ENGINE REPAIR MANUAL ADE 360 SERIES - Barrington Diesel Club · The 360 Series are direct injection, water-cooled four-stroke diesel engines. The cylinders are arranged in line and

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BDCFrom the Library of Barrington Diesel Club

ENGINE REPAIR MANUAL ADE 360 SERIES

ATLANTIS DIESEL ENGINES (PTY) LTD

Part No. 805*&S4iby the Service Departm ent of A tla n tis Diesel Enain®

FOREWORDThe 360 Series are direct injection, water-cooled four-stroke diesel engines. The cylinders are arranged in line and are positioned vertically. Depending on application 360 series engines can be fitted with a turbocharger. The engines have been designed to take advantage of the latest technology, w ith special emphasis on the smallest possible dimensions, a favourable power to weight ratio and low fuel consumption. ADE engines have a left hand rotation when viewed from the rear. Throughout this manual, whenever Left or Right hand side of the engine is referred to, it is the side of the engine when viewed from the flywheel end.This publication has been written to assist all personnel engaged in the maintenance and overhaul of the ADE Diesel Engine. All necessary information contained in this manual is presented in a logical step by step format with the text supported by line illustrations, which are positioned on the right hand side of the page, together with precise instructions on the servicing and overhaul procedure. In addition each section contains a schedule of manufacturing data and dimensions which must be closely followed when overhauling any part of the engine to the Manufacturers standards. Effective maintenance can only be carried out if the personnel concerned are fully conversant with the various components of the engine. Before maintenance operations are commenced, therefore, this manual should be carefully studied, and should at all times be kept where it w ill be needed in the workshop. Certain operations described in this manual require the use of special tools. These tools

' are obtainable from Grundy-Techniform. Full details are given in the appropriate sections.A Product Training Representative, highly skilled in the special characteristics of ADE Engines, is available to assist you with product training through your Original Equipment Manufacturer (O.E.M.).

ENGINE PARTS

Whenever parts are required for ADE Engines, it is essential that the fullest information possible is given, always quote the engine number, type of application, and where possible the part number and description. In accordance with the Preventative Maintenance Plan, your engine will require such items as fuel, oil and air filters. It is in your own interest to ensure that only genuine ADE Parts are used. Each genuine ADEPART, is backed with a six month guarantee ensuring the highest quality, and every part complies with the original specification.

RUNNING-IN PROCEDURE

It is not necessary to gradually run-in a new ADE engine, and any prolonged light load running during early life of the engine can in fact prove harmful to the bedding in of the piston rings and liners. Full load can be applied provided that the engine has reached operation temperature.

This publication is produced by the Service Department of A tlantis Diesel Engines (Pty) Ltd, and every endeavour has been made to ensure that the information contained in this manual is correct at the time of publication, however, continuous development and advancement in product design may reflect changes made to your engine which are not included in this publication.

© COPYRIGHT 1988 ATLANTIS DIESEL ENGINES (PTY) LTD.

Reproduction or translation, in part or full is subject to the written authorization of A tlan tifD iese l Engines (Pty) Ltd.

CONTENTS

TECHNICAL DATA ................................................................................................................................. ......... 08

OPERATING MAINTENANCE SCHEDULE AND LUBRICATING OILS ..............................................09

FAULT FINDING ...............................................................................................................................................10

CYLINDER BLOCK AND LINERS .................................................................................................................11

CYLINDER HEAD .............................................................................................................................................12

PISTONS AND CONNECTING RODS .......................................................................................................... 13

CRANKSHAFT AND MAIN BEARINGS ....................................................................................................... 14

CAMSHAFT, TIMING CASE AND DRIVE-TIMING ................................... ...................................................15

LUBRICATING SYSTEM AND SUMP ............................................................................................................16

FUEL SYSTEM .................................................... ............................................................................................ 17

TURBOCHARGER ........................................................................................................................................... 18A

POWER STEERING ....................................................................................................................................... 18B

EXHAUST BRAKE ........... ....18C

FLYWHEEL ...................................................................................................................................................... 18D

ALTERNATOR AND STARTER MOTOR .................................................................................................... 18E

COMPRESSOR/VACUUM PUMP ..................................................................................................................18F

COOLING SYSTEM ........................................................................................................................................ 19

APPROVED SERVICE TOOLS ......................................................................REFER TO EACH SECTION

SECTION 08-1Technical Data

ADE 364N/C/T/TI

ENGINE DATA

ADE 364N ADE 364C ADE 364T ADE 364TI

B o r e ........................................................................... 97,5 mm ..................97,5 mm ..................97,5 mm ..................97,5 mmS troke ....................................................................... 133 mm ...................133 mm ................... 133 mm ................... 133 mmNo. o f c y l in d e rs .................................................... 4 ................................4 .................................4 ................................. 4C ub ic ca p a c ity ..................................................... 3,972 t .................... 3,972 ( ..................... 3,972 ( ..................... 3,972 fC om press ion ra tio ............................................... 17,25:1 .....................17:1 ........................... 16,5:1 ........................16,5:1C om press ion te s t p ressure a t opera ting tem pera tu re (Max. d iffe re n ce betweenany tw o cy lin d e rs — 400 k P a ) ....................... M in 2000 kPa at 180-200 r/m in M in 2000 kPa at 180-200 r/m in

F iring o rder ............................................................ 1 -3-4-2 ..................... 1-3-4-2 ....................... 1-3-4-2 .......................1-3-4-2C om bustion s y s te m ............................................ D irect in je c tio n ...D irect in je c tio n ...D irect in je c tio n ...D irect in je c tio nC ycle ......................................................................... 4 s troke ................. 4 s troke ..................4 s troke ..................4 s troke

DETAIL OF RATINGS (AUTOMOTIVE) TO SABS 013-1977

M axim um to rque (N.m) ..................................... 266 @ 1400 r/m in 300 @ 1400 r/m in 380 @ 1400 r/m in 408 @ 1400 r/m inO u tp u t Kw ................................................................... 66 @ 2800 r/m in 70 @ 2800 r/m in 85 @ 2600 r/m in 100 @ 2600 r/m in

ENGINE MASS

T yp ica l dry m a s s .................................................. 335 kg ..................... 343 kg ..................... 343 kg ..................... 370 kg

ADE 366N/C/T/TI

ENGINE DATA

ADE 366N ADE 366C ADE 366T ADE 36831

B o r e ............................................................................ 97,5 mm ..................97,5 mm ..................97,5 m m .........97,5 mmS troke ....................................................................... 133 m m ...................133 m m ........... ....... 133 mm ................... 133 mmNo. o f c y l in d e rs .................................................... 6 ................................ 6 ................................ 6 ................................. 6C ub ic ca p a c ity ...................................................... 5,958 f .....................5,958 f .....................5,958 ( ......................5,958 IC om press ion ra tio ............................................... 17,25:1 ..................... 17:1 ............................16,5:1 ........................16,5:1C om press ion te s t pressure at opera ting tem pera tu re (Max. d iffe re n ce betweenany tw o cy lin d e rs — 400 k P a ) ....................... M in 2000 kPa at 180-200 r/m in M in 2000 kPa at 180-200 r/m in

F iring o rde r ............................................................ 1-5-3-6-2-4 ............... 1-5-3-6-2-4................1-5-3-6-2-4.................1-5-3-6-2-4C om bustion system ............................................ D irect in je c tio n ...D irect in je c tio n ...D irect in je c tio n ...D irect in je c tio nC ycle ......................................................................... 4 s troke ................. 4 s troke ..................4 s troke ..................4 s troke

DETAIL OF RATINGS (AUTOMOTIVE) TO SABS 013-1977

M axim um to rque (N.m) ..................................... 402 @ 1400 r/m in 420 @ 1400 r/m in 560 @ 1400 r/m in 640 @ 1400 r/m inO u tp u t Kw ............................................................... 100 @ 2800 r/m in 100 @ 2800 r/m in 125 @ 2600 r/m in 150 @ 2600 r/m in

ENGINE MASS

T yp ica l dry m a s s .................................................. 445 kg ..................... 460 kg ..................... 460 kg ......................495 kg

T hro u g ho u t th is Eng ine R epair M anual, S1 (In te rna tiona l M e tric System ) u n its as approved by the South A frica n Bureau o f S tandards (SABS) are used. A ll m easurem ents are in mm un less o the rw ise ind ica ted .

