ENGINE SERVICE MANUAL PERKINS NEW 700 SERIES
CONSTRUCTION 6-77740NA
SERVICE MANUAL PERKINS NEW 700 SERIES ENGINES
CNH
Bur 6-77740
Copyright © 2004 CNH America LLC. All rights reserved. Printed in U.S.A. Issued November, 2004
Bur 6-77740
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Contents
General information ..................................................................................... 10 Specifications .............................................................................................. 11 Service operations Cylinder head assembly .............................................................................. 12 Piston and connecting rod assembly............................................................ 13 Crankshaft assembly ................................................................................... 14 Timing case and drive assembly .................................................................. 15 Cylinder block assembly .............................................................................. 16 Engine timing............................................................................................... 17 Aspiration system ........................................................................................ 18 Lubrication system....................................................................................... 19 Fuel system ................................................................................................. 20 Cooling system ............................................................................................ 21 Flywheel and flywheel housing .................................................................... 22 List of special tools ...................................................................................... 25
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General information
Alt= to hide template information Alt+ to display template information GENERAL INFORMATION 10-01
10
Introduction ................................................................................................................. 10.02 Engine views ............................................................................................................... 10.03 Engine identification .................................................................................................... 10.04 Safety General safety precautions ......................................................................................... 10.05 Engine lift equipment................................................................................................... 10.06 Viton seals .................................................................................................................. 10.07
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Introduction This workshop manual has been designed to provide assistance in the service and overhaul of Perkins 700 Series engines. Warning! Read and remember the "Safety precautions". They are given for your protection and must be used at all times. The engines that are referred to in this manual are the UA (3.0 litre - direct injection), and the UB (2.6 litre indirect injection). Both engines conform to Stage 1 off-highway emissions to Cl -8 mode cycle ref. ISO 8178 part 4. Where the information applies only to one engine type, this will be indicated in the text. When reference is made to the "left" or "right" side of the engine, this is as seen from the flywheel end of the engine. Special tools have been made available and a list of these tools is given in section 25. Reference to the relevant special tools is also made at the beginning of each operation. Loctite recommended consumable products are listed in section 10. Reference to the relevant consumable products is made at the beginning of operation. Data and dimensions are included at the end of each section. Danger is indicated in the text by two methods: Warning! This indicates that there is a possible danger to the person. Caution: This indicates that there is a possible danger to the engine. Note: Is used where the information important, but there is not a danger.
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Engine identification The 3.0 litre version, is a water cooled, naturally aspirated, four cylinder diesel engine with direct injection. It has been specifically designed for industrial and agricultural applications and is identified with the letters UA. The 2.6 litre version, is a water cooled, naturally aspirated, four cylinder diesel engine with indirect injection. It has been specifically designed for forklift truck applications and is identified with the letters UB. The engine number is stamped on a label (A) which is fastened to the right, rear side of the cylinder block. An example of an engine number is: UA80862Ul23456A The components of the engine number are as follows: UA80862Ul23456A UA
Type code letters 80862
Build list number
U
Built in the UK 123456 A
Engine serial number Year of manufacture
If you need parts, service or information for your engine, you must give the complete engine number to your New Holland distributor.
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Safety
•
Make sure that the engine is operated only from the control panel or from the operator's position.
General safety precautions
•
If your skin comes into contact with high-pressure fuel, obtain medical assistance immediately.
These safety precautions are important. You must refer also to the local regulations in the country of use. Some items only refer to specific applications.
•
Diesel fuel and lubricating oil (especially used lubricating oil) can damage the skin of certain persons. Protect your hands with gloves or a special solution to protect the skin.
•
Only use these engines in the type of application for which they have been designed.
•
•
Do not change the specification of the engine.
Do not wear clothing which is contaminated by lubricating oil. Do not put material which is contaminated with oil into the pockets.
•
Do not smoke when you put fuel in the tank.
•
•
Clean away fuel which has been spilt. Material which has been contaminated by fuel must be moved to a safe place.
Discard used lubricating oil in accordance with local regulations to prevent contamination.
•
•
Do not put fuel in the tank while the engine runs (unless it is absolutely necessary).
Make sure that the control lever of the transmission drive is in the "out-of-drive" position before the engine is started.
•
•
Do not clean, add lubricating oil, or adjust the engine while it runs (unless you have had the correct training; even then extreme caution must be used to prevent injury).
The combustible material of some components of the engine (for example certain seals) can become extremely dangerous if it is burned. Never allow this burnt material to come into contact with the skin or with the eyes.
•
Do not make adjustments that you do not understand.
•
•
Make sure that the engine does not run in a location where it can cause a concentration of toxic emissions.
Always use a safety cage to protect the operator when a component is to be pressure tested in a container of water. Install safety wires to secure the plugs which seal the hose connections of a component which is to be pressure tested.
•
•
Other persons must be kept at a safe distance while the engine, auxiliary equipment is in operation.
Do not allow compressed air to contact your skin. If compressed air enters your skin, obtain medical help immediately.
•
Do not clean an engine while it runs. If cold cleaning fluids are applied to a hot engine, certain components on the engine may be damaged.
•
Install only genuine New Holland parts.
•
Do not permit loose clothing or long hair near moving parts.
•
Keep away from moving parts during engine operation. Warning! Some moving parts cannot be seen clearly white the engine runs.
•
Do not operate the engine if a safety guard has been removed.
•
Do not remove the filler cap or any component of the cooling system while the engine is hot and while the coolant is under pressure, because dangerous hot coolant can be discharged.
•
Do not allow sparks or fire near the batteries (especially when the batteries are on charge) because the gases from the electrolyte are highly flammable. The battery fluid is dangerous to the skin and especially to the eyes.
•
Disconnect the battery terminals before a repair is made to the electrical system.
•
Only one person must control the engine.
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Safety Engine lift equipment Caution: If the sump contains engine lubricating oil and the engine is tilted to an extreme angle or turned onto its side or end faces, lubricating oil can enter the closed breather system, pass into the induction manifold and the cylinder bores. If this occurs, it will cause an hydraulic lock in the engine and the engine may be damaged. If it is necessary to move an engine in this way, the lubricating oil must first be drained. The maximum weight of the engine without coolant, lubricant or a gearbox installed will vary for different applications. It is recommended that lift equipment of 300 kg (662 lbs) minimum capacity is used. Before the engine is lifted: •
Always use engine lift equipment of the approved type and of the correct capacity to lift the engine. It is recommended that lift equipment of the type shown in (A) is used to provide a vertical lift, directly above the engine lift brackets (A1). Never use a single lift bracket to raise an engine.
•
Check the engine lift brackets for damage and that they are secure before the engine is lifted. The torque for the setscrews for the engine lift brackets is 22 N m (16 lbf ft) 2.2 kgf m.
•
To prevent damage to the rocker cover, make sure that there is clearance between the hooks and the rocker cover.
•
Use lift equipment or obtain assistance to lift heavy engine components such as the cylinder block, the cylinder head, the flywheel housing, the crankshaft and the flywheel.
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Viton seals Some seals used in engines and in components installed to engines are made of Viton. Viton is used by many manufacturers and is a safe material under normal conditions of operation. If Viton is burned, a product of this burnt material is an acid which is extremely dangerous. Never allow this burnt material to come into contact with the skin or with the eyes. If it is necessary to come into contact with components which have been burnt, make sure that the precautions which follow are used: •
Make sure that the components have cooled.
•
Use Neoprene gloves and discard the gloves safely after use.
•
Wash the area with calcium hydroxide solution and then with clean water.
•
Disposal of components and gloves which are contaminated must be in accordance with local regulations.
If there is contamination of the skin or eyes, wash the affected area with a continuous supply of clean water or with calcium hydroxide solution for 15-60 minutes. Obtain immediate medical attention.
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Specifications
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11
Basic engine data ..................................................................................... 11A Recommended torque tensions ................................................................. 11B Compression test data .............................................................................. 11C
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Basic engine data
11A
Basic engine data .....................................................................................................11A.02
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Basic engine data Cycle..........................................................................................................................................................Four stroke Number of cylinders................................................................................................................................................... 4 Cylinder arrangement ........................................................................................................................................ In line Firing order ....................................................................................................................................................... 1,3,4,2 Direction of rotation .............................................................................................................. Clockwise from the front Induction system............................................................................................................................ Naturally aspirated Cubic capacity: UA engines............................................................................................................................. 2.956 litres (183 in3) UB engines............................................................................................................................. 2.602 litres (159 in3) Compression ratio: UA engines.................................................................................................................................................... 17.5:1 UB engines.................................................................................................................................................... 22.0:1 Combustion system: UA engines...................................................................................................................................... Direct injection UB engines.................................................................................................................................... Indirect injection Nominal bore: UA engines..................................................................................................................................97.0 mm (3.82 in) UB engines..................................................................................................................................91.0 mm (3.58 in) Stroke........................................................................................................................................100.0 mm (3.94 in) Valve tip clearances (cold): - Inlet and exhaust .........................................................................................................................0,35 mm (0.014 in) Lubricating oil pressure (at normal engine temperature): - Minimum pressure at maximum engine speed..................................................... 280 kPa (41 lbf/ in2) 2.86 kgf/cm2 Typical dry installed engine weight (1) ............................................................................................... 200 kg (440 lb.) (1) Engine weight may alter with final specification
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Recommended torques tensions
11B
General information Thread sealant ..........................................................................................................11B.02 Recommended torques tensions Standard torque tensions ..........................................................................................11B.03 Special torque tensions .............................................................................................11B.03 Cylinder head assembly ............................................................................................11B.03 Pistons and connecting rod assembly .......................................................................11B.03 Crankshaft assembly.................................................................................................11B.04 Timing case and drive assembly ...............................................................................11B.04 Aspiration system......................................................................................................11B.04 Fuel system ..............................................................................................................11B.04 Lubrication system ....................................................................................................11B.04 Cooling system .........................................................................................................11B.05 Flywheel and housing ...............................................................................................11B.05 Auxiliary equipment ...................................................................................................11B.05
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General information Thread sealant When setscrews or studs are installed into holes which are tapped into the inside of the engine, a suitable sealant should be used. M.E.A.S. (Micro encapsulated anerobic sealant) fasteners are installed into the holes that are open to the inside of the engine. A thin layer of sealant is applied to the threads of the fasteners when they are manufactured. The colour of the sealant can be red, yellow or blue. With M.E.A.S. sealed studs, the sealed end must be installed into the cylinder head / cylinder block etc. Make sure that the threaded holes have a 1.59 mm (0.0625 in) 45° chamfer, such that when the new fasteners are installed the M.E.A.S. sealant is not removed. If the fasteners have to be removed and installed again, the threads must be cleaned and a suitable sealant applied.
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Recommended torque tensions Most of the fasteners referred to in this manual have standard torque tensions which are shown in the table below. Those fasteners that need special torque tensions are listed in separate tables together with some standard torque tensions most frequently used. Procedures referred to in this manual will have the torque tensions (standard or special) shown in the text and also listed in the tables for special torque tensions. The torque tensions that are shown in this manual apply to fasteners with dry threads. Standard torques tension for setscrews, studs and nuts Torque tension - setscrews and nuts Thread size
Torque tension - studs (metal end)
Nm
lbf ft
kgf m
Nm
lbf ft
kgf m
M6 x 1.00
9
7
0.9
5
4
0.5
M8 x 1.25
22
16
2.2
11
8
1.1
M10 x 1.50
44
33
4.5
18
13
1.8
M12 x 1.75
78
58
8.0
25
18
2.5
M14 x 2.00
124
91
12.6
-
-
-
M16 x 2.00
190
140
19.3
-
-
-
Special torque tensions for setscrews and nuts
Description
Thread size
Cylinder head assembly
Torque tension Nm
lbf ft
kgf m
See
page
12A.10
Setscrews, cylinder head to cylinder block
M6
9
7
0.9
Setscrews, rocker shaft bracket
M8
22
16
2.2
Nuts, rocker shaft bracket
M8
11
8
1.1
Cap nuts, rocker cover
M8
22
16
2.2
Setscrews, inlet manifold to cylinder head
M8
18
13
1.8
Setscrews, engine lift brackets
M8
22
18
2.2
M9
54
40
5.5
Piston and connecting rod assembly Nuts, connecting rod big end caps
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Torque tension
Thread size
Nm
lbf ft
kgf m
Setscrews, main bearing caps
M14
147
108
15.0
Setscrews, crankshaft pulley to crankshaft
M16
185
136
19.0
Setscrews, timing case to cylinder block
M8
22
16
2.2
Setscrews, timing case to cylinder block
M10
44
33
4.5
pump
M6
9
7
0.9
Setscrews, thrust washer - camshaft for the engine
M6
9
7
0.9
Setscrews, timing case to blanking plate
M8
22
16
2.2
Nuts, timing case to blanking plate
M8
22
16
4.5
Setscrews, timing case to blanking plate
M10
44
32
4.5
M6
9
7
0.9
Nuts, high-pressure fuel pipes
M12
22
16
2.2
Setscrews, atomiser clamps
M8
12
9
1.2
Injector - 704.26 (UB) engines
M20
39
29
4.0
Nuts, low-pressure fuel pipes
M12
20
15
2.0
Setscrews, fuel lift pump to cylinder block
M8
22
16
2.2
Setscrews, cassette pump to cylinder block
M8
22
16
2.2
Nuts, cassette pump to cylinder block
M8
22
16
2.2
Screw, fuel leak-off
M6
12
9
2.2
Nuts, maximum fuel adjustment screw
M8
14
10
1.4
Angleich unit
M16
18
13
1.8
Governor assembly to camshaft gear
M5
7
5
0.7
3/4 UNF
34
25
3.5
Cap screws, oil pump to timing case
M6
9
7
0.9
Setscrews, lubricating oil sump
M8
22
16
2.2
Relief valve assembly to timing case
M18
20
15
2.0
Description Crankshaft assembly
Timing case and drive assembly
Setscrews, retainer plate - camshaft for fuel injection
Aspiration system Setscrews, breather cover Fuel system
Lubrication system Plug, lubricating oil sump
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Torque tension
Thread size
Nm
lbf ft
kgf m
Nuts / screws, coolant pump to cylinder block
M8
22
16
2.2
Setscrews, fan and pulley to coolant pump hub
M8
22
16
2.2
Setscrews, fan and pulley to coolant pump hub
M6
9
7
0.9
M12
100
77
10.7
Nuts, alternator pulley
M17
60
44
6.1
Bolt / nut, alternator to timing case
M10
24
18
2.4
Setscrew, adjusting lever to alternator
M8
12
9
1.2
Glow plugs
M10
17
13
1.7
Glow plug connections
M4
1,5
1
0.2
Description Cooling system
Flywheel and housing Setscrews, flywheel to crankshaft Electrical equipment
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Compression test data
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11C
Compression test data ............................................................................................. 11C.02 How to do a compression test .................................................................................. 11C.02
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Compression test data Tests have shown that many factors affect compression pressures. Battery and starter motor condition, ambient conditions and the type of gauge used can give a wide variation of results for a given engine. It is not possible to give accurate data for compression pressure, but tests have shown that the results should be within 2000/3500 kPa (300/500 lbf/ in2) 21.0/35,0 kgf/CM2 for diesel engines. Compression tests should only be used to compare between the cylinders of an engine. If one or more cylinders vary by more than 350 kPa (50 lbf/in2) 3.5 kgf/cM2, then those cylinders may be faulty. Compression tests should not be the only method used to show the condition of an engine, but they should be used together with other symptoms and tests.
How to do a compression test Caution: Before the compression test, make sure that the battery is in good condition and that it is fully charged. Also make sure that the starter motor is in good condition. 1
Make sure that the valve tip clearances are set correctly.
2
Remove the atomisers.
3
Install a suitable gauge into the hole in the cylinder for the atomiser.
4
Make sure that the engine cannot start:
•
Disconnect the stop solenoid or put the stop control in the no-fuel position.
•
Operate the starter motor and note the pressure indicated on the gauge.
5
Repeat for each cylinder.
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Cylinder head assembly
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12
General description ................................................................................................12A.02 Rocker cover 12A-01 To remove and to install ..............................................................................12A.03 Rocker assembly 12A-02 To remove and to install ..............................................................................12A.04 12A-03 To disassemble and to assemble.................................................................12A.05 12A-04 To inspect ...................................................................................................12A.05 Valve tip clearances 12A-05 To check and to adjust ................................................................................12A.06 Valve springs 12A-06 To change the valve springs (with cylinder head installed) ..........................12A.07 Cylinder head assembly 12A-07 To remove and to install ..............................................................................12A.09 Valves and valve springs 12A-08 To remove and to install ..............................................................................12A.13 12A-09 To inspect and to correct .............................................................................12A.15 Valve guides 12A-10 To inspect ...................................................................................................12A.16 12A-11 To remove and to install ..............................................................................12A.17 Cylinder head 12A-12 To inspect and to correct .............................................................................12A.19 12A-13 To correct a valve seat with a valve seat cutter ..........................................12A.20 12A-14 To install valve seat inserts .........................................................................12A.11 Data and dimensions ..............................................................................................12A.22
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General description Notes: •
The front of the engine is when seen from the end with the timing case assembly.
•
Number one cylinder is at the front of the engine.
In a diesel engine, there is little carbon deposit and for this reason, the number of hours run is no indication of when to overhaul a cylinder head assembly. The factors which indicate when an overhaul is necessary are how easily the engine starts and its general performance. The cylinder head assemblies for both the UA and UB engines contain two valves for each cylinder. From the front of the engine, the sequence for valves is first inlet and then exhaust. The cylinder head for the UB engine contains a precombustion chamber (A1) that is made from a hardened manganese alloy. It will not be possible to, renew this chamber or to machine the bottom face of the cylinder head. Included in the cylinder head assembly for UA and UB engines, there is a valve guide and a valve seat insert for each valve. The inserts and guides can be renewed if necessary. The new valve guides are pre-finished. The face angle for all of the valves is 45° and the angle for all of the valve seats is 45°. The Inlet and the exhaust valves are each installed to the cylinder head with a single valve spring and an oil seal that is installed over the top of the valve guide. The valve and valve spring are held in position with a hardened steel cap and two collets. The glow plugs and the atomisers are both installed into the top of the cylinder head. The tip of the glow plug and the atomiser protrude through the bottom face of the cylinder head (A2) on UA engines, and into the pre-combustion chamber (A3) on UB engines. Caution: The amount of protrusion for both atomiser and glow plug is important for the performance of the engine, therefore only New Holland parts should be used in service.
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Rocker cover To remove and to install
12A-01
The engine is installed with an aluminium rocker cover which includes a closed breather assembly and a connection for the breather pipe. A composite rubber seal is installed into a machined groove (B2) in the flange face of the cover. To remove 1
Disconnect the breather pipe (B1).
2
Remove the cap nuts (A1), the steel washers (A2) and the rubber seals (A3).
3
Lift off the rocker cover (B).
To install 1
Check the condition of the rubber seals (A3) and the steel washers (A2) for the cap nuts (A1). If necessary, the seals for the cap nuts can be renewed.
2
If necessary, check, clean and renew the components of the breather system, operation 18A-02.
3
Check the condition of the rocker cover seal (B2) and renew the seal if necessary.
4
Clean the seal face of the cylinder head and install the rocker cover. When the cover is put on the cylinder head, make sure that the seal remains in the groove.
Caution: If the cap nut (A1) is over tightened, the stud and plate assembly (B3), for the rocker pedestal may be damaged. 5
Install the rocker cover. Make sure that the cap nuts, washers and the rubber seals are installed correctly. Tighten the cap nuts to 11 Nm (8 lbf ft) 1.1 kgf m.). Install the breather pipe.
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Rocker assembly To remove and to install
12A-02
To remove 1
Remove the rocker cover, operation 12A-01.
2
Release the eight setscrews (A1) for the brackets of the rocker shaft. Release gradually and evenly the nuts (A3) and then the nuts (A4) for the brackets of the rocker shaft.
Note: The rocker assembly contains three plates (A2) which include the studs for the rocker cover. The plates must be installed to the correct rocker brackets (A). 3
Remove the nuts and lift off the rocker assembly (B).
Note: A hardened steel pin (B1) is installed in the lower part of the front bracket. The purpose of this pin, is to make sure that the bracket is in the correct position on the rocker shaft. The hole in the bracket will align with the oil hole (B2) in the cylinder head and make sure correct lubrication of the rocker assembly. Protect these holes to make sure that dirt cannot enter. To install Cautions: • Before the rocker assembly is installed, make sure that the oil holes (B1) and (B2) are free of dirt. •
Check that the push rods (B3) install correctly in the sockets of the tappets.
1
Put the rocker assembly (B) onto the cylinder head.
2
Install the plates (A2) to the correct brackets for the rocker shaft.
3
Install the fasteners (A1), (A3) and (A4) finger tight.
5
Tighten gradually and evenly, the eight setscrews (A1) to, 9 Nm (7 M ft) 0.9 kgf m. Tighten the inner setscrews first and then the outer setscrews.
6
Adjust the valve tip clearances, 12A-05.
7
Install the rocker cover, operation 12A-01.
Caution: As the fasteners are gradually tightened, make sure that the ends of the adjustment screws (B4) install correctly in the sockets (B3) of the push rods. 4
Tighten gradually and evenly, the nuts (A4) and then the nuts (A3) to 22 Nm (1 6 lbt ft) 2.2 kgf m.
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Rocker assembly To disassemble and to assemble 12A-03 To assemble 1
Remove the clips (A5) from both ends of the rocker shaft. Make sure that the ends of the rocker shaft are not damaged.
2
Remove the spacer (A4), the rocker levers (A2), the brackets (A3) and the springs (A1).
Note: The bracket (A6), is installed to the rocker shaft with a hardened steel pin (B1) which aligns the oil holes. If either the rocker shaft or the bracket have to be renewed, a new pin must also be used. To assemble 1
Make sure that the oil holes in the rocker shaft and in the rocker levers are not restricted.
2
Before assembly, lubricate the components with clean engine lubricating oil. Assemble the components in the correct sequence; the rocker levers should be installed in the original sequence. Install the spacers and clips to the ends of the rocker shaft.
To inspect 1
12A-04
Clean and inspect all the components for wear and any other damage. Check the clearance between the rocker levers and the rocker shaft. If the clearance is more than 0.124 mm (0.0048 in), either renew the rocker lever or the rocker shaft, or both if necessary.
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05 12A-06 CYLINDER HEAD ASSEMBLY
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Valve tip clearances To check and to adjust
12A-05
Notes: • The valve tip clearance is checked with a feeler gauge between the top of the valve stem and the rocker lever (A), with the engine cold. The correct clearance for both the inlet and the exhaust valves is 0.35 mm (0.014 in). •
The arrangement of the valves is shown in (B). Valve numbers (B1) and (B2) are for number one cylinder which is at the front of the engine.
•
Clockwise rotation is when seen from the front of the engine.
1
Rotate the crankshaft in a clockwise direction until the valve (B7) has just opened and the valve (B8) has not closed completely. Check the clearances of the valves (B1) and (B2) and adjust them, if necessary.
2
Rotate the crankshaft in a clockwise direction until the valve (B3) has just opened and the valve (B4) has not closed completely. Check the clearances of the valves (B5) and (B6) and adjust them, if necessary.
3
Rotate the crankshaft in a clockwise direction until the valve (B1) has just opened and the valve (B2) has not closed completely. Check the clearances of the valves (B7) and (B8) and adjust them, if necessary.
4
Rotate the crankshaft in a clockwise direction until the valve (B5) has just opened and the valve (B6) has not closed completely. Check the clearances of the valves (B3) and (B4) and adjust them, if necessary.
Bur 6-77740
A
PU012
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05
Alt= to hide template information Alt+ to display template information CYLINDER HEAD ASSEMBLY 12A-07
Valve springs To change the valve springs (with cylinder head installed)
12A-06
Special Tools: Valve spring compressor, PD.6118B Stud adaptor, PD.244 Warning! Wear eye protection when the valve spring is compressed. Note: Paragraphs 1 to 12 refer to a change of valve springs for a single cylinder. 1
Remove the rocker cover, operation 12A-01.
2
Turn the crankshaft in the normal direction of rotation until the inlet valve of the relevant cylinder has just opened and the exhaust valve has not fully closed. In this position the piston will be at approximately top dead centre (TDC).
3
Remove 12A-02.
the
rocker
assembly,
operation
4
Install the valve spring compressor (A1) and the adaptor (A2).
5
Compress the valve spring and remove the collets. Make sure that the valve spring is compressed squarely or damage to the valve stem can occur.
11 Check the valve tip clearances, operation 12A05. 12 Install the rocker cover, operation 12A-01. Note: If other or all of the valve springs are to be changed, they can be changed one cylinder at a time in the sequence of cylinders 1 and 4, 2 and 3.
Caution: Do not rotate the crankshaft while the valve springs are removed. 6
Release the valve spring compressor and remove the valve spring caps and the valve spring.
7
Put the new valve spring in position.
8
Install the valve spring cap.
Caution: Make sure that the valve spring is compressed squarely or damage can occur to the valve stem. 9
Install the valve spring compressor, compress the valve spring and install the collets. Remove the valve spring compressor.
10 Install the rocker assembly, operation 12A-02.
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05 12A-08 CYLINDER HEAD ASSEMBLY
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If the rocker assembly has been removed, piston TDC can be found as follows: 1
Install the valve spring compressor and compress the valve spring to open the valve.
2
Turn the crankshaft, by hand, in the normal direction of rotation until the piston touches the valve.
3
Continue to turn the crankshaft, and at the same time, release pressure on the valve spring compressor until the piston is at TDC (A).
