Continental TMD27

CONTINENTAL DIESEL ENGINESOPERATORS GUIDE & REPAIR WIS-CON TOTAL POWER CORP. FOREWORD Good operation anda plannedmaintenance program as outlined in this manual are vital in obtainingmaximum engineperformance andlong enginelife. Theinstructions on the following pages havebeenwritten with this in mind,to give the operatora better understanding of the various problems whichmayarise, andthe manner in whichtheseproblems can best be solved or avoided. Theoperatoris cautioned againstthe useof anyparts, other than genuine Wis-Con Total Power parts, for replacement or repair. Theseparts have beenengineered and tested for their particular job, andthe useof anyother parts may result in unsatisfactory performance andshort enginelife. Wis-Con Total Power distributors anddealers, because of their close factory relations, canrenderthe best andmost efficient service. THE LIFE OF YOURENGINEDEPENDS ON THE CAREIT RECEIVES. The MODEL, SPECIFICATION and SERIALNUMBER of your engine must be given when ordering parts. The MODEL and SPECIFICATION number are on the nameplate. The SERIAL NUMBER is stamped either on the crankcase or the engine’s identification tag. the MODEL, SPECIFICATION and SERIALNUMBER in the spaces provided below so hat it will be availablewhen ordering parts. MODEL SPECIFICATION SERIAL NUMBER To insure promptandaccurateservice, the following informationmustalso be given: 1. State EXACTLY the quantity of eachpart andpart number. 2. State definitely whether parts are to be shipped by express, freight or parcelpost. 3. State the exactmailing address. IMPORTANT READ THESE INSTRUCTIONS CAREFULLY All points of operationand maintenance havebeencoveredas carefully as possible, but if further information is required, sendinquiries to the factory for promptattention. When writing to the factory, ALWAYS GIVE THE MODEL,SPECIFICATIONAND SERIAL NUMBER of the engine referred to. Startincj and Operatinq NewEncjines Careful breaking-in of a newengine will greatly increase its life and result in trouble-free operation. A factory test is not sufficient to establish the polishedbearingsurfaces, whichare so necessaryto the proper performance and long life of an engine. Thesecan only be obtained by running a newengine carefully and under reducedloads for a short time. ¯ Besure the engineis filled to the properlevel with a goodquality engineoil. ¯ For proper proceduresto follow when breaking-in a newengine, see ’Testing Rebuilt Engine’. Thevarious bearing surfaces in a newenginehavenot beenglazed, asthey will be with continued operation, and it is in this period of "running in" that special care mustbe exercised, otherwise the highly desired glaze will never be obtained. A newbearing surface that has once been damaged by carelessness will be ruined forever. illustrations and other itemscan change at anytime. you must satisfy yourself that it is safe for youandothers. Tennessee. adjustments. measurements.These warnings in the RepairManual andon the engineare identified by this symbol: Operations that may result only in enginedamage are identified in the RepairManual by this symbol: &CAUTION Wis-Con Total Powercannot anticipate every possible circumstancethat might involve a potential hazard. You shouldalso ensure that the engine will not be damaged or made unsafeby the procedures you choose. specificationsandillustrations in this manual are based on informationthat wasavailable at the time it waspublished. Thespecifications. READ AND UNDERSTAND ALL SAFETY PRECAUTIONS AND WARNINGS BEFORE PERFORMING REPAIRS ON THIS ENGINE Warning labels havealso been put on the engines to provideinstructions andidentify specific hazards which. device orworkmethod not specifically recommended by Wis-Con Total Power is used. These labels identify hazardswhich maynot be apparent to a trained mechanic. torques. devicesor work methods. Getthe complete andmost currentinformation beforestarting anyjob. the warnings in this manual are not all inclusive.Properrepair is importantto the safe andreliable operationof an engine. tool. contact Wis-Con Total Power. some of whichrequire special tools. pressures of operation.Thereare many potential hazards for an untrainedmechanic andthere is no wayto label the engine againstall such hazards. For parts.Memphis. IMPORTANT: Theinformation. . If a procedure. couldcause bodily injury or deathto youor other persons.This RepairManual outlines basic recommended procedures. or information. These changes can affect the servicegivento the product.if not heeded.therefore. service. Improper repair procedures canbe dangerous andcould result in injury or death. hydraulic pumpsand generators. Improper attire suchas loose clothing. fuel lines or other fuel system components. soft shoesor bare feet couldbe hazardous and should be avoided whenservicing engines. solvents. service or repair your engine.or fuel systems.however. batteries.the appropriate handbooks and safety instructions provided by the manufacturer of the end item should alwaysbe consulted prior to the undertakingof any work on subsystemsattached to the engine. fuel tanks. rings. transmissions. gasoline or other fuels maybe dangerousand can cause injury. clutches. These items are provided by the manufacturerof the end item in which the engine is used. Some of the dangers associated with servicing such items are generally mentionedin this manual. 2 . electrical equipment.fans. ties. hot parts. to avoid any hazardsinherent to these sub-systems. Always wear eye and hearing protection whenworking on or near engines.compressed air. electrical connections or other electrical components. Injuries maybe causedby lack of care whenworking with./ WARNING Most sub-systemsused in conjunction with Wis-Con Total Powerindustrial engines including (but not limited to) radiators.electrical equipment. hoses. / WARNING Read and observeall individual safety warningsas you use this manualto operate. pressurized systems. / WARNING Someequipment and materials used in the overhaul or maintenanceof an engine such as machine tools. or near. Always observe safety precautions. movingparts. Always exercise caution wheneverworking with an engine or any associated system. Useor service of the engine(including the use of modifiedparts or materials) not in accordance with manufacturer’s specifications could damage your engine or cause personal injury. are not supplied by Wis-ConTotal Power. ........................................................................................ SECTION 7 Preventive Maintenance ............... SECTION 9 Trouble Shooting ..................................................... INDEX .................................................................................................. SECTION 3 iLubrication ...................................................................... SECTION 11 Limits &Clearance Data ... Page 5 SECTION 2 Operating Instructions ......................... SECTION 4 Cooling System ....................................... SECTION 8 Engine Repair &Overhaul .................. SECTION 10 Torque Specifications .........CONTENTS CONTINENTAL INDUSTRIAL ENGINES SECTION 1 General Information .................................... Page 7 Page 13 Page 15 Page 21 Page 32 Page 34 Page 39 Page 61 Page 67 Page 69 Page 71 3 ............................................................................................... SECTION 5 Fuel System ................................................... SECTION 6 Charging System ................................................................................................................................................................................................................................... 8 49.36 . Frt.2 1.58 x 4. Main Brg.58 x 4.8 .5 5.2 x 24.96) (6 Quarts) (1 Quart) (7 Quarts) (.88 x .8 (2)73 x 23.94) (1. In most casesa Typical Nameplate .06) (82) CID 20.95 L 4.) TMD20 METRIC 3 91 x 103.60 PSI) 7 PSI 1-3-2 (2.1 Quarts) (420 LBS. Oil Capacity Crankcase Filter Total Valve Clearance Intake Exhaust Water Capacity Engine Weight (Approx.1 Bar 0. When ordering parts.60 PSI) 7 PSI 1-2 (2.014) (.35 L 20.4. INFORMATION FOR ORDERING PARTS specification number is listed.2 2.014) (.94) (1.018) (2.96) (4 Quarts) (1 Quart) (5 Quarts) (.8 73 x 23.94 x .8 73 x 31.0 L 191 Kg ENGLISH 2 (3.88 x .0 L 20.25) (2.06) (164) CID 20. Oil Pressure* Min.1 Bar 0.94 x .8-4.58 x 4.5:1 (40.5:1 2.2 x 24.95 L 5.88 x .1 Bar 0.8 73 x 23.which lists the model andserial number. Rear Conn.5 Bar 1-3-2 73 x 23.94) (2.) (With Accessories) *Higher oil TMD13 METRIC 2 91 x 103.95 L 6.88 x 1.65 L .73 L .2 2.94 x . Main Brg. refer to the enginename plate attached to side of the cylinderblock.8 .8 73 x 31.94) (2.014) (.5 Bar 1-2 73 x 23.94) (2.) pressure maybe experienced during cold starts.06) (123) CID 20.88 x .018) (3 Quarts) (475 LBS.018) (3. Int.68 L 20.5 Bar 1-3-4-2 73 x 23.8 73 x 23.46 2.25) (2.8 Quarts) (557 LBS.94) (1.) TMD 27 METRIC 4 91 x t03.46 3.88 x . Oil Pressure (Idling) Firing Order Main Brg.94) (2.36 .36 .8 73 x 31.5:1 (40 .88 x .8 49.46 2.25) (2.5:1 2.8 73 x 23.4. of Cylinders Bore & Stroke Displacement Compression Ratio Max.8 49. Thrust Main Brg.84 L 216 Kg ENGLISH 3 (3.7 L . Thisdata is of vital importance in obtainingthe correct parts: always includethis information on yourparts order.5 3.68 L .88 x .5:1 2. Rod Brg.5 4.73 L .88 x 1.94) (2.88 x 1.96) (5 Quarts) (1 Quart) (6 Quarts) (.5:1 (40-60 PSI) 7 PSI 1-3-4-2 (2.6 L 253 Kg ENGLISH 4 (3.Industrial Diesel MODEL No.88 x .2 x 24.78 L . The combustion chamber design has been tailored for the required turbulence. Individual Porting. CHOICE OF 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. Individual Porting . This is accomplished by casting the cylinder head with individual intake valve passages for each cylinder and connecting these passages to an intake manifold which also has individualized passages for each cylinder. OHV Design [ .Section I . charge flow and burning characteristics to provide dependable and economical heavy duty service. Someof the principal design features are: 1. Water Jackets -.completely surround all ylinder bores to a depth sufficient to cover the hot piston ring travel.General Information CONTINENTAL DIESEL ENGINE Continental Diesel Engines are Comet V combustion chamber indirect injection diesel engines. page 29). resulting in minimumbore distortion for good oil control yet maintaining low heat rejection to the coolant.of the intake manifold whereby each cylinder is fed with the air charge individually and is not influenced by other cylinders of the engine. Main Bearing Cap & Cylinder HeadBolts Pump Drive Gear Crankshaft Gear Oil Oil Pure Cross section of typicalWis-Con Continental Industrial Diesel .~linder HeadCover Rocker Arm ector Water Header -- Cylinder Head Intake Valve ~r Insert Piston dinder HeadGasket ChromeTop & Oil Rings Water Jacket PumpDriven G~ Connecting Rod Counterweighted Cra Gear Injection Heat Treated Alloy Stee Connecting Rod. Read andobserve safetywarnings on pages 1 and 2. Sparks or flames neara battery could cause anexplosion or fire. WARN NG Stop engine before checking battery terminals or electricalconnections. Bodily injuryor death may resultto individuals during operation of anengine withinanyenclosure notadequately or properly ventilated. STARTING THE ENGINE / WARNING Water DrainCock Fill radiator and water jacket with coolant. Fill Crankcase with oil -. Always wear eye protection. PREPARATION OF A NEW ENGINE FOR OPERATION Beforeplacing a new enginein operation.Section 2 Operating Instructions Theperson operating the engine naturally assumes responsibility for its care while it is being operated. Read andobserve safetywarnings on pages 1 and 2. To supply sufficient air to cooltheengine. Close water drain cock mon the side of the block. Detailedinstructions for bleeding the injection systems are given in section 5. Battery acidcancause corrosive burns. Electrical Connections -.See fuel recommendations on page 29. Engine operation in anyenclosure requiresadequate and proper ventilation to avoid asphyxiationor other interruption of normal breathing. (See Cooling System Section 4). fuel systemmustbe bled to remove any air that mayhave become trapped in the system. The operating and preventive maintenance structions for the Diesel Enginesare simple and shouldbe followed without deviation.) 2. This is a very important responsibility since the care and attention given the enginegoes a long wayin determining howlong a period it will operatesatisfactorily before havingto be shut down for repairs.Usethe oil recommended for the ambienttemperature(see chart on page14). If theengine is new or rebuilt or if fuel filters have been serviced or any low pressure lines disconnected. 3.Checkstorage battery terminals andall electrical connections. Radiator Coolant Inlet . 4.it must be thoroughly inspected for external damage and particular attention paid to the followingitems: 1. (In some cases.this maybe a pipe plug. Fill Fuel Tank-. Bleedthe entire fuel system. provide air to mixwithfuel and to carry away heated air from thebuilding.Useof jumper cables or battery charging should be done only as directedby manufacturers’ safety instructions. Theentire aimin setting forth theseinstructions is to give youa benefit of the knowledge andexperience gainedover a long period of collaboration betweenEngineering Researchand Field Service. Move switch to start position andstart engine. manuallyenergize glow plugs for the appropriate time: either 7 seconds or 20 secondsdependingupon which type glow plugs are usedin the engine. be sure breatheror ventilation system is openso vapor can be expelled. PowerTake-off IMPORTANT! Breaking in a new or rebuilt engine -. 5. 1. . 2. Engine should be operated long enoughto bring oil andwater temperature to normaloperating temperatu re. operation. Read and observe safety warnings on pages 1 and2. condensation will settle on valvestems andguides. 1. CAUTION: After starting newengine-. DisengagePowerTake-Off -. showrooms. CheckWater Temperature / WARNING Starting fluids or aids suchas ether or gasoline mustnot be used in a diesel engine air intake system. Soon valves.as well as other moving parts.The use of these fluids will causesevere internal engine damage and/or bodily injury.STARTlinG PROCEDUP~ 9. Make sure electric shut-off is wiredto permit fuel flow when the starter switchis in the "start" and"run" positions.run it at idle for 5 minutes. are started up for any reason. 3. 10. Check Oil Pressure MODEL TMD OIL PRESSURE* 2.repeat the preheat sequence. 8 WARM UP NEW ENGINES When newengines in distributors or dealers stock. the following adjustments should be made at end of first 50 hrs. 4. rings.1 Bar (40 .). if enginestill doesnot start refer to trouble shootingsection 9. etc. 6. 38°C(100 7.60 PSI) * Higheroil pressure maybe experienced during cold starts. Adjust throttle to idle at 800to 1200 R. they should be brought up to operating temperature in order to eliminate all condensation before stopping.P. RELEASE Water Temperature Gauge 11.M.4. Engage glow plug preheat control and wait until the indicator light is off. etc. Adjust valve tappets to specified clearances. If enginefails to start. If they are stopped while still cold.for peak performance and economical operation.(if equipped) Starting engineunderload throwsoverloadon starter andbattery. turn switch to the "off" position andrepeatthe above steps. If starting is not attemptedwithin 15 to 20 seconds. If the fuel pump is fitted with a mechanical shutoff.then bring oil level to high markon dipstick. Thenopen throttle to abouthalf speed until the coolant reaches ° F.Adjust idle speed to equipment manufacturer’s recommendation. 8. for a few minutesto circulate andwarm the oil.8 . If enginedoesnot usean automatic preheat control. 2. move the control to full open. will bestuckby this rusting and sludging action. and rust and sludgewill form.then stop engineandrecheck oil level in crankcase -. 2. Sludge formation at low temperatures is a close second to dirt in causing engine damage and . If morethan a teacupful of water is drained off. Overheatingis detected by loss of coolant. 9. AMMETER-should register "Charging" at all times engineis rur~ning. the following adjustments should be made at end of first day’soperation. FOLLOW PREVENTIVE MAINTENANCE SCHEDULES RECOMMENDED-thiswill avoid troubles which might cause expensive breakdowns and maintain your engine for dependable and economicaloperation. If the fuel pump is fitted with a mechanicalshutoff. Higher temperatures are acceptable with pressurized systems. 8.).5 Bar (7 PSI) at idle (800-1200 R. The multigrade lubricating oils 5W-20 and 10W-30 are ideal for cold starting with its reduced initial drag until warmed up. the contaminated gases remain in gaseous form and the engine operates clean as long as breather system is kept clean--however temperatures below this will The oil used during cold weather should have a cold test below the lowest anticipated temperatures that will be encountered during its use. Adjust valve tappetsto specified clearances.M. 7. before stopping-too rapid cooling down may cause distortion. CLEAN. (A voltage regulator may limit it to a very low reading). MUFFLER RESTRICTION . the sourceof ingress mustbe foundor else the filter bowl must be drained at morefrequent intervals. when they assume the characteristics of the heavier oil.STOPPING THE ENGINE 1. Inspect mufflers periodically for restrictions to prevent burned valves.allow engineto cool so as to prevent cracking the cylinder block. 4. move the control to full close. run 3. This condensation forms both a sulphuric and sulphurous acid which combines with the oil to becomea highly injurious sludge. 1. 4. WHENENGINE IS OVERHEATED -donotadd water . 3.should not exceed 508mm (20") water.) 2. COLD WEATHER OPERATION Battery condition starting. This is formed by the piston combustion gases mixing with the fine oil mist in the crankcase and condensing on a cold surface. Adjust idle speed to equipment manufacturer’s recommendation. CLEAN AND SERVICE AIR CLEANER-as recommended to maintain its efficiency. 6. Moveswitch to off position. WATERTEMPERATURE-normal operation 81°C-96°C (178-205°F. engine at idle for several minutes to cool.the filter bowl should be drained daily until the amountof water so removedindicates that less frequent draining will be adequate to prevent water from enteringthe fuel injection pump. This dew point is about 57°C (135°F.if hot. after each operating period. BREAKING IN A NEW ORREBUILT ENGINE -for peak performanceand economical operation.)-when crankcase temperatures are higher. is very important for proper wear. 5. 11. WATER FREEFUELis vitally important to the operationof your engineandfuel injection system.P. "FREQUENTREADINGSOF GAUGESHOULDBECOME A HABIT". Use a proper temperature range thermostat and warm engine up thoroughly. or cylinder head.). When the presenceof water in the fuel is suspected. Disengage Power Take-Off 2. OIL PRESSUREshould be up to recommended pressure at operating speedand over 0. AVOID COLD--SLUDGECONDENSATION-by protecting unit to maintain crankcase temperature over 57°C (135°F. 10. IDLINGENGINEslow engine downto low idle for about 5 minutes. 11 "MUSTS" FOR YOUR ENGINES 1. Reduce engine Spe d to Idle. Injection pump warranty will be affected if pump failure results from water in the fuel. per winter grade. If the coolant is hot or if the engine has been running.1" 93. There are several different manufacturers of transmissions and powertake-offs. Wiring . repair leaks and install antifreeze to the level required for winter protection. HighAltitudeOperation--if engine is to berun continuously at a highaltitude (above 5000 ft. Use of jumper cables or battery charging should be done only as directed by manufacturers’ safety instructions.8" 45.ICE Sludge andFreezing of Oil Screens andPumps . LUBRICATION SYSTEM A. schedule to keep during the winter which follows to get your engine Then use the winter maintenance it in peak operating condition months. Check and adjust alternator belt tension. 50" 32" o o Stop engine before checking battery terminals or electrical connections.5 LIQUID CONDENSATION S=udg=no. 3.4°C (85°F.) the pump calibration should be modified to maintain an acceptable smoke level. Ringand ValveStickingand Burning of Bearings. Battery . High Temperature Operation--for every 5°C (10°F. ELECTRICAL SYSTEM A. Replace if required. hoses and engine for water leaks. 30). 250 2oo’.check battery cables.) as shown the following chart: Use the checklist ready for winter. It is vitally important therefore to maintain oil and crankcase temperatures above 57°C (135°F.replenish water and test for condition and state of charge. 