ADE 360 Series

08-2

TORQUE SPECIFICATIONS FOR BOLTS UNDER DIFFERENT GRADE CLASSIFICATIONS

Quality grade 8.8 10.9 12.9

M6 8.6 11.8 14.5

M8 21 29 35.5

M8x1 23 32 38

M10 42 58 70

M10 x 1,5 46,5 65 78

M12 73 100 123

M 12x1,5 76 105 128

M14 114 165 195

M14x1,5 128 178 215

M16 178 250 300

M16x1,5 190 270 320

M18 245 355 415

M18x1,5 280 390 465

M20 350 490 590

M 20x1,5 390 550 660

M22 465 660 800

M22x1,5 520 730 875

M24 600 850 1000

M24x2 660 910 1100

NOTE 1 — The B o lt g rad ing appears on the bo lt head NOTE 2 — B o lt to rque is su b je c t to fem a le thread m a te ria l

ADE 360 Series

TECHNICAL DATA - 08-3

IDENTIFICATION NUMBER POSITIONS

W hen ordering spare parts a llw ays quote the engine num ber in fu ll.

ENGINE IDENTIFICATIONThe eng ine num bering system fo r ADE eng ines con s is ts o f 16 le tte rs and num bers.

E xam ple

ATLANTIS DIESEL ENGINES (PTY) LTDLICENCE DAIMLER-BENZ AG

ENGINE No DB

ADE M J 01002 SA 046315 T

MADE IN RSA

ENGINE FAMILY 300 Series

ENGINE TYPE

i.e.

G =364N L = 366TIH = 364C M = 364TJ = 366N N = 366CK = 366T

BUILD CODE

COUNTRY OF ORIGIN

ENGINE SERIAL NUMBER

YEAR OF MANUFACTURE

S = 1988 U = 1990 W = 1992 T = 1989 V = 1991 X = 1993

Y = 1994

N ote:The le tte r d e n o tin g the year o f m an u fa c tu re changes on the 1st day o f January each year.

The le tte rs I, O, Q, R and Z are not used.

ADE 360 Series

TECHNICAL DATA — 08-4

ADE 360 Series

SECTION 09-1Operating and Maintenance

OPERATING AND MAINTENANCE

Preparation before StartingC heck the rad ia to r co o la n t level.

C heck the eng ine sum p o il level. .

Ensure th a t the re is fue l in the tank.

C heck th a t the b a tte ry is fu lly charged and th a t a ll e lectr ic a l co n n e c tio n s are p roperly m ade and a ll c irc u its are in order.

To Stop the EngineRem ove the eng ine load. D ecrease speed g rad u a lly to avoid hea ting up the coo la n t, then run the eng ine a t id ling speed fo r a sho rt tim e. S hut dow n eng ine.

(a) By a c tu a tin g the s to p p ing cab le .

(b) By m oving th e speed c o n tro l lever to “ s to p ” .

(c) By a c tu a tin g the sh u t-o ff so leno id .

(d) By a c tu a tin g the exhaus t b rake depend ing on the eng ine sp e c ific a tio n .

Points to noteAlw ays ensure tha t the starter p in ion has stopped rota ting before re-engaging th e s ta rte r, as the ring gear o r p in ion m ay be dam aged.

Flame-Proofed EnginesEngines arranged to con fo rm w ith flam e-p roo fing regu latio n s are usu a lly f it te d w ith n on -e lec tr ic s ta rtin g e q u ip m ent. Th is is supp lied by the m anu factu re r o f the app lica tio n and fo r s ta rtin g in s tru c tio n s reference shou ld be m ade to the a p p rop ria te m a n u fa c tu re r ’s handbook.

Preventive Maintenance Category 1

U n its ope ra tin g under norm al co n d itio n s , m ore than 100 000 km o r 2 000 hours annua lly e.g. long haul ope ra tions .

RECOMMENDED SERVICE/ MAINTENANCE INTERVALS

Normal oil and filter changes/service intervals

Category 1 Category 2 Category 3

7 500 km /150 hrs 5 000 km/100 hrs 2 500 km /50 hrs

A t least tw ic e a year w hen serv ice in te rva l is no t reached

EXTENDED oil and filter changes/service intervals

The extended m aintenance and service in tervals may only com m ence a fte r the runn ing in period (app rox im a te ly 20 000 km).

The eng ine lu b rica tin g o ils fo r extended o il change in te rva ls, as sp e c ifie d in the ADE Service B u lle tin on C onsum a b le s have been approved and are m andatory.

The s u cce ss fu l a p p lica tio n o f the extended o il and f ilte r changes/se rv ice in te rva ls w a rran ts ca re fu l serv ice and m a in te n a n ce o f eng ines. As ex tended in te rva ls a lso de pend on ope ra tin g c o n d it io n s o f the eng ines, it is essentia l to a pp ly the 3 ca te go rie s as o u tlin e d below .

Category 1 Category 2 Category 3

15 000 km /300 hrs 10 000 km /200 hrs 5 000 km /100 hrs

A t least once a year w hen se rv ice in te rva l is not reached

Note 1:E ngines th a t leave the fa c to ry are fil le d w ith runn ing-ino il. The o il m ust be changed du ring the f irs t se rv ice at 1 500 km or 30 hours opera tion .

For approved engine lubricants and coolant additives, refer to ADE General Service Bulletin on Consumables.

Category 2

U n its o p e ra tin g under norm a l co n d itio n s , up to 100 000 km or 2 000 hours ann ua lly e.g. m ed ium to long haul ope ra tions .

Category 3

U nits sub jec t to severe opera ting co n d itio ns e.g. extrem ely poo r road co n d itio n s , heavy d us t co n d itio n s , extrem e c lim a tic co n d itio ns (tem perature and hum idity), very short d is ta n ce s in tra ff ic o r c o n s tru c tio n ope ra tion . U n its ope ra ting up to 10 000 km or 200 hours annua lly e.g. un its ope ra ting under lig h t loads o r in te rm itte n t ope ra ting co n d itio n s , such as s tand-by g e n e ra to r se ts and em ergency veh ic les . However, when o p e ra tin g less than the recom m ended se rv ice in te rva ls , the o il and o il f i l te r shou ld be changed once or tw ice a year depending on the lub rica ting o il used. W e recom m end th a t m a in tenance and service be carried ou t acco rd ing to hours o f opera tion rather than m ileage covered.

Pre-delivery Service

1. C heck genera l eng ine in s ta lla t io n i.e. A ll p ipes and hoses fo r t ig h t sea ling , c o n d itio n and rou ting .

2. Open a ir c leaner and ensure e lem en t is p o s itioned c o rre c tly and bo lted dow n.

3. C heck fo r fue l and o il leaks.

4. C heck o il level.

5. C heck coo la n t level.

6. Check coo lan t fo r correct m ixture, i.e. anti-freeze/antico rro s io n agent and co rro s io n in h ib ito r.

7. C heck V-belt tens ion . .

8. C heck e le c trica l eq u ip m e n t and conn ec tio n s .

AGE 360 Series

OPERATING AND MAINTENANCE — 09-2

9. Check in je c tio n pum p linkage fo r to ta l m ovem ent.

10. Check exhaust brake linkage and ad jus tm en t if fitted .

11. C heck th a t the fan has been f it te d co rre c tly .

12. S ta rt up, then check o il p ressure and coo la n t tem pe ra tu re gauges.

13. C heck fo r any unusua l noises.

14. W hile eng ine is w arm ing up check fo r o il and w a te r leaks.

15. C heck ope ra tion o f v isco fan (if fitted ).

16. Run to ope ra ting tem pe ra tu re and check m axim um r/m in.

Daily Before Starting and 8-10 Hours Operation

1. Check engine o il level and pressure upon s ta rt up (ensure m ach ine is s ta n d ing level).

2. C heck coo la n t level in rad ia to r.

3. Service a ir c leaner d us t bow l, p re -filte r if a p p licab le .

4. Check a ir c leaner res tr ic tio n ind ica to r, service filte rs if required.

5. Ensure there is am ple fue l in tank.

6. Ensure fue l tank cap /b rea ther is unobs truc ted .

7. C heck th a t the e x te rio r o f the sum p is c lean w ith an u n re s tr ic te d a ir f lo w over the surface .

8. Ensure rad ia to r f in s have an u n o bs truc ted a irflow .

9. C heck o il p ressure ind ica to r.

10. Drain w a te r from sed im en to r.

11. Drain a ir tank (if fitted ).

Note:

Injectors: S a tis fa c to ry long term fu n c tio n in g o f in je c to rs depends la rge ly on the q u a lity and p u rity o f the fu e ls used. A s p e c if ic se rv ice in te rva l can the re fo re not be p rescribed . D ealers and F lee tow ners shou ld a dop t se rv ice in te rva ls w h ich w ou ld su it the ind iv idua l ope ra ting c ircum stances .