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05
Alt= to hide template information Alt+ to display template information CYLINDER HEAD ASSEMBLY 12A-09
Cylinder head assembly To remove and to install
12A-07
Special tools: 14 mm extended socket spanner To remove Warning! Do not remove the filler cap or any component of the cooling system while the engine is hot and while the coolant is under pressure, because dangerous hot coolant can be discharged. Caution: Some coolant may enter the cylinder bores and the threaded holes for the cylinder head setscrews when the cylinder head is removed. Make sure that any coolant is removed immediately to prevent corrosion. 1
Drain the cooling system, operation 21A-04.
2
Disconnect the battery.
3
Remove the rocker cover, operation 12A-01.
Caution: Use a separate spanner to prevent movement of the outlet connections of the fuel injection pump when the high-pressure pipes are released or tightened. 4
Remove the high-pressure fuel pipes. Install suitable covers to all open connections on the fuel injection pump and the atomisers.
5
Remove the exhaust manifold and gasket (A).
6
Remove the induction manifold and gasket (B).
7
Remove the pipe which is installed between the fuel filter and the connections for the atomiser leak-off.
8
Remove the atomisers, see operation 20A02A/ B. Install suitable covers to the nozzles and to the open connections.
9
Remove the glow plugs, operation 23C-01.
12 Remove the rocker cover, operation 12A-01. 13 Remove the rocker assembly, operation 12A02. 14 Remove the push rods and note their relative positions.
Continued
10 Release the clips on the hose which is installed between the water pump and the thermostat housing and remove the hose. 11 Disconnect the sender unit for the coolant temperature. Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05 12A-10 CYLINDER HEAD ASSEMBLY
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15 Release the cylinder head setscrews evenly and gradually in the reverse sequence to that shown in (A). To release the four setscrews (A1), It will be necessary to use a 14 mm extended socket spanner. Check the setscrews for damage and renew them if necessary. Caution: Do not use a lever to separate the cylinder head from the cylinder block. 16 Remove the cylinder head and put it on a surface that will not damage the face of the cylinder head. To install 1
Clean the bottom face of the cylinder head and top face of the cylinder block. Make sure that there is no debris in the cylinder bores or pre-combustion chambers.
Note: Two dowels (B1) are installed to the cylinder block to make sure that the cylinder head gasket and the cylinder head remain in the correct position when the setscrews are tightened. Cautions: • •
There is a rubber grommet (B2) installed in the cylinder head gasket for UB engines. To prevent damage to the cylinder head gasket, make sure that the dowels are installed in the cylinder block before the gasket and head are installed.
7
Repeat paragraph 6 to make sure that all of the setscrews are tightened to the correct torque.
8
Put the push rods into the sockets of the tappets from which they were removed. Install the rocker shaft assembly, see operation 12A-02.
•
Joining compound must not be used with the cylinder head gasket.
9
2
Put the cylinder head gasket in position; it is stamped "top" (B3) and "front" (B4) for correct assembly.
10 Set the valve tip clearances, see operation 12A-05.
3
Put the cylinder head in position.
4
Lightly lubricate the threads of the cylinder head setscrews and the thrust faces of the setscrew heads. Engage all the setscrews finger tight.
5
Gradually and evenly tighten the setscrews to 70 Nm (52 lbf ft) 7.1 kgf m in the sequence shown in (A). To tighten the four setscrews (A1l). It will be necessary to use a 14 mm extended socket spanner.
6
11 Install the rocker cover, operation 12A-01 and tighten the fasteners finger tight only. 12 Connect the sender unit for the coolant temperature. 13 Install the hose between the water pump and the thermostat housing and tighten the clips. 14 Install the glow plugs, operation 23C-01. Continued
Gradually and evenly tighten the setscrews to 100 Nm (74 lbf ft) 10.2 kgf m in the same sequence.
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05
Alt= to hide template information Alt+ to display template information CYLINDER HEAD ASSEMBLY 12A-11
15 Install the atomisers, see operation 20A-02A/B. 16 Install the pipe which is installed between the fuel oil filter and the connections for the atomiser leak-off. Note: To retain the exhaust manifold, earlier engines were installed with two studs and six setscrews. If these are found to be loose, remove them and install the manifold with eight of the latest type setscrews (A3). The threaded part of the new setscrew is machined to a three lobe shape. The new setscrew was introduced from engine number U#####-801620. The threaded part of the old setscrew (A5) is the standard shape. Caution: If the latest setscrews are installed instead of the old fasteners, and the bosses on the manifold have been machined, a plain washer, part number 0920003, 1.83 mm (0.072 in) thick must be installed under the head of each new setscrew. This is to prevent contact of the new setscrew, which is longer, with the bottom of the tapped hole in the cylinder head. If the manifold bosses have not been machined, it is not necessary to use the plain washer. 17 To make sure correct alignment of the exhaust manifold (A1), install two guide studs (A2) and a new gasket without jointing compound. The gasket can be installed two ways, make sure the gasket is installed the correct way up (A4). Install the exhaust manifold. 18 Install the setscrews and remove the guide studs. Tighten first the inner setscrews, and then the outer setscrews, to 18 Nm (13 lbf ft) 1.8 kgf m. The torque for the earlier fasteners is 22 Nm (16 lbf ft) 2.2 kgf m. 19 To make sure correct alignment of the inlet manifold, install two guide studs (B2) and a new gasket without jointing compound. The gasket may be installed either way around. Install the setscrews and remove the guide studs Tighten the setscrews to 22 Nm (16 lbf ft) 2.2 kgf m. Cautions: • If there is a leakage from the union nut, make sure that the pipe is correctly aligned with the atomiser inlet.
Bur 6-77740
•
Do not tighten the union nuts of the high pressure pipes more than the recommended torque tension as this can cause a restriction at the end of the pipe. This can affect the fuel delivery.
20 Install the high-pressure fuel pipes and tighten the connection nuts to 22 Nm (16 lbf ft) 2.2 kgf m. 21 Install the breather hose to the connections of the cylinder head cover and the induction manifold. 22 Fill the cooling system, operation 21A-05. 23 Connect the terminals of the battery. 24 Connect the air filter. 25 Eliminate air from the fuel system, operation 20A-07. Continued
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05 12A-12 CYLINDER HEAD ASSEMBLY
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26 Remove the rocker cover. 27 Start the engine, run it at low speed and check that oil flows from all the rocker levers, 28 If the oil flow from the rockers is correct, stop the engine and install the rocker cover, see operation 12A-01. If the oil flow is not correct, find the fault.
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05
Alt= to hide template information Alt+ to display template information CYLINDER HEAD ASSEMBLY 12A-13
Valves and valve springs To remove and to install
12A-08
Special tools: Valve spring compressor, MS.1519A To remove Warning! Wear operation.
eye
protection
during
this
1
Remove the cylinder head, see operation 12A07.
2
Clean the bottom face of the cylinder head and check the depth of the valve heads below the face of the cylinder head, operation 12A-09.
3
Make a suitable mark on the head of each valve to make sure that the valves can be installed in their original positions.
Caution: Make sure that the valve springs are compressed squarely or the valve stem can be damaged. 4
Use the valve spring compressor (A) to compress the valve spring (B3) and remove the collets (B2).
5
Release the valve spring compressor and remove the valve spring cap (B1), valve spring (B3), valve stem seal (B4) and the valve (B5).
6
Repeat paragraphs 3 and 4 to remove the remainder of the valves. Continued
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05 12A-14 CYLINDER HEAD ASSEMBLY
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To install Warning! Wear operation.
eye
protection
during
this
Cautions: • Genuine New Holland valve stem seals must be used. If they are not, damage can occur to the valve stems and valve seats. • Make sure that the valve springs are compressed squarely or damage can occur to the valve stem. 1
Lubricate the valve stem (A5) with clean engine oil and install the valve into the valve guide.
2
Install a new valve stem seal (A4) onto the valve guide. Install the valve spring (A3) and the valve spring cap (A1). The valve spring can be installed with either end toward the cylinder head.
3
Use the valve spring compressor to compress the valve spring. Install the collets (A2).
4
Repeat paragraphs 1, 2 and 3 to install the remainder of the valves. A
Bur 6-77740
PC039
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05 To inspect and to correct
Alt= to hide template information Alt+ to display template information CYLINDER HEAD ASSEMBLY 12A-15 12A-09
Special tool: Gauge, valve depth, PD.41D Dial gauge for use with PD.41D, PD.208 1
Check the depth of the valves below the face of the cylinder head before the valve springs are removed. Make sure that the heads of the valves and the bottom face of the cylinder head are clean. Put the valve depth gauge on the face of the cylinder head and set the dial gauge to zero. Carefully put the valve depth gauge in position over the head of each valve (A) and make a note of the measurement. The maximum depth in service, is given in Data and dimensions at the end of this section.
2
If a valve is below the depth limit, check the valve depth with a new valve in position. If the valve depth is still below the limit, the valve seat insert(s) must be renewed, see operation 12A-14.
3
Check the valves for cracks. Check the stems of the valves for wear and for correct install in their valve guides.
4
Check that the seat faces of the valves are not burnt or damaged. Seat faces which are damaged can be ground on a special machine. Valves which have only a little damage can be lapped to their valve seats. When new valves are installed, the valve depths must be checked, see paragraph 1.
5
Check that the load on the valve springs is correct at their installed length, see Data and dimensions. Install new valve springs at every complete engine overhaul.
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05 12A-16 CYLINDER HEAD ASSEMBLY
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Valve guides To inspect
12A-10
To check the valve guides for wear: The maximum clearance (A5), between the valve stem and the bore of the guide is 0.107 mm (0.042 in) for inlet valves and 0.14 mm (0.006 in) for exhaust valves. If the clearance, with a new valve installed, is more than the limit, then a new valve guide (A4) must be installed. It is recommended that the procedure given below is used to check the valve guide clearance: 1
Put a new valve in the valve guide.
2
Put a dial test indicator with a magnetic base (A1) onto the face of the cylinder head
3
With the valve lifted 15.0 mm (0.6 in) and the gauge (A2) in contact with the edge of the valve head (A3), move the valve radially away from the gauge. With the valve held in this position, set the gauge zero.
4
Move the valve radially across the axis of the cylinder head towards the gauge. Make a note of the reading on the gauge. If the reading is equal to or greater than the data given below, a new valve guide (A4) must be installed.
Maximum permissible clearance with a valve lift of 15.0 mm (0.6 in): •
Inlet guide
0.24 mm (0.009 in)
•
Exhaust guide
0.28 mm (0.011 in)
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05 To remove and to install
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Special tools: Remover/replacer for valve guides (main tool), PD.1D/1 Spacer PD.1D/2, used with main tool PD.1D/1 Adaptor PD.249 used with PD.1D-13 Adaptor PD.1D-13 used with main tool PD.1D/1 To remove 1
Install the adaptor PDI D-13 (A4) into the remover/ replacer tool (A3).
2
With the adaptor installed to the tool, put the spacer PD.1D/2 (A5) in position on the tool. Pass the adaptor through the valve guide (A6) and put the spacer and tool in position on the valve seat.
3
Install the attachment (A7) to secure the adaptor to the valve guide.
4
Hold the top handle (A1) and turn the bottom handle (A2) clockwise to pull the valve guide out of the cylinder head. Continued
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05 12A-18 CYLINDER HEAD ASSEMBLY
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To install 1
Clean the parent bore in the cylinder head for the valve guide.
2
Lubricate the outer surface of the new valve guide (A6) with clean engine lubricating oil.
3
Install the adaptor (A5) into the remover/ replacer tool (A3).
4
With the adaptor installed to the tool, put spacer (A4) in position on the tool. Pass adaptor through the cylinder head and put spacer and tool assembly in position on valve seat.
5
Put the new valve guide in position on the adaptor and install the distance piece PD.249 (A7). Install the attachment (A8) to secure the valve guide to the adaptor.
the the the the
Note: The internal recess in the valve guide must be towards the tool. 6
7
Hold the top handle (A1) and turn the bottom handle (A2) clockwise to pull in the valve guide until the distance piece touches the cylinder head.
A
PA065-1
When the valve guide is installed correctly, the top of the valve guide will have a protrusion of 7.7/7.9 mm (0.30/0.31 in) above the valve spring seat (B9).
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05
Alt= to hide template information Alt+ to display template information CYLINDER HEAD ASSEMBLY 12A-19
Cylinder head To inspect and to correct
12A-12
Caution: The bottom face of the cylinder head for the UB engine should not be machined. If it is, the edge of the pre-combustion chamber will be too thin and could break off during the combustion process. If the bottom face of the cylinder head is damaged or the distortion exceeds the service limits, the cylinder head assembly must be renewed. 1
Remove the cylinder head assembly, operation 12A-07.
2
Inspect the cylinder head for signs of gas or coolant leakage.
3
Remove the valve springs and the valves, operation 12A-08.
4
Clean the face of the cylinder head and the passages for coolant and for lubricating oil. The water jacket can be cleaned with a special solvent which must be used in accordance with the manufacturer's instructions.
5
Test the cylinder head for leaks at the pressure given in data and dimensions at the end of the section.
6
When the cylinder head is thoroughly clean, check it for cracks. Check carefully the areas around the valve seats, the holes for the atomiser nozzles and glow plugs (A2), and the port (A1) in the pre-combustion chambers. If there are cracks in these areas, the cylinder head assembly should be renewed.
7
The bottom face of the cylinder head for UA engines (only) can be machined if, there is distortion, deep scratches or the valve depths are below the service limit.
8
Use a straight edge and feeler gauges to check the cylinder head for distortion as shown in Data and dimensions at the end of section 12.
Bur 6-77740
Cautions: •
If the cylinder head of a UA engine has been machined, the maximum nozzle protrusion must not exceed 2.7 mm (0.11 in), when measured with the nozzle seat washer installed.
•
If the cylinder head has been machined, check the depth of each valve head, below the bottom, face of the cylinder head. If necessary, cut the valve seat to obtain the correct dimension, see Data and dimensions at the end of section 12. It is better to work to the minimum limit to allow for later wear.
•
Before any work is done on the valve seats, new valve guides must be installed, operation 12A-11.
•
If a new valve seat insert is to be installed, the back face must be surface ground to make sure that there is no protrusion above the bottom, face of the cylinder head, operation 12A-14.
9
Check the valve seats for wear and for damage.
10 Where there is little damage, the valve and valve seat can be lapped. When the valve seats are lapped, keep the seat as narrow as possible and make sure that all the compound used to lap the valve and the seat is removed. 11 More badly damaged valve seats can be corrected by use of the cutter tool, operation 12A-13, or new inserts can be installed, operation 12A-14.
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05 12A-20 CYLINDER HEAD ASSEMBLY To correct a valve seat with a valve seat cutter
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12A-13
Special tools: Valve seat cutting tool - kit, MS.76A. 1
Before any work is done on the valve seats, new valve guides must be installed, operation 12A-11.
2
Install the pilot (A3) in the valve guide and tighten the pilot.
3
Select the relevant cutter (A2). Set the blades of the cutters to the diameter of the valve seat to be cut. Install the cutter on the pilot and install the handle (A1). Make sure that the cutter is not allowed to fall on to the seat as this can damage the blades.
4
Carefully rotate the cutter in a clockwise direction (A4). Remove only the minimum material to make sure a good seat. Keep the seat as narrow as possible.
5
When the seat is cut, remove the cutter and the pilot. Remove any debris from the area of the valve seat and the port.
6
Install the valve and lightly lap the valve and the seat.
7
Check that the valve depth is within limits, see Data and dimensions at the end of this section.
Note: If a valve seat has become too damaged or too worn to correct, a valve seat insert can be installed, operation 12A-14.
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05 To install valve seat inserts
Alt= to hide template information Alt+ to display template information CYLINDER HEAD ASSEMBLY 12A-21 12A-14
8
Caution: A new valve guide must be installed to the cylinder head before a new valve seat insert is installed. This is necessary to maintain concentricity between the valve guide and the seat for the valve. Note: Cylinder heads that are installed with new valve seat inserts and new valve guides (pre-finished) are available.
- UA engines: 2.15/2.45 mm (0.085/0.096 in) - UB engines: 2.40/2.70 mm (0.090/0.110 in) The depth of the insert should be measured in two places, at 90°0 to each other. 9
1
Remove the valve guide and clean the bore into which the guide is to be installed.
2
Install new valve guides, operation 12A-11.
3
With the bore of the new valve guide used as a pilot, machine out the old valve seat insert. Remove ail debris and clean the recess for the insert.
Make sure that when installed, the bottom face of the insert is in contact with the bottom of the recess in the cylinder head. When installed correctly, the depth of the insert, below the bottom face of the cylinder head should be:
Cut the valve seat at 45° (an included angle of 90°) for the inlet and the exhaust valves (UA and UB engines), operation 12A-13. Make sure that the depth of the valve head below the face of the cylinder head is within the production limits, see Data and dimensions. Work as near as possible to the minimum figure to allow for future wear on the valve seat.
Caution: If the bottom face of the cylinder head has been machined, the depth of the recess for the valve seat may have changed. 4
Measure the depth of the recess in two places 90° apart. The correct depths are: - UA engines: 8.35/8.55 mm (0.329/0.337 in) - UB engines: 8.20/8.40 mm (0.320/0.330 in)
5
If the depth of the recess has been reduced, surface grind the bottom face of the insert by an equivalent amount. Check the depth of the insert and make sure that it is installed correctly.
6
If the insert has been surface ground, make sure that the outer edge of the back face of the insert has a 0.7/1.2 mm (0.03/0.05 in) chamfer at 30°±1° to the vertical.
7
With the bore of the valve guide used as a pilot, and with the rear face of the insert towards the cylinder head, press the insert into the recess with the valve seat insert tool, see Data and dimensions.
Caution: Do not use a hammer or use lubrication to install the insert. Use a hydraulic press or a hand press in one continuous movement.
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05 12A-22 CYLINDER HEAD ASSEMBLY
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Data and dimensions Note: This information is given as a guide for personnel engaged on engine overhauls. The dimensions which are shown are those which are mainly used in the factory. Unless it is indicated to be different, the data shown below is the same for both UA and UB engines.
Cylinder head assembly Angle of valve seat: - Inlet ......................................................................................................................... 45° (90° included angle) - Exhaust.................................................................................................................... 45° (90° included angle) Diameter of parent bores for valve guides ............................................. 12.000/12.027 mm (0.4724/0.4735 in) Leak test pressure........................................................................................... 200 kPa (29 lbf/in2) 2.0 kgf/cm2 Cylinder head thickness ................................................................................ 79.85/80.05 mm (3.148/3.151 in) Minimum permissible thickness after head face has been machined: - UA engines ...................................................................................................................... 79.8 mm (3.142 in) - UB engines ................ The cylinder head for this engine must not be machined, see caution on page 12A.17 Maximum protusion of the atomiser nozzle............................................................................. 2.7 mm (0.11 in) Valves guides Inside diameter ........................................................................................ 7.027/7.052 mm (0.2767/0.2776 in) Outside diameter ................................................................................... 12.034/12.047 mm (0.4738/0.4743 in) Interference install of guide in cylinder head..................................... - 0.007/- 0.047 mm (- 0.0003/- 0.0019 in) Length ................................................................................................................... 45.2/45.7 mm (1.78/1.80 in) Protusion above the valve spring seat ................................................................... 7.70/7.85 mm (0.30/0.31 in) Inlet valves Diameter of valve stem.............................................................................. 8.970/8.985 mm (0.2704/0.2750 in) Clearance install of valve guide ................................................................. 0.042/0.082 mm (0.0017/0.0032 in) Maximum permissible clearance in valve guide: ..............................................................0.107 mm (0.0042 in) Diameter of valve head - UA engine ........................................................................................................... 43.9/44.1 mm (1.73/1.74 in) - UB engine ........................................................................................................... 41.9/42.1 mm (1.65/1.66 in) Angle of valve face ......................................................................................................................................45° Depth of valve head below cylinder head face: - UA engine ............................................................................................... 0.306/0.806 mm (0.0120/0.0137 in) - UB engine ............................................................................................... 0.325/0.675 mm (0.0128/0.0266 in) Service limit: - UA engine ........................................................................................................................ 0.93 mm (0.037 in) - UB engine ........................................................................................................................ 0.72 mm (0.028 in) Overall length of valve........................................................................... 106.275/106.625 mm (4.184/4.197 in) Seal arrangement..................................................................................... Rubber seal installed to valve guide Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05
Alt= to hide template information Alt+ to display template information CYLINDER HEAD ASSEMBLY 12A-23
Exhaust valves Diameter of valve stem ............................................................................ 6.945/6.960 mm (0.2734/0.2740 in) Clearance install of valve in guide ............................................................ 0.067/0.107 mm (0.0026/0.0042 in) Maximum permissible clearance in valve guide .................................................................0.15 mm (0.0059 in) Diameter of valve head: - UA engine ......................................................................................................... 37.1/37.3 mm (1.46/1.47 in) - UB engine .......................................................................................................... 33.9/34.1 mm (1.33/1.34 in) Angle of valve face......................................................................................................................................45° Depth of valve head below cylinder head face: - UA engine ............................................................................................. 0.317/0.817 mm (0.0125/0.0322 in) - UB engine .............................................................................................. 0.425/0.775 mm (0.0165/0.0305 in) Service limit: - UA engine ....................................................................................................................... 0.94 mm (0.037 in) - UB engine ........................................................................................................................ 0.72 mm (0.028 in) Overall length of valve: - UA engine ...................................................................................... 106.125/106.475 mm (4.1781/4.1919 in) - UB engine ....................................................................................... 106.275/106.625 mm (4.1841/4.1978 in) Seal arrangement......................................................................................Rubber seal installed to valve guide Valve springs Installed length.................................................................................................................... 32.0 mm (1.26 in) Load at installed length ........................................................................ 375/415 N (84.4/93.2 lbf) 38.3/42.3 kgf Number of active coils ................................................................................................................................. 3.9 Direction of coils ............................................................................................................................... Left hand Tappets Diameter of tappet stem ....................................................................... 26.959/26.980 mm (1.0613/1.0622 in) Diameter of tappet bore in cylinder block .............................................. 27.000/27.021 mm (1.0631/1.0641 in) Clearance of tappet in cylinder block ......................................................... 0.020/0.062 mm (0.0008/0.0024 in) Rocker shaft Outside diameter.................................................................................. 21.962/21.987 mm (0.8646/0.8656 in) Rocker levers Bore diameter ...................................................................................... 22.013/22.051 mm (0.8667/0.8681 in) Clearance install on rocker shaft ............................................................... 0.026/0.084 mm (0.0010/0.0033 in) Maximum permissible clearance .....................................................................................0.124 mm (0.0048 in) Valve tip clearances (cold) ..................................................................................................0.35 mm (0.014 in)
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05 12A-24 CYLINDER HEAD ASSEMBLY
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Maximum permissible distortion of cylinder head (A) A1 . . . . . . . . . . . . . . . . . . . . . . 0.08 mm (0.003 in) A2 . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in) A3 . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in) AX . . . . . . . . . . . . . . . . . . . . . . . . . 40 mm (1.6 in) AY . . . . . . . . . . . . . . . . . . . . . . . . 106 mm (4.2 in) AZ . . . . . . . . . . . . . . . . . . . . . . . . 106 mm (4.2 in) Dimensions of a recess for valve seat inserts (B) Inlet - UA engines B1 . . . . . . . Radius 0.38 mm (0.015 in) maximum) B2 . . . . . . . . . . . . . . . . . . . . . . . . . . . 45째 chamfer B3 . . . . . . . . . . . . . . . 49.0/49.2 mm (1.93/1.94 in) B4 . . . . . . . 45.175/45.200 mm (1.7785/1.7795 in) B5 . . . . . . . . . . . . . 8.35/8.55 mm (0.329/0.337 in) Exhaust - UA engines B1 . . . . . . . Radius 0.38 mm (0.015 in) maximum) B2 . . . . . . . . . . . . . . . . . . . . . . . . . . . 45째 chamfer B3 . . . . . . . . . . . . . . . 42.5/42.3 mm (1.67/1.79 in) B4 . . . . . . . 38.475/38.500 mm (1.5148/1.5157 in) B5 . . . . . . . . . . . . . 8.35/8.55 mm (0.329/0.337 in) Inlet - UB engines B1 . . . . . . . Radius 0.38 mm (0.015 in) maximum) B2 . . . . . . . . . . . . . . . . . . . . . . . . . . . 45째 chamfer B3 . . . . . . . . . . . . . . . 46.9/47.1 mm (1.84/1.85 in) B4 . . . . . . . 43.325/43.350 mm (1.7057/1.7067 in) B5 . . . . . . . . . . . . . . . . . 8,2/8.4 mm (0.32/0.33 in) Exhaust - UB engines B1 . . . . . . . Radius 0.38 mm (0.015 in) maximum) B2 . . . . . . . . . . . . . . . . . . . . . . . . . . . 45째 chamfer B3 . . . . . . . . . . . . . . . 38.7/38.9 mm (1.52/1.53 in) B4 . . . . . . . 35.125/35.150 mm (1.3828/1.3838 in) B5 . . . . . . . . . . . . . . . . . 8.2/8.4 mm (0.32/0.33 in) Continued
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05
Alt= to hide template information Alt+ to display template information CYLINDER HEAD ASSEMBLY 12A-25
Dimensions for a valve seat insert tool (A) Inlet - UA engines A1 . . . . . . . . . . . . . . . . . . . . . . . .1.5 mm (0.06 in) A2 . . . . . . . . . . . . . . . . . . . . . . . .19.0 mm (0.7 in) A3 . . . . . . . . . . . . . . . . . . . . . . . .6.5 mm (0.26 in) A4 . . . . . . . . . . . . . . . . . . . . . . . . . 60 mm (2.4 in) A5 . . . . . . . . . . . 38.82/38.85 mm (1.528/1.529 in) A6 . . . . . . . . . . . . . . . 44.6/45.1 mm (1.76/1.78 in) A7 . . . . . . . . . . . . . . . . . . . . . . . .0.8 mm (0.03 in)
A
PA069
A8 . . . . . . . . . . . . . . . . . . . . . . . .1.5 mm (0.06 in) A9 . . . . . . . . . . . . . . . . . . . . . . . .1.5 mm (0.06 in) A10 . . . . . . . . . . . . 6.95/6.97 mm (0.273/0.274 in) Exhaust - UA engines
Exhaust - UB engines A1 . . . . . . . . . . . . . . . . . . . . . . . . 1.5 mm (0.06 in) A2 . . . . . . . . . . . . . . . . . . . . . . . . 19.0 mm (0.7 in)
A1 . . . . . . . . . . . . . . . . . . . . . . . .1.5 mm (0.06 in)
A3 . . . . . . . . . . . . . . . . . . . . . . . . 6.1 mm (0.26 in)
A2 . . . . . . . . . . . . . . . . . . . . . . . .19.0 mm (0.7 in)
A4 . . . . . . . . . . . . . . . . . . . . . . . . . 60 mm (2.4 in)
A3 . . . . . . . . . . . . . . . . . . . . . . . .6.5 mm (0.26 in)
A5 . . . . . . . . . . . 28.95/29.02 mm (1.139/1.143 in)
A4 . . . . . . . . . . . . . . . . . . . . . . . . . 60 mm (2.4 in)
A6 . . . . . . . . . . . . . 35.08/35.10 mm (1.38/1.88 in)
A5 . . . . . . . . . . . 31.42/31.45 mm (1.237/1.238 in)
A7 . . . . . . . . . . . . . . . . . . . . . . . 0.8 mm (0.031 in)
A6 . . . . . . . . . . . 38.43/38.45 mm (1.513/1.514 in)
A8 . . . . . . . . . . . . . . . . . . . . . . . . 1.5 mm (0.06 in)
A7 . . . . . . . . . . . . . . . . . . . . . . . 0.8 mm (0.031 in)
A9 . . . . . . . . . . . . . . . . . . . . . . . . 1.5 mm (0.06 in)
A8 . . . . . . . . . . . . . . . . . . . . . . . .1.5 mm (0.06 in)
A10 . . . . . . . . . . . . 6.95/6.97 mm (0.273/0.274 in)
A9 . . . . . . . . . . . . . . . . . . . . . . . .1.5 mm (0.06 in) A10 . . . . . . . . . . . . 6.95/6.97 mm (0.273/0.274 in) Inlet - UB engines A1 . . . . . . . . . . . . . . . . . . . . . . . .1.5 mm (0.06 in) A2 . . . . . . . . . . . . . . . . . . . . . . . .19.0 mm (0.7 in) A3 . . . . . . . . . . . . . . . . . . . . . . . .6.1 mm (0.26 in) A4 . . . . . . . . . . . . . . . . . . . . . . . . . 60 mm (2.4 in) A5 . . . . . . . . . . . . . 37.15/37.22 mm (146/1.47 in) A6 . . . . . . . . . . . 42.75/43.25 mm (1.683/1.703 in) A7 . . . . . . . . . . . . . . . . . . . . . . . .0.8 mm (0.03 in) A8 . . . . . . . . . . . . . . . . . . . . . . . .1.5 mm (0.06 in) A9 . . . . . . . . . . . . . . . . . . . . . . . .1.5 mm (0.06 in) A10 . . . . . . . . . . . . 6.95/6.97 mm (0.273/0.274 in)
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05 12A-26 CYLINDER HEAD ASSEMBLY
Bur 6-77740
Alt= to hide template information Alt+ to display template information
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05
Alt= to hide template information Alt+ to display template information PISTON AND CONNECTING ROD ASSEMBLY 13A-01
Piston and connecting rod assembly
13
General description ................................................................................................13A.02 Big end bearing 13A-01 To remove and to install............................................................................13A.03 13A-02 To inspect .................................................................................................13A.04 Piston and connecting rod assembly 13A-03 To remove and to install............................................................................13A.05 13A-03A To check the piston height above the cylinder block..................................13A.08 Piston rings 13A-04 To remove and to install............................................................................13A.09 Piston and connecting rod assembly 13A-05 To disassemble and to assemble .............................................................13A.10 13A-05A To renew...................................................................................................13A.11 13A-05B To check the length of a connecting rod....................................................13A.12 Piston and piston rings 13A-06 To inspect .................................................................................................13A.13 Connecting rod 13A-07 To inspect .................................................................................................13A.14 Small end bush 13A-08 To remove and to install............................................................................13A.14 Data and dimensions ..............................................................................................13A.15
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Alt= to hide template information Template Date: 1994_04_05 Alt+ to display template information 13A-02 PISTON AND CONNECTING ROD ASSEMBLY General description There are two types of piston used in the 700 Series engines. The UA engine, which has direct injection, has a combustion chamber (A1) in the top of the piston. This chamber is designed to give an efficient mix of fuel and air. The UB engine, which has indirect injection, has a piston with a different design (B1). This works with the pre-combustion chamber in the cylinder head to give an efficient mix of fuel and air. Both piston types have two compression rings and an oil control ring. The pistons and connecting rods are matched to the relevant cylinder. Axial location of the fully floating gudgeon pin is by two circlips. Caution: The big end bolts are installed to the connecting by a special process and must not be removed. If the bolts are removed, the connecting rod, and the bolts will be damaged. The connecting rods (C) are machined from "H" section forged molybdenum steel. The bearing cap is retained by two special bolts and flange face nuts. The big end bearings have a steel back and an aluminium / tin face. The small end bearings are a lead-bronze bush. In the factory, the correct piston height is obtained by the use of six lengths of connecting rod and one piston. The small end bush is machined eccentrically to obtain the different connecting rod lengths. In service, three pistons of different heights are supplied and one connecting rod. The small end bush is machined concentrically. Pistons with a larger diameter are also supplied, to be installed if the cylinder bores are bored oversize. See Data and dimensions at the end of this section, and section 16, Cylinder block assembly. Note: Always use the full engine number to order new parts.