1.9" 121. So. loo’. Etching of Parts. Tighten hose clamps. Note:Some high altitude fuel delivery curve shaping can be performed on someSTANADYNE fuel injection pumps in the field (seepg. Contact manufacturer for recommendations. Putting your engine in proper condition and keeping it that way pays big dividends by reducing costly down time. ° 15o .) inlet air temperature-a powerloss of 1%results. CHECKLIST REACTIONS WITHIN ENGINE DURING CRANKCASE OPERATION c 176. the oil should be examined daily and changed as it mayfreeze. or clog the inlet strainer and cause bearing or oil pump failures. / WARNING warnings on pages 1 and 2.Resulting in Burned Bearings and Stripped Pump Gears.7" 10" 0" -17. Addoil of the pro- types and B. 10 A. 666 SNOW . which puts a heavy load on batteries. Read and observe safety ENGINE PREPARATIONFOR WINTER USE More than 90%of the hard starting complaints in cold weather are the direct result of inadequateattention to preparation for winter use and proper maintenar~ce.) above29. Read and observe safety warnings on pages 1 and 2. Check radiator. loosen the pressure cap to the first stop and let the pressure out o! the cooling system before removing the radiator cap. COOLING SYSTEM When sludging conditions prevail.6" CLEAN ENGINE OPERATION 148. 2. .6" TO TEMPERATURES F / WARNING °. Caution should be used when determining the proper seasonal grade lubricant to assist in cold weather starting.3" ° 65. batteries run downand the engine is blamed for hard starting. An engine not properly prepared requires more cranking energy and time. Battery acid can cause corrosive burns. connections and other wiring. Be sure connections are clean and tight and that cables and wiring insulation are in good condition. Drain oil and changefilter. Always wear eye protection. Sparks or flames near a battery could cause an explosion or fire. 37. Alternator and regulator-run the engine and check the ammeter to be sure the alternator is charging and the regulator is functioning properly. invariably.result in injurious sludge formation. lines andinjectors. Fuel filters -. fill to capacity at the endof each operating period. Cleanfuel m handled by a reliable source having a cetane number of 45 minimum.4.RAT[ON OF ~_JYG]]~I-E FOR SEJ~ONJ~L STOI:tAGE (90 DAYSTO 6 MONTHS) 1. 5.Refill with about2 gallons of a 50-50mixtureof purewhite kerosene and SAE No. INTAKE AIR SYSTEM A. WINTEI~ I~I~INTEN~CE 1. Check the fuel stop and throttle control for satisfactory operationandadjust as required. Normal starting using the glow plugs supplied as standard equipment should be accomplished down to--20°C (~4°F).removing all grease or ot~er foreign matter. Bleedthe system as detailed in section 5. B.With SAENo. To insure against condensation in the fuel tank. Read and observe safety warnings on pag s 1 and 2. Drain cooling systemcompletely. 10 engine preservative oil which meetsMIL-L21260 Grade1 specification. 3. Servicedry type air cleaneras specified. This will avoid excessive sludgein the oil andreduce dilution of oil with rawfuel in the crankcase. Refill crankcase -.mustbe checked moreoften. Drain fuel tankandfilters -. Checkand adjust tappets. Refer to SAEJ313 or your local fuel distributor for detailed information (see page30). particularly the primary stagefilter.operateit for at least an hour oncea week to get it thoroughly warm. Performmaintenance in accordance with instruction manuals. 9. 8. 11. Cleanexterior enginesurfaces -. EXHAUST SYSTEM A. 3. otherwisethis may freeze and stop the fuel flow. to remove all the moisture and condensation separated from the fuel. Check instructions on the air cleaner decal. Be sure all hoses and clampsare properly seatedandtight. Run engine -. Checkthe rain cap. Never wash a hot injection pump with cold waterwhile engine is running. PI:{EPA. Sealall openings air-tight -. Drain crankcase. B.with adhesive tape that will not absorb or retain moisture. is a definite requirementfor easy starting and efficient operation.Anddrain crankcaseoil. 2. Fill coolingsystem-With a solution containing a rust inhibitor.The use of these fluids will causesevere internal engine damage and/or bodily injury. Stop engine-. 6. 7. Contact Wis-Con Total Power for special starting aids for colder temperatures. Sealthe air ventin the tankor filler capwith waterproofedadhesivetape. for proper operation and repair as required. 11 . If unit is only usedfor short periodsanddoesnot get thoroughlywarm. 10 engineoil. MISCELLANEOUS A. Fuel recommendations m the type of fuel to be used should be suitable for the ambient temperature to be expected. 5. 4. Co WAR ilNG Starting fluids r aids uch as ether or gasoline must not be used in a diesel engine air intake system.To thoroughly warm-upoil in crankcase. Changeoil as recommended on page 14. if supplied. 12. 2. FUELSYSTEM A.After engine hascooled. Start engine andrun it at half speed for 15 minutes when the oil will havecirculatedthrough the injection pump. 7. 6. We cannot caution you too seriously about obtaining fuel from a reliable source. 10. NOTES 12 . Theremovalof grit. Tappetsare lubricated by overhead oil return. Note:Onengines equipped with remote oil filters.Section 3 .and the detergentsholding the carbon particles in suspension in the crankcase.Lubrication ENGINE LUBRICATION SYSTEM Continental industrial diesel engines havefull pressure lubrication to all main.) 13 . Failure to do so may result in engine damage dueto momentary oil starvationat start up. stop the engine IMMEDIATELY and find the cause of the trouble. connecting rod and camshaft bearings as well as rocker arms and timing gears. CAUTION: If the oil pressure is erratic or falls below these limits. ~ TAPPET ~ R BEARINGS CAM ~ ~ / (( [~r GALLERY O~L BEARINGS PRRELIEFVALVE ~ CRANK& ROD BEARINGS PUMP OUMP Oil Filter Full-Flow Filter System Theschedulefor changing oil is directly dependent upon the operational environment: an extremely clean operation could go 100 hours while a dirty operation(foundry or cement factory) could be 50 hours or less. sludge and foreign particles causesfilter elements to clog and becomeineffective unless they are normally replaced every 100 hours or moreoften if conditions require. A by-pass valve maintains suitable oil pressure from idle to maximumspeed automatically. Higher oil pressure maybe experienced during cold starts.the lubricating oil in internal-combustion engines becomescontaminated from the by-products of combustion: dirt. (See suggested oil and filter change intervals on page 14.a large capacity gerotor type oil pump is driven off the crankshaft and protected by a screened inlet. A full flow oil filter is providedto remove dirt and foreign elementsfrom the oil. OIL PUMP Onall engines. 1 always fill theoil filter element withmotor oil priorto / installation. unburnedfuel entering the crankcase. Oil PumpPick-up (Typical) OIL CHANGE FREQUENCY Engine oil does not "wear out". water. Refer to trouble shooting section for this information. Refer to page4 for complete oil pressurefigures. However. 15W.40 SAE 15W .LUBRICATION RECOMMENDATIONS Motor oils used for internal-combustion engine lubrication perform many useful functions including: Dissipating heat. fuel systemand general engine conditions canall influence lubricant performance.A. Continental industrial diesel engines operate in a wide range of service conditions and seasonal temperatures.71 °C) The Multi-Grade oil used should cover the single grade recommendation for the atmospheric temperature involved.40 SAE 10W.g.50 20 10W. e. SAEo20W.40 20W. SG. High detergent . type of service.250"F (99 . The lubricating oil recommendation is based upon engine design. 10W . Lube oil andfilter mustalways be changed after the first 50 hours of operation of a new or rebuilt engine.50.30. Lube oil analysisprograms are recommended in all applications for optimum engineperformance andlife.Service Class D Service typical of industrial diesel engines operating under engine manufacturer’swarranties. SUGGESTED OIL ANDOIL FILTER CHANGE INTERVALS Continuous Dutyat Continuous Duty Rating Light DutyOperation (25% Max. 10W . SE/CD .160"F (55 .Oil Classifications maybe used. ~o ~///////////////////~ ~ For engines in continuousduty oil viscosity should be based on sump oil temperature. 130 .Oil Classifications maybe used. and the atmospheric temperature prevailing. Sump Oil Temperature 210 .30.installation.210°F (71 . SF/CD . Continuous Rating) andStandby 200 Hours Max. Standard Continental supplied starters and alternators have sealed bearings requiring no lubrication. 15W. and minimum cost of operation.~9"C) SAE Grade 40 30 30 10W.40 SAE10W . S. sealing piston rings. preventing metal-to-metal contact wear and reducing power loss through friction. Check your specification for accessories which mayrequire periodic lubrication. SAE10W-30 covers SAE-10W.exceedsengine manufacturer warranty requirements. Environmental.30 "////////3 SA~ 10w F///////////////////////////////////~ SA~ ~0w~20 ~////////////////////////~ SA~ =0 V//////. 50 Hours 5W ~ Multi-Grade 15W-50have the the lighter oil characteristics ¯ 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.Oil Classifications maybe used.40. NOTE: 1. OIL BODYGRADES Theoil gradesavailable from the lightest (SAE5W) to the heaviest (SAE50) are: CLEAN DIRTY ENVIRONMENT ENVIRONMENT 100 Hours Max. 14 .SAE 20 and SAE 30.40 20W. long engine life. API SERVICE DESIGNATIONS Werecommend using oil described below for all Continentalindustrial diesel applications. High quality oils are required to assure maximum performance.121°C) 160 .E. 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 °F -30 -20 -18 0 17 20 5 40 16 60 27 80 38+ 100 + "/////////////////////////////////////////~ ~///////////////////////~ SA~ ~0 y///////////////J SAE 20W .~ ~ SA~ ~w. so our recommendations are given for various types of service and ambient temperatures.40 CD. Like all liquids it expands when heated. Thecoolant fromthe pump enters the front of the block.in whichis mounted the positive shut-off thermostat. period.1 pintwill be lost through the radiator overflow pipe by the time the water temperature reaches 81°C (180°F).ectional View showing Coolant Passages in Head andBlock EXPANSION OF WATER Water has always been the most commonly used coolant for internal combustion enginesbecause it hasexcellent heat transfer ability andis readily obtained everywhere. This condi15 . For example: If a 4 gallon coolingsystem is filled completely full ofwaterat4°C(40°F). COOLING SYSTEM All Continental industrial diesel engines have the coolant force-circulated by a water pump and use a thermostat and by-passsystemto control the temperature range.Section 4 . There are instances wherethis corrosive elementhaseaten holes throughcast iron parts suchas water pumpimpellers and bodies. valve seats and guides. Keep engine running whileadding coolant. CAUTION: OVERHEATED ENGINE never pour cold water or coldanti-freeze into theradiator of anoverheated engine. as enginetemperatures mustbe brought up to andmaintained within satisfactory rangefor efficient operation.whichcontrols the opening to the radiator or heat exchanger. Allow the engine to cooland avoid the danger of cracking the cylinderhead or block. This provides for both rapid and eventemperature increase of all engine parts during the warm-up . the thermostat valve opensallowing all the coolant to circulate throughboth the engineandradiator.Upon being discharged from the thermostathousing. WATER FILTERS In some areas. This canleadoperators to believeengines are overheating when theyare actually operating normally. Continental industrial diesel engines operate mostefficiently with coolant temperatures of 81°93°C (180°-200°F) and a thermostat and bypass system is usedto control thesetemperatures. The thermostat valve remainsclosed and only allowsthe coolant to circulate within the engine itself until normal operating temperaturesare reached. the rate of expansion being1/32 liter per liter (1/4 pint per gallon) when the temperature is raised from 4° to 81°C(40° to 180°F). When desired temperature is reached. pistons and bearings. the chemicalcontent of the water is suchthat eventhe best of rust inhibitors will not protect the cooling system from the formationof rust andscale. in order to prevent damage to valves. passingalong and between the cylinder bores and is metered by the headgasket into and across the cylinder headto cool the pre-combustion chambers.depending uponthe application. However. Upon leaving the cylinder head. while shutting off the by-passsystem.Coo ing System Thefunction of the cooling system is to prevent the temperaturesin the combustionchamber from damaging the engine and at the same time keepthe operatingtemperatures within safe limits. the coolant enters the thermostathousing. however. Maintainingthe cooling system efficiency is imo portant. IMPORTANT: Presentthermostats begin to openat 81°C (180°F)andare fully openat 94°C(202°F). whereit is cooledbefore reentry into the engine.this systemmustbe kept from overheating. Operation of engines in this temperature range is not harmful. the coolant enters the radiator or heat exchanger. temperature gauges are not alwaysaccurateand maysometimes indicate higher thanactual temperature. immediately wash skin with water. using compressed air. In standard radiator design fins are connected to the metal tubes to give an extended surface through which heat can be dissipated. Radiator Drain Water forms rust due to its natural tendency to combine chemically with iron and air in the system.23°Cto -34°C (-10° to-30°F circulated. Every 500 hours of operation the radiator and cooling system should be well cleaned and flushed with clean water. Where the use of hard water cannot be avoided an approved water softener can be used. When operating temperatures are below 0°C (32°F. Rust inhibitors for water are inexpensive. This pressure becomesless at higher altitudes and the reduced pressure causes water and other liquids to boil at a lower temperature. OPERATINGTEMPERATURE RANGE ANTI-FREEZE ETHYLENE GLYCOL (permanent type) Whenthere are no leaks add water only to makeup for eval~oration. will serve to keep the cooling surfaces of the core free of dirt and other particles. Read and observe safety warnings on pages 1 and 2. Ratio Ethylene Glycol to water lto4 2to5 ltol CORROSION INHIBITORS / WARNING Corrosion inhibitor can cause damage to the eyes or skin.) an anti-freeze liquid must be added which will lower the freezing point a safe margin below the anticipated temperature of outside air. seek prompt medical attention. water filters should be incorporated in the assembly to remove these troublesome elements and offset the electrolytic action. Hard water will cause scale to form in the radiator and the engine water jackets and cause poor heat transfer. The correct proportion of anti-freeze is also important when the engine is to be operated under high ambient temperature conditions. For the eyes. The adC~ition of a corrosion inhibitor is not necessary if an anti-freeze containing a rust inhibitor is used.tion is caused by electrolysis taking place in the parts involved. 0°to-12°C 12°C to. only soft clean water should be used in the cooling system. In either event. RadiatorCoolant Inlet Blowing out between the fins of the radiator. Where these conditions exist.10°F) .23oc (32°to 10°F / t+ 10°to. forms solid ice and expands about 9% in volume--which causes tremendous pressure and serious damage when allowed to freeze inside the cooling system. simple to use and make cleaning and flushing necessary only after long periods of operation. Operating conditions will determine the frequency of this service. RADIATOR The radiator or heat exchanger consists of a series of metal tubes through which the coolant is 16 Wherever possible. scale and rust on the cooling surfaces prevent normal heat transfer from . in a direction opposite to that of the fan circulated air. immediately flush the eyes with water for several minutes. ANTI-FREEZES Water freezes at 0 °C (32 °F. EFFECT OF ALTITUDE ON COOLING Water boils at 100°C (212 °F.) under atmospheric pressure at sea level.). It is important that these tubes be kept clean on the inside and the fins free of dirt on the outside so the maximum heat transfer can take place in the radiator. Permanent anti-freeze will also raise the boiling temperature of the coolant. I! contact is made. CLEANING COOLING SYSTEM Deposits of sludge. 5. corrective cleaning by reverse flow flushing will most effectively remove the heavy deposits of sludge. with 4. 17 Reverse Flushing Radiator . Shut off the air. Thermostat operation can be checked in the following method: 1. Disconnent the hoses at the engine. Clamp the flushing gun in the lower hose a hose clamp. To Reverse flush the engine water Jacket 1. Dependable cleaning compounds should be used. to avoid radiator damage. the system should be filled with an approved anti-freeze compoundcontaining a rust and corrosion inhibitor. REVERSE FLOW FLUSHING Whenever a cooling system is badly rustclogged es indicated by overflow loss or abnormally high operating temperatures. The appearance of rust in the radiator or coolant is a warning that the corrosion inhibitor has lost its effectiveness and should be cleaned before adding fresh coolant. Put radiator cap on tight. as follows: 1. 4. 2.5 Bar (80 PSI) until the flushing stream is clear. Turn on the water and let it fill the radiator. the unit is defective and should be replaced. 3. clean and examinethe thermostat. 2. WATER FLUSHING GUN AI~ CLOSED FLUSHING GUN AIR Reverse Flushing Engine -NEW HOSE TESTING THERMOSTAT HOSE Remove the water outlet elbow. 3.the metal surfaces to the coolant and in time render the cooling system ineffective to properly maintain normal operating temperatures. Follow the same procedure outlined above for the radiator by alternately filling the water jacket with water and blowing it out with air 5. allOwing the engine to cool as much as possible. Clampthe flushing gun in the upper hose. Follow the procedure recommendedby the supplier. If the valve can be pulled or pushedoff its seat with only a slight effort whencold or it does not seat properly. Removethe thermostat. Before testing. After cleaning and flushing. Partly close the water pumpopening to fill the engine jacket with water before applying the air.g should be performed immediately after draining the cleaning solution. R v rse flush the radiator. Clean and inspect radiator cap. rust and scale. The reverse flow flushin.repeat until the flushing stream runs out clear. 6. 2. Hang thermostat by its frame in a container of water so that it does not touch the bottom. This is of prime importancebecausedifferent cleaners vary in concentration and chemical compositions. again fill the radiator with water and apply air pressure. Apply air pressure gradually. It is advisable to flush the radiator first. 7. Heat the water slowly and check temperature with a thermometer. allowing steam and water to pass out the overflow pipe. Checking Thermostat Wheninstalling a new thermostat in the water header make sure that the temperature sensing unit goes in first or faces toward the cylinder head.200°F. loosen the pressure cap to the first stop and let the pressure out of the cooling system before removingthe radiator cap. Whenadjusted correctly the fan belt deflection on the long side should not exceed 13mm (1/2"). the thermostat should be replaced. If the valve does not start to open at temperatures of 81 °-93°C (180°. the boiling point of the coolant at this pressure is 107°C(224 °F. This spring loaded valve in the cap closes the outlet to the overflow pipe of the radiator and thus seals the system. When a 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. Most pressure valves open at 0. Under no circumstances should a pry bar be used on the alternator to obtain fan belt tension or damage to the bearings will result. loosen the alternator adjusting bolts and pull out on the alternator by hand until the belt is just snug. When replacing the thermostat in" the water header be sure the counterbore is clean. Installing New Gasket 18 . PRESSURE CAP PRESSURECAP CONTACT Installing Thermostat SEAT FAN BELT TENSION Whentightening fan belts.0 Bar (41/2 or 15 PSI).) at sea level. Read and observe safety warnings on pages 1 and 2. however.) or 120 (248 °F.3 or 1.3.) or if it opens well before the 81 °C (180 °F. so that pressure developing within the system raises the boiling point of the coolant and allows higher temperatures without overflow loss from boiling. RADIATOR PRESSURE CAP / Thermostat Open 85°C~ WARNING If the coolant is hot or if the engine has been running. Assemble new water outlet elbow mounting gasket. Many operations use a pressure cap on the radiator to prevent overflow loss of coolant during normal operation. Thermostat flange must seat in counterbore with gasket sealing contact between it and the outlet elbow.) point is reached. 