Schedule A Service

1. C hange eng ine o il, d ra in o il when s t i l l hot.

2. Renew o il filte r.

3. Renew fue l f ilte rs .

4. Drain w a te r from sed im en to r o r fue l f ilte r d ra in cocks.

5. Service a ir c leaner dust bow ls /p re -filte r if app licab le .

6. Check a ir c leaner ind ica to r, service filte rs if required.

7. Service a ir c leane r and f i lte r (oil bath type).

8. C heck a ll a ir c leane r in take duc ts , hoses and c lip s etc., fo r se rv ice a b ility and tig h tne ss .

9. C heck th a t in te rco o le r is free from o b s tru c tio n .

10. Check coo lan t hoses, hose c lip s fo r se rv iceab ility and tig h tn e ss .

11. P ressure te s t co o lin g system .

12. Ensure th a t recom m ended co rro s io n in h ib ito r has been added to th e c o o lin g system .

13. Ensure rad ia to r f in s have an unobs tru c te d a ir flow .

14. Tension all V-Belts, checking sam e for ageing, replacing de fec tive V-Belts. Tw in V -B e lts shou ld o n ly be replaced in pairs. New belts m ust be retensioned a fte r 10-15 m inu tes o f opera tion .

15. C heck exhaust sys tem fo r dam age or leaks.

16. Check con tro l linkage on in je c tio n pum p and exhaust brake fo r co rre c t fu n c tio n and ad ju s tm e n t, lu b rica te a ll jo in ts .

17. C heck a ll lines and hoses fo r t ig h t sea ling , cha fing and leaks.

18. A d ju s t valve c learances.

19. Retighten all v is ib le nuts and bo lts on the engine and in p a rticu la r.

(a) In le t and exhaust m a n ifo ld s and ducts.

(b) E xhaust flange.

(c) S ta rte r m o to r and a lte rn a to r fit t in g .

(d) Nozzle ho lders.

(e) Eng ine m oun t on c ross m em ber and eng ine support.

\ (f) Bell hous ing b o lts and nuts.


21. C heck ope ra tion o f o il pressure and tem pera tu re gauges.

22. C heck ba tte ry e le c tro lite level. In S um m er and hot reg ions once a week.

23. Check ba ttery te rm in a ls fo r tig h tne ss and cond itio n .

24. C heck ope ra tion o f V isco Fan (if fitted ).

A d d itio n a l item s requ iring se rv ic ing a t 50 000 km in te rval lis tin g .

1. C heck carbon brushes in the sta rte r.

2. Inspect and c lean o il co o le r f i l te r e lem en t ADE 360T/TI

Schedule B Service

*1 . Change eng ine o il and o il f ilte r, d ra in w hen s t i l l hot.

2. Drain fue l se d im e n to r o r fue l f i l te r d ra in taps.

3. Service a ir c leane r d u s t b o w l/p re filte r if a pp licab le .

4. Check a ir c leaner ind ica to r, service filte rs if required.

5. C heck a ll a ir c leane r in take d u c ts , hoses and c lip s fo r se rv ice a b ility and tig h tn e ss .

6. C heck th a t in te rco o le r is free from o b s tru c tio n .

7. Check coo lan t hoses, hose c lip s fo r serv iceab ility and tig h tne ss .

8. Pressure te s t c o o lin g system .

9. Ensure rad ia to r f in s have an u n o b s tru c te d a ir flo w .

10. Tens ion V -B e lts ch e ck ing sam e fo r age ing, rep lace d e fec tive V -B e lts . T w in V -B e lts shou ld o n ly be replaced in pairs. Retension new be lts a fte r 10-15 min. o pera tion .

ADE 360 Series

OPERATING AND MAINTENANCE - 09-3

11. C heck exhaust sys tem fo r dam age o r leaks.


13. C heck ope ra tion o f o il p ressure and tem pera tu re gauges.

14. C heck ba tte ry e le c tro lite level. In S um m er and hot reg ions once a week.

15. C heck b a tte ry te rm in a ls fo r t ig h tn e s s and co n d itio n .

A d d itio n a l item s requ iring se rv ic ing at 50 000 km in te rva ls o r to the e q u iva len t show n on the m a in tenance in te rva l lis tin g .

1. C heck the ca rbon brushes in the s ta rte r.

2. C lean tu rb o ch a rg e r im pe lle r, d iffu s e r and o il d ra in pipe.

3. Inspect and c lean o il co o le r f i l te r e lem en t (360T/TI)

Attention! S a tis fa c to ry long te rm ope ra tio n o f the a ir com pressor, depends on m any vary ing fa c to rs . Therefore a s p e c if ic serv ice in te rva l ca n n o t be recom m ended. D ealers and F lee tow ners shou ld adopt serv ice in te rva ls w h ich w ill su it th e ir ind iv idua l ope ra tin g c o n d itio n s .

ENGINE COOLANTIn v iew o f the s ig n ific a n c e o f m a in ta in in g the coo lin g sys tem at a sp e c ifie d level, it is esse n tia l to ensure tha t the fo llo w in g c o o la n t s p e c if ic a tio n s are m ain ta ined .

For the p repara tion o f coo la n ts , use c lean w a te r th a t is not too hard. O ften, d rink ing w a te r (tap w ate r) w ill m eet the desired requ irem ents , but no t a lw ays.

Sea w ater, sa lt water, industria l w aste w ater and b rackish w a te r w h ich inc lu d e s in m os t cases w a te r from dam s, ponds and rivers, shou ld be cons ide red to be unsu itab le , as these may co n tr ib u te heav ily to the fo rm a tio n o f co rros ion .

Specification of fresh waterSum o f a lka lin e earth (w ate r hardness) pH va lue at 20°C C o n te n ts o f c h lo rin e ions:T o ta l co n te n t o f ch lo rid e s and su lpha tes

89.5 — 358 m g /litre

6.5 — 8,5m ax 100 m g /litre

m ax 200 m g /litre

Fu ll in fo rm a tio n on the q u a lity o f d rink ing w a te r shou ld be ob ta ine d from loca l d e p a rtm en ts o f W a te r A ffa irs or loca l a u tho ritie s . It is esse n tia l to p ro te c t you r eng ine at a ll t im e s ag a in s t co rro s io n by the a d d itio n o f A n tico rros ion /A n ti-freeze a d d itive s (e thy lene g lyco l w ith co rros ion inh ib ito rs ) w h ich am ongst o thers, w ill m eet the fo llo w in g dem ands:

• adequate an ti-co rros ion and ca v ita tio n p ro tec tion fo r a ll com p o n e n ts iû the co o lin g system

• low ering the f r e t t in g po in t

• ra is ing the boiHÉÉüfofRt

A t no tim e shou ld the c o b là h t'm ix tu re exceed 55% by vo lum e an ti-freeze /an ti-co rros ion agent as a h ighe r percen tage w ill reduce the an ti-freeze p ro te c tio n as w e ll as lessen the heat d iss ipa tion . As anti-corrosion inh ib ito rs decom pose du ring opera tion , as w e ll as an ti-co rros ion co n ce n tra tio n be ing reduced by to p p ing up the co o lin g system w ith w ater, the fro s t p ro te c tio n m ust be checked regularly. Frost p ro tection o f - 3 0 ° C corresponds w ith 40 to 45 percen t (by vo lum e) an ti-freeze / an ti-co rro s io n c o n te n t in the co o la n t w h ich m ay be de te rm ined by an o p tic a l or m echan ica l hydrom eter, ( -3 0 ° C ) .

The a n ti-co rro s io n o il co n ten t in the c o o la n t i.e. 1% by vo lum e, m ay be de te rm ined by a re frac tom ete r.

O n ly use approved p ro d u c ts fo r m ix tu re w ith the co o la n t as sp e c ifie d in ou r G eneral Service B u lle tin on C onsum ab les and at a ll t im e s s tr ic t ly adhere to the m ix tu re sp e c ifica tio n s .