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05
Alt= to hide template information Alt+ to display template information PISTON AND CONNECTING ROD ASSEMBLY 13A-03
Big end bearing To remove and to install
13A-01
Notes on connecting rods: •
The left side refers to the side of the engine when seen from the flywheel end.
•
The cylinder number (B1) is etched on the left side of the connecting rod and cap.
•
The letter that indicates the length grade for the connecting rod is also etched on the left side (B2).
•
The letter (B3) which is etched on the right side of the connecting rod is the manufacturers reference number.
•
The part number shown on the connecting rod should always be towards the front of the engine.
•
Location tags (A1) for the shell bearings will always be towards the right side of the engine.
To remove Cautions: •
Make sure that the bolts (A1) for the connecting rod do not damage the crank pin when the connecting rod is moved. If necessary, install a temporary plastic sleeve to the big end bolts.
•
The big end bolts are installed to the connecting by a special process and must not be removed. If the bolts are removed, the connecting rod, and the bolts will be damaged.
1
Drain the engine lubricating oil.
2
Remove the lubricating oil sump, operation 19A-03.
3
Remove the lubricating oil strainer and suction pipe, operation 19A-04.
4
Rotate the crankshaft until the relevant connecting rod is at its lowest position.
5
Release the nuts and remove the bearing cap.
6
Remove the lower half of the shell bearing from the cap, but keep it with its relevant cap.
Bur 6-77740
7
Carefully push the connecting rod up the cylinder bore just enough to allow access to the upper half of the shell bearing. Remove the bearing from the connecting rod. Keep the bearings from the connecting rod and cap together. Continued
Issued 11-04
Template Name: SM_2_col Alt= to hide template information Template Date: 1994_04_05 Alt+ to display template information 13A-04 PISTON AND CONNECTING ROD ASSEMBLY To install 1
Clean the bearing faces of the connecting rod and the crank pin.
2
Clean the upper half of the shell bearing and install it to the connecting rod; make sure that the location tag is installed correctly in its recess (A2). Lubricate the bearing surfaces with clean engine lubricating oil. Install the connecting rod to the crank pin; make sure that the assembly number (B1) and the letter for the length grade (B2) are on the correct side of the engine.
3
Clean the bearing face of the cap and the lower half of the shell bearing and install it into the cap; make sure that the location tag is installed correctly in its recess (A1). Lubricate the threads of the bolts.
4
Lubricate the bearing surfaces with clean engine lubricating oil and install the cap to the connecting rod. Make sure that the assembly number on the cap is the same as that on the connecting rod and that both of the assembly numbers are on the same side (B). Install the nuts and tighten them finger tight.
5
Tighten the nuts gradually and evenly to the recommended torque of 54 Nm (40 lbf ft) 5.5 kgf m.
6
After each connecting rod is tightened, make sure that the crankshaft rotates freely.
7
Install the lubricating oil strainer and suction pipe, operation 19A-04.
8
Install the lubricating oil sump, operation 19A-03 and fill the sump to the correct level with lubricating oil of an approved grade.
To inspect
13A-02
Check the bearings and the crank pin for wear or other damage.
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05
Alt= to hide template information Alt+ to display template information PISTON AND CONNECTING ROD ASSEMBLY 13A-05
Piston and connecting rod assembly To remove and to install
13A-03
Special tools: Piston ring compressor, N°. 8 Notes on connecting rods: •
The left side refers to the side of the engine when seen from the flywheel end.
•
The cylinder number (B1) is etched on the left side of the connecting rod and cap.
•
The letter that indicates the length grade for the connecting rod is also etched on the left side (B2). Some early engines had the length grade etched on the right side of the connecting rod and cap.
•
The letter (B3) which is etched on the right side of the connecting rod is the manufacturers reference number.
•
The part number shown on the connecting rod should always be towards the front of the engine.
•
Location tags (A1) for the shell bearings will always be on the right side of the engine.
To remove 1
Drain the lubricating oil.
2
Drain the cooling system, operation 21A-04.
3
Remove the cylinder head assembly, operation 12A-07.
4
Remove all carbon from the top of the cylinder bores.
5
Remove the lubricating oil sump, operation 19A-03.
6
Remove the lubricating oil strainer and suction pipe, operation 19A-04.
7
Cautions: • The big end bolts are installed to the connecting rod by a special process and must not be removed. If the bolts are removed, the connecting rod, and the bolts will be damaged. •
Make sure that the bolts (A1) for the connecting rod do not damage the crank pin when the connecting rod is removed or installed. If necessary, install a temporary plastic sleeve to the big end bolts.
•
The pistons and connecting rods are matched to the relevant cylinder. Note the position of each connecting rod and piston for correct assembly.
8
Push the piston and the connecting rod out through the top of the cylinder. Keep the bearings and caps together to make sure that they can be installed in their original positions.
9
Inspect the crank pins for damage.
Remove the big end caps and the big end bearings from the connecting rods, operation 13A-01.
Continued
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Alt= to hide template information Template Date: 1994_04_05 Alt+ to display template information 13A-06 PISTON AND CONNECTING ROD ASSEMBLY To install Caution: The correct piston height must be maintained in service to prevent damage to the pistons and valves, and make sure that the engine conforms to emissions legislation. 1
Make sure that the piston, the cylinder bore, the crank pin and the big end of the connecting rod are clean. Lubricate the piston and the cylinder liner with clean engine lubricating oil.
Note: Rotate the crankshaft counter-clockwise to make sure that the shell bearing in the big end remains in position. 2
Rotate the crankshaft until the relevant crank pin is at its highest position. Lubricate the crank pin with clean engine lubricating oil.
3
Install the upper half of the shell bearing to the connecting rod. Make sure that the location tag is installed correctly in its recess. Lubricate the bearing with clean engine lubricating oil. Lubricate the threads of the two bolts for the big end.
4
Put the piston ring gaps 120° apart. Lubricate the piston rings with clean engine lubricating oil. Install the tool (A1) to compress the piston rings.
Cautions: • Make sure that the bolts for the connecting rod do not damage the crank pin when the connecting rod is removed or installed. If necessary, install a temporary plastic sleeve to the big end bolts. •
Make sure that the piston and connecting rod assembly is installed to the same cylinder bore from which it was removed.
5
The arrows (B1/C1) must be towards the front of the engine. Install the piston and connecting rod assembly into the correct cylinder bore. In this position the combustion bowl / recess (B2/C2) will be towards the right side of the engine when seen from the rear.
6
Carefully push the piston through the piston ring compressor and check that the connecting rod is onto the crank pin.
7
Rotate the crankshaft counter-clockwise, when seen from the front, until the crank pin is at its lowest position. At the same time carefully apply pressure to the top of the piston with a suitable piece of wood or plastic. This will keep the big end in contact with the crank pin. Continued
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05
Alt= to hide template information Alt+ to display template information PISTON AND CONNECTING ROD ASSEMBLY 13A-07
8
Clean the connecting rod cap and the lower half of the shell bearings. Install the bearing to the cap; make sure that the location tag is installed correctly in its recess (A1). Lubricate the bearing with clean engine lubricating oil.
9
Install the cap and make sure that the assembly number and length grade letters are in the correct position, see notes, page 13A.05. Install the nuts and tighten them gradually and evenly to the recommended torque of 54 Nm (40 lbf ft) 5.5 kgf.
10 Check that the crankshaft will rotate freely. 11 Check the piston height above the top face of the cylinder block, operation 13A-03A. 12 Install the lubricating oil strainer and suction pipe, operation 19A-04. 13 Install the lubricating oil sump, operation 19A-03. 14 Install the cylinder head assembly, operation 12A-07. 15 Fill the sump to the correct level with lubricating oil of an approved grade. 16 Fill the cooling system, operation 21A-05.
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Alt= to hide template information Template Date: 1994_04_05 Alt+ to display template information 13A-08 PISTON AND CONNECTING ROD ASSEMBLY To check the piston height above the cylinder block
13A-03A
Special tools: Piston height tool, PD.41D Dial gauge for use with PD.41D, PD.208 Caution: The correct piston height must be maintained in service to prevent damage to the pistons and valves and make sure that the engine conforms to emissions legislation. 1
Put the piston height tool (A) on the face of the cylinder block and rotate the dial of the gauge to the zero position.
2
Rotate the crankshaft until the piston is just before top dead centre (TDC).
3
Carefully put the tool (A) over the top of the piston with the plunger of the gauge in contact with the piston above the axis of the gudgeon pin. Rotate the crankshaft to make sure that the piston is at the highest position and make a note of the gauge indication.
The piston height above the top face of the cylinder block should be 0.38/0.51 mm (0.015/0.020).
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05
Alt= to hide template information Alt+ to display template information PISTON AND CONNECTING ROD ASSEMBLY 13A-09
Piston rings To remove and to install
13A-04
The pistons used in the 700 Series engines have two compression rings and an oil control ring. All the piston rings are above the gudgeon pin. To make sure that the correct piston rings are obtained, always use the full engine number to order new parts. Note: The piston shown in (A) and (B) is for UA engines. Caution: Only expand the ring gaps enough to make sure that the ends of the rings do not damage the piston when the ring is removed or put into position.
.
To remove Remove the piston rings with a suitable ring expander. Keep the rings with their relevant piston. To install Use a suitable piston ring expander to install the piston rings. 1
2
Install the spring (A3) of the oil control ring in the bottom groove of the piston, with the latch pin (B1) inside both ends of the spring. Install the oil control ring over the spring. Make sure that the ring gap is at 1800 to the latch pin. The manufacturers symbol or the word 'TOP', must be towards the top of the piston.
4
Make sure that the ring gaps are 120° apart.
Install the cast iron ring with the taper face (A2) into the second groove of the piston. The manufacturers symbol or the word 'TOP', must be towards the top of the piston.
New rings for the second groove have a green identification mark which must be on the left of the ring gap when the ring is installed and the piston is upright. The second ring has a chamfer (A4) on the inner, bottom face. 3
Install the top ring, the manufacturers symbol or the word 'TOP', must be towards the top of the piston. New rings for the top groove have a red identification mark on the outer edge. This mark must be on the left of the ring gap when the ring is installed and the piston is upright. The top ring has a small curve on the outer face (A1).
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Alt= to hide template information Template Date: 1994_04_05 Alt+ to display template information 13A-10 PISTON AND CONNECTING ROD ASSEMBLY Piston and connecting rod assembly To disassemble and to assemble 13A-05 Caution: The big end bolts are installed to the connecting rod by a special process and must not be removed. If the bolts are removed, the connecting rod, and the bolts will be damaged. Note: The pistons and connecting rods are matched to the relevant cylinder. Note the position of each connecting rod and piston for correct assembly. To disassemble 1
Remove the piston rings, operation 13A-04.
2
Remove the circlips which retain the gudgeon pin.
3
Put a mark on the piston to indicate the cylinder number as shown on the connecting rod. Put the mark on the piston on the same side as the mark on the big end (A3) to make sure that they are assembled correctly.
4
Push the gudgeon pin out by hand. If the gudgeon pin is tight, heat the piston to 40/50 째C (100/120 째F) for easy removal of the gudgeon pin.
5
Install a new circlip in the groove in the other gudgeon pin boss. Make sure that it fits correctly in the groove.
6
Install the piston rings, operation 13A-04.
To assemble 1
Clean the bore of the small end bush and lubricate it with clean engine lubricating oil.
2
Install a new circlip in the circlip groove of one of the gudgeon pin bosses. Make sure that it fits correctly in the groove.
3
Install the connecting rod to the piston. The piston and connecting rod are correctly assembled when: the arrow (A4) is towards the front of the engine; the bowl / recess (A1) and the reference number (A2) are on the right side of the engine; the assembly number (A3) is on the left side of the engine (right side on some early engines).
4
Lubricate the gudgeon pin bosses with clean engine lubricating oil and push in the gudgeon pin towards the circlip. If the gudgeon pin is a tight install in the piston, heat the piston to 40/ 50째C (100/120째F) before the gudgeon pin is installed.
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05
Alt= to hide template information Alt+ to display template information PISTON AND CONNECTING ROD ASSEMBLY 13A-11
Piston and connecting rod assembly To renew
13A-05A
Caution: The big end bolts are installed to the connecting rod by a special process and must not be removed. If the bolts are removed, the connecting rod, and the bolts will be damaged. In service, pistons are supplied in three height grades, high, nominal and low. Identification is by a letter shown on the piston crown (A). H is for high and L is for low. The nominal grade (same as used in production) is not marked. Oversize pistons are identified in the same way. For details of oversize pistons, see Technical data. In service, only one length of connecting rod is supplied. They are identified by an X etched onto the side of the big end (B2). The manufacturers reference number will be on the right side (B3). These connecting rods are installed with a concentric small end bush. Small end bushes supplied loose also have a concentric bore. Note: If any of the components listed below are renewed and the correct piston height cannot be obtained, it may be necessary to install a new piston and / or new small end bush: - The connecting rod - The small end bush - The cylinder block - The crankshaft 1
Check the length grade of the original connecting rod and select the correct piston, operation 13A-05B.
Caution: The top of the piston must not be machined to obtain the correct height. 6
Check the piston height above the cylinder block, operation 13A-03A.
Caution: Do not use a letter stamp to mark the connecting rod. Note: If it is necessary, install a new small end bush, operation 13A-08. 3
Put the correct cylinder number (B1) onto the connecting rod.
Caution: If the original piston is used, make sure that it is assembled to the correct connecting rod and is used in the original cylinder. 4
Assemble the piston and connecting rod, operation 13A-05.
5
Install the piston and connecting rod assembly, operation 13A-03.
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Alt= to hide template information Template Date: 1994_04_05 Alt+ to display template information 13A-12 PISTON AND CONNECTING ROD ASSEMBLY To check the length of a connecting rod
13A-05B
Caution: The big end bolts are installed to the connecting rod by a special process and must not be removed. If the bolts are removed, the connecting rod, and the bolts will be damaged. Note: To make sure that the piston height above the cylinder block is correct in production, one of six different length grades of connecting rod is installed, see table opposite. If a connecting rod is renewed in service, an 'X’ grade (similar to grade 'D') is supplied and is installed with a concentric small end bush. Production grades are identified by a letter, etched onto the left side of the rod (right side on some early engines). If the grade letter on the side of the connecting rod cannot be seen, the length can be checked by the measurement of the dimension shown in (A). The dimensions for each grade are shown in the table opposite. Note: • Before the length of the connecting rod is measured, make sure that the large and small end bores are square and parallel, operation 13A-07. •
The dimension (A1) is measured from the inside face of the big end parent bore, to, the centre line of the small end bush. For accuracy, measure the dimension (A1) as close as possible to the connecting rod.
To select the correct piston •
If a new connecting rod or small end bush is fitted, use the table opposite to, select the correct piston.
•
If the piston is the only component to be renewed, the nominal grade must always be used.
Caution: All small end bushes supplied for service are concentric.
(1) Measured from centre line of gudgeon pin to piston crown (2) The nominal grade piston and the production grade piston have the same dimensions. Bur 6-77740
Connecting rod dimensions Grade
Length minimum / maximum mm (in)
A
132.08/132.11 (5.200/5.201)
B
132.05/132.08 (5.199/5.200)
C
132.02/132.05 (5.198/5.199)
D
131.99/132.02 (5.196/5.198)
E
131.96/131.99 (5.195/5.196)
F
131.93/131.96 (5.194/5.195)
X
131.99/132.02 (5.196/5.198)
Piston selection data Grade
Original connecting rod grades
H (high)
A and B
Nominal
C and D
L (low)
E and F
Piston dimensions Grade
Height (1) minimum / maximum
H
53.545/53.500 mm
H
2.1080/2.1063 in
Nominal (2)
53.455/53.500 mm
Nominal (2)
2.1045/2.1063 in
L
53.410/53.455 mm
L
2.1027/2.1045 in
X
131.99/132.02 (5.196/5.198) Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05
Alt= to hide template information Alt+ to display template information PISTON AND CONNECTING ROD ASSEMBLY 13A-13
Piston and piston ring To inspect
13A-06
1
Check the piston for wear and other damage.
2
Check that the piston rings are free to move in their grooves and that they are not broken.
3
Remove the piston rings, operation 13A-04, and clean the piston ring grooves and the piston rings.
4
Install new piston rings in the grooves in the piston and check for wear of the grooves with feeler gauges (A). Compare the piston ring clearance in the groove to that given for new components in Data and dimensions. Renew the piston, if the grooves are worn too much.
5
Clean all carbon from the top of the cylinder bores. Install each of the piston rings in the top part of the cylinder bore and measure the ring gap with feeler gauges (B).
6
The coil spring must be installed to the oil control ring when the gap of this piston ring is measured. The piston ring gaps for new and oversize components are given in Data and dimensions.
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Alt= to hide template information Template Date: 1994_04_05 Alt+ to display template information 13A-14 PISTON AND CONNECTING ROD ASSEMBLY Connecting rod To inspect
13A-07
Caution: The big end bolts are installed to the connecting rod by a special process and must not be removed. If the bolts are removed, the connecting rod, and the bolts will be damaged. 1
Check the connecting rod for distortion (A).
Note: The large and small end bores must be square and parallel with each other within the limits of +/- 0,20 mm (0.0007 in) measured 130 mm (5.1 in) each side of the connecting rod axis on a test mandrel. 2 3
Check the small end bush for wear or for other damage and renew it, if necessary. Check the install of the gudgeon pin in the small end bush and check the gudgeon pin for wear, see the Data and dimensions.
4
Ream the bush to get the correct clearance between the gudgeon pin and the bush, see the Data and dimensions.
Caution: Do not use a letter stamp to mark the connecting rod. 5
If necessary, renew the connecting rod, operation 13A-05A.
Remove the original grade mark for the connecting rod and etch an "X" instead to show that a service small end bush has been installed to the connecting rod.
.
Small end bush To remove and to install
13A-08
Notes: • The small end bush that is supplied for service has been machined concentrically. When it is installed to the connecting rod, the new length will become X, which is similar to production grade 'D'. •
Correct piston height must be maintained in service to prevent damage to the piston and the valves, and to make sure that the engine will conform to emissions legislation.
1
Press out the old bush with a suitable adaptor.
2
Clean the connecting rod bore and remove any sharp edges.
3
Press in the new bush. Make sure that the lubrication holes in the bush are aligned with the holes in the connecting rod.
