Continental TMD27

 

CONTINENTAL DIESEL ENGINES

OPERATORS GUIDE

REPAIR

WIS-CON TOTAL POWER CORP.

 

FOREWORD Good peration anda planned plannedmaintenance maintenancerogram rogram s outlined in this manual re vital in obtainingmaximumngine ngineperformance performancend nd ong engine ife. The nstructions on the following pages avebeen avebeenwritten written with this in mind, o give the operator operatora a better understandingf understandingf the various problemswhich whichmay mayarise, and he mannern which heseproblems an best be solved or avoided. Theoperator s cautioned gainst he use Theoperator useof of anyparts, anyparts, other than genuineWis-Conotal Power parts, for replacement r repair. Theseparts have been beenengineered engineered nd tested for their particular job, and he use useof of anyother anyother parts mayesult mayesult in unsatisfactory erformancend ndshort short engine ife. Wis-Con otal Power istributors anddealers, because f their close factory relations, can ender he best and andmost most fficient service. THE LIFE OF YOURENGINE ENGINEDEPENDS DEPENDS N THE CARE T RECEIVES. The MODEL,SPECIFICATION SPECIFICATIONnd SERIALNUMBER SERIALNUMBERf your engine must be given when ordering parts. The MODELnd SPECIFICATION umber re on the nameplate. The SERIAL umber NUMBER s stamped ither on the crankcase r the engine’s dentification tag. the MODEL, PECIFICATIONnd SERIALNUMBER SERIALNUMBER n the spaces provided below so hat it will be available availablewhen when rderingparts. MODEL

SPECIFICATION

SERIAL

NUMBER

To nsure promptand and accurateservice, accurateservice, the following informationmust informationmustalso also be giv given: en: 1. Sta State te EXA EXACTL CTLY he Y quantity of eachpart eachpart andpart number. 2. State definitely whether arts are to be shipped y express, reight or parcel parcelpost. post. 3. State he exactmailing exactmailing address.

 

IMPORTANT READ THESE INSTRUCTIONS CAREFULLY All points of operationand operationand maintenanceave maintenanceavebeen beencovered coveredas as carefully as possible, but if further information s required, send nquiries to the factory for prompt promptattention. attention. When writing to the factory, ALWAYSGIVE THE MODEL, MODEL,SPECIFICATION SPECIFICATIONAND AND SERIAL NUMBERf the engine engin e referred to.

Startincj and Operatinq New NewEncjines Encjines Careful breaking-in of a newengine newengine will greatly increas increase e its life and result in trouble-free operation. A factory test is not sufficient to establish the polished bearing bearingsurfaces, surfaces, whichare whichare so necessary o the proper performance nd ong life of an engine. These Thesecan can only be obtained by running a newengine newengine carefully and under reduced oads for a short time. ¯ Be sure the engine s filled to the proper evel with a good goodquality quality engineoil. engineoil. ¯ For proper procedures o follow when reaking-in a new newengine, engine, see ’Testing Rebuilt Engine’. The various bearing surfaces n a new newengine enginehave havenot not beenglazed, beenglazed, astheywill be with continued operation, and t is in this period of "running in" that speci special al care must mustbe be exercised, otherwise the highly desired glaze will never be obtained. A new newbearing bearing surface that has once been damaged y carelessness will be ruined forever.

 

Proper epair is important o the safe and eliable operation operationof of an engine. engine.This This RepairManual RepairManual outlines basic recomme recommended nded rocedures, ome f which equire special tools, devices devicesor or work methods. Improper epair procedures anbe dangerousnd dangerousndcould could result in injury or death. READ AND UNDERSTAND ALL SAFETY PRECAUTIONS AND WARNINGS BEFORE PERFORMING REPAIRS ON THIS ENGINE Warningabels havealso havealso beenput on the engineso provide ns nstructions tructions and dentify specific hazards hich, f not heeded, ould ouldcause cause odily injury injury or death o youor other persons.These These labels identify hazards hazardswhich which maynot maynot be apparentto a trained mechanic.There Thereare many potential hazardsor hazardsor an untrainedmechanic mechanicnd nd here s no way o label the engine gainstall suchhazards.These hazards.Thesewarnings warningsn n the RepairManual RepairManual ndon the engine engineare are identified by this symbol:

Operationshat may esult only in engine Operationshat enginedamage damagere re identified in the Repair RepairManual Manual y this symbol:

&CAUTION

Wis-Con otal Powercannot Powercannot anticipate every possible circumstance hat might involve a potential hazard; h herefore, erefore, the warnings warningsn n this t his manual re not all inclusive. If a procedure, tool, deviceorwork orworkmethod method ot specifically recommended y Wis-Con otal Powers Powers used, you must atisfy yourself that it is safe for you youand andothers. others. You houldalso houldalso ensurehat ensurehat the engine will not be damaged damagedrr made nsafeby nsafeby the procedures ou choose. IMPORTANT: he nformation, specificationsand llustrations in this manual re based on information hat wasavailable wasavailable at at the time it waspublished. waspublished. Thespecifications, Thespecifications, torques, pressuresof operation, measurements measurements,djustments, , llustrations and other itemscan items can changend t any ime. These hanges hangesan an affect the service givento the product. Get the complete ndmost most urrent nformation efore eforestarting starting any ob. obgiven . Forto parts, service, or information, contact Wis-Con otal Power,Memphis, Power,Memphis, ennessee.

 

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WARNING

Most sub-systemsused sub-systemsused n conjunction with Wis-ConTotal Power ndustrial engines including (but not limited to) radiators, hoses, ans, fuel tanks, fuel lines or other fuel system omponents, batteries, electrical connections or other electrical components, lutches, transmissions, hydraulic pumpsand pumpsand generators, are not supplied by Wis-Con Wis-ConTotal Total Power. These tems are provided by the manufacturerof manufacturerof the end tem in which the engine s used. Some f the dangers associated with servicing such items are generally mentioned n this manual; however, he appropriate handbooks nd safety instructions provided by the manuf manufacacturer of the end item should always be consulted prior to the undertaking of any work on subsystemsattached systems attached to the engine, to avoid any hazards nherent to these sub-systems.

/

WARNING

Read nd observe all individual safety warnings warningsas as you use this manual o operate, service or repair your engine. Always exercise caution whenever wheneverworking working with an engine or any associated system. Injuries maybe maybe causedby causedby lack of care whenworking whenworking with, or near, moving movingparts, parts, hot parts, pressurized systems,electrical equipment, equipment,or or fuel systems. Always wear eye and hearing protection when whenworking working on or near engines. Improper ttire such suchas as loose clothing, ties, rings, soft shoes shoesor or bare feet could be hazardous nd should be avoided avo ided when whenservicing servicing engines. Useor service Useor serv ice of the engine including the use of modified modifiedparts parts or materials) not in accordance with manufacturer’s ma nufacturer’s specifications could damage damageour our engine or cause personal injury.

/

WARNING

Someequipment and materials used in the overhaul or maintenance of an engine such as Someequipment machineools, machine ools, electrical equipment, equipment,compressed compressedir, ir, solvents, gasoline or other fuels may maybe be dangerousand dangerous and can cause njury.

2

Always observe safety precautions.

 

CONTENTS CONTINENTAL INDUSTRIAL

ENGINES

SECTION 1 General nformation .................................................................. Page 5 SECTION 2 Operating nstructions .. .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... ....

Pa Page ge 7

SECTION 3 iLubrication .......... ..... .......... .......... .......... .......... .......... ......... ......... .......... .......... .......... .......... .......... .......... ......... ....

Page 13

SECTION 4 Coolingystem ystem .......................................................... ...................................... ................................. .............

Page 15

SECTION 5 Fuel ystem ............... .......... .......... .......... .......... .......... .......... ......... ......... .......... .......... .......... .......... .......... ........ ...

Page 21

SECTION 6 Charging ystem ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...

Page Page 32

SECTION 7 Preventiveaintenance Preventive aintenance ......................................... ..................... ..................................... .................

Page 34

SECTION 8 Overhaul Engineepair ......................................................

Page 39

SECTION 9 Trouble hooting hooting ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...

Page Page 61

SECTION 10 Torquepecifications pecifications ........................................ .................... ......................................... .......................

Page 67

SECTION 11 Limits Clearanceata................... ....................................... ...................................... ..................

Page 69

INDEX ......................................... .................... ......................................... ........................................ ............................. .........

Page 71

3

 

Industrial Diesel MODEL

TMD13

TMD20

TMD 27

METRIC

ENGLISH

METRIC

ENGLISH

METRIC

ENGLISH

No. of Cylinders

2

2

3

3

4

4

Bore & Stroke Displacement Compression Ratio

91 x 103.2 1.35 L 20.5:1 2.8 - 4.1 Bar 0.5 Bar 1-2 73 x 23.8

(3.58 x 4.06) (82) CID 20.5:1

(3.58 x 4.06) (123) CID 20.5:1

(40 - 60 PSI) 7 PSI 1-2 (2.88 x .94)

73 x 31.8 73 x 23.8 49.2 x 24.5

(2.88 x 1.25) (2.88 x .94) (1.94 x .96)

91 x 10 103.2 2 .0 L 20.5:1 2.8 - 4. 4 .1 Bar 0.5 Bar 1-3-2 73 x 23.8 73 x 23.8 73 x 31.8 73 x 23.8 49.2 x 24.5

(40- 60 60 PSI) 7 PSI 1-3-2 (2.88 x .94) (2.88 x .94) (2.88 x 1.25) (2.88 x .94) (1.94 x .96)

91 x t03.2 2.68 L 20.5:1 2.8-4.1 Ba B ar 0.5 Bar 1-3-4-2 73 x 23.8 (2)73 x 23.8 73 x 31.8 73 x 23.8 49.2 x 2 24 4.5

(3.58 x 4.06) (164) CID 20.5:1 (40-60 PSI) 7 PSI 1-3-4-2 (2.88 x .94) (2.88 x .94) (2.88 x 1.25) (2.88 x .94) (1.94 x .96)

3.78 L .95 L 4.73 L

(4 Quarts) (1 Quart) (5 Quarts)

4.73 L .95 L 5.68 L

(5 Quarts) (1 Quart) (6 Quarts)

5.7 L .9 5 L 6.65 L

(6 Quarts) (1 Quart) (7 Quarts)

.36 .46

(.014) (.018)

.36 .46

(.014) (.018)

.3 6 .4 6

(.014) (.018)

2.0 L

(2.1 Quarts)

2.84 L

(3 Quarts)

3 .6 L

(3.8 Quarts)

191 Kg

(420 LBS.)

216 Kg

(475 LBS.)

253 Kg

(557 LBS.)

Max. Oil Pressure* Min. Oil Pressure (Idling) Firing Order Main Brg. Frt. Main Brg. Int. Main Brg. Thrust Main Brg. Rear Conn. Rod Brg. Oil Capacity Crankcase Filter Total Valve Clearance Intake Exhaust Water Capacity Engine Weight (Approx.) (With Accessories) *Higher oil

pressure maybe maybe experienced experienced during cold starts.

INFORMATION

FOR ORDERING PARTS

When rderingparts, refer to the enginename enginename plate attachedo attachedo side of the cylinderblock, cylinderblock,which lists the model model ndserial ndserial number.n most asesa asesa

Typical

specification umber s listed. Thisdata Thisdata s of vital importancen obtaining he correct parts: always include his informationon yourparts order.

Nameplate

 

Section I - General Information CONTINENTAL DIESEL ENGINE Continental Diesel Engines are Comet V combustion chamber indirect injection diesel engines. The combustion chamber design has been tailored for the required turbulence, charge flow and burning characteristics to provide depend depend-able and economical heavy duty service. Someof Some of the principal

design features are:

1. Individual Porting- of the intake manifold whereby each cylinder is fed with the air charge individually and is not influenced by other cylinders of the engine. This is accomplished by casting the cylinder head with individual intake valve passag passages es for

OHV Design

each cylinder and connecting these passages to an intake manifold which also has individualized passages for each cylinder.   Water Jackets -- completely completely surround al alll [ylinder bores to a depth sufficient to cover the

hot piston ring travel, resulting in minimumbore distortion for good oil control yet maintaining low heat rejection to the coolant. coolant. CHOICE OF FUELS--Continental FUELS--Continental Industrial Diesel Engines have been tailored for heavy duty operation for use with #1 or #2 diesel fuel that meet a minimum cetane number of 45 (see fuel recommendations, page 29).

Individual Porting

 

~linder HeadCover HeadCover

Rocker Arm

ector Water Header --

Cylinder Head

Intake Valve ~r Insert Piston dinder HeadGasket HeadGasket ChromeTop Chrome Top & Oil Rings

Water Jacket PumpDriven G~

Connecting Rod

Counterweighted Cra Gear

Injection PumpDrive Gear Heat Treated Treated Alloy Stee Connecting Rod, Main Bearing Cap & Cylinder Head HeadBolts Bolts Crankshaft Gear

Oil

Oil Pure

Cross ection f typicalWis-Con Continental ndustrialDiesel Diesel

 

Section 2 Operating Instructions Thepersonoperating the engine naturally asTheperson sumesesponsibility sumes esponsibility for its care while it is being operated. This is a very important responsibility since the care and attention given the enginegoes enginegoes a long way n determining ow ong a period it will operatesatisfactorily operate satisfactorily before having o be shut down for repairs. he operating and preventive preventive maintenance structions for the Diesel Enginesare Enginesare simple and shouldbe should be followed without deviation. Theentire aim n setting forth these nstructions Theentire is to give youa benefit of the knowledgend knowledgendexpeexperience gainedover gainedover a long period of collaboration betweenEngineering between Engineering Researchand Researchand Field Service. PREPARATION OF A NEW ENGINE FOR OPERATION

Beforeplacing Before placing a new nginen operation, t must be thoroughly inspected for external damage nd particular attention paid to the following tems:

2. Fill Crankcase ith oil -- Use he oil recommendedor the ambient emperature see chart on page14). page 14). 3. Fill Fuel Tank-- See uel recommendationsn recommendationsn page29.

WARN NG Stop ngine efore heckingatteryerminalsr erminalsr electricalconnections. connections. parksrr flames eara parks eara battery ould ausen ausenexplosionr fire. fire. Battery acidcan acid cancause causeorrosiveurns.Always Alwaysear ye protection.Use protection. Useof of jumper ables ablesor battery charging hould e done nly as directedby directedby manufacturers’ afetynstructions. Read ndobserve ndobserveafetywarningsnpages and .

Checkstorage storage bat4. Electrical Connections- Check tery terminals andall andall electrical connections.

si de of the 1. Close water drain cock mon the side block. (In some ases, his maybe maybe a pipe plug.) plug.)

STARTING THE ENGINE

/

WARNING

Bodilynjuryor Bodilynjury or deathmay mayesult esult o individuals individuals during perationf perationf an engine ithinany ithinanyencloenclosurenot notadequately adequatelyr properly entilated.EnEngineoperationn operationn anyenclosure anyenclosureequires equiresadadequatend equate ndproperentilationo entilationo avoid avoid sphyxiaWater rainCock rainCock Fill radiator and water jacket with coolant. (See Cooling System ection 4).

tion tionor or othernterruption other nterruptionf f normal reathing. reathing. o supplyufficient supply ufficient ir to cool cool heengine, heengine, rovide air to mixwith mixwith uel ando carry way eated eatedir ir from hebuilding. hebuilding. Read ndobserve ndobserveafetywarningsn pages and .

If theengine theengines new r rebuilt or if fuel filters have been serviced or any low pressure lines disconnected, fuel systemmust systemmustbe be bled to remove ny air that mayhave mayhave becomerapped becomerapped in the system.

Radiatoroolant Radiator oolantnlet

Bleed he he entire entire fuel system.Detailed nstructions for bleedinghe injection systemsre given in section .

 

STARTlinG

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PROCEDUP~

WARNING

Starting fluids or aids suchas suchas ether or gasoline mustnot must not be used n a diesel engine air intake system.The The useof these fluids will causesevere internal engine damage damagend/or nd/or bodily injury. Read and observe observe safety warnings on pages 1 and2. and 2.

9. Check Oil Pressure MODEL

OIL PRESSURE*

TMD

2.8 - 4.1 Bar (40 - 60 PSI)

* Higheroil Higheroil pressuremay maybe be experienced uring coldstarts. 10. CheckWater CheckWater Temperature

1. DisengagePower DisengagePowerTake-Off Take-Off -- (if equipped) Starting engineunder engineunderoad throwsoverload throwsoverloadon starter andbattery. and battery.

RELEASE

Water TemperatureGauge

11. CAUTION:fter fter starting newengine-- run it at idle for 5 minutes, hen stop engineand engineand echeck il level in dipstick. crankcase- then bring oil level to high markon mark on PowerTake-off Power Take-off

2. Make ure electric shut-off is wired o permit uel flow whenhe starter switch s in the "start" and run" positions. 3. If the fuel pumps fitted with a mechanicalhutmechanicalhutoff, movehe movehe control to full open. 4. Engage lowplug preheat control and wait until the indicator light is off. If enginedoes enginedoesnot not usean automatic preheat control, manuallyenergize manuallyenergize glow plugs for the appropriate ime: either seconds seconds 20 seconds dependingupon depending upon which type7glow plugsr are used n the engine. 5. Move Mo ve witch to start position andstart andstart engine. 6. Adjust hrottle to idle at 800 o 1200R.P.M. or a few minutes o circulate andwarm andwarmhe he oil. Thenopen throttle to abouthalf abouthalf speed ntil the coolant reaches 38 38° °C 100 10 0° F.). 7. If engine ails to start, turn switch to the "off" position and epeat he above teps. If starting is not attemptedwithin attempted within 15 to 20 seconds, epeat the preheat sequence. 8. if enginestill enginestill doesnot start refer to trouble shootingsection shooting section 9. 8

IMPORTANT IMPORTAN T reaking in a new or rebuilt engine -- for peak performance and economical operation, the following adjustments should be made t end of first 50 hrs. operation. 1. Adjust valve tappets o specified clearances. 2.Adjust idle speed to equipment manufacturer’s recommendation.

WARM UP NEW ENGINES

When ewengines ewengines or any dealers stock, showrooms, tc. in tc. aredistributors started up for reason, they should shoul d be brought up to operating temperature in order to eliminate all condensation before stopping. If they are stoppedwhile still cold, condensation will settle on valvestems valvestems ndguides, ndguides,as as well as other moving arts, and rust and sludge sludgewill will form. Soon alves, rings, etc. will bestuck bestuckby this rusting and sludging action. Engine should be operated long enough o bring oil andwater andwater temperatureo normaloperating operating temperatue; temperatu e; be sure breatheror breatheror ventilation system is openso openso vapor can be expelled.

 

STOPPING THE ENGINE 3. Moveswitch Moveswitch to off position.

1. Disengage Power Take-Off 2. Reduce engine Spe d to Idle- if hot, engine at idle for several minutes to cool.

11 "MUSTS"

run

4. If the fuel pumps pumps fitted with a mechanical hutoff, movehe control to full close.

FOR YOUR ENGINES

1. OIL PRESSUREhould be up to recommended pressure at operating speedand speedand over 0.5 Bar (7 PSI)at idle (800-1200 .P.M.) 2. AMMETER-should egister "Charging" at all egister times engine s rur~ning. (A voltage regulator may limit it to a very ow reading). 3. WATERTEMPERATURE-nor WATERTEMPERATURE-normal mal operation 81°C-96 81° C-96° °C (178-20 (178 -205° 5°F.) F.).. Higher High er temperat temp eratures ures are acceptable with pressurized systems. Overheatings detected by los loss s of coolant. "FREQUENTREADINGS QUENT READINGSOF OF GAUGESHOULD GAUGESHOULDBECOME BECOME A HABIT". 4. MUFFLER ESTRICTION should not exceed 508mm 20") water. Inspectmufflers periodically for restrictions to prevent urned alves. 5. CLEAN AND SERVICE AIR CLEANER-as recommended o maintain its efficiency. 6. WHENENGINE WHENENGINE S OVERHEATEDdonotadd water- allow engine o cool so so as to prevent cracking the cylinder block, or cylinder head. 7. AVOID COLD--SLUDGECONDENSATION-by COLD--SLUDGECONDENSATION-by protecting unit to maintain crankcase temperature temperat ure over 57°C 57°C (135°F.). (135°F.). Use a proper temperature range thermostat and warmengine up thoroughly.

8. BREAKING N A NEWOR ORREBUILT REBUILTENGINE ENGINEfor for peak performanceand performanceand economicaloperation, the following adjustments should be madeat end of first day’soperation; day’soperation; 1. Adjust valve tappets o specified clearances. clearances. 2. Adjust idle speed to equipment manufacturer’s recommendation. 9. FOLLOW PREVENTIVE MAINTENANCE SCHEDULES ECOMMENDED-thiswill ECOMMENDED-thiswill avoid troubles which might cause expensive breakdowns nd maintain your engine for dependable and economical economicaloperation. 10. IDLINGENGINEIDLINGENGINE-low low engine down down o low idle for about 5 minutes, after eachoperating period, before stopping-too stopping-too rapid cooling down may cause istortion. 11. CLEAN,WATERREE WATERREEFUEL FUELs vitally important to the operationof operationof yourengineand engineand uel injection system. njection pumpwarranty will be affected if pump ailure results from water in the fuel. Whenhe Whenhe presenceof presenceof water in the fuel fuel is suspected, he filter bowlshouldbe drained drained daily until the amountof amountof water so removedndicates that less frequent draining will be adequate adequateo prevent water rom entering he fuel injection pump.f pump.f more han a teacupful of water s drained off, the sourceof source of ingress must mustbe be foundor foundor else the filter bowl must mustbe drained at more requent intervals.

COLD WEATHER OPERATION Battery condition starting.

is very important

for proper

The oil used during cold weather s should hould have a cold test below the lowest anticipated temperatures that will be encountered during its use. The multigrade lubricating oils 5W-20 and 10W-30are ideal for cold starting with its reduced initialcharacteristics until ofwarmed up, when the charadrag cteristics the heavier oil. they assume Sludge formation at low temperatures is a close second to dirt in causing engine damage and

wear. This is formed by the piston combustion gases mixing with the fine oil mist in the crankcase and condensing on a cold cold surface. This condensation forms both a sulphuric and sulphurous acid which combines with the oil to becomea become a highly injurious sludge. This dew point is about 57° 57°C C (135° (135°F.)-F.)-when crankcase temperatures are higher, higher, the contaminated contaminated gases gases remain in gaseous and the system engine operates clean as long asform breather is kept kept clean--however temperatures below this will

 

result in injurious injurious sludge ormation. It is vitally important therefore to maintain o oilil and crankcase temperatures temperatur es above 57°C 57°C (135°F.) (135°F.) as shown the following chart:

Use the checklist ready for winter. schedule to keep during the winter

which follows to get your engine engine Then use the winter maintenance it in peak operating condition months.