ENGINE PRESERVATION

W hen an engine is laid-up for a prolonged period, it should be p roperly p ro tec ted aga ins t co rros ion . Preservation m easures shou ld be carried ou t in acco rdance w ith the d iffe re n t ca tago ries lis ted in th e fo llo w in g sections.

1.0 General

2.0 Installed Engines2.1 La id up fo r up to 12 m on ths2.2 Laid up fo r 12 to 36 m on ths2.3 Laid up fo r m ore than 36 m onths

3.0 Non-installed Engines3.1 Laid up fo r up to 12 m on ths3.2 Laid up fo r 12 to 36 m on ths3.3 Laid up fo r m ore than 36 m onths

4.0 Preparing Engine for operation

1.0 General

An eng ine is c la ss ifie d as “ la id u p ” w hen it has not opera ted fo r over one m onth. Laid up veh ic les or engines should be stored in dry, w e ll-ventilated rooms and m us t a lw ays be p ro te c te d a g a in s t d ire c t m oisture , e.g. rain o r sp lash w ater. If th is is not possible, laying up cond itions are c lass ified as extrem e and the tre a tm e n t sp e c ifie d fo r a g iven period shou ld be increased, e.g. if an eng ine is to be la id up fo r up to 12 m on ths, it m us t receive trea tm e n t o f an eng ine to be la id up fo r 12 to 36 m onths.1.1 On any la id up eng ine a ll m ach ined externa l

unp ro tec ted su rfaces, e.g. f lyw hee ls , V-belt pu lley grooves, e tc. shou ld be coa ted w ith a preserving agent o r grease.

V -be lts m ust be s lackened o ff and be rem oved from the grooves.

A ll open ings m ust be sealed a ir t ig h t. Th is includes exhaust and a ir in le t ducts/c leaners on in s ta lle d eng ines. '

B a tte ries m ust be d isco n n ec te d in la id up veh ic les and shou ld be recharged ou ts id e the veh ic le as required.

2.0 Installed Engines

These m easures app ly to a ll eng ines in veh ic les, trac to rs , as w e ll as in d u s tria l eng ines.

2.1 Laid up for up to 12 months

2.1.1 NEW ENGINES (d is tance covered up to 300 km or 6 hours o f opera tion):

The engines m ust be filled to the m axim um level w ith app roved se rv ice p ro d u c ts . A m b ie n t tem pera tu res m ust be taken in to cons ide ra tion when se le c tin g SAE grades. No fu rth e r preserva tion m easures are requ ired.

2.1.2 USED ENGINES (d is tance covered m ore than 300 km or 6 hours opera tion):

ADE 360 Series

OPERATING AND MAINTENANCE - 09-4

Run eng ine u n til warm and dra in eng ine o il. (R unn ing-in o il m ay rem ain in the engine). Renew o il f i l te r ca rtridge . F ill w ith an approved runn ing -in o il (an ti-co rros ion eng ine oil). F ill o r to p up c o o lin g system w ith the sp e c ifie d c o o la n t m ix tu re . Run eng ine a t m ed ium speed fo r approx. 5 to 10 m in u te s u n til ope ra ting tem pera tu re is reached (coo lan t tem pe ra tu re 75-79° C). S w itch o ff eng ine, f i l l the sum p and the o il bath a ir f ilte r (if fitted ) to m axim um level.

2.2 Laid up for 12 to 36 months

A ll the m easures set ou t in S ec tio n s 1.0 “ G enera l” and 2.1 “ M easures fo r Ins ta lled E ngines Laid up fo r up to 12 m on th s ” , m us t be carried out.

In a d d itio n , the fue l system , the com b u s tio n cham bers and the a ir com presso r m ust be preserved In acco rdance w ith the fo llo w in g in s truc tio n s .

Note 1: The procedure in th is se c tio n shou ld a lso be fo llow ed a fte r less than 12 m onths in the case o f sea sh ip m e n ts and in trop ica l areas.

2.2.1 Preservation of Fuel System:

A dd app rox im a te ly 10% runn ing-in o il to d iesel fue l and opera te the eng ine w ith th is m ix tu re fo r app ro x im a te ly 5 to 10 m inutes.

If a num ber o f veh ic le , tra c to r o r in d u s tria l eng ines are to be preserved a t the sam e tim e, the fue l and th e runn ing -in o il may be m ixed in a separa te co n ta ine r before feed ing the s o lu tio n in to the fue l system via a three-way or fou rway cock valve. Th is enables the concen tra tion o f o il in d iese l fue l to be increased to 15-20%.

2.2.2 Preservation of Combustion Chambers:

O il may be sprayed in to the co m b u s tio n cham bers v ia the in je c to r po rts a fte r rem oval o f the in je c to rs w h ich m ay be im m ersed in o il fo r added p ro tec tion .

For best resu lts the m etered am ount o f o il m ust be in jec ted in to the com bustion cham ber under pressure to ensure co m p le te sp ray ing o f a ll areas. Upon com ple tion of each cy linder (piston down), ro ta te the eng ine a t least one fu ll tu rn by hand.

Note 2: During the above ope ra tion the in je c tio n pum p/governor co n tro l m ust be in the sh u t-o ff p os ition .

Oil Per Cylinder 8-10 ml

Note 3: Do not exceed above am oun ts as th is may lead to h yd ra u lic lock and poss ib le eng ine dam age.

R efit a ll parts rem oved and ensure th a t sea ls and g aske ts are in p lace. R e-position the in je c tio n pum p governor c o n tro ls to the ope ra ting pos itio n .

Note 4: E ngines m us t not be s ta rted a fte r the co m bu s tio n cha m b e r p rese rva tion has been ca rried out.

2.2.3 Preservation of Air Compressors:

A ir com presso r preservation shou ld be done in co n ju n c tio n w ith the co m b u s tio n cham bers. A m axim um o f 5 cub ic cen tim e tre s o f runn ing -in o il shou ld be in jec ted or poured in to each

c y lin d e r via the com presso r a ir in take w herea fte r th e e n g in e ,m u s t be ro ta ted at least one h a lf a turn.

2.3 Laid up for more than 36 months

If the laying-up period is extended fo r more than 36 m onths, p reserva tion m easures m ust be repeated every 3 years o r 18 m onths in a cco rdance w ith S ection 2.2 in fu ll.

3.0 NON-INSTALLED ENGINES

These m easures cover new non-ins ta lled engines, as w e ll as rem anu factu red engines.

3.1 Laid up for up to 12 months:

NEW ENGINES w hich have on ly been subjected to the runn ing-in period at ADE, do not requ ire any a d d itio na l preserva tion m easures.

R unn ing-in o il may be le ft in the eng ines. C oo lan t m ust be co m p le te ly d ra ined. Remove the th e rm o s ta t/s and inse rt one C hadpack Tab le t (ADE Part No 36170072) in to the housing. R e fit the th e rm o s ta t/s and c lo s in g cove r/ou tle t and ensure th a t th e jo in ts fo rm a good sea l. A ll eng ine open ings m ust be sealed a irtigh t.

Note 5: F o llow th e in s tru c tio n s fo r sea sh ip m e n ts or tro p ica l areas.

USED ENGINES m ust be treated in accordance w ith the m easures set ou t in Item s 2.1.2 and2.2.1 before being la id up o r d ism oun ted .

C oo lan t m ust be d ra ined co m p le te ly and a C hadpack T ab le t m ust be Inserted in the th e rm osta t housing.

REM ANUFACTURED ENGINES m ust in all cases be preserved in accordance w ith S ection2.2 in fu ll.

3.2 Laid up for 12 to 36 months:

The preserva tion m easures set ou t in Section2.2 m ust be carried ou t in fu ll.

3.3 Laid up for more than 36 months:

If the laying-up period is extended fo r more than 36 m onths, preservation m ust be repeated every 36 m onths (3 years) or 18 m onths in accordance w ith S ection 2.2 in fu ll.

If the re is o il in the eng ine, th is may be dra ined o ff a t room tem pera tu re (about 20°).

It Is not neccesary to renew the o il f i l te r ca rtridge .

4.0 PREPARING ENGINE FOR OPERATION

4.1 Remove sea ling from a ll open ings.

4.2 Remove preserv ing agent o r grease from the grooves o f V-belt pulleys, flyw heel and o ther unp ro tec ted surfaces.