Bur 6-77740
Issued 11-04
Template Name: SM_1_col Template Date: 1994_04_05
Alt= to hide template information Alt+ to display template information PISTON AND CONNECTING ROD ASSEMBLY 13A-15
Data and dimensions Note: This information is given as a guide for personnel engaged on engine overhauls. The dimensions which are shown are those which are mainly used in the factory. The information applies to all engines, unless an engine type code is shown. Pistons Type - UA engines ........................................................................................................ Re-entrant combustion bowl - UB engines ......................................................................................................Flat top with recess for valves Height of piston above top face of cylinder block ....................................... 0.386/0.511 mm (0.0152/0.0201 in) Diameter of bore for gudgeon pin .......................................................... 30.003/30.009 mm (1.1812/1.1814 in) Width of groove for top ring - UA engines ..................................................................................................... 2.06/2.08 mm (0.081/0.082 in) - UB engines ..................................................................................................... 2.08/2.10 mm (0.082/0.083 in) Width of groove for second ring......................................................................... 2.06/2.08 mm (0.081/0.082 in) Width of groove for third ring ............................................................................. 4.04/4.06 mm (0.159/0.160 in) Service height grades ..................................................................... H, Nominal / Production (no marks) and L Oversize piston ........................................................................................... 0.5 mm (0.020 in) on the diameter Piston rings Top compression ring................................................................................................. Chromium / barrel faced Second compression ring ............................................................................................Taper face, barrel faced Oil control ring........................................................................................... Coil spring loaded, chromium faced Width of top ring ................................................................................................ 1.97/1.99 mm (0.077/0.078 in) Width of second ring ......................................................................................... 1.97/1.99 mm (0.077/0.078 in) Width of third ring .............................................................................................. 3.97/3.99 mm (0.156/0.157 in) Clearance of top ring in groove - UA engines ..................................................................................................... 0.07/0.11 mm (0.003/0.004 in) - UB engines ..................................................................................................... 0.003/0.005 mm (0.09/0.13 in) Clearance of second ring in groove ................................................................... 0.07/0.11 mm (0.003/0.004 in) Clearance of third ring in groove ....................................................................... 0.05/0.09 mm (0.002/0.004 in) Gap of top ring ................................................................................................... 0.20/0.48 mm(0.008/0.019 in) Gap of second ring ............................................................................................ 0.30/0.63 mm (0.012/0.025 in) Gap of third ring ................................................................................................ 0.20/0.48 mm (0.008/0.019 in) Continued
Bur 6-77740
Issued 11-04
Template Name: SM_1_col Alt= to hide template information Template Date: 1994_04_05 Alt+ to display template information 13A-16 PISTON AND CONNECTING ROD ASSEMBLY Connecting rods Type ................................................................................................................................................ 'H' section Diameter of parent bore for big end........................................................56.000/56.015 mm (2.2047/2.2053 in) Diameter of parent bore for small end ....................................................32.930/32.955 mm (1.2964/1.2974 in) Length between centres (parent bores) ..............................................159.975/160.025 mm (6.2982/6.3002 in) Length grades .............................................................................................................. see operation 13A-05B Big end bearings Type ............................................................................................................... Steel back, aluminium / tin face Width ............................................................................................................ 22.87/23.13 mm (0.900/0.911 in) Clearance on big end ................................................................................ 0.018/0.064 mm (0.0007/0.0025 in) Thickness at centre of bearings ................................................................ 1.500/1.506 mm (0.0591/0.0593 in) Available undersize bearings ........................................................................................... -0.25 mm (-0.010 in) ........................................................................................................................................ -0.51 mm (-0.020 in) ........................................................................................................................................ -0.76 mm (-0.030 in) Gudgeon pins Type ............................................................................................................................................ Fully floating Outside diameter....................................................................................29.995/30.000 mm (1.1809/1.1811 in) Clearance install in piston boss ................................................................. 0.003/0.014 mm (0.0001/0.0006 in) Small end bushes Type .................................................................................................................... Steel back, lead bronze face Inside diameter (reamed) .......................................................................30.012/30.025 mm (1.1816/1.1821 in) Clearance install on gudgeon pin ...........................................................0.008/0.023 mm (0.00031/0.00091 in)
Bur 6-77740
Issued 11-04
Template Name: SM_1_col Template Date: 1994_04_05
Alt= to hide template information Alt+ to display template information PISTON AND CONNECTING ROD ASSEMBLY 13A-17
Piston pins Production: Type............................................................................................................................................. Fully floating Outside diameter................................................................................... 39.694/39.700 mm (1.5628/1.5630 in) Clearance install in piston boss ................................................................. 0.003/0.015 mm (0.0001/0.0006 in) Piston end bushings Type............................................................................................Steel back, lead bronze tin bearing materials Outside diameter....................................................................................... 43.11/43.15 mm (1.6972/1.6988 in) Inside diameter (reamed) ...................................................................... 39.723/39.738 mm (1.5638/1.5645 in) Surface finish grade .......................................................................................................... Ra 0.8 micrometers Clearance between bushing in piston end and piston pin .......................... 0.023/0.044 mm (0.0009/0.0017 in)
Bur 6-77740
Issued 11-04
Template Name: SM_1_col Alt= to hide template information Template Date: 1994_04_05 Alt+ to display template information 13A-18 PISTON AND CONNECTING ROD ASSEMBLY
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05
Crankshaft assembly
Alt= to hide template information Alt+ to display template information CRANKSHAFT ASSEMBLY 14A-01
14
General description ................................................................................................14A.02 Crankshaft pulley 14A-01 To remove and to install ............................................................................14A.03 14A-01A To install a wear sleeve.............................................................................14A.04 Rear oil seal 14A-02
To remove and to install ...........................................................................14A.05
Thrust washers 14A-04 14A-05
To check crankshaft end-float ...................................................................14A.06 To remove and to install ............................................................................14A.06
Main bearings 14A-06 14A-07
To remove and to install (with the crankshaft in position) ..........................14A.08 To inspect .................................................................................................14A.09
Crankshaft 14A-08 14A-09 14A-14 14A-10A
To To To To
remove and to install ............................................................................14A.10 inspect .................................................................................................14A.14 install a wear sleeve.............................................................................14A.14 overhaul ...............................................................................................14A.14
Data and dimensions ..............................................................................................14A.16
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05 14A-02 CRANKSHAFT ASSEMBLY
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General description The induction hardened crankshaft is a forging of alloy steel and has five main bearing journals. The crankshaft rotates in five pre-finished shell bearings which have a steel back and an aluminium / tin face. The shell bearings are held in position by tags which install into recesses machined in the bearing housing and the bearing caps. The end-float of the crankshaft is controlled by two half thrust washers, installed into the cylinder block, either side of number four main bearing housing. The crankshaft webs are drilled to give full rotation balance. To seal the crankshaft pulley and the palm of crankshaft, Viton seals are installed in the timing case and in the rear faces of the cylinder block / housing for the rear main bearing. The seals include a dust lip to the outside of the main lip and oil return grooves on the face of the main lip. Warning! Read the safety precautions for "Viton" seals on page 10A.07. For location, the crankshaft pulley is installed to the nose of the crankshaft with a single key and is retained by a plain washer and setscrew.
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05
Alt= to hide template information Alt+ to display template information CRANKSHAFT ASSEMBLY 14A-03
Crankshaft pulley To remove and to install
14A-01
To remove 1
Remove the drive belt.
2
Lock the crankshaft to prevent its counter clockwise movement.
3
Release the setscrew (A2) which retains the pulley and remove the setscrew and the thick washer (A1). Remove the pulley.
Caution: Remove the device used to lock the crankshaft. 4
Clean the components and check for damage. Renew damaged components.
Note: If the surface for the oil seal is damaged or there is a deep groove that has been caused by the seal, it may be possible to install a wear sleeve to the pulley, operation 14A-01A. To install 1
Lubricate the main lip of the seal with clean engine oil.
2
Install the pulley onto the key (B1) in the crankshaft nose.
3
Lubricate lightly the threads of the setscrews with engine lubricating oil. Install the thick washer (A1) to the setscrew (A2) and install the setscrew finger tight.
4
Lock the crankshaft to prevent its clockwise movement.
5
Tighten the setscrew to 185 Nm (l 36 lbf ft) 19.0 kgf m
Caution: Remove the device used to lock the crankshaft. 6
Install the drive belt.
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05 14A-04 CRANKSHAFT ASSEMBLY To install a wear sleeve
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14A-01A
Note: It is not possible to install a wear sleeve to the type of pulley shown (A). If the surface on this pulley is damaged or there is a deep groove that has been caused by the oil seal, the pulley will have to be renewed. If the pulley installed to the engine is the type shown in (B), then a wear sleeve can be installed. To install With the pulley removed, carefully install the wear sleeve (C1) in accordance with the manufacturers instructions (supplied with the sleeve). Make sure that the sleeve (C1) is installed correctly (D1) to the pulley.
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05
Alt= to hide template information Alt+ to display template information CRANKSHAFT ASSEMBLY 14A-05
Rear oil seal To remove and to install
14A-02
Special tools: Replacer tool for the rear oil seal, PD.255 To remove: 1
Remove the drive components from the rear end of the engine.
2
Remove the starter motor
3
Remove the flywheel and the flywheel housing, see section 22.
Caution: When the screws are installed to the seal, do not damage the crankshaft palm or the recess for the oil seal. 4
Install two small self-tapping screws and flat washers (A3) into the front face of the oil seal (A1).
Note: Install the screws 180° apart. 5
Use suitable levers (A2) and remove the seal.
To install 1
2
Clean the crank palm and the recess for the oil seal and inspect them both for damage and wear. If there is a deep groove in the crankshaft palm that has been caused by the oil seal, it may be necessary to install a wear sleeve to the palm of the crankshaft, operation 14A-10A.
Note: The seal will be installed correctly when it protrudes 1.5 mm (0.06 in) (132) from the rear face of the cylinder block / bearing cap. 4
Remove any excess oil from the seal and crank palm.
Lubricate the lip of the oil seal with clean engine lubricating oil. Carefully install the seal over the crank palm and up to the rear face of the recess.
Note: Lubrication of the seal is necessary to prevent damage to the lip of the seal when the engine is first started. Caution: Do not damage the crank palm when the seal is installed. 3
With tool number PD.255 (A1), install the new oil seal into the recess.
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05 14A-06 CRANKSHAFT ASSEMBLY
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Thrust washers To check crankshaft end-float
14A-04
The end-float of the crankshaft is controlled by two half thrust washers, installed into the cylinder block (A1), either side of number four main bearing housing. The end-float can be checked with a feeler gauge (A2) between a thrust washer and the crankshaft or by the use of a dial test indicator (B1) on one end of the crankshaft. If the end-float is more than the tolerance allowed, oversize thrust washers are available to, reduce the end float.
To remove and to install
14A-05
To remove The thrust washers install in recesses machined into the cylinder block (A1) each side of number four main bearing cap. Make sure that the correct size thrust washers are installed. 1
Remove the flywheel and flywheel housing, see section 22.
2
Drain the lubricating oil and remove the lubricating oil sump, operation 19A-03.
3
Release the two setscrews which retain number four main bearing cap. Remove the setscrews and carefully remove the bearing cap. Make sure that the shell bearing remains installed correctly to the cap and is kept clean.
Caution: If the crankshaft is rotated, the shell bearing in the cylinder block may be pulled into an incorrect position. 4
Remove the two thrust washers (A1). Use of a suitable piece of plastic (A2) to push them out. continued
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05
Alt= to hide template information Alt+ to display template information CRANKSHAFT ASSEMBLY 14A-07
To install 1
Lightly lubricate the two thrust washers with clean lubricating oil. Push (A2) each thrust washer into position in the recess (A1) on each side of the main bearing housing. The oil grooves (B1) in the thrust washers must be towards the crankshaft web.
2
Inspect the main bearing setscrews for damage or distortion, renew them if necessary.
3
Make sure that the shell bearing is installed correctly in the cylinder block.
4
Lubricate the bearing in the cap with clean engine lubricating oil and put the bearing cap into position.
5
Lightly lubricate the setscrew threads with clean engine lubricating oil. Install the setscrews and tighten them gradually and evenly to 147 Nm (108 lbf ft) 15.0 kgf m. Rotate the crankshaft and check the end-float, see operation 14A-04.
6
Install the sump, operation 19A-03. Fill the sump to the correct level with an approved lubricating oil.
7
Install the flywheel housing and the flywheel, see section 22.
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05 14A-08 CRANKSHAFT ASSEMBLY
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Main bearings To remove and to install (with the crankshaft in position)
14A-06
Special tool: Seal replacer tool, PD.243 Consumable products: Produit Loctite Silicone adhesive Note: The front and rear, bearing caps are installed to the cylinder block with special seals, see page 14A.13.
5
To remove the second or third bearing cap, remove the suction pipe from the cylinder block, operation 19A-04. Release the setscrews of the bearing cap and remove the bearing cap. Remove the lower half of the shell bearing from the cap.
6
Use a suitable tool (A1) to push the upper half of the shell bearing from the side opposite to the location tag. Carefully rotate the crankshaft to release the bearing from its housing. Keep the bearing halves in their relevant positions.
To remove 1
Drain the lubricating oil and remove the sump, operation 19A-03.
2
If the front main bearing cap is to be removed, proceed as follows:
-
Remove the timing case and backplate, section 15.
3
Release the setscrews of the front bearing cap and remove the bearing cap. Remove the lower half of the shell bearing from the cap.
4
If the rear main bearing cap is to be removed, proceed as follows:
-
Remove the flywheel and the flywheel housing, see section 22.
-
Release the setscrews of the bearing cap and remove the bearing cap. Remove the lower half of the shell bearing from the cap.
continued
Notes: •
The rear bearing cap provides half of the recess for the rear oil seal. When the cap is removed, remove the seal and check for wear, renew if necessary, operation 14A-02.
•
The procedure to remove number four cap is the same as for numbers two and three except that It will not be necessary to remove the suction pipe. Make sure also that the thrust washers remain in position.
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05
Alt= to hide template information Alt+ to display template information CRANKSHAFT ASSEMBLY 14A-09
To install Caution: The shell bearings (A1) which do not have an oil hole must only be installed to the cap. If they are fitted to the cylinder block, the bearing will not receive lubricating oil and cause a seizure of crankshaft and bearings 1
Clean the upper half of the shell bearing and lubricate the bearing surface with clean engine lubricating oil.
2
Put the bearing (with the oil hole) onto the journal and slide the plain end around between the journal and the cylinder block until the tag is installed correctly into the recess (A3).
3
10 Install the flywheel housing and the flywheel, see section 22.
Clean the lower half of the bearing and the bearing cap, lubricate the bearing surface with clean engine lubricating oil.
To inspect
4
Install the bearing into the cap with the tag of the bearing installed correctly in the recess (A2) in the cap.
Inspect the bearings for wear and for other damage. If a bearing is worn or damaged, replace both half of the shell bearings and check the condition of the other bearings.
5
Install the bearing cap with the location tags of both bearings on the same side.
6
Inspect the setscrews for damage and for distortion and renew them if necessary. Lightly lubricate the setscrew threads with clean engine lubricating oil. Install the setscrews and tighten them gradually and evenly to 147 Nm (108 lbf ft) 15.0 kgf m.
7
After each cap is tightened, make sure that the crankshaft turns freely. If the thrust washers have been removed and installed, check the crankshaft end float, operation 14A-04.
8 •
If the front or rear main bearings were removed: Install the special seals to the front and rear bearing caps, see page 14A.13 Install the rear oil seal, operation 14A-02 Check the alignment of the bearing caps with the faces of the block, page 14A.12 Install the backplate for the timing case assembly, operation 15A-09 Install the timing case assembly, operation 15A-01
• • • • 9
14A-07
Install the lubricating oil sump, operation 19A-03. Fill the sump to the correct level with an approved lubricating oil.
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05 14A-10 CRANKSHAFT ASSEMBLY
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Crankshaft To remove and to install
14A-08
Consumable products: Produit Loctite Silicone adhesive Special tools: Seal replacer tool, PD.243 Warning! Use lift equipment or obtain assistance to lift heavy engine components such as the flywheel, the flywheel housing and the crankshaft. To remove Note: New Holland recommends, for safety reasons, that this operation is done with the engine upside down. This will ensure that the crankshaft can be lifted out and that the pistons will be retained in the cylinder bores. 1
Drain the lubricating oil.
2
Drain the cooling system, operation 21A-04.
3
Remove the fan and the drive belt.
4
Remove 14A-01.
the
crankshaft
pulley,
operation
5
Remove the timing case, operation 15A-01.
6
Remove the idler gear, operation 15A-03.
7
Remove the starter motor.
8
Remove the flywheel and the flywheel housing, see section 22.
9
oil
suction
12 Release and remove the setscrews for the main bearing caps. Remove the main bearing caps together with the lower halves of the shell bearings. Keep the bearings with the relevant caps. Note: When the rear cap is removed, the rear oil seal will be exposed and should be removed. 13 Remove the thrust washers.
Remove the lubricating oil sump, operation 19A-03.
10 Remove the lubricating operation 19A-04.
Note: Numbers two, three and four main bearing caps have an arrow and number (A2) on the top to indicate front and sequence. The front and rear caps because of their shape, are easy to identify. The rear cap (A1) has no marks and the front cap (A3) has a number only.
14 Lift out the crankshaft. Remove the upper halves of the bearings and keep them with the relevant caps. Note: If the main bearings are to be used again, they must be installed in the same positions from which they were removed. The rear oil seal should be renewed.
pipe, continued
11 Release and remove the nuts of the connecting rods. Remove the big end bearing caps and keep the bearings with the relevant caps, operation 13A-01.
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05
Alt= to hide template information Alt+ to display template information CRANKSHAFT ASSEMBLY 14A-11
To Install Caution: The shell bearings (A1) which do not have an oil hole must only be installed to the bearing cap. If they are installed to the cylinder block, the bearing will not receive lubricating oil which will cause a seizure of crankshaft and bearings 1
Make sure that all lubricating oil passages in the crankshaft and cylinder block are clean and free from restriction.
2
Clean the main bearing housings and the upper halves of the shell bearings. Install the bearings to the cylinder block. Make sure that the location tags are correctly installed into, the recesses (A3). Lubricate the bearings with clean engine lubricating oil.
3
Make sure that the main journals of the crankshaft are clean. Carefully put the crankshaft into position on the upper bearings.
4
Clean and lubricate the thrust washers. Slide them into the recesses in the cylinder block either side of number four journal. The grooves in the thrust washers must be towards the crankshaft (B1).
5
Clean the bearing caps and the lower half of the bearings. Install the bearings to the caps with the location tags installed correctly in their recesses (A2). Lubricate the bearings with clean engine lubricating oil.
6
Apply a small amount of silicone adhesive to the corners of the cylinder block (C) for the rear main bearing cap.
continued
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05 14A-12 CRANKSHAFT ASSEMBLY
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Note: Numbers two, three and four main bearing caps have an arrow and number (A2) on the top to indicate front and sequence. The front and rear caps because of their shape, are easy to identify. The rear cap (A1) has no marks and the front cap (A3) has a number only. 7
Put the bearing caps in their correct positions.
8
Check the main bearing setscrews for distortion and thread damage and renew them as necessary. Make sure that only the correct setscrews are used.
Note: Before the front and rear bearing caps are fully tightened, use a straight edge (B) to check their alignment with the front / rear faces of the cylinder block. 9
Install the setscrews to the main bearing caps and tighten them gradually and evenly to 147 Nm (108 1 lbf ft) 15.0 kgf m.
10 After each cap is tightened, make sure that the crankshaft is free to rotate. Caution: After the rear cap has been tightened, it is important to remove any sealant from inside the recess for the rear oil seal. If this is not done, the oil seal will not install correctly and will cause oil leakage. 11 Install the connecting rods and caps, operation 13A-01. 12 After each cap is tightened, make sure that the crankshaft is free to rotate.
continued
Bur 6-77740
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Template Name: SM_2_col Template Date: 1994_04_05
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Cautions: • The seals for the front and rear bearing caps have a curve at one end (A1) which must be installed towards the side of the engine (A2,) and with the curve inserted first into the hole. • The seals have a soft metal insert. Be careful not to bend the seal when it is first inserted into the hole. 13 Inject a small quantity of sealant (A4) into the holes for the seals, each side of the front and rear main bearing caps. 14 Install the seals initially by hand (A3) and push, approximately 30% of the seal into the hole. 15 Slide the tool PD.243, over each seal (B2) and press the seals fully into their holes (B1). 16 Use a small drift (C1) to push the seal below the surface of the cap until a resistance is felt; the seal is now installed to the bottom of the hole. Remove any excess sealant from around the holes. 17 Install the two smaller seals to the holes (D), in the front main bearing cap. 18 Install the lubricating oil suction pipe and strainer, see section 19. Install the lubricating oil sump, operation 19A-03. 19 Install the rear oil seal, operation 14A-02. 20 Install the flywheel housing and the flywheel, see section 22. 21 Install the starter motor. 22 Install the backpIate for the timing case assembly, operation 15A-09. 23 Install the timing case assembly, operation 15A-01. 24 Install the crankshaft pulley, operation 14A-01. 25 Install the drive belt, operation 23A-03 and the fan, operation 21A-04. 26 Fill the lubricating oil sump to the correct level with an approved oil. 27 Fill the cooling system, operation 21A-05.
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05 14A-14 CRANKSHAFT ASSEMBLY To inspect
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14A-09
Check the crankshaft for wear and other damage. The maximum permissible wear and ovality on the crankshaft journals and crank pins is 0.04 mm (0.0016 in). The main journals and the crank pins of standard size crankshafts can be machined to 0.25 mm (0.010 in), 0.50 mm (0.020 in) or 0.75 mm (0.030 in) undersize on diameter, see data and dimensions at the end of this section. Special undersize bearings are available. If the seal position on the crankshaft palm is worn, a wear sleeve can be installed to the palm, operation 14A-10A.
To install a wear sleeve
The heat treatment is induction hardened
14A-10
To install 1
Remove the crankshaft, operation 14A-08.
2
Install the wear sleeve (A2), in accordance with the manufacturer's instructions, supplied with the sleeve. Make sure that the sleeve (A2) is installed to the crank palm (A4) to a dimension (A3) of 12.0 mm (0.47 in).
Note: Induction hardened crankshafts need not be hardened after they have been machined undersize. continued
Caution: After the sleeve has been installed, the curved part (A1) which is used to install the sleeve, must be removed. If this is not done, when the crankshaft is installed, the sleeve will be in contact with the cylinder block. When the engine is started, the sleeve, the cylinder block and the oil seal will be damaged.
Crankshaft overhaul
14A-10A
Notes: • Check the crankshaft for cracks before and after it is ground. Demagnetize the crankshaft after it has been checked for cracks. • After the crankshaft has been machined, remove any sharp corners from the lubricating oil holes. • Surface finish and fillet radii must be maintained. • Further information can be found in data and dimensions at the end of this section. Caution: After the crankshaft has been overhauled, it must be thoroughly cleaned and the oil holes inspected for debris. Crankshaft heat treatment: Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05
Alt= to hide template information Alt+ to display template information CRANKSHAFT ASSEMBLY 14A-15
Crankshaft overhaul The finished sizes for crankshaft journals (A) which have been ground undersize are given in the table below: item
0.25 mm (0.010 in)
0.50 mm (0.020 in)
0.75 mm (0.030 in)
1
64.70/64,72 mm (2.547/2.548 in)
64.45/64.47 mm (2.537/2.538 in)
64.20/64.22 mm (2.527/2.528 in)
2
52.70/52.72 mm (2.075/2.076 in)
52.45/52.47 mm (2.065/2.066 in)
52.20/52.22 mm (2.055/2.056 in)
3
33.00/33.04 mm (1.299/1.300 in)
-
-
4
32.80/34.20 mm (1.290/1.350 in)
-
-
5
32.95/33.05 mm (1.297/1.301 in)
-
-
6
30.05/32.95 mm (1.183/1.297 in)
-
-
7
94.965/95.000 mm (3.7837/3.7401 in)
-
-
8
3.30/3.70 mm (0.30/0.14 in)
-
-
Note: The surface finish for the journals, the crank pins and the fillet radii must be 0.4 microns (16 micro inches). The surface finish for the seal area of crankshaft palm must be 0.4/1.1 microns (16/43 micro inches).
Continued
Bur 6-77740
Issued 11-04
Template Name: SM_1_col Template Date: 1994_04_05 14A-16 CRANKSHAFT ASSEMBLY
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Data and dimensions Introduction Note: This information is given as a guide for personnel engaged on engine overhauls. The dimensions which are shown are those which are mainly used in the factory. Crankshaft Diameter of main journals................................................................................64.951/64.970 mm (2.5571/2.5578 in) Maximum wear and ovality on journals and crank pins ...............................................................0.04 mm (0.0016 in) Width of front journal ...................................................................................................32.80/34.20 mm (1.29/1.35 in) Width of number four journal ...................................................................................32.95/33.05 mm (1.299/1.300 in) Width of all other journals ........................................................................................32.95/33.05 mm (1.297/1.301 in) Diameter of crank pins.............................................................................................52.95/52.97 mm (2.085/2.085 in) Width of crank pins ..................................................................................................30.05/32.95 mm (1.183/1.297 in) Diameter of crankshaft palm............................................................................94.965/95.000 mm (3.7837/3.7401 in) Depth of recess for spigot bearing...................................................................................11.6/12.6 mm (0.46/0.50 in) Bore of recess for spigot bearing.....................................................................40.000/40.025 mm (1.5748/1.5757 in) Crankshaft end-float ............................................................................................0.040/0.275 mm (0.0015/0.0108 in) Maximum permissible end-float.................................................................................................0.405 mm (0.0159 in) Fillet radii of journals and crank pins ...................................................................................3.3/3.7 mm (0.13/0.14 in) Undersize journals and crank pins ............................................................................................. - 0.25 mm (0.010 in) .................................................................................................................................................... - 0.50 mm (0.020 in) .................................................................................................................................................... - 0.70 mm (0.030 in) Crankshaft heat treatment ...................................................................................................................................................... Induction hardened Crankshaft run-out With the crankshaft on mountings at the front and rear journals, the maximum run-out (total indicator reading) at the journals must not be more than shown below. Run-out must not be opposite. The difference in run-out between one journal and the next, must not be more than 0.10 mm (0.004 in).
