7.2. 11.4 9

1020

1115

1165

121 5

600 r/min

^“ AI)K

Sc M

fcapfing»»» W««l Clu b

ercedes

li ri ni » order» a

nd valve set

Cylinder Arrangement Le

Firing Orders:

LEp j

5 6

1 2

6 7

1 2

7

3

8

8

4

9 10

7

1

8

2

3

9

3

4

10

4

5

11

5

12

6

| F lywheel |

VS = 1,5,7 ,2,6,3, 4,8 V 1 0 = 1,6, 5,10 ,2, 7,3, 8,4, 9 VI 2 = 1,12,5, 8,3,10,6, 7,2,11,4,9

Flywheel

Valve Set Va lve s Rockiny, Set VK I'mn p Set V 10 linn}? SetV 12firing

6

1

2

3

4

7

8

9

If)

8 9

5 6

7 10

5 3 8

6

6 7

1 3

2

]

2 5 11

2 10

4

3

4 1 12

5

4

9

11

12

8

7

Throughout the Workshop Manual, SI (International Metric Systems) units as approved by the Bureau ofindicated. Standards (SABS) are used. All measurements are South in mm African unless otherwise

7/90

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Workshop Manual for AD E 422, 423,424

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_______________SECTION

09-1 Operating and Maintenance

P reparation before starting

repeatcranking. W hen oil pressure is notedon the gau ge, or the lowpressure light goes off, release the rack from the "noel"fu position to allow engine start to . Do not revup the engine immediately.

Check the radiator coolant level. Check the engine sump il olevel. (See "Oil specifica tion for runningin after a major overhaul" below)

If vehicle is fitted with keyoperated stop: Start engine an d run at idling speed. Keep a check on engine oil pressure gau ge. Pressure must be indicated after prox. ap 10 seconds.

OPERATING AND MAINTENANCE

(Refer to "Approved consumables & service intervals" bulletin for list of approved runninginls)oiincorporated in section 9.

ENGINE MAINTENANCE CATEGORIES

Ensure that there is fuel in the tank. Check that the battery is fully charged and that all electrical connections are properly made and all circuits are in order.

Category 1

Units operating under norm al condi tions, morethan 100 000 km or 2000 hours annually, e.g. long haul operations.

S tarting and stopping the engine Category 2

Starting:

Units operating under norm al conditions, up to 100 000 kmor 2000 hours annually,g.e.mediumto long haul operations. Set accelerator half open andrntuthe starter switch. Whe n the engine starts bring the accelerator to idle position and check the oil pressure. Do not engagethe starter continuously for longer han t C ategory 3 15 seconds. Units subject to severe operating conditions, e.g. extremely po or road cond itions, heavy dust conditions, extreme climatic conditions (temperature and humidity), very short distances in traffic or construction operation.nits U operating up to 10 000 km or0 20 P oints to note hours annually, e.g. units operating under light loads or intermittent operatin g conditions, uch s as standby generator sets and emerAlways ensure that the starter pinion has stopped rotating before v ehicles. However, when operating less than th e reengaging the starter, as the ring gear or pinion may gency be recommended service intervals, the oil and oil filter should be damaged. changed once or twice a year, depending on the lubricating oil used. We recommend that maintenance and service be carried out Check the oil pressure gauge immediately after starting. according to hours of operation rather than mileageered. cov S hould no oil pressure be registered, stop h t e engine

After an unsa tisfactory starting attem pt, allow the batt ery a 1530 seconds recovery time.

immediately and investigate. NORMAL SERVICE INTERVALS

Stopping: R ecommended oil and filter changeintervals Relieve the load from the engine and gradually cut down engine It is critical that the correct quality of oil is used when prescribing speed to idle.Let it run for one minute hent stop the engine. service intervals to ens ure maximum life from your engine.

Stopping (Turbocharged Engine) The stopping procedure is more critical for a turbocharged engine, due to the operational speeds reached bythe turbocharger rotor assembly.Turning theengine off without allow ing the engine to idle for at leas t three min utes after ful l load operation may damage the turbocharger bearings whic h rely on theengine oil press ure for positive lubrication.

Oil specification for running-in after a major engine overhaul.

Runningin oil must be used after either: a. Fitting newblock assembly b. Fitting newpistonrings and liners c. Fitting newcrankshaft bearings to a regr ound crankshaft.

While the quality of commercially available oils and the design of engines are being continually upgraded, the demands placed on them have also increased. Extensive testing has proved it necessary to specify different service intervals for the various quality oils.

APPROVED CONSUMABLES AND SERVICE INTERVALS

Details of appro ved lubricating oils, antifreeze/cool ant inhibit ors and powersteering oils are to be found in the latest issue of the ADE Approved Consumables and Service Intervals bulletin.

Service intervals based on fuel usage

Because of the high sulphur levels(>0,3%) in the fuels that are commercially availab le in South Africa a nd its degrading effects on the oils, It is necessary to limit the service intervals based on fuel Ensure that the oil ter fil bowl isprimed w ith oil prior to cranking. throughput. For example a 366N engine having MultiSeries Super Engine startup after fitting a new shortblock or major overhaul Plus Series 3 Quality oil as ted lis on pag e 9 of our bullet in should be in such a wayhat t oil press ure is noted before actu al long haul operations (i.e. Operating C ategory I) should engine start (i.e. crank engine with startermotor and hold injection operating in be serviced at either 22 500 km , 450 hours or after 5 200 litres f o pump rack in "no fuel" pos ition). However, crank only for 10 fuel usage, whichever occurs first. seconds then allow starter motor to cool for 60 seconds before S tart-up procedure after major engine overhaul

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Workshop Manual for AD E 422, 423,424

OPE RATING AND MAINTENANCE 092 TABLE 1 - Service & calibration intervals of F.I.E.

Maintenancefunction

Enginetype

Serviceinterval

300/360 Series

400/440 incl.

152,236 & 354

420/440V

Service injectors

★

Service and calibrate injection pump

max. hrs

Fuel lb

1200

21 000

1800

34 500

60 000 *

Renew injector nozzle

max. km

*

90 000 120000

* *

*

42 000

2400

180 000

3 600

69 000

180 000

3 600

63 000

270 000

5 400

103 000

2. Check coola nt level inthe radiator

Recommended S ervice & Calibration intervals for injection pumps and injectors.

3. Service air cleaner dust bow l and prefilter if applicable. As a general rule normal operating conditions apply ot usages of 100 000 km or 2 000 ho urs per annum. For severe operating conditions such as forest, quarry, offroad mining, aroundown t delivery, etc. the ges usa should be halv ed.

4. Check aircleaner restriction indicator, se rvice filtersIf required. 5. Ensure there is am ple fuel in theank. t

Injectors should beerviced s at least onc e per annum , and fuel injection pumps at least once every second year. 6. Ensure thatthe fuel ank t cap/breather is unobs tructed. Service calibrations must be performed by authorised diesel equipment agencies, and pump testreports should be requested. 7. Ensure thatthe exterior ofhe t sump isclean with an unobstructed airflow over the surface. Predelivery Service 8. Ensure radiator fins have an unobstructed airflow. 1. Check general engine installation, i.e all pipes an d hoses for tight sealing, condition and routing. 2. Open air cleaner and ensure that theelementis position ed correctly and bolted down. 3. Check for fuel and ilo leaks.

9. Check oilpressure ind icator.

Recommended Service/Maintenance Schedule

1. Change engineoil, drain o il while still ot. h Dependent on oil change interval in accordance with chosen operating category.

4. Check oil le vel. 5. Check coolant lev el. 6. Check coolant for correct mixture, i.e antifreez e/anticorrosion agent and corrosion inhibitor.

2. Renew oil filter. e Dpendent on oil chang e interval in accordance with chosen operating category. 3. Renew fuel filters every 2nd oil change/service.. 4. Check aircleaner indicator, service filters if required.

7. Check Vbelttension. 8. Check electrical equipmentdan connections.

5. Check all air cleaner intake ducts, hoses an d clips et c. for serviceability and tightness.

9. Check injec tion pump linkage foraltot movement.

6. Check that h t e intercooler is free from obstructions.

10. Check exhaust brake linkage and adjus tment if fitted .

7. Check coolanthoses and hose clips for serviceabity and itghtness.

11. Check thatthe fan hasbeen fitt ed correctly. 8. Pressure testcooling system . 12. Start up, then chec k the oil pressure and coolantemperature t gauges.

9. Ensure that therecomm ended corrosion inhibitorhas been added to the cooling system.

13. Check for any unusual noises. 10. Ensure th at the radiatorfins have an unobstructed airflow 14. While the engine is warming up eck ch for oil and water leak s. 15. Check operation of visco fan (if fitte d).

11. Tension all Vbeltsand check for ageing. Replace defective Vbelts, Twin Vbelts must only be replaced pairs. in New belts must be retensioned after 1015 minutes of operation.

16. Run to operating temperature andckche maximumr/min 12. Check exhaust system for damage or leak s. Daily Before Starting and after 8 10 Hours Operation 1.

Check engine oillevel and pressure upon startup (ensure machine is standing level).

13. Cpeck control link age on injection pump andhaust ex brake for correct function and adjustment, lubricate all joints. 14. Check all lines an d hoses for tight sealing, chafing and leaks

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Workshop Manual for AD E 422, 423,424

OP ER ATING AND MAINTENANCE 15. Adjust valve clearance every second service. 16. Retighten all visible ts nuand bolts on the engine and in particular at: a. Inlet and exhaust manifolds and ducts b. Exhaust flange c. Starter motor and ernator alt fitting d. nozzle holders e. Engine mount no cross member andengine support f. Bell housing bolts and nuts. 17. Check for fuel and iloleaks. 18. Check operation of oil pressure and emperature t gauges.

093

ENGINE P RESE RVATION

When an engine is laidup for a prolonged period, it should be properly protected against corrosion.Preservat ion measures should be carried out in accordance with the different categories listed in the following sections.

1.0

General

2.0 Installed E ngines 2.1 Laid up for upto 12 months 2.2 Laid up for 12to 36 months 2.3 Laid up for m ore h t an 36 months

19. Check batteryelectrolyte leve l. In summerand hotregions once a week. 20. Check batteryterminals for tightness and condi tion.

3.0 Non-installed Engines 3.1 Laid up for upto 12 months 3.2 Laid up for 12to 36 months 3.3 Laid up for m ore h t an 36 months

21. Check operation ofisco v fan (if fitt ed). 22. Check oil filler cap and dipstick foroper pr sealing P reparing Engine for operation

23. Inspect turbocharger turb ine and compressor blades for damage, free rotation, end and side play.

1.0

Note:

 Renew coolant every 2nd year Attention: Satisfactory longterm operation of the air compressor depends on m any varying factors. Therefore aspecific service interval cannot be recom mended. Dealers and Fl eetowners should adopt service intervals which will suit their individual operating conditions.  Renew breather every 2nd year

General

An engine is classified as "laid up"when ithas not operate d for over one month. Laid up vehicles or engines should b e stored in dry, well ventilated rooms, and must always be protectedagainst direct moisture, e.g. rain orsplash wat er. If this is not possible, laying up conditions are classified as extrem e and h t e treatm ent specified for a given period should be increased, e.g. if an engine is to be laid up for up to 12 months it must receive the same treatment as an engine which si to be laid up for 12 to 36 months. 1.1

S pecification of fresh water

Sum of alkaline earth (water hardness) pH value at 20°C Contents of chlorine ions: Total contents of chlorides and sulphates

On any laidup engineall machined external unprotec ted surfaces, e.g. flyw heels, Vbelt pulleygrooves, etc. should be coated with a preserving gent a or grease.

89,5  358 mg/litre

Vbelts must be slackened off and removed.

6,58,5 max. 100 mg/litre

All openings must be sealed airtight. This includes exhaust and air inlet ducts/cleaners on installed engines. Batteries musteb disconnected inlaid upvehicles and

max. 200mg/litre

Full information on the quality of drinking water should be obtained from local department s of Water Affairs or local aut horities. It is essential to protect your engine at all times against corrosion by2.0 the addition of anticorrosion/antifreeze additives (ethylene glycol with corrosion inhibitors) which among others, will meet the following demands:  adequate anticorrosion and cavitation protection for all components in the cooling system  lowering the freezing point  raising the boiling point. At no time shouldthe coolant mixture exceed 55% by volume antifreeze/anticorrosion agent, as a higher percentage will reduce the antifreeze protection as well as lessen the heat dissipation. As corrosion inhibitors decompose during operation and the anticorrosion concentration is being reduced by topping up the cooling system with water, the frost protection must be checked regularly. Frost protection of 30°C corersponds with 40 to 45% (by volume) antifreeze/anticorrosion content in he t coolant w hich may be determined by an optical or mechanical hydrometer, (30°C). The anticorrosion oil content in the coolant, i.e. 1% by volume, may be determined by a refractometer.

Only use approved products for mixture with the coolant as specified in the ADE Approved Consumables and Service Intervals bulletin (incorporated in this section) and at all times strictly adhere to the mixture specifications.

should be recharged outs ide thevehicle as required. Installed Engines

These measures apply to all engines in vehicles, tractors and industrial engines. 2.1

Laid up for up to 12 months

2.1.1 NEW ENGINES (distancecoveredup to 300 km or 6 hours of operation): The engines must be fitted to the maximum level with approved service products. Ambient temperatures must be taken in to consideration wh en selecting SAE grades No further preservation measures are required. 2.1.2 USED ENGINES (distance covered more than 300 km or 6 hours of operation): Run engineuntil warm and drain engineoil. (Running in oil m ay remain in the engine).Renew oil filter cartridge. Fill with anapproved runni ngin oil (anti corrosion engineoil). Fill or top up cooling systemwith the specified coolantmixture. Run the engine at medium speed for approx. 5 to 10 minutes until operating temperature is reached (coolant tem perature 7579°C).Switch off h t e engine, fill h t e sump and the oil bath air filter (if fitted) to maxi mum level.

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Workshop Manual for AD E 422, 423,424

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OP ER ATING AND MAINTENANC E 094

2.2

Laid up for 12 to 36 months

3.1

NEW ENGINES which have only been subjected to the

All the measures set out in sections 1.0 "General" and 2.1 "Installed engines , laid up for upto 12 months", must be carried out. In addition, the fuel system, the combustion chambers and the air o c mpressor must be pres erved in accordance withthe following instructions .

runningin period at ADE do notrequireany additional preservation measures. Runningin oil d m y be left in the . Coolantand m ustinbe comp letely ra ained. Remov e tengines he thermostats sert one Chadpack Tablet (ADE partno. 3617 0072) into the housing. Refit h t e therm ostats, close cover/outlet and ensure that the joints form agood seal. All engine openings must be sealed airtight.

Note: The procedure in this section should also be followed after less than 12 months in the case f sea o shipments andin tropical areas. 2.2.1 P reservation of Fuel System:

Add approximately 10% nningi ru n oilto diesel fuel and operate the enginewith this mixt ure for approxim ately 5 to 10 minutes.

Note: Follow the instructionsfor sea shipments or tropical areas.

USED ENGINES must be treat ed in accordancewith the measures set out in items 2.1.2 and 2.2.1 before being laid up or dis mounted.

If a number of vehicle, tractoror industrialengines are to be preserved at the same ime, t thefuel andthe runningin oil may be mixed ina separate containerbefore feeding the solution into the fuel system via a threeway or fourway cock valve. This enablesthe concentration of oil in diesel fuel to be increased to 1520%.

Coolant must be draine d completely anda Chadpack Tablet must be inserted in the thermostat housing. RE MANUFA CTUR ED ENGINE S must in all cases be preserved in accordance with section 2.2 in full.

2.2.2 Pres ervation o f Combus tion Chambers:

Oil may be sprayed intothe combustion chambers iav the injector ports after removal of the injectors, which may be immersedin oil for addedprotection. For best results h t e metered amountof oil must be injected into the combustion chamber under pressure to ensure complete sprayingof all areas.Upon complet ion of each cyli nder (piston down), rotate the engine at least one full turn by hand.