CHECKLIST REACTIONS

WITHIN WITHIN

TO TEMPERATURES

ENGINE DURING

CRANKCASE OPERATION c

F

176.6" CLEAN ENGINE OPERATION

250

148.9" 121.1"

2oo’.

93.3"

.15o

65,5°

loo’, 50" 32" o

=udg=no, Etching of Parts, LIQUID CONDENSATION Ringand Ring andValve ValveSticking Stickingand and Burningf Bearings. 666 SNOW - ICE

Sludge ndFreezing ndFreezing f Oil Screens and andPumps Pumps Resulting n Burned Bearings ndStripped nd Stripped Pump ears.

37.7" 10" 0" -17.8"

/

WARNING

Stop engine before checking battery battery terminals or electrical connections. Sparks or flames near a battery could cause an explosion or fire. Battery acid can cause corrosive burns. Always wear eye protection. Use of jumper cables or battery battery charging should be done only as directed by manufacturers’ safety instructions. Read and observe safety

warnings

on pages 1 and 2.

1. ELECTRICAL SYSTEM A. Battery - replenish water and test for condition and state of charge. Replace f required.

45.6"

Wiring - check battery cables, connections and When ludging conditions prevail, the oil should be examined aily and changed s it may reeze, or clog the inlet strainer and cause bearing or oil pump failures.

HighAltitudeOperation--if HighAltitude Operation--if ngines ngines to berun berun continuouslyt a highaltitude (above 000 000t.) t.) the pump alibration should be modified to maintain an acceptable smoke evel. Contact manufacturer for recommendations. ote:Some igh altitude fuel delivery curve shaping ote:Some can be performedon someSTANADYNE someSTANADYNE uel injection pumps n the field (see (seepg. pg. 30). High Temperature Temperatur e Operation--for Operation-- for every 5°C (10°F.) above29.4° above29.4°C C(85° (85°F.) F.) inlet air temperatur temperature-e-a power oss of 1% esults.

ENGINE PREPARATIONFOR PREPARATIONFOR WINTER USE More than 90%of 90%of the hard starting complaints in cold weather are the direct result of inadequateattention to preparation for winter use and proper maintenar~ce. An engine not properly prepared requires more cranking energy and time, which puts a heavy load on batteries. So, invariably, batteries run downand the engine is blamed for hard starting. Putting your engine in proper condition and keeping it that way pays big dividends by reducing costly down time. 10  

other wiring. Be sure connections con nections are clean and tight and that cables and wiring insulation are in good condition. Alternator and regulator-run regulator-r un the engine and check the ammetero be sure the alternator is charging and the regulator is functioning properly. Check nd adjust alternator belt tension. 2. CO COOL OLIN ING G SYST SYSTEM EM

/

WARNING

If the coolant is hot or if the engine has been running, loosen the pressure pressure cap to the ffirst irst stop and let the pressure out o radiator cap.

the cooling system before

Read and observe observe safety

removing the

warnings on pages 1 and 2.

A. Check radiator radiator,, hoses hoses and engine engine for water water leaks. Tighten hose clamps, repair leaks and install antifreeze to the level required for winter protection. 3. LUBRIC LUBRICATI ATION ON SYST SYSTEM EM A. Drai Drain n oil and change change ilter. ilter. per winter grade.

Addoil of the pro-

different types and B. There are several manufacturers of transmissions and powertake-offs. Caution should should be used when determining the proper seasonal grade lubrilubricant to assist in cold weather weather starting.

4.

FUELSYSTEM A. Checkhe fuel stop and hrottle control for satisfactory operationand operationandadjust adjust as required. Fuel filters -- mustbe checkedmore moreoften, often, particularly the primary tage ilter, to remove all the moi moisture sture and condensation eparated from the fuel, otherwise his may reeze and stop the fuel flow. Co

Clean uel m handled by a reliable source having a cetane number f 45 minimum,s minimum,s a definite requirement or easy starting and efficient operation. We annot caution you too seriously about obtaining fuel fue l from a reliable source. Fuel recommendations the type of fuel to be used should be suitable suitable for the ambient temperature to be expected. Refer to SAEJ313rr your local fuel distributor for SAEJ313 detailed information (see page30). page30). To nsure against condensationn condensationn the fuel tank, fill to capacityat the endof endof each perating period.

5.

WAR ilNG Starting fluids r aids uch as ether or gasoline must not be used in a diesel engine air intake system.The The useof these fluids will causesevere internal engine damage damagend/or nd/or bodily injury. Read and observe safety warnings on pag s 1 and2. and 2.

3. If unit is only used or short periodsand periodsanddoes doesnot not get thoroughlywarm, thoroughlywarm,operate operate t for at least an hour oncea once a weeko weeko get it thoroughlywarm. his will avoid excessive ludge n the oil and educe ilution of oil with raw uel in the crankcase. PI:{EPA,RAT[ONOF ~_JYG]]~I-E FOR SEJ~ONJ~L STOI:tAGE (90 DAYSTO DAYSTO 6 MONTHS) 1. Run engine -- To thoroughly warm-upoil warm-upoil in crankcase. 2. Stopengine-- And Anddrain drain crankcaseoil. crankcaseoil.

EXHAUST SYS SYST TEM

3. Refill crankcase -- With SAENo. SAENo. 10 engine preservative oil which meetsMIL-L21260 meetsMIL-L21260Grade Grade1 1 specification.

A. Checkhe rain cap, if supplied, supplied, for proper operation and repair as required.

4. Fill coolingsystem--With With a solution containing a rust nhibitor.

6. IN INTA TAKE KE AI AIR R SYST SYSTEM EM A. Be sure all hosesand clampsare properly seatedand seated and ight. B. Check Checknstructions nstructions on the air cleaner decal. Servicedry Service dry type air cleaneras cleaneras specified. 7. MI MISC SCEL ELLA LAN NEOUS EOUS A. Normal tarting using the glowplugs supplied as standard equipment should be accomplished plishe d down to--20°C to--20°C (~4°F). (~4°F). Contac Contactt Wis-Con otal Poweror Poweror special starting aids for colder temperatures. B. Checkand Checkand adjust tappets. WINTEI~ I~I~INTEN~CE

1. Performmaintenance Performmaintenancen accordancewith instruction manuals.

5. Drain fuel tank tankand and ilters -- Refill with about2 about2 gallons of a 50-50mixture 50-50mixtureof of purewhite purewhite kerosene nd SAENo. 10 engineoil. engineoil. 6. Bleed he system s detailed in section 5. 7. Start engine nd un t at half speedor speedor 15 minutes when he oil and will njectors. have irculated hrough he injection pump, ines ines 8. Seal he air vent n the tank tankor or filler capwith capwith waterproofedadhesive proofed adhesive ape. 9. Drain crankcase. 10. Drain cooling system ompletely. 11. Clean Cleanexterior exterior enginesurfaces enginesurfaces-- After engine hascooled; has cooled; emovingll emovingll grease r ot~er oreign matter. Neverwash hot injection pump ith cold waterwhile engines running. 12. Sealall Sealall openingsir-tight -- with adhesiveape adhesiveape that will not absorb r retain moisture.

2. Changeoil Changeoil as recommendedn page 14. 11  

NOTES

12

 

Section 3 - Lubrication ENGINE

LUBRICATION

SYSTEM

Continental industrial diesel engines have ull pressure lubrication to all main, connecting rod and camshaftbearings as well as rocker arms and timing gears. Tappetsare lubricated by overhead oil return. OIL PUMP Onall engines,a Onall engines,a large capacity gerotor type oil pumps pump s driven off the crankshaft crankshaft and protected by a screenednlet. screenednlet. A by-pass by-pass valve maintains suitable oil pressure from idle to maximumspeed maximumspeed automatically. Higher oil pressure maybe experienced during cold starts. Refer to page4 page4 for complete il pressure igures. CAUTION:f the oil pressure is erratic or falls below CAUTION:f these limits, stop the engine IMMEDIATELYnd find the cause of the trou trouble. ble. Refer to trouble shooting section for this information.

A full flow oil filter is provided o remove irt and foreign elements rom the oil. The emovalof emovalof grit, sludge and foreign particles causes ilter elements to clog and becomeneffective unless they are normally replaced every 100 hours or moreoften more often if conditions require.

~

Oil PumpPick-up PumpPick-up (Typical)

OIL

CHANGE FREQUENCY

Engine oil does not "wear out". However, he lubricating oil in internal-combustion engines becomescontaminated becomes contaminated from the by-products of combustion: dirt, water, unburned uel entering the crankcase,and and he detergentsholding detergentsholding the carbon particles in suspensionn suspensionn the crankcase. Note:On Onengines engines quipped ith remote il filters, 1 lwaysill ill theoil theoil filter elementiithmotor thmotorilil prior o / installation. Failure o do so mayesult mayesult in engine damageue o momentary il starvationat starvationat start up.

R BEARINGS

TAPPET ~

CAM

~

BEARINGS

~

/ ((

O~L

GALLERY

[~r PR PRRELIEF RELIEFVALVE

~ CRANK CRANK& & ROD BEARINGS

PUMP

OUMP

Full-Flow Filter

System

Oil Filter

Theschedule The schedule or changing il is directly dependent upon the operational environment: an extremely clean operation could go 100 hours while a dirty operation(foundry or cement cementactory) actory) could be 50 hours or less. (See suggested il and ilter changentervals change ntervals on page 14.) 13

 

LUBRICATION

RECOMMENDATIONS

Motor oils used for internal-combustion engine lubrication perform many useful functions functions including: Dissipating heat, sealing piston rings, preventing metal-to-metal contact wear and reducing power loss through friction. The lubricating oil recommendation is b based ased upon engine design, type of service, and the atmospheric temperature prevailing. High quality oils are required to assure maximum performance, long engine life, operation.

and minimum cost of

Continental industrial diesel engines operate in a wide range of service conditions and seasonal temperatures, so our recommendations are given for various types of service and ambient temperatures.

The following SAE grades are general recommendations for Continental Industrial diesel eogines during changing seasonal atmospheric temperatures: AVERAGE AMBIENT TEMPERATURE AT WHICH ENGINE STARTING IS REQUIRED: °C

-30

-18

17

5

16

°F

-20

0

20

40

60

27 80

38+ 100 +

  ///// /////// //// ///// ///// //// //// ///// ///// //// //// ///// ///// //// //// ///// ///// //~ ~

SA SA~ ~0

SA~ 0 V//////,~ SA~~0w~20////////////////////////~   ////////3SA~0w///////////////////////////////////~

~ y///////////////J

SAE 20W - 40

~

SAE 15W - 40 SAE 10W

SA~

~w.

40

AE10W AE10W - 30

~o

~

~

~

For engines in continuous continuousduty duty oil viscosity shouldbe based on sump oil temperature.

API SERVICE DESIGNATIONS We ecommend sing oil

described below for all

Sump Oil Temperature

SAE Grade

210 - 250"F (99 - 121 °C)

40 30

160 - 210°F

30

Continental ndustrial diesel applications.

(71 - ~9"C)

10W 30, 10W 40 20W 40, 15W 40 20W 50, 15W 50

CD Service Class D

130 - 160"F (55 71 °C)

20 10W 30, 10W 40

Service typical of industrial diesel engines operating under engine manufacturer’swarranties. manufacturer’swarranties. High detergent - exceedsengine exceedsengine manufacturer warranty requirements. SE/CD Oil Classifications Classifications maybe maybe used. SF/CD Oil Classifications maybe maybe used. SG Oil Classifications maybe maybe used.

S.A.E.

The Multi-Grade oil used should cover the single grade recommendation for the atmospheric temperature involved, e.g. SAE10W-30 SAE10W-30 covers SAE-10W, SAEo20W,SAE SAEo20W,SAE 20 and SAE 30. SUGGESTEDIL ANDOIL ANDOIL FILTER CHANGE NTERVALS Continuous utyat utyat Continuous uty Rating

OIL BODY GRADES

Theoil gradesavailable Theoil gradesavailable from the lightest (SAE (SAE5W) 5W) to the heaviest (SAE50) (SAE50) are:

CLEAN DIRTY ENVIRONMENT NVIRONMENT 100 Hours Max.

5W ~ Multi-Grade 15W-50have the 15W-50have the lighter oil characteristics

14

¯

20

~ 15W-50

Oils such as SAE 5W-20 and SAE starting grade characteristics of and after warm up have the running of the heavier grade.

Light DutyOperation DutyOperation (25% Max. Continuous Rating)andStandby

50 Hours

200 Hours Max.

NOTE:1. 1. Lube il and ilter mustalways always e changedfter changedfter the first 50 hours f operation f a new r rebuilt engine. Environmental,nstallation, fuel systemand systemand general ngine onditions anall anall influenceubricant performance.ube performance.ube il analysisprograms analysisprogramsre re recommended n all applications for optim optimum um engineperformance engine performancend ife.

Standard Continental alternators have sealed supplied bearings starters requiring and no lubrication. Check your specification for accessories which may equire periodic lubrication.

 

Section 4 - Coo ing System The unction of the cooling systems systems to prevent the temperatures n the combustionchamber combustionchamberrom damaginghe engine and at the sameime keep he operating emperatures ithin safe limits. Maintaining he cooling system fficiency is imo portant, as engine emperaturesmust mustbe be brought up to andmaintained andmaintained ithin satisfactory range or efficient operation; however, his systemmust systemmust be be kept from overheating, in order to prevent damageo damageo valves, pistons and bearings. NGINEever NGINE ever pour cold CAUTION: VERHEATED water r coldanti-freezento the adiatorof anoveranoverheatedngine. heated ngine. llow heengineo engineo cooland coolandavoid he danger f crackinghe crackinghe cylinderhead cylinderhead r block. Keep Keep engineunningwhile whileadding adding oolant.

COOLING

period. When esired temperature s reached, the thermostat valve opensallowing opensallowing all the coolant to circulate throughboth throughboth the engineand engineand adiator, while shutting off the by-passsystem. by-passsystem. resent hermostats hermostats egin to openat openat IMPORTANT: 81°C 81° C 180° 1 80°F) F) and an dare fully openat openat 94°C 202°F). Operationf engines n this temperature anges not anges harmful. However,emperature emperatureauges re not alwaysaccurate ways accurateand and may ometimesndicate ndicate higher thanactual than actual emperature.his emperature.his can eadoperatorso believeengines believe engines re overheating henhey henhey are actually operatingormally. operatingormally.

SYSTEM

All Continentalndustrial Continentalndustrial diesel engines engines ave he coolant force-circulated by a water pump nd use a thermostat and by-passsystem by-passsystem o control the temperature range. The oolant rom he pumpnters he front of the block, passingalong passingalong and betweenhe cylinder bores and s meteredby the headgasket headgasket nto and across the cylinder head o cool the pre-combustion hambers, valve seats and guides. Uponeaving the cylinder head, he coolant enters the thermostathousing, thermostathousing, n which s mountedhe positive shut-off thermostat,which thermostat,which ontrols he opening to the radiator radiator or heat exchanger.Upon exchanger.Uponbeing dischargedrom the thermostathousing, thermostathousing, he coolant enters the radiator or heat exchanger,depending exchanger,depending upon he application, wheret is cooledbefore cooledbefore reentry into the engine. Continental industrial diesel engines operate mosteffici most efficiently ently with coolant temperatures temper atures f 81°93°C 93° C (180°-200° (180°-200°F) F) and a thermostat thermo stat and bypass systems system s used o control these emperatures. The thermostat valve remainsclosed remainsclosed and only allows he coolant o circulate withinthe enginetself enginetself until normal operating temperaturesare temperaturesare reached. This provides for both rapid and even emperature increase of all engine parts during the warm-up

;ectional View howing oolant assages n Head nd ndBlock Block

EXPANSION OF WATER Water has always been th the e most commonly sed coolant for internal combustion nginesbecause nginesbecausett hasexcellent heat ransfer ability and s readily obtained everywhere. ike all liquids it expandswhen heated,he rate of expansioneing expansioneing1/32 1/32 iter per iter (1/4 pint per gallon) whenhe whenhe temperatures temperatures raised ° ° from 4 to 81°C 81°C 40 to 180°F). For example:f example:f a 4 gallon coolingsystems systems filled completelyull ofwaterat4° at4°C C 40°F), 1 pintwill pin twill be ost through the radiator overflow pipe by the time the water temperature temper ature reaches reach es 81°C 81°C (180°F). WATER FILTERS In some reas, reas, the chemicalcontent content of the water is such hat even he best of rust inhibitors will not protect the cooling systemrom systemrom the formation of rust andscale. andscale. There are instances where his corrosive elementhas ment has eaten holes throughcast throughcast iron parts suchas suchas water pump mpellers and bodies. This condi15

 

tion is caused by electrolysis taking place in the parts involved. Where these conditions exist, water filters should be incorporated in the assembly to remove these troublesome elements and offset the electrolytic action. EFFECT OF ALTITUDE ON COOLING Water boils at 100°C (212 °F.) °F.) under atmospheric pressure at sea level. This pressure becomes ess at higher altitudes and the reduced pressure causes water and other liquids to boil at a lower temperature. ANTI-FREEZES Water reezes at 0 °C (32 °F.), forms solid ice and expands about 9% in volume--which causes tremendous pressure and serious damage when allowed to freeze inside the cooling system. When operating operati ng temperatures tempera tures are below 0°C (32°F.) (32° F.) an anti-freeze anti-fr eeze liquid must be added which will lower the freezing point a safe margin below the anticipated temperature of outside air. Permanent anti-freeze will also raise the boiling temperature of the coolant. The correct proportion of anti-freeze is also important when the engine is to be operated under high ambient temperature conditions. OPERATINGTEMPERATURE OPERATING TEMPERATURE ANGE ANTI-FREEZE ETHYLENE GLYCOL (permanent type) When here are no leaks add water only to makeup makeup for eval~oration.

0° °o o -1 -12 °C 12 °C o ..2 23 3o oc (32 (32°o °o 10°F / t+ 10°o.10° 10°o.10°F)

.23 .23° °C o -34° -34 °C (-1 (-10° 0°toto-30° 30°F

Ratio Ethylene Glycol to water lto4

2to5

circulated. In standard radiator design fins are connected to the metal tubes to give an extended surface through which heat can be dissipated. It is important that these tubes be kept clean on the inside and the fins free of dirt on the outside so the maximum eat transfer can take place in the radiator.

RadiatorCoolant Coolantnlet nlet

Blowing out between the fins of the radiator, using compressed compressed air, in a direction opposite to that of the fan circulated air, will serve to keep he cooling surfaces of the core free of dirt and other particles. Operating conditions will will determine the frequency of this service. Every 500 hours of operation the radiator and cooling system should be well cleaned and flushed with clean water.

ltol

CORROSION INHIBITORS

/

WARNING

Corrosion inhibitor can cause damage to the eyes or skin. I contact is made, immediately wash skin with water. For the eyes, immediately flush the eyes with water for sev eral minutes. In either event, seek prompt medical attention. Read and observe safety

warnings on pages 1 and 2. Radiator

Water forms rust due to its natural tendency to combine chemically with iron and air in the system. Rust inhibitors for water are inexpensive, simple to use and make cleaning and flushing necessary only after long periods of operation. The adC~ition of a corrosion inhibitor is not necessary if an anti-freeze containing a rust inhibitor is used. RADIATOR The radiator or heat exchanger consists of a series of metal tubes through which which the coolant is 16  

Drain

Wherever possible, only soft clean water should be used in the cooling system. Hard water will cause scale to form in the radiator and the engine water jackets and cause poor heat transfer. Where the use of hard water cannot be avoided an approved water softener can be used.

CLEANING COOLING SYSTEM Deposits of sludge, scale and rust on the cooling surfaces prevent normal heat transfer from

the metal surfaces to the coolant and in time render the cooling system ineffective to properly maintain normal operating temperatures. The appearance of rust in the radiator or coolant is a warning that the corrosion inhibitor inhibitor has lost its effectiveness and should be cleaned before adding fresh coolant. Dependable cleaning compounds should be used. Follow the procedure recommendedby recommended by the supplier. This is of prime importancebecause importancebecausedifferent cleaners vary in concentration and chemical compositions. After cleaning and flushing, the system should be filled with an approvedanti-freeze compoundcontaining pound containing a rust and corrosion inhibitor. REVERSE FLOW FLUSHING Whenevera cooling system is badly rustclogged es indicated by overflow loss or abnormally high operating temperatures, corrective cleaning by reverse flow flushing will most effectively remove the heavy heavy deposits of sludge, rust and scale. The reverse flow flushin.g should be performed immediately after draining the cleaning

5. Apply air pressure gradually, to avoid radiator damage. 6. Shut Shut off the air, again fill the radiator with water and apply air pressure- repeat until the flushing stream runs out clear. 7. Clean and inspect radiator cap. To Reverse Reverse flush the engine water Jacket 1. Remove he thermostat. 2. Clamp he flushing gun in the upper hose. 3. Partly close the water water pumpopening pumpopening to fill the engine jacket with water before applying the air. 4. Follow the same procedure outlined above for the radiator by alternately filling the water jacket with water and blowing it out with air 5.5 Bar (80 PSI) until the flushing stream is clear.

WATER FLUSHING GUN AI~

solution. It is advisable first, allOwing the engineto toflush coo coollthe as radiator much as possible. R v rse flush the radiator, as follows: 1. 2. 3. with 4.

Disconnent the hoses at the engine. Put radiator cap on tight. Clamp the flushing gun in the lower hose a hose clamp. Turn on the water and let it fill the radiator.

CLOSED

FLUSHING

GUN AIR

-NEW

Reverse

HOSE

Flushing

Engine

TESTING THERMOSTAT HOSE

Removehe water outlet elbow. Before testing, Removehe clean and examine he thermostat. thermostat. If the valve can be pulled or pushedoff pushedoff its seat with only a slight effort whencold whencold or it does not seat properly, the unit is defective and should be replaced. Thermostat operation can be checked in the following method:

Reverse

Flushing

Radiator

1. Hang thermostat by its frame in a container of water so that it does not touch the bottom. 2. Heat the water slowly and check temperature with a thermometer. 17

 

3. If the v valve alve does not s start tart to open at ° temperatures of 81 °-93°C (180 200° 200°F.) F.) or if it opens well before the 81 °C (180 °F.) point is reached, the thermostat should be replaced.

Assemble new water outlet elbow mounting gasket. Thermostat flange must seat in counterbore with gasket sealing contact between it and the outlet elbow.

When replacing the thermostat in" the water header be sure the counterbore is clean.

RADIATOR PRESSURE CAP

/ Thermostat Open

85°C~

Checking Thermostat

When nstalling a new thermostat in the water header make sure that the temperature sensing unit goes in first or faces toward the cylinder head.