Bur 6-77740
Journal
Crankshaft
1
Mounting
2
0.08 mm (0.003 in)
3
0.15 mm (0.006 in)
4
0.08 mm (0.003 in)
5
Mounting
Issued 11-04
Template Name: SM_1_col Template Date: 1994_04_05
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Main bearings Type........................................................................................................................... Steel back, aluminium / tin face Width of bearing ..........................................................................................................25.70/26.00 mm (1.01/1.02 in) Thickness at centre of bearing ............................................................................1.993/1.999 mm (0.0784/0.0787 in) Clearance between bearing and journal..............................................................0.032/0.092 mm (0.0013/0.0036 in) Available undersize bearings...................................................................................................... - 0.25 mm (0.010 in) .................................................................................................................................................... - 0.50 mm (0.020 in) .................................................................................................................................................... - 0.75 mm (0.030 in) Main bearings Type.......................................................................................................... Steel back, lead / bronze bearing material Position.......................................................................In cylinder block only, each side of number four main bearing Thickness .................................................................................................................................................................... - Standard..................................................................................................................................2.38/2.44 mm (0.0 in) - Oversize ....................................................................................................................2.58/2.64 mm (0.102/0.104 in)
Bur 6-77740
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Template Name: SM_1_col Template Date: 1994_04_05 14A-18 CRANKSHAFT ASSEMBLY
Bur 6-77740
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Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05
Alt= to hide template information Alt+ to display template information TIMING CASE AND DRIVE ASSEMBLY 15A-01
Timing case and drive assembly
15
General description ................................................................................................15A.02 Timing case 15A-01 To remove and to install ...........................................................................15A.03 15A-01A to renew ...................................................................................................15A.05 Front oil seal 15A-02
To remove and to install ...........................................................................15A.06
Idler gear 15A-03 15A-04
To remove and to install ...........................................................................15A.07 To renew the bushes for the idler gear .....................................................15A.08
Idler gear hub 15A-05
To remove and to install ...........................................................................15A.09
Camshaft assembly for the fuel injection pump 15A-06
To remove and to install ...........................................................................15A.10
Camshaft assembly and tappets for the valves 15A-07
To remove and to install ...........................................................................15A.12
Crankshaft gear 15A-08
To remove and to install ...........................................................................15A.14
Backplate for the timing case 15A-09
To remove and to install ...........................................................................15A.15
Data and dimensions ..............................................................................................15A.16
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05 15A-02 TIMING CASE AND DRIVE ASSEMBLY
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General description The aluminium timing case assembly contains: the oil seal (A2) for the crankshaft pulley; the support bush (A1) for the camshaft gear; the lubricating oil pump assembly (A5); the lubricating oil relief valve assembly (A6); the adjustment screw (A4) to set the maximum fuel position; and the fuel injection pump linkage (A3). The governor weight assembly (B5) is installed to the front of the gear for the fuel injection pump. The timing case assembly also covers the hardened steel timing gears that have helical teeth to reduce noise. The drive from the crankshaft gear (B4), passes through the idler gear (B2) to the gear (B3) for the camshaft for the valves and the gear (B1) for the camshaft for the fuel injection pump. It also passes to the gear that drives the lubricating oil pump (A5). A gear for a power take-off can be driven from the gear (B3). The camshafts for the valves and the fuel injection pump both rotate at half the speed of the crankshaft gear. The camshaft for the fuel injection pump is made from steel with induction hardened cams. Generally, the camshaft for the valves is made of cast iron with chill-hardened cams. If the engine is installed with a high-rated power take-off, a camshaft is used that has a steel nose. The oil seal (A2) which is made of Viton, operates on the spigot of the crankshaft pulley. The seal has a dust lip which protrudes from the front of the seal. This lip protects the main lip of the oil seal. Warning! Read the safety precautions for "Viton" seals in section 10 .
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05
Alt= to hide template information Alt+ to display template information TIMING CASE AND DRIVE ASSEMBLY 15A-03
Timing case To remove and to install
15A-01
To remove 1
Disconnect the battery.
2
Release the fasteners and remove the drive belt and the alternator, section 23A.
3
If one is installed, remove the fan, operation 21A-03.
4
Remove 14A-01.
5
If one is installed, remove the auxiliary drive assembly, operation 24A-01.
6
Record the maximum fuel position of the fuel control rack, 20A-11.
7
Disconnect the link (A1) for the governor control, operation 20A-06.
8
Clean around the edge of the joint face of the timing case assembly. If this is not done, dirt may fall onto the timing gears when the timing case assembly is removed.
the
crankshaft
pulley,
operation
Caution: The maximum fuel setting will be affected if: a sealant is used on the joint faces of the timing case or backplate; the joint faces are damaged when the old joint is removed. 9
Remove the setscrews for the timing case assembly. Note the position of the setscrews as they are of different lengths and thread sizes. To prevent damage to the threads, they must be installed to the correct holes.
10 Hold the control link (A1) and carefully remove the timing case assembly. To install 1
If a new gear has been installed, check the backlash (B). The backlash between the crankshaft gear and the other gears that are in mesh with it is 0.076 mm (0.003 in). The backlash between the idler gear and the gears for the camshafts is 0.05 (0.002). continued
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05 15A-04 TIMING CASE AND DRIVE ASSEMBLY
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Caution: The maximum fuel setting will be affected if: a sealant is used on the joint faces of the timing case or back plate; the joint faces are damaged when the old joint is removed. 2
Clean the faces of the timing case assembly and the backplate (B1). Install a new joint (B2), without sealant, to the timing case assembly.
3
Make sure that the joint between the cylinder block and the backplate is not damaged. Install a new 'O' ring (B8) into the front of the idler gear hub.
4
Make sure that the oil hole (B5) is not restricted and lubricate the bush (B4) with clean engine. Lubricate the teeth on all the gears with clean engine oil.
Note: Before the timing case is installed, install the adjustment screw for the maximum fuel to its original setting and then release by two full turns. Install the sealing washer and the lock nut. 5
Hold the control link (B3), and put the timing case assembly together with the new joint into position on the studs (B6/B10), the dowels (B9), and the spigot (B7) on the camshaft gear. At the same time, it may be necessary to align the teeth on the gear for the oil pump with teeth on the crankshaft gear.
6
Install, finger tight, the fasteners to retain the timing case assembly.
7
Install the governor control link (A1) and the cover plate, operation 20A-06.
Caution: To make sure that there will be no side loads on the camshaft gear, tighten the fasteners for the timing case gradually and evenly, except for the setscrew in the centre, which must be tightened last. 8
Tighten gradually and evenly, the M8 fasteners for the timing case assembly to 22 Nm (16 lbf ft) 2.2 kgf m.
9
Tighten the M8 setscrew in the centre of the timing case assembly to 22 Nm (16 M ft) 2.2 kgf/ m.
11 If one is installed, install the auxiliary drive assembly, operation 24A-01. 12 Install the crankshaft pulley, operation 14A-01. 13 Install the alternator and the drive belt, section 23A. 14 If one is installed, install the fan, operation 21A-03. 15 Set the adjustment screw for the maximum fuel setting.
10 Check that the camshaft gear has a minimum backlash of 0.05 mm (0.002 in).
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05 To renew
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Caution: When the fuel injection pump linkage is removed / renewed, or a new timing case is installed, the setting for the maximum fuel may be affected. 1 Remove the timing case assembly, operation 15A-01 2 Remove from the timing case assembly, the components listed below: • Lubricating oil pump assembly (A4), operation 19A-06 • Lubricating oil relief valve assembly (A5), operation 19A-08 • Engine speed control lever assembly (A3), operation 20A-09 • The fuel injection pump linkage (A1), operation 20A-10 • The adjustment screws for the maximum fuel setting(B1), and the high idle (B2) and the low idle (B3). 3
Install these components to the new timing case assembly. Install the adjustment screw for the maximum fuel setting to its original position. Install the adjustment screws for the high and low idle.
4
Install the timing case assembly, operation 15A-01.
Bur 6-77740
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Template Name: SM_2_col Template Date: 1994_04_05 15A-06 TIMING CASE AND DRIVE ASSEMBLY
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Front oil seal To remove and to install
15A-02
Special tools: Replacer tool for front oil seal (main tool), PD.170 Adaptor for use with PD.170, PD.259 Adaptor plate for use with PD.170, PD260-4 To remove 1
Disconnect the battery.
2
Remove the drive belts, operation 23A-03.
3
Remove 14A-01.
4
Remove the oil seal with a suitable lever behind the main lip of the oil seal. Do not damage the edge of the oil seal housing.
the
crankshaft
pulley,
7
Remove the replacer tool and lightly lubricate the seal location area of the crankshaft pulley with clean engine lubricating oil. Install the crankshaft pulley, operation 14A-01.
8
Install the drive belt, operation 23A-03.
9
Connect the battery and start the engine. When it has reached its normal temperature of operation, stop the engine and check for oil leakage around the seal.
operation
To install 1
Clean the oil seal housing. Inspect the new seal for damage. If a scratch can be seen across the lip of the seal, do not install the seal.
2
Lubricate the outer circumference of the oil seal with clean engine lubricating oil and enter the seal into the housing. Make sure that the spring loaded lip of the oil seal is towards the inside of the timing case assembly and that the oil seal is square to the bore of the seal housing.
3
Install the adaptor, PD.259, (A8) to the nose of the crankshaft (A7) and tighten the nut (A6). Put the adaptor, PD.260-4, (A3) over the nose of the crankshaft and against the seal (A4). Make sure that the adaptor has the side stamped 700, towards the seal.
4
Install the threaded bar, PD. 170, (A9) onto the adaptor (A8).
5
Install a rod through the hole (A1) in the end of the threaded bar to prevent movement of the bar when the nut is tightened.
6
Tighten the nut with the washer (A2) against the adaptor (A3) to push the seal into the housing.
Note: When the seal is installed correctly, the rear face of the seal will be against the back face of the recess (A5) in the seal housing. Bur 6-77740
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Template Name: SM_2_col Template Date: 1994_04_05
Alt= to hide template information Alt+ to display template information TIMING CASE AND DRIVE ASSEMBLY 15A-07
Idler gear To remove and to install
15A-03
To remove Note: When the timing marks on the gears are aligned and the idler gear is removed, do not rotate the crankshaft. If the crankshaft is rotated, top dead centre (TDC) will have to be set on number 1 cylinder, operation 17A-01. 1
Remove the timing case assembly, operation 15A-01.
2
Rotate the crankshaft until the marked teeth of the crankshaft gear, the gear for the camshaft for the valves, and the gear for the camshaft for the fuel injection pump, are aligned with the marked teeth of idler gear (A).
3
Remove the idler gear assembly (B2) from its hub (B1).
4
Inspect the gear, the hub, the bushes (B3), and the thrust washers (B4) for wear and other damage. If necessary, renew the bushes, operation 15A-04. If necessary, renew the idler gear hub, operation 15A-05.
To Install 1
Make sure that the oil hole (B6) is not restricted and that the hub is clean.
2
Make sure that the bushes (B3) are clean and apply a small amount of clean engine lubricating oil to their surfaces.
3
Install the two thrust washers (B4) correctly to the idler gear with the oil grooves (B5), away from the gear.
4
Slide the idler gear (B2) onto the hub (B11) with the marked teeth of the idler gear, aligned with the marked teeth of the crankshaft gear, the camshaft gear and the gear for the fuel pump camshaft (A).
5
Install the timing case assembly, operation 15A-01.
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05 15A-08 TIMING CASE AND DRIVE ASSEMBLY To remove and to install the bushes for the idler gear
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15A-04
To remove Caution: When the bushes for the idler gear are removed and installed, make sure that the teeth on the gear are not damaged. 1
With the idler gear removed, use a suitable tool to press out the old bushes (A2).
To install Notes: • The new bushes are supplied with an internal diameter of 27.425/27.610 mm (1.0797/1.0870 in). After the new bushes have been installed, they must be reamed to a finished size (131) of 28.077/28.098 mm (1.1054/1.1062 in). • The installed position of the cut-outs (A1/B3) is not important. 1
Make sure that the bore of the gear is clean and is not damaged. Press a new bush into each side of the gear until the edges with the cut-outs (A1/B3), protrude (B2) 1.5/2.0 mm (0.06/0.08) above the side face of the gear.
2
Ream the bushes to the correct size, see note above.
Bur 6-77740
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Template Name: SM_2_col Template Date: 1994_04_05
Alt= to hide template information Alt+ to display template information TIMING CASE AND DRIVE ASSEMBLY 15A-09
Idler hub To remove and to install
15A-05
Special tools: Remover tool (slide hammer) PD.184 Adaptor for use with PD.184, PD.258 Replacer tool for use with MS550, PD.256 Universal drive handle, MS.550 To remove 1
Remove the timing case assembly, operation 15A-01.
2
Remove the idler gear, operation 15A-03.
3
Install the adaptor PD.258 (A2), and the slide hammer PD.184 (A1), to the hub (A4) for the idler gear. Note the position of the oil hole (A3) in the hub.
4
Use the slide hammer to remove the old hub from the cylinder block.
To install 1
Before the new hub is installed, make sure that: the oil hole (B4) is not restricted; the bore for the hub is clean and free of debris; the edges (B5) of the bore are smooth such that they will not damage the new hub when it is installed.
2
With the oil hole (B2) towards the top, install the new hub (B3) initially, with a soft hammer (B1) until the edge of the hub is just inside the bore. Make sure that it is square to the front face of the cylinder block.
Caution: Make sure that the replacer tool is clean and smooth, and does not damage the new hub when it is installed. 3
Install the replacer tool (C2) onto the hub (C1), and continue to install the hub to the cylinder block. The new hub will be installed correctly when the front face of the tool (D1) is in contact with the cylinder block.
4
Make sure that the new hub is not damaged. Install the idler gear, operation 15A-03.
5
Install the timing case assembly, operation 15A-01.
Bur 6-77740
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Template Name: SM_2_col Template Date: 1994_04_05 15A-10 TIMING CASE AND DRIVE ASSEMBLY
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Camshaft assembly for the fuel injection pump To remove and to install
15A-06
To remove 1
Remove the timing case assembly, operation 15A-01.
2
Check that the camshaft end-float (A) is within the limits shown in Data and dimensions.
Note: When the gear and the fuel pump camshaft are removed, do not rotate the crankshaft. If the crankshaft is rotated, top dead centre (TDC) will have to be set on number one cylinder, operation 17A-01. 3
Rotate the crankshaft until the marked teeth of the crankshaft gear, the gear for the camshaft for the valves, and the gear for the camshaft for the fuel injection pump, are aligned with the marked teeth of idler gear (B).
4
Remove the lift pump, operation 20A-03.
5
Remove the fuel injection pump, operation 20A06.
6
Remove 20A-08.
7
Release the setscrew (C1) for the plate (C2) that retains the camshaft bearing. Rotate the plate 180° and tighten the setscrew. This will hold the plate away from the bearing.
8
Remove the camshaft assembly (D), make sure that the cams on the camshaft are not damaged.
the
governor
weight
B
assembly,
Note: If the bearings, the cams or the gear is worn, a new camshaft assembly will have to be installed. If this occurs, the fuel injection timing will have to be set, operation 17A-03. continued
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05
Alt= to hide template information Alt+ to display template information TIMING CASE AND DRIVE ASSEMBLY 15A-11
To install 1
Make sure that ail bearing surfaces are clean.
2
Install the camshaft assembly (B). When the camshaft gear and the idler gear are in mesh, make sure that the marks on the gears are aligned (A).
3
Release the setscrew (C1) for the plate that retains the camshaft bearing. Rotate the plate (C2) 180° and tighten the setscrew. The plate will now be across the edge of the bearing and prevent it from moving.
4
Install the 20A-08.
5
Install the fuel injection pump, operation 20A-06.
6
Install the lift pump, operation 20A-03.
7
Install the timing case assembly, operation 15A-01.
governor
assembly,
operation
B
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05 15A-12 TIMING CASE AND DRIVE ASSEMBLY
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Camshaft assembly and tappets for the valves To remove and to install
15A-07
To remove 1
Remove the cylinder head assembly, operation 12A-07.
2
Remove the timing case assembly, operation 15A-01.
Note: When the timing marks on the gears are aligned and the gear and the camshaft are removed, do not rotate the crankshaft. If the crankshaft is rotated, top dead centre (TDC) will have to be set on number 1 cylinder, operation 17A-01. 3
Rotate the crankshaft until the marked teeth of the crankshaft gear, the gear for the camshaft for the valves, and the gear for the camshaft for the fuel injection pump, are aligned with the marked teeth of idler gear (A).
4
Check that the camshaft end float (B) is within the limits shown in Data and dimensions.
5
Remove the tappets (C1) and note their correct position for assembly.
6
Remove the two setscrews (D1) that retain the thrust plate for the camshaft.
7
Remove the camshaft assembly (D3) from the cylinder block, make sure that the cams (D2) are not damaged.
8
Inspect the camshaft and the tappets for wear, also inspect the gear and the camshaft bush. Renew these components as necessary. continued
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05
Alt= to hide template information Alt+ to display template information TIMING CASE AND DRIVE ASSEMBLY 15A-13
To install 1
Make sure that all the oil holes in the cylinder block and on the camshaft (A4) are not restricted. Clean the camshaft and lubricate the journals, the cams and the teeth of the gears with clean engine oil.
2
With the marked teeth on the camshaft gear aligned with the marked teeth on the idler gear (B), install the camshaft assembly (A3) to the cylinder block, make sure that the cams (A2) are not damaged during this operation.
3
Install the two setscrews (A1) that retain the thrust plate for the camshaft.
4
Check that the camshaft end float (C) is within the limits shown in Data and dimensions.
5
Ensure that tappets are clean and that the oil drain holes (D2) are not restricted. Lubricate the tappets with clean engine oil and install them in the correct positions and with the flat face (D1) towards the cams.
6
Install the timing case assembly, operation 15A-01.
7
B
Install the cylinder head assembly, operation 12A07.
C
Bur 6-77740
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Template Name: SM_2_col Template Date: 1994_04_05 15A-14 TIMING CASE AND DRIVE ASSEMBLY
Bur 6-77740
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Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05
Alt= to hide template information Alt+ to display template information TIMING CASE AND DRIVE ASSEMBLY 15A-15
Crankshaft gear To remove and to install
15A-08
To remove 1
Remove the timing case assembly, operation 15A-01.
2
Rotate the crankshaft until the marked teeth of the crankshaft gear, the gear for the camshaft for the valves, and the gear for the camshaft for the fuel injection pump, are aligned with the marked teeth of idler gear (A).
3
Remove the idler gear, operation 15A-03.
4
The crankshaft gear is an interference install on the crankshaft. It may be removed with a suitable puller. If this is not possible, it will be necessary to remove the crankshaft, operation 14A-08, and press the gear off.
To install Warning! Heat is used to install the gear, make sure that suitable leather gloves are worn to protect the hands. 1
To install the gear, it will be necessary to heat the gear before it will install onto the crankshaft. Heat the gear gradually to not more than 300°C (572 °F). Do not use a flame as this can cause local damage. Install the gear with the timing marks towards the front.
2
Install the idler gear, operation 15A-03 and make sure that all the timing marks are correctly aligned.
3
Install the timing case assembly, operation 15A-01.
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05 15A-16 TIMING CASE AND DRIVE ASSEMBLY
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Backplate for the timing case To remove and to install
15A-09
Caution: The setting for the maximum fuel position may be affected when the timing case is removed. To remove 1
Remove the timing case assembly, operation 15A-01.
2
Remove the idler gear, operation 15A-03.
3
Remove the camshaft assembly for the fuel injection pump, operation 15A-06.
4
Remove the tappets and the camshaft assembly for the valves, operation 15A-07.
5
Remove the backplate from the engine.
Caution: The maximum fuel setting will be affected if: sealant is used on the joint faces of the timing case or back plate; the joint faces are damaged when the old joint is removed To install 1
Remove the old joint from the faces of the cylinder block (A5), and the backplate (A2).
2
Make sure that the joint faces are completely free of the old joint. Install the backplate with a new joint (A3), of the correct specification and without sealant, onto the studs (A1/A4) and the dowels (A6).
3
Install the tappets and the camshaft assembly for the valves, operation 15A-07.
4
Install the camshaft assembly for the fuel injection pump, operation 15A-06.
5
Install the idler gear, operation 15A-03.
6
Install the timing case assembly, operation 15A-01.
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05
Alt= to hide template information Alt+ to display template information TIMING CASE AND DRIVE ASSEMBLY 15A-17
Data and dimensions Introduction Note: This information is given as a guide for personnel engaged on engine overhauls. The dimensions which are shown are those which are mainly used in the factory.
Timing case and drive assembly Camshaft Diameter of camshaft journals.........................................................................47.945/47.975 mm (1.8876/1.8887 in) Clearance of journals in cylinder block: - number one .......................................................................................................0.025/0.155 mm (0.0010/0.0060 in) - number two, three, four and five........................................................................0.050/0.115 mm (0.0020/0.0040 in) maximum permissible camshaft journal wear................................................................................0.05 mm (0.002 in) Cam lift: - Inlet............................................................................................................................7.06/7.16 mm (0.278/0.282 in) - Exhaust .....................................................................................................................7.71/7.79 mm (0.289/0.293 in) End-float: - Production limit..........................................................................................................0.10/0.25 mm (0.004/0.010 in) - Service limit .................................................................................................................................0.35 mm (0.014 in) Camshaft thrust washer: - Type .................................................................................................................................................................. 360° - Thickness ..................................................................................................................2.30/2.40 mm (0.091/0.095 in) Camshaft gear
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05 15A-18 TIMING CASE AND DRIVE ASSEMBLY
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Number of teeth60 Fuel pump gear Number of teeth60 End float for fuel pump camshaft0.00/0.02 mm (0.0000/0.0008 in) Crankshaft gear Number of teeth30 Diameter of bore31.936/31.961 mm (1.2573/1.2583 in) Diameter of crankshaft nose31.979/32.000 mm (1.2590/1.2600 in) Interference install of gear on crankshaft- 0.018/ 0.064 mm (- 0.0007/ - 0.0025 in)
Continued Idler gear and hub Number of teeth59 Diameter of bore of bushes in gear28.077/28.098 mm (1.054/1.062 in) Diameter of hub installed to cylinder block28.048/ 28.061 mm (1.1043/1.1048 in) Clearance install of gear on hub0.016/0.050 mm (0.0006/0.0020 in) Backlash for gears: - Crankshaft to oil pump and idler gears0.76 mm (0.003 in) minimum - Gears other than those referred to above0.05 mm (0.002 in) minimum
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05
Bur 6-77740
Alt= to hide template information Alt+ to display template information TIMING CASE AND DRIVE ASSEMBLY 15A-019
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05
Cylinder block assembly
Alt= to hide template information Alt+ to display template information CYLINDER BLOCK ASSEMBLY 16A-01
16
General description ................................................................................................16A.02 Cylinder block 16A-01 16A-02
To disassemble and to assemble .............................................................16A.03 To inspect ................................................................................................16A.05
Data and dimensions ..............................................................................................16A.06
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05 16A-02 CYLINDER BLOCK ASSEMBLY
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General description The cast iron cylinder block is made without cylinder liners. The cylinder bores are plateau honed with silicon carbide tools to a controlled finish to make sure long life and low oil consumption. A bush is installed in the cylinder block for the camshaft front journal, the other journals run directly in the cylinder block. Cylinder blocks that are supplied for service, are installed with a steel back, copper / lead bush for the camshaft front journal, and a new hub for the idler gear.
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05
Alt= to hide template information Alt+ to display template information CYLINDER BLOCK ASSEMBLY 16A-03
Cylinder block
13 Remove the auxiliary drive assembly, operation 24A-01.
To disassemble and to assemble 16A-01 Consumable products: Loctite 242e Nutlock Loctite Hylosil Note: If the cylinder block is to be renewed, it may be necessary to install new pistons and small end bushes, operation 13A-05A. This will occur if the correct piston height above the block face cannot be maintained with the original piston and connecting rod assemblies, operation 13A-03A. If all or most of the original pistons and connecting rod assemblies cannot be used it may be cost effective to install a short engine. • If the cylinder block is renewed, it will be necessary to check the timing of the fuel injection pump.
14 Remove 14A-01
the
crankshaft
pulley,
operation
15 Remove the timing case assembly, operation 15A-01. 16 Remove the backplate for the timing case assembly, operation 15A-09.
•
17 Remove the lubricating oil filter assembly, the dipstick tube, the lubricating oil sump and the lubricating oil suction pipe, section 19. 18 Remove the piston and connecting assemblies, operation 13A-03.
rod
19 Remove the flywheel and the flywheel housing, section 22.
To disassemble
20 Remove the crankshaft and the rear oil seal, section 14.
1
Disconnect the battery.
21 Inspect the cylinder block, operation 16A-02.
2
Drain the cooling system, operation 21A-04.
3
Drain the lubricating oil.
4
Disconnect as necessary, any electrical cables, control wires, hoses and note where they are installed.
5
Remove the engine from the vehicle or machine.
6
Remove the alternator drive belt, the alternator and the mounting brackets.
7
Remove the fan, the water pump and the thermostat housing.
8
Remove the starter motor.
9
Remove the electrical stop solenoid.
10 Remove the high-pressure and the lowpressure fuel pipes, the fuel filter, the fuel lift pump, the atomisers and the fuel injection cassette pump, section 20. 11 Remove the glow plugs. 12 Remove the cylinder head assembly.
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05 16A-04 CYLINDER BLOCK ASSEMBLY
Alt= to hide template information Alt+ to display template information 19 Connect electrical cables, control wires and hoses.
To assemble 1
Clean thoroughly the cylinder block. Make sure that all the oil and all the coolant passages are clean and free from debris.
20 Fill the cooling system, operation 21A-05.
2
If a new cylinder block is to be installed, remove the threaded plugs from the old cylinder block and clean the threads. Seal the threads with Loctite Nutlock, or a similar sealant, and install the threaded plugs into the new cylinder block.
22 Connect the battery.
3
Install the crankshaft and the rear oil seal, section 14.
4
Install the flywheel housing and the flywheel, section 22.
5
Install the piston and connecting assemblies, operation 13A-03.