3.2

3.3

Laid up for more than 36 months:

If the laying up periodis extended for more than 36 months, preservation mus t be repeated everyJ 36 months (3 years) or 18 months in accordance with section 2.2 in full. If there is oil in the engine,this maybe drained offat room temperature (approx. 20°C).

8-10ml

Note: Do not exceed the above amounts as this may lead to hydraulic lock and possible engine damage.

Refit all parts removed and ensure that seals and gaskets are in place. Reposition the injection pum p governorcontrols ot the operating position.

Laid up for 12 to 36 months:

The preservation measures set out in section 2.2 must be carried out in full.

Note: During the above operation the injection pump/governor control must be in the shutoff position. Oil per cylinder

Laid up for up to 12 months:

It is not necessary to renew the oil filter cartridge.

4.0 PREP ARING THE ENGIN E FOR OP ERATION 4.1

Removesealingfrom all openings.

Note: Engines must not be started after the combustion chamber preservation has been carried out.

4.2

Removepreserving agent or grease fromthe grooves of Vbelt pulleys, flywheel and other unprotect ed surfaces.

2.2.3 P reservation o f Air C ompressors:

4.3

Reposition and tension Vbelts in accordance with instructions.

4.4

If not alreadyinstalled, fit engineto machine.

4.5

Fill wit h approved lubricating and coolant service products or top up to maximum level.

Air compressor preservation should be done conin junction with the combustion chambers. A maximum of 5 cubic centimet res of runningin oilshould be in jected or poured into each cylinder via the compressor air intake after which ths engine must be rotated at least one half turn. 2.3

Laid up for more than 36 months

If the layingup period is extended formore th an 36 months, pres ervation measure s must be repeatedvery e 3 years or 18 monthsin accordance with section 2.2 in full.

3.D NON INS TAL LE D ENGINE S

These measures cover new noninstalled engines, as well as remanufactured engines.

Note: Engines which have noteceived r heir t first service must be filled with runningi n oil, all others should be filled with approved operating oils. 4.6

Rechargeand reconnect batteries.

4.7

Run engineto operatingtemperature(coolant temperature 7579°C) while monitoring pressures and temperatures.

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Workshop Manual fo r ADE 422, 423,424 S e e H nM ‘

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SECTION 101 Fault Finding

Fault Finding Chart FAULT

.

S tarter motor turns engine too slowly

POSSIBLE CAUSE 1. 2, 3. 4.

Will not start

5, 6, 7. 8. 9, 10, 12, 13, 14. 15, 16,17, 18. 19, 20, 22, 31, 32, 33.

Difficult starting

5, 7, 8. 9. 10, 11, 12, 13, 14, 15,16. 18, 19, 20, 21, 22, 24. 29, 31, 32, 33.

Lack of power

8,9,10,1 1,12, 13,14,18.19,20.21,22,23,24,25,

Misfiring

8, 9, 10, 12, 13, 14,16. 18, 19, 20, 25, 26, 28, 29, 30, 32.

Excessive fuel consumption

11, 13, 14, 16,18, 19, 20, 22, 23 , 24, 25, 27, 28, 29 , 31, 32, 33, 63.

Black exhaust

11, 13, 14, 16, 18, 19. 20, 22, 24, 25,27,28,29,31,32, 33,60.

26,27,31,32,33,60,62,63.

Blue/W hite exhaust

4, 16. 18. 19. 20. 25, 27, 31, 33, 34. 35, 45. 56, 61.

Low oil pressure

4, 36, 37, 38. 39, 40, 42. 43, 44, 58.

Knocking

9, 14, 16, 18, 19, 22. 26, 28, 29, 31, 33, 35, 36, 45, 46, 59.

E rratic running

7, 8, 9, 10, 11. 12, 13, 14, 16, 20, 21, 23, 6, 2 28, 29, 30, 33, 5 3, 45, 59.

Vibration Highoilpressure

13, 14, 20, 23, 25, 26, 29, 30, 33, 45. 47.48, 49. 4.38.41.

Overheating

11, 13. 14. 16. 18, 19, 24, 25, 45, 50, 51, 52, 53, 54, 57.

Excessive crankcase pressure

25.31,33, 34,45, 55.

P oor compression

11. 19. 25, 28. 29. 31. 32, 33, 34, 46, 59.

S tarts and stops

10. 11. 12.

Key to Fault Finding Chart 1. B attery capacity low. 2. Bad electrical connections. 3.F aulty starter motor. 4 Inco rrect grade of lubricating oil. 5 Starter motor turns engine too slowly 6.F ueltankempty 7. F aulty stop control operation. 8 Blocked fuel feed pipe. 9 F aulty fuel lift pump. 10. Choked fuel filter. 11 R estriction in induction system. 12 Air in fuel system. 13 F aulty fuel injection pump. 14. F aulty atomisers or incorrec t type. 15. Incorrect use of cold start equipment. 16. F aulty cold starting equipment. 17. Broken fuel injection pumpdrive. 18. Incorrect fuel pump timing. 19. Incorrect valve timing. 20. P oor compression. 21. Blocke d fuel tank vent 22. Incorrect type or grade of fuel. 23. S ticking throttle or restricted movement. 24. E xhaust pipe restriction 25. C ylinder head gasket leaking. 26 Overheating. 27.Coldrunning. 28. Incorrect tappet adjustment. 29. S ticking valves 30. Incorrecthighpressurepipes. 31. Worn cylinder bores.

35.

11

32. P itted valves and seats. 33. Broken, worn or s ticking piston ring(s). 34. Worn valve stems and guides. Overfull air cleaner or use of incorrect grade of oil

36. Worn or damaged bearings. 37. Insufficient oil in sump. 38.I naccurategauge. 39. Oil pump worn. 40. P ressure relief valve sticking open. 41. P ressure relief valve sticking closed. 42. Broken relief valve spring. 43 F aulty suction pipe. 44. C hoked oil filter. 45. Piston seizure/pick up. 46. Inco rrect piston height. 47. Damaged fan. 48. F aulty engine mounting (housing). 49. Incorrectly aligned flywheel housing or flywheel. 50. F aulty thermostat. 51. R estriction in water jacket. 52. Loose water pump drive belts. 53. C hoked radiator. 54. F aulty water pump. 55. Choked breather pipe 56. Damaged valve stem oil deflectors (if fitted). 57. C oolant level too low. Bloc ked sump strainer. 58. 59 Brokenvalvespring. 60. Damaged or dirty turbocharger impeller. 61. Leaking turbocharger oil seals. 62. Leaking boost control pipe. 63. Leaking induction system.

W IfllTingto., Diesel dub

Workshop Manual for ADE 422, 423,424

S e c H nM ‘ B e g in thru to section

__________________________

11

SECTION 111 Cylinder Block Tombak Seal

Cylinder Block 1 Cylinder block 2 Dowel pin 3 Hollow pin 4 Bolt 5 Bolt 6 C amshaftbearing 7P lugC amshaft 8 Plug 9 Seal 10 Plug 11 Seal 12 Plug 13 Seal 14 Plug 15 Seal 16 Plug 17 Plug 18 Plug 19 Plug 20 Seal

21 Hollow pin 22 Hollow pin 23 Pin 24 Ball 25 Tube 26 C onnector 27 Seal 28 P lug 29 Seal 30 Plug 31 Seal 32 Plug 33 Seal 34 Plug nut 35 Seal 36 Plug 37 Seal 38 Adapter 39 Seal 40 Cover

41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61

Seal Seal Gas ket Spring washer Bolt “O” Ring seals (bottom) “O ” Ring seal t(op) Tombak seal Oil jet Seal Connector Transmitter Seal Transmitter Seal Breather Breather Seal Vent tube Hose Vent tube

62 Clamp

7/90

4 l|' JdMMhgton Diesel dub

Begin thru to sect ion 11

Workshop Manual for AD E 422, 423,424

CYLINDER BLOCK — 11-2

B orefocr ylinde liner r flange

154,0 153,9

“A ”

Flange depth

“B”

Bore for cylinder liner fit

Upper fit/lower fit

9.99 9.97

upper“C”

145.840 145.800

lower “D”

144.540 144.500

ovality

max.0.01

O vality for repair

max. 0.08

Deviation of flange face to block face

max. 0.02

C ylinder block

150 kP a

leakage t est under water wit h c ompress ed air

C rankshaftbearingbasicbore

111.022 111.000

new

111.040 110.970

for repair

P ermissible ovality

0.01

P ermissible t aper of bore

0.01

C ams haft bearing basic bor e

76.030 76.000

Roughness of upper joint surfaces

7/90

Rz 10^m — Rmax 16^m

W If llT in gto. , D iese ldub

Workshop Manual for ADE 422, 423, 424

S e e Ho iee:

Begi n thru to se ction 1

CYLINDER BLOCK — 113

—

-c-

— u

/ ' 0 r CD| <

/ /

/

/

1

A

/ / / /

I

/

■

/



AA

■ ■ ■ 

)

-

F

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

Liner insi de diameter “A ”

128,010 127,990

Flange outside Dia. “B”

153,757 153,657

Upper fit dia. “C ”

145,800 145,778

Dia. of step on liner sealing face “D”

142.0 141.8

Outside dia. “E”

145.0 144.7

Lower fit dia. “F”

144.475 144.451

Flange thickness “G”

10.07 10.05

Height of step above sealing face “H”

1.10 1.00

O verall length "K ”

253.5 252.5

Max. lateral runout of liner flange “a” to centerline

0.02

Max. runout between lower and upper fit “c”

0.025

O vality or taper at lower fit “ F”

Before fitme nt Installed

max. 0.06 max. 0.04

P rotrusion ab ove block face

new for repair

0.05  0.09 0.03  0.09

Flange shim thicknes s

for repai r

0.8/1.0/1.5

Liner wear at upper return

0.06

S urface roughness o f honed lin er

R3z 3  5/ifn

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Begi n thru to sect ion11

Workshop Manual for AD E 422, 423,424

CYLINDER BLOCK — 114 TORQUE SP ECIF ICATIONS Main bearing cap bolts (see section 14)............................

M18 x 2

Main bearing cap side b o lts .............. ............ ............ .......... Note: Tighten stretch bolts prior to bearing cap side bolts Blankoff Plugs ............. ............ .............. ............. ............ ........

M12 x 1,5

Initial torque Final torque Max, stretch length

50 N.m 80 N.m 120 N.m 150 N.m 47 N.m 25 N.m 35 N.m 100 N.m 8 N.m 110 N.m 50 Nm

M 14x 1,5 M 18x 1,5 M 1,5 M 26x 30x 1,5 M 14x 1,5 M8 M22 x 1,5 M 22x 1,5 M6 M12 M14 x 1,5

Piston cooling nozzles/camshaft spray nozzles Front oil seal cover bolts to cylinder block Tac hograph cable nut to ad ap tor ............. Blanking nut to rev. counter drive............ Crankcase breather to cylinder block ..... Engine mountingfront to cylinder block . Adaptor for cooling system vent lin e .....

T ightening torques for S tandard bo lts and nuts (normal and fine pitch) in N.m (Valid only if no other torque is specified).

Thread

8,8

M6 M8 M8 1x M10 M10x1 M12 M12 x 1,5 M14 M14x1,5 M16 M16 x 1,5 M18 M18 x 1,5 M20 M 20x 1,5 M22 M22 x 1,5 M24 M24 x2

8,6 21 23 42 46,5 73 76 114 128 178 190 245 280 350 390 465 520 600 660

C lassification of S trength 10,9 12,9 11,8 29 32 58 65 100 105 165 178 250 270 355 390 490 550 660 730 850 910

300 N.m 90° — 100° 156 mm 80 N.m

14,5 35,5 38 70 78 123 128 195 215 300 320 415 465 590 660 800 875 1000 1100

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Workshop Manual for AD E 422, 423,424

Begi n thru to sect ion11

CYLINDER BLOCK — 115 Introduction The cylinde r blocks of the ADE 420 S eries E ngines are made of grey cast iron with the sides extending below the crankshaft centre line. Interchangeable (Wet) cylinder liners are fitted, wh ich once the cylinder head and pistons have been removed can easily be extracted. On replacement considerable care should be exercised to ensure that the cylinder liners are correctly seated and sealed.

REMOVING AND REPLACING CYLINDER LINERS Removing 1. Mark cylinder liners and cylinder block with paint, to ensure that the liners are returned to the srcinal position. 2. F it puller studs opp osite to each other into bolt holes in cylinder block. 3. Insert puller. Part number 40200433, into cylinder liner (fig. 111). 4. Open jaws of puller to inner diameter of cylinder liner.

5. F it support of puller onto studs, tighten nuts and screw down centre nut on puller shaft. 6. Hold cen tre shaft of puller with a ring spanner and continue turning centre nut pulling out liner from cylinder block (fig. 211). 7. R etract jaws of puller. Uns crew support studs from cylinder block, and remove together with puller.

8. L ift out cylinder liner from cylinde r block (fig. 311). 9. Remove O rings from cylinder block and liner. 10. It is essential that the outer surface of the cylinder liner, together with the bores in the cylinder block are thoroughly cleaned before replacement.

Fig. 311

7/90

4 l|' JdNMhgton Diesel dub

Workshop Manual for AD E 422, 423,424

CYLINDER BLOCK — 116 REMOVING AND REPLACING CYLINDER LINERS Replacing 1. Insert new Orings into cylinder liner bores in crankcase (dry). 2. F it new Oring into upper recess of cleaned cylinde r liner. 3. Apply approximately a3mm dia bead of sealing compound onto seal (fig. 411).

Fig. 411 4. Apply a light coating of grease to the bottom of the cylinder liner, outer surface. 5. Insert cylinder liner while rotating it 90° from the srcinal fitted position (fig. 511).

Fig. 511

6. Fit puller studs oppos ite to each other into bolt holes in cylinder block (fig. 611). 7. P lace steel disc on top of cylinder liner. 8. F it support of puller onto studs, tighten nuts. Screw up nut on centre shaft to back of puller support.

Fig. 611 9. Using a ring spanner screw down centre shaft of puller, inserting cylinder liner. Tighten with torque wrench to 120 N.m and leave pressure applied for five minutes (fig. 711). 10. Using a suitable plastic knife, remove excess s ealing compound forced out between cylinder block and liner. 11. R emove puller from cylinder block.

Fig. 711

Begi n thru to sect ion11

W IfllTingto., Diesel dub

Workshop Manual for ADE 422, 423,424

S e e H nM ‘ B e g in thru to sec t i° n 11

CYLI NDE R BLOC K 12. Measure the inside diameter ofthe cylinder liner at the bottom, using a suitable internal measuring instrument, at three points offset 60° to each other (fig.811). than 0,04 mm deviation is measured, check Note: If more seating of lower Oring seal.

13. To prevent the cylinder liner moving while fitting the pistons, keep the liner under preload with two fa bricated sleeves (approx. 30 N.m). (fig. 911).

Important If used pistons are replaced, it is essential to replace the top piston ring on all pistons removed.

Fig. 911

11-7

4 W lo rr in gtc Diesel Club CYLINDER BL OCK 

Workshop Manual for AD E 422, 423,424 118

Note It is essential that when the cylinder liners have been removed or replaced, the liner protrusion is measured, to ensure correct sealing of the cylinder liners. The correct specification of liner protrusion must be adhered to. The cylinder liner protrusion can be altered by the addition or subtraction of shims, which can be obtained at your nearest ADE parts stockist.

MEASURING PROTRUSION OF CYLINDER LINER 1. R emove cylinder heads (See section 12). 2. P lace gauge plate Part number 40201953 on cylinder liner. Insert short cylinder head bolts fitted with spacers, and tighten to 50 N.m (fig. 1011). Note: Check inside diameter of gauge plate prior to fitment and if necessary machine to 144 mm.

3. P lace dial gauge holder ongauge plate and insert dial gauge, so that sensor probedial rests on the cylinder block with preload. Tighten gauge. Set dial gauge to “O” on cylinder block, at each measuring point. Maximum tolerance between four points, for each liner is 0,02 mm (fig. 1111).