4.3 R epos ition and tens ion V -be lts in acco rdance w ith in s tru c tio n s .

4.4 If no t a lready ins ta lled , f i t eng ine to m ach ine.

4.5 F ill w ith approved lu b ric a tin g and c o o la n t se rv ice p rod u c ts o r to p up to m axim um level.

ADE 360 S eries

OPERATING AND MAINTENANCE — 09-5

Note 6: E ngines w h ich have not received th e ir firs t serv ice m ust be fille d w ith runn ing-in o il, a ll o thers shou ld be fille d w ith approved opera ting o ils .

4.6 Recharge and reconnect ba tteries .

4.7 Run eng ine to opera ting tem pera tu re (coo lan t te m p e ra tu re 75-79° C) w h ile m o n ito r in g p ressures and tem pera tu res.

ADE 360 Series

TECHNICAL DATA — 09-6

LUBRICATING OILS

VISCOSITY GRADES

Ambient Air Temperature SAE Grades

°C

■

o 1«

mm.« o

=£in

o

5SoCM

35in

DUE TO CONTINUOUS DEVELOPMENT, ATLANTIS DIESEL ENGINES ARE CONSTANTLY REVISING THEIR OIL RECOMMENDATIONS.

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

ADE 360 Series

SECTION 10-1 Fault Finding

CONTENTS OF THIS SECTION

STARTER MOTOR TURNS ENGINE TOO S LO W LY .......................................................... 10-2

HARD STARTING WHEN C O L D ............................................................................................. 10-3

ENGINE TURNS OVER BUT REFUSES TO S T A R T .......................................................... 10-4

ENGINE DIFFICULT TO S T A R T .............................................................................................. 10-5

ENGINE LO C K-U P ...................................................................................................................... 10-6

ENGINE CUTS OUT AFTER S TA R TIN G ............................................................................... 10-7

ENGINE O VER H EATIN G .......................................................................................................... 10-8

E N G IN f RUNNING TOO C O L D .............................................................................................. 10-9

ENGINE KNOCKING . . . : ..........................................................................................................10-10

ENGINE V IB R A T IO N .................................................................................................................. 10-11

ENGINE M IS F IR E S .....................................................................................................................10-12

LOSS OF PO W E R ........................................................................................................................ 10-13

BLACK SMOKE FROM EXH AU ST...........................................................................................10-14

BLUE SMOKE FROM E XH AU ST........................................................... 10-15

WHITE SMOKE FROM E XH AU ST...........................................................................................10-16

EXCESSIVE FUEL CO N SU M PTIO N ....................................................................................... 10-17

ABNORMAL OIL C O NSUM PTIO N.......................................................................................... 10-18

LOW OIL PR ESSU R E................................................................... 10-19

OIL PRESSURE TOO H IG H ......................................................................................................10-20

ENGINE OIL S LU D G E ................................................................................................................10-21

FAULTFINDING - 10-2

COMPLAINT

FAULT FINDING - 10-3

COMPLAINT


COMPLAINT

NOTE: Refer also to pages:

10-2) Starter motor turns engine too slowly

10-5) Engine is d ifficu lt to start

10-3) Hard starting when cold

ADE 360 Series


COMPLAINT

ADE 360 Series


COMPLAINT

ADE 360 Series


COMPLAINT

ADE 360 Series


COMPLAINT

ADE 360 Series


COMPLAINT


COMPLAINT


COMPLAINT

ADE 360 Series


COMPLAINT

ADE 360 Series


COMPLAINTS

ADE 360 Series

FAULTFINDING - 10-14

COMPLAINT

ADE 360 Series


COMPLAINT

ADE 360 Series


COMPLAINT

ADE 360 Series


COMPLAINT

ADE 360 Series


COMPLAINT

ADE 360 Series


COMPLAINT

ADE 360 Series


COMPLAINT

ADE 360 Series


COMPLAINT

__________SECTION 111Cylinder Block and Liners

CONTENTS OF THIS SECTION

PageINTRODUCTION ........................................................................................................................................... 11-3

SPECIFICATIONS ........................................................................................................................................11-3

CHECKING CYLINDER BORES FOR WEAR ................................. 11-5

REBORING CYLINDER BLOCK ............................................................................................................... 11-6

REMOVING CYLINDER LINERS ...............................................................................................................11-7

REPLACING CYLINDER LINERS ............................................................................................................. 11-8

CRANKCASE VENTILATION SYSTEM ..................................................................................................11-11

REMOVING BREATHER ...........................................................................................................................11-13

REPLACING BREATHER ............................................................................ 11-14 11-14

Ade 360 Series

SECTION 11Cylinder Block and Liners

CYLINDER BLOCK

1 REAR M A IN O IL S EA LS2 S UM P3 S U M P G A S K E TS4 M A IN B E A R IN G C A PS5 G A S K ET6 T IM IN G G EA R C A SE

7 GASKET8 TIMING COVER9 OIL SEAL

10 COVER11 GASKET12 O-RING

13 SIDE COVER14 CYLINDER LINER .15 CRANKCASE BREATHER16 CYLINDER BLOCK17 GASKET18 OIL COOLER

ADE 360 Series

CYLINDER BLOCK AND LINERS — 11-3

INTRODUCTION

The cylinder block is designed to form an integral casting with the crankcase and is manufactured from high grade cast iron, alloyed with copper and chrome. Utilising the latest in engineering technology, the cylinder block is machined to very fine tolerances and is subject to a rigorous quality control inspection.Interference fit, dry cylinder liners (Sleeves), are fitted to the ADE 364T and 366T/TI. Engines fitted with cylinder liners can be identified by a “ Z” , stamped on the cylinder block, to one side of the push rod cover.

SPECIFICATIONS

CYLINDER LINER

Repair stages Nominal diam eter of cylinder Cylinder bore Total height of

cylinder block

S tandard (N/C/T/TI) 97,50 97,510

97,490

359,10----- — (STD)359,00

Rep s tage 1(N) + 0,5 Rebore* 98,0098,010

97,990 358,80

Rep s tage 1 (N/C/T/TI)358,70

Rep s tage 2 (N/C/T/TI) 97,50 97,510

97,490

358,50----- ’— ( - 0,6)358,40

Rep stage 3 (N/C/T/TI)358,20-------— ( - 0,9)358,10

*1 s t Rep stage fo r n a tu ra lly asp ira ted o p tio na l I.e. e ith e r rebore fo r oversize p is ton o r f i t sleeve.

L ine r Parent Bore 100,435100,400

4 8L ine r F lange Recess — depth ’4,6

103,626

103,572— d ia

C y lin d e r L iner O.D. 100495_______________________________________________________________■_____________________________________100,475

C y lin d e r L ine r F lange O.D. 103,428103,375

NOTE 1:Stam ped numbers appear on the side of the cylinder block for each cylinder. The numbers are for grading purposes during production only.

ADE 360 Series


NOTE 2:It is essential to machine to a piston clearance depth of at least 250 mm when reboring the 360 Series Naturally aspirated engine to next repair stage or for liner fitm ent. (See item B illustration below.)

D im ension A = 9 8 ,0 -9 8 ,3 mmD im ension B = 251 - 2 5 2 mmD im ension C = 2 2 4 -2 2 5 mmD im ension h i = B lock H eight from centre o f m ain

bearing bore to jo in t face o f cy lin d e r head.