3. 4. 2. Remove seal (5). Removefasteners holding the pump body to the front of the block and remove the pump assembly. The inlet of the water pump is connected to the lower radiator connection and the outlet flow from the pumpis through integral passages cast in the block. Remove fan by taking out four cap screws. No lubrication of the pump is required as the bearings are of the permanently sealed type and are packed with special lubrication for the life of the bearing.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 seal that needs replacement. Adjusting Fan Belt Tension CYLINDER BLOCK COOLANT DRAINS Whenthe cooling system is to be drained. Use puller to remove impeller (4) taking precautions to prevent damageto the casting. Coolant Drain Removing Water Pump WATER PUMP The water pump is located on the front of the cylinder block and is driven by the fan belt from the crankshaft pulley. Loosen alternator so that fan belt can be slacked off enoughto slide over pulley. disassembly must be in the following sequence in order to prevent damageto the pump. Remove countersunk screws (1) holding cover (2) removing cover and gasket (3). 1. DISASSEMBLY OF WATER PUMP When replacement of any internal parts becomes necessary. Use puller to removefan hub (11) from shaft. 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. Drain coolant. 19 . REMOVING WATER PUMP The water pump assembly can be removed from the engine as a unit for service or repair in the following manner: 1. 3. 4. 2. C!ark Water Pump 2O . ~ Please reference SPB88-374. 6. 3. Use thick soapsuds on both the seal and shaft when assembling in order to prevent damageto the seal. replacing worn or failed parts. Removelock rings (7) holding bearing and shaft assembly in body after which shaft (10) can be forced out through the front with an arbor press or lead hammer. Pull out the alternator by hand. Mount pump assembly on block using a new housing gasket. The fan hub must be installed prior to replacing rear plate. as bearing damage will result with a pry bar. REASSEMBLY AND INSTALLATION 1. Seal contact surfaces must be smooth and flat. 5. Reassemble pump. DO NOT ATTEMPT TO DRIVE WATER PUMP SHAFT (10) OUT THROUGH REAR OF HOUSING. Refill cooling system. A light film of lubricant applied to the face of the seal will facilitate seating and sealing. To do so will damage the housing beyond repair. 4. The bushing should be replaced if scored or cut. 2. The shaft must be supported during this operation to prevent damageto the seal and bushing. Install fan belt and adjust belt tension to have 13mm (1/2") deflection on long side.l Drive Shaft out in this direction Disassembling Water Pump 5. check for actual batteryvoltageto the unit before declaring it to be bad! Usinga Voltmeteror test light . suchas suctionleaksat joints in the supplyline can cause erratic enginebehavior. Various components are made with the utmost precision and maybe easily damaged when removed. If voltageis present at the fuel pump make one last test before declaring the pump bad! Loosen the fuel line fitting onthe inlet fuel line onthe injection pump. It shouldbe bornein mindthat minor troubles. etc. distributes it in the propersequence to the various cylinders. CAUTION: There should be notampering with the injectionpump assembly.fuel supply pump. one for each cylinder.Secl "on Fuel System Thebasicpurpose of the fuel system is to store. with a container. throughthe nozzles. All injection pumps should be calibrated and repaired at authorizedservice stations. Not the least of theseare the filtration elements. This connection is usually foundat the fuel shut off solenoidon the fuel injection pump. high-pressuresteel lines connectingthe pump discharge outlets to the nozzles.check for voltageat the first wire connection closestto the electric fuel pump. Read andobserve safetywarnings on pages 1 and 2. A brokenstreamwith bubbles anddribblesor no fuel at all indicatesthe fuel pump is probablybador that there are restrictions somewhere 21 . It is unlikely that the injection pump itself wouldrequire overhaul beforeit has several thousand hours of operation. and nozzle holders and nozzle assemblies. or removal of it for inspection.to catchthe fuel as it comes out of the open line. (See Bleeding the Fuel System. Improper handling of fuel could result in an explosion orfire causing bodily injury to yourself or others. electric fuel pumps to transfer fuel fromthe fuel tank to the fuel injection pump.fuel filters.the correct pattern of sprayfor the combustionchamber. Beprepared. as fine particles of dirt in the fuel are extremely destructive to high-pressure pumps of any description. When fuel pump trouble is suspected.checkthe equipment electrical circuit for blownfuses. but volumeor flow needs to be checked . unless engine operation is seriously impaired and the cause of thedifficultyis directlytraceable to thepump unit. unlessfactory trained personnel are available with the proper tools andtest equipment.simplydisconnect the fuel inlet line fromthe fuel injection pump andturn the ignition switchon. ELECTRIC FUEL TRANSFER PUMP ManyContinental TMD Industrial engines use WARN NG Smoking or open flameshould be avoided any timethe fuel system is being repaired or serviced. bad switches. commences the individual injections with fine precision in timing. broken wires. forces it through the filters anddelivers it to the injection pump. Fuel should flow and the pump should beginticking if it is operating properly.)Theydrawlittle battery currentandonly a slight drain is usuallyseen on the storagebattery during the bleeding process. The injection systemof a diesel engineincludes an injection pumpassembly complete with governor. A steadysolid stream of fuel indicatesthat the fuel pu mp is probably OKfor continueduse. Electric fuel pumps will operate withouthaving to crank the engine over. and producesuniformly. These electric pumps are usually mountedto the crankcase fuel pumppad cover wherea mechanical fuel pump wouldnormally be mounted. meters it with great accuracy. Thefuel transfer pump drawsthe fuel from the supplytank. If the pump is operating.Theareashould beproperly ventilated.If you can’t hear or feel the fuel pump operating . If no voltage is present .always check that the pump is getting voltage from the ignition circuit and that the BLACK groundwire is intact beforedeclaringthe pump is bad! A "quick" test for voltageis to turn the ignition switch"on" andfeel the bodyof the pump. convey andinject the fuel into the engine. dueto the danger that dirt will enter the exposed connections and the possibility of mishandling the equipment through lack of knowledge of its design and construction. Carelessor too frequent removalof elements of the fuel injection system for "inspection" or "cleaning" is generally far moreharmfulthan beneficial. This makes themextremely useful when bleeding the air from the fuel system.The fuel injection pump places it underthe high pressurerequired for mechanical atomization. Youcanactually feel the pump operating andhearit ticking if the work areais quite enough. Loosen the filter outlet connection (A) or the fuel injection pump inlet connection (B) whicheveris the higher and allowfuel to flow until free of air. When fuel freefrom air flowsfromthevents. arein a neutral position before attempting to crank the engine. Also. Turnthe ignition switchto the "on" position. Tighten the connection. lighten the housing vent screwandthen the governor vent screw. Tighten connections. Tighten nuts. or the fuel injection pump inlet connection (B) whichever is the higher. 1. this must bedone irrespective of theheight of thefilter in thesystem.becertainthat the wheels are"chocked" and the parking brake is set.after anysubsequent removal. CAV-DPA Fuel System Before bleeding and venting the CAVmDPA fuel system ensurethat the outside of the vent screws and surroundingarea is thoroughlyclean to preventdirt and foreign matter entering the system. InjectionPump Vents (CAV--DPA) Note: Filters of thefourboss typemust alsobevented at the plugged boss. Note: Electrical equipment such as startersshould be shieldedwith non-conductive material during the bleeding process to prevent damage fromfuel entry. If a wheeled vehicle is involved . (Refer to page8.loosen connection (B). Turn the ignition switchto the "on"position. BLEEDING THE FUEL SYSTEM Bleeding is necessary on initial installation of the fuel injection system.) 6. be certain that all transmissions. Start the engine. Stanadyne Fuel System 1. 5. they are most likely found to beeither plugged fuel filters or trash on the inlet side of the electric fuel pump. andallow fuel to flow until free of air. Loosen the filter outlet (A). Loosen anytwo injector high pressurepipe nutsatthe injector end.Crank engine until fuel free fromair flows. andthe vent screw(D) on the governorhousing. etc. hydraulic controls. andif the system shouldbe drainedafter havingrun outof fuel. gearboxes. 22 TypicalSTANADYNE Fuel System Schematic . 2.Set the accelerator to the fully openposition and ensurethat the stop controlis in the "run"position. CAV--DPA Fuel System Schematic Note: Electrical equipment such as starters should be shielded duringbleeding to prevent fuel entry. 4. Energize the glow plugs. If restrictionsaresuspected in the fuel circuit. There could alsobe anair leakin the fuel pick up line on the suction side of the pump causingthe pump to cavitate. Note: If connection (A) is inaccessible due to the type of filter in use-. Loosen the vent valvefitted on oneof the two hydraulic headlocking screws (C). 2. 3.in the fuel circuit. to separate and settle to the bottom of the filter. (Reference page 23. Lubethe newelement grommets with clean diesel fuel andpushinto place. Cleanthe inside of the bowl andcenter tube. Continental diesels are normally equipped with the filter installed between the fuel injection pump and the transferpump outlet.Setthe accelerator to the fully open position.3. Stanadyne Fuel System.when clean fuel is not available. crankthe engineuntil fuel free from air flows. Todrain the waterfromthe filter. It shouldbe replaced at the regularly scheduled periodic maintenance interval or if there is reason to believethat it is plugged. No attempt should be made to clean this type element. Snap the spring clampsinto position and bleed the fuel system. Energize the glowplugs. Thisallows the water.an additionalprimary fuel filter andwaterseparator should be installed beforethe fuel transferpump. Install newO-ring on the center stud. newfilter elementin position and replace the bowl. 5. If water contamination is anticipated. Tightenthe line nuts. Placethe Stanadyne FuelFilter (# TMD20FO0400) 23 . FUEL FILTERS CleanFuel is a Mustin diesel operation. It should be replaced whenperiodical maintenance is being carried out or if there is reason to believe that the elementis plugged.Extreme conditions mayrequire additional filters to provide longer filter change periods. andwith the ignition switch "on". 2./ft. which is heavier. Fit the newupperand lower sealing washers. water shouldbe drained from the fuel filter approximately oncea week. Bleed the fuel system(refer t page22.so the filter is onthe pressure side of the transfer pump. CAVmDPA fuel system). Loosen anytwoinjector high pressure pipe nuts at the injector end. Leave the drain plugopen until water-free fuel is observed. Tightenthe drain plug.Poor fuel quality andharshworkconditionscanshortenthe weekly drain interval to daily intervals.Tighten centerstudto 6-8 lb. Not : It is bestto drainthewater after the engine has been at rest for awhile.) 5.) CAV-DPA Fuel Filter Thefuel filter is of the paperelement type. Under normalconditions. Toreplacethe filter element: 1. 4. Start the engine.Remove anddiscard the upperand lower elementsealing washers and O-ring from the center stud.(Refer to page8. andno attemptshouldbe made to cleanthe element. Discardthe dirty element. Under normal conditions the element should be renewedevery 400 hours. (8-11Nm). Always drain thewater from thefuelfilter withthe engine dead andelectric fuel pump off. This period shouldbe decreased if unavoidable contamination of the fuel is experienced. simplyloosen the drain plugat the bottom of the filter assembly 1/2 to 1 turn. Remove filter bowl. 4. Theperiod for changing the elementwill largely depend uponthe quality and condition of the fuel available. Glow Plugs Stanadyne Fuel Filter Note: Thisfuel filter is not a water separator. Not : Electrical equipment such as startersshould be shielded with non-conductive materialduringfilter replacing and priming to prevent fuel entry. To replace the metal canister elementsimply releasethe two spring clamps andpull the old elementoff the filter bracket. 3. Increased fuel consumption.1 BAR) *A newinjector is an injector with no engine "run time" onit. connect it to the tester. Anydisassembly of the fuel injectors shouldbe done in an extremely clean workarea. Engineoverheating. 5. Smoky exhaust(black or white). Thenozzles are identified by verysmall lettering on the outsideof the nozzleas follows: CAV--stamped just abovethe large hex portion of the nozzle. It is impossible to adjust thesetting of theinjectorwith anydegree of accuracy without proper equipment. Thefaulty injector or injectors may be locatedby loosening the line fitting nut oneach. Therefore it is recommended that adjustments and/orrepairsbe made only by authorized CAV or Stanadyne repair centers. in turn. turn it upside down andshake it. CAUTION: Noattemptshouldbe made to adjust the injection pressure withouta proper testing pump and pressure gauge. determine the brandname of the fuel injector aboutto be tested. because of different operatingpressures. / WARNING Side View Tighteninjectors evenlyto 50-55LB-FT (70 Nm). Lossof power. STEP 1 : Set tester so that it will applypressure and then work the pump handle several sharp strokes. TMD engines currently use injectors made by two different companies. 6. Usea special hydraulic injector tester equipped with a filter so that onlyclean oil enters the injector. Becarefulnot to flush anydebrisinto the open ports of the injector. Thisallowsthe fuel to escape andnot enter the cylinder. HeatShield & Injector.1 BAR) TESTING Injectors should not be disassembled unlesstesting shows that cleaningor other service is needed. 4. Theinjector least affecting the engineperformance shouldbe removed fromthe cylinder head andreconditioned or replaced. Bodily injury may result duringthis operationif care is not exercised. The high velocity f spray maypuncture the skin and cause blood poisoning. **A serviceinjector is considered to be anyinjector that hasbeen in use or any injector that has beenreconditionedandno new parts wereinvolved. 7.7-155. Before testing eachinjector. They look very much alike. Beforetesting.Compare to the following chart. with the engine running at a fast idle. but are nevermixed togetheron anyoneengine. Misfiring. STANADYNEmstamped just under one of the bleedoff tubes. One company is CAV and the other is STANADYNE. ) Injector NozzleSide manufacturer’s instructions for correct andsafe operation of the test equipment chosen. Injectors shouldbe takenout only if engineis malfunctioning as outlined below: 1. Thelower acceptable limit figures for the service injectors are necessary dueto nozzle needleembedment andspring relaxation that takes placeafter a nozzlehasbeen put into use. STEP2: Nowwork the pumphandle slowly and observe the opening pressure. 3. Read and observe safety warnings on pages 1 and 2.2-155. This will dislodgesome light carbon build-up fromthe tip of the nozzleand may remove anyvery fine dirt particles in the nozzle cavities. Keep hands and face away from nozzle spray. To performa compression test. Injectors that fail to meet the acceptable pressure limits should be adjusted by addingor subtracting . Knocking in one(or more)cylinders. CAV STANADYNE Acceptable Pressure Limits *New Injector=2150-2250 PSI (148.depending upon the type system involved. This may get rid of anydebristhat has just entered the nozzleduring the removal andcleaning process.(Reference page 59. After havingidentified the nozzle. Thereare manytesters on the market--follow the 24 Acceptable Pressure Limits New Injector=1900-2016 PSI (131-139 BAR) **Service Injector=1755-2016 PSI **Service Injector=1925-2250 PSI (121-139 BAR) (132. 2.INJECTORS When replacing injectorsin the cylinderhead it is essential that a newheat shield washer be fitted between the nozzlecapandthe cylinder head. Theexterior of the injectors shouldbe rinsedwith cleaningsolution before testing. Disconnect any low pressurefuel lines.) CheckingInjector Opening Pressure STEP 3: Oncethe pressure setting has been confirmed. Check that spraypattern is a "straight shot"or that it isn’t aimed off to oneside. Thepump is flange mounted to the engine. Watch for dribble from the sprayorifice. If in doubt. linkagerods or electrical wires that need to come off to allow injection pump removalfrom the engine.andincorporates no ball or roller bearings. Also. Remove the three long bolts that go completely throughthe timing gear coverandremove the injection pump.shims. by the trained eye of the CAVor STANADYNE technician. look for leaksalongthe body of the nozzleholderitself.the "judgement call" should be made . incorporating a sensitive all-speed governor. Shimsshould be available from the CAV or STANADYNE service center which is performing the adjustment. Thespray pattern should exit the injector in the formof a thin line o stream that gradually gets a little widerbeforedevel opinginto a small mist cloud out at the end. Wideor non-uniform spraypatterns are questionable. FUEL IN]ECTION PUMP Thefunctionof a diesel fuel injection pump is to accurately meteranddeliver fuel to a nozzlein each cylinder andto inject it at high pressure into the combustion chamber at precisely timedintervals. It is a relatively simpledesign. Not: It is always a good practice to haveall the injectors of anyoneengineset as nearlyalike as possible.This makes for a smoother running engine. Replaceany injector that cannot be adjustedto meet the above pressurelimit specifications. DO NOT separatethe injection pump from the adaptor mounting plate unless absolutely necessary.is a compact. POOR Typical CAV-DPA Fuel Injection Pump GOOD Nozzle Spray Patterns CAV-DPA INJECTION PUMP TheDPA distributor type fuel injection pump. (SeeShort Method pg. which indicates a leak between the holder and the valve bodylappedsurfaces. Thenumber of workingparts remainsthe same irrespective of the number of enginecylinders the pump is required to serve. The extreme precision necessary canwell be appreciated since this cycle mustbe repeated thousands of time per minutewith virtually no variation in timing or amount of fuel injected. self-contained unit for multi-cylinderdiesel engines. This will save you muchtime during reinstallation of the pump if the pump is goingback onto the same engine.gearsor highly stressed springs. checkthe nozzlespraypattern. Check the specification of your enginefor your particular fuel injection pump. which indicatesabad seat. Holdconstant pressure on the tester lever to maintainthe opening pressureof the nozzle.It is 25 STEP 4: Nowwork the pump handle rapidly (about 100 strokes per minute) and observethe spray pattern produced. 