MACHINING CYLINDER LINER SHOULDER DEPTH 1. Remove pistons and cylinder liners. 2. P reparations Pack the bores in the cylinder block with clean rag or a suitable material, as far up as possible in the machining area, to protect the crankshaft and bearings against falling swarf and dirt. Cover all oil galleries particularly the neighbouring cylinders, e.g. with a plastic sheet. 3. Clean surface of cylinder block and bores for cylinder liners. 4. Determining linershoulder depth: Shoulder of cylinder liner distance (measured at 4 points, max. differenc e of 4 measuring points per liner 0,02 mm). + Thickness of shim  S pecified liner protrusion = S houlder depth.

Example (0.8 mm thick shim) Liner shoulder mean distance 10,05 mm + measured thickn ess of shim 0,80 mm  S pecified liner protrusion

10,85 mm 0,09 mm

10,76 mm = S houlder depth a = shoulder depth (fig. 1211)

Begi n thru to sect ion11

4 l|' JdNMhgton Diesel dub

Workshop Manual for AD E 422, 423,424

Begi n thru to sect ion11

CYLIN DER BLOCK  5. C lean machining and cu tting tool (with compressed air), prior to inserting tool. Give cutting tool and insert a light coating of oil (fig. 1311).

Fig. 1311

P ull up quick adjus ting ring and guide cu tting tool in to holder. Insert cutting tool so that centring roller is on the side of cu tting tool ho lder marked with “R ”, and feed' threads on cutting tool face away from quickadjusting ring (fig. 1511). Note 1: Remove protective paint on solenoid flange with thinners, prior to initial use (fig. 1411).

Note 2: Ce ntralise machine on c ylinder bore.

Fig. 141 1 6. C onnect power supply. P lace machine on cylinde r bore to be machined and switch on solenoid.

F ig. 1511 7. P ull up quick adjus ting ring with two fingers of each hand. Hold quicka djusting ring with two fingers of one hand, and push cutting tool with other hand until centring roller is on side wall of liner recess in cylinder block (fig. 1611). Note: C orrect height of cen tring roller is adjusted with

feed nut.

8. Move switch to position 2. This energises the solenoid ring and holds the machine on the cylinder block.

F ig. 1611

119

4 W la rr in gt c Diesel dub

Workshop Manual for AD E 422, 423,424

CYLINDER BLOCK — 1110 9. Turn crank slowly cloc kwise and chec k to see if the centring roller rests on surface around the entire circumference of the liner recess, and the machine has not moved (with switch in centre position). I f the machine has moved, turn crank clock wise, and at the same time hold feed ring with two fingers. If centring roller loses contact with shoulder recess, turn crank anticlockwise while at the same time holding the feed ring, until roller has contact on the entire circumference of shoulder recess (fig. 1711). Note: When centred correctly, the centring roller will have uniform contact all round and machine willnot move when switching to “O".

Fig. 1711 10. A fter centring correctly, move switch to po sition 1. P ull up quickadju sting ring and push in cutting tool until cutter con tacts liner recess to be machined, but not against side wall (fig. 1811). 11. Turn crank and feed nut together clockwise, until cutting tool makes contact with liner recess seat. 12. L ift quick adjus ting ring and push back cutting tool, to position above the liner recess seat.

13. Unscrew alien cap screws for vernier adjustment. Set vernier ring to "O " and tighten a lien cap screws (fig. 1911). 14. A djust cutting depth to 0,05 mm with feed nut. Note: G raduation of vernier = 0,01 mm.

15. Turn crank clockwise, h olding the feed ring with the other hand (fig. 2011).

Begi n thru to sect ion11

W Iflfpingtoi, Diesel dub

Workshop Manual for ADE 422, 423,424

S e e H nM ‘

B e g in thru to section 11

CYLINDER BLOCK — 1111 Note 1 Measure shoulder recess depth from surface of cutting machine after each cut (0,05 mm) (fig. 2111). Note 2: The cu tting too l is ground in suc h a way as to prevent the desired diameter being exceeded. In other words, the face of the cutting tool runs on the liner recess diameter, if there is resistance, release feed ring immediately and turn crank several times.

Only grind cutting tools according to drawings supplied with machine.

Fig. 2111

Important The feed nut mus t not move wh ile turnin g the crank, as this would change the depth setting of the cutting tool. If necessary tighten screw located in feed nut (fig. 2211).

Fig. 2211

16. P ull back quickadjusting ring with 2 fingers, and push back cutting tool to starting position; set 0,05 mm cutting depth with feed nut and continue cutting procedure until desired depth is obtained (fig. 2311).

F ig. 2311

Note 1: Remove machine approximately 0,3 mm before reaching desired shoulder recess depth, and recheck depth with a dial gauge. Recheck depth once again before final machining, to make sure that the desired depth has been reached (fig. 2411). Centre machine after each measurement, (fig. 1711).

Fig. 2411

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Workshop Manual for AD E 422, 423,424

Begi n thru to sect ion11

kd rring ton Di es el tlub

ADE 422, 423,424 Workshop Manual

SECTION 12-1 Cylinder Head

C ylinder Head 1 2 3 4 5 6 7

C ylinder hea d with va lve guides Core plug Core plug S ealing ring Blanking plug Valve guide Valve seat insertinlet

8 9 10 11 12 13 14 15 16

Valve seat insert exhaust Gasket assemblycylinder head Hex bolt Hex bolt Hex bolt Cylind er head gasket R ocker cover R ocker cover (with oil filler) Oil filler cap

17 18 19 20 21 22 23 24 25

S ealing ring Gasket Spring washer Bolt Nozzle holde r with nozzle Nozzle holder Injector Sealing ring Injector securing nut

BK (a p H n gt on Di es el Club

ADE 422, 423,424 Workshop Manual

CYLINDER HEAD — 12-2

114.0

Overall height of cylinder head

113.9 M inimum cylinder head height after mac

hining1)

113.4

P eaktoval ley surf ace finish of ma ting s urface in ^ m

016

Max. unevenness of ma

0.015

ting su rface

Max. parallel deviation between upper and lower surface

0.1

Injector protrusion

1.6—2.4

Valve head recess below mating surface

0.71.1

1) Check injector protrusion after machining cylinder head mating surface and, if necessary, correct with injector washers.

Machining of cylinder head mating surface In order to attain the specified surface finish adhere to the following specifications when grinding: S pe ed :

n

=

Feed:

u

=

C utting veloc ity:

Vs

=

1400 r/min 920 mm /min. 27 m/sec .

Th e s pe cifie d c uttin g ve loc ity is given by us ing a se gme nt gr ind ing whe el w ith a dia me ter o f 370 mm. W hen using a differe nt diame ter (depending on ma chine ty pe), the s peed mus t be changed so that there is no grea ter variation than ±10% from Vs = 4 ? =27 m /sec. “

1000 60

Impo rtant: S lower f eed o r manual f eed will change the grinding

pattern c ons iderably and t here will be no

guarantee of reaching a surface finish of Rz = O to 16/u m. Leakage test under water with compressed air

250 kPa

Barrington Diesel

Club

ADE 422, 423,424 Workshop Manual CYLINDER HEAD — 12-3

Inlet Valve Seat Insert Repair 1 Standard Repair 2

Exhaust Valve Seat Insert Standard R epair 1 R epair 2

Basic bore “a” in

60.030

60.230

60.430

53.030

53.230

53.430

cylinder head Valve seat insert outside dia. “a1"

60.00 60.11 60.10

60.200 60.31 60.30

60.400 60.51 60.50

53.000 53.11 53.10

53.200 53.31 53.30

53.400 53.51 53.50

Valve seat insert interference fit in cylinder head Bore depth “ b” in cylinder head Valve seat insert height “e”

Dimension between cyl. head mating surface and valve seat insert face

0.070.11

0.070.11

12.6 12.5

12.8 12.7

13.0 12.9

12.6 12.5

12.8 12.7

13.0 12.9

previous level

8.9 8.8

9.1 9.0

9.3 9.2

9.7 9.6

9.9 9.8

10.1 10.0

new level *

8.4 8.3

8.6 8.5

8.8 8.7

9.2 9.1

9.4 9.3

9.6 9.5

previous level

3.8 3.6

3.0 2.8

new level*

4.3 4.1

3.5 3.3

45°

45° 1.8 1.6

Chamfer “c” Chamfer depth “d” Max. runout of valve seat to valve guide

— measured at O 57 mm 0.01

measured at O 49 mm 0.01

"F o r new level Turbo Head with “T” stamp

7/90

BK (a p H n gt on Di es el Club

ADE 422, 423,424 Workshop Manual

CYLINDER HEAD — 12-4

InletValve SeatInsert Diameter ‘‘a"

Distance “b”

E xhaustValve SeatInsert

previous level

57.01 56.99

49.01 48.99

new level**

55.01 54.99

48.01 47.99

previous level

4.05 3.90

3.55 3.40

new level**

4.65 4.50

4.05 3.90

30°

45°

Valve seat angle “c” Distance between cylinder head mating surface and valve head face Max. outofround of valve seat to valve guide

0 .71,1 

0.71,1

measured at O 5 7 mm 0.01

measured at O 4 9 mm 0.01

**For new level Turbo Head with “T ” stamp

Old Level Valves Breakpoints

ADE 420N — upto ........SA002748 N ADE 420T/TI — up to SA 002902 N •■D" “E” “C” Width Height Valve Head Dia New Min New Max

Dimensions (mm)

“A" Seat Angle

•B " Dia Seat Centre

Inlet

30°

57,01 56,99

59,0 58,8

3,2 4,3 2,7 3,0 3.3

E xhaust

45°

49,01 48,99

51.1 50,9

2,7 4,5 2,2 5,5 2,5 3,5

7

“F" Stem Dia

Stem Hardness

11,950 HRC 11,932 54

IS

11,940 HRC 11,922 54

New Level Valves Breakpoints

ADE 420N — ADE 420T/TI —

SA 002749 N and UP S A002903 N and UP

Dimensions (mm)

"A" Seat Angle

Inlet

30°

55,01 54,99

59,0 58,8

3.8 5,5 3,3 6,5 3,6 4,5

11,950 11,932 i54 HRC

Ex haust

45°

48,01 47,99

51,1 50,9

3,2 5,5 2,7 6,5 3,0 4,5

11,940 i 11,922 t54

Dia Seat Centre

“C” "D" “E" Valve Height Width Head Dia New Min New Max

“F” Stem Dia

Stem Hardness

HRC

Max. runout between valve seat and stem

0.03

Max. runout between valve head and stem

0.20

Max. valve seat ovality

0.01

7/90

Barrington Diesel

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ADE 422, 423,424 Workshop Manual CYLINDER HEAD — 12-5

Valve Springs Engine Model/ Spring Allocation

Inside Dia.

Spring

Wire Dia.

Relaxed Length

Prelc>aded Length Load

Final .oaded Length Load

N 420N inlet and Exhaust valves and

Outer'

420T/TI inlet valves

Inner

420T/TI exhaust valves only

32 ± 0.3

4.7±0.03

32 ±0.3

4.8 + 0.05

22.8 + 0.2

3.0 ±0,025

Outer

33±0.3

4.5±0.03

Inner

22.8 ±0.2

3.2 ± 0.025

64

N

46.8

345±15

59

46.8

345±15

65.5

46.3

143± 12

32.3

280 ± 20

46.8

355 ± 15

32.8

670±30

46.3

195 ±12

32.3

350 ± 20

68 70

32.8

740±30

33.1

720 ± 50

'O ptiona l due to different suppliers

Valve guide protrusion. Dimension “D” Max. deviation of valve seat to valve guide centre

17.1  17.4 0.03

Max. misalignment of valve seat to valve guide measured at

57 mm dia. for inlet 49 mm dia. for exhaust

0.01

7/90

Barrington Diesel

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ADE 422, 423,424 Workshop Manual

CYLINDER HEAD — 12-6

Valve C learance (mm) — C old E ngine MODEL

ADE 422N ADE422T/TI

BR E AKP OINTS

Up to SA 002762 M SA002763Mandup Up to SA 003441 P SA003442Pandup

INLE TVALVE

0,40

EXHAUST VALVE

0,25

0,35 0,60

0,30

0,50 0,60

0,40

0,60

0,40

— ADE 423N ADE 423T/TI ADE 424N ADE 424T/TI

S tillineffect To be advised

0,30 0,40

* *

S till effect in To be advised

0,50 0,60

0,40

0,60

0,30

0,50 0,40

0,60

INLET VALVE Opens BTDC C loses ABDC

EXHAUST VALVE Opens BBDC Closes ATDC

** At new level since the first day of manufacture.

Valve Timing Degrees ENGINE MODEL

PRODUCTION BREAKPOINTS

ADE 422N

Up to SA 002762 M SA 002763 M and up

21,4° 16°

57,4° 42°

52,8° 57°

14,8° 13°

ADE 422T/TI

Up to SA 003441 P SA 003442 P and up

13° 17°

27° 29°

55° 71°

13° 13°

 ADE 423N ADE 423T/TI

16° S till in effect To be advised

42°

57°

13°

13° 17°

27° 29°

55° 71°

13° 13°

16°

42°

57°

13°

13° 17°

27° 29°

55° 71°

13° 13

— ADE 424N ADE 424T/TI

S till in effect To be advised

** At new level since the first day of manufacture.

7/90

(drH n gto n Die sel Club

ADE 422, 423,424 Workshop Manual CYLINDER HEAD — 12-7

TO RQU E S P E C IF IC AT IO NS C ylinder head to cylinde r block:

S ingle hexagon bolts

M15 x 2

Duo hexagon bolts

Rocker shaft pedestal to cylinder head ........................... Valve adjusting screw loc kn ut .............. ............. ............ ...... Rocker cover to cylinder head .............. ............. ............ ...... Inlet manifold to cylinder head ............ ............ .............. ..... Exhaust manifold to cylinder head ............. ....................... Injector securing nut to cylinder head (see section 17) T urbocharge r to exhaus t manifold (see s ection 18) Blanking plug to cylinder head ............ ............ .............. .....

1st stage 2nd stage 3rd stage 4th stage Final Torque 1st stage 2nd stage 3rd stage 4th stage Final Torque Max. stretch length: short medium

c,/ iong M10_ I>7 C M12 x 1 M8 M8 M10 Check during each service M22 x 1,5

X

10 N.m 50 N.m 100 N.m 140 N.m 90° 100° 10 N.m 60 N.m 120 N.m 180 N.m 90°100° 111 mm 146 mm 170 mm 75 N.m 50 N.m 25 N.m 25 N.m 50 N.m

100 N.m

7 /o n

Barrington Diesel

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ADE 422, 423,424 Workshop Manual

CYLINDER HEAD — 128 Introduction The ADE 420 Series E ngines are fitted with an ind ividual cylinder head for each cylinder. As this type of cylinder head is the same throughout the 420 series of engines, it makes for greater standardisation and ease of service.

REMOVING AND REPLACING ROCKER COVER Removing 1. Unsc rew and remove bolts from rocker cover. L ift off cover (fig. 112). 2. R emove cover gasket.

Fig. 112

Replacing 1. F it new rocker cover gasket. 2. R eplace rocker cover and tighten bolts to 25 N.m (fig.212).

Fig. 212

Barrington Diesel

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ADE 422, 423,424 Workshop Manual

CYLIN DER HEAD

REMOVING CYLINDER HEAD P reparation 1. Drain engine coolant. 2. Disconn ect inlet pipe. 3. Remove exhaust manifold

1. U sing special ring spanner Part number 40200705, remove injector pipes (fig. 312). 2. Remove rocker covers (see fig. 112).

3. U nscrew injec tor pipes from injection pump, using special ring spanners 40200970 & 40200705 (fig. 412). 4. P ull fuel leak off pipes from injector.

5. Unscrew and remove rocker arm brackets (fig. 512). 6. R emove push rods.

Fig. 512

-

12-9

kd rring ton Di es el tlub

ADE 422, 423,424 Workshop Manual

CYLINDER HEAD — 1210

7.

Unscrew and remove cylind er head bolts (fig. 612).