(Refer to co lum ns, cy lin d e r b lock and cy lin d e r line r fo r s tandard and repa ir • s tages fo r b lockhe igh t)

O va lity o f cy lin d e r bore 0,01

Taper o f cy lin d e r bore 0,01

V e rtica l dev ia tion o f cy lin d e r bores w ith in a d is ta n ce o f 200 mm in re la tion to c ran ksh a ft ax is 0,04

R oughness o f bore a fte r hon ing R3Z 3-5 jim R max. 6-11

Leakage te s t pressure w ith cy lin d e r b lock subm erged in w a te r at 70°C 200 kPa

D is to rtio n lim it — LengthN ot to exceed 0,015 mm over a d is tance of

0,03 150 mm

P iston p ro trus ion /recess ion to upper cy lin d e r b lock su rface

+ 0,30 - 0,088

W ear lim it o f bore top p is ton ring upper return pos itio nha lfw a y s troke

0,120,05

C a m sha ft bearing bas ic bore 60,030

60,000

M ain bearing basic bore new 93,022

93,000

lim it fo r repa ir 93,040

92,970

O va lity o f m ain bearing basic bore 0,01

Taper o f m ain bearing basic bore 0,01

R oughness upper jo in t face o f cy lin d e r b lock 8-16

TORQUE SPECIFICATIONS

O il g a lle ry p lugs (fron t and re a r ) .................................................. M 1 6 x 1 ,5 ............................................... 40-45 N.mM 1 8 x 1,5 ............................................... 70-90 N.mM20 x 1,5 ............................................... 90-110 N.m

C o nnection plug fo r ta c h o m e te r .............................................. M 2 6 x 1 ,5 ............................................... 60 N.mPushrod cover to c y lin d e r b lo c k ............................................... M8 ........................................................... 15 N.m _Engine m oun ting b racke t to c ra n k c a s e ................................... M 1 4 x 1 ,5 ............................................... 150-190 N.mP iston co o lin g n o z z e ls ................................................................... M 1 0 x 1 .................................................. 25 N.mB lank ing p lugs (for p is ton co o lin g n o z z e ls ) ......................... M 1 0 x 1 .................................................. 10 N.mS idecover (w ater ja cke t) to c y l in d e r ......................................... M8 ........................................................... 25 N.m

ADE 360 Series

CYLINDER BLOCK A N D ^PE R S - 11-5

CHECKING CYLINDER BORES FOR WEARIn the event o f Excessive O il C onsum p tion and in a d d ition to a visual check, m easurements o f the cylinder bores w ill be necessary. Before a tte m p tin g to m easure the cy linder bores they should be thorough ly cleaned and free from o il and carbon depos its .

1. Using com pressed air, c lean the to p o f the cy linde r b lock , (fig. 11-1).

2. W ipe cy lin d e r bores us ing c lean rag. (fig. 11-2).

r r —m fT "“<H It—<~I [mmtrasFig. 11-2

3. C heck cy lin d e r b lock top face fo r loca lised d is to rtio n us ing a s u ita b le s tra ig h t edge, (fig. 11-3).

4. Set in te rna l m easuring ins trum en t, (fig. 11-4).

ADE 360 Series

5. Insert m easuring ins tru m e n t in to c y lin d e r bores, (fig. 11-5).

CYLINDER BLOCK AND LINERS - 11-6

6. Check cy linde r bores at po in ts 1, 2 and 3. The checks shou ld be made in d irec tio n A = Centre line and B = 90° from cen tre line, (fig. 11.6).

W hen p is to n s are no t rem oved, the m easuring po in t 3 is ju s t above the p is ton at BDC.

REBORING CYLINDER BLOCK FOR OVERSIZE PISTONS OR FITMENT OF LINERS

1. A fte r the c y lin d e r b lock has been th o ro u g h ly c le a n ed it shou ld be secu re ly m ounted under the boring bar, (fig. 11-7).

2. A lign and cen tre the bo ring bar above the cy lin d e r to be m achined.

3. Insert to o l in to boring bar head and ad jus t to the req u ired d im ens ion , (fig. 11-8).

Attention!If more than one cy liinde r requires boring fo r line r fitm en t the fo llo w in g sequence shou ld be fo llow ed :Bore cy lin d e rs 1-3-5-2-4-6 — (6 cy linder),

2-4-1-3 — (4 cy linder).W hen us ing th is sequence o f boring excessive the rm a l stress w ill be avoided.

F ig. 11-7

ADE 360 Series


4. Bore cy linde r to 0,05 mm below the fina l cy linder bore d im ens ion , (fig. 11-9).

Attention!M ach ine o r su rface g rind c y lin d e r b lock top face by 0,3 mm to next b lock he igh t repa ir stage, i.e. fo r oversized p is to n s o r line r f itm e n t (see s p e c ifica tio n s ) and ensure co rrec t repa ir s tage p is tons are used.

5. Securely m ount cylinder b lock under honing machine. Hone cy lin d e r line rs to fin a l d im ens ions , (see sp e c ifica tio ns ), (fig. 11-10).

6. Before assem b ling the eng ine th o ro u g h ly c lean the cylinder block and crankcase inside and out. B low out o il ga lleries ensuring that no residue from the m ach in ing p rocess is le ft.

REMOVING CYLINDER LINERS

1. Securely m ount crankcase under boring m achine, (fig.11 - 11 ).

2. A lig n and cen tre boring bar above the cy lin d e r to be m ach ined.

Attention!If more than one cy lin d e r requ ires boring, the fo llo w in g sequence shou ld be fo llow ed :Bore cy lin d e rs 1-3-5-2-4-6 — (6 cylinder),

2-4-1-3 — (4 cylinder).W hen using th is sequence o f bo ring excessive therm al s tress w ill be avoided.

3. Insert too l in to boring bar head and ad just so th a t the c y lin d e r line r w ill be bored o u t to app ro x im a te ly ha lf its fo rm er th ickn e ss , (fig. 11-12).

F ig. 11-9

ADE 360 Series


4. Re-set to o l in boring bar head and m ach ine cy linde r line r to 0,2 mm be low ou ter d iam ete r o f cy linde r liner (Standard Size). Bore cy linder liner and remove flanqe, (fig. 11-13).

Attention! A t th is se ttin g the flange o f the lin e r w ill becom e de tached from the sleeve.

5. Insert boring bar head in to cy lin d e r bore, w ith cu ttin g tool s ta tionary and in con tact w ith cylinder liner. Move c u ttin g too l ve rtica lly up and dow n cy lin d e r bore, a llow ing cu ttin g too l to break through w a ll o f cy linder liner. Remove c y lin d e r line r from c y lin d e r b lock, (fig. 11-14).

Fig. 11-13

Fig. 11-14

REPLACING CYLINDER LINERS

1. T ho rough ly c lean bore fo r c y lin d e r line r and flange seat, (fig. 11-15).

2. M oun t cy lin d e r b lo ck under press and a lign cy linde r bore.

3. A pp ly a ligh t co a tin g o f grease to bore in cy linde r b lock.

F ig. 11-15

4. Loca te cy lin d e r line r over bore in c y lin d e r b lock and a lign , using a set square, (fig. 11-16).

F ig. 11-16

ADE 360 Series


5. F it a s u ita b ly stepped stee l p la te betw een press head and cy lin d e r liner. Press c y lin d e r line r in to cy linder b lock un til it protrudes approxim ate ly 20 mm, (fig. 11-17).

6. Before p ressing lin e r fu lly home, check line r flange and seat fo r m eta l p a rtic le s and d irt. B low out w ith com pressed air, (fig. 11-18).

7. Press cy lin d e r line r fu lly home, re lieve pressure fo r a sho rt period and press once aga in , re ta in ing pressure fo r 5 seconds.

8. M ach ine or su rface g rind cy lin d e r b lock top face by 0,3 mm to next b lock h e ig h t repa ir s tage (in c lu d ing p ro trud ing c y lin d e r liner) see s p e c ific a tio n s fo r requ ired su rface fin ish , (fig. 11-19).

Attention!Before m ach in ing observe cy lin d e r b lock he igh t and repa ir s tage and ensure co rrec t repa ir stage p is to n s are used. Refer p is ton com press ion heigh and b lock he igh t sp e c ifica tio n s .

9. A fte r m ach in ing /su rface g rind ing , check cy lin d e r b lo ck face w ith a s tra ig h t edge, (fig. 11-20).

ADE 360 Series


10. A fte r the cy lin d e r b lock has been th o ro u g h ly c le a n ed it shou ld be secu re ly m ounted under the boring bar, (fig. 11-21).

11. A lign and cen tre the boring bar above the c y lin d e r to be m achined.

12. Insert to o l in to bo ring bar head and a d ju s t to the requ ired d im ens ion , (fig. 11-22).

13. Bore cy lin d e r lin e r in several s tages to 0,050 mm be low the requ ired bore d im ens ion , (fig. 11-23).

Attention!If m ore than one cy lin d e r required boring, the fo llo w in g sequence shou ld be fo llow ed :Bore cy lin d e rs 1-3-5-2-4-6 (6 cy linder),

2-4-1-3 (4 cy linder).

W hen using th is sequence o f boring , excessive therm a l s tress w ill be avoided.