6
Install the lubricating oil suction pipe, the lubricating oil sump and the lubricating oil filter assembly, section 19.
7
Install the backplate for the timing case assembly, operation 15A-09.
8
Install the timing case assembly, operation 15A-01.
9
Install the crankshaft pulley, operation 14A-01.
21 Fill the lubricating oil sump to the correct level with an approved lubricating oil.
23 Eliminate air from the fuel system, section 20. 24 Start the engine and check for fuel, lubricating oil and coolant leaks. Allow the engine to reach the normal temperature of operation before it is stopped.
rod
10 Install the auxiliary drive assembly, operation 24A01. 11 Install the cylinder head assembly, operation 12A-07. 12 Install the glow plugs. 13 Install the fuel injection pump, the atomisers, the fuel lift pump, the fuel filter, and the high and the low pressure fuel pipes, section 20. 14 Install the electrical stop solenoid. 15 Install the starter motor. 16 Install the thermostat housing, the water pump and the fan, section 21. 17 Install the alternator, its mounting brackets and the alternator drive belt. 18 Install the engine into the vehicle or machine. Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05 To inspect
Alt= to hide template information Alt+ to display template information CYLINDER BLOCK ASSEMBLY 16A-05 16A-02
1
Clean the passages for the coolant and for the oil.
2
Check the cylinder block for cracks and for other damage.
3
The top face of the cylinder block must not be machined as this will affect the piston height above the top face of the cylinder block.
4
Check the condition of the cylinder bores. The condition of a cylinder bore is decided by: The amount and location of any polished areas. The amount of wear. Damage to the cylinder wall.
• • • 5
Check the camshaft bush for wear. If the bush is to be renewed, use a suitable adaptor to remove the old bush. Do not damage the bore in the cylinder block.
Caution: Make sure that the oil holes in the bush are aligned with the oil holes (A1) in the cylinder block. 6
When the new bush is installed, check in six places, that the diameter (A2) of the bush is correct.
To check the condition of a cylinder bore 1
Inspect the surface for cracks and deep scratches.
2
Check for areas where the honed finish has been polished away. Check especially the area around the top of the bore just below the carbon ring. In this area, there is maximum thrust from the top piston ring.
3
Check the cylinder bores for wear and other damage. The bores should be checked at the top, the centre, the bottom and in two directions, across the engine and along the centre line. If the cylinder bores are worn by more than 0.25 mm (0.01 in), the bores can be bored and honed 0.5 mm (0.020 in) oversize in diameter and oversize pistons installed. To make sure that the engine will conform to emissions legislation after it has been bored, the bores must bored and then diamond honed, silicon carbide base honed and then silicon carbide plateau honed to the surface finish shown in Data and dimensions.
Caution: If the cylinder block is to be bored, all cylinders must be bored and new pistons installed as a complete set. Specialist training and equipment is needed to machine the cylinder bores. For further information contact your nearest New Holland Distributor.
Caution: An engine can have high oil consumption with very little wear of the bores, if the surfaces of the bores are glazed.
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05 16A-06 CYLINDER BLOCK ASSEMBLY
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Data and dimensions Note: This information is given as a guide for personnel engaged on engine overhauls. The dimensions which are shown are those which are mainly used in the factory.
Cylinder block assembly Cylinder block Height between top and bottom faces ................................................... 360.95/361.05 mm (14.211/14.214 in) Diameter of parent bore for main bearing........................................................69.000/69.019 mm (2.7165/2.7173 in) Diameter of bores for camshaft: - Number one (for bush) ................................................................................ 51.84/51.87 mm (2.041/2.042 in) - Number two, three, four and five ......................................................... 48.025/48.500 mm (1.8904/1.9094 in) Diameter of cylinder bores: - UA engines ......................................................................................... 97.000/97.025 mm (3.8189/3.8199 in) - UB engines ......................................................................................... 91.000/91.025 mm (3.5827/3.5837 in) Maximum permissible wear in cylinder bore ......................................................................... 0.25 mm (0.01 in) Oversize bores Diameter of oversize cylinder bores before they are honed: - UA engines ................................................................................................. 97.35/97.42 mm (3.833/3.835 in) - UB engines ................................................................................................. 91.35/91.42 mm (3.596/3.599 in) Surface finish ............................................................................................................. RA 3.0/5.0 micro-meters Surface finish of the diamond hone Hone angle (cross hatch) ..................................................................................................................... 30째/35째 Surface finish size, diamond honed: - UA engines ......................................................................................... 97.467/97.472 mm (3.8373/3.8374 in) - UB engines ......................................................................................... 91.467/91.472 mm (3.6011/3.6012 in) Grade of surface finish ............................................................................................... RA 2.2/3.0 micro-meters Maximum ovality and taper..............................................................................................0.012 mm (0.0005 in) Surface finish of the silicone carbide base hone Hone angle (cross hatch) ..................................................................................................................... 30째/35째 Surface finish size, silicon carbide (base hone): - UA engines .................................................................................................................97.507 mm (3.8388 in) - UB engines .................................................................................................................91.507 mm (3.6026 in) Grade of surface finish ............................................................................................... RA 1.3/1.6 micro-meters Maximum ovality and taper..............................................................................................0.020 mm (0.0008 in)
Continued Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05
Alt= to hide template information Alt+ to display template information CYLINDER BLOCK ASSEMBLY 16A-07
Surface finish of the silicone carbide plateau hone Final surface finish size, silicon carbide (plateau hone): - UA engines ......................................................................................... 97.500/97,525 mm (3.8386/3.8396 in) - UB engines ......................................................................................... 91.500/91.525 mm (3.6024/3.6033 in) Final surface finish grade, silicon carbide (plateau hone) ............................................... 0.65/1.3 micro-meters
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05 16A-08 CYLINDER BLOCK ASSEMBLY
Bur 6-77740
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Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05
Engine timing
Alt= to hide template information Alt+ to display template information ENGINE TIMING 17A-01
17
General description ................................................................................................17A.02 17A-01 17A-02 17A-03
To set accurately number 1 piston to TDC on the compression stroke......17A.03 To check the valve timing .........................................................................17A.04 To check the timing of the fuel injection pump ..........................................17A.05
Data and dimensions ..............................................................................................17A.07
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05 17A-02 ENGINE TIMING
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General description Notes: • The front of the engine is when seen from the end with the timing case assembly. • Number one cylinder is at the front of the engine. The timing gears for the engine are stamped with timing marks to make sure that they are assembled correctly (A). When the engine is set at top dead centre (TDC) on the compression stroke for number one cylinder, operation 17A-01, the timing marks on the fuel pump, the camshaft and the crankshaft gears may not necessarily be aligned. This may occur because the gears rotate at different speeds. The mark on the crankshaft pulley will be aligned with the mark on the timing case when the piston for number one cylinder is at TDC, see operation 17A-01. The fuel injection pump installed to this engine is of the in-line cassette type. The gear for the fuel pump, the roller bearings and the camshaft for the fuel pump, are supplied as an assembly. To adjust the timing of the fuel injection pump, a shim (B1) of a specific size is installed between the flange of the pump and the flange on the cylinder block. Six different size shims are available. Included within the thickness dimension of each shim, is an amount of sealant that is necessary to prevent oil leakage from the flange. When the timing for the fuel pump has been set, it should only alter if the camshaft for the fuel pump, or the cylinder block are renewed. If this occurs, it will be necessary to check the timing. If the original fuel injection pump is removed and installed for any other purpose, and a shim of the same size is installed, the injection timing should not alter. The part number and code letters for the pump are shown on the plate (B2). For timing details, see Data and dimensions.
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05
Alt= to hide template information Alt+ to display template information ENGINE TIMING 17A-03
To set accurately number 1 piston to TDC on the compression stroke 17A-01 Special Tools: Valve spring compressor, PD.6118B Stud adaptor for use with PD.6118B, PD.244 Warning! Wear operation.
eye
protection
during
this
Note: Clockwise / counter-clockwise direction is when seen from the front of the engine. 1
Remove the rocker cover, operation 12A-01.
2
Rotate the crankshaft, clockwise, until the push rod for the inlet valve of the rear cylinder just tightens. The piston for number one cylinder will be near to TDC and the mark on the crankshaft pulley should be near to the mark on the timing case (A1).
3
Remove the spring clip and the spacer from the front of the rocker shaft. Release the fasteners of the first two pedestals of the rocker shaft. Release the tappet adjustment screw and remove the front rocker lever. Tighten the fasteners of the rocker shaft pedestals.
B
Caution: When the valve spring is removed, make sure that the collets do not fall into the holes for the push rods. 4
Remove the valve spring and the cap from the front valve with the valve spring compressor PD.6118B (B1) and the adaptor PD.244 (B2), for the pedestal studs. Allow the valve to be held by the top of the piston.
5
Fasten a dial test indicator with its plunger in contact with the top of the valve stem (C1) and with a reading shown on the gauge. Rotate slowly, the crankshaft counter-clockwise 45°. Then rotate slowly, the crankshaft clockwise until the clockwise movement of the dial gauge pointer stops.
6
With the pointer in the maximum clockwise position, the piston for number one cylinder will be at TDC on the compression stroke.
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05 17A-04 ENGINE TIMING To check the valve timing
Alt= to hide template information Alt+ to display template information 17A-02
1
Check and, if necessary, adjust the valve tip clearances, operation 12A-05.
2
Rotate the crankshaft, clockwise from the front, until the valve (B7) is fully open. The piston for number one cylinder is now on the compression stroke.
3
Set the valve tip clearance for valve (B1) to 0.59 mm (0.023 in).
4
Rotate the crankshaft, clockwise from the front, until the push rod for valve (B1) just tightens. In this position, check if the mark (A1) on the crankshaft pulley is within ±2.5° of the mark on the timing case. If it is, the valve timing is correct.
5
If the timing is more than 2.50 out of position, the timing gears are probably not in correct mesh.
Note: Use the formula below to find the measurement on the pulley which is equal to 2.5°. CxP 360 Where: - C = the circumference of pulley - P = 2.5° 6
Rotate the crankshaft, clockwise from the front, until the valve (B7) has just opened and the valve (B8) has not closed completely. Set the valve tip clearance of the valves (B1) and (B2) to 0.35 mm (0.014 in).
7
Install the rocker cover, operation 12A-01.
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05 To check the timing of the fuel injection pump
Alt= to hide template information Alt+ to display template information ENGINE TIMING 17A-05 17A-03
The method used to check the timing of the fuel injection pump is spill timing. Notes: • The timing marks on the crankshaft pulley and on the timing case (A1) are not accurate enough when the engine is spill timed. • Clockwise / counter-clockwise direction is when seen from the front of the engine. 1 Disconnect the battery. 2
Set the piston for number one cylinder to top dead centre (TDC) on the compression stroke, operation 17A-01.
3
With the dial gauge still on the first valve, rotate the crankshaft counter-clockwise until the dial gauge pointer moves counter-clockwise 5.08 mm (0.20 in).
4
Remove the electrical stop solenoid, operation 23D-01.
5
Disconnect from the fuel injection pump, the fuel inlet pipe (B3).
6
Disconnect the high-pressure fuel pipe (B1) for number one outlet (B2).
Cautions: • When the delivery valve holder (B2) is removed from the pump, the crankshaft must not be rotated. If this does occur, the injection pump will be permanently damaged. • Extreme care must be used with the components (C) when the delivery valve assembly is removed and installed during the spill timing procedure. • The area inside the delivery valve chamber must remain completely clean at all times. 7 Remove the delivery valve holder (B2/C1) for number 1 cylinder and remove the delivery valve (C4), the spring (C3) and the location pin (C2). Keep these components in clean diesel fuel. Note: Because the pump is installed at an angle, when the delivery valve, spring and location pin are removed, the delivery valve seat (C6) will slide to the side of the delivery valve chamber. This will make it difficult to install the holder (C1) to the pump.
Bur 6-77740
8
To make sure that the valve seat will remain centred, dry thoroughly the bottom face of the valve seat and the top face of the plunger assembly. Put the valve seat onto the top face of the plunger and slowly rotate the seat. The seat should then remain centred when the delivery valve holder is installed.
continued
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05 17A-06 ENGINE TIMING
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Caution: Do not tighten the delivery valve holder unless the components are aligned. If they are not the injection pump will be permanently damaged. 9
Install in the correct sequence, the holder (B1), the washer (B5,) and the seat (B6) to the pump.
10 Connect a suitable clean tank, with a capacity of approximately 0.75 litres (1.32 pints) and a valve, to the inlet (A4) of the fuel pump. 11 Connect a swan neck pipe (A1) to the delivery valve holder for number one cylinder. Put a suitable container below the swan neck pipe to retain the spilt fuel.
17 Remove the delivery valve holder from the pump.
Note: The outlet from the tank should be approximately 152 mm (6 in) above the pump. This will make sure that the fuel is supplied to the pump at a constant pressure. 12 Add 0.5 litres (0.9 pints) of clean fuel to the container. 13 Open the valve. 14 Make sure that the lever (A3) is held in the maximum fuel position during this procedure. 15 Turn the crankshaft slowly in a clockwise direction, until the flow of fuel from the swan neck pipe, is reduced to one drop every 7-10 seconds. 16 Note the reading on the dial test indicator (A2). Notes: • The reading on the indicator shows piston displacement. For the correct displacement static timing angles, see Data and dimensions. • If it is necessary to adjust the timing, remove the pump and install a shim of the correct thickness, operation 20A-06. • To retard the timing; install a thicker shim. To advance the timing; install a thinner shim. • The timing will change approximately 1° for each 0. 10 mm (0.004 in) of shim thickness. • If the shim has to be changed, it will be necessary to repeat paragraphs 14 to 20. • When the timing is correct, remove the swan neck pipe and the tank assembly.
B 18 Assemble the components of the delivery valve assembly in the correct sequence (B) and install the assembly to the pump. Tighten the holder to 43 Nm (32 lbf ft) 4.3 kgf m. 19 Install the high-pressure fuel pipes and tighten the union nuts to 22 Nm (16 lbf ft) 2.2 kgf m. 20 Install the low-pressure fuel pipe and tighten the banjo bolt to 22 Nm (16 lbf ft) 2.2 kgf m and the nut to 12 Nm (9 lbf ft) 1.2 kgf m. 21 Remove the dial test indicator. 22 Install the valve spring and cap, the rocker lever, the washer and the circlip and set the valve clearance for number one inlet valve to 0.35 mm (0.014 in). 23 Install the rocker cover. 24 Install the electrical stop solenoid, operation 23D-01.
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05
Alt= to hide template information Alt+ to display template information ENGINE TIMING 17A-07
25 Connect the battery and start the engine. Check for fuel and lubricating oil leaks.
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05 17A-08 ENGINE TIMING
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Data and dimensions
Direction of rotationClockwise from drive end Fuel pump code lettersSee table below
Introduction Note: This information is given as a guide for personnel engaged on engine overhauls. The dimensions which are shown are those which are mainly used in production.
For identification purposes, a plate which shows the part number of the pump and the rating code letters is installed to the side of the pump (17A.02/ B2). An example of this is: - Pump part number2644D051 - Pump code lettersAJ
Timing data
Timing details for fuel injectionSee table below
Fuel injection pump
Timing data for 700 Series engines
MakeZexel PFR-KX, in-line cassette type
Piston displacement
Engine type
Fuel pump code letters
Static timing position in degrees before TDC
mm
in
UA
AJ
16
2.54
0.100
UA
BJ
16
2.54
0.100
UB
CJ
14
1.93
0.076
UB
DJ
10
1.004
0.040
Timing shims Thickness mm (in) 0.1 (0.004) 0.2 (0.008) 0.3 (0.012) 0.4 (0.016) 0.5 (0.020)
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05
Bur 6-77740
Alt= to hide template information Alt+ to display template information ENGINE TIMING 17A-09
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05
Aspiration system
Alt= to hide template information Alt+ to display template information ASPIRATION SYSTEM 18A-01
18
Closed breather system 18A-01
Bur 6-77740
To renew the engine breather assembly ...................................................18A.02
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05 18A-02 ASPIRATION SYSTEM
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Closed breather system The engine breather assembly is installed to the top of the rocker cover and consists of: the breather cover (A3); four setscrews (A2) to retain the cover; the diaphragm and location ring assembly (A6) and the spring (A5). The crankcase gases pass from the breather assembly, through a pipe (Al) and into the induction manifold.
To renew the engine breather assembly
18A-01
Cautions: • It is important that the area around the vent hole (A7) is kept clean and the vent hole is not restricted. • Make sure that the pipe (A1), when installed, does not contact other components as this may cause the failure of the pipe. • Make sure that the components of the breather assembly are installed in their correct positions (A). If they are installed incorrectly, the engine can be damaged. 1
Release the four setscrews and remove the breather cover.
2
Remove the diaphragm and location ring assembly (A6). Remove the spring (A5).
3
Release the clips that retain the breather pipe and remove the breather pipe.
4
Clean the breather cavity (A4) in the rocker cover, the breather pipe (A1) and the vent hole (A7). Make sure that the vent hole is not restricted.
5
Install a new spring (A5) into the cavity in the rocker cover.
6
Install a new location ring (B2) onto the new diaphragm (B1) and install this assembly onto the spring. Make sure that the location ring is on the spring (A5).
7
Install the breather cover, Install and tighten the four setscrews.
8
Install the breather pipe and tighten the clips.
Bur 6-77740
Notes: • The breather assembly (component numbers A5 and A6) should be renewed every 2000 hours. • The breather pipe should be removed and cleaned every 1000 hours.
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05
Lubrication system
Alt= to hide template information Alt+ to display template information LUBRICATION SYSTEM 19A-01
19
General description ................................................................................................19A.02 Filter canister 19A-01
To renew ...................................................................................................19A.03
Filter head 19A-02
To remove and to install ............................................................................19A.04
Sump 19A-03
To remove and to install ...........................................................................19A.05
Oil strainer and suction pipe assembly 19A-04 19A-05
To remove and to install............................................................................19A.06 To inspect ................................................................................................19A.06
Lubricating oil pump 19A-06 19A-07
To remove and to install............................................................................19A.07 To inspect .................................................................................................19A.08
Relief valve 19A-08 19A-09 19A-10
To remove and to install............................................................................19A.09 To disassemble and to assemble ..............................................................19A.09 To inspect .................................................................................................19A.09
Data and dimensions ..............................................................................................19A.10
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05 19A-02 LUBRICATION SYSTEM General description Pressure lubrication is supplied by a rotor type pump contained within the timing case. The pump is driven by the crankshaft gear. Lubricating oil from the sump passes through a strainer and pipe to the suction side of the pump. The pump has an inner rotor and an outer rotor which are off-center to each other. The inner rotor has four lobes which mesh with the five lobes of the outer rotor. When the inner rotor rotates, the space between the lobes of the inner and outer rotors increases to cause a suction as it passes the inlet chamber. The space between the lobes is then filled with oil. As the rotors pass the outlet chamber, the space decreases which causes a pressure increase. This forces the oil into the outlet chamber and into the relief valve. The lubricating oil, at increased pressure, passes from the outlet of the pump to the relief valve, which is contained within the timing case. As engine speed increases the output of the oil pump increases, and more oil flows into the system. The increase in flow causes an increase in pressure in the system. When the oil pressure on the plunger of the relief valve is greater than the spring pressure, the valve will open. When the valve opens, surplus oil is returned to, the sump. This action will reduce the oil pressure and the valve will close.
Alt= to hide template information Alt+ to display template information An extra hole in the bore for each main bearing, allows oil to pass through passages to lubricate the journals of the camshaft for the valves. The bush for the front journal has an oil supply from the front main journal of the crankshaft. The camshaft for the fuel injection pump is lubricated by splash and oil mist. Lubricating oil also passes from the upper pressure rail through a hole drilled across the front of the cylinder block, which connects with a vertical passage to the front of the cylinder head. Oil passes through a passage from the front of the cylinder head to a restriction in the first pedestal of the rocker shaft. The restriction reduces the oil pressure to lubricate the rocker assembly. The oil passes through the rocker shaft to the bore of each of the rocker levers and leaves the bores through holes in the top of the rocker levers. Oil passes along channels in the top of the rocker levers to the valve stems, the valve springs and the tappets which are lubricated by splash and oil mist. The hub of the idler gear is lubricated by oil from the pressure rail and the timing gears are splash lubricated. Lubricating oil from the timing case returns to the sump. .
Lubricating oil, at pressure, passes from the relief valve chamber, along an oil pressure rail, which is drilled the full length of the right side of the cylinder block, and into the full flow oil filter. The oil passes through the filter and up the centre tube into another pressure rail, parallel to, but above the other pressure rail. The oil filter can be installed in one of two positions on the right side of the engine. The filter canister is either installed to the cylinder block or is installed to, a filter head, which is installed to the cylinder block. Lubricating oil passes through drilled holes in the upper pressure rail, through passages in the main journals of the crankshaft, to the main bearings. Lubricating oil also passes through passages in the crankshaft to the big end bearings. The small end bearings, the pistons and the cylinder bores are lubricated by splash and oil mist.
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05
Alt= to hide template information Alt+ to display template information LUBRICATION SYSTEM 19A-03
Filter canister To renew
19A-01
Warning! Discard the used canister and lubricating oil in a sale place and in accordance with local regulations. Cautions: • Make sure that the application is on a level surface to make sure an accurate reading on the dipstick. •
When the sump is filled with lubricating oil, make sure that the level of the oil is not above the notch (B2) on the dipstick. If the engine operates with too much oil in the sump, the engine will be damaged.
Note: Some applications have a separate filter head that is installed to the cylinder block, directly onto the filter mounting face. The filter canister is then installed to the filter head. Use the same procedure given below to change this type of filter. 1
Put a tray under the filter to retain spilt lubricating oil. Clean thoroughly the outside surfaces of the filter assembly.
2
Use a strap wrench or similar tool to loosen the filter canister. Remove and discard the canister. Make sure that the adaptor (A1) is secure in the filter head.
3
Clean inside the filter head, or the mounting face.
4
Lubricate the seal (A2) on top of the canister with clean engine lubricating oil.
5
Install the new canister and tighten by hand until the seal contacts the filter head, or the mounting face. Tighten the canister a further 1/2 to 3/4 of a turn by hand only. Do not use a strap wrench.
6
Make sure that there is lubricating oil in the sump. Make sure that the engine will not start and operate the starter motor until oil pressure is obtained. To make sure that the engine will not start, disconnect the electrical stop control of the fuel injection pump. Oil pressure is indicated when the warning light is extinguished or by a reading on the gauge.
Bur 6-77740
Caution: Do not fill the sump past the notch (B2) on the dipstick. 7
Start the engine and check for leakage from the filter. Stop the engine. After 15 minutes, check the oil level on the dipstick and, if necessary, put more lubricating oil into the sump. Fill the sump to the notch (B2) on the dipstick (B1) with an approved lubricating oil.
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05 19A-04 LUBRICATION SYSTEM
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Filter head To remove and to install
19A-02
1
Put a tray under the filter head to contain spilt lubricating oil.
2
Remove the filter canister, operation 19A-01.
3
Release the setscrew (A1) and remove the filter head (A3) from the cylinder block. Discard the "0" rings (A2) on the setscrew. Discard the "0" ring (A4) on the filter head.
4
Thoroughly clean the flange face of the filter head and the flange face of the cylinder block. Install the filter head together with a new "0" ring. Install new "0" rings to the setscrew tighten the setscrew to 80 Nm (59 M ft) 8.2 kgf m.
5
Install a new filter canister, operation 19A-01.
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05
Alt= to hide template information Alt+ to display template information LUBRICATION SYSTEM 19A-05
Sump To remove and to install
19A-03
Consumable products: Loctite Silicone adhesive Warnings! • Discard the used lubricating oil in a safe place and in accordance, with local regulations. •
If a cast iron sump is used, it will be heavy, make sure that there is enough support for the sump or obtain assistance when it is removed or installed.
Cautions: •
Make sure that the application is on a level surface to make sure an accurate reading on the dipstick.
•
When the sump is filled with lubricating oil, make sure that the level of the oil is not above the notch (B2) on the dipstick. If the engine operates with too much oil in the sump, the engine will be damaged.
Note: Some agricultural applications have an engine with a divided sump to allow for a drive shaft. If this sump is used, both drain plugs must be removed to make sure that all of the lubricating oil is drained from the sump. 1
Remove the sump drain plug(s) and the "0" ring(s) and drain the oil. If necessary, remove the dipstick and the dipstick tube.
2
Provide a support for the sump. Remove the setscrews and the two nuts which fasten the sump to the cylinder block and to the timing case. Lower the sump.
3
Wash the sump with an approved cleaning fluid, make sure that all of the cleaning fluid is removed. Thoroughly clean the flange faces of the sump and the cylinder block and make sure that they are free of oil or grease.
4
Put a bead of Loctite Silicone adhesive (A1) along the flange of the sump.
5
Carefully install the sump onto the cylinder block. Install a setscrew on each side of the sump to make sure that it is in the correct position. Loosely install the remainder of the setscrews.
Bur 6-77740
6
Tighten all the fasteners to 22 Nm (16 lbf ft) 2.2 kgf m. Install the drain plug(s) together with a new "0" ring and tighten the plug(s) to 34 Nm (25 lbf ft) 3.5 kgf m. Where necessary, install the dipstick tube and the dipstick. Fill the sump to the notch (B2) on the dipstick (B11) with an approved lubricating oil.
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05 19A-06 LUBRICATION SYSTEM
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Oil strainer and suction pipe assembly To remove and to install
19A-04
The oil strainer (A1) is an integral part of the suction pipe (A2). No regular service is necessary, but wash the strainer assembly when it is removed. 1
Remove the sump, operation 19A-03.