Fig. 612

C ylinder head bolt underne ath injector, can be loosened with sp ecial spanne r 40200530, but it cann ot be removed from the cylinder head (fig. 712). Note:

8.

R emove cylind er head.

Note: Unless the injector has been removed, always lay the cylinder head on its side to avoid damage.

kdrrington Diesel Club

ADE 422, 423,424 Workshop Manual

CYLINDER HEAD — 12-11

RE MOVING AND RE P LACING VALVES

,

Removing 1. P lace cylind er head into clamp and secure. 2. A djust fork to diameter of valve spring retainer. 3. F it push rod into eyeof lever and push down on valve spring retainer. Remove collets from valve stem (fig. 8- 12). 4. Release pus h rod. R emove valve spring retainer and valve springs.

5. P ull valve stem se als from valve guides. 6. Remove cylinder head from clamp and removevalves. 7. Remove spacers for valve springs (fig. 912).

Replacing 1. L ubricate valve stem with engine oil and insert into valve guide. 2. P lace cylinder head into clamp and secure. 3. F it spacers for valve springs. 4. Replace valve stem sea ls using spec ial tool P art number 40201555 (fig. 1012).

5. F it inner and outer valve springs with c lose c oils towards the cylinder head. Fit valve spring retainer. 6. F it push rod into eyeof lever and push down on valve spring retainer. Insert collets in grooves of valve stem. Ensure the collets are correctly located (fig. 1112).

(drH n gto n Die sel Club CYLINDE

R HEAD -

ADE 422, 423,424 Workshop Manual

12-12

FITTING VALVE STEM SEALS 1. Lubricate valve stems with engine oil and insert val ves into guides. 2. P lace cylinder head into clamp, and secure. 3. Using special tool P art number 40201555, fit valve stem seal over valve (fig. 1212).

4. P ress valve stem seal onto valve guide. 5. Remove special tool and repeatprocedure on second valve (fig. 1312).

REMOVING AND REPLACING VALVE GUIDES 1. C lamp cylinder head. 2. K nock valve guides out of cylinde r head, from the combustion side using special tool Part number 40200815. 3. Measure bore for valve guide n i cylinder head and ream to next repair stage if required. 4. C oat new valve guide with graphite oil and knock in using special tool and spacer (fig. 1412). 5. Use special reamer Part number 40200831 and ream valve guide inner diameter to specified dimension.

Fig. 1412

ftdt't'ingtor. Diesel

Club

ADE 422, 423,424 Workshop Manual

CYLINDE

REMOVING AND REPLACING VALVE SPRINGS Removing 1. P lace cylinder head into clamp and secure. 2. Ad just fork to diameter of valve spring retainer. 3. F it push rod into eye of ever l and push down on valve spring retainer. Remove collets from valve stem (fig. 1512).

Fig. 1512

Replacing 1. Clean valve springs, and check spec ific values using a suitable spring tester (fig. 1612).

Fig. 1612

2. Insert inner and outer valve springs with close co ils towards the cylinde r head. F it valve spring retainer. 3. F it push rod into eye of leverand push down on valve spring retainer. Insert collets into grooves of valve stem. Ensure the collets are correctly located (fig. 1712).

Fig. 1712

R HEAD -

12-13

(drH n gto n Die sel Club CYLI NDER HE

AD -

ADE 422, 423,424 Workshop Manual

1 2 -1 4

GRINDING VALVES

1. C lean carbon de pos its from valve. 2. C heck to see if valves can be reused. Valve ends must not have surface damage. C ollet grooves must not be worn and chrome coating on valve stems must be without flaws. Always replace burnt valves. 3. C heck dimens ions and run out of valves. Do not attempt to straighten bent valve stems. 4. S light run out of valve stems can be corrected by grinding the valve face. 5. Insert and clamp the valve immedia tely behind the valve head to avoid vibration when grinding (fig 1812).

6. Set correct grinding angle on scale. 7. Move valve towards ro tating grinding wheel at a slow feed rate until valve makes contact with grinding wheel face. (fig. 1912). 8. G rind face of valve with a light feed un til it is ground on its entire circumference.

F ig. 1912

Note: A fter grinding valve height “D” must not be less than outlined in the specification.

9. S hould it be nec ess ary the valve stem face can be ground on a Vblock mounted on the valve grinding machine (fig. 2012).

Fig. 2012

Barrington Diesel

Club

ADE 422, 423,424 Workshop Manual

CYLINDER

REMOVING AND REPLACING ROCKER ARM Removing 1. C lamp rocker arm bracket in a vice fitted with s oft jaws. 2. Unscrew and remove locknut and valve adjusting screw (fig. 2112).

3. Re move rocke r arm circ lip (fig. 2212).

4. Re move thrus t washer and roc ker arm (fig. 2312). 5. C lean all parts t horo ughly and check for wear .

REPLACEMENT OF ROCKER ARMS 1.

F it rocker arms and thrust washer to rocker ar m bracket (fig. 2412).

Fig. 2412

HEAD -

1 2-15

B5C

Bd t't' ingto»! Diese l Club

CY LINDER HEAD  2.

3.

ADE 422, 423,424 Workshop Manual

1216

Insert circlip on rocker arm shaft (fig. 2512).

S crew valve adjusting screw and locknut into rocker arm (fig. 2612).

Fig. 2612

(drH n gto n Die sel Club

ADE 422, 423,424 Workshop Manual

CYLIN DER HEAD -

REPLACING CYLINDER HEAD 1. Clean cylinder head bolt holes in cylinder block thoroughly prior to replacing cylinder heads. It is particularly important to remove any water trapped in the bolt holes. 2. C lean cylinder head and cylinde r block faces.

3. P lace new cylin de r head gasket over dowel sleeves in cylinder block face (fig. 2712).

F ig. 2712

1

4. Place cylinder head carefully onto cylinder head gasket. 5. Measure bolts to ensure stretch limit is not exceeded. 6. Give cylinder head bolts a light coating of engine oil, insert bolts and tighten in the sequence shown (fig. 2812), according to torque steps listed under specifications. Note:

The stretch bolts do not need to be retorqued.

N ote 1: Use special spanner for bolt underneath the fuel injector. Note 2: If one of the bolts has been tightened excessively, unscrew all 6 bolts of the cylinder head, check for stretch and tighten again beginning w ith step 1 (fig. 2912).

F ig. 2912

12-17

Barrington Diesel

Club

ADE 422, 423,424 Workshop Manual

CYLINDER HEAD — 1218 6. Insert pushrods. 7. F it rocker arm brac ket and tighte n bolts only finge r tight. Align rocker arms with valves and pushrods. 8. Tighten rocker arm bracket bolts to 75 N.m (fi g. 3012).

9. A djust valve clearance. 10. R eplace rocker covers and tighten bo lts to spec ified torque. 11. F it fuel injector pipes and tighten conne ctions on injec tor holder to 25 N .m (fig. 3112).

Note: Hold injection pump nuts with special spanner Part number 40200970. Tighten connections of injection pump td*25 N.m using crowfoot socket Part No 4020 0721. (fig. 3212).

12.

C onnec t fuel leak off pipe to injec tors.

Note: C ylinder head bolts need no longer be retightened.

Fig. 3212

BK ftd rr in g to n Diese l Club

ADE 422, 423,424 Workshop Manual

CYLINDER HEAD — 12-19

ADJ USTING VALVE CLE ARANCE (Meth od, 1) Note: Adjustment of valve clearance can be carried out with the engine Cold.

1. R emove rocker covers and gasket. (See page 122) 2. F it special engine turning tool P art number 40200093 (fig. 3312), to timing case 8 x 20 mm bolts, and turn engine in direction of rotation, until piston of cylinder to be adjusted is at firing TDC. Valves should be closed, rocker arms completely relaxed and push rods free to turn, (see fig. 3412 to identify valves rocking in relation to cylinder firing).

F ig. 3312

Location of cylinders ADE 420 Series E ngines

Valves rocking no: Cylinder Firing 422 set no: 423setno: 424setno:

V12

V12

V10

©

©

V10

VB

©

©

©

©

©

©

©

©

©

©

©

©

©

©

©

©

©

©

©

©

©

©

©

©

©

©

©

©

V8

12 3

4 5 6

7 8

9 10 11 12

6 8 5 73 1 4 2 7 9 61 08 3 1 5 2 4 6 5 4 3 2 1 12 11 10 9 8 7

F iring Order: ADE 422 15726348 ADE 423 16510273849 ADE 424 112583106721149 Valve Clearance cold

Refer to specifications in accordance with breakpoints.

X

F ig. 3412

X — Flywheel end

3. Insert feeler gauge between rocker arm of inlet or exhaust valve. Valve clearance is correct when feeler blade can be pulled through with slight resistance. 4. If the clearanc e requires adjustment, inse rt screw driver and ring spanner and adjust in the normal manner (fig. 3512).

F ig. 3512 5. Turn the engine to the next cylinder TDC firing po sition each time, and set all the valves in firing order sequence. 6. Replace rocker covers, renew damaged gaskets, tighten rocker cover bolts to 25 N.m (fig. 3612). 7. R emove spec ial turning tool from timing case.

EK ftd rrin gt on Die se l Club

ADE 422, 423,424 Workshop Manual

CYLINDER HEAD — 1220 ADJ UST ING VALVE C

LEAR ANCE (Met ho d 2)

1. R emove rocker covers and gas kets. (See page 12 2) 2. F it special engine turning tool P art number 40200093 (fig. 3312). to timing case 8 x 20 mm bolts, and turn engine in direction of rotat ion, until the No. 1 cylinder TDC mark is a ligne d with the ed ge o f the ins pe ction hole. 3. C heck to see if No . 1 cylinder i s at TDC, rocking or firing. (At TDC firing both valves will be closed and the push rods will turn easily). Th e fo llow ing valves can then be ad justed at N o. 1 firing TDC :

Location of cylinders ADE 420 Series Engines E ngine

V8

V12

V12

V10

©

©

V10

©

©

©

©

422 & 422T 423 424

Inletvalve

E xhaustvalve

1, 2, 5, 7 1, 3, 4, 8 1;% 8, 9 1, 2, 5, 6, 9, 10 1, 2S4, 7, 9, 11 ** 1, 3, 5, 8, 9, 12

V8

Th e follow ing valves can be adju sted at No. 1 R ocking TDC :

©©©©©© © ©

©

©

©

©

©

©

©

©

©

©

©

©

©

©

©

©

Engine

422 & 422T 423 424

X X — Flywheel end

F ig. 3712

4. Inse rt feeler gauge between roc ker arm of inlet or exhaust valve. Valve clearance is correct when feeler blade can be pulled through with slight resistance. 5. If the clearance requires adjustment, insert screw driver and ring spanner and adjust in the normal manner (fig. 3812).

Fig. 3812 6. Re place rocker covers, r enew damaged gas kets, tighten rocker cover bolts to 25 N.m (fig. 3912). 7. R emove sp ecia l turning tool from t iming case.

Inlet valve

2, 5, 6, 7 2, 3, 5, 6, 7, 10 3, 5, 6, 8, 10, 12

E xhaust valve

3, 4, 6, 8 3, 4, 7, 8 2, 4, 6, 7, 10,11

-

Ba rr ing*

» * D i e se l Club

ADE 42 2, 423 ,424

Workshop Manual

if'5 28-’7 '

F,g 2817

7/90

Etc

BdPPihcjton Diesel Cltlb

M erc

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Se

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D E 4 2 2 , 4 2 3 ,4 2 4 S y st em

W o rk sh o pM a n u al

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BdPPihcjton Diesel Cltlb

M erc

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Se

i on

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es an : F

dA u el

D E 4 2 2 , 4 2 3 ,4 2 4 S y st em

W o rk sh o pM a n u al

Etc

BdPPihcjton Diesel Cltlb

M erc

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Se

i on

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dA u el

D E 4 2 2 , 4 2 3 ,4 2 4 S y st em

W o rk sh o pM a n u al

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BdPPihcjton Diesel Cltlb

M erc

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D E 4 2 2 , 4 2 3 ,4 2 4 S y st em

W o rk sh o pM a n u al

^13® &ar*Hngt°n Diesel Club

AD E 422, 423,424

Worksho p Manual

Se cti on :

18 - V ariou

SECTION 18-1

Air Compressor 1 2 5 6 7 8 9 10 11 12 13 14 15 17

DRIVE GEAR CRANKSHAFT BOLT BEARING BEARING RETAINING PLATE SCREW FLANGE BUSH SEALING RING CONNECTING ROD DOWEL BOLT BEARING SHELL CYLINDER LINER WITH PISTON

29 30 31 32 33 34 35 36 37 38 39 40 41 42

GASKET SCREW SPRING WASHER CYLINDER HEAD GASKET VALVE VALVE PLATE VALVE PLATE HOLDER BOLT GASKET BOLT SPRING WASHER SCREW PLUG SEALING WASHER

18 21 22 23 24 25 26 27 28

CYLINDER LINER WITH PISTON PISTON RING PISTON RING PISTON RING GUDGEON PIN CIRCLIP PLUG SCREW CONNECTOR SEALING RING

43 44 45 46 47 48

SCREW PLUG CONNECTION SEALING RING INTAKE PIPE NUT HOSE CLIP

s

^a rrin gto n Di esel Hub COMPRE SSOR

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AD E 422, 423,424

Worksho p Manual

Se cti on :

18 - V ariou

18-2

A ir Co m p res s o r C ylinder

1

Bore

90

Stroke

46

Displacement

292 cm3

Pressure

810 kP a/1000 kP a

Delivery capacity (engine at 2.300 r/min)

against

100 kP a

470 f/min

810 kPa

400 f/min

90.030

Bore diameter

90.000 89.950

P iston diameter

89.910 0.08

P iston clearance

0.10

P iston retrusion from upper

0.4

edgeof cylinderliner

1 .2

20.000

Gudgeon pin diameter

19.996 0.020

Gudgeon pin clearance in conrod bush

0.037 0.003

Gudgeon pin clearance in piston

0.012

31.975

C rankshaft journal diameter

P iston ring gap

31.959 Groove 1 Groove 2 Groove 3

Groove 4

P iston ring side clearance

0.35 0.55

0.25 0.40

Groove 1 G roove2 Groove 3

0.520 0.052

Groove 4

Note: C ylinder

liners and piston will be supp lied matchin g the given toleranc e under one part n umber.

s

Diesel Club

ftdrrington

ADE 422, 423,424 Workshop Manual

Secti

on :

18 - V ari ou s

COMPRESSOR — 183

*

A i r C o m p r e s s o r (c o n t d .) C onrod big end bor e

36.016 36.000

C onrod beari ng

32.008 31.994

Length of conrod from CL big end/small end bore

105.00 104.95

W idth of conrod

small end

20.060 20.000

big end

19.935 19.883

TO R QU E S P E C IF IC AT IO NS AIR COMPRESSOR F ittings — suction/pressu re pipe to cylinder head ... .... Compressor drive gear to camshaft ........... .............. .......... Driven gear to air compressor crankshaft .......................

M 26x 1,5 M10 M18 x 1,5

......... Air compressor cylinder barrel to timing housing C onnec ting rod to cranks haft ............. .............. ............ ....... P ressure valve to intermed iate plate ................................. Intermediate plate to cylinder head .............. ............ ......... C ylinder head to cylinde r barrel ............... ............... ............ Inner bearing cage to timing housing ............................... Inner bearing retaining plate to cage ............................... S teering pump or cover to timing housing ...................... Blanking plugs air compressor cylinder head ................

M8 M8 M6 M8 M8 M8 M8 M10 M22 x 1,5 M 26x 1,5 M14 x 1,5 M 22x 1,5 M 16x 1,5 M8 M8

F itting — C oolant supply to cyli nder barrel .................... F itting — C oolant return to cylinde r head ....................... Coolant pipes to fittings ............ ............... ............... .............. Air compressor blanking plate (timing housing) ............ Air compressor blanking plate crankcase ........................