14. Remove cy lin d e r b lock from boring m achine.

15. Securely m ount cy linder b lock under honing machine. Hone cy lin d e r liners to fina l d im ens ions , (see sp e c ifica tio ns ), (fig. 11-24).

16. Before assem b ling the eng ine th o ro u g h ly c lean the cy linder b lock and crankcase inside and out. Blow out o il ga lleries ensuring that no residue from the m ach ining process is lef*

F ig. 11-24

ADE 360 Series


CRANKCASE BREATHER - OPERATION AND PROBLEM DIAGNOSIS

Introduction

D epending on a p p lica tio n , the c rankcase brea ther may be m ounted to the rocker cover, pushrod cover or tim in g gear hous ing, (fig. 25).The crankcase b rea ther c o n tro ls the pressure in the crankcase w ith in a prescribed operating range. The device is open to crankcase gasses a t the low er end (7) w ith a con n ec tio n to the in d u c tio n m an ifo ld (4) and a vent to a tm osphere (3).

Note 1: For proper ope ra tion the area around the a ir vent (3) m ust be kep t c lean to prevent b lockage. In add itio n a ll jo in ts , co n n ec tio n s and o il f i l le r cap m ust fo rm a t ig h t seal to prevent crankcase depression losses and/or d ir t en try in to the engine.

Note 2: The fle x p o in t o f the b rea the r d iaphragm is su b je c t to d e te rio ra tion e.g. harden ing or c rack ing . It is the re fo re strongly recommended that the breather be replaced after every two years operation, as a p recautio n a ry m easure.

- 4

Fig. 25

1.0 Operation1.1 A tm osphe ric pressure acts on the ou te r surface

of the d iaphragm (1) via the vent (3). Before s ta rtup, a tm ospheric pressure w ill a lso be present in the crankcase and in duc tion system s. The pressure on both s ides o f the d iaphragm w ill thus be equal.

1.2 The spring (9) a c ts aga ins t the d iaph ragm and ho lds the valve (2) o ff its seat in the open p o s itio n . To c lose the valve, s u ffic ie n t depression m ust o ccu r in the crankcase to a llow a tm o s pheric pressure ac ting on the ou te r su rface o f

- the d iaphragm , to overcom e the spring fo rce . The opera tion o f the breather is there fo re dependent on eng ine opera tion .

1.3 A t eng ine id le speeds, the spring fo rce w ill be s u ffic ie n t to hold the valve from its seat aga inst a tm osphe ric pressure a c tin g on the ou te r su rface o f the d iaphragm . C rankcase gasses w ill susequen tly be drawn d irec tly in to the com bustion cham bers and w ill be burn t during the com bus tio n process.

1.4 A t norm al ope ra ting speeds and loads the ever changing in duc tion m an ifo ld depression acting w ith in the breather, is h igher than the required crankcase depression. The breather w ill react to the high m an ifo ld depression and con tro l c rankcase depression.e.g. Should the crankcase depression approach the upper negative lim it in the ope ra ting range, the valve w ill move tow a rds the c losed pos ition to reduce the e ffe c t o f m an ifo ld depression w ith in the crankcase.The valve in tu rn w ill react when crankcase depress ion is reduced tow a rds the low er or pos itive lim it and w ill open m arg in a lly to a llow the high m an ifo ld depression access to the crankcase.In th is m anner the b rea ther w ill c o n tin u o u s ly sense and acco rd ing ly , respond to m an ifo ld depress ion under various opera ting c o n d itio n s and thereby, con tro l crankcase depression w ith the desired opera ting range.

1 — D iaphragm2 — Valve3 — A ir Vent4 — To In let M an ifo ld5 — O il Drain H ole6 — Gauze7 — From C rankcase8 — Perfora ted P lates9 — Spring

10 — ‘O ’ Ring

mm +

4 0 _

5 0 _

m m -

Q

tX

t

X J Fig. 26

OPERATING RANGE

SERVICE SPECIFICATION FOR ALL BREATHERS:

+ 10 TO - 100 mm H20

Note: X — EXAMPLE ONLY = m anom eter re a d in g - 60m m H20

ADE 360 Series


1.5 C rankcase gasses passing v ia the brea ther are o il bearing and m ost o f the o il w ill be trapped by the gauze mesh (6). Excess o il no t traped by the gauze w ill return to the crankcase via a drain hole (5) provided in the b rea ther neck. However, it is norm a l fo r a sm a ll q u a n tity o f o il, in the fo rm o f m is t to be transfe rred to the in take a ir to lub rica te the valves (3 — 5 g/hr). The dam pness crea ted by the o il fum es is norm a lly evident in the in le t/m an ifo ld o f eng ines u tiliz ing th is type o f b rea th ing system and is not necessa rily in d ica tive o f a problem .

2.0 Operational Test2.1 Park the veh ic le on level ground and ensure tha t

the o il level is co rrec t (not over-filled).

2.2 Use a water m anom eter (see fig . 26) and connect one end o f the gauge to the eng ine d ip s tic k gu ide tube. The other end o f the tube is le ft open to a tm osphe ric pressure. Before s ta rtin g the eng ine ensure th a t the in s tru m e n t reg is te rs a zero read ing in bo th co lum ns.

2.3 S ta rt and run the engine at id le speed. A te n dency tow ards a negative reading ( - ) shou ld be noted.

2.4 G radua lly increase the engine speed to app rox im ate ly 1 500 r/m in. The ins trum en t shou ld ind icate a negative reading increasing w ith in the opera ting range.

2.5 Further increase the eng ine speed to a p p ro x im ate ly 2 000 r/m in. The negative reading shou ld raise w ith in the ope ra ting range. T h is w ould ind ica te th a t the valve is w ork ing.

Note 3: The o pe ra tiona l ch a ra c te r is tic s o f a b rea ther w ill depend on the c o n d itio n o f the engine e.g. am ount o f b low by.

3.3 Excessive positive reading is indicated at all engine speeds.

CAUSE REMEDY

a) Broken collapsed spring — Renew

breather

b) Valve stuck in closed — Renewposition breather

c) Blockage o f breather gauze — Wash in clean

by sludge* diesel If th isfails, renew

breatherd) Severe com bustion gas — Repair as

blowby necessary

'Inve stig a te reason for sludge and rectify.

Note 4: As a rule c rankcase pressure depression shou ld rem ain w ith in the prescribed range (+ 10 to - 1 0 0 mm H2O). If th is is not the case and all possib le con tribu ting fa c to rs have been e lim ina ted , it may be assum ed th a t the b rea ther is fau lty .

4.0 ConclusionA fa u lty crankcase breath ing system cou ld resu lt in the fo llo w in g prob lem s:4.1 Excessive o il consum p tion .

4.2 D ust en try v ia — a) A rup tu red or punctu reddiaphragm ,

b) A poor seal a t the “ O ” ring (10),

c) O ther in le t or crankcase connec tions , cou ld cause se rious dam age to the engine.