26. Removal of the Fuel Injection Pump Remove all highpressure fuel lines beingcareful not to bendthem. Thepump rotor is driven by the enginethrougha pinned hub and gear. DO NOT attempt to adjustthe timing without the pump mounting bolts securely torqued. uneven running and excessivesmoking. and components which affect timing are designed with oneassembly position only to ensureprecision. The fuel then flows through the passagesto the pumping elements. Injection pumps mustbe installed on the engine in accuratealignmentandtimedto correct relation with the crankshaftfor properengineoperationwith maximum power and economy and to prevent complaints of hardstarting. Pressure maintained within the pump housing prevents the entranceof dust. Thepressure rise is controlledby a regulatingvalve assembly located in the pump end plate.oil-tight. This is the injection stroke. WORKINGPRINCIPLE The internal camring. OVERHAULPROCEDURE Dismantling. andduring operationall moving parts are lubricated by fuel oil underpressure. Mostpumps havean automatic device which varies the point of commencement of injection. overheating. Fuel entering the pump through the maininlet connection is pressurized by a sliding vanetransfer pump carried on the rotor inside the hydraulic head. andeliminates havingto balancethe deliveries from eachof the high-pressure delivery lines. TheTMD engineis equipped with either a CAV-LUCAS injection pumpor a STANADYNE injection pump. the inlet port is cut off and the single distributor port in the rotor registers with an outlet port in the hydraulichead. At the same timethe 26 plungers are forcedinwards by the rollers contacting the camlobes. call your local distributor for assistance. Fuel is accurately metered to the pumping element. Theinstallation andtiming procedure for the fuel injection pump will be separated into a ShortMethod and a Long Method. Look for nameplates or raisedletters onthe body of the pump for identification purposes. assembly. Thegovernorflyweight assembly is mounted on the drive shaft andis contained entirely within the pump body. Fuel injection is effected by a single element havingtwin opposed plungerslocated within a transverseborein a central rotating member whichacts as a distributor and revolves in a stationary member known as the hydraulic head. Theplungersare forced inwards simultaneously as the rollers contact the diametrically opposed cam lobes. Theintegral governor is of the mechanical flyweight type.testing and adjustment of the DPA pump must be carried out by trained personnel. Contact your Continental distributor for details. and gives accurate control of engine speed underall load conditions. Linkage transmits the movement of the governor flyweightsto the control lever on the metering valve. so that no additional lubrication system is required. If identificationof the pump is difficult. Asthe rotor turns. The plungers are returned by pressure of the inflowing fuel andthis formsthe charging stroke. anda similar number of outlet ports in the hydraulic head. mountedin the pump housing. TIMING OF INJECTION PUMP TO THE ENGINE WARNING Bodily injurymay resultduring thetiming operation of the fuel injection pump if the engine is running. Thepump plungersare actuated by lobes on an internal camring. In consequence. The outward travel of the opposedpumping plungersis determined by the quantity of fuel metered. Thecam lobes are contoured to providerelief of pressure in the injector lines attheend of the injection cycle. Besureto havethe enginemodelnumber.and the high pressurechargesare distributed to the engine cylinders at the required timing intervals through ports in the rotor andthe hydraulichead. and fuel under injection pressure passes up the central bore of the rotor throughthe alignedports to oneof the injectors. The single pumpingelement ensures uniform delivery of fuel to eachenginecylinder. waterandother foreign matter. normally has as many lobes as there are engine cylinders and operates the opposedpump plungersthrough cam rollers carried in shoes sliding in the rotor body. Installation procedures andtiming methods will vary depending on the make and modelof the Fuel Injection Pump in use. Therotor normally has as manyinlet ports as the engine has cylinders. Theaccurate spacingof cam lobes anddelivery ports ensures the exactequalityof the timing interval betweeninjections.Be sure of the kind of pump involvedbeforeattempting the installation and timing procedures that follow. The governorcontrol mechanism is enclosed in a housing mounted on the pump body. this givesa sharpcut-off of fuel andprevents "dribble"at the nozzles. . using specializedtools andtest apparatus. the rollers which operatethe plungersdo not follow the contourof the internal cam ring but contactthe cam lobesat points whichvary accordingto the degreeof plunger displacement. specification number andserial number available when youcall. whichvaries in accordance with the setting of the metering valve. However.it can be reinstalled using the Short Method. Remove the screw plug and washer located on the front side of the timing gearcover. 11. Welding rod or brazing rod minus the flux worksgood here.mp gear. LBS. 10. and lock washers.(2734 Nm). linkage rods. Also. 13. Re-connect all electrical wires.Tighten screwsfinger tight. shut down cables. 7.236" (6mm) deadendhole the injection pump gear. Guide the injection pump into position and install the three long M10 mounting bolts. (27-34 Nm). simply rotate the crankshaft pulley one complete revolution clockwise and check for the beveledtooth again. because this engine ° will run with the injection pump installed 180 out of time. 3. Use three M8screws (P/N X22132)and lock washers for mounting the gear.If the beveled tooth is not visible in the opening. Install a new gasket to the front of the injection pump.flat washers. Check that the three M8 bolts that fasten the injection pump to the adapter mountingplate are tight at 15-18FT. Torque the long M10 mounting bolts to 25-30 FT. Note:Steps9 and10 maybe unnecessary if the injection pump wasneverloosened from or separated fromthe adapter mounting plate during removal of the pump fromthe engine. LBS. 14. LBS. Not : Some engines have DCmarkson the flywheel anda pointer pin fixed into the bell housing.The Long Methodmust be used any time a new or reconditioned injection pump is involved or any time a newor other than original adaptor mounting plate is used. if repairs are necessary to the fuel injection pump. Check that the scribe markon the injection pump flange is matched up with the scribe mark on the injection pump adapter mounting plate. The two marksshould look "as one" whenthe job is complete. TDC is when the notch on the front pulley lines up with the DCmarkon the pointer plate. Holdthe gearin a soft jawedvise andtorque the three M8screwsto 20-25 FT. Long Method . Note: Leave anytwoof the injector line nutsloose at the nozzles whichis part of Bleeding the Fuel system (see page 22). A newplate will haveno scribe mark.CAV Thefollowing steps are for reinstalling and timing the original Fuel Injection Pump andAdaptor Plate onto the engine from which it was removed: 1. Install the adaptermounting plate onto the injection pump using the M8screws. Install a newO ring (P/N X07837) into the groove on the adapter mounting plate. Rotate the crankshaft pulley clockwise (viewedfrom the front) until the notchon the ° degreeBeforeTopDead pulley is atthe 190-20 Center (BTDC) markon the pointer plate.CAV Thefollowingstepsare for installing andtiming a newor reconditionedor other than original Fuel Injection Pump: 1. 9. It is positioneddirectly in front of the injection pu. low pressure fuel lines. 2. Usuallytheseare hiddenby an access cover. (34-40 Nm). LBS. 4. (Gasket P/N TMD27B00300) 3. 27 . Rotate the crankshaft pulley clockwise (viewedfrom the front) until the #1 piston is TOP DEADCENTER (TDC) on the COMPRESSIONstroke. Remove the 1/4" roundstock from the gear coverandre-install the screwplug andwasher. Lightly lubricate the Oring with motoroil. any time an injection pump is transferred from one engine to another.it is nowconsidered to be "reconditioned" and the Long Methodmust be used. 7.(20-24Nm). Grindor file off anyexisting scribe mark that maybe on the injection pump adaptormounting plate. Install the high pressurefuel lines and torquethe fuel line nuts to 20-25FT. 12. 2. 5. However. If an injection pump has beentested. Install the injection pump gear along with alignment dowelpin onto the injection pump shaft. Bleedthe fuel system(see page22). but no repairs werenecessary. Find a piece of roundstock approximately 1/ 4" in diameterand 5" to 6" long. etc. 5. Insert the 1/4" roundstock throughthe gear cover andinto the . lock washers and nuts that secure the adaptor mounting plate to the engine. 8. 6. Short Method . The COMPRESSION stroke is determined by looking for the single beveledtooth on the rear side of the injection pump drive gear while the engineis at TDC. 4. it runs very poorly in that condition.Theinjection pump drive gearis the smallerof the twogearsvisible in the openingwherethe injection pump mounts to the engine. Lightly lubricate the Oring with motoroil. TheShortMethod is usedonly when the original injection pump.adaptor mounting plate and crankcase are assembled together. 8. This is very important. Install a newO ring (P/N X07837) into the groove on the adaptor mountingplate. 6. Theinjection pump drive gear is the smaller of the two gears visible in the openingwherethe injection pump mountsto the engine.be certain that youare working with the BTDC marks. Guidethe injection pump into position and install the three long M10 mounting bolts. If this is the case. 9. rotate clockwise. However. linkage rods. Mark Injection Pump Timing Mark 11. Bleedthe fuel system(see page22). 10. Then ° BTDC. WARNING Bodily injurymay resultduring thetiming operation of the fuel injection pump if the engine is running. 15. it runs very poorly in that condition. Restampthe pumpto adaptor mounting plate scribe marks. 13. DO NOT attempt to adjustthe timing without the pump mounting bolts securely torqued. 14. 12. rotate the body of the injection pump until it is. because this engine ° will run with the injection pump installed 180 out of time. Rotate the crankshaft counter clockwise about 1/4 turn (viewed from the front).(34-40 Nm). Re-connect all electrical wires.(2734 Nm). TypicalCAV-DPA FuelInjectionPump Typical CAV-DPA Fuel Injection Pump (cut-a-way) 28 . Torquethe M10 bolts to 25-30 FT. Check that line "A"is still lined upwith the flat end of the snap ring. etc. If not. 17. shut down cables. Note: Leave anytwoof the injector line nutsloose at the nozzles whichis part of Bleeding the Fuel System (see page22). (20-24 Nm). Install the high pressure fuel lines and torque the fuel line nuts to 20-25FT. LBS. Remove the timing hole cover from the side of the injection pump housing. LBS.simply rotate the crankshaftclockwise onerevolutionandit will be visible. 19.Turn the injection pump gear until line "A" on the rotating shaft lines up with the flat endof the snapring (see below). Torquethe three M8bolts that fasten the injection pump to the adaptormounting plate to 15-18 FT. If it isn’t. low pressurefuel lines. If the beveledtooth is not visible in the opening.Not: Some engines usemarks on the flywheel and a pointer pinfixedinto thebell housing. lock washers and nuts that secure the adaptor mountingplate to the engine.Bell housing pointersare usually hiddenby an access cover. LBS. 16. Install the timing hole coveronto the injection pumphousing. stopping at 19°-20 Re-check that line "A" is still lined up with flat endof snapring. reset. 18. Check that the engineis on the compression stroke by looking for the single beveled tooth on the rear side of the injection pump drive gear. This is very important. contains essentiallythe same number of partsregardless of the number of cylinders served. distributor type pump. Thehigh pressure injection lines to the nozzlesare fastenedto thesedischarge fittings. or by anelectrical solenoid. Install a newO ring (P/N X07837) into the grooveon the adaptor mounting plate. This method is identical to the STANADYN E Long Method that follows except that youomit the first (5) five steps when performingthe Short Method. inherent in the pump design. To determine the correct injection pumptiming for your particular engine. Use three M8screws(P/N X22132) and lock-washers for mounting the gear. Tightenscrews finger tight. Note:Thereis a chisel type scribe mark that is stamped into the injection pump mounting flangeand the adaptor mounting plate. As a result. 2. In most cases. LBS. if thisis thecase. The metering valvecanbe closedto shut off fuel through solid linkage by an independently operated shut-off lever. 4. Install a newgasket(P/NTM D27B00300) to the front of the injection pump. Precisedistribution between cylinders.flat washers andlock washers. capableof close speedregulation. A newplate will haveno scribe mark.refer to Service Parts Bulletin 92-420.andthe ability to presetfuel flow eliminates lengthy periods on the test stand. Thehydraulichead containsthe borein whichthe rotor revolves. transfer pump blades. Rotatethe crankshaftpulley clockwise(viewed fromthe front) until the notch onthe pulleyis atthe timing setting prescribedin SPB 92-420. 8. 3 cylinder and 4 cylinder engine models. The most important point about timing the STANADYNE injection pump is the alignment of the internal timing marks(Ref. WorkingPrinciple Themainrotating components are the drive shaft. at the end of Step 15. Thedistributor rotor incorporates two chargingports and a single axial bore with one discharge port to serviceall head outlets to the injection lines. The DB2pumpcontains its own mechanical governor. The face of the regulator assembly is compressed against the liner and distributor rotor and forms anend seal for the transfer pump.Thepump is self-lubricated. 7. Step 15) andthe corresponding locationof the front pulleytimingmark (Flywheel timing mark on some engines). the charging ports andthe head discharge fittings. the centrifugal force of the weights in their retainer is transmittedthrougha sleeveto the governor armand through a positive linkage to the metering valve.positive displacement. Long Method . Check that the engine is on the compression 29 . 6.distributor rotor. 5.the metering valve bore.DO NOT attempt to adjustthe timing without the pump mounting boltssecurely torqued. 1. there are numerous injection pump timing settings required to cover the manySTANADYNE applications. Thedrive shaft engages the distributor rotor in the hydraulichead. Install the adaptor mounting plate onto the injection pump using the M8 screws. Theinjection pump is designed so that endthrust is against the faceof the transferpump pressure regulator.(27-34 Nm). Holdthe gearin a soft jawed vise andtorquethe three M8screwsto 20-25 FT. TheDB2 pump incorporates a single pumping chamber.However.these twomarks will line up. Lightly lubricate the Oring with motor oil. Note: There are various types of STANADYNE fuel injection pumps used on the TMDengine.STANADYNE --Installing andTiminga New or Reconditioned or other than original Fuel Injection Pump. The plungers are actuated toward each other simultaneously by an internal cam ring through rollers andshoes whichare carried in slots at the drive end of the rotor. SeeSPB 92-420 for the timingsetting required on yourparticularengine. Grindor file off anyexisting scribe mark that maybe on the injection pump adaptor mounting plate. WARNING Bodily injurymay resultduring the timing operation of the fuel injection pump if the engine is running. Theautomaticadvance is a hydraulic mechanism whichadvances or retards the pumping cycle.Thedrive endof the DB2 rotor incorporates two pumping plungers. becertainthat youareworking with thecorrectset of marks. Thenumber of cam lobesnormallyequals the number of enginecylinders. Install the injection pump gearalongwith alignment dowelpin onto the injection pump shaft. They are usedin the 2 cylinder. don’t bealarmed if theymiss lining upby a smalldistance.STANADYNE MODELDB2 INJECTION PUMP Themodel DB2 injection pump is describedas an opposed plunger. 3. 9. inlet metered. Short Method .STANADYNE --Re-installing andtiming the originalFuelInjection Pump andadaptor plate ontothe enginefromwhich it wasremoved. andgovernor. Various equipmentapplications having different speed ranges and load ranges are involved. Note:Some engines usemarks on the flywheelanda pointer pinfixed intothebell housing. Thetransferpump at the rear of the rotor is of the positive displacement vanetype andis enclosedin the endcap. Theendcapalso houses the fuel inlet strainer andtransfer pump pressureregulator. Bell housing pointersareusuallyhidden by an access cover. Turn theinjection pump gear until theinternaltiming marks are lined up. Not ¯ Leave anytwoof the fuel line nutsloose at the nozzles whichis part of Bleeding the FuelSystem. If not. rotatethe body of theinjectionpump oneway or the otheruntil the marks line up. If thebeveled toothis not visible in the opening simply rotate the crankshaft one revolution clockwise and it will be. 19.because the pump gearis probably out of time. Thesimplest method is to run the machine at maximum output at high altitude. 18.Guide theinjection pump intoposition and install the threelongM10 mounting bolts. Re-connect all electrical wires. assembly. low 30 Speed droop governor control Only minor throttle levertrimming is necessary.Torque the threeM8 belts that fasten the injection pump to the adaptor plateto 15-18 It. Turn theinjection pump gear until timing mark is aligned withthepointer. Inspectthe internal timingmarks again. 17. Bleedthe fuel system. it runs verypoorly in that condition. The extemal controlknob with aninternalscrew thread pitchsimilarto thegovernor spring pitchis adjusted to add or subtract activecoils. After the proper droop setting is achieved. Retighten the jamnut. the torquescrew may bebacked out to restorefull sealevel power. testing andadjustment of the DB2 pump must be carried out by trained personnel.repeat step12. Re-check the timing marks after eliminatingthe backlash and playthat may bein thetiminggeartrain. Ibs. Ibs. (SeeTorque Screw Location.linkage rods. (See Below).page 31 . 10. TIMING MARK pressure fuel lines. .000feet. The setting may be done either onan injection pump test stand or by trial-and-error on a completemachine. Remove the timingholecoverfromthe side of the injection pump housing. Tuming the speed droop screw clockwise broadensregulation and reduces instability. Thus a single springmay allowa droop adjustment of approximately 2 to 5%. Asinglegovernor spring may alsobeselected which will regulate this droop adjustment range at beth1500 and 1800 RPM. (20-24 Nm). 14. Noadjustment will normallybe requiredfor operationunder3. 12. 11. youmust judgeas to whether the pump gear is one toothor more out of timeor if a minor rotation of the injection pump body will align the marks. If the machine is returnedto operation at sealevel. highidle mustbe readjusted.stroke bylooking for thesinglebeveled tooth ontherear sideof theinjection pump drivegear. STANADYNE DB2 INJECTION PUMP Welder or Generator Set Governor Normally. Loosen the torque screw jamnut andturn the torquescrew in (clockwise) until exhaust smoke is reduced to acceptable levels. Torque the M10 bolts to 25-30ft. (SeePage 23). the DB2 canproduce stablegoverning at 3% regulation for welder or generator sets.) . Fuel Delivery CurveShaping for High Altitude use on Welder and Generator Set Pumps Maximum fuel delivery on welderandgenerator set pumps is adjustable to reduceexhaustsmoke under highaltitude conditions. lock washers and nuts that secure the adaptor mounting plateto the engine. Install the highpressure fuel lines and torque the fuel line nutsto 20-25 ft. (34-40Nm). 15. Overhaul Procedure Dismantling. with the injection pump installed 180 However. 13. (SeePage 23).Thetwo marks should look like oneunbroken horizontalline.Thiscan beobtained at either1500 (50Hertz) or 1800 RPM (60Hertz). Install the timingholecoverand gasket ontothe injection pump housing. as shown. 16.The speed droop controlis used where theregulation is adjusted while thegenerator setis operating. the speed droopcontrol must beadjusted to providethe sharpest regulation possible withoutsurge or combustion instability. usingspecialized tools andtest apparatus. etc. Thisis done byrotatingthe crank pulleycounter clockwiseapproximately 1/4 turn (viewed fromthe front). Ibs.the injection pump drivegear is thesmaller of thetwogears visiblein the opening where the injectionpump mounts to the engine.If the marks are veryclosetogether. Thisis veryimportant because this engine will run ° out of time. Dudng initialset-upof awelderorgeneratorset. If the marks arefar apart. 1. The inherent self goveming feature of inlet metering is especially advantageous for such closegoveming control. Then rotatethecrank pulleyclockwise until it is back to the prescribed timingposition. (27-34 Nm).Check the internal timing marks onceagainandadjust if needed. This is further aidedby the extremely low masses and resultinginertia forcesof the metering valveand govemor components. Water in fuel causes corrosion. handling and filtration is of great importance. Total Sulphur Corrosion (Copper) 3 Hours @ 212°F. cloggedfilters. causing pintle sticking and smoke. 