N.m 80 65 N.m without special tool 360 N.m with special tool 270 N.m 30 N.m 30 N.m 14 N.m 30 N.m 30 N.m 25 N.m 50 N.m 60 N.m 80 N,m 80 N.m 50 N.m 80 N.m 35 N.m 25 N.m 30 N.m

ALTERNATOR AND STARTER MOTOR Alternator suppo rt bracket to cylinder bl o c k ................... Support bracket to alternator ........... .............. ............ .......... Alternator adjusting bolt to sump ............. ............ ............ . Adjusting bolt clamp to alternator ............ .............. ........... A lternator pulley retaining n u t ............. ............ .............. ...... S tarter motor to timing hous ing

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

M14 M10 M10 M 12x 1,5 M 14x 1,5 M24 1,5 x M 12x 1,5

160 N.m50 N.m50 35 55 140 N.m 80

N.m

N.m N.m N.m

7/90

+m

Diesel Club COMPRE

SSOR

-

AD E 422, 423,424

Worksho p Manual

18-4

Introduction The ADE 420 S eries E ngines are fitted with a s ingle cylinder water cooled Westinghouse air compressor, mounted on the timing housing and driven by gears. The compressor provides air for the use in the vehicle braking system, and the operation of ancillary air devices.

REMOVING, DISMANTLING, ASSEMBLING, AND REPLACING AIR COMPRESSOR Dismantling 1. Unscrew coolant feed pipe from cylinder head (fig. 118).

Fig. 218 4. R emove timing case top cover. 5. R emove end cover from timing case. 6

. Unscrew and remove cylinder head, with suction valve (fig. 318).

Fig. 318

S ecti on :

18 - V ariou

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^a rrin gto n Di esel Hub

AD E 422, 423,424

Worksho p Manual

Se cti on :

18 - V ariou

COMPR ESS OR 7. Unscrew and remove cylinder barrel (fig. 418).

8

. R emove circlips and push out gudgeon pin rom f piston (fig. 518).

9. Remove connecting rod bearing bolts. L ift off bearing cap, with bearing shells, and pull out connecting rod (fig. 618).

10. Unscrew and remove power steering pump, from end of compressor, and take off drive plate (fig. 718).

Fig. 718

18-5

s

^13® &ar*Hngt°n Diesel Club

AD E 422, 423,424

Worksho p Manual

Se cti on :

COMPRESSOR — 186 11. Turn cran ksh aft toTD C , and insert locking tool, Part number 40201238 and bolt down (fig. 818).

Fig. 818 12. Unscrew and remove drive gear using s pecial tool, P art number 40201225. 13. Unscrew and remove cran ksha ft loc king tool. 14. Lever out crankshaft from bearings, so that rearbearing flange can be removed. Lift crankshaft out through top of housing (fig. 918).

15. R emove bearing retaining plate (fig. 1018). 16. Uns crew inner bearing cage bolts from timing case.

Fig. 1018 17. Using a suitable puller remove bearing and cage from timing case (fig. 1118).

Fig. 1118

*

18 - V ariou

s

^l3® &a r*H ngt°n Dies el Club

AD E 422, 423,424

Worksho p Manual

Se cti on :

18 - V ariou

COMPRESSOR — 187 18. Using a special puller Part number 40201160 and support, Part number 40200585, pull bearing from cage (fig.1218).

Fig. 1218 19. Knock or press bush from bearing flange using a suitable drift (fig. 1318). 20. Unscrew and remove valve plate from cylinder head. 21. R emove exhaust valve retaining bolts and remove valve.

Fig. 1318

Assembling 1. Check condition of exhaust valve and renew if necessary, the valve must not be scored or distorted (fig. 1418).

Fig. 1418 2. P lace exhaust valve on valve plate, curved surface facing upwards. Insert bolts and tighten to 14 N.m (fig. 1518). F it valve plate to cylinder head, and tighten bolts to 30 N.m.

Fig. 1518

s

^l3® &a r*H ngt°n Dies el Club

AD E 422, 423,424

Worksho p Manual

COMPRESSOR — 188 3. K nock bush into bearing flange with a suitable drift and ream to size 30,020 to 30,041 mm (fig. 1618).

Note: Ensure that oil drillings in bush and flange are in alignment.

4. Using a su itable drift knock bearing i nto front flange (fig. 1718).

5. Inse rt bearing flange into timing case and locate with 2 bolts (fig. 1818).

6. K nock in bearing flange with a su itable drift replace all bolts and tighten to 25 N.m (fig. 1918).

Fig. 1918

Se cti on :

18 - V ariou

s

^13® &ar*Hngt°n Diesel Club

AD E 422, 423,424

Worksho p Manual

Se cti on :

18 - V ariou

COMPRESSOR — 189 7. Insert bearing retaining plate, and bolts, tighten to50 N.m (fig. 1918). 8. Insert crankshaft, with balance weights facing upwards into crankcase and knock into bearing with a soft hammer.

Fig. 2018

9. Lubricate rear bearing bush, fit new Oring to flange and insert into crankcase ensuring that oil drillings are in allignment (arrowed) (fig. 2118).

Fig. 2118

10. Insert bolts into bearing flange and tighten progres sively (fig. 2218).

Fig. 2218

11. R emove bolts from flange. 12. Insert locking tool, and bolt down. 13. R eplace drive gear for compressor (fig. 2318).

s

^13® &ar*Hngt°n Diesel Club

AD E 422, 423,424

Worksho p Manual

COMPRESSOR — 1810 14. T ighten drive gear bolt to 270 N.m using s pec ial tool P art number 40201225 (fig. 2418). Note: The figure of 270 N.m is equal to 360 N.m without using the special tool.

Fig. 2418

15. R emove locking tool (fig. 2518). 16. Re place power steering pump and tighten bo lts to 60 N.m. 17. Insert connecting rod, beairings, bearing cap and bolts. Tighten bolts to 30 f'i.m.

Fig. 2518

18. P lace piston over con nec ting rod and insert gudgeon pin. 19. Inse rt cir clip s and lock gudgeon pin (fig. 2618).

F ig. 2618

20. Offset piston rings by 180° to each other. Using piston ring clamp Part number 40201212, compress rings to outer diameter of piston, allowing slight movement of clamp. 21. Insert piston into cylinder barrel, fitted with new gasket, and push in. Remove ring clamp (fig. 2718).

F ig. 2718

Se cti on :

18 - V ariou

s

80C fta rri n g to n Diesel C lub

AD E 422, 423,424

Worksho p Manual

Se cti on :

18 - V ariou

COMPRESSOR  22. B olt on cylinder barrel to timing case, and tighten to 25 N.m. 23. P lace inlet valve plate over locating pins on cylinder head (fig. 2818). 24. F it cylinder head gasket, with the word “TOP ” fac ing inlet valve, over locating pins on cylinder head. 25. Replace c ylinder head and tighten b olts to 30 N.m.

26. Re place and tighten b olts of timing case top cover to 25 N.m in sequence shown in (fig. 2918). 27. F it end cover of timing c ase and tighten bolts to 25 N.m.

28. Re connect air pressure feed pipe and induction feed hose to cylinder head (fig. 3018).

F ig. 3018 29. R econnect coo lant feed pipe to cylinde r head (fig. 3118).

Fig. 3118

1811

s

80C fta rri n g to n Diesel C lub

AD E 422, 423,424

Worksho p Manual

Se cti on :

18 - V ariou

SECTION 18-13 Flywheel

Flywheel 1 RING GEAR 2 WEAR RING 3 FLYWHEEL 4 FLYWHEEL BOLT

s

^a rrin g to n Diesel H ub

ADE 422, 423,424 Workshop Manual

Section:

18 - Va rious

FLYWHEEL — 1814

Flywheel Diameter for starter ring gear

432.645 432.490

Diameter for wear sleeve (Rear seal)

115.015 114.980

Maximum material removal from clutch surface

2.0

Max. radial runout measured on wear sleeve locating surface

0.05

Max. radial runout measured on starter ring gear locating surface

0.1

Max. radial runout on clutch locating flange

0.05

Max. lateral runout on clutch friction surface

0.1

TO RQU E S P E C IF IC AT IO N FLYWHEEL AND HOUSING Flywheel to crankshaft ............... ............ ............ .............. ............

M16 x 1,5

New dual hexagon bolts Max. stretch length Flywheel (timing) housing to cylinder block (see section 15) Top cover to timing housing (see section 15)

7/90

Bolt length

Initial torque 100 N.m Final torque 90°— 100° 200—220 N.m Initial torque 90°— 100° Final torque 74 mm — max. 75 mm 80 mm — max. 81 mm 85 mm — Max. 86 mm

80C ^a rri n g to t» Diesel Club

AD E 422, 423,424

Worksho p Manual

Secti

on :

18 - V ari ou s

FLYWHEEL — 1815

Starter Ring Gear

Ring gear inside diameter

432.155 432.000

Ring gear clearance

0.3350.645

Installation temperature for fitting starter ring gear

200230° C

Max. lateral runout of mounted starter ring gear

0.5

Ring gear width

(yellow colour)

18.6 18.4

*3 ® B arrin gto n Di esel Club

AD E 422, 423,424

FLYWHEEL — 1816 REMOVING AND REPLACING FLYWHEEL Removing 1. Loosen mounting bolts on flywheel. Unscrew two op posite bolts, screw in guide mandrels Part number 40200077 (fig. 3218).

2. R emove remaining flywhee l bolts, sc rew in F lywheel P os itioning H andles P art number 40201982 and slide off flywheel (fig. 3318). 3. Remove guide mandrels and flywheel positioning handles. Clean and check flywheel for damage.

Replacing 1. Screw guide mandrels into end of crankshaft and flywheel pos itioning handles into flywhe el (fig. 3418). 2. P lace flywheel on mandrels an d push in against en d of crankshaft .

Note: Ensure that locating dowel in crankshaft is aligned with hole in flywheel. 3. M eas ure length of flywhee l bolts (fig. 3518). Note: F lywheel bolts may s till be used if stretch does not exceed 75 mm.

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FLYWHEEL — 1817 4. L ightly oil threads o f flywheel bolts, screw in two bolts, remove guide mandrels and flywheel positioning handles. Replace remaining flywheel bolts. 5. Tighten flywheel bolts crosswise to 100 N.m and then to a further torque angle of 90° +10° (fig. 3618).

REMOVING AND REPLACING WEAR RING ON FLYWHEEL Removing and Replacing 1. Using a suitable puller and support pa d, pull wear ring from flywheel (fig. 3718).

2. Heat new wear ring to approximately 150°C. 3. Insert new wear ring into mandrel P art number 40200268 (rounder edge of outside diameter facing forward). P lace mandrel on flywheel and knock into position (fig. 3818).

REMOVING AND REPLACING SPIGOT BEARING Replacing spigot bearing 1. Using su itable drift, knock out spigo t bearing from flywheel (fig. 3918).

Fig. 3918

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1818

2. Turn over flywheel, insert new sp igot bearing and knock into flywheel (fig. 4018).

Fig. 4018

Note: The sp igot bearing can be removed and replaced with the flywhee l in pos ition using pu ller Part number 40200064. This requires removing the flywheel mounting bolts, and inserting both guide mandrels. Replace and tighten flywheel bolts to specification (fig. 4118).

F ig. 4118

MACHINING FLYWHEEL

Operation Note I: To determine if the flywheel can still be m ac hined, measure the thickness of the flywheel and compare the figures with spe cification. If the measurement is lower than the specified value, minus material removed, the flywheel can no longer be used, and must be replaced.

1. To machine, clamp flywheel into a suitable lathe, machine and surface grind face (fig. 4218). 2. Remove flywhee l and che ck once more for surface heat cracks. Note II: If the flywheel is still cracked after machining, and the cracks cannot be removed to retain specifications for flywheel thickness, renew flywheel.

3. Using compressed air, clean swarf from tapped holes for clutch pressure plate attachment. 4. R eplace flywheel, and tighten bolts to spe cification.

F ig. 4218

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FLYWHEE L  RE NEWAL OF STARTER RING GEAR

'

Operation 1. R emove flywheel (see page 1816). 2. P lace flywheel under a press. Support starter ri ng gear at several points, using supports of uniform height. 3. R apidly heat starter ring gear with a welding torch, and press flywheel from ring gear. 4. Check seating of ringgear on flywheel for score marks machine if necessary to specifications. Note I: Renew flywheel if score marks are excessive.

5. Heat new ring gear to specified temperature (see specifications), and press onto flywheel. Note II: When fitting new starter ring gear to flywheel, make sure that the ring gear is pressed on squarely. Ring gears on which teeth are damaged, can be turned around and used again. Note III: In some instances where no drillings are provided for the bolts holding the clutch pressure plate, it will be necessary to drill and tap the ring gear M10x15mm

(fig. 4318). 6. When cooled, check flywheel and ring gearfor runout. 7. R eplace flywheel, (see page 1816).

Fig. 4318

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SECTION 18-21 Turbocharger

Turbocharger 1 2 3 4 5 6 7 8 9 10 11 12 13 14

Bearing housing C irclip Bearing Oring Turbine wheel and shaft P iston type seal rings H eat shield T hrust washer Spacer B earing (Thrust) Seal carrier/Thrust washer Oil defle ctor Rivet Data plate

15 16 17 18 19 20

End plate Allan cap screw C ompressor wheel S haft nut C ompressor housing S pringwasher and compres sor side clamping segment

21 Bolt 22 T urbine housing 23 Nut & bolt 24 S pringwashe r and turbine side clamping segment

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TURB OC HA RGE R — 1 8 -2 2

9

T urbo cha rger and M an ifold 1 2 3 4 5 6 7 8 9 10 11 12 13

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Turbocharger Turbocharger Nut Air intake manifold Air intake manifold Threaded insert Spring washer Gasket Bolt Bolt Plug Seal Plug

14 Air intake pipe 15 Hose 16 Hose 17 Bracket 18 Bolt 19 Adapter 20 Seal 21 Air transverse pipe 22 Gasket 23 Bolt 24 Seal 25 PL ug 26 Shield 27 Bolt

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TU R BO C HA R G E R — 1823

Tu rbocharge r C rosssec tion

TO R QU E S P E C IF IC AT IO N TU R BO C HA R G E R Oil return manifold to turbocha rger. .................................. Secu ring nut for oil return fitting to timing h ousing (side) Oil return tube fitting to timing housing (top) ................ .............. ............ ... Inlet manifold to cylinder heads ............ T urbocharge r to exhaust manifold .............. .............. ......... Oil supply pipe to turbocharger ............... ............ ............ ... Oil supply pipe to cylinder bl o c k ............ ............ .............. .. Heat shield to timing housing (422T)................................. Heat shield to oil return manifold (424T) ......................... C onnec ting manifold to inlet manifold LHRH ............... Air transverse pipe............ .............. ............. ............ ............. .....

M8 M26x 1 ,5 M 26x 1.5 M8 M10 M8 M 14x 1,5 M16 M8 M10 M8

25 N.m 30 N.m 120 N.m N.m 25 50 25 25 150 25 N.m50 N.m 25

N.m N.m N.m N.m N.m

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Introduction The G arrett/AiR ese arch T urbocharger for internal com bustion engine application comprises of a gas turbine and radial compressor, which utilize a common shaft. The turbine and compressor wheels are mounted at opposite ends of the shaft, which is enclosed and supported by the centre housing. The turbine and compressor wheels are enclosed by cas t housings attached to the centre housing. After the engine is started, the flow of exhaused gases from the engine pass throught the turbine housing and cause the shaft assembly to rotate. The compressor wheel mounted at the opposite end of the shaft draws ambient air into the compressor housing, compresses the air and delivers it to the engine. During operation, the turbocharger responds to the engine load demands by reacting to the flow of exhaust gasses. As the power of the engine increases, the flow of the exhaust also increases and the speed and output of the rotating assembly increases proportionately.

REMOVING AND REPLACING TURBOC HAR GE R Removing 1. Unscrew exhaust pipe from turboc harge r manifold. 2. Unscrew air pipe from exhaust brake cylinder. 3. Remove oil feed and return pipes ot turbocharger, (fig. 4418).

4. Unscrew air intake hose clips (fig. 4 518).

Fig. 4518

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TURBOCHAR GE R  5. Remove manifold between turboc harge r and 'cooler (fig. 4618). 6.