WARNING

If the coolant is hot or if the engine has beenrunning, loosen the pressure cap to the first stop and let the pressure out of the cooling sys system tem before removing he radiator cap. Read and observe safety warnings on pages 1 and 2.

Many operations use a pressure cap on the radiator to prevent overflow loss of coolant during during normal operation. This spring spring loaded valve in the cap closes the outlet to the overflow pipe of the radiator and thus seals the system, so that pressure developing developing within the system raises the boiling point of the coolant and allows higher temperatures without without overflow loss from boiling. Most pressure valves open at 0.3 or 1.0 Bar (41/2 or 15 PSI), allowing steam and water to pass out the overflow pipe, however, the boiling point of the coolant at this pressure is 107°C 107°C 224 °F.) or 120 (248 °F.) at sea level. When pressure cap is used an air tight cooling system is necessary with particular attention to tight connections and a radiator designed to withstand the extra pressure.

PRESSURECAP

PRESSURECAP PRESSURECAP CONTACT

Installing

SEAT

Thermostat

FAN BELT BELT TENS TENSION ION When ightening fan belts, loosen the the alternator adjusting bolts and pull out on the alternator by hand until the belt is just snug. Under no circumstances should a pry bar be used on the alternator obtain fan fan belt tension or damageo damageo the bearings bearingstowill result. Installing

18

New Gasket

Whenadjusted correctly the fan belt deflection Whenadjusted on the long side should not exceed 13mm1/2").

 

The water pump requires no attention other than bearing replacement when it shows excessive looseness or if a coolant leak develops which shows a damaged or badly worn sea seall that needs replacement.

REMOVING WATER PUMP

Adjusting Fan Belt Tension

CYLINDER BLOCK COOLANT DRAINS When he cooling system is to be drained, there is a drain plug on the side of the cylinder block which drains which might be trapped in the base of

completely right hand all coolant the block.

Coolant Drain

The water pump assembly can be removed from the engine as a unit for service or repair in the following manner: 1. Drain coolant. 2. Remove an by taking taking out four cap screws. 3. Loosen alternator so that fan belt can be slacked off enough o slide over pulley. 4. Remove asteners holding the pump body to the front of the block and remove the pump assembly.

Removing Water Pump

WATER PUMP

DISASSEMBLY OF WATER PUMP

The water pump s located on the front of the cylinder block and is driven by the fan belt from the crankshaft pulley. The inlet of the water pump is connected to the lower radiator radiator connection and the outlet flow from the pump pump s through integra integrall passages cast in the block.

When replacement of any internal parts becomes necessary, disassembly must be in the following sequence n order to prevent damage o the pump.

No lubrication of permanently the pump s sealed requiredtype as and the bearings are of the are packed with special lubrication for the life of the bearing.

cover (2) puller removing and impeller gasket (3).(4) taking 3. Use tocover remove precautions to prevent damage o the casting. 4. Removeeal Removeeal (5).

1. Use puller to remove an hub (11) from shaft. 2. Remove Remove countersunk screws (1) holding

19

 

l

rive Shaft

out in this direction

Disassembling

Water Pump

5. Remove ock rings (7) holding bearing and shaft assembly in body after which shaft (10) can be forced out through through the fron frontt with an arbor press or lead hammer. DO NOT ATTEMPT TO DRIVE WATER PUMP SHAFT (10) OUT THROUGH REAR OF HOUSING. To do so will damage the housing beyond repair. REASSEMBLY REASSEMB LY AND AND INSTALLATION 1. Reassemble pump, replacing worn or failed parts. Seal contact surfaces must be smooth and flat. The bushing should be replaced if scored or cut. A light film of lubricant applied to the face of the seal will facilitate seating and sealing.

2O

2. Use thick soapsuds on both the seal and shaft when assembling in order to prevent damage o the seal. 3. The fan hub must be installed prior to replacing rear plate. The shaft must be supported during this operation to prevent damage o the seal and bushing. 4. Mount pump assembly on block using a new housing gasket. 5. Install fan belt and adjust belt tension to have 13mm1/2") 13mm 1/2") deflection on long side. Pull out the alternator by hand, as bearing damagewill result with a pry bar. 6. Refill cooling system.

~

Please reference SPB88-374, SPB 88-374, C ark Water Pump

 

Secl "on Fuel System Thebasic The basicpurpose f the fuel systems systems to store, convey nd nject the fuel into the engine. The uel transfer pump raws he fuel from the supply ank, forces t throughhe throughhe filters anddelivers anddelivers it to the injection pump.The pump.The fuel injection pump places it under he high pressure equired for mechanicalatomization,meterst meterst with great accuracy, distributes it in the propersequenceo the various cylinders, commences he individual injections with fine precision in timing, and producesuniformly, producesuniformly, through he nozzles, he correct pattern of spray or the combustionchamber. combustionchamber. The njection systemof systemof a diesel engine ncludes an injection pumpassemblycomplete with governor,fuel supplypump, uel filters, high-pressuresteel high-pressure steel lines connecting he pump discharge outlets to the nozzles, and nozzle holders and nozzle assemblies, one for each cylinder. Not the least of theseare theseare the filtration elements, s fine particles of dirt in the fuel are extremely destructive to high-pressure pumps of any description. Carelessor too frequent removalof Carelessor of elements f the fuel injection systemor "inspection"or "cleaning" is generally ar moreharmful moreharmful han beneficial, beneficial, due o the dangerhat dirt will enter the exposed onnections and he possibility of mishandlinghe equipment hrough lack of knowledge f its design and construction. Various componentsre componentsre madewith the utmost precision and maybe maybe easily damaged hen removed. CAUTION: here hould e no ampering ith the njection pump ssembly, r removalfmpairednd it for inspection,nless inspection, nless engine peration s seriouslympaired seriously nd he cause caus ef thedifficulty the difficulty s directly raceable o thepump thepumpnit. It shouldbe shouldbe borne n mind hat minor roubles, suchas suction eaksat joints in the supply ine can suchas causeerratic enginebehavior. t is unlikely that the injection pumptself would equire overhaul efore t has several thousandhours of operation. All injection pumps hould be calibrated and repaired at authorizedservice authorizedservice stations, unless actory trained personnelare are available with the proper tools and est equipment. ELECTRIC FUEL TRANSFER PUMP

ManyContinental Many Continental TMDndustrial TMDndustrial

engines use

WARN NG Smokingr open lameshould Smokingr lameshould e avoided ny time he fuel systems being epaired r serviced. viced.The Improperandling Improper Thearea andling areashould should f fuel eproperly could esult entilated. in an explosionr ire causingodily odilynjury njury o yourself or others. Read ndobserve ndobserveafetywarningsnpages and .

electric fuel pumpso transfer fuel from he fuel tank to the fuel injection pump. hese lectric pumpsre pumpsre usually mounted o the crankcasefuel pumppad pumppad cover wherea wherea mechanicaluel pumpwouldnormally be mounted. Electric fuel pumpsill pumpsill operatewithout withouthaving having o crank the engine over. This makes hemextremely hemextremely useful when leeding theSystem.)They air fromTheydraw the fuel fue l system. (See Bleeding he Fuel System.) draw ittle batterycurrentand currentandonly only a slight drain is usuallyseen usuallyseen on the storagebattery during the bleeding process. process. Whenuel When uel pump rouble is suspected always check that the pumps pump s getting voltage from the ignition circuit and hat the BLACKround roundwire wire is intact beforedeclaring beforedeclaring he pumps bad A "quick" est for voltage s to turn the ignition switch on" and eel the bodyof bodyof the pump.Youcan Youcanactually feel the pump operating ndhear ndhear t ticking if the workarea s quite enough. f you can’t hear or feel the fuel pump operating checkor checkor actual batteryvoltage batteryvoltage o the unit before declaring it to be bad Usinga Usinga Voltmeteror Voltmeteror test light - checkor checkor voltageat voltageat the first wire connection closest o the his connection is usually foundat found at electric the fuelfuel shutpump. off solenoidon solenoid on the fuel injection pump. If no voltage is present - check he equipment electrical circuit for blown uses; brokenwires; bad switches;etc. etc. If voltage s present t the fuel pump make ne ne ast ast test before declaring the pump ad Loosenhe he fuel line fitting on he nlet fuel line on he injection pump.Fuel should flow and the pump should egin icking if it is operating roperly. If the pumps pumps operating, but volumeor volumeor flow needso needs o be checked simply simplydisconnect disconnecthe he fuel inlet line from he fuel injection pumpnd pumpnd urn the ignition switchon. switch on. Beprepared, Beprepared,with a container, o catch he fuel as it comes ut of the openine. openine. A steadysolid steadysolid stream f fuel indicates the fuel pu mp s probably OK or continueduse. continued use. Ahat broken brok enstream streamwith with bubbles anddribbles and dribblesor or no fuel at all indicates he fuel pumps probablybad bador or that there are restrictions restrictions somewhere 21

 

in the fuel circuit. There ouldalso alsobe be anair anair leak n the fuel pick up line on the suction side of the pump causing he pumpo pumpo cavitate. If restrictionsare restrictionsaresuspected n the fuel circuit, circuit, they are mostikely mostikely found o be beeither either pluggeduel filters or trashon the inlet side of the electric fuel pump. BLEEDING THE FUEL SYSTEM

Bleedings Bleeding s necessaryn necessaryn nitial installation of the fuel system, system,after after anysubsequent emoval, emoval, and finjection the system syste m houldbe hould be drained after having un outof out of fuel. Note: lectrical equipmentuchas starters starters should should e shieldedwith non-conductive aterial during the bleeding rocesso rocesso prevent amage rom uel entry. rom Also, be certain that all transmissions,earboxes, hydraulic ontrols, tc. are n a neutral osition efore attemptingo crankhe engine.f a wheeledehicles involved becertain becertain hat the wheels wheelsre"chocked" re"chocked" nd the parking rakes rakes set. CAV-DPA Fuel System Before bleeding and venting the CAVmDPA uel system nsure hat the outside of the vent screwsand surroundingarea s thoroughlyclean thoroughlyclean to preventdirt and oreign matter entering entering the system.

InjectionPumpents PumpentsCAV--DPA) Note: ilters of the ourboss our bossype ypemust must lsobe lsobevented vented at the pluggedoss; his must edone edonerrespective f theheight the height f the ilter in thesystem. thesystem. 3. Loosenhe vent vent valve itted on one oneof of the two hydraulic head ocking screws C), C), and he vent screw(D) on the governorhousing. governorhousing. Whenuel Whenuel free rom ir flows rom hevents, hevents,ightenhehousing vent screwand screwand hen the governor ent screw. 4. Loosen ny wo end.Set injector high pressureopipe nuts atthe njector end. Set he accelerator acceleratoro the fully openposition openposition and ensure hat the stop control s in the "run"position.Crank position.Crank ngine ntil fuel free fromair fromair flows. Tighten uts. 5. Energize he glow plugs. (Refer to page8.) page8.) 6. Start the engine. StanadyneFuel System 1. Turnhe ignition switch o the "on"position. "on"position. 2. Loosenhe filter outlet connectionA) or the fuel injection pumpnlet connectionB) connectionB) whichever s the higher higher ndallow uel to flow until free of air. Tightenhe connection. Note:f connection Note:f A) is inaccessibleue o the type of filter in use - loosenonnection B).

CAV--DPAuel System System chematic Note:Electrical Electrical equipmentuch uch s starters starters should e shielded uringbleeding uringbleedingo preventuel preventuel entry. 1. Turn he ignition switch o the "on" "on" position. 2. Loosenhe filter outlet (A), or the fuel injection pumpnlet connectionB) connectionB) whichevers whichevers the higher, andallow and allow fuel to flow until free of air. Tighten connections. 22  

TypicalSTANADYNE uelSystemchematic

3. Loosenny Loosenny wo njector high pressure ipe nuts at the njector end.Set end.Set he acceleratoro the fully open osition, andwith andwith the ignition switch "on", crank he engineuntil engineuntil fuel free from air flows. Tighten he line nuts. 4. Energize page8.) Energizehe he glowplugs. glowplugs. Refer to page8.) 5. Start the eng engine. ine.

new ilter elementn position and replace the bowl.Tighten bowl. Tighten enterstud enterstud o 6-8 b./ft. (8-11Nm). 5. Bleed the fuel system refer t page22, CAVmDPA uel system).

FUEL FILTERS

CleanFuel s a Must n diesel operation.Extreme CleanFuel conditionsmay equire additional filters to provide longer ilter change eriods when lean fuel is not available. Continental diesels are normally equippedwith the filter installed betweenhe fuel injection pump nd the transferpump transferpumputletutlet- so he filter is on he pressure side of the transfer pump. Theperiod The period for changinghe changinghe elementwill will largely depend pon he quality and condition of the fuel available. Under normal conditions the element should be renewedevery renewedevery 400 hours. This period shouldbe should be decreasedf decreasedf unavoidable ontamination f the fuel is experienced. Not Electricalequipmentuch s startersshould e shieldedwith non-conductiveaterial aterialduring during ilter replacing ndpriming primingo o preventuel preventuel entry.

CAV-DPA uel Filter The uel filter is of the paperelementype, ype, andno andno attemptshould attempt shouldbe be madeo clean he element. element.tt should be replaced whenperiodical whenperiodical maintenances maintenances being carried out or if there is reason o believe that the element s plugged. Under ormalconditions, conditions, water shouldbe shouldbe drained from the fuel filter approximately ncea ncea week.Poor week.Poor fuel quality andharsh andharshwork workconditions conditionscan canshorten shorten he weekly rain nterval to daily intervals. To Todrain drain he water rom he filter, simply oosenhe oosenhe drain plugat the bottom f the filter assembly/2 to 1 turn. Leavehe Leavehe drain plugopen ntil water-free uel is observed.Tighten Tighten he drain plug.

Glow lugs

Stanadyne uel Filter Note: his uel filter is not a water eparator.f water contamination s anticipated,an anticipated,an additionalprimary additionalprimary fuel filter andwater andwater eparator hould e nstalled before he fuel transferpump. transferpump. No attempt should should be made o clean this type element.tt shouldbe element. shouldbe replaced t the regularly r egularly scheduled periodic maintenancenterval or if there is reasono reason o believe hat it is plugged. To replace the metal canister elementsimply elementsimply release he two spring clamps ndpull ndpull the old elementoff ment off the filter bracket. Lube he new newelement element grommetsith grommets ith clean diesel fuel andpush andpush nto place. Snaphe spring clamps nto position and bleed the fuel system. (Reference page 23, Stanadyne uel System.)

hewater water fter the engine engineas Not It is best o drain he been t rest or awhile. hisallows hisallowshe he water,which whichs heavier, o separate nd ettle to the bottom f the filter. Alwaysrain hewater hewaterrom romhe he uel ilter with he engine ead ndelectric ndelectric fuel pumpff. pumpff. Toreplace he filter element: 1. Remove ilter bowl. ilter 2. Discard he dirty element.Remove element.Removend nddiscard discard the upperand upperand ower element ealing washers nd O-ring rom the the center stud. 3. Clean he inside of the bowlandcenter andcenter ube. 4. Fit the newupper upperand and ower sealing washers. Install newO-ring on the center stud. Place he

StanadyneuelFilter uelFilter (# TMD20FO0400) 23

 

INJECTORS

Wheneplacing eplacingnjectors njectors n the cylinderheadt headt is essential that a newheat newheat shield washer e fitted betweenhe nozzle capand he cylinder head. Reference age 9, HeatShield HeatShield & Injector. ) Injector Nozzle NozzleSide Side

Side View Tighten njectors evenly o 50-55LB-FT 50-55LB-FT70 70 Nm). Injectors shouldbe shouldbe takenout only if engine s malfunctioning s outlined below: 1. Misfiring. 2. Knoc Knocki king ngn one or more)cylinders. more)cylinders. Engineoverheating. overheating. 3. Engine 4. Lossof power. 5. Smokyxhaust xhaust black black or white) white).. 6. Increased Increaseduel consumption. consumption. 7. To perf perfor orm ma compressionest. The aulty injector injectors injoneach, ectors may e ocatedby ocated loosening he line fittingornut on each,n n turn, with by he engine unning t a fast fast idle. Thisallows he fuel to escape ndnot ndnot enter the cylinder. The njector least affecting the engineperformance engineperformancehould houldbe be removed from he cylinder head nd econditioned r replaced. CAUTION:oattempt attemptshould shouldbe be madeo adjust the injection pressure pressure ithout ithouta a proper estingpumpnd pumpnd pressureauge.t is impossible o adjust hesetting hesetting f the njectorwith njectorwith anydegree anydegreeff accuracyithout accuracyithout roper equipment.herefore equipment. hereforet is recommended hat adjustments nd/or epairsbe epairsbe madenly madenly byauthorized AV or Stanadyne epair centers,depending dependingpon ponhe he type systemnvolved.

manufacturer’snstructions for correct andsafe andsafe operation of the test equipmenthosen.

/

WARNING

Bodily injury may esult during his operation f care is not exercised. The high velocity f spray maypuncture may puncture the skin and cause blood poisoning. Keep hands and face away from nozzle spray. Read and observe observe safety warnings on pages 1 and 2.

Before esting, determinehe brandname brandname f the fuel injector about o be tested. TMDngines TMDngines urrently use njectors made y two different companies.One companys CAV nd the other is STANADYNE. hey look very much like, but are nevermixed nevermixed ogetheron ogetheron any oneengine, oneengine, because f different operatingpresoperatingpressures. Thenozzles The nozzlesare dentified by verysmall lettering on the outsideof outsideof the nozzleas nozzleas follows: CAV--stamped ust above he large hex portion ust of the nozzle. STANADYNEmstamped ust under one of the bleedoff bleed off tubes. After having dentified the nozzle, connectt connectt to the tester. STEP : Set tester so that it will applypressure applypressure nd then work the pump andle several sharp strokes. This will dislodge omeight carbon uild-up from he tip of the nozzleand may emove nyvery fine dirt particles n the nozzle avities. STEP2: Nowwork STEP2: Nowwork the pumphandle pumphandle slowly and observehe observe he opening ressure.Compare o the following chart. CAV

TESTING

Injectors should ot be disassemblednless esting showshat showshat cleaningor cleaningor other service s needed. Anydisassembly Any disassemblyff the fuel injectors shouldbe shouldbe done in an extremely lean workarea. workarea. Theexterior Theexterior of the injectors shouldbe shouldbe rinsedwith cleaningsolution cleaningsolution before testing. Becareful Becarefulnot not to flush any anydebris debris nto the open orts of the injector. Before esting eachnjector, turn it upside own andshake and shaket. t. This may et rid of any debris hat has just entered he nozzle nozzleduring during he removal removal ndcleanndcleaning process. Usea Use a special hydraulic njector tester equippe equipped d with a filter so hat onlyclean onlycleanoil enters he njector. Thereare many esters on the market--follow the 24  

Acceptableressure Acceptable ressure imits Newnjector=1900-2016SI Newnjector=1900-2016 (131-139BAR)

STANADYNE

Acceptableressure Acceptable ressureimits imits *Newnjector=2150-2250SI *Newnjector=2150-2250 (148.2-155.1 AR)

**Servicenjector=1755-2016SI **Servicenjector=1925-2250 **Servicenjector=1755-2016 SI (121-139BAR) (132.7-155.1 AR) *A new njector is an njector with no engine runtime" on t. **A service njector njector is consideredo be any njector that has hasbeen been in use or any injector that has been econditioned econditionedand andno no new parts were nvolved. The ower acceptableimit acceptableimit figures for the service injectors are necessary ue o nozzle needle needleembedment embedment andspring and spring relaxation that takes placeafter placeafter a nozzlehas nozzlehasbeen been ut into use.

Injectors that fail to meethe meethe acceptableressure acceptableressure limits should be adjusted by addingor addingor subtracting

shims. Shimsshould Shimsshould be available available from the CAV r STANADYNE ervice center which is performing the adjustment. Replaceany Replaceany injector that cannot be adjusted o meet he above ressure imit specifications. Not It is always good ractice ractice to haveall the injectors of any oneengine oneengine et as nearlyalike as possible.This possible. This makesor a smootherunning unning ngine.

by the trained eye of the CAV CAVor or STANADYNE technician. FUEL IN]ECTION PUMP

The unctionof unctionof a diesel fuel injection pumps to accuratelymeter meterand anddeliver deliver fuel to a nozzle n each cylinder and o inject it at high pressurento pressurento the combustionhamber hambertt precisely imed ntervals. The extreme recision necessaryan well be appreciated since this cycle must mustbe repeated housands f time per minutewith minute with virtually no variation in timing or amountff fuel injected. amount Checkhe Check he specification of your engine or your particular fuel injection pump. Removal f the Fuel Injection Pump

Checking njector OpeningPressure

STEP : Once he pressure setting has been confirmed, check he nozzlespray nozzlespraypattern. Holdconstant Holdconstant pressure n the tester lever to maintain he opening pressureof pressure of the nozzle. Watchor Watchor dribble from the sprayorifice, spray orifice, whichndicates whichndicatesabad abad eat. Also, ook for leaksalong leaks along he body f the nozzleholder nozzleholder tself, which indicates a leak between he holder and the valve body appedsurfaces. appedsurfaces.

Removell highpressureuel pressureuel lines beingcareful beingcareful not to bend hem.Disconnect ny ow pressure pressure uel lines, linkagerods or electrical wires that need o come ff to allow injection pumpemoval pumpemoval rom the engine. Remove he three long bolts that go completely he through he timing gear cover coverand emovehe emovehe injection pump.DO DOmounting NOTeparate he unless injectionabsolutely pump pumprom rom the adaptor plate necessary. This will save you much ime during reinstallation of the pumpf the pumps goingback onto the same ngine. (SeeShort (SeeShort Method g. 26.)