2
Release the setscrew (A4) which holds the bracket (A3) to the cylinder block. Remove the suction pipe and strainer.
3
Remove the "0" ring (A5) from the hole in the cylinder block for the suction pipe.
Caution: When the setscrew for the suction pipe bracket is tightened, make sure that a downward load (towards the block), is applied to the pipe (A2). When installed, it should not be possible to move the pipe by hand. 4
Install a new "0" ring into the groove (A6) in the hole in the cylinder block for the suction tube. Lubricate the "0" ring with clean engine lubrication and install the suction tube. Put the bracket in position and tighten the setscrew to 22 Nm (16 lbf ft) 2.2 kgf m. Make sure that there is no stress on the suction pipe.
5
Some engines have a different suction pipe to that shown in (A). The other type has two support brackets, one as in (A4), and a second one that is installed to the centre main bearing cap. Tighten both setscrews to 22 Nm (16 lbf ft) 2.2 kgf m.
Cautions: • Make sure that the application is on a level surface to ensure an accurate reading on the dipstick. •
When the sump is filled with lubricating oil, make sure that the level of the oil is not above the notch (B2) on the dipstick. If the engine operates with too much oil in the sump, the engine will be damaged.
6
Install the sump, operation 19A-03, and fill the sump to the notch (B2) on the dipstick (B1) with an approved lubricating oil.
Bur 6-77740
To inspect
19A-05
1
Wash the assembly in an approved cleaning fluid and dry it thoroughly.
2
Check the pipe, the strainer and the welded joints for cracks and other damage. Check that the mounting bracket is secure.
3
If the strainer assembly is cracked or damaged, it must be renewed.
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05
Alt= to hide template information Alt+ to display template information LUBRICATION SYSTEM 19A-07
Lubricating oil pump To remove and to install
19A-06
To remove 1
Remove the timing case, operation 15A-01.
2
Release the three cap screws (A1) and remove the oil pump (A2).
To install 1
Make sure that the flange face of the oil pump and the flange face of the timing case for the oil pump are clean. Align the two dowels (A3) and put the oil pump in position. Install and tighten the cap screws (A1) to 22 Nm (16 lbf ft) 2.2 kgf m.
2
Install the timing case, operation 15A-01.
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05 19A-08 LUBRICATION SYSTEM To inspect
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19A-07
If any part is worn enough to have an effect on the performance of the oil pump, the complete oil pump must be renewed. 1
Remove the oil pump, operation 19A-06.
2
Remove the outer rotor and clean thoroughly all the parts. Check for cracks and any other damage.
3
Install the outer rotor and check the outer rotor to body clearance with a feeler gauge (A).
4
Check the inner rotor to outer rotor clearance (B).
5
Check the rotor end-float with a straight edge and a feeler gauge (C). For all the above clearances, see data and dimensions at the end of this section.
6
Install the oil pump, operation 19A-06.
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05
Alt= to hide template information Alt+ to display template information LUBRICATION SYSTEM 19A-09
Relief valve The relief valve (A) is installed in the timing case and prevents too much pressure in the lubricating oil system. As engine speed increases the output of the oil pump increases, and more oil flows into the system. The increase in flow causes an increase in pressure in the system. When the oil pressure on the plunger of the relief valve is greater than the spring pressure, the valve will open. When the valve opens, surplus oil is returned to the sump. This action will reduce the oil pressure and the valve will close. Oil which passes the relief valve reaches the oil filter.
To remove and to install
19A-08
1
Release the relief valve (A2) from the timing case (A1) and discard the "0" ring (A3).
2
Install a new "0" ring to the relief valve and install the relief valve into the timing case. Tighten the relief valve to 20 Nm (15 lbf ft) 2.0 kgf m.
To disassemble and to assemble 19A-09 1
2
3
Apply pressure to the end of the plunger (B2), release and discard the circlip (B1). Carefully release the pressure to remove the plunger and the spring (B3) from the valve body (B4). Remove the "0" ring (B5). Make sure that all the components are cleaned and then lubricated lightly with clean engine lubricating oil.
2
Check the plunger for wear and other damage and make sure that it slides easily in the bore of the relief valve.
3
Check the body for wear and other damage.
4
Renew worn or damaged components.
Install the spring into the plunger and install the plunger into the bore of the valve body. Apply pressure to the end of the plunger and install the circlip into its groove in the valve body. Release the plunger. Install a new "0" ring.
To inspect
19A-10
Do not try to change the operation pressure of the relief valve. If necessary, install new components. 1
Check the spring for wear and other damage and, if possible, check the load necessary to compress the spring to its installed length, see data and dimensions at the end of this section.
Bur 6-77740
Issued 11-04
Template Name: SM_1_col Template Date: 1994_04_05 19A-10 LUBRICATION SYSTEM
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Data and dimensions Introduction Note: This information is given as a guide for personnel engaged on engine overhauls. The dimensions which are shown are those which are mainly used in the factory.
Lubrication system Lubricating oil pump Type ................................................................................................................... Differential rotor, gear driven Number of lobes ......................................................................................................Inner rotor 4, outer rotor 5 Maximum permissible clearance of outer rotor pump body ..................................................0.19 mm (0.007 in) Inner rotor to outer rotor ......................................................................................................0.25 mm (0.010 in) Inner and outer rotor end clearance ....................................................................................0.15 mm (0.006 in) Lubricating oil relief valve Diameter of bore in pump body ..............................................................11.000/11.018 mm (0.5605/0.5625 in) Outside diameter of plunger ...................................................................10.970/10.982 mm (0.5585/0.5595 in) Clearance install of plunger in bore ........................................................... 0.018/0.048 mm (0.0007/0.0019 in) Length of spring (installed) ..................................................................................................25.5 mm (1.004 in) Load on spring (installed) ...........................................................................26.2/27.7 N (5.9/6.2 lbf) 2.7/2.8 kgf Pressure to open valve ..............................................................240/290 kPa (34.8/42.1 lbf/in2) 2.4/3.0 kgf m2 Lubricating oil filter Type .............................................................................................................. Full flow, screw-on type canister Pressure to open by-pass valve ............................................................ 55/83 kPa (8/12 lbf/in2) 2.4/3.0 kgf m2
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05
Fuel system
Alt= to hide template information Alt+ to display template information FUEL SYSTEM 20A-01
20
General description ................................................................................................20A.02 Fuel filter element 20A-01
To renew ..................................................................................................20A.03
Atomisers Atomiser fault ..........................................................................................20A.04 20A-02A To remove and to install - UA engines ......................................................20A.05 20A-02B To remove and to install - UB engines ......................................................20A.06 Fuel lift pump 20A-03 20A-04 20A-05
To remove and to install ..........................................................................20A.07 To disassemble and to assemble .............................................................20A.08 To test .....................................................................................................20A.09
Fuel injection pump 20A-06 20A-07
To remove and to install ..........................................................................20A.10 To eliminate air from the fuel system .......................................................20A.13
Fuel injection pump controls 20A-08 20A-09 20A-09A 20A-10 20A-10A 20A-11 20A-11A
To To To To To To To
remove and to install the governor weight assembly ............................20A.14 remove and to install the engine speed control lever assembly............20A.15 renew the components of the engine speed control lever assembly .....20A.16 remove and to install the fuel injection pump linkage ...........................20A.17 renew the fuel injection pump linkage ..................................................20A.19 record the maximum fuel position of the fuel control rack.....................20A.21 set the adjustment screw for the maximum fuel setting ........................20A.22
Data and dimensions ..............................................................................................20A.24
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05 20A-02 FUEL SYSTEM
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General description Caution: •
The fuel injection equipment must only be checked and adjusted by personnel who have had the correct training.
•
Do not allow dirt to enter the fuel system. Clean thoroughly the area around all of the components before they are removed and install suitable covers to ail open connections.
The fuel injection pump used on the 700 Series engine is a Zexel PFR cassette type pump (A) which is installed directly into the cylinder block. The cassette, contains the delivery valves, the pump elements and the fuel control rack. The pump elements are operated by a separate camshaft that is part of an assembly that is installed into the front of the cylinder block. The drive gear is driven by the idler gear. The governor weight assembly is installed to, the front of the gear for the camshaft for the fuel injection pump. The linkage that operates the fuel injection pump is contained within the timing case assembly. The fuel injection timing, is set at the factory and should only alter if the cylinder block or the camshaft for the fuel injection pump are renewed. If this occurs, the timing will have to be checked and if necessary, set to the correct figure. The timing is controlled by the use of a specific size shim (A1) that is installed between the flange of the fuel injection pump and the cylinder block. If the injection pump is removed, it can be installed with a new shim, of the same size, and the timing will not alter.
A The atomisers are set in the factory and must be checked in accordance with the preventive maintenance schedules shown in the users handbook. The pressure at which the atomisers operate can be adjusted by a change of shim, installed above the spring. The setting pressures for both types of atomiser are listed in Data and dimensions. The fuel lift pump is a diaphragm type and is mechanically driven from an eccentric on the camshaft for the fuel injection pump. The pump is installed to the right side of the cylinder block and has a priming lever. The fuel filter is a separate element type that is held between the filter head and a bottom cover. The filter head is installed to the right, rear side of the cylinder block.
To assist cold starts, the rack of the fuel injection pump is returned automatically to the excess fuel position when the engine stops. A data plate (A2) is installed on the side of the pump flange. The plate shows the part number and the code letters of the pump. An example of this is: 2644DO51AJ For full details of all pump codes, see Data and dimensions. The two stage atomiser for the UA engine is installed to, the cylinder head with a clamp assembly. The single stage atomiser for the UB engine has a threaded body and fits directly into the cylinder head. Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05
Alt= to hide template information Alt+ to display template information FUEL SYSTEM 20A-03
Fuel filter element To renew
20A-01
Cautions: •
It is important that only the genuine New Holland fuel filter element is used. The use of a wrong element can damage the fuel injection pump.
•
Do not allow dirt to enter the fuel system. Clean thoroughly the area around all of the components before they are removed and install suitable covers to ail open connections.
1
Clean the outside surfaces of the fuel filter assembly.
2
Hold the bottom cover of the filter element and release the setscrew (A1) which is installed through the filter head above the centre of the element.
3
Lower the bottom cover (A6) of the filter.
4
Remove the element (A4) and discard it.
Warning! Discard the used canister and fuel in a safe place and in accordance with local regulations. 5
Clean the inside surfaces of the filter head and of the cover.
6
Renew the seals (A2 and A5) and the '0' ring (A3) and lightly lubricate them with clean fuel. The larger seal is installed to the filter head and the smaller seal is installer to the bottom cover.
7
Put the bottom cover under the new element and hold the element squarely to the filter head. Make sure that the element is installed in the centre against the '0' ring in the filter head. With the assembly in this position, engage and tighten the setscrew.
8
Eliminate the air from the fuel filter, see operation 20A-07.
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05 20A-04 FUEL SYSTEM
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Atomisers Atomiser fault
20A-01
Warnings! •
If your skin comes into contact with high pressure fuel, obtain medical assistance immediately.
•
Keep a way from moving parts during engine operation. Some moving parts cannot be seen clearly white the engine runs.
An atomiser fault can cause an engine misfire. In order to find which atomiser is defective, operate the engine at a fast idle speed. Loosen and tighten the union nut (A1/B1) of the high-pressure fuel pipe at each atomiser. Do not loosen the union nut more than half a turn. When the union nut of the defective atomiser is loosened, it will have little or no effect on the engine speed.
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05 To remove and to install: - UA engines
Alt= to hide template information Alt+ to display template information FUEL SYSTEM 20A-05 20A-02A
Note: Identification letters for the atomiser are shown on the nozzle holder (A2). Caution: Do not allow dirt to enter the fuel system. Before a connection is disconnected, clean thoroughly the area around the connection. After a component has been disconnected, install a suitable cover to all open connections. To remove 1
Remove the fuel leak-off pipe.
Caution: Use a separate spanner to prevent movement of the outlets of the fuel injection pump when the high-pressure pipes are released or tightened. 2
3
Remove the union nuts of the high-pressure pipe from the atomiser and from the fuel injection pump. Do not bend the pipe. If necessary, remove the pipe clamps. Remove the setscrew (A7) of the atomiser clamp and remove the clamp (A6), the spacer (A5), the atomiser (A2) and its seat washer (A3).
2
Install the high-pressure fuel pipe and tighten the union nuts to 22 Nm (16 lbf ft) 2.2 kgf m. If necessary, install the pipe clamps.
3
Renew the sealing washers and install the leak-off pipe. Tighten the banjo bolts to 9 Nm (7 lbf ft) 0.9 kgf m.
4
Eliminate air from the fuel system, operation 20A-07.
5
Operate the engine and check for leakage of fuel and air.
To install Caution: A new clamp (A5) must be used every time the atomiser is installed to the engine. 1
Put the new atomiser in position together with a new seat washer and a new 'O' ring (A1), make sure that the sharp edges (A4) do not damage the new "0" ring. Install the atomiser into the cylinder head with a new clamp (A6) and spacer (A5). Engage the screw, make sure that the atomiser is not tilted and tighten the setscrew to, 22 Nm (16 lbf ft) 2.2 kgf m.
Cautions: • If there is a leakage from, the union nut, make sure that the pipe is correctly aligned with the atomiser inlet. •
Do not tighten the union nuts of the high-pressure pipes more than the recommended torque tension as this can cause a restriction at the end of the pipe. This can affect the fuel delivery.
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05 20A-06 FUEL SYSTEM remove and to install: - UB engines
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To
20A-02B
Consumable products: Loctite Atomiser thread sealant Note: Identification marks for the atomizer are stamped onto the side face of the nut (A4). Caution: Do not allow dirt to enter the fuel system. Before a connection is disconnected, clean thoroughly the area around the connection. After a component has been disconnected, install a suitable cover to all open connections. To remove
Cautions: •
If there is a leakage from the union nut, make sure that the pipe is correctly aligned with the atomiser inlet.
Caution: Use a separate spanner to prevent movement of the outlets of the fuel injection pump when the high-pressure pipes are released or tightened.
•
Do not tighten the union nuts of the high-pressure pipes more than the recommended torque tension as this can cause a restriction at the end of the pipe. This can affect the fuel delivery.
2
Remove the union nuts of the high-pressure pipe from the atomizer and from the fuel injection pump. Do not bend the pipe. If necessary, remove the pipe clamps.
3
Remove the plastic caps and install the highpressure fuel pipes, Tighten the union nuts to 22 Nm (l16 lbf ft) 2.2 kgf m. If necessary, install the pipe clamps.
Caution: The atomizer must be loosened and tightened with the nut (A4). Do not use the nut (A3) as this will split the body of the atomizer assembly.
4
Renew the sealing washers and fit the leak-off pipe. Tighten the banjo bolts to 9 Nm (7 lbf ft) 0.9 kgf m.
3
Use a 22 mm extended socket spanner to remove the atomiser from the cylinder head.
5
Operate the engine and check for leakage of fuel and air.
4
Clean thoroughly the threads on the body of the atomizer.
6
Eliminate air from the fuel system, operation 20A-07.
1
Remove the fuel leak-off pipe.
To install 1
Apply a 2 mm bead of Loctite atomizer thread sealant to extend 6 mm around each of the first two thread (A6). Make sure that the sealant does not contact the body (A2) of the atomizer
Caution: Do not move the atomizer alter it has been tightened, the seal that is made when torque has been applied will be broken and corrosion of the threads may occur. 2
Install a new flame shield washer (A1) with the red identification mark to the top. Put the atomizer in position together with a new seat washer (A5). Tighten the nut (A4) of the atomizer to 39 Nm (29 lbf ft.) 4.0 kgf m.
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05
Alt= to hide template information Alt+ to display template information FUEL SYSTEM 20A-07
Fuel lift pump To remove and to install
20A-03
1
Disconnect the fuel pipes from the fuel lift pump.
2
Release the setscrews and remove the fuel lift pump (A).
3
Make sure that the camshaft eccentric is in the minimum lift position before the lift pump is installed. Clean the joint face of the lift pump and the cylinder block and install the lift pump together with a new joint. Install the setscrews and tighten them gradually and evenly to 22 Nm (16 lbf ft) 2.2 kgf m.
4
Connect the fuel pipes.
5
Release the banjo bolt on the fuel filter head and operate the priming lever of the fuel lift pump to eliminate any air between the lift pump and the fuel filter. Operate the lift pump until fuel, free of air, comes from the banjo connection. Tighten the banjo bolt.
6
Operate the engine and check for any fuel or air leakage.
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05 20A-08 FUEL SYSTEM
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To disassemble and to assemble 20A-04 Note: The only components that can be renewed are: the inlet and the outlet valves and seals; the diaphragm; the joint to install the pump to the cylinder block To disassemble 1
Clean the outside surfaces of the fuel lift pump.
2
Make a mark across the flanges of the two halves of the pump to make sure correct relationship when the pump is assembled.
3
Release the setscrews and separate the two halves of the pump.
4
Turn the diaphragm assembly (A3) 90° to, release the pull rod from the link arm (A6) and remove the diaphragm assembly. Carefully remove the stem seal (A4), the spring seat washer (A5) and the spring (A7) from the pull rod. The diaphragm and pull rod are renewed as an assembly.
5
The valves (A2/A9) are peened into the upper part of the pump body and can be removed with a suitable lever. Some of the peened metal will have to, be removed before the valves can be removed.
6
round section of the pull rod. 3
Put the diaphragm assembly in position over the lower half of the body with the blade of the pull rod aligned with the slot in the link arm. Press lightly on the diaphragm until the notch in the pull rod is in the slot in the link arm and rotate the diaphragm 90° in either direction. This action will engage and retain the pull rod in the slot of the link arm.
4
Push the rocker arm towards the pump body until the diaphragm is level with the body flange and install the top half of the body in position with the marks on the flanges aligned. Keep the pressure on the rocker arm; install the spring washers and the screws and tighten them evenly
Check the components for wear and other damage. If components other than the valves and the diaphragm are worn, the complete pump will have to be renewed
To assemble 1
2
Thoroughly clean the valve housings. Install new seat washers (A1 /A8) and push the new valves (A2/A9) into position. As the valves are the same, but one valve is installed in reverse of the other, it is possible to install the valves upside down. To make sure that the valves are installed correctly, install them as shown in A. When the valves are correctly installed, peen the edge of the valve housings in six places, evenly divided, to keep the valves in position. Make sure that no metal debris remains in the pump body.
.
Carefully install the diaphragm spring (A7) into its location under the diaphragm (A3) and put the spring seat washer (A5) and the stem seal (A4) into position on the pull rod. Make sure that the small diameter at the top of the seal is on the
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05 To test
Alt= to hide template information Alt+ to display template information FUEL SYSTEM 20A-09 20A-05
1
Disconnect the fuel outlet tube from the fuel lift pump. Install a 0-70 kPa (0-10 lbf/in2) 0-0.7 kgf/ cm2 pressure gauge to the outlet of the lift pump. Release the connection at the gauge and operate the priming lever of the lift pump to eliminate air from the tube. When fuel, free of air, flows from the tube tighten the connection. Make sure that there are no leaks at the connections between the pump and the gauge.
2
Operate the starter motor for 10 seconds with the engine stop control in the stop position or with the stop solenoid disconnected.
3
Note the maximum pressure indicated on the gauge. If the pressure indicated is less than the test pressure of 31 kPa (4.5 lbf/in2) 0.32 kgf/m2, repair or renew the pump. Also check the rate at which the pressure reduces to half the maximum pressure obtained. If this is less than 30 seconds, repair or renew the pump.
4
Remove the gauge and connect the outlet pipe to the lift pump. Release the vent screw on the fuel filter head and operate the priming lever until fuel, free of air, flows from the vent screw. Tighten the vent screw.
5
Connect the engine stop solenoid.
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05 20A-10 FUEL SYSTEM
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Fuel injection pump To remove to install
20A-06
The fuel injection pump is installed directly into the cylinder block and is retained in position by two dowels, four flanged setscrews and two flanged nuts. The fuel injection timing is set at the factory and should only alter if the cylinder block or the camshaft for the fuel injection pump are renewed. If this occurs, the timing will have to be checked and if necessary set to the correct figure. The timing is controlled by the use of a specific size shim that is installed between the flange of the fuel injection pump and the cylinder block. If the fuel injection pump is removed for any other reason, it can be installed again with a new shim, of the same size, and the timing will not have altered. For this operation, the position of the crankshaft is not important. Cautions: • Clean around the edges of the fuel injection pump before it is removed. Dirt may enter the inside of the engine if this is not done. •
Use a separate spanner to prevent movement of the outlets of the fuel injection pump, when the high-pressure pipes are released or tightened.
To remove 1
Disconnect the battery.
2
Remove the fuel pipe (A3) that is installed between the fuel injection pump and the fuel filter.
3
6
Remove the support bracket / blanking plate (B1) from the side of the cylinder block. Record the position of the four setscrews because on some earlier engines, they are of different lengths.
Continued
Remove the fuel pipe (A1) that is installed between the fuel pump and the leak-off connection on top of the fuel filter.
Caution: Use a separate spanner to prevent movement of the outlets of the fuel injection pump when the high-pressure pipes are released or tightened. 4
Release the union nuts (A2) of the high-pressure pipes from the atomisers and from the fuel injection pump and remove the pipes. Do not bend the pipes.
5
Remove the electrical stop solenoid.
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05 7
Alt= to hide template information Alt+ to display template information FUEL SYSTEM 20A-11
Disconnect the spring (A1) from the groove in the peg (A2) on the.
Caution: When the spring (A3) is disconnected from, the peg (A2), it is possible for the spring to become disconnected from the pin (A4). If this occurs, the spring can fall into the sump. 8
Disconnect the spring (A3) from the groove in the peg on the rack.
9
Disconnect the governor control link (A5) from the peg on the rack.
10 Remove the four flanged setscrews (A6), the two flanged nuts (A7) and lift the pump from the cylinder block. To install Cautions: • Debris may fait into the engine if the hole in the cylinder block for the pump is not protected. •
When the pump is installed, new shim of the correct size must be installed, without sealant. A thin layer of sealant is included within the final thickness of each new shim. Extra sealant will affect the timing of the fuel injection.
1
Clean the surface of the flanges for both the pump and the cylinder block. Install a new shim (B1) of the correct size (see table opposite) to the flange on the cylinder block.
2
3
4 5
Make sure that the peg (B2) is aligned with the cutout (B3) and that the shim is installed onto the two dowels (B4). Carefully install the pump onto the studs and the dowels and make sure that the link (A5) is not damaged. Install the nuts (A7) and setscrews (A6) and tighten them evenly to 22 N m (16 lbf ft) 2,2 kgf m. Install the governor control link (A5) onto the peg (A2) on the rack.
6
Install the spring (A1) into the groove on the peg.
Timing shims Part number
Thickness mm (in)
3621F011
0.1 (0.004)
3621F012
0.2 (0.008)
3621F013
0.3 (0.012)
3621F014
0.4 (0.016)
3621F015
0.5 (0.020)
Continued
Install the spring (A3) to the groove in the peg (A2) on the rack.
Caution: The spring (A1) must retain at all times, the spring (A3) and the governor control link (A5) onto the peg (A2). If the governor control link becomes separated from the peg, control of the engine speed will be lost! Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05 20A-12 FUEL SYSTEM 7
Clean the surfaces for the joint for the blanking plate (A1). Install a new joint and the blanking plate to the side of the cylinder block.
8
Install the stop solenoid.
9
Install the high-pressure fuel pipes and tighten the union nuts (B2) to 22 Nm (16 lbf ft) 2.2 kgf m.
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Cautions: •
If there is a leakage from the union nut, make sure that the pipe is correctly aligned with the atomiser inlet.
•
Do not tighten the union nuts of the high-pressure pipes more than the recommended torque tension as this can cause a restriction at the end of the pipe. This can affect the fuel delivery.
10 Install the fuel pipe (B1) that is installed between the pump and the leak-off connection on the top of the fuel filter, and tighten the union nuts to 20 Nm (15 lbf ft) 2.0 kgf m. 11 Install the fuel pipe (B3) that is installed between the pump and the fuel filter and tighten the union nuts to 20 Nm (15 lbf ft) 2.0 kgf m. 12 Eliminate air from the system, operation 20A07. 13 Connect the battery. 14 Operate the engine and check for leakage of fuel and air.
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05 To eliminate air from the fuel system
Alt= to hide template information Alt+ to display template information FUEL SYSTEM 20A-13 20A-07
If air enters the fuel system, it must be eliminated before the engine can be started. Air can enter the system if: • The fuel tank is drained during normal operation. •
The low-pressure fuel pipes are disconnected.
•
A part of the low-pressure fuel system leaks during engine operation.
In order to eliminate air from the fuel system, proceed as follows: 1
Loosen the vent plug (A1) on the side of the fuel injection pump.
2
Operate the priming lever of the fuel lift pump (A2) until fuel, free from air, comes from the vent point. Tighten the vent plug.
3
Turn the start key to the "ON" position.
4
Operate the starter motor for intervals of 15 seconds until the engine starts. If the engine runs correctly for a short time and then stops or runs roughly, check for air in the fuel system. If there is air in the fuel system, there is probably a leakage in the low pressure system. Stop the engine and turn the start key to the "OFF" position.
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05 20A-14 FUEL SYSTEM
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Fuel injection pump controls The components listed below are part of the timing case assembly and are used to control the engine speed, performance and emissions: the governor control lever (A1); the Angleich (torque control) unit (A2); the adjustment screw for the maximum fuel setting (A3); the engine speed control lever (A4); the fuel control lever (A5); the governor control link (A6). Items (A1), (A2), (A5) and (A6) are referred to as "the fuel pump linkage" in operation 20A-10A. The governor weight assembly (A7), is installed to the front of the gear for the camshaft for the fuel injection pump.