Unscrew turbocharger from exhaust manifold and remove.

Replacing Note: P rior to replacing turbocharger, the intake manifold, and manifold flange ahead of the compressor, exhaust manifold, and exhaust pipe, as well as oil feed and return

pipes, must be inspected thoroug hly for foreign particles, dirt and damage. Blanking plugs on openings of turbocharger should be removed shortly before replacement. F ill bearing housing with clean engine oil through oil inlet, before connecting oil feed pipes. Turn rotating parts by hand to give bearings a coating of oil. 1. F it turbocharger with new gasketto exhaust manifold, and tighten bolts to 50 N.m. 2. R eplace and tighten manifold between turbocharge r and air cooler (fig. 4718).

3. C onnec t oil feed and return pipes to turbocharger. 4. R eplace air inlet hose clamps and tighten (fig. 4818). 5. R eplace air inlet pipe to exhau st brake. 6

. Attach exhaus t pipe to man ifold and tighten bo lts to specification.

Fig. 4818

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18-26

TURBOCHARGER TROUBL

ESHOOTI NG

C ondition

P ossible Cause

C orrection

Unusual exhaust gas density and power loss.

Insufficient air and charge pressure to low.

Check flange and hose connections of turbocharger air pipe for leaks.

Dirt on inside of compressor housing.

Remove and clean compressor housing.

C logged air cleaner (excessiv e vacuum ahead of compressor, also oil leak on compressor side.)

Clean air cleaner or replace filter cartridge. Check intake. Check pipe behind turbocharger for leaks.

Exhaust pipe behind turbocharger, or silencer dirty or damaged.

Clean or repair. Check opening of engine brake valve.

Leaks at connections and flanges of air and exhaust pipes.

Check flange and hose connections, replacing gaskets if necessary.

R otor scraping due to excessive bearing play.

Remove pipes and check housing on turbine and compressor sides for signs of scraping.

Unusual noise (e.g. whistle)

Repair or replace turbocharger in case of wear.

C hecking Turbocha rger in vehicle Disc onnec t air intake manifold. Turn rot or, chec king for easy and uniform running. If nec essary turn back and forth sever al times until rotor is freed of oil carbon deposits. Th e turboc harge r rotor has gyros cop ic stab ilization , and runs in fixed bearings. To check, move rotor.in and ou t. If there is no contact on the turbine or charger sides, this means that the end play is correct. Move and turn the rotor up and down, if no scraping occurs, the side play is also correct.

T urbocha rger o il leaks The bearing hous ing on all types o f turboc harge rs used on ADE engines are fitted with oil controlling piston type rings, to provide a seal between the oil and the air/exhaust gas. The function o f these s eals is based on the pressure built up in the compressor housing. However there could be a vacuum at fast idle speed of while coasting, which would favour oil leakage and coating of the inlet ports with oil. The amount of oil lost in this way is extremely low and has no, measurable influence on the engines oil consumption.

F itting a R econditioned T urbocharger P rior to fitting the turbocharger, the inlet and flanged manifold ahead of the compressor, the exhaust manifold and the exhaust pipe, as well as the oil feed and return pipes, must be inspected very thoroughly for dirt and damage. P lugs on the openings of the turbocharger should be removed only shortly before fitting. F ill the bearing housing w ith clean engine o il through the oil inlet port before connecting the oil feed pipe. In doing so, turn the rotating parts by hand to give the bearings a coat of oil.

If oil covered inlet ports are found when servicing, there is no reason to remove the turbocharger as long as an inspection of the turbocharger did not show defects. Another cause for oil leaks could be a damaged (deformed) or clogged oil return pipe. The reduced cross sec tion size of the pipe would lead to an increase in flow resistance, cau sing the oil level in the turbocharger to rise and oil to leak past the seals on the turbine and compresso r sides. In this case clean or replace the oil return pipe. '

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TU RB OC HAR GE R — 1827 CHECKING TURBOCHARGER Measuring Shaft End Play 1. C lamp turbocharger in a vice fitted with soft jaws (turbine side facing up). 2. F it dial gauge in holder. 3. P lace dial gauge measuring tip on sh aft end of turbine wheel (fig. 4918). 4. P ush down turbine sha ft and set dial gauge to “0” . 5. P ush turbine shaft up against dial gauge and readend play. Maximum permitted end play =0,16 mm.

Measuring Side Play Note: Side play is measured only on turbine side.

1. P ush turbine wheel o t one side, measure gap betw een turbine wheel and housing with a feeler gauge, note measurement (fig. 5018). 2. P ush turbine wheel in oppo site direction, measure gap at the same point with a feeler gauge, note measurement. 3. The differenc e between the two measurements is the clearance = 0,45 mm. Note: Measure at least two different points.

Fabricated Tool

Fig. 5118

A Knurled surface B Ada pted t o available rotor

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TU RBOCHAR GE R — 1828 DISMANTLING AND ASSEMBLING TURBO CHAR GE R Dismantling Note: Clamp is selfmade to drawing on page 1827.

1. Mark pos ition of turbine housing in relation to bearing housing. 2. Unlock locking plates on clampi ng segments of turbine housing (fig. 5218).

F ig. 5218

3. Unscrew bolts from turbine hous ing and remove with clamping segments and lock plates. 4. Using a soft faced hammer knockturbine housing and bearing housing apart (fig. 5318). Note: Ensure that blades of turbocharger are not damaged when removing housing.

Fig. 5318

5. Mark position of bearing housing in relation to com pressor back plate and compressor housing (fig. 5418).

Fig. 5418

6

. U nscrew compress or housing from back plate ( fig. 5518).

7. Loos en and remove comp ress or housing from bearing housing, with light knocks from a soft faced hammer. Note: Ensure that blades of compressor are not damaged when removing compressor housing.

Fig. 5518

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TURB OC HAR GE R  8. Insert bearing housing into clamp (self made), and unscrew compressor shaft nut (fig. 5618). Note: When unscrewing shaft nut, do not damage the shaft by twisting. Always use a Tsocket spanner to unscrew shaft nut, to avoid bending shaft.

9. Heat comp ress or wheel with suitable hot air blower (fig. 5718).

10. P ress shaft from compressor wheel (fig. 5818). Note: The heat shield should be centred to avoid damage to piston ring seals and shielding.

11. Remove bearing housing and heat shield from shaft. 12. Unscrew compressor back plate and remove with seal and Oring (fig. 5918).

Fig. 5918

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TURBOCH AR GE R — 1830 13. Remove oil deflector (4), spacer (3), thrust bearing (2 ), and thrust washer (1) (fig. 6018).

14. Remove compressor bearing from housing (fig. 6118).

15. Remove circ lips and turbine bearings from bearing housing (fig. 6218).

ASSEMBLING Note: Clean and ing and blades cracks, signs of piston ring type

check all parts for damage. Check housof turbine and compressor wheels for foreign particles and scraping. Check seals and grooves for wear.

1. Check turbocharger rotor shaft for run out. P lace shaft on two Vblocks at height of bearings and measure runout 20 mm from end of rotor shaft, using a dial gauge. Maximum permissible runout = 0,007 mm, (fig. 6318).

Fig. 6318

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TUR BOC HAR GE R  2. Insert circlip in bearing housing, lubric ate turbine end bearing with engine oil, and insert with 2nd circlip (fig. 6418). Note: Insert circlips so that the rounded side faces bearing.

3. Turn bearing housing around and insert compressor end bearing with circlips.

4. Insert seal rings on to shaft, with gaps set at180° in relation to each other (fig. 6518).

5. P lace heat shie ld over seal rings on rotor shaft (fig. 6618).

6. F it bearing housing over seal rings, so that the seal ring gap is at 90°, in relation to the oil inlet and outlet flanges (fig. 6718). Note: The heat shie ld should s till turn eas ily after fitting the bearing housing.

F ig. 6718

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TU R BOCHAR GE R — 1832 7. Insert thrust washer (1) and spacer (3). Fit thrust bearing (2) with oil groove facing bearing housing, and dowel pin holes in alignment with dowel pins in bearing housing. F it oil deflector (4) (fig. 6818).

F ig. 6818

8. Lu bricate Oring with brake cylinder grease, and insert into compressor end plate (fig. 6918). 9. Insert seal rings onto seal carrier with gaps set at 1 80° in relation to each other. 10. F it seal carrier with seal rings into compres so r end plate, so that the piston ring gap is at 90°, in relation to the oil inlet and outlet flanges.

F ig. 6918

11. C oat se aling surface between bearing housing and compressor end plate, with a suitable sealing compound. 12. F it comp ress or end plate, lining up marks on bearing housing. Coat bolts with Loctite, insert and tighten to 8 N.m (fig. 7018).

F ig. 7018

13. F it Oring to compressor end plate (fig. 7118).

F ig. 7118

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TUR BOC HARG ER — 1833 14. Heat compressor wheel to a maximum of 130°, and fit onto rotor shaft (fig. 7218).

15. C oat rotor shaft nut with Loctite, and fit to shaft, tighten nut to 12 N.m (fig. 7318).

16. F it compressor housing, lining up marks on compressor end plate. Fit clamping segments, insert bolts, and tighten to 7 N.m (fig. 7418).

17. Attach turbine housing, lining up with marks on bearing housing. F it clamping segments, and lockplates. Insert bolts with high temperature grease, and tighten crosswise to 20 N.m. 18. Lock mounting bolts (fig. 7518). 19. C heck turbocharger shaft for free running. Note: F ill bearing housing through oil inle t port with engine oil prior to operating turbocharger.

Fig. 7518

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Introduction Depending on application the ADE 420 Series Engines are fitted with an exhaust brake consisting of a butterfly valve, which pivots on a spindle within the exhaust manifolds. The butterfly valves are s ituated at the flywheel end of each manifold. The butterfly valves are actuated by a pneumatically operated lever, which is secured to the butterfly valve spindles, where the spindles protrudes through the housing. When the footoperated exhaust brake valve (located on the floor of the cab, drivers side) is pressed, compressed air flows past the valve and enters an air operated cylinder. A piston, inside the cylinder and attached to the spind le levers, pushes the levers towards the rear of the vehicle and thus closes the butterfly valves. At the same time, the fuel supply to the injectors is cut off (ie the speed control lever moves to the stop position). The back pressure build up in the exhaust manifold exerts a braking effect via the transmission, to the wheels of the vehicle.

CHECKING EXHAUST BRAKE Checking exhaust brake adjustment 1. Unscrew and remove exhaust pipe from manifold. 2. Check to see if the engine brake retardervalve is wide open, and marks on engine brake shaft, and valve are in alignment (fig. 7618).

3. Operate engine brake andcheck to see if retarder flap is closed completely (fig. 7718).

REMOVING AND REPLACING EXHAUST BRAKE VALVE AND SHAFT Removing 1. Unscrew and remove exhaust pipe from manifold. 2. D isconn ect engine brake cylinder. 3. Unscrew and remove lever operating brake valve. 4. Remove spacer and bracket (fig. 7818).

Fig. 7818

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EXHAUST BRAKE — 1835 5. Knock out engine brake shaft, and remove valve (fig. 7918).

Fig. 7918 6. Gently knock out shaft bushes from exhaust manifold, (fig. 8018).

Fig. 8018

Replacing 1. Knock new shaft bushes into exhaust manifold, so that the engine brake valve has an end play of 0,2 to 0,5 mm (fig. 8118).

Fig. 8118

2. Insert engine brake shaft hrough t valve, so that marking on shaft is in alignment with engine brake valve, (fig. 8218).

Fig. 8218

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EXHAUST BRAKE — 1836 3. F it stop bracket over valve operating shaft and insert spacer. 4. F it brake operating lever onto shaft, so that with the valve fully open the brake cylinder can be fitted without tension (fig. 8318).

Fig. 8318

Note: Fine adjustment can be made on the brake cylinder. On turbocharged engines the stop of the valve operating lever must rest against the bracket, when the engine brake valve is fully open (fig. 8418).

5. T ighten clamp bolt of engine brake cylinde r so that the shaft has an end play of 0,2 to 0,5 mm. 6. F it engine brake cylinder. 7. Operate engine brake and check to see if the engine brake valve is fully closed. 8. Replace exhaust pipe, fitted wit h a new gasket, and securely tighten nuts.

REMOVING AND REPLACING STARTER MOTOR Removing 1. Disconnect battery. 2. D isco nnec t cables to starter motor. 3. U nscrew and remove mounting nuts (fig. 8518). 4. Remove starter motor from below.

Replacing 1. F it starter motor onto studs from below (fig. 8618). 2. R eplace nuts and tighten to 80 N.m. 3. C onnect cables to starter motor. 4. C onnec t battery.

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SECTION 18-37 A l t er n at o r an d St ar t er M o t o r

SECTIONAL VIEW OF THE K 1 CLAWPOLE ALTERNATOR

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ALTERNATOR AND STARTER MOTOR — 1838 ALTERNATOR P recautions The diodes in the alternator function as oneway valves and the transistors in the regulator/control box operate as fast switches. Both are accurate and sensitive. They do not wear out and seldom require adjustment, but because they are sensitive to voltage changes and high temperature, the following precautions are vital to prevent them from being destroyed. (a) DO NOT disconnect the battery while the engine is running. This will cause a voltage surge in the alternator charging system that will immediately ruin the diodes or transistors. (b) DO NOT disc onnec t lead without first stopping the engine and turning all electrical switches to the off position. (c) DO NOT cause a short circuit by connecting leads to incorrect terminals. Always identify a lead to its correct terminal. A short circuit or wrong connection giving reverse polarity will immediately and permanently ruin transistors or diodes. (d) DO NOT connect a battery into the system without checking for correct polarity and voltage. (e) DO NOT “flash” connections to check for currentflow. No matter how brief the contact the transistors may be ruined.

Maintenance The alternator charging system will normally require very little attention. It should be kept free from buildup of dirt, and a check made if it fails to keep the battery charged.

(a) R egularly inspect the driving belts for wear and correct tension. It is important to ensure that all belts on a multiple belt drive have equal tension and are each carrying their share of the load. Slack belts will wear rapidly and cause slip which will not drive the alternator at the required speed. Drive belts which are too tight impose severe side thrust on the alternator bearings and shorten their life. Periodically ensure that he t alternator is correctly aligned to the drive. (b) Do not replace faulty belts individually in a multibelt system. A complete matched set of drive belts must always be used. (c) Keep the alternator clean with a cloth moistenedin a suitable c leaning fluid. Ensure that ventilation slots and air spaces are clear and unobstructed. (d) Remove any dirt accumulated on the regulator/control box housing, and ensure that cooling air can pass freely over the casing.

Testing the Alternator in P osition F irst check the driving belt for condition and tension. The nominal hot outputs 6 000 follows:— 14V 28V 28V

r/min (alternator speed) are as — — —

35A 28A 55A

These figures may be exceeded slightly when the alternator is running cold. A dust proofed alternator can be fitted as an option, depending on application.

Trouble S hooting If a malfunction should develop in the current generating system, it must be kept in mind that trouble sources may exist in the battery, cables or other locations besides the alternator or regulator. The most common fault symptoms are listed in the chart below with probable causes and appropriate corrective measures:

Cause

Correction

Battery is dead or insufficiently charged: 1. Open circu it or con tact resistance in charging circuit

1. Remove open circu it or contact resistance

2. Defective battery

2. R eplace battery

3. Defective alternator

■ 3. Have alternator repaired in authorized workshop

4. Defective regulator

4. Replace regulator

5. VBelt too loose

5. Tighten VBelt

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ALTE RNATO R A ND STARTER MOTOR — 1839 Charge indicator lamp does not burn with engine stopped and ignition on: 1. Ind icator bulb is burned out

1. R eplace with new bulb

2. Dead battery

2. R emove battery for charging

3. Defective battery

3. R eplace battery

4. Loose or damaged cables

4. R eplace or tighten cables

5. Defective regulator

5. R eplace regulator

6. S horted positive diode in the alternator

6. Have alternator repaired in authorized workshop

7. Worn carbon brushes

7. R eplace brushes

8. Oxide layer on sliprings, or broken wire in rotor winding

8. Have alternator repaired

Charge indicator lamp continues to burn brightly during higher engine speeds: 1. C able D + /61 is shorted to ground

1. R epair or replace cable

2. D efective regulator

2. Replace regulator

3. Overvoltage protec tion device defective

3. R eplace overvoltage protec tion device

4. Defective rectifier, dirty sliprings, short in cable “DF " or in rotor winding

4. Have alternator repaired in authorized workshop.

Charge indicator lamp burns brightly with engine stopped, but on dims or glimmers with engine running: 1. P oor con nec tions (contact) resistance) in the charging circuit or in the cable to the charge indicator lamp

1. Remove con tact resistance

2. Defective regulator

2. R eplace regulator

3. Defective alternator

3. Have alternator repaired

Charge indicator lamp flickers: 1.