POOR

Typical CAV-DPAuel Injection Pump

GOOD NozzleSprayPatterns

STEP : Nowwork the pump andle rapidly (about 100 strokes strokes per minute) and observe he spray pattern produced. heckhat heckhat spraypattern spraypattern s a "straight "straight shot" or that it isn’t aimed ff to oneside. oneside. The pray pattern hould houl d xit the njector n the formof a thin line streamhat stream hat gradually ets a little widerbefore widerbeforedevel devel oping nto a small mist cloudout at the end. Wideor Wide or non-uniform praypatterns are questionable. If in doubt, he "judgementall" all" should e made

CAV-DPA INJECTION PUMP TheDPA istributor type fuel injection pump, TheDPA incorporating a sensitive all-speed al l-speed governor, s a compact,elf-contained compact, elf-contained nit for multi-cylinderdiesel multi-cylinderdiesel engines. It is a relatively simpledesign, simpledesign,and and ncorporates no ball orThe roller bearings,gears bearings, gearsor or highly hi ghly stressed springs. number f working parts remains he samerrespective of the number f enginecylinders enginecylinders the pumps required o serve. Thepump The pumps s flange mountedo the engine. t is 25

 

oil-tight, andduring andduringoperationall operationall moving arts are lubricated by fuel oil underpressure, underpressure, so that no additional lubrication systems systems required. Pressure maintained within the pump ousing prevents the entranceof dust, waterandother andother foreign matter. Fuel injection is effected by a single element having win win opposedlungers opposedlungersocatedwithin a transversebore n a central rotating memberhich memberhichacts acts as a distributor and revolves in a stationary member known s the hydraulic head. Thepump Thepump lungersare lungersare actuated by lobes on an internal cam ing. Fuel is accurately meteredo meteredo the pumping pumping lement,and lement,and he high pressure hargesare hargesare distributed to the engine engine cylinders at the required timing intervals through ports in the rotor and he hydraulichead. hydraulichead. The ntegral governors governors of the mechanicalllyyweight type, and gives accurate control of engine speed nderall nderall load conditions. Mostpumps Mostpumps avean avean automatic device which varies the point of commencementf injection. The single pumpingelement pumpingelement ensures uniform delivery of fuel to eachengine eachenginecylinder, cylinder, andelimiandeliminates having o balance he deliveries from eachof eachof the high-pressure elivery lines. WORKINGPRINCIPLE WORKING PRINCIPLE The internal cam ing, mounted n the pump housing, normally has as manyobes manyobes as there are engine cylinders and operates the opposedpump opposedpump plungers hrough am ollers carried in shoes liding in the rotor body. Theplungersare plungersare forced inwards simultaneously s the rollers contact the diametrically opposedam amobes. obes. This s the injection stroke. The plungers are returned by pressure of the inflowing fuel and his forms he charging troke. troke. Thepump The pumpotor otor is driven by the engine hrougha hrougha pinned hub and gear. Theaccurate The accuratespacingof spacingof camobes camobes anddelivery anddelivery portsensureshe ensureshe exactequality exactequalityof of the timing nterval between njections, and components hich affect timing are designedwith oneassembly oneassembly osition only to ensureprecision. ensureprecision. Fuel entering the pumphrough pumphrough the main nlet connections connection s pressurized y a sliding vane ransfer pump arried on the rotor inside the hydraulic head. Thepressure The pressure ise is controlledby a regulatingvalve regulatingvalve assemblyocated assembly ocated in the pump nd plate. The fuel then flows through the passages o the pumping elements. The outward travel of the opposedpumping opposedpumping plungers s determined y the quantity of fuel metered, whichvaries whichvaries in accordanceith accordanceith the setting of the metering alve. In consequence, he rollers which operate he plungersdo plungersdo not follow the contourof contourof the internal cam ing but contact he camobes camobesat at points whichvary which vary according o the degreeof degreeof plunger displacement. As he rotor turns, the nlet port s cut off and he single distributor port in the rotor registers with an outlet port in the hydraulichead. hydraulichead.At At the sameime sameime he 26  

plungers re forced nwards y the rollers contacting the cam obes, and fuel under njection njection pressure passes p the central bore of the rotor through he alignedports aligned ports to oneof oneof the injectors. The otor normally has as many nlet ports as the engine has cylinders,anda anda similar numberf numberf outlet ports in the hydraulic head. Thecam The camobes obes are contouredo contouredo provide elief of pressuren the njector lines attheend attheendof the njection cycle; this givesa sharpcut-off sharpcut-off of fuel andprevents andprevents "dribble"at the nozzles. nozzles. Thegovernor The governor lyweight assemblys assemblys mounted n the drive drive shaft and s contained ntirely within the pump ody. Linkage ransmits the movementf the governorlyweights lyweights o the control ever on the metering valve. The governorcontrol governorcontrol mechanism s enclosed in a housingmounted n the pump ody. OVERHAULPROCEDURE Dismantling, assembly, esting and adjustment of the DPA umpmust be carried out by trained personnel,using using specialized ools and est apparatus. Contact ourContinental istributor for details. TIMING OF INJECTION PUMP TO THE ENGINE

WARNING Bodilynjurymay mayesult esultduring duringhe he iming peraperation of thefuel injection ump f theengines running.DO DONOT ttempto ttempto adjust he timing without the pumpmounting olts securely torqued. Injection pumps ustbe ustbe installed on the engine in accuratealignment alignmentand and imed o correct relation with the crankshaft or properengineoperation operationwith with maximumower maximum ower and economy nd to prevent complaints of hardstarting, hardstarting, overheating, neven nevenunning andexcessivesmoking. excessivesmoking. Installation procedures nd iming methods ill vary depending n the make nd modelof modelof the Fuel Injection Pumpn use. TheTMD TheTMD ngine s equipped with either a CAV-LUCAS njection pumpor njection pumpor a STANADYNE njection pump.Be pump.Be sure of the kind of pumpnvolved nvolvedbefore beforeattempting attempting he installation and timingprocedureshat follow. Lookor nameplatesr raised etters etters on he body f the pump pumpor identification purposes.f identificationof identificationof the pump s difficult, call your ocal distributor for assistance.Besure Besure o have he engine enginemodel modelnumber, number, pecification number andserial and serial number vailable when ou call. Thenstallation and iming procedure procedureor the fuel injection pump ill be separatednto a Short ShortMethod Method and a Long Method.

The Long Methodmust Methodmust be used any time a new or reconditioned reconditioned njection pumps pumps involved or any time a newor newor other than original adaptor mounting plate is used. Also, any time an injection pumps pumps transferred from one engine to another. TheShort The ShortMethod Methods usedonly whenhe whenhe original injection pump,adaptor pump,adaptor mountingplate and crankcase are assembledogether. If an injection pump has been ested, ested, but no repairs werenecessary, t can be reinstalled using the Short Method.However, if repairs are necessaryo necessaryo the fuel injection pump, is nowconsidered now considered to used. be "reconditioned" and thet Long Method must be Short Method - CAV The ollowing steps are for reinstalling and timing the original Fuel Injection Pump ndAdaptor ndAdaptor Plate onto the engine from which t wasremoved: 1. Install a newO newO ring (P/N X07837)nto X07837)nto the groove on the adaptor mountingplate. mountingplate. 2. Lightly lubricate the O ing with motoroil. motoroil. 3. Rotate the crankshaft pulley clockwise (viewed rom the front) until the #1 piston is TOP DEADCENTER DEADCENTER TDC) on the COMPRESSION SIONstroke. stroke. TDCs TDC s when he notch on the front pulley lines up with the DCmark DCmarkon on the pointer plate. Not : Some ngines have DCmarks DCmarkson on the flywheel nda nda pointerpin fixed into the bell housing. Usually heseare hiddenby hiddenby an access over. The COMPRESSION troke is determined by looking for the single beveled ooth on the rear side of the injection pump rive gear while the engine s at TDC.The TDC.The njection pump rive gear s the smallerof smallerof the twogears twogearsvisible visible in the openingwhere opening where he injection pumpmounts mountso o the engine. f the beveledooth beveledooth is not visible in the opening, simply rotate the crankshaft pulley one complete revolution clockwise and check for the beveled ooth again. This is very important, becausehis becausehis engine will run with the injection pumpnstalled pumpnstalled 180 out of time. However,t runs very poorly n that condition. 4. Removehe screw plug and washer ocated on the front side of the timing gearcover. gearcover. It is positioneddirectly in front of the injection pu.mp gear. 5. Find a piece of roundstock roundstock approximately approximately / 4" in diameterand diameterand 5" to 6" long. Weldingod Weldingod or brazing rod minus he flux worksgood here. 6. Insert the 1/4" roundstock roundstock through through he gear cover and nto the .236" (6mm) eadend eadendhole hole the injection pump ear. 7. Guide he injection pumpnto pumpnto position and install the three long M10mounting olts, lock washers and nuts that secure the adaptor

mounting late to the engine. 8. Torquehe long M10mounting olts to 25-30 FT. LBS. (34-40 Nm). 9. Checkhat Checkhat the scribe markon markon the injection pumplange pump lange is matched p with the scribe mark on the injection inj ection pump daptermounting late. The two marks should look "as one" when he job is complete. 10. Checkhat Checkhat the three M8bolts that fasten the injection pump o the adapter mountingplate mountingplate are tight at 15-18FT. 15-18FT. LBS. (20-24 Nm). Nm). Note:Steps9 Note:Steps 9 and10 and10 maybe maybe unnecessaryf the injection pump asnever asnever oosenedrom oosenedrom or separated from he adaptermounting late duringreduring removalof of the pumprom he engine. 11. Removehe 1/4" roundstock roundstock from the gear coverand e-install the screwplug screwplug andwasher. andwasher. 12. Install the high pressure uel lines and torque he fuel line nuts to 20-25FT. LBS. 2734 Nm). Note: eave ny woof woof the injector line nuts oose at the nozzleswhichs part of Bleeding Bl eedinghe he Fuel systemsee system see page 2). 13. Re-connect ll electrical wires, linkage rods, low pressureuel lines, shut down ables, etc. 14. Bleed he fuel system see page page22). 22). Long Method - CAV The ollowing stepsare stepsare for installing and iming a newor newor reconditionedor reconditionedor other than original Fuel Injection Pump: 1. Grindor Grindor file off anyexisting anyexisting scribe markhat markhat maybe may be on the injection pump daptormounting daptormounting plate. A newplate newplate will haveno haveno scribe mark. 2. Install a new asket asketo o the front of the injection pump. (Gasket P/N TMD27B00300) 3. Install the adaptermounting adaptermounting late onto the injection pump sing the M8 M8screws, screws, lat washers, and ock washers.Tighten washers.Tighten screws inger tight. 4. Install the injection pump ear along with alignment dowel pin onto the injection pump shaft. Use hree M8screws M8screws (P/N (P/N X22132)and X22132)and lock washersor washersor mounting he gear. 5. Hold he gear n a soft jawedvise jawedvise and orque the three M8screws M8screws o 20-25 FT. LBS. (27-34 Nm). 6. Install a newO newO ring (P/N X07837)nto X07837)nto the grooveon the adapter mountingplate. 7. Lightly lubricate the O ing with motoroil. motoroil. 8. Rotate the crankshaft pulley clockwise (viewed rom the front) until the notchon notchon the   pulley is atthe 190-20 degree degreeBefore BeforeTop TopDead Center (BTDC)markon markon the pointer plate. 27

 

Not Some ngines semarks n the flywheel and a pointer in ixed nto thebell thebell housing.f this is the case,be case, be certain that youare youare workingwith the BTDC marks.Bell Bell housing ointersare ointersare usually hiddenby an access over. 9. Checkhat Checkhat the engine s on the compression stroke by looking for the single beveledooth beveledooth on the rear side of the injection pump rive gear. The njection pump rive gear is the smaller of the two gears visible in the openingwhere openingwhere he injection pumpmounts o the engine. If the beveled ooth is not visible in the opening,simply opening, simply rotate the crankshaftclockwise one evolutionand t will be visible. This is very important, becausehis becausehis engine will run with the injection pumpnstalled pumpnstalled 180 out of time. However,t runs very poorly n that condition. 10. Removehe timing hole cover from the side of the injection pump ousing.Turn ousing.Turn he injection pump ear until line "A" on the rotating rotating shaft lines up with the flat endof endof the snap ing (see below).

Note: eave ny woof woof the injector line nuts oose at the nozzleswhichs part of Bleeding he Fuel Systemsee System see page22). page22). 17. Re-connectall all electrical wires, linkage rods, low pressure uel lines, shut down ables, etc. 18. Bleed he fuel system see page22). page22). 19. Restamp he pump o adaptor mounting plate scribe marks.

WARNING Bodilynjury njurymay mayesult esultduring duringhe he iming peration of thefuel injection ump f the engines running.DO DONOT ttempto ttempto adjust he timing without the pumpmounting olts securely torqued.

Mark Injection Pumpiming PumpimingMark 11. Guide he injection pumpnto pumpnto position and install the three three long M10mounting olts, lock washers and nuts that secure the adaptor mountingplate mounting plate to the engine. Torque he M10 bolts to 25-30 FT. LBS. (34-40 Nm). 12. Checkhat line "A" s still lined upwith upwith he flat endof the snap ing. If it isn’t, rotate the body f the injection pump ntil it is. 13. Torque he three M8bolts M8bolts that fasten the injection pumpo pumpo the adaptormounting adaptormounting late to 15-18 FT. LBS. (20-24 Nm). 14. Rotate the crankshaft counter clockwise about 1/4 turn (viewed from the front). Then rotate clockwise, clockwi se, stopping stoppi ng at 19°-20 19°-20° BTDC. Re-checkhat hat line "A" is still lined up with flat endof end of snap ing. If not, reset. 15. Install the timing hole coveronto coveronto he injection pumphousing. pumphousing. 16. Install the high pressure fuel lines and torque the fuel line nuts to 20-25 20-25FT. FT. LBS. 2734 Nm). 28  

TypicalCAV-DPA CAV-DPA uel njectionPump

Typical CAV-DPAuel Injection Pump Pumpcut-a-way) cut-a-way)

STANADYNEMODEL MODELDB DB

INJECTION PUMP

ThemodelDB2njection DB2njection pumps describedas describedas an opposed lunger, inlet metered,positive metered,positive displacement, distributor type pump.TheDB2 TheDB2 umpncorpoumpncorporates a single pumping hamber. Precisedistribution Precise distribution betweenylinders, betweenylinders, inherent in the pumpesign, pumpesign,and and he ability to preset uel flow eliminatesengthy eliminates engthy eriods n the test stand.Thepump Thepumps self-lubricated,contains self-lubricated, contains ssentially he same umberf parts egardless f the numberf cylinders erved. WorkingPrinciple Working Principle Themain otating componentsrre Themain e the drive shaft, transfer pumplades, pumplades,distributor distributor rotor, andgovernor. andgovernor. Thedrive The drive shaft engages he distributor rotor in the he hydraulichead. hydraulic head.The Thedrive drive endof endof the DB2otor DB2otor incorporates two pumping lungers. The plungers are actuated toward each other simultaneouslyy simultaneously y an nternal caming cam ing through ollers andshoes and shoeswhichare carried in slots at the drive end of the rotor. Thenumber Thenumberff camobes camobesnormally normallyequals equals the number f engine ylinders. ylin ders. The ransferpump ransferpumptt the rear of the rotor is of the positive displacement ane ype and s enclosed n the endcap. endcap. Theend Theendcap capalso houseshe houseshe fuel inlet strainer and ransfer pump ressure egulator. The face of the regulator assemblys compressedgainst the iner anddistributor rotor and orms nend eal for the transfer pump. he njection pumps designed o that end hrust is against he faceof the transferpump transferpump pressureegulator. pressure egulator. Thedistributor Thedistributor rotor incorporates two chargingports chargingports and a single axial bore with one dischargeort to serviceall serviceall head utlets o the injection ines. Thehydraulic The hydraulichead head ontains he bore n which he rotor revolves, he metering alve bore,the charging ports and he head ischargeittings. ischargeittings. Thehigh Thehigh pressure injection lines to the nozzlesare nozzlesare fastened o thesedischarge these dischargeittings. ittings. The DB2pump DB2pumpcontains contains its own mechanical governor, capableof capableof close speed egulation, the centrifugal force of the weightsn their retainer is transmitted hrougha hrougha sleeve o the governor rmand rmand througha positive linkage to the metering alve. The metering alvecanbe canbe closed o shut off fuel through solid linkage by an ndependently perated hut-off lever, or by anelectrical anelectrical solenoid. Theautomatic The automaticadvance advances s a hydraulic mechanism whichadvances which advances r retards the pumping ycle. Note: There are various types of STANADY STANADYNE NE u uel el injection pumps used on the TMDengine. TMDengine. They are used n the 2 cylinder, 3 cylinder and 4 cylinder engine models. Various equipmentapplications equipmentapplications having different speed ranges and load ranges are involved. As a result, there are numerousnjection pumpiming pumpiming settings required to cover the manySTANADYNE manySTANADYNE pplications. To determinehe correct injection pumptiming o orr your particular engine, efer to ServiceParts Bulletin Bulletin 92-420.

Short Method - STANADYNE --Re-installing nd iming he originalFuel originalFuel njection Pumpnd Pump ndadaptor adaptorplate ontothe engine rom r omwhich which it was emoved. This methods identical to the STANADYN Long Long Methodhat follows except hat youomit youomit the first (5) five steps whenperforming he Short Method. Note:There s a chisel type scribe mark hat is Note:There stamped nto the injection pump ountinglange nto langeand and the adaptormountinglate. mountinglate. In most ases, t the end of Step 5, hesewo hesewomarks marks ill line up.However, up.However, on’t bealarmed bealarmedf theymiss theymissining ining upby upby a smalldistance. distance. The most important point about timing the STANADYNE njection pumps pumps the alignment of the internal timing marks Ref. Step 15) and he corresponding ocationof the front pulley iming ocationof imingmark markFlywheel Flywheel timing mark n some ngines). See SeeSPB SPB 2-420or the timingsetting timing setting required n yourparticular yourparticularengine. engine. Long Method - STANADYNE --Installing andTiming andTiminga New r Reconditionedr Reconditionedr other than original Fuel Injection Pump.

WARNING

Bodilynjurymay Bodilynjury mayesult esultduring duringhe he timing peration of the fuel injection ump f the engines running.DO DONOT ttempto ttempto adjust he timing withouthe hepumpounting pumpounting oltssecurelyorqued. oltssecurely 1. Grindor Grindor file off any existing scribe mark hat maybe may be on the injection pump daptor mounting plate. A newplate will haveno haveno scribe mark. 2. Install a newgasket P/NTM P/NTMD27B00300) o the front of the injection pump. 3. Install the adaptor mounting late onto the injection pump sing the M8 crews, lat washers and ock washers. ightenscrews ightenscrews inger tight. 4. Install the injection pumpear pumpearalong alongwith with alignment owelpin pin onto he injection pumphaft. pumphaft. Use three M8screws M8screws P/N X22132) nd ock-washers for mountinghe mountinghe gear. 5. Hold he gear n a soft jawed ise and orque he three M8screws M8screws o 20-25 FT. LBS. (27-34 Nm). 6. Install a newO newO ring (P/N X07837)nto X07837)nto the grooveon groove on the adaptor mountingplate. 7. Lightly ubricate he O ing with motor il. 8. Rotate he crankshaftpulley pulley clockwise viewed from he front) until the notch n he h e pulley s atthe timing setting prescribed n SPB 2-420. Note:Some Somengines ngines se marks marks n the flywheeland flywheelanda a pointer in ixednto hebell hebell housing, f this s thecase, thecase, becertain becertain hat youare youareworking working ith hecorrect hecorrectset set of marks. ell housingointers housingointersare areusuallyhidden usuallyhidden y an access over. 9. Checkhat Checkhat the engine s on the compression 29

 

stroke ylookingor thesingle thesinglebeveled beveledooth n he ear sideof side of the njectionpump pumprive rivegear, gear, he njectionpump drivegear drive gears s thesmaller thesmaller f the wogears wogears isible n the opening herehe herehe njectionpump njectionpump ountso the engine. If thebeveled thebeveledooth s not visible in the opening simply otate the crankshaft ne evolution lockwise andt will be. This s very mportantecause mportantecause his engine ill run his ° out of time. with the injection pumpnstalled 180 However, t runs erypoorly erypoorlyn n that condition. 10. Remove he timinghole timingholecover cover rom heside of the injection pumpousing. pumpousing. 11.Turn 11. Turnhe he njectionpumpear ntil the nternal iming marksre ined up. (SeeBelow). .

1. TIMINGMARK

Turnhe Turn he njection umpear ntil timing marks aligned ith hepointer. hepointer. 12.Guidehe njection ump 12.Guide ntoposition ndnstall nto ndnstall the three ongM10mounting mountingolts, olts, lock washersnd washersndnuts that securehe securehe adaptormountinglate mountinglate o the engine. Torquehe Torque he M10 olts to 25-30 t. Ibs. (34-40 (34-40Nm). Nm). 13. Inspect he nternal timingmarks timingmarks gain.The gain.The wo marks houldook houldook ike oneunbroken oneunbrokenorizontal ine. If not, youmustudge mustudgeas to whetherhe whetherhe pump ear is one oothor oothor more utof timeor timeor if a minorotation of the injection pump odywill align the marks. If the marksre marksre ar apart, epeat tep12, tep12,because because the pumpear s probablyut probablyut of time. f the marksre veryclosetogether, otate he body f the njectionpump njectionpump oneway one way r the otheruntil otheruntil the marksine up. 14.Torque 14. Torquehe threeM8 threeM8 elts that fastenhe fastenhe njection pumpo the adaptorlate adaptorlate o 15-18t. Ibs. (20-24 m). 15. Re-check he timing marks fter eliminating he he backlashnd backlash ndplay hat may e n the iming imi nggear gear rain. This s done y otating hecrank ulleycounter ulleycounter lockwiseapproximately wise approximately/4 /4 turn (viewedrom (viewedrom he front). Thenotate Then otate hecrank hecrank ulleyclockwise ulleyclockwisentil ntil it is back to the prescribediming imingposition. position.Check Checkhe nternal timing marks nceagain nceagainand andadjust adjust if needed. 16. Install the timinghole timingholecover coverand andgasket nto he injection pump ousing. 17. Install the highpressure highpressureuel lines andorque andorquehe he fuel line nuts o 20-25t. 20-25t. Ibs. (27-34Nm). Not Leave nyswoof wo of the fuel line nuts oose at the nozzles which part of Bleedinghe Bleeding he FuelSystem. Fuel System. (SeePage (See Page 3). 18. Re-connectll electrical wires; inkage ods; ow 30  

pressureuel lines, etc. 19. Bleed he fuel system. SeePage SeePage 3). Overhaul Procedure Dismantling, ssembly,esting esting andadjustment andadjustment f the DB2 ump ust e carried out by trained personnel, usingspecialized using specializedools ools and est apparatus. STANADYNEDB

INJECTION PUMP

Welder or Generator Set Governor Normally,he he DB2 anproduce anproducetable tablegoverning governingtt 3% regulationor welderr welderr generatorets.This ets.This an eobtained eobtained at either1500 either150050 50Hertz) r 1800 PM 60Hertz).The Hertz).The peed droop ontrols usedwherehe egulations adjusted hile thegenerator the generatoret s operating.he operating.he xtemalontrol ontrol nob ith an nternal crewhread itchsimilar itchsimilar o thegovernor thegovernorpring pring pitch s adjustedo add r subtract ctivecoils, ctivecoils, as shown.