98o/o maximum limit insurespenetration andatomizations.05°/o maximumby volume 10° below lowest anticipated operating temperature 30 minimim (A. Higher number--better To prevent premature vaporization during hot weather operation. Degrees) . (38 °C) Water and Sediment Pour Point A. The fuel not only supplies the energy for all the work done by the engine. abrasives.it also lubricates the parts of. state to prevent clogging due Lower Gravity Fuels contain more heat Units/Gal. Higher end points only partially burn.P.oorindicateScombustion. Amount of non-combustible material causes pump wear. copper strip is abrasive and .heavy oil fractions which Viscosity is a measure of flow resistance--the low limit minimizes leakage and lubrication and the higher 650 °F. or sulphur in excess of our recommendedspecifications can cause extensive damageto the injection pump and engine.Contact your Continental distributor for details. Torque screw location Typical DR2Fuel Injection Pump FUEL RECOMMENDATIONS Diesel fuel selection. DIESEL FUEL SPECIFICATIONS Continental Diesels have been designed and developed to use ONLY No. causing build up of deposits in energy cell and nozzle. maximum EFFECT Quality. Gravity ~_~60 °F.40 seconds .01% maximum by weight 31 rapid pumpwear and Fuel Oil must be in fluid to congealing wax. in order of importance) RECOMMENDED LIMITS 50 desired 45 minimum 320 °F. maximum 700°F. 1-D (light fuel) and preferably No. 31 . the fuel injection system which operate with very close tolerances. Fuel that contains water. minimum 550 °F. Ash Indicative of Ignition Starting and Idling.I. (listed DIESEL FUEL CHARACTERISTICS Cetane Number Volatility: Initial Boiling Point 50% recovery 90% recovery End Point Distillation Recovery SU Viscosity 100 °F.whichcan be a cracked residual. Sulphurous acids corrode and increase engine wear. a blend of preferably a straight-run distillate havingthe following characteristics: Refer to page 11 for seasonal fuel recommendations. 2-D (heavyfuel) -.I. % causeL°wer smoke recoverYand p. Less smoke with fuel at low 50% and 90% Recovery Temperatures. Discoloration or pitting on polished shows same effect on engine parts.P.5O/o maximum pass test . regulator and battery (including all ground connections). SWITCH LOW OIL AMP WARNING FL1 I LIGHT ~ L. 4 GLOWPLUG TYPICALPOWER UNIT WIRINGDIAGRAM STARTER The chargingcircuit consists primarily of an alternator. ll=-]-~l~ U NO. regulator. When analyzing the charging circuit...Section E.~] I I . It providesa sourceof current for starting the engine. ~l~l~ WIRING NOTE: ALL WIRING TO BE STRANDED... for a limited time. furnish current whenthe electrical demands of the unit exceed the output of the alternator. It has two major functions: 1. ~ .Charging System ~to W~RE l .r damage. 32 . is an electrochemical device for converting chemical energyinto electrical energy. Also inspect all connections to the alternator. battery and wiring. DIAGRAM MURPHYSWITCH SWITCH HIGH WATER TEMPERATURE HOURMETER (OPTIONAL) IE~. It can. The lead-acid storage battery. ~C #8 /// ABLE SOLID MOToRG FUSE I ~~ ~ ~ " ~CmT ~ I 5~ ~’~ ELAY ~ 2~ ~4 ~ I TR I OL CO~ UNIT~ I ment with connectors pointd°wn t WlREing GLOW PLUGS INDICATOR LAMP 2W MAX. the components should be checkedin the following order: II.DI~. used on automotive and industrial applications. . RECTI~ Y--4 "~\ =PUMP SOLENO. */ TO FUEL SHUT~OFF SOLENOID I OIL & WATER SW TCH ALL WIRE #16 AWGUNLESS OTHERWISENOTED SYMBOLS ----’~F INTERNAL GROUND PUSH ON CONNECTOR-PUSH ON CONNECTOR -FEMALE MALE (// ALTERNATOR (// ~ #8 AWG PUSH BOTTON ~ ~ ~’ /-- ONTACTOR L~c~:::::~T~h ~JL-~J NOT FURNISHED ’~ E~ll c= ~. 2. Wiring Wiring in the charging circuit should be carefully inspectedfor frayed insulation "or othe.. Battery Battery condition is very important for proper starting. and clean and tighten as required.and replace any wiring that is defective. will cause severe damage to the units and/or wiring. Refer to equipment manufacturer for battery recommendations. To avoid damageto the regulator. negative to negative. 33 . before connecting or disconnecting test instruments (except voltmeter) or before removing or replacing any unit or wiring. ammeteror accessories. 6. 5. Start engine and observe ammeter. on this system. between the alternator and the regulator. 2. 6. Sparks or flames near a battery could cause an explosion or fire. at any time. 3. Battery acidcancause corrosive burns. Disconnect battery cable at battery terminal. the following steps should be observed during installation. and it can be assumed that this type regulator will outlive the other components in the charging system. Grounding of the field terminal either at the alternator or regulator will damage the regulator. (positive to positive. Th field circuit must never be grounded. The comparatively small values of current supplied to the field may be conducted without difficulty through small brushes and rotating slip rings. Battery polarity should be checked with a voltmeter before connecting the battery.C. These cannot be adjusted or repaired. regulator. Installation of Regulatorfor Alternator To insure proper operation and to protect the alternator and regulator.C. Alternator The alternator differs from the conventional D. Use of jumper cablesor battery charging shouldbe doneonly as directed by manufacturers’ safetyinstructions. 2. Any attempt to do so may result in damage to the alternator.) IV. 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 D. Regulator Most regulators are fully transistorized and completely sealed. If a booster battery or fast chargeris used. generator of comparable electrical size and is equally as simple to service and test./ WARNING Stop engine before checking batteryterminals or electrical connections. Other regulators are adjusted and repaired in accordance with the manufacturer’s instructions. 9. The alternator is somewhatlighter and more compact in design than the conventional D. Disconnect the battery. Grounding of the alternator output terminal maydamage the alternator and/or circuit and components. If it is necessary to solderanylead to a rectifi r lead. 7. Always wear eyeprotection. Note: Whenservicing the charging system. III. 1. No polarization is required. Reference always should be made to the manufacturer’s maintenance manuals for complete trouble shooting instructions. or circuits. 7. Alternating current is rectified (changed to direct current) by meansof diode rectifiers rather than mechanically with brushes coming into contact with the various segments of the rotating armature on the generator. Connect alternator in accordance with the manufacturer’s instructions. A "High" charge rate is normal for the first few minutes. 4. Make sure the mounting area of the alternator and regulator base are clean and make a good tight connection. but will decrease as the battery recharges. its polarity must be connected correctly to prevent damageto the electrical system components. 8. Do not flash field or ground terminals of the regulator. 5. 3. Read andobserve safetywarnings on pages 1 and2. generator. use a pair of pliers as a heat dambetween the solder joint and the rectifier. The alternator must not be operated on open circuit with the rotor windingenergized. Makesure regulator is of the same voltage and polarity as the alternator and battery. Each bearing is prelubricated which eliminates the need for periodic lubrication. 4. With this construction. Reconnect battery cable. shunt generator in that the armature is the stationary member and is called the stator: while the field is the rotating memberand is called the rotor. connectbattery to the regulator field terminal. alternator. Precautions to be observed whentesting or servicing the alternator system: 1.C. Accidental grounding or shorting at the regulator. Reversed battery connections maydamagethe rectifiers. Do n t attempt to polariz the alternator. do not. wiring or other components of the charging system. never remove a unit until tests have shown it to be defective. WAR ilNG Check Oil Levelof Engine 3. when heated.coveringDaily. Thefollowing pages. Onany air cleaner. 2. oil or water connectionsmtighten if found.) Remove cover and cartridge after removing wing bolt . 4. consume several thousand cubic feet of air per hour. Themostefficient oil level is between the two dipstick levels. FILL FUELTANK Fill fuel tankat endof day’soperation to prevent condensation forming in tank. They should normally be serviced every 50 hours in the following steps: (Extremeconditions will requiredaily cleaning. Clean cartridge by gently tapping flat on a smooth horizontal surface to loosen and remove the heavierdirt deposits.Visually inspect fan andbelt for condition and adjustment. CAUTION: Donot damage the gasketsealingsurface or bend theouterscreen portion of thecartridge while cleaning. Sincedusty air is full of abrasivematter. .wear can be reducedby careful operation and a planned maintenanceprogram. 50. Haphazard maintenance will only lead to faulty engineperformance and shortenenginelife. CHECKRADIATOR Fill radiator with a clean 50/50water/anti-freeze mixture to normallevel maintaineddue to expansion 34 Wear protective glasses or a faceprotect r wh neverair hoses areused. 400 and 500 hour maintenance. OVERALLVISUAL INSPECTION OF ENGINE Lookfor evidence of fluid leakson floor. All moving parts in the engineare subjectto wear. the enginewill soonwear excessively if the air cleaner doesnot remove the dust before enteringthe cylinders. CHECKOIL LEVEL OF ENGINE Thedipstick indicates the high andlow oil level in the crankcase--make allowancefor additional oil drainage back into oil pan if engine has not been stopped15 minutes. cylinder headand block. Read and observe safetywarnings onpag s I and 2. have been worked out with our field servicedivision as "Minimum Requirements" to keep your engine in dependable operating condition. Replace thecartridge if in doubt! The cartridge can also be cleaned with compressed air. IMPORTANT: Donot add oil until oil level approaches the lowmark--then add onlyenough to bringit to highlevel-NEVER above. Never useair pressur that is more than 2 Bar(30 pounds persquare inch)and make sure theair line is equipped witha water flit r to prevent damage to parts. DRY TYPE REPLACEABLE AIR FILTER Dry type air filters are standardequipment on many enginesandit is mostimportantthat the dirt buildupin the cartridge doesnot reduce the air flow sufficient to cause a noticeableloss in power. One basic type of air cleaneris normallyused-the dry replaceableelementtype.donot allowdirt to fall into ~eexposed carburetor. operating environment dictates the air cleaner service periods. In general. a definite maintenance program should be set-up and followed. 250. indicating loose fuel. In dust protected areas the air cleaner should be serviced when changingoil. whenoperating. but it is importantto usethe following guidelines: ¯ ALWAYS keep air pressure adjusted to less than 30 psi (2 Bar). however. DAILY PREVENTIVE MAINTENANCE SCHEDULE 1. In extremely dusty operationsthis may be onceor twice daily. fuel and oil and maintaining coolant operating temperaturesof 81 °-93°C (180°-200°F.Section 7 Prevenl:ive Maintenance In order to obtain maximum efficiency from your diesel engine. diesel engine operation demands carefulattentionto the cleanliness of air. CHECKAIR CLEANER All engines. Donot operate the engine with oil below lowlevel mark.). Cleanfiller cap and areaaround spoutbeforefilling to prevententrance of dust into fuel system. 5. CAUTION: Failure to comply with the above guidelines will damage the cartridge and lead to severe engine damage.60 PSI) Higher oil pressuresmay be experienced during cold starts. NOTE: A 1/4 teaspoon of dust per hour can ruin an engine in one 8 hour day.8. Note oil pressure gaugewhich should indicate the following pressurerangeat full throttle anda minimum of 0. cartridge gasket surface. Servicing of the PCVsystem is confined to checking the conditions of the hosesand connections. Replace cover and assemble wing bolt finger tight to insureair filter seal. PCV SYSTEM All connectionsmustbe air tight. 35 . ¯ ALWAYS blow th cartridge clean from the inside out. Replace immediately if bent. The element should be replaced every 250 hoursor when servicing doesnot result in full powerrecovery. Replace the cartridge if in doubt! Oftenin cleaning the cartridge it is tapped against surfacesthat are not flat. CleaningDry TypeAir Filter Wipeinside screen. Dry type air cleaners are efficient only as long as top and bottom sealing edges are not damaged.5 Bar (7 pounds)pressure at idling speed. must be clean and not damaged. MODEL OIL PRESSURE TMD 2. Place cartridge on mounting seat-make sure outer edgeof cartridge fits inside edgeof bottom plate. morefrequent replacement will be required. inside cover and mountingseat before installing element. thus damaging sealing edges.1 Bar (40.4. Also surface of air cleaner base and cover whereair cleaner cartridge seals. crushed or damaged.such as dents or bends. if edges are damaged dirt will enter the engine.¯ ALWAYS keepthe tip of the air nozzleor air hose at least 2 inches (50mm) from the paperportion of the cartridge. Blow-by circulates into the intake manifold maintaining crankcase pressure within a narrow range regardless of operating speedor load. CHECKOIL PRESSURE ReplacingNewCartridge. Typical TeledyneContinental Motors PCV System Installation CAUTION: Do not wash or oil cartridge.Regardless of howclean the paperis.whichever occursfirst. Under extremedust conditions. 4. 36 . Adddistilled water.).) than 27°C (80@F. Thoroughlyclean the sealing surfaces before replacing new element and gasket. Always weareye protection. some of the kerosene will be trappedandremainto thin out the new oil. then turn the engineover with the starter--In the belief they are doing a better job of crankcase cleaning. Fan Belt Tension 5. Theschedule for changing oil is directly dependent upon the operational environment: an extremely clean operation could go 100 hours while a dirty operation(foundry or cement factory) could 50 hours or less.) is reduced60% -18°C (0°F.NOTE ANY UNUSUAL NOISE Operatorsfamiliar with daily engineoperation soonbecome alert to anynoise not normallypresent. Checkspecific gravity of each cell--which should be at least 1. note alignmentand checkbelt tension whichshould allow not over 13mm (1/2") deflection on the long span. therefore. 3. In doingthis. 2. reducingits lubricating qualities. Some operators unwisely put kerosene in the crankcaseafter draining the engineoil. to raise level 9. Replace the oil filter element everytime the oil is changed.The best method is to drain the oil when the engineis thoroughly heatedmwhich will carry off mostof the sediment. Do not put kerosene into the crankcase. Thisis veryvaluable in correcting defectsin the early stages and preventingexpensive repairs or delays.250.5mm (3/8") abovethe separators. the main oil header and the branches leading into the engine bearings--thereby washing away the protectiveoil film.Thecranking powerof a fully chargedbattery @27°C (80°F. Sparks or flames neara batterycould cause anexplosion or fir . Read and observe safety warnings onpages I and 2. SERVICE AIR CLEANER Cleanelementwith compressed air. CHECKFAN BELT TENSION Inspect wearcondition of fan belt. Battery acidcancause corrosive burns. if required. CHECKBATTERY / WARNING Stop engine before checking batteryterminals r electrical connections. (See Daily Instructions. CHANGECRANKCASE OIL Enginelife is dependent upon clean oil being circulated to all moving parts.) Be sure that no unfiltered air can enter the engine.)---but yet the power requiredto crankthe engineis 2 1/2 timesgreater at -18°C(0°F. the frequency of oil changes and oil filter replacement is very important and should be madeat regular. Use of jumper cables or battery chargingshould bedone onlyasdirected bymanufacturers’ safety instructions. scheduled periods. EVERY 50 HOURS 1. Checking Battery Particular attention shouldbe giventhe battery during cold weather. REPEATDAILY OPERATIONS OUTLINED Follow previous Instructions. In addition. kerosene is circulated through the oil pump. . page23. DRAIN WATER FROM FUEL FILTERS(S) Note:Some fuel filters are not equipped with a water drain.page 23) EVERY 250 HOURS Check all connections for leaks. COOLINGSYSTEM Clean radiator core by blowing out with compressedair. 3. IF DRY REPLACEABLE ELEMENT AIR CLEANERIS USED. Inspect mounting and gaskets. CAUTION: Never allow cool water to comein contact with the fuel injection pump while the engine is running! Injection pump seizure mayresult.46mm (. EVERY 400 HOURS 1. FIRST 250 HOURSRECOMMEND ADJUSTING VALVE TAPPET CLEARANCE. 2. FUEL SYSTEM (See fuel filters Replace fuel filter element. SAFETY AND THERMALCONTROLS 4. EVERY 500 HOURS 1. EXHAUST 0. REPEATDALLY AND 50-HOUR SCHEDULES Follow previous Instructions. MODEL TMD INTAKE 0. 5. Inspect control wires andconnections. (SeeFuel Filters. 2. Inspect radiator mounting. REPLACEELEMENT.36ram (. 37 . Inspect water pump and connectionsfor leaks.018") Glow Plugs 4. Checkfan and accessorydrive belts. CHECKGLOWPLUGS Inspect glow plug wiring. ADJUST VALVE TAPPET CLEARANCE Check and adjust intake and exhaust valve tappets to following clearancesat operating temperature. REPEATDALLYAND 50-HOUR SCHEDULES Followprevious Instructions. 2. ADJUST IDLE SPEED TO EQUIPMENT MANUFACTURERSRECOMMENDATION Repeatagain at end of 500 hours. otherwise any good commercialengine cleaner to washdownthe engine. 1. CLEANEXTERIOROF ENGINE Use steamif available.) 7.6. REPEAT DALLYm 50 HOUR AND250 HOUR SCHEDULES.014") 3. NOTES 38 . This method serves to break the hydraulic connection and permits lifting the push rods out and leaving the tappets in place. Place a protective cap over ends of injector for keeping openings clean. 39 . CYLINDER HEAD The cylinder head is the most important part of the engine assembly since it contains the complete combustion chamber including valves. REMOVING THE CYLINDER HEAD 1. and cored passages for air. 2. Remove cylinder head cover by removing the capscrews holding the cover to the cylinder head. Refer to fuel injection system for testing procedures. 3. Grip the push rods and snap them sideways out of the tappet sockets as shownin the illustration. Drain water from engine and disconnect radiator or heat exchanger hoses. This will prevent an interference between the socket and the leak-off nipple.Engine Repair and Overhaul This section includes instructions for repairs and overhaul of the componentunits of Continental industrial diesel engines. these should be included in your equipment. Remove injection nozzle assemblies. Disconnect the injectors and leak-off lines at both the nozzle and pump connections. Removerocker arm shaft assembly and push rods. 4. Provide a clean place to work and clean the engine exterior before you start disassembling-dirt causes engine failures. This will prevent any dirt or foreign matter from entering. Be sure to cut a relief in the inside of your socket for clearance. page 24.Section 8 . Use only genuine Continental parts in Continental engines since years of development and testing have gone into these specifications to assure maximumlife and performance. exhaust and water flow. Many shop tools have been developed to save time and assure good workmanship. Socket relief clearance Caution should be used when replacing the fuel injectors to prevent loosening the injector leak-off nipples. fuel injection nozzles. Disconnecting Injector Leak-off Line CAUTION:Always cover openings with protective caps at any time whenlines are disconnected. Removing Push Rod from Ball Socket of Tappet 5. glow plugs. DISASSEMBLY OF CYLINDER HEAD 1. Remove precombustion chamber inserts from cylinder head and place in a rack indicating the cylinder from which each was removed. Injector with Protective Caps and Nozzle Removal 6. retainers. Glow Plugs 7. Using a C removethe valve rotors. springs placing all parts type valve spring compressor. 4O Precombustion Chamber Inserts . Remove the 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. Lift the cylinder headoff the engine and carry to a clean bench for further disassembly. 8. Capping Injector Connections Removing Valve Springs 2. Loosen and remove the capscrews holding the cylinder head to the block. Valves in Rack 3. Removeglow plugs. spring retainer locks. and oil seals on valve stems-in a container of solvent. 3.05mm (. Use puller for removing faulty insert. Replace all guides that are worn bell-mouthed or have increased 0. VALVE GUIDES 1. Chill insert in container with dry ice for 20 minutes before assembling. Remove all carbon from combustion areas using scraper and wire brush. Whenrequired to replace with new insert. Insert maythen be installed in the counterbore using a piloted driver and arbor press. Inspect carefully for cracks. Total indicator reading of the run-out must not be more than 0. clean and counterbore for 0. page 42. 