1.

R eplace regulator

C ontact regulator may be incorrectly adjusted or regulating resistor is burned out

STARTER MOTOR General S liding G ear S tarter Motor Type KB This starter motor, designed for large internal combustion engines, operates in two stages in order to protect the pinion and ring gear. The armature is fixedmounted in the driveend bearing plate and in the commutator end shield; the armature shaft is hollow and is designed to serve as the housing for a multidisc clutch on its drive end. This clutch housing is sealed on the end face by a cover on which a rolling or plain bearing is mounted to support the armature in the driveend bearing plate. On the commutator end the armature is supported in a plain bearing. A solenoid switch for the pinion and a control relay for the two switching stages are flanged to the commutator end shield. In this type of starter motor the pinion is shifted forward (sliding gear) by the solenoid switch acting through an engagement rod leading through the hollow armature shaft. The resistance, or opposing, winding located in the solenoid switch of the starter motor serves to adjust the starter motor torque when meshing. In order to prevent

oil, dirt, or dust penetrating into the inside of the starter motor, a radial loptype oil seal is fitted on the drive end bearing plate. The commutator end shield and the solenoid switch are enclosed by an end cover or a cover band. The drive spindle, on the spiral splines of which the multidisc clutch is mounted, is supported in a roller bearing in the driveend bearing plate and in a needle roller bearing in the armature shaft. The pinion is joined in a positive mechanical connection with the spindle by means of a feather key. The solen oid sw itch is de signed to drive the pinion forward in two stages. For this purpose it is fitted with a locking device, with a trigger, a stop plate, and a release lever. Th is type of starter motor is also fitted with a multidisc clutch between the armature and pinion, but in this case the clutch does not have an initial meshing stage.

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ALTE RNATOR AND STARTER MOTOR 

Worksho p Manual

1840

Maintenance Bas ic P oints When wo rk is perfor med on the electrical pa rts of the installed starter motor the danger of shortcircuits exists. F or this reason it is strongly recommended that be fore such work is started the ground cable be disconnected from the battery. Do not lay tools on the battery!

Brushes In those cases where the brushes are easily accessible, they should be checked from time to time to see that they are in good c on dition. A fter removal of the end cover or the cover band, the best procedure is to use a hook to lift the spring which presses the carbon brush against the com mutator (do not ben d the spring to the side when doing this, and do no t lift the spring farther than neces sary); a check can then be made to see if the brush can move freely in its holder. The brushes and the brush holders must be free from dust, oil, and grease. If these parts are dirty or if they tend to stick, they should be cleaned with a clean cloth (because the threads c atch eas ily, do not use co tton waste or waste rag). Do not work on the bright rubbing surfaces of the brushes with emery paper, file, or knife. Clean the brush holder out well with dry compressed air. If a brush is broken, if the soldered connection has come open, or if the brush has become so worn that a danger exists that the spring or the shunt (pigtail) leading to the brush can contact the brush holder, the brush must be replaced. When installing the brush be sure that the spring is seated correctly on it. When the engine is given a major overhaul, the brushes should be replaced in any event. Every time the brushes are replaced the commutator should be turned down.

C ommut ator T he c om mu tator sh ould have a s mo oth unifo rm surfac e and must be free from oil and grease. Dirty commutators should be cleaned with a clean cloth (not with cotton waste). C omm utators that hav e become sc ored and out of round through use must be roughturned, the mica insulation undercut, and then precision turned in a suitably equipped workshop. In no case should o nly emery paper or a file be used to work on a commutator.

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ALTERNATOR AND STARTER MOTOR — 1841 REMOVING AND REPLACING ALTERNATOR Removing 1. D isconn ect battery conne ctions. 2. Dis connec t elec trical connec tions to alternator. 3. Unsc rew lock nut of Vbelt adjuster and release tension (fig. 8718).

4. Unsc rew and remove alternator mounting bolts and lift off alternator (fig. 8818).

Replacing 1. F it alternator to mounting bracke ts and tigthen bo lts to 50 N.m (fig. 8918). 2. Insert bolt in Vbelt adjuster, on alternator.

3. F it Vbelt and tension, using s pecial too l (fig. 9018). Should this tool not be available, the Vbelt tension can be adjusted as follows : Without using undue pressure it should be possible to depress the Vbelt approximately 10 mm, with the thumb applying pressure at a point midway between the water pump and alternator pulley. 4. Tighten Vbelt tens ione r lock nut.

Fig. 9018

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RE PLACING V BELT 

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Worksho p Manual

1842

1. Uns crew lock nut of Vbelt adjuster, and release tension (fig. 9118). 2. L ift Vbelt from pulleys.

F ig. 9118

3. F it new Vbelt and tighten.

Note: See fig. 8918 for mounting bolt torque tensions.

4. Check Vbelt for correct tension using special tool (fig. 9218). Should this tool not be available, the Vbelt tension can be adjusted as follows: W ithout using undue pressure it should be possible to depress the V belt approximately 10 mm, with the thumb applying pressure at a point midway between the water pump and alternator pulley.

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SE CT ION 18-43

_________________

Power Steering Pump Introduction The ADE 420 Series E ngines are fitted with two types of Rotary, Power Steering Pumps, both of which operates as follows: When the drive shaft and its rotor are urned, t the vanes are guided in slots and being radially mobile are pressed against the guide path of the cam ring by the action of centrifugal force and oil pressure. Two successive vanes are classed as a cell (a total of 10), which are laterally restricted by the pressure plates. Each cell delivers the maximum effective cellvolume twice per revolution. The suction and pressure chambers are arranged so that the hydraulic and radial forces acting on the rotor, will neutralize each other. The coverend front plate, and the drive end front plate are provided with 4 grooves so that the pressurized oil reaches the internal face of the pump vanes, which will then be supported by the centrifugal force. From the pressure chamber the oil travels thr ough holes to the flow restricting valve, and by the way of a throttle restriction to the pressure line. The reduced pressure behind the throttle restrictionis transmitted via holes to the springloaded end of the flow restricting piston, and therefore to the relief valve. Increasing speed or pump delivery will produce a growing pressure drop behind the throttle restricter and also against the spring end of the valve piston. As soon as the hydraulic power (pressure differential times piston area) exceeds the spring force, the piston will move towards the spring, and the oil delivered in excess will flow through the now exposed ejection hole into the suction duct of the pump. As a result, an almost constant oil flow for the steering gear is provided throughout the entire speed range.

DISMANTLING Removal of Rotor and Cam Ring ZF High P ressure Vane P ump 7673 1. Loosen nut on drive shaft and pull off Vbelt pulley. 2. P ull out spring clip from groovein pump housing (fig. 9318).

Fig. 9318

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Worksho p Manual

POWER STEERING PUMP — 18-44 3.

Remove cover, compre ss ion spring and face plate from housing (fig. 9418).

4.

T ilt pump body and remove cam ring and rotor (fig. 9518).

R emoval of Drive S haft 5.

R emove circlip (fig. 9618).

6. K nock drive shaft from hous ing (fig 9718).

Fig. 9718

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POWER STEERING PUMP — 1845 7. Using a hide faced hammer knock drive end face plate from housing. ' 8. remove volume c ontrol valve. 9. Using a suitable punch knock needle bearing and shaft seal from housing (see fig. 9818). 10. R emove Orings from housing, removefitted pin. Take Oring from drive end face plate.

11. The bearing can be pressed from drive sha ft after removing circlip (fig. 9918).

F ig. 9918

R emoval of F low and P ressure R es triction Valve Z.F. High P ressure Vane P ump 7637 1. R emove blanking plug from housing (fig. 10018). 2. Remove compression spring and valve completely from housing bore.

Dismantle, Inspection and Assembly of Flow and P ressure R es triction Valve 1. C heck pressure an d flow res triction valve for score marks and wear. The flow control piston should not bind in housing bore. Check tolerance number on housing (on face end of valve bore) and on piston (Item 1) (fig. 10118).

F ig. 10118

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^a rrin gto n Di esel Hub POWER ST

EERI NG PUMP -

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1 8-4 6

2. Uns crew valve seat screw from press ure restriction valve (do not clamp in vice). Ensure that none of the washers, the ball, the spring guide and t he co mpression springs are lost. The thickness of the washer is critical for the response range of the pressure relief valve. To prevent the possibility of damage, the washers available prior to dismantling must be replaced (fig. 10218). 3. Clean control valve and valve screw and blow out with compressed air. Reinsert compression spring, guide pin and ball. Scre w valve seat scre w into control piston together with previously installed washers and tighten.

1 VALVE PISTON 2 COMPRESSION SPRING PRESSURE RELIEF VALVE 3 SPRING GUIDE PIN 4 VALVE BALL 5 ADJUSTING WASHERS 6 VALVE SEAT SCREW 7 COMPRESSION SPRING VOLUME CONTROL VALVE 8

Installation Valve

of Flow and Pressure R

estriction

4. F irst insert assembled valve piston with thin shaft into bore. Ch eck fo r corre ct toleranc e (fig. 10318).

5. S lide compres sion s pring on valve piston and insert blanking plug into thread hole placing sealing washer underneath (fig. 10418).

BLANKING SCREW WITH SEALING RING

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Worksho p Manual

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POWER STEER ING PUMP  P reassembly of P ump Ho using

,

Note: P rior to asse mbly, clean all parts, moisten s lightly with ATF oil and replace all sealing rings and Orings. 1. Using a su itable mandrel, press needle bearing into housing (fig. 10518).....

... until face end of needle bearing is 37,0 to 37,2 mm from face end of housing (fig. 10618). Note: The needle bearing is installed only in pumps with Vbelt drive.

2. P ress shaft seal int o housing with a mand rel. Install seal with bearing grease between sealing lips (fig. 10718). 3. Using a socket spanner, screw blanking plug into pump housing and tighten. 4. P lace Oring into bottom groove in housing.

5. Insert fitted pin into hole provided (fig. 10818).

F ig. 10818

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1847

80C fta rri n g to n Diesel C lub

AD E 422, 423,424

POWER STEERING PUMP — 1848 Assembly and Installation of Drive Shaft 6. P ress ball bearing on drive sh aft and replace circlip. F it key (fig. 1091 8).

7. Insert preassembled drive shaft into housing until ball bearing rests against housing flange (fig. 11018).

8.

Inse rt cir clip loca ting ball bearing (fig. 11118).

R eplacement of Drive End Face P late 9. 10.

Inse rt Oring into groove in neck of face plate. S lide face plate on pin as shown and press with neck into housing (fig. 11218).

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POWER STEERING PUMP — 1849 Installation of Cam Ring and Rotor 11. Insert Oring (1) into groove in housing (fig. 11318).

12. Insert cam ring. The smaller hole holds the hollow pin and the two larger ones are above the ducts of the face plate. The cast, half arrow points towards driving direction of pump (see fig. 11418).

Fig. 11418

13. F it rotor with smooth bore on drive shaft (fig. 11518).

14. Insert the ten vanes with the roundedoff outer surfaces facing the cam ring, into slots of rotor (fig. 11618).

Fig. 11618

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POWER STEERING PUMP — 1850 R eplacement of E nd Face P late and Cover 15. F it face p late on cam ring as shown. The pin is in one of the two smaller holes (fig. 11718).

16. Insert Oring (1) (fig. 11818).

17. I nse rt comp ress ion spring into bore of face plate. P osition cover with recess inwards and push into hous ing u ntil the circ lip can be inserted (fig. 11918). 18. Inse rt flow and press ure restriction valve.

Vickers High Pressure Oil Pump VT27 Dismantl ingR emoval of R otor and Cam R ing 1. Remove screws on pump hous ing to which housing cover is connected, and remove pump housing. 2. Remove compre ss ion spring from thru st plate. Mark thrust plate, cam ring and housing cover together (refer to arrow) (fig. 12018).

1 2

O-RING THRUST

3

COMPRESSION

PLATE SPRING

4

CAM RING

5 6

O-RING HOUSING

COVER

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POWER STEERING PUMP — 1851 3. R emoving thrus t plate from fitted pins and take off cam ring (fig. 12118). •

F ig. 12118 2

THRUST

4

CAM RING

PLATE

6 HOUSING

COVER

7 MARKING

LINE

4. Remove rotor with pump vanes from driveshaft spline (fig. 12218).

F ig. 12218 4

C A MR I N G

6

HOUSING COVER

7

M A RK ING LINE

3

FITTED PIN

9

R O TO R

10

VANES

OIL INFLOW FROM SUPPLY

a.

CONTAINER b.

HYDRAULIC OIL OUTFLOW ON CAM RING

c.

I N TA K EB O R E S

5. Remove Oring from ho using cove r (Item 1 & 5) (fig 12318). 6. Remove volume control valve. 7. C lean all parts thorou ghly and rinse.

1

O-RING

2

THRUST

3

COMPRESSION

PLATE SPRING

4

CAM RING

5

O-RING

6

HOUSING

COVER

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Worksho p Manual

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POWER STEERING PUMP — 1852 R emoval and D isma ntling of Volume C ontrol and P ressure R elief Valve 1. K nock locking pin from pump housing. 2. Remove blanking cover of volume control valve, and compression spring from pump housing (fig. 12418).

Note: C aution! The compres sion spring may push off the blanking cover and the colume control valve after removing the loc king pin. If the blanking cover remains in housing, loosen by applying light hammer blows against cover. Be sure not to damage the volume control valve.

1

BLANKING

2

LOCKING

3

O-RING

COVER PIN

4

VOLUME CONTROL VALVE

5

COMPRESSION SPRINGS

6

PUMP HOUSING

3. C lamp volume control valve at its unground end in a vice and unscrew valve screw of pressure relief valve. Ensure that no adjusting screws are lost. Remove valve cone and compression spring from volume co ntrol valve (fig. 12518). 4. P rior to replacement, check ground surface of volume control valve and bore in pump housing for wear and damage. If the surfaces are showing score marks, replace complete oil pump. Never replace volume control valve only.

Special Tool S elfmade (fig. 12618).

A

INSTALLA TION TOOL

B

INSTALLAT ION TOOL

C

INSTALLA TION SLEEVE

F ig. 12518 •

1

BLA NKIN G COV ER WIT H O-RING

2

VOLUME

3

COMPRESSION SPRING FOR

4

VALVE CON E

-* ODj

CONTR OL VALVE

5

ADJUSTING

6

VALVE SCREW

7

COMPRESSION SPRING

PRES SURE RELIEF

VAL VE

WASHER FOR VOLUME

CONTROL V

ALV E

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POWER STEERING PUMP 

1853

R eplaceme nt of Drive Sha ft and Se aling Ring

w /M m t 1. P ress drive from housing cover, paying attention to shell halves (Item 10) (fig. 12718).

14-------------- R

2. L ift oil seal from hous ing cover using a screw driver.

-

13

F ig

12

tl

10

9

8

i — ty

7

6

\\/

8

12718

1 ORING PUMP HOUSING 3 THRUST PLATE 4 OIL GUIDE PLATE 5 COMPRESSION SPRING 6 CAM RING 7 ROTOR WITH PUMP VANE 2

3. P lace both shell halveson drive shaft, then press drive shaft into housing cover (fig. 12818). Note: The shell halves determine the end play of the drive shaft, which is maximum 0,7 mm for new high pressure oil pumps and should not be more than 1 mm for used pumps. Replace high pressure oil pump, if end play is higher.