Speedroop overnorontrol ontrol Onlyminor minorhrottle hrottle evertrimming s necessary.hus single springmay spring may llowa llowa droop djustmentf approximatelyto 5%.Asingle singlegovernor governorpring pringmay lsobe lsobeselected selected hich ill regulatehis regulate his droop djustment ange t beth1500 beth1500 nd1800 RPM.he RPM. henherent nherentelf elf goveming eature f inlet meterings especiallyadvantageous or such losegoveming losegovemingontrol. ontrol. This s further aidedby the ex extremely tremelyow ow massesnd massesnd resulting nertia forcesof forcesof the meteringalve meteringalveand andgovemor components.udngnitialset-upof awelderorgeneratorset, the speed roop ontrol must eadjusted o provide he sharpestegulation sharpest egulationpossiblewithout urge r combustion instability. Tuming he speed roop crew lockwiseroadhe lockwiseroadensAfter egulation and educes the proper roop nstability. etting s achieved, achieved,igh igh dle mustbe must be readjusted. Fuel Delivery CurveShaping CurveShaping or High Altitude use on Welder and Generator Set Pumps Maximum uel delivery on welder uel welderand andgenerator generator et pumpss adjustable to reduceexhaust reduceexhaustsmoke smoke nder high altitude conditions.The The etting may e done ither onan onan njection pumpest stand r by rial-and-erroron a completemachine. completemachine. Thesimplest methods methods to run the machine t maximumutput at high altitude. Loosenhe Loosenhe torque screwam screw amnut nut and urn the torquescrew torquescrewn n (clockwise) until exhaust mokes reducedo reducedo acceptableevels. acceptableevels. Retightenhe Retighten he jam nut. If machine smay returned o operation t sea evel, thethe torquescrew torque screw ebacked ebacked out to restore ull sea evel power.Noadjustment Noadjustmentill normallybe normally be required or operation operationunder under3,000 3,000 eet. (SeeTorque (See Torque crew ocation,page ocation,page 1 .)

Contact your Continental distributor distributor

Torque screw location

for details.

Typical DR2Fuel DR2Fuel Injection Pump

FUEL RECOMMENDATIONS Diesel fuel selection, handling and filtration is of great importance. The fuel not only supplies the energy for all the work work done by the engine- it also lubricates the parts of. the fuel injection system which operate with very close tolerances. Fuel that contains water, abrasives, or sulphur in excess of our recommended pecifications can cause extensive damage o the injection pump and engine. DIESEL

FUEL SPECIFICATIONS

Continental Diesels have been designed and developed to use ONLY o. 1-D (light fuel) and preferably No. 2-D (heavy uel) -- whichcan whichcan be a cracked esidual, a blend of preferably a straight-run distillate having he following characteristics: Refer to page 11 for seasonal fuel recommendations. (listed

in order of importance)

DIESEL FUEL CHARACTERISTICS

RECOMMENDED LIMITS

EFFECT

Cetane Number

Indicative of Ignition Starting and Idling.

Volatility: Initial Boiling Point

To prevent prematu premature re vaporization during hot weather operation.

50% recovery 90% recovery End Point Distillation

Recovery

SU Viscosity 10 100 0°F. (3 (38 8 °C) °C)

Quality,

Higher number--better

50 desired 45 minimum 320 °F. minimum mini mum

Less smoke with fuel at low 50% and 90% Recovery Temperatures. Higher end points only partially burn, causing build up of deposits in energy cell and nozzle, causing pintle sticking and smoke.

550 °F. maximum

causeL°wer mokerecoverYand ,oorindicateScombustion.heavy il fractions hich Viscosity is a measure of flow resistance--the low limit minimizes leakage and lubrication and the higher

98o/o

limit insurespenetration insurespenetrationndatomizations. ndatomizations.

rapid pump pumpwear wear and

650 °F. maximum maximu m 700°F.

maximum

31 - 40 seconds

Water and Sediment

Water in fuel causes corrosion; clogged ilters,

Pour Point

Fuel Oil must be in fluid to congealing wax.

A.P.I. Gravity ~_~60 ~_~60 °F.

Lower Gravity Fuels contain more heat Units/Gal.

Total Sulphur

Sulphurous acids corrode and increase engine wear.

.5O/o maximum

Corrosion 3 Hours (Copper) @ 212°F. 212°F.

iscoloration or pitting onparts. polished copper strip shows same effect on engine

pass test

Ash

Amount of non-combustible non-combustible m material aterial causes pump wear.

.01% maximum by weight

state to prevent clogging due

is abrasive and

.05°/o maximumby maximumby volume 10° below lowest anticipated operating temperature 30 minimim (A.P.I. Degrees)

31  

Section E; - Charging System

8

FUSE

~C

RECTI~

l

~toW~RE

Y--4"~\ Y--4 "~\ =PUMP OLENO,D.

I~.

I

///

~~ ~

ELAY ~

ABLE

~CmT ~

"

I 5~

~’~

~

~ 2~ ~4

GLOW PLUGS MOToRG

IE~;;

AMP WARNING FL1

WlREing

I ment with with connectors pointd° d°wn wn

INDICATOR LAMP 2W MAX.

~ ..... ~l~l~ WIRING

DIAGRAM

NOTE: ALL WIRING TO BE STRANDED.

MURPHYSWITCH

SWITCH LOWOIL

ROL I CO~ UNIT~ t

-

SOLID

SWITCH HIGH WATER TEMPERATURE

I

I LIGHT

HOURMETER (OPTIONAL)

TO FUEL SHUT~OFF SOLENOID

L.~]

~

I

I

*/

,

I OIL & WATER

SW TCH

ALL WIRE #16 AWG AWGUNLESS UNLESS OTHERWISENOTED OTHERWISENOTED SYMBOLS

(//

(//

PUSH BOTTON

~ #8 AWG

----’~F

INTERNAL GROUND

~ ~

PUSH ON CONNECTOR PUSH ON CONNECTORCONNECTOR -

FEMALE MALE

ALTERNATOR

~’ /--

NTACTOR L~c~:::::~T~h ~JL-~J NOT FURNISHED ’~ E~ll

c= ~.

U NO.

4

GLOWPLUG GLOW PLUG

ll=-]-~l~

TYPICALPOWER NIT TYPICALPOWER WIRINGDIAGRAM WIRING DIAGRAM

STARTER

The chargingcircuit chargingcircuit consists primarily of an alternator, regulator, battery and wiring. When analyzing the charging circuit, the components components should be checked n the following order:

Wiring Wiring in the charging circuit should be carefully inspected or frayed insulation "or othe.r damage,and damage, and replace any wiring that is defective. Also inspect all connections connectionso o the alternator, regulator and battery (including all ground connections), and clean and tighten as required. 32  

II. Battery Battery condition is very important for proper starting. The lead-acid storage battery, used on automotive and industrial applications, is an electrochemical device for converting chemical energy nto electrical electrical energy. It has two major functions: 1. It p prov rovid ides esa sourceof sourceof current for starting the engine.

2. It can, for a limited time, furnish current when he ele electrical ctrical demands f the unit exceed the output of the alternator.

/

WARNING

Stop ngine efore heckingattery heckingattery erminals r electrical connections. parksrr flames eara battery ould parks causenexplosionr explosionr fire. Battery cidcan cidcancause causeorrosiveburns.Always Alwaysear ye yeprotection. protection. seof jumper cablesor cables or battery charging houldbe houldbe doneonly doneonly as directed y manufacturers’ afety nstructions. Read ndobserve ndobserveafetywarningsn warningsn pages and2. and2. Refer to equipment manufacturer for battery recommendations. III.

Alternator The alternator differs from the conventional D.C. shunt generator in that the armature is the stationary memberand is called the stator: while the field is the rotating member memberand and is called the rotor. Alternating current is rectified (changed to direct current) by means meansof of diode rectifiers rather than mechanically with brushes coming into contact with the various segments of the rotating rotating armature on the generator. With this construction, the higher current values involved in the armature or stator maybe conducted to the external circuit through fixed leads and connections rather than through the rotating commutator and brushes as in in D.C. generator. The comparatively small values of current supplied to the field may be conducted without difficulty through small brushes and rotating slip rings. The alternator is somewhat ighter and more compact in design than the conventional D.C. generator of comparable electrical size and is equally as simple to service and test. Each bearing is prelubricated which eliminates the need for periodic lubrication.

Precautions to be observed when esting or servicing the alternator system: 1. Disconnect the battery, before connecting or disconnecting test instruments (except voltmeter) or before removing or replacing any unit or wiring. Accidental grounding or shorting at the regulator, alternator, ammeteror ammeteror accessories, will cause severe damage to the units and/or wiring. 2. To avoid damage o the regulator, do not, at any time, connectbattery connectbattery to the regulator field terminal. 3. Th field circuit must never be grounded, on this system, between the alternator and the regulator. Grounding of the field terminal either at the alternator or regulator will damage the regulator. 4. If it is nece necess ssar ary yo solderany solderany ead to a rectifi r lead, use a pair of pliers as a heat dambetween dambetween the solder joint and the rectifier.

5. The altern alternator ator must not be operate operated d on open circuit with the rotor winding windingenergized. energized. 6. Do n t attemp attemptt to po polar lariz iz the al alter ternat nator. or. No polarization is required. Any attempt to do so may result in damage to the alternator, regulator, or circuits. 7. Grounding Grounding of the al alternat ternator or output termin terminal al maydamage may damage he alternator and/or circuit and components. 8. Rev Revers ersed ed batter battery y connec connectio tions ns may maydamage damage he rectifiers, wiring or other components f the charging system. Battery polarity should be checked with a voltmeter before connecting the battery. 9. If a booster boosterbatter battery y or fast charger charger s used, its polarity must be connected correctly to prevent damage o the electrical system components. (positive to positive, negative to negative.) IV. Regulator Most regulators are fully transistorized and completely sealed. These cannot be adjusted or repaired, and it can be assumedhat this type regulator will outlive the other componentsn the charging system. Other regulators are adjust adjusted ed and repaired in accordance with the manufacturer’s instructions. Installation of Regulator or Alternator To insure proper operation and to protect the alternator and regulator, the following steps should be observed observed during installation. Makesure regulator is of the s same ame voltage 1. Makesure and polarity as the alternator and battery. 2. Disconnect battery cable at battery terminal. 3. Make Make sur sure e the mounti mounting ng area area of the alteralternator and regulator base are clean and make a good tight connection. 4. Connect Connect altern alternator ator in accordanc accordance e with the the manufacturer’s instructions. 5. Do not flash field or ground ground terminals terminals of the regulator. 6. Reconn Reconnect ect batter battery y cable. cable. 7. Start engine engine and observe observe ammeter. ammeter. A "High" "High" charge rate is normal for the first few minutes, but will decrease as the battery recharges.

Note: When Whenservicing servicing

the charging system, never

remove a unit until tests shown to to be defective. Reference always alwayshave should beitmade the manufacturer’s maintenance manuals for complete trouble shooting instructions. 33

 

Section 7 Prevenl:ive Maintenance In order to obtain maximumfficiency from your diesel engine, a definite maintenance program should be set-up and followed. Haphazardmaintenancewill only lead to faulty engineperformance engineperformancend nd shortenengine shorten engine ife. All moving arts in the engineare engineare subject o wear; however,wear however, wear can be reducedby reducedby careful operation and a planned maintenanceprogram. maintenanceprogram. In general, diesel engine operation demands carefulattention careful attention o the cleanliness f air, fuel and il and maintaining coolant operating temperaturesof temperaturesof 81 °-93° -9 3°C C(180 (1 80° °-2 -200 00° °F. F.). ). The ollowing pages,covering pages,coveringDaily, Daily, 50, 250, 400 and 500 hour maintenance, have been worked out with our field servicedivision servicedivision as "Minimumequirements" "Minimumequirements" to keep our enginen enginen dependableperating ondition. DAILY PREVENTIVE MAINTENANCE SCHEDULE 1. OVERALL OVERALLVISUAL VISUAL INSPECTION OF ENGINE Look or evidence f fluid leaks on floor, cylinder headand head and block, indicating loose fuel, oil or water connectionsmtighten f found. 2. CHECKOIL CHECKOIL LEVEL OF ENGINE Thedipstick The dipstick indicates the high and ow oil level in the crankcase--makellowance or additional oil drainage back nto oil pan f engine has not been stopped15 stopped 15 minutes. Themost Themostefficient oil level is betweenhe between he two dipstick levels. IMPORTANT: onot addoil until oil level approaches he lowmark--then low mark--thenddonly onlyenough enough o bring t to high evel-NEVERbove. Donot operatehe engine ith oil belowow evel mark. mark.

when eated. Visually inspect i nspect fan andbelt andbelt for condition and adjustment. 4. FILL FUELTANK FUELTANK Fill fuel tankat endof endof day’soperation day’soperationo prevent condensationorming condensation orming in tank. Clean iller cap and areaaround area around poutsystem. poutbefore before illing of dust nto fuel

to prevententrance prevententrance

5. CHECK CHECKAIR AIR CLEANER All engines, whenoperating, whenoperating, consumeeveral consumeeveral thousand ubic feet of air per hour. Sincedusty Sincedusty air is full of abrasivematter, abrasivematter, the enginewill enginewill soonwear soonwear excessivelyff the air cleaner doesnot excessively doesnot removehe removehe dust before entering he cylinders. Onany On any air cleaner, operating environment ictates the air cleaner service periods. In extremely dusty operations his may e onceor twice daily. In dust protected areas the air cleaner should be serviced when hangingoil. hangingoil. One asic type of air cleaner s normallyused-normallyused-the dry replaceableelement replaceableelement ype. DRY TYPE REPLACEABLEAIR FILTER Dry type air filters are standard standardequipment equipment n many nginesand nginesand t is most mportant hat the dirt buildup n the cartridge doesnot doesnot reduce he air flow sufficient to causea noticeable oss in power. They should normally be serviced serviced every 50 hours in the following steps: (Extremeconditions will requiredaily requiredaily cleaning.) Removeover and cartridge after removingwing bolt - donot donot allowdirt to fall into ~e ~eexposed exposedarburetor. arburetor. Clean cartridge by gently tapping flat on a smooth orizontal surface to loosen and remove removehe he heavierdirt heavier dirt deposits. CAUTION: onot damage he gasketsealing he gasketsealingsurface or bendhe bendheouter outerscreen screenortion f thecartridge thecartridgewhile cleaning. eplace hecartridge hecartridgeff in doubt The cartridge can also be cleaned with compressed ir, but it is important o use he following guidelines: ¯ ALWAYSeep air pressure adjusted to less than30 psi (2 Bar).

WAR ilNG Check il Levelof Levelof Engine 3. CHECK CHECKRADIATOR RADIATOR Fill radiator with a clean50/50water/anti-freeze 50/50water/anti-freeze mixture to normal evel maintaineddue maintaineddue o expansion 34  

Wear rotective lasses r a faceprotect faceprotect whneverair ever air hosesre reused. used.Never Never seair seair pressurhat hat is more han pou ndsersquare ersquare nch)and nch) make ure he2 heair airBar line30ispounds equipped itha ith a waterlit water litand r to prevent am amage age o parts. Readndobserve observeafety afetywarnings warningsnpag I and .

¯ ALWAYS eep he tip of the air nozzle eep nozzleor or air hose at least 2 inches (50mm) from the paperportion paper portion of the cartridge. ¯ ALWAYSlow th cartridge clean from the inside out. CAUTION:ailure to complywith the aboveguidelines will damagehe damagehe cartridge and lead to severe engine damage.Replace Replacehe cartridge if in doubt

Often n cleaning the cartridge it is tapped against surfaces hat are not flat, thus damaging sealing edges.Regardless edges.Regardless f howcleanhe howcleanhe paper s, if edges re damagedirt will enter the engine. The element should be replaced every 250 hoursor hours or when ervicing doesnot doesnot result in full power ecovery whichever ccur ccurs s irst. Under extremedust conditions, more requent replacement ill be required. NOTE:A 1/4 teaspoon of dust per hour can ruin an engine engine in one 8 hour day.

PCV SYSTEM All connectionsmust connectionsmustbe be air tight. Blow-by circulates into the intake manifold maintaining crankcase pressure within a narrow range regardless of operating speed speedor or load. Servicing of the PCVsystem PCVsystem is confined to checking he conditions of the hosesand hosesand connections. CleaningDry TypeAir TypeAir Filter

Wipe nside screen, cartridge gasket surface, inside cover and mountingseat mountingseat before installing element. Place cartridge on mounting seat-make sure outer edgeof edgeof cartridge fits inside edgeof edgeof bottom plate. Replace cover and assemble wing bolt finger tight to insureair insureair filter seal. Typical TeledyneContinental TeledyneContinental Motors P PCV CVSystemnstallation CAUTION:Do Do not wash or oil

cartridge.

ReplacingNew Replacing NewCartridge. Cartridge. Replace immediately if bent, crushed or damaged. Dry type air cleaners are efficient only as long as top and bottom sealing edges are not damaged. Also surface of air cleaner base and cover whereair where air cleaner cartridge seals, must be clean and not damaged, uch as dents or bends.

CHECKOIL CHECK OIL PRESSURE Note oil pressure gaugewhich gaugewhich should indicate the following pressure angeat angeat full throttle anda anda minimum f 0.5 Bar (7 pounds)pressure pounds)pressure at idling speed. MODEL

TMD

OIL PRESSURE

2.8- 4.1 Bar (40- 60 PSI)

Higher oil pressures pressuresmay may e experienced uring cold starts.

35

 

NOTE ANY UNUSUAL NOISE Operators amiliar with daily engineoperation engineoperation soonbecome soon becomelert lert to anynoise not normallypresent. normallypresent. This s veryvaluablen valuablen correctingdefects n the early stages andpreventingexpensive preventingexpensive epairs or delays. EVERY 50 HOURS

1. REPEAT REPEATDAILY DAILY OPERATIONSOUTLINED Follow previous Instructions. 2. CHANGE CHANGECRANKCASE CRANKCASEOIL Engine ife is dependent pon clean oil being circulated to all moving arts; therefore, the frequency f oil changes nd oil filter replacements very important and should be made madeat at regular, scheduledperiods. heschedule hescheduleor or changing il is directly dependent upon the operational environment: an extremely clean operation could go 100 hours while a dirty operation foundry or cementactory) cementactory) could 50 hours hours or less. Replacehe oil filter element very ime the oil is changed. Thoroughlyclean Thoroughly clean the sealing surfaces before replacing new element and gasket. Donot put kerosene nto the crankcase.The crankcase.The best methods methods to drain the the oil when he engine s thoroughlyheatedmwhichill heatedmwhichill carry off mostof the sediment.

Fan elt Tension 5. CHECKBATTERY CHECKBATTERY

/

WARNING

Stop ngine efore heckingattery heckingattery erminals electrical connections.parks parks r flamesnear neara a batterycould battery could ause n explosion explosionr fir . Battery acid acidcan cancause cause urns.Always Ar lways ear eareye eye protection. se orrosive f jumperables jumperables battery hargingshould ing should edone edone nlyas nlyasdirected directed ymanufacturymanufacturers’safetynstructions. safetynstructions. Readnd bserveafetywarningsnpages and .

Checkspecific gravity of each cell--which Checkspecific should be at least 1.250. Adddistilled Adddistilled water, if required, to raise level 9.5mm3/8") 9.5mm 3/8") above he separators.

Some perators perators unwisely put kerosene n the crankcaseafter crankcase after draining the engineoil, engineoil, then turn the engineover engineoverwith the starter--In the belief they are doing a better job of crankcase leaning. In doing his, kerosenes circulated through he oil pump, he main oil header and the branches leading into the engine bearings--therebywashing awayhe away he protectiveoil film. In addition, some f the kerosene ill be trappedand trappedand emain o thin out the new il, reducingts lubricating qualities. 3. SERVICE AIR CLEANER Cleanelementwith elementwith compressedir. compressedir. (See Daily Instructions.) Be sure that no unfiltered air can enter the engine. 4. CHECKFAN CHECKFAN BELT TENSION Inspect wearcondition wearcondition of fan belt; note alignmentandcheckbelt mentand checkbelt tension whichshould whichshould allow not over 13mm1/2") deflection on the long span. 36  

Checkingattery Particular attention shouldbe shouldbe given he battery during cold weather.The weather.Thecranking crankingpowerof powerof a fully chargedbattery charged battery @27° @27°C C (80°F.) (80°F.) is reduced redu ced 60% -18°C -18° C 0°F.)---bu F.)- --butt yet the power pow erequired equired o crank he engines 2 1/2 timesgrea timesgreater ter at -18°C -18°C 0°F.) than 27°C 27° C (80@ (80@F.). F.).

6. DRAIN WATER ROMFUEL FILTERS(S) Note:Some Note: Someuel filters are not equipped ith a water drain. (SeeFuel (SeeFuel Filters, page23.) page23.) 7. ADJUST IDLE SPEED TO EQUIPMENT MANUFACTURERSRECOMMENDATION Repeatagain Repeat again at end of 500 hours.

EVERY 400 HOURS 1. REPEAT REPEATDALLY DALLY AND AND 50-HOUR SCHEDULES Follow previous nstructions. 2. FUEL YSTEM See fuel filters Replaceuel filter element. Inspect mountingand gaskets.

EVERY 250 HOURS

Check ll connectionsor connectionsor leaks.

1. REPEAT REPEATDALLY DALLYAND AND 50-HOUR SCHEDULES Followprevious nstructions. 2. CLEANEXTERIOROF EXTERIOROF ENGINE

- page 23)

EVERY 500 HOURS

Use steam f available, otherwise any good commercialengine engine cleaner to washdown washdown he engine.

1. REPEATDALLY DALLYm m 50 HOURAND250 HOUR SCHEDULES.

CAUTION:ever allow cool water to come n contact with the fuel injection pumpwhile the engine is running Injection pump eizure may esult.

2. COOLING COOLINGSYSTEM SYSTEM Clean radiator core by blowing out with compressedair.

3.

Inspect radiator mounting.

CHECKGLOWPLUGS CHECKGLOW PLUGS

Inspect water pump nd connections or leaks.

Inspect glow plug wiring.

Check an and accessory accessorydrive drive belts. 3.

ADJUST VALVE TAPPET CLEARANCE

Check and adjust intake and exhaust valve tappets to following clearancesat clearancesat operating temperature. MODEL

INTAKE

EXHAUST

TMD

0.36ram

0.46mm

(.014")

(.018")

Glow Plugs

4. SAFETY AND THERMALCONTROLS THERMALCONTROLS 4. IF DRY REPLACEABLE ELEMENT AIR CLEANER S USED, REPLACEELEMENT. REPLACEELEMENT.

Inspect control wires andconnections. andconnections.