41 VALVE SEAT INSERTS (IF SUPPLIED) 1. be sure to go deep enough with the toot to clean up the bottom so that the insert will have full contact to carry away the heat. Inspect carefully for cracks. indicate the seat. This assures it being seated firmly on the bottom of the counterbore.038mm (. Newinsert installation must have a press fit.0015) in diameter. Clean the cylinder head thoroughly with a solvent or degreasing solution and blow it off with air pressure. as all valve seats must be ground concentric and square with either new or worn valve stem guide holes.002"). Remove all valve guides when necessary by pressing them out from the combustion chamber side. The exhaust valve seat insert is held in place by a shrink fit. Whenmachining the counterbore. Clean the valve stem guides. Before removing the arbor. CleaningCombustion Pocket Clean insert and combustion pocket. removing lacquer or other deposits. Usea pilot having a solid stem with a long taper. Inspect all exhaust valve inserts in the head and replace any that are loose. Continental does not recommend installing new inserts having the same outside diameter as the one removed. 2. Grind the intake and exhaust valve seats in the head in accordance with instructions in the Valve Guide Data.CAUTION: Whenreplacing guides do not ream since theseare all pre-reamed before being ferrox coated--any further reaming will remove the coating. Removing Valve Guides from Combustion Chamber Side . 3. Do not use tools that remove metal.010") larger insert using counterbore tool with correct fitting pilot. 4.25mm (. page 42. See Limits and Clearance Section for maximum diameter permissible to determine actual amount it has increased. 5. cracked or otherwise damaged. without the possibility of shearing the side walls. Check guides for wear by using a telescope gauge and 1" micrometer. Replace worn guides as required by pressing in new guides to the correct depth as given in the valve guide data. 4 (2.38) 43.4 (2.3432/.3422) 47.319) 29.65 (1.692 (.69) 60.77 (1.VALVE GUIDE DATA Model TMD Intake A B C D E F G Valve Seat Angle Diameter of Seat Diameter of Choke Distance (From Bottom of Cylinder Head) Length of Guide Inside Diameter Guide Distance Intake to Exhaust 30 °15’ 39.38) 8.69) 60.38) 8.3422) 42 .0 (1.0 (1.566) 35.14) 43.717/8.0 (1.692 (.0 (1.3432/.876) Exhaust 45° 15’ 33.50 (1.717/8. 4mm (1/64") on either side where the blue does not show. oscillating it slightly to transfer the blue pattern to the valve face.002"). Indicating Valve Seat VALVES Inspect valves for condition and replace any that are "necked". cracked or burned. Never allow valves to set downinside th seat. the seat should be retouched lightly with the original stone to remove burrs or feathered edge.Checking ValveFacein "V" Blocks Grinding Valve Seat Check all refaced or new valves in V-blocks with indicator to determine if the contact face is true with the stem within 0.002") over the maximum allowable limits. If the contact is over 3. the seat in the ° stone to head may be narrowed by using a 15 reduce the outside diameter or using a 60° or 75° stone to increase the inside diameter.2mm (1/16" to 3/32") and should fall well within the width of the valve face.05mm (. also any of which valve stems are bent or worn more than 0. After the valves and seats have been refaced and reground. After the narrowed-down seat is brought within specifications.62 to 3. Checking for Proper Valve Seating AllowableHead Thickness of Refaced Valves All valves having less than 50% margin thickness (outer edge of valve head) after refacing has been completed must be replaced. This should showa contact width of 1. repeat the refacing operation.2mm (3/32") wide. leaving at least 0. 43 . To check this dimension.05mm (. Reface or replace all valves. compare the refaced valve with a new valve. not. coat the seat lightly with Prussian blue and drop the valve into position. Notice that the lapped area of the valve and the seat no longer match each other. Nowyou can see that the effects of the lapping job are lost completely.. Valve SpringTester Springs. do not lap valves in after Coat the valve stem with a light film of engine oil.RIGHT So remember. The thin line visible here shows where the valve lapped into its seat.." For example. must fall within the specifications shownon the Limits and Clearance chart when new. when compressed to the "valve open" or "valve closed" length. and must not show more than 10% loss to re-use. VALVE SPRINGS Check all valve springs on a spring tester to make sure they meet specifications regarding weight and length. after the valve has been hand lapped. ValveAssembly 44 . it would look like this whencold. This illustration shows the samevalve only now it has reached normal operating temperature. ValvePosition in Head "A poor valve grinding job cannot be correct d by valve lapping. grinding. This is perfectly normal due to expansion of the valve. Keep in mind that the engine is now at rest and cold. Measuring Original Bore Diameter Above Ring Travel o Check in samemannerthe top of the ring travel area approximately 6mm (1/4") below the shoulder. replace after the cylinder head is installed. 2. Reassemble the valves and springs in the headwith the seal. Inspect push rods for bends or twist and examine the ball and cup ends for excessive wear.008") re-boring recommended. Blow out oil holes with air. Replace all defective rocker arms or any having over 0. If the shaft has "shoulders" on it due to wear. All intake and exhaust valves have umbrella seals. PREPARING CYLINDER WALLS FOR RE. Clean the ring of carbon from aroundthe top of the cylinder bore formed above the travel of the top ring.13mm (.005") clearance between shaft and arm. replace. The maximumdifference in the above checks. If less than 0. re-ringing will suitable and if over 0. Inspect the rocker arm brackets for cracks or other damage.20mm(. To prevent damage to push rods. 2.RINGING OR RE-BORING 1.2. 3. approximately 45 Installing Umbrella Seals ROCKER ARMS 1. Soak in boiling water for several minutes prior to installation. retainer and retainer lock. CHECKING BORE WEAR 1.20mm (. 3. VALVE PUSH RODS 1. Inspect the rocker arm shaft for wear. Examinerocker arms for cracks.008"). Please see Procedure 87-371. Ridge ream the cylinders to 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. Replace rods that are faulty or excessively worn. Determine the original diameter of the cylinder barrel by checking this unwornareawith an inside micrometer or a dial bore gaugeat intervals of °. indicates the amount of cylinder bore wear. condition of valve contact surface and worn bores. 2. Push Rod Inspection for Runout Ridge Reaming Top of Cylinder Bore 45 . bright finish of 0.’ If the cylinder glaze is not removed. A smooth. Use a hand drill and surface hone cylinder with a rapid up and down motion to produce a good crosshatch pattern.0. (This is to prevent loading the stones.you will have no assurance as to when the rings will begin to function properly and control the oil. Cover the entire crankshaft with a clean. To get the correct cross hatch pattern with a cylinder hone.P. 5.Several good makes of ridge reamers are available which will reamthe 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. Keepthe cap and bolts in numerical order so that when the pistons and rods are removed from the engine. 3. carrying with them all the carbon and metal chips left from the cleaning and ridge reaming operation. Drain the crankcase and remove the oil pan. When doing this.it can cause shaving of the piston skirts.250. every precaution must be taken to prevent damageto cylinder bores by the sharp corners and rough edges of the connecting rods.25. The honing operation will produce a sharp edge at the bottom of the bores. Remove the cap screws holding the connecting rod caps to the rod. Push the pistons and connecting rods up through the top of the cylinder. Clean the loose abrasives from the stones by using kerosene and a wire brush. the cap can be reassembled and kept with its mating part. Keep applying keroseneduring honing to prevent stones from drying out and causing an incorrect honing pattern. The following recommended: step by step procedure is a. It is important to remove the glaze on the cylinder bores by using a cylinder hone. or less and 280 grit stones. 2. wet cylinder wall and stones with kerosene. . Remove the excess carbon deposits from the top of the cylinder wall before beginning the glaze breaking operation. use a top quality electric drill with a speed of 500 R. Honing Cylinders 46 The most desirable cylinder finish is 0. with an adjustable stone tension.M. this is esp ciall¥ true whenchromerings are used. IMPORTANT: Stones must be used wet. If this edge is not removed. 4.38 Micro Meters (10 to 15 micro inches) is desired.38 Micro Meters (10-15 micro inches). with this finish the 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. Upon completion of the honing operation.) Insert hone in cylinder and expand to cylinder wall with slight tension. in order to assure quick seating of the new pistion rings. Apply kerosene continuously and increase tension on hone adjustment until a good pattern and finish is obtained. remove this sharp edge with a piece of number 500 emerycloth. Using a clean brush. Removing SharpEdgeAfter Honing e. slightly oily cloth to prevent abrasives and dirt from getting on the crankshaft. . If not. Pistons should be fitted with the °block and piston at room temperature 20. Kerosene or other solvents will not remove the grit. the bores must be rewashed. Checking Block for Cleanliness Checking Piston Fit in Bore 47 . hot water and a stiff brush to remove all traces of grit.08mm (. run a clean. PISTONS Check the pistons for excessive ring groove wear. a half-inch thickness Chart.003") Checkthe piston fit in the bore using wide strip of feeler stock. dry paper towel through the bores.5 kg (5 to 10#) Pull) TMDseries 0.0 21. Rinse the block with clean. of the specified in the Limits and Clearance feeler being attached to a small scale imately 7 kg (15 Lbs. Cleaning Bores PISTON FIT ON STANDARDPISTONS (with 2.0 °C (68 °-70 °F). The cylinder walls and pistons must be perfectly clean and dry when fitting pistons in the cylinder bores. As soon as the bores have dried. the of approx- When you have finished cleaning the block.Desirable Crosshatch Pattern Obtained with a Cylinder Hone Oiling Bores After all honing operations are complete. thoroughly wash the bores with soap.3 to 4. clear water and dry with compressedair. The paper towel should comeout clean.) capacity. This completes the honing operation. lubricate with engine oil immediately to prevent rust. and replace any that exceed the allowable limits in our Limits and Clearance Data. 08 or 0. In any event. PISTON AND CONNECTING ROD ASSEMBLY 1.When the correct fit is obtained you must be able to withdraw the feeler with a pull of 2. it maybe reamed first. but regardlessof this preliminary 48 . with the feeler inserted betweenthe piston and the cylinder midway betweenthe piston pin bosseswherethe diameter of the piston is the greatest. The piston pin hole in the connecting rod must be parallel to and in plane with. NEW BUSHINg OLD BUSHING Checking Connecting Rod for Twist and Alignment Pressing in Piston Pin Bushing This may be checked on a fixture with the piston pin assembledin the rod before assembling the piston. press out the old bushing and press in the new one making sure the oil supply holes line up--after which the bushing mustbe honedto obtain the correct fit of the pin in the bushingas shownon Limits and Clearance Chart. the final operation should be donewith a honeto obtain the desired fit with better than 75%bearing area contact on the pin. Assemble the pistons on the connecting rod.005") oversize. Heating them in hot water will facilitate assembly.5 kg (5-10 pounds) on the scale. Checkthe fit of the piston whenit is approximately 50mm (2") down to the cylinder bore in an inverted position. an oversize piston pin may be obtained in 0. Checking Piston Pin Bushing for Wear The piston pin hole in the piston and the bushing in the connectingrod maybe honedto increasetheir diameterto obtain the desired fit as shownin our Limits and ClearanceChart. PISTON PINS Checkthe bushing in the upper end of the connecting rod for wear.13mm (. 2. Notethat while the chart specifies a light press fit of the pin in the piston.3-4. If there is an excessof stock in the piston pin bushing. If wornandyou are using the original pistons.003 or . making sure they are fully seated in place. When heated. then honed. the piston pin will enter the piston very easily and can be tapped through the connecting rod and into place without distorting the piston. there is a definite clearanceof the piston pin in the connectingrod. Using the arbor press. The snap rings mustbe assembled in the grooves. CONNECTING RODS Replace the bushing in the connecting rod if new pistons are used. the large bore in the bearing end of the connectingrod. PISTON RINGS Check the piston rings in the cylinder for gap. If ring to land clearance exceeds maximum serviceable limits. Oil Ring 2. Prior to installing the rings on the piston. and this must be taken into consideration when checking alignment of the assembly.002") twist or out of squareness checked over a spread of approximately 100mm (4"). This is done by rotating each unassembledring around its groove to be sure of free action. RECOMMENDED METHOD OF INSTALLINGPISTON RINGS 1.05mm (. Prior to ring assembly check the ring grooves for nicks and burrs. replace the rod. file one end of the ring until sufficient clearance is obtained. since the diameter in line with the piston pin would be less at the top of the skirt than at the bottom. Check the gap between the ends of the ring with a feeler gauge in accordance with specifications shown in the Limits and Clearance Chart. 49 Checking Ring Clearance in Groove . pistons must be replaced. If excessive. from the top side so skirt will not be scratched. insert a piston in the cylinder bore in an inverted position and then insert each ring one at a time about 50mm (2") downin the bore. check each ring in its respective groove to the limits specified in the manual. Pistons are cam and taper ground.check the completed piston and rod assembly must be rechecked and there must not be more than 0. The oil ring should be installed first on the piston. If the ring does not have sufficient end gap clearance. Installing Rings with RingExpander Tool Checking RingGap To do this. 6. removepulley from crankshaft. To install the balance of the rings.CRANKSHAFT AND MAIN BEARINGS 1. Pass the expanded ring and tool recessed side downover the piston to the proper groove. Apply pressure on handles so ring is completely expanded. use a ring tool with recess side up and place the ring in with the bottom side up. -. and inspect the bearing and crankshaft journals. Be sure to install pistons with notch or arrow in top toward the front of the engine. 5. Removescrews and remove gear cover. Using a puller. If any difficulty in tapping piston and ring assembly into the cylinder is encountered. 2.they must be replaced. When pistons are ready for installation in the cylinders. removecamgear and injection pumpdrive gears. oil generously. Compressrings 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. Removethe crankshaft keys. 50 . and some rings have the top side rharked with a color band or a PIP mark. Oil Piston and Rings 3. gear and woodruff 4. Removethe oil pump and key by removing cap screws holding pumpto front of the engine. Remove each main bearing cap. Position ring in the tool so the expanding fingers will fully engage both ends. 3. Using a puller. These are clearly marked "TOP" on the side to be up when assembled on piston. CAUTION: Somepiston rings are taper faced. scoring or actual wear. Start with the lowest ring first. one at a time. Removing CamGear with Puller 4. b. If there is any indication of flaking out. Removing Injection PumpDrive Gear CAUTION:The pistons have offset piston pins. a. the compressor should be removed and rings checked for correct installation in the groove. Removing Crank Gear Install Tapered Rings with "Top" Side Up. If the visual inspectionappears satisfactory. The ungrooved bearing shell must be placed in thebearing cap. Scored Bearing Due to Dirt or Lack of Oil operation will change their appearance completely. the head of this pin picksupthe bearing shell andforcesit out of the bore in the block. almost cellular in appearance. a very few hours of Removing MainBearing Appearance of a Good Bearing 7. notin theblock. andif this thicknesshas been reducedmore than 0. the clearance of the bearingshould be checked. This appearance is a natural characteristic of this type bearingandin no wayindicatesfailure. Measuring Bearing Thickness 8.or oil to the bearings will becutoff. The bearing surface becomesa leaden gray in color and developsminutecraters.0005") beyond the maximum allowable tolerance the bearing shell mustbe replaced. they should be removed and checkedfor thickness using a ball micrometer.BEARINGS Tri-metal bearings whennew are smoothand highly polished. However. Bearing Damage Dueto Corrosion CAUTION: The upper main bearing shells are grooved. If visual inspectionof the crankshaft shows no indication of excessive wear or scoring.013mm (. which is a pin with anangular head. To remove the upperhalf of the bearingshell use a special tool obtainableat mostparts houses. It may beinsertedin the oil hole of the crankshaftandas the crankshaftis turnedin a clockwise direction.Thelower mainbearingshells on some models. Thethickness of the bearing shells is givenin the Limits andClearance Chart. are not. 51 . ///-////. or wornenough so that new bearings will not fit with the required clearance. L 52 AVOID SEE ~ SHARP ~INSUFFICIENT CHART BELOW . Crankshafts must be nit mpered after regrinding. Excess wearat these positions require replacement of the shaft.002") indicator reading. If clearance is equalto or greaterthan the amount indicatedunderwearlimits.//. check the diameter of the camshaft journals to determine the next step.~ /////. (See SPB89-389 for details.11") on all crankpins 3. Standard crankshafts may be reground to decrease the diameter a maximum of 1.// RIGHT WRONG WRONG . Remove the screws holding the camshaft thrust plate to the front of the cylinder block.12") on all mains’ CrankshaftFillet Radii Checking Bearing Clearancewith Plastigage By placing the Plastigage on the crankshaft bearing surface and tightening the bearing and cap in place.05mm (.it mustbe checked for straightness and straigtened if necessary to be within 0.0mm (.040").8R(. Check eachbearing. Tappets canthen be lifted out andlined up in sequence./. If the front camshaftjournal bore becomes wornbeyond limits. method DO NOT TURN would destroy the If crankshaft is scored. Replacing Bearing 1. it should be removed and reground.) 4. Measure the camshaft bearing journals and bores.9.~.0R(. there is a service camshaft bushing available as p/n F400G00222. Before shaft is reground. for installation in the same location unless inspection shows that they require replacement. the width of the Plastigage after crushing will determinethe bearing clearance. When reground. 2. 3. CAUTION: When using this the crankshaft as that Plastigage.// ~RS ~ET / ////. TMD 2. one at a time. the fillet radii mustbe within dimensional limits and must be perfectly blendedinto thrust and bearing surfaces. by using a piece of Plastigage of a diameter specified to check certain clearances. which makes it possibleto pull the camshaft forwardout of the bearings. in this case. Check the outsidediameter with a micrometer to determine if replacement is necessary because of wear. A damaged tappetcouldmean possibledamage to the camshaft. The rear crankshaft oil seal has a stiffener ring imbedded in the rubber and no metal retainer is required. Install crankshaft oil seals "A"--on engine block and main bearing cap.CAUTION: When installing camshaftuse special care to prevent camshaft bumpingand loosening expansion plug at rear of crankcase causingan oil leak. 1.Referto limits andclearance section.if carefully installed. Inspecteach tappetcarefully. c C D Installing Sealin Rear MainBearing Cap andFiller Block Filler BlockandSeal E 53 . NOTE: This oil seal can be installed without removing the crankshaft. REAR CRANKSHAFTOIL SEALS The overhead valve engines have the rear crankshaft oil seals incorporated in the combination rear main bearing cap and filler block.Install seal with lip pointing towardengine. Applypressureto the seal so that it will hug the crankshaft whichwill also help moving it in place. Wornoil seals should be replaced in the following manner: l. The overhead valve engines have a good. contacting the groove with sealing compound. trouble-free rear crankshaft oil seal -. TAPPETS IMPORTANT: Installing rear oil seals correctly demands careful workmanship. 