Fig. 12818 10

SHELL

11

DRIVE SH AF T

HALF

14

HOUSING

COVER

4. P ress bearing bush with installation tool into housing cover (fig. 12918).

Fig. 12018 12

BEARING

BUSH

14

HOUSING

COVER

B

INSTALLATION

TOOL

8 9 10 11 12 13 14

ORING BEARING BUSH SHELL HALF DRIVE SHAFT BEARING BUSH OIL SEAL HOUSING COVER

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POWER STEERING PUMP — 1854 5. R eplace assembly sleeve on drive shaft and press oil seal into housing cover with installation tool (fig. 13018).

13

OIL SEA L

14

HOUSING

A

INSTALLATION

TOOL

COVER

Installation of Rotor and Cam Ring 1. Mois ten all parts with ATF oil. 2. Install volume control valve. 3. P lace rotor on drive shaft so that the countersunk end of the splined bore faces housing cover. 4. P lace cam ring on fitted pins so that the respective markings on the housing cover and on the cam ring are in alignment (fig. 13118).

11

DRIVE SH AF T

14

HOUSING

16

MARKING

LINE

COVER

a Note: When a new cam ring is installed, position it so that the hydraulic oil bores are located accurately above the recesses in the housing cover (Item 4 & 5, fig. 13218). 5. Insert pumpvanes into slots of rotor so hat t the rounded ends are facing outwards toward the cam ring. 6. P osition thrust plate on cam ring and fitted pins lin ing up markings (fig. 13218). Note: The outlet holes for the hydraulic oil should be above the hydraulic oil bores of the cam ring (Item 5).

a

OIL INFLOW

FROM SUPPL Y CONTAINER

b

HYDRAULIC

OIL OUTF LOW ON CAM RING

1

ROTOR

2

PUMP VANE

3

HYDRAULIC

4 5

RE CE SS ON HOUSING FOR INLET INTO HYDRAULIC OIL BORE HYDRAULIC OIL BORE

6

CAM RING

OIL UNDER PUMP

VANE OF HYDRAULI

C OIL

7

INTAKE

BOR ES

8

DRIVE SHA FT

TO RQU E S P E C IF IC AT IO NS POWER STEERING PUMP Steering pump to timing housing .

M10

60 N.m

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Se ct io n s:

19 thru 21 (E N D )

SECTION 19-1 Cooling System

Water Pump 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Water pump S haft C arbon ring seal Impeller Sleeve C eramic ring C irclip Hub Gasket Spring washer Bolt R epair kit R epair kit Thermostat Seal

20 21 22 23 24 25 26 27 28 29 30 31 32 33 34

Pipe P ipe Coupling nut Ferrule Clamp Nut Lockwasher Bolt Water outlet Water inlet Bolt Gasket Bolt Bolt Spring washer

16 17 18 19

P ulley P ulley Bolt Spring washer

35 36 37 38

O utlet adapter Gasket Spring washer Bolt

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COOLING SYSTEM 

ADE 422, 423 ,424 Workshop Manual

Se ct io n s:

19 thru 21 (E N D )

192

Cooling System T he rmo stat

S tan da rd V ers ion

S tarts to open °C at

279 +

S troke in mm

71 ±2

min 8

F °C open ully at

Special application

94

min 8 85

Coolant Pump S pecifications and pump illustration can alter dependi ng on application

S haft dia.

15,039 15,028

Dim. „A '! Impeller bore

Bearing dia.

15,018 15,000 54,994 54,981

Dim. ,,B’ Housing bore

P ulley sh aft dia.

54,970 54,940 25,061 25,048

Dim. „C ” P ulley flang e bore

Dim. „D "

Distance impeller to housing

Dim. ,,E"

F lange dia. for pulley location

25,021 25,000 1 ,0 - 1,4

55.970 55.940

Max. runout between “C” and “E”

0.03

Lateral runout of pulley flange at radius 52

0.02

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Se ct io n s:

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COOLIN G SYSTEM 

193

TO RQUE S P E CIF IC AT IONS Water p ump to cylinder b lo c k ............. .............. ............ ........ P ulley to wa terpump ........... .............. ............ .............. ............ . C oolant drain plug on optional oi l co o le r ........................ C ooling fan to hub (solid fan ) ............. .............. ............ ........ Visco fan to hub/vibration damper ............ ............ .............. C oolant outlet to water p um p ............. .............. ............ ........

M8 M8 M12 X 1,5 M8 M8 M8

25 25 50 30 30 25

Fan guard to engine mounting/sump ................................. Fan guard to bracket ............ .............. ............ ............. ............ Inlet to water pump (Depending on application) ............ M10

M10 M10

50 N.m 50 N.m N.m 25 N.m

FAN RETAINING BOLTS (DIN933) — TIG HT E NING TOR QUE BOLT DIA

M8 M8 M10 M10

QUALITY

8,8 10,9 8,8 10,9

TOR QUE

23 30 42 58

N.m N.m N.m N.m

( [ M8

50

N.m N.m N.m N.m N.m N.m

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ADE 422, 423 ,424 Workshop Manual

COOLING SYSTEM — 194 Introduction The circ ulation of the c oolant is ass isted by an impeller type water pump mounted on the front of the cylinder block, and driven by a Vbelt from the crank shaft. Co oling by a finned radiator (water/air) or heat exchange (water/water). Automatic temperature control by two thermostats connected in parallel.

REMOVING AND REPLACING THERMOSTAT Removing 1. Dis conn ect coolant hose from thermos tat housing, and remove. 2. Unscrew and remove thermostat cover (fig. 119).

Fig. 119

3. R emove thermos tat from housing (fig. 2 19).

Replacing 1. Inse rt thermostat in housing. 2. F it new Oring to thermostat housing (fig. 319). 3. F it new gasket to thermostat cover and replace, tighten bolts to 25 N.m. 4. R eplace and tighten clip s of coolant hose.

Fig. 319

Se ct io n s:

19 thru 21 (E N D )

B0C B arr in gt on Die se l C lu b

ADE 422, 423 ,424 Workshop Manual

Se ct io n s:

19 thru 21 (E N D )

COOLING SYSTEM  CHECKING THERMOSTA T Attach thermostat to a piece of wire and hang In a tank filled with boiling water. The main valve of the thermostat must be fully open after six to eight minutes (approximately 8 mm). Checking for start of opening. 1. Attach thermostat to a piece of wire and hang in a tank filled with water. 2. Using a suitable source, heat water. IMPORTANT! From approximately 8°C below start of opening temperature (depending on version), the heating speed must not exceed 10to 2° per minute. Stir water so as to produce a uniform temperature.

Note: Never use a welding torch or soldering iron to heat the thermostat.

REMOVAL AN D R EP LACEMENT OF WA TER PUMP Removal 1. If filled with antifreeze or an inhibitor, drain coolant into a clean container. Disconnect and remove water pump hoses. 2. Loosen lock nut on Vbelt adjuster and release tension. 3. R emove Vbelt. 4. Unscrew and remove mounting bolts for water pump, lift off water pump. 5. Remove old gasket, and clean surface of water pump and cylinder block.

Replacing 1. R eplace water pump, fitted with new gasket, insert bolts and tighten to specified torque. 2. Check Vbelt forcorrect tension using special tool (fig. 419). S hould this tool not be available, h t e Vbelt tension can be adjusted as follows: Without using undue pressure it should be possible to depress the V belt approximately 10 mm, with the thumb applying pressure at a point midway between the water pump and alternator pulley. 3. Replace water pump hoses and tighten hose clamps. 4. F ill radiator with coolant. Note: Add 1% radiator inhibitor (anticorrosion oil) throughout the year.

Fig. 419

195

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ADE 422, 423 ,424 Workshop Manual

COOLING SYSTEM — 196 DISMANTLING AND ASSEMBLING WATER PUMP Dismantling 1. Unscrew and remove thermostat housing cover, remove thermostats (fig. 519).

Fig. 619

3. Using a suitable puller, remove drive flange from water pump shaft (fig. 719).

F ig. 719

4. Remove circ lip from water pump shaft housing (fig. 819).

Fig. 819

Se ct io n s:

19 thru 21 (E N D )

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Se ct io n s:

19 thru 21 (E N D )

COOLIN G SYSTEM  5. P ress water pump shaft and bearing from water pump housing (fig. 919).

6. Knock carbon ring seal from water pump body. 7. Remove ceramic ring and rubbersleeve from mpeller, i (fig. 1019).

Assembling 1. F it new carbon ring seal in water pump body, using special tool, P art number 40202020 (fig. 1119).

2. P ress new water pump bearing into water pump housing (fig. 1219).

197

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ADE 422, 423 ,424 Workshop Manual

Se ct io n s:

19 thru 21 (E N D )

COOLING SYSTEM — 198 3.

Insert circlip into water pump bearing housing (tig. 1319).

4. P ress drive flange onto water pump shaft (fig. 1419).

—^

1

'

Fig. 1419

5. Insert new ceramic ring and rubber sleeve into impeller (fig. 1519).

6. P ress water pump impeller onto water pump bearing shaft, leaving aclearance of 1 + 0,4 mm between impeller and water pump body (fig. 1619).

Fig. 1619

//x

P

--------

BDC

B drrin gton Di es el Club

ADE 422, 423 ,424 Workshop Manual

Se ct io n s:

19 thru 21 (E N D )

COOLIN G SYSTEM  7.

R eplace pulley and tighten bolts to25 N.m (fig. 1719).

8.

Insert thermo stats, with new seals into water pump housing, and replace thermostat cover (fig. 1819).

Fig. 1819

Page 19-10 blank

199

»»cscl

Club

ADE 422 , 423, 424 Workshop Manual

S e ct io n s:

19 thru 21 (E N D )

Page 19-10 blank

SECTION 19-11 Visco Fan

Representation of Basic Fan Model 1

AL LE N CA P SC RE W

2

COVER , COMP LETE

3

COVER GASKET

4

ALLEN CAP SCREW

5

PRIMARY

6

SPAC ER RIN G

DISC

7

BEARING

8

SEALING

9

BODY WITH BLADE

RING

10

LOCKING

11

COUNTER SUNK SCREW

DEVICE

12

FLANGED

SHAF T

Page 19-12blank

BDC

Bdrrington Diesel Club

ADE 422 , 423, 424 Workshop Manual

19 thru 21 (E N D )

SECTION 1913 Visco Fan

Page 19-12 blank

F illing Capacities

Introduction

Some ADE 420 Series Engines are fitted with a thermostatica lly controlled viscous drive fan, which is mounted on the water pump hub, and driven by the Vb elt from the crankshaft. The visco us drive fan does not have a rigid conne ction of the water pump pulley. A driven member which is fitted to the pulley can move within a chamber of the fan with a small clearance. On reaching a predetermined temperature the thermostat opens allowing oil to enter the chamber, as a result of the friction created by the oil within the fan chamber, the non driven body of the fan will turn thus driving the fan.

C hecking and locking viscous

S e ct io n s:

S ilicon Oil Fan Model

Viscosity +) cS t

Qty. cm3

T 18 I

12.500 12.500 12.500 12.500 12.500 12.500 12.500

35 35 30 42 42 42 42

T 18 II T 18 II KW

12.500 12.500 12.500

42 45 40

T 21 II T 21 II K W

12.500 16.500 12.500 16.500 12.500 16.500 16.500

42 45 45 45 45 45 45

T 21 II D

16.500 12.500 12.500

42 42 42

drive fan

If there is an abnormal rise in coolant temperature, the following check should be carried out. When the engine is cold, the viscous silicon fluid flows back into the thermostat chamber. With the engine at operating temperature, it should therefore be difficult to turn the fan by hand. S tart up the cold engine, and allow it to run for 12minutes at medium speed, then switch off the engine. The fan must now rotate easily when moved by hand, this is due to the fact that the s ilicon fluid has been thrown to the outside of the chamber, and since it is controlled by the thermostat, it cannot flow back when the engi ne is still cold. Check whether the viscous drive fan engages properly when the engine is warm. With the vehicle stationery, cover the radiator, start engine and allow it to run at medium speed until the water temperature has risen to 9095°C. Remove the radiator covering. The thermostat is now heated by the hot air from the radiator allowing silicon fluid to flow into the fan chamber. The fan speed sho uld increase within a few minutes (increasing fan noise), and the water temperature should return to normal operating temperature. If the engine is now switched off, it should be difficult to turn the fan by hand as the oil is s till in the fan chamber. In the event of failure of the viscous fan drive, the device can be locked. The locking device at the rear end of the fan serves to couple the fan rigidly to the pulley. To do this, unsc rew the locking nut (fig. 1819) up to the lock stop, then turn the fan slowly by hand until the pin of the locking device is felt to snap into place, aided by the spring pressure. T he visco us drive fan can be used for a limited period when in the locked cond ition. P rolonged operation in this con dition is no t advisable, the fan should be exchanged as soon as possible at your nearest A tlantis Diesel E ngine, parts stockist.

Note:

The vis cous drive fan s hould always be transported and stored in a vertical position (as fitted to the engine) to prevent the silicon oil from running out.

F ig. 1819

B0C B ar rin gto n Di es el Club

ADE 422, 423 ,424 Workshop Manual

Se ct io n s:

19 thru 21 (E N D )

SECTION 201 Lubricating Oils

VISCOSITY GRADES Ambient Air

SAE Grades

T empe rature

30

20

o 10

O CM I

5

£

o

0

5 10

o i

0

I

1

o in o CM CO

o

$

I

CM

$

o

CM

I

15

20

o CM in

*At prolonge d ambie nt tempe rature above 20°C S AE 40 can be used.

DUE TO CONTINUOUS DEVELOPMENT, ATL REVISING THEIR OIL RECOMMENDATIONS.

ANTIS DIE SEL ENGINES ARE CONSTANTL

TO OBTAIN THE LATEST OIL RECOMMENDATIONS, PLEASE REFER TO OUR SERVICE BULLETINS, OR CONSULT YOUR NEAREST OIL COMPANY FOR THEIR ADVICE.

Y

1^5 $ B arrin gto n Di es el Club

ADE 422, 423 ,424 Workshop Manual

Se ct io n s:

19 thru 21 (E N D )

SECTION 21-1 A p p ro v ed Serv ic e To o ls Distributed by: GrundyTechniform (Pty) Ltd, Bruman Road, Deal Party Estate, P ort Elizabeth 6001

Tool

Tool No.

Engine turning tool

4020 0093

Crow foot socket for cylinder head bolts 17 mm

4020 0530

Ring spanner for injection pump pipe connec tions

4020 0970

Ring spanner for injector pipes

4020 0705

Castleated socket for removal and replacement of injector securing nut (pipes in place)

4020 1047

Castleated socket for removal and replacement of injector (pipes removed)

Injector dismantling socket

4020 1050 I

T

& V/

4020 0938

B0C B arr in gt on Die se l C lu b

ADE 422, 423 ,424 Workshop Manual

Se ct io n s:

19 thru 21 (E N D )

A P P R O V E D S E R V IC E T O O L S — 21 -2

Tool

Tool No.

Valve stem seal installer

4024 0778

Drive tool Flywheel wear ring

4020 0268

Drive tool Crankshaft front wear ring

4020 1801

Drive tool removal/replacement timing case oil seal

4020 0116

Drive tool Flywheel spigot bearing

4020 0064

/ T '\ Drive tool Crankshaft front cover oil seal

ll

'

RBHBV »

4020 0129

P uller for 4020 1160 & 4020 1652

4020 0585

P uller for 4020 1665

4020 0598

Valve guide reamer 11.99 mm

4020 0831

1^ 5$ (drH n gto n D ies el du b

ADE 422, 423 ,424 Workshop Manual

Se ct io n s:

19 thru 21 (E N D )

APPROVED SERVICE TOOLS — 213

Tool

’

Tool No.

C rankshaft hardn ess tester

4020 0501

Drive tool for compressor roller bearing in timing gear case

4020 1199

Drive tool for bush in compressor bearing flange.

7'