5. HOURSRECOMMEND HOURS RECOMMENDDJUSTDJUSTINGFIRST VALVE250 TAPPET CLEARANCE.

37  

NOTES

38  

Section 8 - Engine Repair and Overhaul This section includes instructions for repairs and overhaul of the componentunits componentunits of Continental industrial diesel engines.

4. Disconnect the injectors and leak-off lines at both the nozzle and pump connections.

Provide a clean place to work and clean the engine exterior before you start disassembling-dirt

causes engine failures.

Many shop tools have been developed to save time and assure good workmanship; these should be included in your equipment. Use only genuine Continental parts in Continental engines since years of development and testing have gone into these specifications to assure maximum ife and performance.

CYLINDER HEAD The cylinder head is the most important part of the engine assembly since it contains the complete combustion chamber ncluding valves, fuel injection nozzles, glow plugs, and cored passages for air, exhaust and water flow flow.. REMOVING THE CYLINDER HEAD 1. Drain water from engine and disconnect radiator or heat exchanger hoses.

Socket relief

clearance

Caution should be used when replacing the fuel injectors nipples. to prevent loosening the injector leak-off Be sure to cut a relief in the inside of your socket for clearance. This will prevent an interference between the socket and the leak-off nipple.

2. Remove ylinder head cover by removing the capscrews holding the cover to the cylinder head. 3. Remove ocker arm shaft assembly and pus push h rods. Grip the push rods and snap them sideways out of the tappet sockets as shown shown n the illustration. This method serves to break the hydraulic connection and permits lifting the push rods out and leaving the tappets in place.

Disconnecting Injector

Leak-off Line Line

CAUTION:Always cover openings with protective caps CAUTION:Always at any time when ines are disconnected. This will prevent any any dirt or foreign matter from entering.

Removing Push Rod from Ball Socket of Tappet

5. Removenjection Removenjection nozzle assemblies. Place a protective cap over ends of inject injector or for keeping openings clean. Refer to fuel injection system for testing procedures, page 24. 39

 

DISASSEMBLY OF CYLINDER HEAD 1. Using a C remove he valve rotors, springs placing all parts

Capping Injector

type valve spring compressor, spring retainer locks, retainers, and oil seals on valve stems-stems-in a container of solvent.

Connections

Removing Valve Springs

2. Removehe Removehe valves and place them in order in a rack with holes numbered for both intake and exhaust so they will not be mixed in handling.

Injector with Protective Caps and Nozzle Removal

6. Removeglow Removeglow plugs. Valves in Rack

3. Remove precombustion chamber inserts from cylinder head and place in a rack indicating the cylinder from which each was removed.

Glow Plugs

7. Loosen and remove the capscrews holding the cylinder head to the block. 8. Lift the cylinder headoff headoff the engine and carry to a clean bench for further disassembly. 4O

Precombustion Chamber Inserts

 

CAUTION:When When eplacing guides do not ream since these theseare are all pre-reamed efore being ferrox coated--any further reaming will remove he coating.

CleaningCombustion Cleaning Combustionocket Clean insert and combustion pocket. Inspect carefully for cracks.

VALVE SEAT INSERTS (IF SUPPLIED)

4. Remove all carbon from combustion c ombustion areas using scraper and wire brush.

1.

5. Clean the cylinder head thoroughly with a solvent or degreasing solution and blow it off with air pressure. Inspect carefully for cracks. VALVE GUIDES 1. Clean the valve stem guides, removing lacquer or other deposits, Do not use tools that remove metal. 2. Check guides for wear by using a telescope telescope gauge and 1" micrometer. Replace all guides that are worn bell-mouthed or have increased 0.038mm (.0015) in diameter. See Limits and Clearance Section for maximum iameter permissible to determine actual amount it has increased. increased. Remove ll valve guides when necessary by pressing them out from the combustion chamber side. 3. Replace worn guides as required by pressing in new guides to the correct depth as given in the valve guide data, page 42.

The exh exhaus austt valve valve seat seat insert insert is held held in place place by a shrink fit. Inspect all exhaust valve inserts in the head head and replace any that are loose, cracked or otherwise damaged. Use puller for removing faulty insert. When equired to replace with new insert, clean and counterbore for 0.25mm (.010") larger insert using counterbore tool with correct fitting pilot. Whenmachining the counterbore, be sure Whenmachining to go deep enough with the toot to clean up the bottom so that the insert will have full contact to carry away he heat. Continental does not recommendnstalling recommendnstalling new inserts having the same outside diameter as the one removed.

New nsert ininstallation must a press fit. Chill insert container with dry dry have ice for 20 minutes before assembling. Insert may hen be installed in the counterbore counterbore using a piloted driver and arbor press, without the possibility of shearing the side walls. This assures it being seated firmly on the bottom of the counterbore. 3. Grind the intake intake and exhaust valve seats in the head in accordance with instructions in the Valve Guide Data, page 42. Before removing the arbor, indicate the seat. Total indicator reading of the run-out must not be more than 0.05mm.002").

Removing Valve Guides from Combustion Chamber Side

Useall a pilot solidbestem withconcentric a long taper, as valvehaving seats amust ground and square with either new or worn valve stem guide holes. 41

 

VALVE GUIDE DATA

Intake

42  

Model TMD

Exhaust

A

Valve Seat Angle

30 °15 15’’

45° 15’

B

Diameter of Seat

39.77 (1.566)

33.50 (1.319)

C

Diameter of Choke

35.0 (1.38)

29.0 (1.14)

D

Distance (From Bottom of Cylinder Head)

43.0 (1.69)

43.0 (1.69)

E

Length of Guide

60.4 (2.38)

60.4 (2.38)

8.717/8.692 (.3432/.3422)

8.717/8.692 (.3432/.3422)

F

Inside

G

Distance Intake to Exhaust

Diameter Guide

47.65 (1.876)

Checking alveFace alveFace n "V" Blocks

Grinding alveSeat

Check all refaced or new valves in V-blocks with indicator to determine if the contact face is true with the stem within 0.05mm.002"). 0.05mm.002"). not, repeat the refacing refacing operation. After the valves and seats have been refaced and reground, coat the seat lightly with Prussian blue and drop the valve into position, oscillating it slightly to transfer the blue pattern to the valve face. This should showa showa contact width of 1.62 to 3.2mm 1/16" to 3/32") and should fall well within the width of the valve face, leaving at least 0.4mm 1/64") on either side where the blue does not show. If the contact is over 3.2mm3/32") 3.2mm3/32") wide, the seat in the head may may be narrowed by using a 15° stone to reduce the outside diameter or using a 60° or 75° stone to increase the inside diameter.

Indicating alveSeat VALVES Inspect valves for condition and replace any that are "necked", cracked or burned, also any of which valve stems are bent or worn more than 0.05mm (.002") over the maximum allowable limits. Reface or replace all valves.

Checkingor ProperValveSeating

AllowableHead Allowable Head hicknessof Refaced alves All

valves

having

less

than 50% margin

thickness (outer edge of valve head) after refacing has been completed must be replaced. To check this dimension, compare the refaced valve with a new valve.

Never allow valves to set down nside th seat. After specifications, the narrowed-down brought within the seat seat isshould be retouched lightly with the original stone to remove burrs or feathered edge. 43

 

RIGHT

So remember.., grinding.

do not lap valves in after

Coat the valve stem with a light film of engine oil. VALVE SPRINGS Check all valve springs on a spring tester to makesure they meet specifications regarding weight and length. ValvePosition Valve Position in Head

"A poor valve grinding job cannot be correct d by valve lapping." For example, after the valve has been hand lapped, it would look like this whencold. The thin line visible here shows where the valve lapped into its seat. Keep in mind that the engine is now at rest and cold.

ValveSpring SpringTester Tester This illustration shows he samevalve samevalve only now it has reached normal operating temperature. Notice that the lapped area of the valve and the seat no longer match each other. This is perfectly normal due to expansion of the valve. valve. Nowyou Nowyou can see that the effects of the lapping job are lost completely.

Springs, when compressed to the "valve open" or "valve "valve closed" length, must fall within the specifications shownon shownon the Limits and Clearance chart when new, and must not not show more than 10% oss to re-use.

ValveAssembly Valve Assembly 44  

2. All intake and exhaust valves have umbrella seals. Soak in boiling water for several minutes prior to installation. 3. Reassemble the valves and springs in the headwith the seal, headwith seal, retainer and retainer lock.

CHECKING

BORE WEAR

1. Clean the ring of carbon rom around he top of the cylinder bore formedabove the travel of the top ring. 2. Deter Determine mine the original original diameter diameter of the cylinder cylinder barrel by checking this unwornareawith unwornareawith an inside micrometer or a dial bore gaugeat intervals of . approximately 45

Installing

Umbrella Seals

ROCKER ARMS

Measuring Original

1. Inspect the rockeronarm wear. If the shaft has "shoulders" it shaft due tofor wear, replace. Blow out oil holes with air. 2. Examine ocker arms for cracks, condition of valve contact surface and worn bores. Replace all defective rocker arms or any having over 0.13mm (.005") clearance between shaft and arm. 3. Inspect the rocker arm brackets for cracks or other damage. VALVE PUSH RODS 1. Inspect push rods for bends or twist and examine the ball and cup ends for excessive wear. Replace rods that are faulty or excess excessively ively worn. 2. To prevent damage to push rods, replace after the cylinder head s installed. Please see Procedure 87 371,

Push Rod Inspection

for Runout

o

Bore Diameter Abo Above ve Ring Travel

Check n samemanner samemanner he top of the ring travel area approximately 6mm (1/4") below the shoulder. The maximumdifference maximumdifference in the above checks, indicates the amount amount of cylinder bore wear. If less than 0.20mm .008"), re-ringing will suitable and if over 0.20mm.008") re-boring recommended.

PREPARING CYLINDER WALLS FOR RE.RINGING OR RE-BORING 1. Ridge ream the cylinde cylinders rs

to remove remove the unworn

area at the top so that the new rings when assembled will not bump and distort both themselves and the piston lands.

Ridge Reaming Top of Cylinder

Bore 45

 

Several good makes of ridge reamers are available which will ream he top of the bore in direct relation to the worn area so that should the worn area be off center slightly there will be no partial ridge remaining. 2. Drain the crankcase and remove the oil

pan.

3. Remove the cap screws holding the connecting rod caps to the rod. Keep he cap and bolts in numerical order so that when the pistons and rods are removed from the engine, the cap can be reassembled and kept with its mating part. 4. Push the pistons and connecting rods up through the top of the cylinder, carrying with them all the carbon and metal chips left from the cleaning and ridge reaming operation. When doing this, every precaution must be taken to prevent damage o cylinder bores by the sharp corners and rough edges of the connecting rods. 5. It is important to remove remove the glaze on the cylinder bores by using a cylinder hone, with an adjustable stone tension, in order to assure quick seating of the newpistion rings.’ If the cylinder glaze is not removed,you you will have no assurance as to when the rings r ings will begin to function properly and control the oil; this is esp ciall¥ true when whenchrome chrome ings are used. The following recommended:

Cover the entire crankshaft with a clean, slightly oily cloth to prevent prevent abrasives and dirt from getting on the crankshaft. crankshaft. Remove the excess carbon deposits from the top of the cylinder wall before beginning the glaze glaze breaking operation. (This is to prevent loading the stones.) Insert hone in cylinder and expand to cylinder wall with slight tension. Using a clean brush, wet cylinder wall and stones with kerosene. Use a hand drill and surface hone cylinder with a rapid up and down motion to produce a good crosshatch pattern. Apply kerosene conti continuously nuously and increase tension on hone adjustment until a good pattern and finish is obtained. A smooth, bright finish of 0.25- 0.38 Micro Meters(10 to 15 micro inches) is desired. The honing operation will produce a sharp edge at the bottom of the bores. Upon completion of the honing operation, remove this sharp edge with a piece piece of number 500 emerycloth. emery cloth. If this edge s not removed, it can cause shaving of the piston skirts.

step by step procedure is

a. To get the correct cross hatch hatch pattern with a cylinder hone, use a top top quality electric drill with a speed of 500 R.P.M. or less and 280 grit stones.

RemovingharpEdge harpEdgeAfter After Honing e. Clean the loo loose se abrasives abrasives from the stones stones by using kerosene and a wire brush.

IMPORTANT:tones tones must be used wet. Keep applying keroseneduring keroseneduring honing to prevent stones from drying drying out and causing an incorrect incorrect honing pattern.

HoningCylinders 46  

The most desirable cylinder finish is 0.250.38 Micro Meters (10-15 micro inches); with this finish the depressions depressions in the surface tend to keep a supply of lubrication between the mating partsl This finish can be obtained by using 280 grit stones on the hone.

Desirable Crosshatch Pattern Obtained with a Cylinder Hone

After all honing operations are complete, thoroughly wash he bores with soap, hot water and a stiff brush to remove all traces of grit. Kerosene or other solvents will not remove he grit. Rinse the block with clean, clear water and dry with compressedair. compressedair.

Oiling Bores

If not, the bores must be rewashed. As soon as the bores have dried, lubricate with engine oil immediately to prevent rust. This completes the honing operation. PISTONS Check the pistons for excessive ring groove wear, and replace any that exceed the allowable limits in our Limits and Clearance Data. The cylinder walls and pistons must be perfectly clean and dry when fitting pistons in the cylinder bores. Pistons should be fitted with the block and piston at room temperature 20.0 21 21.0 .0 °C (68 °-70 -7 0 °F) °F).. PISTON FIT ON STANDARDPISTONS STANDARDPISTONS (with 2.3 to 4.5 kg (5 to 10#) Pull) TMDseries TMD series 0.08mm (.003")

Cleaning Bores

When you have finished

cleaning

the

block, run a clean, paper towelcomeout through the bores. The paperdry towel should come out clean.

Checking Block for Cleanliness

Check he piston fit in the bore using a half-inch wide strip of feeler stock, of the thickness specified in the Limits Limits and Clearance Chart, the feeler being attached to a small scale of approximately 7 kg (15 Lbs.) capacity.

Checking Piston Fit in Bore

47  

Whenhe correct fit is obtained you must be able to withdrawhe withdrawhe feeler with a pull of 2.3-4.5 kg (5-10 pounds) n the scale, with the feeler inserted between he piston and the cylinder midwaybetween he piston pin bosseswhere he diameter of the piston is the greatest. greatest. Check he fit of the piston when t is approximately 50mm2") 50mm2") down to the cylinder bore n an inverted position.

PISTONPINS Check he bushing n the upper end of the connecting rod for wear. If wornand wornandyou you are using the original pistons, an oversize piston pin may e obtained in 0.08 or 0.13mm.003 or .005") oversize.

Note hat while the chart specifies a light press fit of the pin in the piston, there is a definite clearanceof clearance of the piston pin in the connecting od.

CONNECTING RODS Replace he bushing in the connecting rod if new pistons are used. Using the arbor press, press out the old bushing and press in the new one making sure the oil supply holes line up--after which the bushing mustbe honed o obtain the correct fit of the pin in the bushingas bushingas shownon shown on Limits and Clearance Chart. If there is an excessof excessof stock in the piston pin bushing, it maybe maybe reamed irst, then honed. In any event, the final operation should be donewith donewith a hone o obtain the desired desired fit with better than tha n 75%bearing 75% bearing area contact on the pin.

PISTON AND CONNECTING ROD ASSEMBLY 1. Assemblehe Assemblehe pistons on the connecting rod. Heating them in hot water will facilitate assembly.When eated, the piston pin will enter piston veryrod easily and can bewithout tapped through the connecting and into place distorting the piston. The snap rings mustbe assembled in the grooves, making sure they are fully seated n place.

Checking Piston Pin Bushing for Wear

2. The piston pin hole in the connecting rod must be parallel to and in plane with, the large bore in the bearing end of the connecting od.

The piston pin hole in the piston and the bushing n the connecting od maybe maybe honed o increase heir diameter o obtain the desired fit as shown n our Limits and ClearanceChart. ClearanceChart.

NEW BUSHINg

OLD BUSHING

Pressing in Piston Pin Bushing

48  

Checking Connecting Rod for Twist and Alignment

This may be checked on a fixture with the piston pin assembled n the rod before assembling the piston; but regardlessof regardlessof this preliminary

check the completed piston and rod assembly must be rechecked and there must not be more than 0.05mm 0.05mm (.002") twist or out of squareness checked over a spread of approximately 100mm (4"). If excessive, replace the rod. Pistons are cam and taper ground, and this must be taken into consideration when checking alignment of the assembly, since the diameter in line with the piston pin would be less at the top of the skirt than at the bottom.

RECOMMENDEDMETHOD OF INSTALLINGPISTON INSTALLING PISTON RINGS 1. Prior to ring assembly check the ring grooves for nicks and burrs. This is done by rotating each unassembled ing around its groove to be sure of free action.

PISTON RINGS Check he piston rings in the cylinder for gap.

Installing Ringswith RingExpander RingExpanderool

Checking ingGap ingGap To do this, insert a piston in the cylinder bore in an inverted position and then insert each ring one at a time about 50mm2") 50mm2") down n the bore. If the ring does not have sufficient end gap clearance, file one end of the ring until sufficient clearance is obtained. Check the gap between the ends of the ring with a feeler gauge n accordance with specifications shown n the Limits and Clearance Chart. Prior to installing the rings on the piston, piston, check each ring in its respective groove to the limits specified in the manual. If ring to land clearance exceeds maximum serviceable limits, pistons must be replaced.

Oil Ring

CheckingRingClearancen Clearancen Groove

2. The oil ring should be installed first on the piston, from the top side so skirt will not be scratched. 49

 

CRANKSHAFT ND MAIN BEARINGS 1. Using a puller, removepulley removepulley from crankshaft. 2. Removescrews Removescrews and remove gear cover. 3. Remove he crankshaft keys.

gear and woodruff

4. Using a puller, removecam removecamgear gear and injection pumpdrive gears. pumpdrive 5. Remove he oil pump and key by removing cap screws holding pump o front of the engine. Oil Piston and Rings

3. To install the balance of the rings, use a ring tool with recess side up and place the ring in with the bottom side up. Start with the lowestring lowest ring first. a. Position ring in the tool tool so the expanding fingers will fully engage both ends. b. Apply pressure on handles so ring is completely expanded. Pass the expanded ring and tool recessed side down downover over the piston to the proper groove. Removing Crank Gear

Install

Tapered Rings with "Top" Side Up.

Somepiston rings are taper faced. These are CAUTION:Somepiston clearly marked "TOP" on the side to be up when assembled on piston, and some rings have the top side

Removing CamGear with Puller

rharked with a color band or a PIP mark.

4. When istons are ready for installation in the cylinders, oil generously. Compress Compress ings carefully using a good ring compressor and a light tap on the head of the piston will allow the assembly to go into the cylinder very easily. If any difficulty in tapping piston and ring assembly into the cylinder is encountered, the compressor should be removed and rings checked for correct installation in the groove.

Removing Injection

PumpDrive PumpDrive Gear

6. Remove each main bearing CAUTION:The pistons have offset piston pins. Be sure CAUTION:The to install pistons with notch or arrow in top toward the front of the eng engine. ine.

50  

cap, one at a

time, nals. and inspect the bearing and crankshaft jourIf there is any indication of flaking out, scoring or actual wear, -- they must be replaced.

BEARINGS

Tri-metal bearings whennew whennew are smoothand smoothand highly polished. However,a However, a very few hours of

Removingain ainBearing Bearing Appearance f a Good earing

7. If the visual inspectionappears inspectionappears atisfactory, they should be removed nd checked or thickness using a ball micrometer. To removehe upperhalf upperhalf of the bearingshell bearingshell use a special tool obtainableat obtainableat mostparts mostparts houses,which which is a pin with anangular anangular ead. t may e nserted n the oil hole of the crankshaftand crankshaftandas as the crankshaft s turned n a clockwise irection, the head f this pin picksup picks up he bearing hell and orces t out of the bore in the block.

BearingDamageue o Corrosion

The hickness f the bearing hells s given n the Limits andClearance andClearance hart, and f this thicknesshas thicknesshas been reducedmore than 0.013mm.0005") 0.013mm.0005") beyond the maximumllowable tolerance the bearing shell mustbe must be replaced. CAUTION:he upper main bearing shells are grooved.The ower main bearing shells on some models, re not. The ngroovedearing hell must must e placedn thebearing thebearingap, ap, ot n theblock, theblock,or or oil to the bearingsill bearings ill becut becut off.

Scoredearing Scored earing ueo ueo Dirt or Lack f Oil operation will changeheir changeheir appearanceompletely. appearanceompletely. The bearing surface becomesa becomesa leaden gray in color and developsminute developsminutecraters, craters, almost cellular in appearance. his appearances a natural characteristic of this type bearing and n no way ndicates ailure.

Measuringearing hickness 8. If visual inspectionof inspectionof the crankshaft hows o indication of excessive ear r scoring, he clearance of the bearing should be checked. 51

 

9. Check achbearing, one at a time, by using a piece of Plastigage of a diameter specified to check certain clearances.

TMD

2.8R .11") on all crankpins 3.0R .12") on all mains’

CrankshaftFillet Fillet Radii

Checking Bearing Bearing Clearancewith Clearancewith Plastigage

By placing the Plastigage on the crankshaft bearing surface and tightening the bearing and cap in place, the width of the Plastigage after crushing will determine he bearing clearance. CAUTION: Whenusing this CAUTION:When the crankshaft as that Plastigage.

method DO NOT TURN would destroy the

If crankshaft s scored, or wornenough o that new bearings will not fit with the required clearance, it should be removed nd reground. Standard crankshafts may be reground to decrease the diameter a maximumof 1.0mm (.040"). Before shaft is reground, t mustbe mustbe checkedor straightness and straigtened if necessary to be within 0.05mm .002") indicator reading. When reground, the fillet radii mustbe within dimensional limits and must be perfectly blended nto thrust and bearing surfaces. Crankshaftsmustbe nit mperedfter regrinding. AVOID SEE ~ SHARP ~INSUFFICIENT CHART BELOW

L

- ~ ////.///-////,/,//

RIGHT

52

 

~RS WRONG

/ ////.//.~.// ~ET

WRONG

Replacing Bearing

1. Removehe Removehe screws holding the camshaft thrust plate to the front of the cylinder block, which makest possible o pull the camshaftorward camshaftorwardout out of the bearings. 2. Measurehe Measurehe camshaftbearing journals and bores. If clearances equal o or greater han he amount indicatedunder indicated underwear imits, checkhe diameter f the camshaftournals camshaft ournals to determinehe next step. step. Excess wearat these positions require replacement f the shaft. 3. If the front camshaft ournal bore becomes wornbeyond worn beyondimits, there is a service camshaft ushing available as p/n F400G00222.See SPB89-389 SPB89-389 for details.) 4. Tappets an hen be ifted out and ined up n sequence,or installation in the sameocation unless inspection showshat showshat they require replacement.