2. Two or threesmall pits onthe contact faceis acceptable. Remove rear bearing cap and filler assembly by using a puller. Removeold seals and thoroughly contact surfaces. more thanthat calls for replacement of the tappet.break edge "C" slightly on both cap and block to avoid cutting the seals during installation and coat seal edge "E". use only light greasein the seal grooveto assist sliding the seal in place. Before installing -. block clean all ACCEPTABLE NOTACCEPTABLE ValveTappetWear Comparison 2. Allow to becometacky before assembling. Installing RTV in Rear Filler BlockChannels 54 . Force the RTVinto the channels until a steady flow comes out the corner chamfers. Apply a light coat of cement(national oil seal or EC-847)to the butting ends of the crankshaft oil seal halves.NOTE: Oil leakagewill occur if any voids are left along these slots. After the rear cap is in. Priorto installing oil pan. inject RTVinto each side seal slot ’. Ft. Carefully install the combinationrear bearing cap and filler block on to the dowels. Install Crankshaft. This insert insures complete cure of the RTV. Insert the capscrews and torque to 150-162 Nm (110-120Lb. The pump is driven by a hardened key mounted in the crankshaft. place and torqued. (Seepage 60.) Install Curing Insert 8. Lightly coat the crankshaft contact edge of the seal with graphite grease to prevent damage prior to use. 7. 5. Install curing insert until approximately 5/8" protrudesfrom slot. 4. Dowel holes ~ with~~RTV ~/ Applying RTV to Rear Bearing Cap and Filler Block OIL PUMP The oil pumpis assembled to the front of the cylinder block and front main bearing cap and is held in place by capscrews.) ~-~-’~ Please see Pleasesee SPB 87-361. apply a small bead of RTV material to the rear bearing capandfiller blockas shown. Crankshaft Oil Sealin Block 3.’D" as shown in illustration. Apply a light coating of RTVGasket Material to surface "B" and graphite grease to the oil seal lip. Cut off flush with panrail. Applying RTV to Rear Filler Block 6. Dip the curing insert in clean water. ) NOTE: When replacing any oil pumps on engines built beforeS/N88096321. 55 . The oil pumpmust be fully seated in the counterbore. If scored or wornbadly they must be replaced.issuedOctober. TwoO-Ringsare required after S/N 88096321.Pr vious Oil Pump Impel ter (inn (Outer) ~Adapter ~/ashe r PIun ~ Sprlng Cap ~ O-Ring Current Oil Pump --E~ective S/N 88096321 Note: Refer to ServiceBulletin 88-379.1988. replace. Timinggears shouldbe inspectedfor excessive wearand/or pitting andreplacedif necessary. the oil suctiontubemust be replacedalso. Examine the pick-up screen for clogging or damage. Oil PumpRemoval Engine oil pressure must be maintained to specificationfor satisfactoryengine life. examine the impellers. O-Rings When the pump is removed and disassembled. If damaged.Nogasketsare usedin this assembly. Install mounting capscrews and tighten to 20-24 Nm(15-18 Lb. (SeeSPB 88-379. Inspecting the key and keyway at the same time. cover and cavity for wear. Ft.) TIMING GEARS O-Ringat Pump Inlet 1. Examine the O-Ringat the pump inlet. 8604usesa different cam gear and injectionpump drivegear set up. Installing Injection Pump Drive Gear Checking Camshaft End Play InstallingCamshaft Gear 56 4. CAUTION: NEVERUSE THE CAMSHAFT NUT TO PRESSTHE GEAR ONTOTHE CAMSHAFT. which assures you of the crankshaft and camshaft being in time. atthe same 8me holding the camshaftforward with suitable bar throughthe fuel pump opening in the block so there is no possibility of the camshaft bumping the expansion plugat the rearend and forcingit outof position. Assemble camshaft nut and torque to specification (see torque specifications section). thuscausing anoil leak. Please reference SPB 87-372. Refer to limits and clearance section for correct dimension.Forassembly inform ationsee SPB 87-372. Torquing Cam Gear Nut Check camshaft end play as shown in illustration. spec. Assemble the injeclJon pump drive gearwith key and cam gearto the camshaft by driving or pressing each on. a new thrust plate should be assembled. NOTE: TMD20. Drive the crank gear on the shaft making sure that the marked teeth on the cam gear straddle the marked tooth on the crank gear.This will break the threaded end off cast iron camshafts. Do not use impact wrench or over torque cam nut.2. Examinethe camshaft thrust plate carefully for scoring and wear and if any indication of either shows. Camshaft Thrust Plate 3. . 0067") and 0. in either position.20mm (. 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.17mm(.04mm(.008").008"). Caution: When checking runout remove glow plugs to allow engine to be turned over freely. at the same time holding against it to counteract end play. Flanged BearingControls Crankshaft EndPlay FLYWHEEL Install screws. check the crankshaft end play. End play should be between the 0. mount the indicator on the flywheel so that it contacts the housing face and turn the crankshaft.Timing Gears Assembled Accordingto TimingMarks CRANKSHAFT END PLAY Checking FlywheelRun-Out The flywheel is machined and balanced so that the clutch face and locating counterbore will run true with its axis. No shims are required. Mount an indicator on the flywheel housing and check the flywheel for runout.20mm (. AND FLYWHEEL HOUSING cap flywheel housing using special NOTE:Special capscrews having sealing bands are used in the upper holes to mountthe flywheel housing to the cylinder block. When assembled. In both cases the maximum indicator reading must not be more than 0. The crankshaft end play is controlled by the center flanged bearing. Using a dial indicator.0015") limits. The indicator should be set up so that it contacts the clutch face or the vertical surface of the clutch counterbore. If the end play exceeds 0. Special Capscrews Checking flywheel Housing Face 57 .007") replace the flanged bearing. The maximum indicator reading must not exceed 0. Re-locate the indicator to check the inside diameter of the counterbore. is probably caused by dirt in or damageto counterbore locating the flywheel on the crankshaft flange.18mm (. These special capscrewsmust be used to prevent oil leakage. 10mm (.004") low in the center lengthwise. In most cases. and tighten them to the torque specified. locate them carefully in order to protect the bearing surfaces. REASSEMBLINGENGINE In the foregoing. Installing Pistons Checking Housing Bore Once more. Always lubricate the bearings with clean engine oil when assembling. Checking Cylinder Head Flatness Lengthwise NOTE:The pistons have offset piston pins. The maximumpermissible is 0. we call attention to care demanded to prevent connecting rods damagingthe cylinder bore finish and at the same time as they are assembled over the crank pin. Checking Cylinder Head Flatness Crosswise 58 . use a good ring compressor and oil the bores thoroughly. When reassembling pistons and connecting rods. INSTALLING HEAD 1.076ram (. A hammer handle may be used to bumpthe p!stons out of the ring compressor into the cylinder bore. gradually decreasing towards the ends. we have outlined procedures for checking. smooth and flat. replace the cylinder head. The samerunout limits prevail. Make sure that gasket contact surfaces on the head and block are clean. If these limits are exceeded. repairing or replacing the many wearing parts in the engine. the instructions have covered the reassembly of parts or subassemblies made up of several parts.Re-locate the indicator to contact the housing bore and check this in the same manner.003") crosswise or in localized low spots. or 0. Check flatness with straight edge and feeler gauge in three positions lengthwise and five crosswise. Be sure to install pistons with notch or arrow in top toward the front of the engine. 5. Use new cylinder head gasket. 4. lower the cylinder head assemblyevenly over the Iocator stud. 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 load and head Installing Glow Plugs Injector Nozzle Side NOTE:Always use new steel heatshield washers when installing injectors in cylinder head. I capscrew torque. Tap: M10x 1. Tighten with torque wrench in recommended sequence to the correct torque shownin torque chart on page 68. Before installing any headcap screwsin the block.5 CLASS 6G M12x 1. Side View Torquing Cylinder Head Capscrews Installing Heat Shield and Injector 59 . Using a chain hoist. Havingthe injectors and gl0w plugs in now. which is precoated.75 CLASS 6G 6. thus no cementis required. eliminates the risk of dirt andforeign objects falling into the cylinder. making sure they are fully seated. be sure the threadsin the block andon the cap screws have been properly cleaned. Install the injectors and glow plugs at this point.003") projection.076mm (. 7.Insert projection in reference with cylinder head surface is flush to 0.2. by going over them two times before pulling them downto the final torque specification on the third round. Precombustion Insert Projection 3. Replace the Iocator stud with the proper cylinder head capscrew. care should be taken to use the proper tap. Should these tapped holes need cleaning or reconditioning. Install precombustion chamber inserts. Cutoff flush withpan rail. MIn 6.Place gasket must intersect vertical cs¥1tlee both sides IMPORTANTAfter assembly of the bearing cap to the crankcase.0~0) die.INSTALLING OIL PAN Beforeassembling the oil pan. 6O .In-Piece gasket matedal to plu~ holes. (Seepage54.014") EXHAUST 0. making certain theinsert is centrally located in sideslot Installcuring insert until approximately 5/8" protrudes from slot. make sure the contactsurfaces are flat andcleanof anygasket material or oil. The form-in-place gasketshould be appliedto the oil panandfiller blocks as shown here.0ram (.46ram (. Bottom View OII Pan Contact Face Typical RTV Oil Pan Application for the Diesel Overhead Valve Engine.) NOTES: 1. Sealant mustb~eed out chamfer at crankcase split line The twocuringinserts(pipe cleaners) included in the kit must beused asfellows: Dipthe curing insertin1:oa Con:airier of clean wa’~er and insertfull lengthinto bearing cap sideslot cavities filled with RTV material.set tappets according to the following chart: MODEL TMD INTAKE 0. fill bearing cap side capacity usingRTV andsyringe furnished in kit. Top View C}ankcesecontact face Rear Bearing Cap and Filler Block Form.238) deep from contact surfsce.O mm(. A form-in-placegasketmaterial is usedfor sealing the engineoil panto the crankcase. Tightenthe screws in accordance with limits prescribed in the torque chart--to avoidlooseness or overstressing. Read Labels.35) This urea ot Foam-in. Caution mustbe used in handling the gasket materials. When engine is completely assembled andfilled withproper oil (seelubrication section).018") 2. 2.36mm (. Parts must be assembledwithin 20 minutes after applying gasketmaterial. bead el Fonlt4n-Place gasketmetedalapplied to oil pan and filler block as shown OIL PAN Notes 1 and 2) Form-In-Piece Gasket g.0~m (. 5 --Replace switch or relay.Poor ground connection CORRECTION 1 --Recharge or replace battery. (A) Engine Won’t Turn Over 4 --Loose or faulty wiring connections. Operators should depend on their welldeveloped senses of feeling. Remember the cause is usually Simple. hearing. Read andobserve safetywarnings on pages 1 and2. lubrication and adjustment as recommendedin our Maintenance Section will prevent the greater portion of Diesel troubles.if unable to do this. 3 --Inspect and tighten ground cable. Engine operation in any enclosure requires adequate andproper ventilation to avoidasphyxiation or other interruptionof normal breathing. check for foreign objects in gears. to supply sufficientair to coolthe engine. Failure of a Diesel engine to perform satisfactorily is generally due to difficulties with the fuel supply system.with a generousamountof "Common Sense".Replace Battery. such as air leaks in the suction line due to loose connections or restrictions to fuel flow because of clogged filters. seeing and smelling and replace their sense of taste in this type of work -. 5 --Starting switch faulty 6 --Starting motor defective 7 --Internal engine seizure 61 . Following are listed some of the normal complaints encountered in routine operation of all Diesel engines--the probable causes and the recommended steps required to correct the difficulty: Bodily Injury or death may resultto individuals during operation of an engine withinanyenclosure not adequately or properly ventilated.Section 9.Trouble Shooting / WARNING Any attempt to disassemble or repair fuel injection pumps must be made only by persons fully qualified and equipped. provide air to mix withfuel and to carryaway heated air from the building. 4 --Clean and tighten connections. rather than the injection pumpor nozzles. 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. A Preventive-Maintenance system including inspection. drive spring and mounting bolts. COMPLAINTS PROBABLE CAUSE 1 --Dead or weak battery 2 -. on top of piston or for piston seizure. 6 --Check brushes. commutator. 7 --Turn engine manually -.rather than mysterious and complicated.Inadequate battery capacity 3 -. 2 -. no combustion can take place. the cause mightbe an injector sticking open in the cylinder which immediately precedes that cylinder in the engine firing order.COMPLAINTS PROBABLE CAUSE 1 -.Theuseo( these fluids will cause severeinternal engine damage and/orbodily injury. Hence. 62 . 6 n Retimepump to engineaccordingto recommedations. During injection to the cylinderwhich hasthe injector stickingin the open position. 5 n DrainFuel System .NoFuel Supplyto Pump 2 -.causing a scavenging effect in the pump distributor rotor and a void which cannot be recharged to a sufficient degree to provideopening pressure of fuel to the following injector.Replace or correct.Refill with clean fuel or strain through chamois and bleedsystem.Use cold starting equipment -- (B) EngineTurns But Won’tStart 6 -. 4 -. Please note this well. (c) Runs"Rough" With Excessive Vibration Note: A characteristic of a fuel injection pump is that if engine misfiringoccurs.Disassemble andcleanprimary filter and replace secondary filter if clogged.Check connections and bleedFuel System. the fuel rushesinto that cylinder with no restriction whatsoever.Fill FuelTank or open Shut-Off Valve.Lowatmospheric temperature WARNING Starting fluids or aids suchas ether or gasoline must not be usedin a diesel engine air intake system.Glow plugsfaulty or inoperative 8 -. and it is traced to a certain cylinder in which no combustionis taking place.Crankingspeedlow 5 -. Readand observesafety warnings on pagesI and 2. as knowledge of this characteristicmightprovidea great saving in servicetimein such a given situation. 3 -. check starter.Wrong injection pump timing 7 -.Water in Diesel Fuel CORRECTION 1 -.Air in FuelInjectionLines 3 ---Clogged or dirty filters 4 -.Recharge or replacebattery. repairif necessary. 8 b Low compression 9 -.Seerecommendations in "G" 9 -. 2 -. 7 -. Keep engine speed up. 6 m See "G" recommendations.Use recommendedDiesel Engine Fuel that meets specifications (See Pages11 & 29). leakage and pattern. and clean. 8 --Remove and have checked at an authorized service center. 2 --Fan belts slipping 2 -3 -4 -5 -6 -- (E) Overheating 3 --Overloading the engine or in- 4 --Thermostats sticking operative 5 --Fuel injection timing wrong 6 --Back pressure in exhaust line Add water. Inspect belt condition and adjust tension. 3 --Clean Primary Filter and replace secondaryfilter if necessary. tighten connections. Tighten hose connections and repair leaks as required.Injection nozzles faulty 8 --Injection pumpfaulty (13) Loss of Power 1 --Retime pump to engine according to recommendations.Use Diesel engine fuel that meets specifications. 2 -.Poor Compression 7 -. Reduce load.Increase to recommended speed. 5 -. Remove. 2 --Check connections and bleed fuel system. 4 --Service Air Cleaner and Connections. 4 -. 1 --Lack of coolant. 6 -. 3 -. Retime pump according to recommendation. Clean and test injector for pressure.Poor fuel 1 --Wrong injection 2 --Air in fuel lines pump timing 3 --Clogged or dirty filters 4 --Restriction in air flow 5 --Poor fuel 6 -. Inspect for restriction in muffler and exhaust system.COMPLAINTS PROBABLE CAUSE 1 --Misfiring cylinder or cylinders CORRECTION 1 --Loosen fuel line to injector one at a time--no noticeable change indicates that cylinder is misfiring. 5 -.Clean and service air cleaner.clean and check thermostats and replace if required.Check connections--Bleed fuel system.Check thermostat. 7 mClean and Test Faulty Nozzle for pressure leakage and spray pattern. (c) Runs "Rough" with Excessive Vibration 2 --Too low operating temperature--below 3 --Air in fuel lines 4 --Clogged air cleaner 165°F 5 --Engine idles too slowly 6 -. 63 . Lowenginewater temperature 1 -.Overloading engine 3 -.Replace 1 -. Reface or replaceas required.Coolantleaks into combustion chamber 6 -. 1 -. 5 -.Reduce load. 1 -.Check thermostat.Poor compression 5 -.Glow plugsnot usedat start-up (F) Excessive Smoke BLUE SMOKE -.check for cylinder headwarpage.Restriction in air supply 4 -. 2 -.Take pump to an authorized service center. 5 -.Valvesholding open~ no tappet clearance 2 -. 6 -. 2 -.Broken or weak valve springs 6 -.Check andreplaceanynot up to specifications. 2 -.Clean headandblock surfaces. valve stemor valve stemseal BLACK SMOKE 1 -. 7 -.Worn pistons and bores 1 -.MayIndicate Misfiring 1 mLowengine temperature 2 -. 2 -.Burned or sticking valvesor incorrect valvetiming 5 -. 4 -. Replace gasketandtorque to Specification.Check thermostat. 3 ~ Clean air cleaner. (SeePages 11 & 29) 4 -. 3 -. (See SPB 87-371-.Use Dieselfuel that meets specifications.Re-ring with recommended service kit.Cleanandgrind valves.If necessary rebore& replace pistons.Energize glowplugsbeforestarting.See"G" recommendations.COMPLAINTS PROBABLE CAUSE WHITE SMOKE -.increase enginetemperature.Check thermostat -.) 3 -. 6 -. leakage andspraypattern.Adjusttappetclearance to specifications.cleanandtest faulty nozzlefor pressure.(SeeTorque Specification Section 10.Check andcorrect if necessary.Excessive fuel rate 2 -. 3 -.Faultyinjectors CORREC~ON 3 --Poor fuel 4 -.Worn or stuckrings 2 -.Wrong valve timing 4 -.Indicates High Oil Consumption 1 -.Piston rings wornor broken 7 -.) 64 .Lowenginewater temperature 3 m Worn valve guide.Check headgasket. 4 -.Leaky cylinder headgasket (G) Poor Compression (Under325#at 150 RPM) 3 -.See (I) highoil consumption recommendation.Cutout individualinjectorswith enginerunning -. 6 --Adjust tappets .Replace 10 --Replace 1 --Operating with low coolant temperature 2--Wrong fuel (J) Poor Fuel Economy 3 --Loss of power 4 --Incorrect injection ing 5 -. leakage and spray pattern. --Inspect lines and check with Master Gauge.Low oil level 2 --Oil pressure gauge or line faulty 3 --Oil too light--diluted 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 CORRECTION --Add oil to dipstick level. 5 --Clean and free up valve--check spring tension.46 (.018) exh.COMPLAINTS PROBABLE CAUSE 1 -.014) int. -. 2 aMaintain oil level between high and low marks on dip stick. --Remove screen and clean in solvent. repair or replace pump. --Change oil and follow recommendedlubrication. 5 --Cut out faulty injector--clean and test for pressure. (Reference page 60) 65 . 7 --Re-ring with recommendedservice rings. w Replace (H) Low Oil Pressure 1 --Oil leaks 2 --Too high oil level maintained 3 --Incorrect grade of oil used High Oil Consumption 4 --Clogged crankcase breather 5 --Oil pressure too high--relief valve stuck 6 --Piston rings not properly run-in 7 --Worn.Nozzles faulty 6 --Incorrect tappet clearance pumptim- 1 -.4 °C-85 °C (175°F-185°F) for maximum economy and performance. 8 --If necessary rebore & replace pistons 9 -.Follow "D" recommendations. 3 --Use recommended type and SAEnumberof lubricating oil. 2--Use Diesel fuel that meets specifications. 6 --Break in all new and rebuilt engines as recommended.Replace --Remove. --Clean or replace spring.36 (.Locate and repair. 3 -. 4Follow recommended timing procedure. and . 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 1 -. 4--Clean thoroughly.Maintain 79. 5 --Sharp. check opening pressure. 2. 2 --Clogged or dirty filters--check lines for obstruction or break. Replace pin with oversize. 4 --Replace transfer pump. Adjust to specifications. 6 -. 5--Drain system and refill with clean fuel or strain remaining fuel through chamois.Use only #2 diesel engine fuel oil for good performance and economy. main bearings.Main bearings 3--Connecting rod bearings 4 --Loose piston pin 5 --Broken piston ring or pin 6--Tappet noise 7 --Timing gear noise 1 --"Short out cylinders" by loosening fuel line to nozzle one at a time--if no change in sound. knock is not occurring in that cylinder.COMPLAINTS PROBABLE CAUSE 1 -. dull knock when accelerating under load. 2 --Heavy. Removepistons. clicking noise that cannot be eliminated by shorting out. Examine bearing lining for wear or excessive clearance. 3.Injection nozzle sticking 1 -. 66 . 3-.Follow recommended timing procedure.Reduce load or increase speed. Refit new set of gears if loose or worn badly. MECHANICAL KNOCKS 1 --To locate knock 2 -.Bleed fuel system. 