To remove and to install the governor weight assembly
20A-08
To remove 1
Remove the timing case assembly, operation 15A-01.
2
Remove the thrust sleeve (B2) from the spigot on the gear.
3
Remove the four flange face setscrews (B1) and withdraw the weight assembly (B4) from the front of the gear.
4
Check the components for wear and renew them as necessary.
To install 1
Install the weight assembly (B4) with the four flange face setscrews (B1) to the front of the gear and tighten the setscrews (B1) to 7 Nm (5 lbf ft) 0.7 kgf m.
2
Lubricate with clean engine lubricating oil, the spigot on the gear and install the thrust sleeve (B2). Make sure that the flange of the sleeve is installed into the recess (B3) in each weight.
3
Move the thrust sleeve backwards and forwards along the shaft, to make sure that the four weights (B5) operate correctly.
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05
Alt= to hide template information Alt+ to display template information FUEL SYSTEM 20A-15
To remove and to install the engine speed control lever assembly 20A-09 Consumable products Loctite platelock To remove 1
Remove the timing case assembly, operation 15A-01.
2
Remove the nut, the spring washer and the plain washer from the shaft (A4) and withdraw the lever (A1) from the shaft. Unless the lever or the spring (A5) are to renewed, it will not be necessary to disconnect the spring from the lever.
3
Withdraw the lever assembly (B4) from the bush (B3). Check the components for wear or damage.
Caution: The bush (B3) is installed to the timing case with a special adhesive and must not be removed. If the bush is removed, the threads in the timing case will be damaged. To install 1
Clean and lubricate the shaft (B1) and the 'O' rings (B2) with a small quantity of grease. Install the lever assembly (B4) into the bush (B3).
2
Make sure that both ends of the spring (A5) are installed securely to both levers.
3
Install the lever (A1) with the spring onto the flat section (A3) of the shaft.
Caution: Make sure that Loctite does not enter the bush (A2). 4
Apply a small quantity of Loctite Platelock to the threads of the shaft (A4). Install the plain washer, the spring washer and the nut and tighten the nut to 10.5 Nm (8 lbf ft) 1.1 kgf m.
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05 20A-16 FUEL SYSTEM
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To renew components of the engine speed control lever assembly 20A-09A To renew 1
Remove the engine speed assembly, operation 20A-09.
2
Remove the nut (A3).
3
Remove the lever (A2) from the shaft (A1).
4
Remove the '0' rings (A6) from the shaft.
5
Renew the components as necessary.
6
Install the '0' rings to the shaft.
7
Install the lever to the shaft. Make sure that the lever is installed correctly to the key (A5) on the shaft.
8
Make sure that the slot (A4) is clean. Install the nut and tighten to a torque of 45 Nm (33 lbf ft) 4.6 kgf m.
9
Install the engine speed control lever assembly, operation 20A-09.
Bur 6-77740
control
lever
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05 To remove and to install the fuel injection pump linkage
Alt= to hide template information Alt+ to display template information FUEL SYSTEM 20A-17 20A-10
Consumable products Loctite platelock Note: The fuel injection pump linkage is contained within the timing case assembly. The linkage contains two lever assemblies, one for the governor control and one for the fuel control. Caution: When the fuel injection pump linkage is remove / renewed, or a new timing case is installed, the setting for the maximum fuel may be affected. To remove 1
Remove the timing case assembly, operation 15A-01.
2
Remove the nut, the spring washer and the flat washer from the shaft (A4) and remove the lever (A1) from the shaft.
3
Remove the brass plug (B1) from the side of the timing case (B2).
4
Remove the two spring clips (C5) that hold the levers (C3) and (C4) in position. Remove the outer shaft (C1) that retains the inner shaft (C2). Remove the inner shaft.
5
Remove the governor control lever assembly (C3) and the fuel control lever assembly (C4). Check the components for wear and renew as necessary, operation 20A-10A.
Continued
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05 20A-18 FUEL SYSTEM
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To install 1
Clean and lubricate the shafts (A1) and (A2) with clean engine lubricating oil.
2
Install the inner shaft (A1) and then the outer shaft (A2) into, the timing case assembly until the inner shaft has just entered the lever assembly (A3).
3
Align the holes in the lever (B1) with the holes in the lever (B3). Continue to push the outer shaft into the timing case assembly until the inner shaft has passed through both the levers and into the boss (B2). Install the clips (B4).
4
Install the plug (C1) with the sealing washer to the timing case (C2). Tighten the plug to 13 Nm (10 lbf ft) 1.3 kgf m.
5
Move the levers in both directions to make sure that there is no restriction to their movement.
6
Make sure that both ends of the spring (D5) are installed securely to the levers and install the lever (D1) onto the flat section (A3) of the shaft (D4).
Caution: Make sure that Loctite does not enter the bush (D2). 7
Apply a small quantity of loctite Platelock to the threads of the shaft (B4). Install the plain washer, the spring washer and the nut and tighten the nut to 10.5 Nm (8 lbf ft) 1.1 kgf m.
8
Operate the lever for the engine speed control to make sure that there is no restriction to movement.
9
Install the timing case assembly, operation 15A-01.
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05 To renew the fuel injection pump linkage
Alt= to hide template information Alt+ to display template information FUEL SYSTEM 20A-19 20A-10A
Consumable products Loctite platelock Note: The fuel injection pump linkage is contained within the timing case assembly. The linkage contains two lever assemblies, one for the fuel control (A) and one for the governor control (20A.20/A). Caution: When the fuel injection pump linkage is remove / renewed, or a new timing case is installed, the setting for the maximum fuel may be affected. To disassemble the fuel control lever assembly 1
Remove the fuel injection pump linkage, operation 20A-10.
2
Disconnect the spring (A3) from the pegs (A1/ A2).
3
Remove carefully, the spring (B3) from the Angleich (torque control) unit (B1).
4
Remove the Angleich unit.
5
Inspect the components for wear and renew as necessary.
To assemble the fuel control lever assembly Caution: Make sure that adhesive does not enter the joint line (C2). 1
Apply a small amount of Loctite Platelock to the first two threads (C1) and install the Angleich unit to the lever. Tighten the Angleich unit to 18 Nm (13 lbf ft) 1.3 kgf m.
2
Install carefully, the spring to the Angleich unit. Make sure that the closed coils (B3) are towards the arm (B2).
3
Install the spring (A3) to the pegs (A1/A2). Continued
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05 20A-20 FUEL SYSTEM
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To disassemble the governor control lever assembly 1
Remove the circlip (B2) from the end of the pin (A3).
2
Compress the spring (A4) and remove, the pin from the lever (A2).
3
Release the spring and remove it from the link (A1).
4
Remove the spring (A5) from the link.
5
Inspect the components for wear and renew as necessary.
To assemble the governor control lever assembly 1
Install the spring (B6) to the link (B11). Make sure the large hook is furthest from the lever (B3).
Note: The purpose of the large hook is to retain the governor link to the peg on the fuel control rack. 2
Install the spring (B5) to the link.
3
Compress the spring and hold the link against the outside of the lever (B3) and insert the pin (B4).
4
Install the circlip (B2). To check that it is installed correctly in the groove, rotate the circlip.
5
Install the fuel injection pump linkage, operation 20A-10.
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05 To record the maximum fuel position of the fuel control rack
Alt= to hide template information Alt+ to display template information FUEL SYSTEM 20A-21 20A-11
Special tool: Lever clamp and rack setting tool, PD.254 The two lever assemblies of the fuel pump linkage operate together to control the fuel settings and the governor control of the engine. The maximum fuel position of the fuel lever (and fuel control rack) is controlled by the adjustment screw installed to the top of the timing case. The position of this screw is set at the factory and under normal conditions of operation, it must not be altered. If the timing case and fuel pump linkage are removed / renewed, the adjustment screw must be set to give the correct setting for maximum fuel. 1
Disconnect and remove the return spring from the engine speed control lever.
Caution: Make sure that the components behind the 'D' plug are not damaged. 2
Remove the 'D' plug (A4) from the timing case (A1).
3
Remove the access plate (B1) from the cylinder block.
4
Put the tool into the timing case such that the end of the tool (C1) points downwards.
5
When the end of the tool (C2) is entered far into the timing case, rotate the tool counter-clockwise 90° (C5) to engage the lever (C3). The end of the tool (C6) should now be behind the lever (C8).
6
Tighten the adjustment screw (C4), finger tight, to compress the Angleich unit between the two levers. Make sure that the sides of the tool do not touch the bore (A1) for the 'D' plug. Continued
Notes: • The Angleich, is a spring loaded component. •
The levers (C7/C8) should be compressed between the end of the tool (A2/3).
•
To Make sure that the tool has compressed both the levers, move the tool backwards and forwards. The peg should move with the tool.
7
Remove the low-pressure fuel pipes and the fuel filter assembly.
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05 20A-22 FUEL SYSTEM
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8
Remove the electrical stop solenoid. Make sure that the joint is removed.
9
Install the setting tool (A3) to the flange for the electrical stop solenoid.
Caution: During the setting procedure, make sure that the fuel control rack (B2) is held in the maximum fuel position. 10 Push (towards the rear of the engine) the tool (B3) and the rack (B2) to the maximum (excess) fuel position. With the rack held in this position, turn carefully the adjustment screw (B1) of the setting tool until the tip (A2) is felt to just touch the end of the rack (A1). Tighten the nut (B5) to lock the tool in this position. 11 Remove the clamp tool from the levers in the timing case. 12 Disconnect the governor link from the peg (B2) operation 20A-06, paragraphs 7, 8 and 9. 13 Remove the cap nut and record the setting position for the screws for the maximum fuel (C1), the high idle (C2) and the low idle (C3).
To set the adjustment screw for the maximum fuel setting
20A-11A
Special tool: Lever clamp and rack setting tool, PD.254 Consumable products: Loctite Platelock Loctite 518 Liquid gasket 1
Install the timing case assembly, operation 15A-01.
2
Install carefully, the clamp tool and tighten finger tight only, the screw to compress the two levers (D).
Continued
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05
Alt= to hide template information Alt+ to display template information FUEL SYSTEM 20A-23
Caution: During the setting procedure, make sure that the fuel control rack (B2) is held in the maximum fuel position (towards the rear of the engine). 3
Push the tool (B3) and the rack (B2) such that it just touches the tip of the setting tool (A2). The rack will now be in the maximum (excess) fuel position. With the rack and tool held in this position (C2) turn carefully the adjustment screw (C1) for the maximum fuel setting until it just touches the lever (D1).
4
Use a screwdriver (C3) to hold the adjustment screw (C5) in this position, and tighten the lock nut (C4) to 12 Nm (9 lbf ft) 1.2 kgf m.
5
Check that the rack and tool are still in the maximum fuel position (B).
6
Install the sealing washer and the cap nut (C6) and tighten the cap nut to 12 Nm (9 lbf ft) 1.2 kgf m.
7
Set to their original settings, the adjustment screws for the high and the low idle speeds.
8
Carefully remove the clamp tool for the levers.
9
Apply Loctite Liquid gasket to, the side faces of the 'D' plug and fit the plug to the timing case.
10 Remove the setting tool and install the electrical stop solenoid. 11 Install the fuel filter assembly and the low pressure fuel pipes. 12 Check again that the governor link and springs are installed securely and install the access plate and joint. 13 Install the return spring to the engine speed control lever. 14 Eliminate air from the fuel system, operation 20A-07. 15 Connect the battery and control cables. Start the engine and check for oil leakage, the maximum no-load and idle speeds. 16 When the speeds are correct, seal against interference, the adjustment screws for the maximum no-load speed and the maximum fuel setting. Bur 6-77740
Issued 11-04
Template Name: SM_1_col
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Template Date: 1994_04_05 20A-24 FUEL SYSTEM
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Data and dimensions Introduction Note: This information is given as a guide for personnel engaged on engine overhauls. The dimensions which are shown are those which are mainly used in the factory. Fuel injection pump Make.................................................................................................................... Zexel PFR-KX in-line cassette type Direction of rotation .............................................................................................................Clockwise from drive end Fuel pump code letters: - UA engines..................................................................................................................................................... AJ, BJ - UB engines..................................................................................................................................................... CJ, DJ Code letters, see table below: Fuel lift pump Type........................................................................................................................................................... Diaphragm Method of drive.................................................................................... Eccentric on camshaft for fuel injection pump Static pressure - no delivery .......................................................................... 42/70 kPa (6/10 lbf/in2) 0.4/0.7 kgf/cm2 Test pressure 75% of minimum static pressure ....................................................... 31 kPa (4.5 lbf/in2) 0.32 kgf/cm2 Atomisers Atomisers code letters: - UA engines (two stage injection).......................................................................................................................... UA - UB engines (single stage injection) ...................................................................................................................... UB
Setting pressures for atomisers Engine type
Code letter
UA UB
Set pressure (1) Bar (lbf/in2) Mpa
Re-set pressure (2) Bar (lbf/in2) Mpa
Stage one
Stage two
Stage one
Stage two
UA
190 (2793) 19.25
230 (3381) 23.3
200 (2940) 20.3
243 (3572) 24.6
UB
120 (1764) 12.2
---
130 (1911) 13.2
---
(1) For original atomisers (2) For atomisers which have been overhauled (for example, installed with new springs)
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05
Cooling system
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21
General description ................................................................................................21A.02 Thermostats 21A-01
To remove, to install and to test ............................................................. 21A.03
Coolant pump 21A-02
To remove and to install ..........................................................................21A.04
Fan 21A-03
To remove and to install ..........................................................................21A.05
Cooling system 21A-04 21A-05
To drain...................................................................................................21A.06 To fill .......................................................................................................21A.06
Data and dimensions ..............................................................................................21A.07
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05 21A-02 COOLING SYSTEM
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General description Coolant from the bottom of the radiator passes through the centrifugal coolant pump, which is installed onto the front of the cylinder block to assist the flow of the coolant through the system. The pump is driven by a 'V' belt from the crankshaft pulley. From the pump, the coolant passes into the front of the cylinder block. The coolant then passes around the cylinders and up into the cylinder head. The coolant leaves the cylinder head at the front and passes into the thermostat housing. When the engine is cold the thermostat is fully closed and the coolant goes directly through a bypass valve in the thermostat to the inlet side of the coolant pump. As the engine warms the thermostat begins to open and some of the coolant flows to the top of the radiator. The thermostat will open fully when the engine reaches the normal temperature of operation. When the thermostat is open, the by-pass valve is closed and the coolant passes to the top of the radiator. The thermostat maintains the correct engine temperature by a balance of by-pass flow and full flow to the top of the radiator. Air passes over the radiator fins and heat is removed from the coolant as it passes through the radiator. The coolant leaves the radiator through the bottom hose and returns to the coolant pump.
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05
Alt= to hide template information Alt+ to display template information COOLING SYSTEM 21A-03
Thermostats To remove, to install and to test
21A-01
To remove 1
Drain the cooling system, operation 21A-04.
2
Release the clip (A1) from the outlet connection and remove the hose.
3
Release the two setscrews (A2) and remove the cap (A3) from the thermostat housing. Remove the thermostat (A4).
To install 1
Make sure that the seat in the thermostat housing for the thermostat is clean. Put the thermostat (A4) into position in the housing. Make sure that the jiggle pin (A5) is at the top, see the arrow in A, and is free to move.
2
Make sure that the joint faces of the housing and the cap are clean. Install a new joint to the cap and install the cap to the housing. Tighten the two setscrews to 22 Nm (16 lbf ft) 2.2 kgf m.
Make sure that the outlet connection is clean and install the hose. Tighten the hose clip. Fill the cooling system, operation 21A-05. .To test 1
Hang the thermostat unit in a suitable container filled with coolant.
2
Heat the coolant gradually. Use a thermometer to check the temperature at which the valve starts to open and at which it is fully open. The correct temperature is given in the Data and dimensions.
Caution: If the thermostat does not operate correctly, it must be renewed. Do not try to adjust the settings.
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05 21A-04 COOLING SYSTEM
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Coolant pump To remove and to install
21A-02
To remove 1
Drain the cooling system, operation 21A-04.
2
Remove the drive belt, operation 23A-03.
3
Remove the fan, operation 21A-03, the fan extension and the pulley.
4
Release the hose clips (A1). Remove the hoses from the coolant pump.
5
Remove the four nuts (A2) that fasten the pump to the cylinder block and remove the pump (B1) from the engine.
6
Remove the spacer (B2).
To install 1
Thoroughly clean the mounting faces of the cylinder block, the spacer (C1) and the rear plate for the coolant pump.
2
Renew the "0" ring (C2) on each side of the spacer and install the spacer.
3
Install the coolant pump to the timing case and tighten the four nuts to 22 Nm (16 lbf ft) 2.2 kgf m.
4
Connect the hoses to the coolant pump and tighten the clips.
5
Put the pulley onto the hub and the fan extension onto the pulley and install the fan, operation 21A-03.
6
Install the drive belt, operation 23A-03.
7
Install the cooling system, operation 21A-05.
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05
Alt= to hide template information Alt+ to display template information COOLING SYSTEM 21A-05
Fan To remove and to install
21A-03
To remove Release the four setscrews and remove the fan. If necessary, install the setscrews to retain the fan extension and the pulley to the hub. To install Clean thoroughly the rear of the fan where it fits onto the fan extension. Also make sure that all paint is removed from this area. Put the pulley into position on the hub and the fan extension onto the pulley. Clean the front face of the fan extension. Install the fan and tighten the setscrews to 22 Nm (16 lbf ft) 2.2 kgf m.
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05 21A-06 COOLING SYSTEM
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Cooling system To drain
21A-04
Warnings! • Do not drain the coolant while the engine is still hot and the system is under pressure because dangerous hot coolant can be discharged. •
Discard used coolant in a safe place and in accordance with local regulations.
1
Make sure that the machine is on a horizontal surface.
2
Remove the filler cap of the cooling system.
3
Remove the drain plug (A1) from the side of the cylinder block in order to drain the engine. Make sure that the drain hole is not restricted.
4
Open the tap or remove the drain plug at the bottom of the radiator in order to drain the radiator. If the radiator does not have a tap or drain plug, disconnect the hose at the bottom of the radiator.
5
Flush the system with Loctite Easy Flush.
6
Install the drain plugs and the filler cap. Close the radiator tap or connect the radiator hose.
To drain
21A-05
Warnings! • If coolant is to be added to the system during service, allow the engine to cool before the coolant is added. Remove the filler cap slowly, dangerous hot coolant could be discharged if the cooling system is still under pressure. •
too quickly, or if coolant is added when the machine is not on a horizontal surface. •
If the engine is operated with air in the system, the temperature of operation will be too high and the engine will be damaged.
1
Make sure that the machine is on a horizontal surface.
2
Slowly remove the filler cap of the header tank.
3
Slowly fill the cooling system to the correct level as shown in the manufacturers handbook for the application. Allow time for air bubbles to be released from the system and install the cap.
4
Start the engine. When it has reached its normal temperature of operation, stop the engine and allow it cool.
5
Slowly remove the filler cap of the header tank and if necessary, add coolant to the correct level as shown in the Operator’s Manual for the machine. Install the filler cap.
Do not put too much coolant in the cooling system. There is a relief valve in the filler cap which will open and release hot coolant if too much coolant is added.
Cautions: •
If coolant is added to the system during service, it must be of the same specification as the original that was used to fill the system. See "Coolant specification" in section 5 of the users handbook.
•
Air will remain in the system if coolant is added
Bur 6-77740
Issued 11-04
Template Name: SM_1_col Template Date: 1994_04_05
Alt= to hide template information Alt+ to display template information COOLING SYSTEM 21A-07
Data and dimensions Introduction Note: This information is given as a guide for personnel engaged on engine overhauls. The dimensions which are shown are those which are mainly used in the factory. Cooling system Type............................................................................................................Thermostat controlled - pump assistance Water pump Type.........................................................................................................................................Centrifugal, belt driven Thermostat Type.............................................................................................................................................Single, wax element Nominal temperature stamped on the base of the by-pass valve
"Start to open" temperature
"Fully open" temperature
Minimum valve lift, fully open
82.0 °C (179.6 °F)
77/85 °C (170.6/185.0 °F)
92/98 °C (197.6/208.4 °F)
9 mm (0.35 in)
76.0 °C (159.8 °F)
67/75 °C (152.6/167.0 °F)
85/88 °C (185.0/190.4 °F)
9 mm (0.35 in)
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05 21A-08 COOLING SYSTEM
Bur 6-77740
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Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05
Alt= to hide template information Alt+ to display template information FLYWHEEL AND FLYWHEEL HOUSING 22A-01
Flywheel and flywheel housing
22
General description ................................................................................................22A.02 Flywheel 22A-01
To remove and to install .........................................................................22A.03
Ring gear 22A-02
To remove and to install .........................................................................22A.04
Flywheel housing 22A-03
Bur 6-77740
To remove and to install ..........................................................................22A.04
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05 22A-02 FLYWHEEL AND FLYWHEEL HOUSING
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General description The flywheel is installed with a hardened starter ring. The flywheel housing is normally made of cast iron.
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05
Alt= to hide template information Alt+ to display template information FLYWHEEL AND FLYWHEEL HOUSING 22A-03
Flywheel To remove and to install
22A-01
Consumable products: Loctite 603 (oil tolerant) Warning! The flywheel is heavy, use lift equipment or get help to assist with the lift operation before removal of the flywheel fasteners. To remove 1
Remove two opposite setscrews from the flywheel and install temporarily two guide studs to make sure of safety when the flywheel is removed and installed.
2
Remove the remainder of the setscrews and washers and remove the flywheel.
3
Check the flywheel and ring gear for damage and renew, if necessary.
To install 1
Make sure that the location faces of the crankshaft and the flywheel are clean and free from damage.
2
Install temporarily two guide studs in opposite holes in the crankshaft palm to make sure safety when the flywheel is installed. Install the flywheel over the guide studs. Apply Loctite Retainer (oil tolerant) to the first three threads of the setscrews and Install four setscrews and their washers. Remove the guide studs and install the remainder of the setscrews and the washers. Tighten the setscrews to 100 Nm (74 lbf ft) 10.2 kgf m.
3
Check the flywheel run-out with a dial test indicator (A). This must be less than 0.30 mm (0.012 in) total indicator reading.
4
Check the alignment of the flywheel face (B). The error in alignment must not be more than 0.03 mm (0.001 in) total indicator reading for every 25 mm (1.0 in) of the flywheel radius from the crankshaft axis to the indicator plunger. During this operation, keep the crankshaft pressed toward the front to remove the effect of crankshaft end-float.
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05 22A-04 FLYWHEEL AND FLYWHEEL HOUSING Ring gear To remove and to install
2
Install the housing onto the dowels and tighten the setscrews and the two cap screws to 44 Nm (32 lbf ft) 4.5 kgf m.
3
Install the flywheel, operation 22A-01 and the starter motor, operation 23B-01.
22A-02
To remove
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Warning! wear eye protection during this operation. Note: To make sure that the new ring gear is installed correctly, record the direction of the chamfer of the gear teeth. Install the new gear with the chamfer in the same direction. To remove the ring gear use a hammer and a chisel to break the ring. Make sure that the flywheel is not damaged during this operation. To install The ring gear is heated onto the flywheel. When a new gear is to be installed, make sure that it is not heated to more than 250°C (480 °F). Make sure that the chamfer on the teeth of the gear is in the correct direction.
Flywheel housing To remove and to install
22A-03
Warning! The flywheel housing is heavy, use lift equipment or get help to assist with the lift operation before removal of the flywheel housing fasteners. To remove 1
Remove the starter and the flywheel, operation 22A-01.
2
Release the six setscrews and the two cap screws. Carefully hit the housing, with a soft face hammer, to remove it from the dowels.
To install 1
Make sure that the rear face of the cylinder block and the faces of the housing are clean and free from damage. Make sure that the location dowels are installed correctly. If a felt seal is installed to the rear flange of the sump, replace the seal.
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05
List of Special Tools
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25-01
25
List of special Tools ..................................................................................................25A.02
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05
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25-02
SPECIAL TOOLS Number
Description
PD.1D
Remover/replacer for valve guides (main tool)
PD.1D/2
Spacer used with main tool PD.1D
PD.1D-13
PD.41D
Illustration
Adaptor for use with PD.1D
Gauge for piston height, valve depth, cylinder liner potrusion, for use with PD.208
PD.170 Replacer tool for seal of timing case cover (main tool)
Bur 6-77740
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05
PD.184
Slide hammer
PD.208
Dial gauge for use with PD.41D
PD.243
Rubber plug replacer tool
PD.244
Adaptor for PD.6118B
PD.249
Adaptor for valve guide depth, used with PD1D.13
Bur 6-77740
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25-03
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05
25-04
PD.254
Kit, governor arm lock consists of tools to measure rack movement
PD.255
Replacer tool for rear oil seal, use with MS.550
PD256
Replacer tool for idler gear hub, use with MS.550
PD.258
Adaptor / remover idler hub for use with PD.184
PD.259
Adaptor / main tool to crankshaft nose, for use with PD.170
PD.260
Adaptor for front seal, for use with PD.170
Bur 6-77740
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Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05
PD.6118B
Set of adjustable cutters for valve seats
MS.550
Universal drive handle
No.8
Bur 6-77740
25-05
Valve spring compressor
MS.76A
MS.1519A
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Valve spring compressor
Piston ring compressor
Issued 11-04
Template Name: SM_2_col Template Date: 1994_04_05
25-06
Bur 6-77740
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Issued 11-04
CNH America LLC 245 E NORTH AVENUE CAROL STREAM, IL 60188 U.S.A
Part Number North American English Printed in U.S.A.
6-77740NA November 04 Bur