CAUTION: Whennstalling When nstalling camshaftuse camshaftuse special care to prevent camshaft bumpingand bumpingand loosening expansion lug at rear of crankcase ausing ausingan an oil leak.

The overhead valve engines have a good, trouble-free rear crankshaft oil seal -- if carefully installed.

IMPORTANT: nstalling rear oil seals correctly demands areful workmanship. nstall seal with lip pointing towardengine. towardengine.

TAPPETS

Wornoil seals should be replaced in the following manner: l. Remove rear bearing cap and filler assembly by using a puller.

ACCEPTABLE

NOTACCEPTABLE

ValveTappet Valve TappetWear WearComparison Comparison

1. Inspecteach Inspecteachappet appetcarefully. carefully. Two r three threesmall small pits on he contact contactace ace s acceptable; orehan hat calls for replacement f the tappet. A damaged tappetcould tappet couldmeanossible meanossibledamage damage o the camshaft. 2. Checkhe outsidediameter outsidediameter ith a micrometero determinef replacements necessary ecausef determinef wear.Refer Refer o limits and learance learanceection. ection. REAR CRANKSHAFTOIL CRANKSHAFTOIL SEALS

Removeold Remove old seals and thoroughly contact surfaces.

block clean all

seals "A"--on engine 2. Install crankshaft oil seals block and main bearing cap. Before installing -- break edge "C" slightly on both cap and block to avoid cutting the seals during installation installation and coat seal edge "E", contacting the groove with sealing sealing compound.

NOTE: his oil seal can be installed without remov remov-ing the cran crankshaftkshaft- in this case, use only light grease n the seal groove o assist sliding the seal in place. Applypressure Applypressure o the seal so that it will hug he crankshaft whichwill whichwill also help moving movingtt in place.

The overhead valve engines have the rear crankshaft oil seals incorporated in the combination rear main bearing cap and filler block. The rear crankshaft oil seal has a stiffener stiffener ring imbedded n the rubber and no metal retainer is required.

c C

D Installing Seal n RearMainBearing MainBearingCap ndFiller ndFiller Block

E

Filler Blockand BlockandSeal Seal 53

 

NOTE: il leakagewill leakagewill occur if any voids are left along these slots.

7. Dip the curing insert in clean water. Install curing insert until approximately /8" protrudes rom slot. Cut off flush with pan ail. This insert insures completeure of the RTV. Crankshaft il Seal n Block cement ement(national oil seal 3. Apply a light coat of c or EC-847) o the butting ends of the crankshaft oil seal halves. Allow to become acky before assembling. Lightly Lightly coat the crankshaft contact edge of the seal with graphite grease to prevent damage rior to use. 4. Install

Crankshaft.

RTVGasket Material to 5. Apply a light coating of RTVGasket surface "B" and graphite grease to the oil seal lip. Carefully install the combination ear bearing cap and filler block on to the dowels. Insert the capscrews and torque to 150-162 Nm (110-120Lb. (110-120 Lb. Ft.)

Install Curingnsert Curingnsert

8. Prior o installing il pan, pply small ead of RTVmaterial materialo o the rear bearin bearing g ap apand and iller blockas block as shown.Seepage Seepage 0.)

~-~-’~

Please see

Pleasesee Pleasesee SPB 7-361,

ApplyingRTV RTVo o Rear iller Block 6. After the rear cap is in. place and torqued, inject RTVnto each side seal slot ’.’D" as shown in illustration. Force the RTV nto the channels until a steady flow comes out the corner chamfers.

Dowel

holes

with~~RTV

~

~/

Applying

RTV to

Rear

Bearing

Cap

and

Filler

Block

OIL PUMP The oil pump s assembled to the front of the cylinder block and front main bearing cap and is held in place by capscrews. Installing RTVn RTVn Rear Rear iller BlockChannels BlockChannels 54  

The pump s driven by a hardened key mounted in the crankshaft.

Pr vious Oil Oil Pump Impeler Impel er (inn (Outer)

~Adapter ~/ashe r

~

PIun Sprlng

O-Ring

Cap

Current Oil Pum Pump-E~ective S/N 88096321

Note: Refer to Service ServiceBulletin Bulletin 88-379, ssuedOctober, ssuedOctober,1988. 1988.

O-Rings Whenhe pumps Whenhe pumps removed nd disassembled, examinehe examine he impellers, cover and cavity for wear; Inspectingthe key and keyway t the sameime. sameime. If scored or wornbadly they must be replaced. replaced. Examinehe pick-up screen for clogging or damage. Examinehe Examine he O-Ringat O-Ringat the pumpnlet. pumpnlet. If damaged, replace. TwoO-Rings TwoO-Ringsare are required after S/N 88096321. Oil PumpRemoval PumpRemoval

Engine oil pressure must be maintained to specification or satisfactoryengine satisfactoryengineife. ife. The oil pumpmust pumpmust be fully seated in the counterbore.Nogaskets Nogasketsare are used n this assembly. Install mounting apscrewsnd apscrewsnd ighten to 20-24 Nm 15-18 Lb. Ft.) NOTE:When Wheneplacing eplacing any oil pumps n engines built beforeS/N beforeS/N88096321, 88096321, he oil suction ubemust ubemust bereplacedalso. replacedalso. (SeeSPB (SeeSPB 8-379.)

TIMING GEARS O-Ringat O-Ring at Pumpnlet Pumpnlet

1. Timinggears Timinggearsshouldbe shouldbe inspected or excessive wearand/or wearand/or pitting and eplaced f necessary. 55

 

2. Examine he camshaft thrust plate carefully for scoring and wear and if any indication of either shows, a new thrust plate should be assembled.

Assemble camshaft nut and torque to specification (see torque specifications section). Do not use impact wrench or over torque cam nut.

Camshaft Thrust Plate

3. Assemble he injeclJon pump rive gear he gearwith with key and and cam ear o the camshafty camshafty drivingor pressing ach n, atthe same me olding the camshaft orward with suitable bar through he fuel pump peningn peningn the block so there is no possibility of the camshaftumping camshaftumpinghe he expansionlug expansionlugat the rearend nd ndorcing orcing t outof position, hus huscausing causingnoil noil leak. NOTE:MD20,pec. NOTE:MD20, pec.8604uses 8604usesa a different cam ear and injectionpump injection pumprive rivegear gear et up.Forassembly Forassembly nform tionsee tionsee SPB 7-372.

Torquing

Cam Gear Nut

Check camshaft end play as shown n illustration. Refer to limits and clearance section for correct dimension.

CAUTION: NEVER NEVERUSE USE THE CAMSHAFT UT TO PRESSTHE GEAR ONTOTHE ONTOTHE CAMSHAFT.This CAMSHAFT.This will break the threaded end off cast iron camshafts.

Please eference SPB 7-372. Installing

Injection

PumpDrive Gear

Checking Camshaft End Play

4. Drive the crank gear on the shaft making sure

InstallingCamshaftear Camshaftear 56  

that the marked teeth on the cam gear straddle the marked tooth on the crank gear, which assures you of the crankshaft and camshaft being in time.

TimingGears Timing GearsAssembledccording o Timing TimingMarks Marks CRANKSHAFT

END

PLAY

Checking lywheelRun-Out lywheelRun-Out

The crankshaft end play is controlled by the center flanged bearing. No shims are required. Using a dial indicator, check the crankshaft end play. If the end play exceeds 0.18mm (.007") replace the flanged bearing. End play should be between the 0.17mm .0067") and 0.04mm .0015") limits.

The flywheel is machined and balanced so that the clutch face and locating counterbore will run true with its axis. Mount an indicator on the flywheel housing and check the flywheel for runout. Caution: When checking runout remove glow plugs to allow engine to be turned turned over freely. The indicator

should be set up so that it

con-

tacts the clutch face or the vertical surface of the clutch counterbore, then turn the flywheel at least one full revolution at the same time holding against the crankshaft to offset the possibility of end play. Excessive runout of the flywheel, in either position, is probably caused by dirt in or damage o counterbore locating the flywheel on the crankshaft flange.

FlangedBearing BearingControls ControlsCrankshaftEndPlay EndPlay FLYWHEEL Install screws.

AND

flywheel

FLYWHEEL

HOUSING

housing using special

cap

NOTE:Special capscrews having sealing bands NOTE:Special are used n the upperholes to mount he flywheel housing to the cylinder block. These special capscrewsmust capscrews mustbe used to prevent oil leakage.

Special Capscrews

Re-locate the indicator to check the inside diameter of the counterbore. In both cases the maximum indicator reading must not be more than 0.20mm .008"). When assembled, mount the indicator on the flywheel so that it contacts the housing face and turn the crankshaft, at the same time holding against it to counteract end play. The maximum indicator reading must not exceed 0.20mm .008").

Checkinglywheel Housing ace 57

 

Re-locate the indicator to contact contact the housing bore and check this in the same manner. The same unout limits limits prevail.

Installing

Checking Housing Bore

REASSEMBLING ENGINE In the foregoing, we have outlined procedures for checking, repairing or replacing the many wearing parts in the engine. In most cases, the instructions instructions have covered the reassembly of parts or subassemblies made up of several parts. When reassembling pistons and connecting rods, use a good ring compressor and oil the bores thoroughly. A hammerhandle may be used to bump he p stons out of the ring compressor nto the cylinder bore.

Pistons

Once more, we call attention to care demanded to prevent connecting rods damaging he cylinder bore finish and at the same time as they are assembled over the crank pin, locate them carefully in order to protect protect the bearing surfaces. Always lubricate the bearings with clean engine oil when assembling, and tighten them to the torque specified.

INSTALLING HEAD 1. Make sure that gasket

contact surfaces on the head and block are clean, smooth and flat. Check flatness with straight edge and feeler gauge in three positions lengthwise and five crosswise. The maximumpermissible maximumpermissible is 0.10mm (.004") low in the center lengthwise, lengthwise, gradually decreasing towards tthe he ends, or 0.076ram (.003") crosswise or in localized low spots. If these limits are exceeded, replace the cylinder head.

Checking Cylinder Head Flatness Lengthwise

NOTE:The The pistons have offset piston pins. Be sure to install pistons with notch or arrow in top toward the front of the e engine. ngine. Checking Cylinder

58  

Head Flatness Crosswise

2. Install precombustion hambernserts, hambernserts, making sure they are fully seated. nsert projection in reference with cylinder head surface is flush to 0.076mm.003") projection.

I

Precombustion Insert

capscrew orque. Tighten with torque wrench in recommended equence to the correct torque shown n torque chart on page 68, by going over them two times before pulling them down o the final torque specification on the third round. 7. Install the injectors and glow plugs at this point. Having he injectors and gl0w plugs in now, eliminates he risk of dirt and oreign objects falling into the cylinder.

Projection

3. Use new cylinder head gasket, which is precoated, thus no cement s required. 4. Using a chain hoist, lower the cylinder head assemblyevenly over the Iocator stud. Replace assemblyevenly the Iocator stud with the proper cylinder head capscrew. 5. Before nstalling any headcap headcap screws screws n the block, be sure the threads n the block andon andon the cap screws have been properly cleaned. Should these tapped holes need cleaning or reconditioning, care should be taken to use the proper tap. Tap:

M10x 1.5 CLASS G M10x M12x M12 x 1.75 CLASS G

Installing

Glow Plugs

NOTE:Always use NOTE:Always new teel heatshield heatshield washers when installing injectors n cylinder head.

Injector

Nozzle Side

Side View

6. The cylinder head capscrews require no sealant but should be installed with a very light coating of engine oil or lubriplate to reduce friction and insure proper clamp clamp load and head

Torquing Cy Cylinder

Head Capscrews

Installing

Heat Shield and Injector

59  

INSTALLING OIL PAN

Beforeassemblinghe oil pan, make ure the Beforeassembling contactsurfaces contact surfaces re flat andclean andcleanof of anygasket anygasket material r oil. oil. A form-in-placegasketmaterial gasketmaterial is used or sealing the engineoil engineoil pan o the crankcase. he form-in-place asketshould asketshould e applied o the oil panand pan and iller blocks s shown ere. Tighten he screwsn screwsn accordance ith limits prescribedn the torquechart--to avoid ooseness or overstressing.See overstressing.Seepage page54.) 54.)

NOTES: . Parts must be assembledwithin 20 minutes fter applying asketmaterial. asketmaterial. 2. Caution mustbe mustbe usedin handling the gasket materials. ReadLabels.

Whenngines ngines completelyssembled completelyssemblednd illed withproper with proper il (see ubrication ection),set ection),set tappets accordingo the following hart: MODEL

INTAKE

EXHAUST

TMD

0.36mm (.014")

0.46ram (.018")

Notes 1 and 2) Form-In-Piece Gasket

2.0~m (.0~0) die. bead el Fonlt4n-Place gasketmetedal gasket metedalapplied applied to oil pan and filler block as shown OIL PAN

g.O mm(.35) This urea ot Foam-in.Place gasket must intersect vertical cs¥1tlee both sides

Top View C}ankcesecontact C}ankcese contact face

Rear Bearing Cap and Filler Filler

Form.In-Piece

gasket matedal to plu~

holes. MIn 6.0ram (.238)

deep from contact surfsce.

Typical

6O  

Block

RTV Oil Pan Application

IMPORTANTfter assembly f the bearing cap capo o thecrankcase, ill bearing ap ide capacity singRTV singRTV ndsyringe ndsyringe furnishedn furnished n kit. Sealantmustb~eed mustb~eed ut chamfert crankcaseplit plit line The wocuring wocuring nserts pipe cleaners) cleaners) includedn the kit must eused s ellows: Dip he curingnsert nsertn1:o n1:oa a Con:airier f cleanwa’~er nd nsert ull lengthnto length nto bearingap bearing ap ideslot ideslotcavities cavities illed with RTVmaterial,makingertain he nsert s centrallyocatedn sideslot sideslot Install Installcuring curing insert until approximately//8" 8" protrudes from lot. Cutoff Cutoff flushwithpan withpan ail.

Bottom View OII Pan Contact Face

for the Diesel Overhead Valve Engine.

Section 9- Trouble Shooting /

WARNING

Bodilynjury Bodily njury or deathmay mayesult esult o individuals uring operation f an enginewithinanyenclosure anyenclosureot ot adequately r properly entilated.Engineperation Engineperationn any enclosure equires dequatend dequate proper entilation o avoid avoidasphyxiation asphyxiation r other ndproper interruptionof interruption of normal breathing,o supply ufficientair to cool he e engine, ngine, provide ir to mixwith uel and o carryaway carryaway eatedir eatedir from he building. Read ndobserve ndobserveafetywarnings afetywarningsn n pages and2. and2.

A Preventive-Maintenance system including inspection, lubrication and adjustment as recommended n our Maintenance Section will prevent the greater portion of Diesel troubles. Failure of a Diesel engine to perform satisfactorily is generally due to difficulties difficulties with the fuel supply system, such as air leaks in the suction line due to loose connections or restrictions to fuel flow because of clogge clogged d filters, rather than the injection pumpor pumpor nozzles.

COMPLAINTS

Any attempt to disassembleor repair fuel injection pumps must be made only by persons fully qualified and equipped. Operators should depend on their welldeveloped senses of feeling, hearing, seeing and smelling and replace their sense of taste in this type of work -- with a generous generousamount amountof of "Common Sense". A good rule to follow in locating trouble is to never make more than one adjustment at a time--then locate the trouble by a process of elimination. Remember he cause is usually Simple- rather than mysterious and complicated. Following are listed some of the normal complaints encountered in routine operation of all Diesel engines--the probable causes and the recommended teps required to correct the difdifficulty:

PROBABLE CAUSE 1 --Dead or weak battery 2 -- Inadequate battery capacity 3 -- Poor ground conne connection ction

(A) Engine Won’t Turn Over

4 --Loose or faulty

wiring connec-

tions. 5 --Starting 6 --Starting

switch faulty motor defective

7 --Internal

engine seizure

CORRECTION 1 --Recharge or replace battery. 2 -- ReplaceBattery. 3 --Inspect and tighten ground cable. 4 --Clean and tighten connections. 5 --Replace switch or relay. 6 --Check brushes, commutator, drive spring and mounting bolts. 7 --Turn engine manually -- if unable to do this, check for foreign objects in gears, on top of piston or for piston seizure.

61  

COMPLAINTS

PROBABLE CAUSE 1 -- NoFuel NoFuel Supply o Pump 2 -- Air in Fuel njectionLines njectionLines 3 ---Cloggedr dirty filters 4 -- Cranking peed ow 5 -- Watern Watern Diesel Fuel

(B) EngineTurns Engine Turns But Won’tStart Start

6 -- Wrongnjection pumpiming 7 -- Lowatmospheric Lowatmosphericemperature

CORRECTION 1 -- Fill FuelTank FuelTank r openShut-OffValve. Valve. 2 -- Check onnections nd bleedFuel System. 3 -- Disassemblendclean ndcleanprimary primary ilter and eplace econdary ilter if clogged. 4 -- Recharger replacebattery, replacebattery, check starter, repair f necessary. 5 n DrainFuel DrainFuel System Refill with clean fuel or strain through hamoisnd hamoisnd bleedsystem. 6 n Retimepump Retimepumpo o engineaccording engineaccording o recommedations. 7 -- Use old starting equipment-

WARNING Starting fluids or aids such s ether or gasolinemust ot be usedn used n a diesel engine ir intake system.The system.Theuse useo( o( these fluids will cause evere nternal engine amagend/or nd/orbodily bodily injury. Readand Read and observesafety observesafety warnings n pages and and2. 2.

8 b Low compression 9 -- Glow lugs aulty or inoperative

(c)

Runs"Rough" With Excessive Vibration

8 -- See ecommendations n "G" 9 -- Replace Replacerr correct.

Note: A characteristic of a fuel injection pumps pumps that if engine misfiringoccurs, misfiring occurs, ndt is traced o a certain cylinder in which no combustion s taking place, the causemightbe an njector sticking open in the cylinder which immediately recedeshat recedeshat cylinder in the engine engineiring iring order. Duringnjection During njection o the cylinderwhich cylinderwhich has he injector sticking n the open position, the fuel rushes nto that cylinder with no restriction whatsoever,causing whatsoever, causing a scavenging effect in the pumpistributor pumpistributor rotor and a void which cannot be rechargedo recharged o a sufficient degreeo degreeo provideopening provide opening ressure f fuel to the following injector. Hence,no Hence,no combustion an take place, Please note his well, as knowledgef this characteristicmightprovide mightprovidea great saving savingn n service ime n sucha sucha given situation.

62  

COMPLAINTS

1 --Misfiring

(c)

Runs "Rough" with Excessive Vibration

cylinder or cylinders

2 --Too low operatin operating g temperature--below 3 --Air in fuel lines

165°F

4 --Clogged air cleaner 5 --Engine idles

too slowly

6 -- Poor fuel

1 --Wrong injection

pump timing

2 --Air in fuel lines 3 --Clogged or dirty filters (13) Loss of Power

CORRECTION

PROBABLE CAUSE

4 --Restriction in air flow 5 --Poor fuel 6 -- Poor Compression Compression 7 -- Injection nozzles faulty 8 --Injection

pump aulty

1 --Loosen fuel line to injector injector one at a time--no noticeable change ndicates that cylinder cy linder is misfiring. Clean and test injector for pressure, leakage and pattern. 2 -- Check thermostat. 3 -- Check connections--Bleed fuel system. 4 -- Clean and service air cleaner, tighten connections. 5 -- Increase to recommended speed. 6 -- Use Diesel engine fuel fuel that meets specifications.

1 --Retime pump to engine according to recommendations. 2 --Check --Check connections and bleed fuel system. 3 --Clean Primary Filter and replace secondary ilter if necessary. 4 --Service Air Cleaner and Connections. 5 -- Use recommended recommendedDiesel Diesel Engine Fuel that that meets specifications (See Pages11 Pages11 & 29). 6 m See "G" recommendations. 7 mClean and Test Faulty Nozzle for pressure leakage and spray pattern. 8 --Remove and have checked at an authorized service center.

1 --Lack of coolant.

(E)

Overheating

2 --Fan belts slipping

2 --

3 --Overloading

3 --

the engine

4 --Thermostats sticking operative 5 --Fuel in injection

or in-

timing wr wrong

6 --Back pressure in e ex xhaust line

4 -5 -6 --

Add water. Tighten hose connections and repair leaks as required. Inspect belt condition and adjust tension. Reduce load. Keep engine speed up. Remove,clean Remove, clean and check therthermostats and replace if required. Retime pump according to recommendation. Inspect for restriction in muffler and exhaust system, and clean.

63  

COMPLAINTS

PROBABLE CAUSE

CORREC~ON

WHITE MOKE - May ndicate Misfiring Mi sfiring 1 mLow Lowengine engine temperature 2 -- Faulty njectors

3 --Poor uel 4 -- Poor compression 5 -- Coolant eaks into combustion chamber 6 -- Glow lugsnot lugsnot usedat usedat start-up

1 -- Checkhermostat - increase engine emperature. 2 -- Cutout Cutout ndividual njectorswith njectorswith engine unning - cleanand cleanand est faulty nozzle or pressure,eakage pressure,eakage andspray and spraypattern. pattern. 3 -- UseDiesel uel that meets specifications. (SeePages (SeePages 1 & 29) 4 -- See G" recommendations. 5 -- Check eadgasket. eadgasket. 6 -- Energize low lowplugs plugsbefore before tarting.

 F)

Excessive Smoke

BLUE MOKE - Indicates High Oil Consumption 1 -- Worn r stuckrings 2 -- Lowengine Lowenginewater water temperature 3 m Worn alve guide, valve stem stemor or valve stem eal

1 --- See I) highoil consumption recommendation. 2 -- Check Checkhermostat. hermostat. 3 -- Replace

BLACKSMOKE 1 -- Excessiveuel rate 2 -- Overloading ngine 3 -- Restrictionn Restrictionn air supply 4 -- Lowengine Lowenginewater water temperature

1 -- Valvesholding Valvesholding open~ open~ no tappet 2 -- clearance Leaky ylinder headgasket headgasket (G) Poor Compression (Under325# (Under 325#at at 150 RPM)

3 -- Wrongalve timing 4 -- Burned r sticking valvesor valvesor incorrect valve iming 5 -- Broken r weak alve springs 6 -- Piston rings wornor wornor broken 7 -- Wornpistons and bores

64  

1 -- Take umpo an authorized ervice center. 2 -- Reduceoad. 3 ~ Clean ir cleaner. 4 -- Check Checkhermostat. hermostat.