6--Turn engine manually--if uanble to do so check for foreign object in combustion chamber or for piston or bearing seizure.Checktappet clearance. Replace if necessary. Removenozzle. 2 -. 4 --Sharp metallic rap at idling speed or when starting cold. (Reference page 60) 7 --Loose or worn-gears rattle. clean and adjust. Check and correct as in Para. Check gear fit and examineteeth. replace piston pin or rings if necessary. 7 --Repair or replace 3 --Air in fuel lines 4 --Transfer pumpfaulty 5 --Water in fuel (K) Sudden Stopping 6 --Internal engine seizure 7 --Faulty electrical shut-off on injection pump COMBUSTION KNOCKS(Excessive) 1 --"Lugging" (L) Engine Knocks and Noises 2 --Poor quality fuel 3 --Injection timed too early 4 -.No fuel 2 --Restriction in fuel flow CORRECTION 1 --Refill fuel tank and bleed fuel system. 3 --Condition noted at idle or light load and disappears at full load. tight-gears whine. m LB.819.8 8. 110-120 50-55 45-50 15-18 25-30 25-30 10-14 15-18 17-20 6-8 15-18 25-30 55-60 90-100 140-150 65-70 120-130 23-28 50-55 20-25 50-55 5-6 20-25 Accessories And Misc.8/9.9 12.8 8.8 8.8/9.8/9.9) and Black Oxide Coated Fasteners (Class 8.8/9.8 150-162 68-75 61-68 20-24 34-40 34-40 14-19 20-24 23-27 8-11 20-24 34-40 75-81 122-135 190-203 88-95 163-176 31-38 68-75 27-34 68-75 7 -8 27-34 head. DO NOT Torque beyondhigh limit.8 8.s Oil Pans (Sheet Steel) Oil Pump To Engine Rocker Shaft Supports THD SIZE MAT’L CLASS 3/8 SAE GR 8 61-68 45-50 M14 M10 M10 M8 M10 M10 M8 M8 M8 M6 M8 M10 M12 M14 M16 7/8 M16 M12 M22 5/16 M24 M8 M12 12. Brackets Camshaft Nuts (cast iron camshaft) Crankshaft Pulley Glow Plugs Nozzle To Holder Fuel Injection PumpDriven Gear To Fuel Injection Pump *Injector to Cylinder Head Rocker Cover High Pressure Fuel Lines 8 9.9 12.8/9.8 8.8/9.8/9.8 and cylinder Always use a new steel heat shield washer between inlector 67 .8 8.8/9.8/9. CYLINDER HEAD ENGINE SERIES TMD SEE CHART Page 68 TORQUE N. ITEM Connecting Rods CAUTIONHigh limit is maximum.9 8.9 & 12.8 8.8).8 8.8 8.8/9.Section 10-Torque Specifications NOTE: The following Torque Values are based on Phosphate Coated Fasteners (Class 10.8 8.8 & 9.FT. Main Bearing Caps Flywheels Flywheel Housings Rear End Plates Manifolds (Seezpruf) Gear Covers Water Pump.8 9.8 8. THD SIZE M6 M8 M 10 M 12 M 14 M 16 M20 Torque Value for specific part to be installed TORQUE (Phosphate Coated Fasteners) Class 8. Marking shall be located on the top of the head. PROPERTY CLASS IDENTIFICATION SYMBOL BOLTS.Lbs.9 N-m LBoFT.8 Class 9. N.8 9. 85-90 30-35 80-85 N-m 115-122 41-47 108-115 (HH) He x Head Ca p Screw NOTE:(SH) = Socket Head Cap Screw ® Torque all 68 ® cylinder @ head capscrews using the proper torquing sequence shown here.8 9.FT.FT.9. PROPERTYCLASS MARKING BOLTS AND SCREWS: The property class symbols for metric bolts and screwsare given in table at right. 30-35 10-15 25-30 N-m 41-47 14-20 34-41 TORQUE SEQUENCE Step 2. Torquewith HandTorqueWrench to: ¢ TMD20 M10~ 12 9 10 I1 Screw Size (SH) M12 (HH) M10 (HH) M12 Ft.m LB.Lbs.8 10. Retorque with Hand Torque Wrench (after enginereachesnormal operating temperature) to the followingvalues.8 10. the marking may be indented on the side of the head for hex head products. If marked.9 12. STU DS: All metric studs used on TMD enginesare of property class 10.Lbs.markingwill be at nut end. 95-100 35-40 90-95 N-m 129-136 47-54 122-129 Hot Retorquing Procedure TMD27 MI0---~15 14 11 I1~ 13 Step 4. Torquewith HandTorqueWrench in one single smooth motion: Screw Size (SH) M12 (HH) MIO (HH) M12 Ft.only if is not listed on preceding sheets.8 N. Alternatively. ." ColdTorquing Procedure Step 1.Lbs. SCREWS AND STUDS 8.9 CYLINDER HEAD TMD13 MIO--=. 8-11 6-8 8-11 6-8 20-24 15-18 20-24 15-18 34-40 25-30 34-40 25-30 75-81 55-60 75-81 55-60 122-135 90-100 122-135 90-100 190-203 140-150 190-203 140-150 Class 10.9 12.m LB.in onesingle smooth motion: ScrewSize (S H) M (HH) alO (HH) M12 Ft.NOTE: The Following Torque Values are to be used. 60-65 20-25 55-60 N-m 81-88 27-34 75-81 Step 3. Torquewith HandTorqueWrench to: Screw Size (SH) M12 (HH) MIO (HH) M12 Ft.9 STUDS SMALLER THAN M12 (~ -I’- 8. 142 0.8#) (47. Jr.0978/.554 1.511147. of Brg.0607) (1. "Wear Limits.0019) (.016 0.486 44.175/30.20 (1.187 49.006) (. Thickness *Wear Limits--Min. of Main Brg.3422) (.64018.212/49.2810. Length--Valve open Load--Valve open *Wear Limits--Min.372) (1.6535) (52.0709) (.0037/.162 0.0/70.0021) Bore--Inside Dia.88 47.0052/.0015) PISTON PIN Length Diameter "Wear Limits--Min.575/28.091 0.1880/1.9965) (.028 0.048 0.9978) (.745511. in Bushing Desired Pin Fit 71.775 (2 3/8) (.625/47.00151.3402) (. Thickness "Wear Limits--Min.324/25.03810.0030/. Dia.450/44. #1 #2 #3 TMD METRIC 47.096 0.058 0.364125.6565) (.425 42. CI.6#) (93.0055/.7 28.3432/.001) Under MinimumNewShaft Diameter 47.571 28. Brg.1250/1.9365) (1.15 0.344 0. Desired Fit Bush.032 0.471 2.862/42.075/0.9986/. Dia.1259/1.133/0.09510. 44°45 0.9970/. Wgt.0973) (.0012) (.8740) (1.04 (3. Pin CI.65751.073 (.0067/.5KgF (1.17/0.5#) MAIN BEARINGS Dia.375/52.0716/3.870511. Dia.3409/. Stem.944 72.683011. *Wear Limits--Max. CI. 8. Hole Dia.025 (.484/2. Dia. 8.1255) (1.013/0.0 24KgF 21.080/0. Min. Dia.4 16.542 49.54KgF 42.3447) *Wear Limits--Min.089 0.0617/.567/1.0008 TAPPET Outside Dia.Section 11.1269) (0.0612) (. Dia. ENGINE MODEL VALVE GUIDE (Intake & Exhaust) Length Outside Dia.0031/.8730/2.0615) (. Length--Valve Closed Load--Valve Closed "Wear Limits--Min.575 .Limits and Clearance Data NOTE: Dimensions shown are for standard engines.0070) CONNECTING RODS VALVES.0035) (.3#) (1.795/2. *Wear Limits--Min.0036) (. Thk.13910.592 .642 8. Seat Angle Stem Clearance Limits *Wear Limits--Max.3376) ’) (44°45 (. CI. Clearance Limits Disired Clearance "Wear Limits--Max. Hole E)ia.974172.008) VALVE SPRINGS Outside Dia. 29°45 0. Seat Angle Stem Clearance--Limits *Wear Limits--Max.717/8.019/78. EXHAUST Stem Dia. Desired Stem Clear. #1 #2 #3 Bore--Clearance Limits End Play 0.0620/2.85 42.6865) VALVES.--Fin.9375/1.750011. *Wear Limits--Max.1245) (1.311 25.5KgF 32.--Crank Pin "Wear Limits--Min.918 0.8708) (.362 1.723 (ENGLISH) (1. Hole Dia. Bore in Block "Wear Limits 25. Clearance Limits Desired Clearance C/S End Play 78.052 0.837 (1.562 Light Push 28.0011) 0.7490) (1.011/.783) (1.749/42. Wgt. "Wear Limits--Min.125 0. Dia.0029) Bush.005) 69 .623 0.598/28. Dia. Brg.3394) (.8718) (2.622 8.9355) (.150 52.8750/1.0056) (.178 (.7445) (1.3383) ’ ) (29°45 (. 34.053 (. INTAKE Stem Dia. Side Play Desired Side Play 30.336/44.8695) (1.0049) (.00 2.459 72.6820) Dia.0006) (.311 42.13 (. Thk.700/16.0038) (. TMD METRIC (ENGLISH) ENGINE MODEL CAMSHAFT Brg.0968) (2.675 8.0005/0. Hole Dia. Journal Dia.660/8.1248) (1.588 28.600 44. Desired Stem Clear.0020) (.1870) (2.692 8.294) (104. Dia.0023) (.3402/. 0. 60.6875/1.020 (2. Bore in Block t~rg. ENGINE MODEL PISTONS Cylinder Dia. *WearLimits--Cyl. Bore Piston Pin Hole Dia. Ring GrooveWidth--#1 Max. WearLimit Width Ring GrooveWidth #2-*Max Wear Limit Width #2-Ring GrooveWidth #3 *Max WearLimit Width Piston Fit-Feeler Gauge Lbs. Pull PISTON RINGS Ring Width--#1 *WearLimits--Min. Width Ring Width--#2 *WearLimits--Min. Width Ring Width #3 WearLimits--Min. Width Ring GapClear--#1 Ring GapClear--#2 Ring GapClear--#3 Ring Side Clear--#1 Ring Side Clear--#2 Ring Side Clear--#3 METRIC 91.039/91.000 0,20 28.583/28.578 2.560/2.540 2.611 2.06012.040 2.111 4.060/4.040 4.109 0.08 2.3-4.5Kg TMD (ENGLISH) (3.584213.5827) (.008) (1.1253/1.1251 (mI0081.1000) (1.028) (.0811/.0803) (.0831) (.1598/.1591) (.1618) (.003) (5-10#) 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) (.1546) (.0161.026) (.016/.026) (,012/.024) (.0032/.0020) (.0032/.0020) (.0032/.0020) NOTES 70 Index / WARNING Read andobserve all individual safetywarnings as youusethis manual to operate, serviceor repair y ur engine.Seepages 1 and2. Important Safety Notice and Warnings ................................................................................................ 1 &2 Contents ............................................................................................................................... ~......................... 3 Industrial Cntinental Diesel Specifications .............................................................................................. SECTION 1 - General Information Continental Diesel Engine ..................................................................................................................... 4 5 SECTION 2 - Operating Instructions Preparation of a New Engine for Operation .......................................................................................... 7 Starting the Engine ................................................................................................................................ 7 Stopping the Engine ............................................................................................................................... 9 11 "Musts". ............................................................................................................................................. 9 Cold Weather Operation ........................................................................................................................ 9 Engine Preparation forWinter Use ...................................................................................................... 10 Preparation of Engine for Seasonal Storage ....................................................................................... 11 SECTION 3 - Lubrication Engine Lubrication System .................. : ............................................................................................... 13 OilPump ...............................................................................................................................................13 OilChange Frequency ......................................................................................................................... 13 Lubrication Recommendations ............................................................................................................ 14 SECTION 4 - Cooling System Cooling System .................................................................................................................................... Effect of Altitude on Cooling ................................................................................................................ Anti-Freezes ......................................................................................................................................... Cleaning Cooling System ..................................................................................................................... Testing Thermostat .............................................................................................................................. Radiator Pressure Cap ........................................................................................................................ Fan Belt Tension .................................................................................................................................. Water Pump ......................................................................................................................................... 15 16 16 16 17 18 18 19 SECTION 5 - Fuel System Electric Fuel Transfer Pump ................................................................................................................ 21 Bleeding the Fuel System .................................................................................................................... 22 Fuel Filters ...........................................................................................................................................23 Injectors ................................................................................................................................................ 24 Testing .................................................................................................................................................. 24 Fuel Injection Pump ............................................................................................................................. 25 Timing of Injection Pump to theEngine ............................................................................................... 26 Fuel Recommendations ....................................................................................................................... 31 SECTION6 - ChargingSystem Charging System .................................................................................................................................. 32 71 SECTION 7 - Pr ventive Maint nanc Daily Preventive Maintenance Schedule ............................................................................................. Dry Type Replaceable Air Filter........................................................................................................... PCV System ......................................................................................................................................... Check OilPressure .............................................................................................................................. 50- Hour Preventive Maintenance Schedule ...................................................................................... 250 - Hour Preventive Maintenance Schedule .................................................................................... 400 - Hour Preventive Maintenance Schedule .................................................................................... 500 - Hour Preventive Maintenance Schedule .................................................................................... 34 34 35 35 36 37 37 37 SECTION 8 - Engine Repair and Overhaul Cylinder Head ...................................................................................................................................... 39 Disassembly of Cylinder Head ............................................................................................................. 40 Valve Guides ........................................................................................................................................ 41 Valve Seat Inserts (if supplied) ............................................................................................................ 41 Valve Guide Data ................................................................................................................................. 42 Valves ................................................................................................................................................... 43 Valve Springs ....................................................................................................................................... 44 Rocker Arms ........................................................................................................................................ 45 Valve Push Rods .................................................................................................................................. 45 Checking Bore Wear ............................................................................................................................ 45 Preparing Cylinder Walls for Re-Ringing or Reboring ......................................................................... 45 Pistons .................................................................................................................................................. 47 Piston Pins ...........................................................................................................................................48 Connecting Rod ................................................................................................................................... 48 Piston and Connecting Rod Assembly ................................................................................................ 48 Piston Rings ......................................................................................................................................... 49 Recommended Method of Installing Piston Rings .............................................................................. 49 Crankshaft and Main Bearings ............................................................................................................ 50 Bearings ............................................................................................................................................... 50 Camshaft ..............................................................................................................................................52 Tappets ................................................................................................................................................ 53 Rear Crankshaft OilSeals ................................................................................................................... 53 OilPump ............................................................................................................................................... 54 Timing Gears ........................................................................................................................................ 55 Crankshaft End Play ............................................................................................................................ 57 Flywheel and Flywheel Housing .......................................................................................................... 57 Reassembling Engine .......................................................................................................................... 58 Installing Head ..................................................................................................................................... 58 Installing OilPan .................................................................................................................................. 60 SECTION 9 - Trouble Shooting Engine Won’t Turn Over ...................................................................................................................... 61 Engine Turns, butWon’t Start .............................................................................................................. 62 Runs "Rough" with Excessive Vibration .............................................................................................. 62 Loss ofPower ...................................................................................................................................... 63 Overheating .......................................................................................................................................... 63 Excessive Smoke ................................................................................................................................. 64 Poor Compression (under 325# at 150 RPM) ..................................................................................... 64 Low OilPressure .................................................................................................................................. 65 High OilConsumption .......................................................................................................................... 65 Poor Fuel Economy ............................................................................................................................. 65 Sudden Stopping .................................................................................................................................. 66 Engine Knocks and Noises .................................................................................................................. 66 SECTION 10- Torque Specifications ................................................................................................... SECTION 11- Limits and Clearance Data ........................................................................................... 67-68 69-70 72 NOTES . NOTES . Tennessee 38181 Phone: (901) 365-3600 TOLLFREE: 1-800-932-2858 TELEX:462-1058 (IT1") FAXNO: (901) 369-4050 EUROPEAN: Rue JosephDeflandre.O. WIS. 13 B-4920 Chaudfontaine(Liege) Belgium Phone: (32) (41) 675320 TELEX: 42631 TDYTP B FAX NO: (32) (41) January/1993 TTP10148 . Box 181160 Memphis.SERVICEAND PARTS Available from your Authorized WlS-CON TOTAL POWER Service Center CALIFORNIA P~oposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer. birth defects. and other reproductive harm. HEADQUARTERS: 3409 Democrat Road P.CON TOTALPOWER coRP.