1 -- Adjust appetclearance appetclearanceo specifications. 2 -- Clean eadand eadandblock block surfaces. Replace asketand asketand orque to Specification. SeeTorque SeeTorque Specification ection 0.) 3 -- Check ndcorrect ndcorrect if necessary. 4 -- Clean Cleanand andgrind grind valves. Reface r replaceas required. 5 -- Check nd eplaceany eplaceanynot not up to specifications. 6 -- Re-ring with recommended ervice kit. 7 -- If necessaryebore ebore& & replace pistons. (See SPB 7-371 - check for cylinder headwarpage.) headwarpage.)

COMPLAINTS

PROBABLE CAUSE 1 -- Low oil level 2 --Oil pressure gauge or line faulty 3 --Oil too light--diluted

(H) Low Oil Pressure

4 --Dirt in relief valve or broken spring 5 --Suction screen plugged 6 --Worn bearings 7 --Worn oil pump 8 --Pick-up tube O-ring damaged or missing

1 --Oil leaks 2 --Too high oil level maintained 3 --Incorrect

grade of oil

used

4 --Clogged crankcase breather 5 --Oil pressure too hi high--relief gh--relief High Oil Consumption

valve stuck 6 --Piston rings not properly run-in 7 --Worn, broken or stuck piston rings and clogged oil control rings 8 --Worn pistons or bores 9 --Worn bearings and valve guides 10 --Intake valve seals

(J) Poor Fuel Economy

CORRECTION --Add oil to dipstick level. --Inspect lines and check with Master Gauge. --Change oil and follow recommended ubrication. --Clean or replace spring. --Remove screen and clean in solvent. -- Replace --Remove, repair or replace pump. w Replace

1 -- Locate and repair. 2 aMaintain oil level between high and low marks on dip stick. 3 --Use --Use recommended type and SAEnumber SAE numberof of lubricating oil. 4--Clean thoroughly. 5 --Clean and free up valve--check spring 6 --Break in all new and tension. rebuilt engines as recommended. 7 --Re-ring with recommended ervice rings. 8 --If necessary rebore & replace pistons 9 -- Replace 10 --Replace

1 --Operating with low coolant temperature

1 -- Maintai Main tain n 79.4 °C-85 C-8 5 °C (175°F-185°F) for maximum

2--Wrong fuel

economy 2--Use Diesel and fuelperformance. that meets specifications. 3 -- Follow "D" recommendations.

3 --Loss of power 4 --Incorrect injection ing

pump im-

5 -- Nozzles faulty 6 --Incorrect

tappet clearance

4-

Fo Foll llow ow reco recomm mmen ende ded d ti timi ming ng procedure. 5 --Cut out faulty injector--clean and test for pressure, leakage and spray pattern. 6 --Adjust tappets .46 (.018) exh. and 36 (.014) int. (Reference page 60)

65

 

COMPLAINTS

PROBABLE CAUSE 1 -- No fuel 2 --Restriction in fu fuel el flow

(K) Sudden Stopping

3 --A --Air in fuel lines 4 --Tra --Transfer nsfer pump ault aulty y 5 --W --Wate aterr in ffuel uel 6 --Internal

engine seizure

7 --Faulty electrical shut-off on injection pump

COMBUSTIONKNOCKS Excessive) 1 --"Lugging" (L) Engine Knocks and Noises

2 --Poor quality fuel 3 --Injection

timed too early

4 -- Injection nozzle sticking MECHANICAL KNOCKS 1 --To locate knock

2 -- Main bearings

3--Connecting

rod bearings

4 --Loose piston pin 5 --Broken piston ring or pin

6--Tappet

noise

7 --Timing gear noise

66  

CORRECTION 1 --Refill fuel tank and bleed fuel system. 2 --Clogged or dirty filters--check lines for obstruction or break. 3- Bleed fuel system. 4 --Replace transfer transfer pump. 5--Drain system and refill with clean fuel or strain remaining fuel engine throughmanually--if chamois. 6--Turn uanble to do so check for foreign object in combustion combustion chamber or for piston or bearing seizure. 7 --Repair or replace

1 -- Reduce load or increase speed. 2 -- Use only #2 diesel engine fuel oil for good performance and 3-- economy. Follow recommended timing procedure. Removenozzle, Remove nozzle, check opening pressure, clean and adjust. 1 --"Short out cylinders" by loosening fuel line to nozzle one at a time--if no change n sound, knock knock is not occurring in that cylinder. 2 --Heavy, dull knock when accelerating under load. Examine bearing lining for wear or excessive clearance. Replace if necessary. 3 --Condition noted at idle or light load and disappears at full load. Check and correct as in Para. 2, main bearings. 4 --Sharp metallic rap at idling speed or when starting cold. Replace pin with oversize. 5 --Sharp, clicking noise that cannot be eliminated by shorting out. Removepistons, Removepistons, replace piston pin or rings if necessary. 6 -- Check appet clearance. Adjust to specifications. (Reference page 60) 7 --Loose or worn-gears rattle; tight-gears whine. Check Check gear fit and examine eeth. Refit new set of gears if loose or worn badly.

Section 10-Torque Specifications NOTE: The following Torque Values are based on Phosphate Coated Fasteners (Class 10.9 & 12.9) and Black Oxide Coated Fasteners (Class 8.8 & 9.8).

CYLINDER HEAD ENGINE SERIES TMD

ITEM Connecting Rods CAUTIONHigh CAUTION High limit is maximum. DO NOT Torque beyondhigh limit. Main Bearing Caps Flywheels Flywheel Housings Rear End Plates Manifolds (Seezpruf) Gear Covers Water Pump.s Oil Pans (Sheet Steel) Oil Pump To Engine Rocker Shaft Supports

Accessories And Misc. Brackets Camshaft Nuts (cast (cast iron camshaft) Crankshaft Pulley Glow Plugs Nozzle To Holder Fuel Injection PumpDriven PumpDriven Gear To Fuel Injection Pump *Injector to Cylinder Head Rocker Cover

SEE CH CHART Page 68 TORQUE

THD SIZE

MAT’L CLASS

N.m

LB.FT.

3/8

SAE GR 8

61-68

45-50

M14 M10 M10

12.9 12.9 12.9

150-162 68-75 61-68

110-120 50-55 45-50

M8 M10 M10

8.8/9.8 8.8/9.8 8.8/9.8

20-24 34-40 34-40

15-18 25-30 25-30

M8

9.8

14-19

10-14

M8 M8

8.819.8 8.8/9.8

20-24 23-27

15-18 17-20

M6 M8

8.8/9.8 8.8/9.8

8-11 20-24

6-8 15-18

M10 M12 M14 M16 7/8 M16

8.8/9.8 8.8/9.8 8.8/9.8 8.8/9.8

34-40 75-81 122-135 190-203

25-30 55-60 90-100 140-150

8.8

88-95 163-176

65-70 120-130

8

31-38 68-75 27-34

23-28 50-55 20-25 50-55

9.8

68-75 7 -8 27-34 head.

20-25

M12 M22 5/16 M24 M8

High Pressure Fuel Lines M12 Always use a new new steel heat shield washer between inlector

and cylinder

5-6

67  

NOTE:The Following Torque Values are to be used- only if is not listed on preceding sheets.

Torque Value for specific

TORQUEPhosphate Coated Fasteners) TORQUEPhosphate Class 8.8 Class 9.8 N.m LB.FT. N,m LB.FT.

THD SIZE M6 M8 M 10 M 12

8-11 20-24 34-40 75-81

6-8 15-18 25-30 55-60

8-11 20-24 34-40 75-81

M 14 M 16 M20

122-135 190-203

90-100 140-150

122-135 190-203

part to be installed

Class 10.9 N-m LBoFT.

6-8 15-18 25-30 55-60 90-100 140-150

PROPERTYCLASS PROPERTY CLASS MARKING BOLTS AND SCREWS: The property class symbols for metric bolts and screwsare screws are given in table at right. Marking shall be located on the top of the head. Alternatively, the marking may be indented on the side of the head for hex head products. STU DS: STUDS: All metric studs usedon TMD nginesare nginesare of property class 10.9. If marked, marked,marking markingwill will be at nut end.

IDENTIFICATION SYMBOL

PROPERTY CLASS

BOLTS, SCREWS AND STUDS

8.8

8.8

9.8

9.8

10,9 12.9

10.9 12.9

STUDS SMALLER THAN M12 (~ -I’-

CYLINDER HEAD

TMD13

ColdTorquing Cold Torquing rocedure Step 1. Torquewith Torquewith HandTorque HandTorqueWrench Wrencho: o:

MIO--=,"

TORQUE SEQUENCE

Screw Size SH) M12 (HH) MIO (HH) M12

Ft.Lbs. 30-35 10-15 25-30

N-m 41-47 14-20 34-41

Step 2. Torquewith Torquewith HandTorque HandTorqueWrench Wrencho: o: ¢

TMD20

12

9

10

I1

M10~

Screw Size (SH) M12

Ft.Lbs. 60-65

N-m 81-88

(HH) (HH) M10 M12

2 0-25 55-60

2 7-34 75-81

Step 3. Torquewith HandTorque HandTorqueWrench Wrenchn n one single smoothmotion: Screw Size SH) M12 (HH) MIO (HH) M12

Ft.Lbs. 95-100 35-40 90-95

N-m 129-136 47-54 122-129

Hot Retorquing rocedure TMD27

15

14

11

MI0---~-

® Torque all 68  

® cylinder

@

I1~

13

Step 4, Ret Retorque orque ith Hand Han d orqueWrench Wrenchafter after engine eachesnormal operatingemperature) operating emperature)o the followingvalues, followingvalues, n one ingle smooth smooth otion: ScrewSize ScrewSize (S H) M (HH) alO (HH) M12

NOTE: SH) SH) = Socket Head Cap CapScrew

head capscrews using the proper torquing

N-m 115-122 41-47 108-115

Ft.Lbs. 85-90 30-35 80-85

(HH) Hex H Head ead Cap S Screw crew

sequence shown here.

Section 11- Limits and Clearance Data NOTE: Dimensions shown are for

ENGINE MODEL VALVE GUIDE

standard

TMD METRIC

(ENGLISH)

60.4 16.700/16.675 8.717/8.692 8.775

(2 3/8) (.65751.6565) (.3432/.3422) (.3447)

(Intake & Exhaust) Length Outside Dia. Stem. Hole E)ia. *Wear Limits--Max.

Dia.

8.660/8.642 8.592 29°45 0.075/0.032 0.125 0.053

(.3409/.3402) (.3383) )(29°45 (.0030/.0012) (.0049) (.0021)

8.64018.622 8.575 44°45 0.09510.052 0.142 0.073

(.3402/.3394) (.3376) ()44°45 (.0037/.0020) (.0056) (.0029)

34.85 42.0 24KgF 21.5KgF 32.88 47.54KgF 42.5KgF

(1.372) (1.6535) (52.8#) (47.3#) (1.294) (104.6#) (93.5#)

VALVE SPRINGS Outside Dia. Length--Valve Closed Load--Valve Closed "Wear Limits--Min. Wgt. Length--Valve open Load--Valve open *Wear Limits--Min. Wgt.

Brg. Journal Dia, #1 #2 #3

Dia.

Bore--Inside Dia. #1 #2 #3

VALVES, EXHAUST Stem Dia. "Wear Limits--Min. Dia. Seat Angle Stem C Cllearance--Limits *Wear Limits--Max. C CII. Desired Stem Clear.

ENGINE MODEL CAMSHAFT

*Wear Limits--Min.

VALVES, INTAKE Stem Dia. "Wear Limits, M Miin. Dia. Seat Angle Stem Clearance Limits *Wear Limits--Max. CI. Desired Stem Clear.

engines.

Bore--Clearance Limits End Play

TMD METRIC

(ENGLISH)

47.511147.486 44.336/44.311 42.749/42.723

(1.870511.8695) (1.745511.7445) (1.683011.6820)

0.025 (.001) Under Minimum MinimumNew NewShaft Shaft Diameter 47.625/47.600 44.450/44.425 42.862/42.837

(1.8750/1.8740) (1.750011.7490) (1.6875/1.6865)

0.13910.089 0.03810.178

(.0055/.0035) (.00151.0070)

30.175/30.150 52.375/52.362 1.567/1.554 1.542 49.212/49.187 49.162 0.080/0.016 0.048 0.091 0.2810.15 0.20

(1.1880/1.1870) (2.0620/2.0615) (.0617/.0612) (.0607) (1.9375/1.9365) (1.9355) (.0031/.0006) (.0019) (.0036) (.011/.006) (.008)

78.019/78.00 2.484/2.471 2.459 72.974172.944 72.918

(3.0716/3.0709) (.0978/.0973) (.0968) (2.8730/2.8718) (2.8708)

0.133/0.058 0.096 0.17/0.04

(.0052/.0023) (.0038) (.0067/.0015)

71.0/70.7 28.575/28.571 28.562 Light Push 28.598/28.588 28.623 0.013/0.028 0.020

(2.795/2.783) (1.1250/1.1248) (1.1245) (1.1259/1.1255) (1.1269) (0.0005/0.0011) 0.0008

25.324/25.311 25.364125.344 0.13

(.9970/.9965) (.9986/.9978) (.005)

CONNECTING RODS Bush. Hole Dia. Brg. Hole Dia. Brg. Thickness *Wear Limits--Min. T Th hk. Dia.--Crank Pin "Wear Limits--Min. Dia. Clearance Limits Disired Clearance  Wear Limits--Max. CI. Side Play Desired Side Play

MAIN BEARINGS Dia. o off B Brrg. Bore in Bl Block t~rg. Thickness "Wear Limits--Min. Thk. Dia. of Main Brg. Jr. *Wear Limits--Min. D Diia. Clearance Limits Desired Clearance C/S End Play

PISTON PIN Length Diameter "Wear Limits--Min. Dia. Desired Fit Bush. Hole Dia.--Fin. *Wear Limits--Max. Dia. Pin CI. in Bushing Desired Pin Fit

TAPPET Outside Dia. Bore in Block "Wear Limits

69

 

ENGINE MODEL PISTONS Cylinder Dia. *WearLimits--Cyl. Bore *WearLimits--Cyl. Piston Pin Hole Dia. Ring GrooveWidth--#1 GrooveWidth--#1 Max. WearLimit WearLimit Width Ring GrooveWidth GrooveWidth #2-*Max Wear Limit Width #2-Ring GrooveWidth GrooveWidth #3 *Max WearLimit WearLimit Width Piston Fit-Feeler Gauge Lbs. Pull

PISTON RINGS Ring Width--#1 *WearLimits--Min. *Wear Limits--Min. Width Ring Width--#2 *WearLimits--Min. *Wear Limits--Min. Width Ring Width #3 WearLimits--Min. Wear Limits--Min. Width Ring GapClear--#1 GapClear--#1 Ring GapClear--#2 GapClear--#2 Ring GapClear--#3 GapClear--#3 Ring Side Clear--#1 Ring Side Clear--#2 Ring Side Clear--#3

NOTES

70  

TMD METRIC

(ENGLISH)

91.039/91.000 0,20 28.583/28.578 2.560/2.540 2.611 2.06012.040

(3.584213.5827)

2.111 4.060/4.040 4.109 0.08 2.3-4.5Kg

(.0831) (.1598/.1591) (.1618) (.003)

2.49012.478 2.423 1.99011.978 1.923 3.99013.978 3.927 0.40/0.65 0.40/0.65 0.30/0.60 0.082/0.050 0.082/0.050 0.082/0.050

(.0980/.0976) (.0954) (.0783/.0779) (.0757) (.1571/.1566)

(.008)

(1.1253/1.1251 (mI0081.1000) (1.028) (.0811/.0803)

(5-10#)

(.1546)

(.0161.026) (.016/.026) (,012/.024) (.0032/.0020) (.0032/.0020) (.0032/.0020)

Index /

WARNING

Read ndobserve ndobservell ll individualsafetywarnings safetywarningss youuse youuse his manualo operate, erviceor erviceor repair y ur engine.See engine. Seepages pages and2. and2.

.. .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... Important afety oticend Warnings

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Contents .............................................................................................................................. ~ ........................ 3 Industrialntinental ntinentalieselpecifications ieselpecifications .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... ....

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SECTION - General Information Continental ieselngine iesel ngine ... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... ..

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SECTION - Operating Instructions Preparation f a New ngine or Operation or .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... Starting h he eEngine ............................................................................................................................... Stopping heEngine ..............................................................................................................................

7 7 9 11Musts". ........................................................................................................................... ......................................................... ................................................................................... ................. 9 Cold Weather Weather peration ... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. 9 Enginereparation orWinterse...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. 10 Preparation f Engine or Seasonal or torage .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .. 11

SECTION - Lubrication Engine ubrication ystem...... ............ ........... ..... : ........... ................. ........... ........... ........... ........... ........... ........... ........... ........... ........... ........... ........... ........... ........... ........... ....... 3. OilPump Pump ..............................................................................................................................................13 13 OilChange Oil Change requency ........... ..... ........... ........... ........... ........... ........... ........... ........... ........... ........... ........... ........... ........... ........... ........... ........... ........... ........... ........... ........... .......... ..... 13 Lubricationecommendations ........................................................................................................... 14 SECTION - Cooling System Coolingystem ................................................................................................................................... 15 Effect f Altituden AltitudenCooling ............................................................................................................... 16 Anti-Freezes ................................................................................................................................ .............................................................. .......................................................................... ........ 16 Cleaning oolingystem ooling .................................................................................................................... Testinghermostat ............................................................................................................................. Radiatorressure ressure ap....................................................................................................................... Fan elt ension ................................................................................................................................. Waterump ump ........................................................................................................................................

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SECTION - Fuel System Electric uel ransferump ump ............................................................................................................... 21 Bleeding heFuel ystem ................................................................................................................... 22 Fuelilters..........................................................................................................................................23 23 Injectors ...............................................................................................................................................4 Testing .................................................................................................................................................4 Fuelnjectionump njectionump ............................................................................................................................ 25 Timingf Injection ump o theEngine theEngine .............................................................................................. 26 Fuel ecommendations ...................................................................................................................... 31 SECTION6 - ChargingSystem Charging ystem .................................................................................................................................

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SECTION - Pr ventive Maint nanc DailyPreventiveaintenance chedule ............................................................................................ Dry ype eplaceable ir Filter .......................................................................................................... PCVystem ........................................................................................................................................ CheckililPressure Pressure ............................................................................................................................. 50 Hour reventiveaintenance chedule ..................................................................................... 250 Hour reventiveaintenance chedule ................................................................................... 400 Hour reventiveaintenance chedule ................................................................................... 500 Hour reventiveaintenance chedule ...................................................................................

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SECTION - Engine Repair and Overhaul Cylinderead ead ..................................................................................................................................... 39 Disassembly f Cylinderead ............................................................................................................. ........................................................................................................... 40 Valveuides Valve uides ....................................................................................................................................... 41 Valveeat Valve eatnserts nsertsif supplied) ........................................................................................................... 41 Valveuide Valve uideata................................................................................................................................ 42 Valves ..................................................................................................................................................3 Valveprings Valve prings ...................................................................................................................................... 44 Rocker rms ....................................................................................................................................... 45 Valveush Valve ushods ods .................................................................................................................................. ................................................................................................................................ 45 Checking ore ear ........................................................................................................................... 45 Preparingylinder allsor allsor Re-Ringing r Reboring ........................................................................ 45 Pistons ................................................................................................................................................. .................................................................................................................................................7 7 Pistonins.......................................................................................................................................... 48 Connecting od.................................................................................................................................. 48 Pistonnd Piston nd onnecting od ssembly ............................................................................................... 48 Pistonings Piston ings ......................................................................................................................................... ....................................................................................................................................... 49 Recommended ethodf InstallingPiston ings............................................................................. 49 Crankshaft ndMain earings ........................................................................................................... 50 Bearings ..............................................................................................................................................50 50 Camshaft .............................................................................................................................................52 .............................................................................................................................................52 Tappets ...............................................................................................................................................53 Rearrankshaft ililSeals Seals.................................................................................................................. 53 OilPump Pump ..............................................................................................................................................54 54 Timingears ....................................................................................................................................... 55 Crankshaft ndlay ndlay........................................................................................................................... 57 Flywheel nd lywheel ousing ......................................................................................................... 57 Reassembling ngine ......................................................................................................................... 58 Installingead Installing ead .................................................................................................................................... 58 Installing ilPan Pan................................................................................................................................. 60 SECTION - Trouble Shooting Engineon’t Engine on’turn urn ver...... ......... ...... ...... ...... ....... ....... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ....... ....... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ....... ....... ...... ...... ...... ... 61 Engineurns,u utWon’t tWon’ttart tart............................................................................................................. ............................................................................................................. 62 RunsRough"iith thExcessive ibration .... . ..... .... .... .... ..... ..... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... ..... ..... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... 62 LossffPower Loss ..................................................................................................................................... 63 Overheating ......................................................................................................................................... 63 Excessive moke ............ ...... ............ ............ ............. ............. ............ ............ ............ ............ ............ ............. ............. ............ ............ ............ ............ ............ ............. ............. ........... ..... 64 Poor ompression under25# under 25# t 150 PM) .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .. 64 Low ilPressure Pressure ............. ....... ............ ............ ............ ............ ............ ............. ............. ............ ............ ............ ............ ............ ............. ............. ............ ............ ............ ............ ............ ...... 65 High ilConsumption ilConsumption ............ ...... ............ ............ ............. ............. ............ ............ ............ ............ ............ ............. ............. ............ ............ ............ ............ ............ ............. ........... .... 65 Pooruel Poor uel conomy ............................................................................................................................ 65 Sudden topping ............. ...... ............. ............ ............ ............ ............ ............ ............. ............. ............ ............ ............ ............ ............. ............. ............ ............ ............ ............ ............ ...... 66 Enginenocks nd oises nd ................................................................................................................. 66 SECTION 0 Torque pecifications pecifications .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... ..

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SECTION 1 Limitsnd Limitsnd learance ata.... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... ..

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SERVICEAND PARTS SERVICEAND Available from your Authorized WlS-CON TOTAL POWER Service Center

CALIFORNIA P~oposition 65 Warning Diesel engine exhaust and some some of its constituents are known to the State State of California to causecancer, birth defects, and other reproductive harm.

WIS.CON TOTALPOWER TOTAL POWERoRP. HEADQUARTERS: 3409 Democrat Road P.O. Box 181160 Memphis, Tennessee 3 38181 8181 Phone: (901) 365-3600 TOLL TOLLFREE: FREE: 1-800-932-2858 TELEX:462-1058 TELEX:462-1058 (IT1") FAXNO: FAXNO: (901) 369-4050 EUROPEAN: RueJosephDeflandre, 13 B-4920 Chau Chaudfontaine dfontaine Liege) Belgium Phone: (32) (32) (41) 675320TELEX: 42631 TDYTP TDYTP B FAX NO: (32) (41)

January/1993 TTP10148