4.3 A h igh crankcase pressure cou ld fo rce o il past the c ran ksh a ft and tu rbocha rge r seals.

3 .0 Evaluation of Test Results3.1 Minimal negative reading at low r/min with

little or no change at high r/min.CAUSE REMEDY

a) Gauge connections leaking — Secure

connections

b) Leak in vacuum line to m anifold

c) Poor seal at breather m ounting

d) Diaphragm cracked/holed

— Check and

correct— Check/replace

O-ring or

gasket

— Renew breather

3.2 Excessively high negative reading.

CAUSE

a) Valve not closing

b) Vent hole blocked

c) Vent hose pinched

d) Foreign partic le on valve seat

e) Diaphragm ruptured

REMEDY

— Check b, c, d

below, or renew breather

— Clear and

retest— Repair hose

and retest— Remove object

and retest— Renew

breather

ADE 360 Series


REMOVAL AND REPLACEMENT OF BREATHER Removal

1. U nscrew c lip on pipe lead ing to in le t m an ifo ld , (fig. 11-27).

2. Remove p ipe w ith c lip , (fig. 11-28).

3. U nscrew c lam p on crankcase end of brea ther pipe, (fig. 11-29).

4. Pull o ff b rea ther from m ou n tin g pipe, (fig. 11-30).

Fig. 11-30

ADE 360 Series


5. Remove o-ring from the ins ide o f the brea ther pipe, (fig. 11-31).

Fig. 11-31

Replacing

1. F it new o-ring in the b rea ther p ipe, (fig. 11-32).

2. S lide brea ther w ith o-ring in to p lace over m oun ting pipe, (fig. 11-33).

3. A lign breather to in le t m anifo ld and secure c lam p over in le t pipe, (fig. 11-34).

ADE 360 Series


4. Replace pipe lead ing to the in le t m anifo ld , (fig. 11.35).

5. T igh ten c lip on the pipe, (fig. 11-36).

ADE 360 Series

" QaM*ington Diesel Club

ADE 364 and ADE 366

Workshop ManualSection 12 - Cylinder Head

B o n in g to n D iesel C lub

http://www.barringtondieselclub.co.za/

SECTION 12Cylinder Head

3 2

1 GASKET (EXHAUST M ANIFOLD) 12 INLET VALVE 22 ROCKER S H A FT RETAINING2 GASKET (INLET M ANIFO LD) 13 EXHAUST VALVE GRUB SCREW3 CYLINDER HEAD GASKET 14 VALVE SPRING ASSEMBLEY 23 ROCKER GEAR4 CYLINDER HEAD 15 VALVE COLLETS RETAINING BOLT5 INJECTOR SEALING W ASHER 16 PUSH ROD 24 ROCKER ASSEM BLEY6 INJECTOR 17 ROCKER COVER GASKET 25 ROCKER SHAFT7 CYLINDER HEAD BOLT 18 ROCKER COVER COUPLING BUSH*8 EXHAUST VALVE SEAT INSERT 19 O IL FILLER C AP (SCREW TYPE) 26 SPRING9 INLET VALVE SEAT INSERT 20 O IL FILLER C AP (CLIP TYPE)

10 VALVE GUIDE 21 ROCKER GEAR11 VALVE STEM O IL SEAL RETAINING BOLT * NOT FITTED ON ADE 364

ADE 360 Series

SECTION 12-1Cylinder Head

CONTENTS OF THIS SECTIONPage

INTRODUCTION ............................................................................................................................... ........ 12-3

SPECIFICATIONS .....................................................................................................................................12-3

TORQUES ....................................................................................................................................................12-6

REMOVING ROCKER COVER ................................................................................................................12-7

REMOVING CYLINDER HEAD ............................................................................................................... 12-7

CHECKING VALVE RECESSION ...........................................................................................................12-11

REMOVING VALVES .................................................................................................................................12-11

CHECKING VALVE STEM/GUIDE CLEARANCE ................................................................................ 12-12

VALVE FACING .......................................................................................................................................... 12-13

VALVE SEAT FACING ...............................................................................................................................12-14

REMOVING VALVE GUIDES ...................................................................................................................12-14

REPLACING VALVE GUIDES................................. 12-14

CHECKING CYLINDER H E A D ............................................................................................................... 12-16

REPLACING VALVES ..................... 12-16

INJECTOR PROTECTION SLEEVES .....................................................................................................12-18^

CHECKING INJECTOR PROTRUSION ................................................................................................. 12-19

REPLACING CYLINDER HEAD ...............................................................................................................12-20

VALVE CLEARANCE ADJUSTMENT 364 ............................................................................................ 12-23

VALVE CLEARANCE ADJUSTMENT 366 ............................................................................................ 12-24

REPLACING ROCKER COVER ...............................................................................................................12-24

CHECKING COMPRESSION PRESSURE ............................................................................................ 12-25

SPECIAL SERVICE TOOLS ...................................................................................................................... 12-27

ADE 360 Series

CYLINDER HEAD — 12-3

INTRODUCTION

Utilising the latest in automotive engineering technology, the ADE 360 series cylinder head is of advanced design common for all cylinders and is manufactured from high grade grey cast iron alloyed with copper and chrome, and machined to a very high tolerance. The fuel injectors are mounted w ith in the cylinder head and enclosed by a light alloy rocker cover.Separate inlet and exhaust manifolds are fitted, providing enhanced gas flow and improved fuel efficiency.

SPECIFICATIONS

O vera ll he igh t o f c y lin d e r head (new) 92,1

91,9

M in im u m he igh t a fte r m ach in in g * 90,9

Peak to va lley fin ish o f m ating su rface in (m icrons) 8,16

D is to rtio n lim it over Length o f head 0,150over d is ta n ce o f 150 mm 0,040

M ax pa ra lle l dev ia tion betw een upper and low er surface

0,1

In je c to r nozzle p ro trus ion 1,6-2,6

Leakage te s t pressure w ith cy lin d e r head subm erged in w a te r at 70°C

200 kPa

*C heck nozzle p ro tru s io n a fte r each m ach in ing stage o f c y lin d e r hSiad m ating su rface and co rre c t w ith nozzle sh im s if requ ired . W hen m in im um h e ig h t is reached f it 1 mm spacer under rocke r pedesta ls .

i § . ! i z

--------- D -------- ► t

I/ALVE SEAT INSERTS

In le t valve seat insert Exhaust valve seat inse rtS tandard Rep. s tage 1 Rep. s tage 2 S tandard Rep. s tage 1 Rep. s tage 2

OD “ D” 43,88 44,18 44,38 38,080 38,380 38,580o f valve seat insert 43,87 44,17 44,37 38,070 38,370 38,570

B as ic bore “ D 1” in 43,825 44,125 44,325 38,025 v \ 38,325 38.525 ■/.-c y lin d e r head fo r 43,800 44,100 44,300 38,000 '■ 38,300 38,500valve seat inse rt

In te rfe rence f i t o f seat insert in c y lin d e r head

0,045-0,080 0,045-0,080

Depth “ t ” o f bore 11,2 11,2in cy lin d e r head 11,0 11,0

H e igh t “ H ” o f 7,4 6,1valve sea t inse rt 7,3 8,0

D is tance “ t1 ” betweenm ating su rfa ce o f c y lin d e r head and face

3,6-3,9 2,9-3,2

o f va lve sea t inse rt


VALVE SEATS

In le t 30°

Valve seat ang le =----------------------------------------

Exhaust 45°

D iam ete r “ A ” of valve seat ' n e t 41’3w ith new valve seat inse rts a fte r m ach in ing ------------------------------------------------------------

Exhaust 35,3

In le t 1,3-2,4

W id th ,,B” :---------------- =-----Exhaust 1,8-3,0

Size “ C ” ln le t 3,6-3,9Inspec tion size---------------------------------------------------------------------------------------------------------------------------------------- :--

Exhaust 2,9-3,2

Valve recess ion * 0,7-1,1

* l f the valve recession is exceeded a fte r m ach in ing the valye seat inserts , new inserts m ust be fitte d .

VALVE SPRINGS

Preloaded Final LoadID ’ Wire Unloaded Length (1) Load (N) Length (2) Load (N)

dia. length

2 5 ,0 -2 5 ,4 4,25 60,5 46,7 285 - 315 35,18 570 - 630

1)( In in s ta lle d co n d itio n . C orresponds to leng th w ith valve c losed .2) -.4n ins ta lle d co n d itio n . C orresponds to leng th w ith valve opened.

CYLINDER HEAD - 12-5

In le t Exhaust

VALVE GUIDES

S tages ODValve gu ide ID

Valve gu ide leng th B.ore in

c y lin d e r head

In te rfe rence in cy lin d e r

head

" C learance o f valve s tem in

valve gu ideIn le t Exhaust In le t Exhaust In le t Exhaust

S tanda rd 15,04615,028

9,022*9,000

10,022**10,000

(“ B” )

72

(“ C ” )

67

15,01815,000

0,010to

0,046

0,050to

0,087t t ' f

0,097

Rep. s tage 1 15,14615,128

15,11815,100

Rep. s tage 2 15,246

15,228

15,218

15,200

Rep. s tage 3 15,54615,528

15,51815,500

* W ear lim it 9,050 “ W ear lim it 10,050

M axim um o f f cen tre o f valve sea t to valve gu ide 0,04

M axim um cy lin d r ic a l dev ia tion o f valve seat to valve g u ide at 42 mm d ia fo r in le t

0,0134 mm d ia fo r exhaust

“ A ” — R ep lacem ent Valve gu ide in s ta lla tio n he igh t 17,517,0

Valve s tem /gu ide c learanceIn le t valve — read ing not to exceedExhaust va lve — read ing not to exceed

0,2 mm 0,3 mm

NOTE: R ep lacem ent valve gu ides m ust be used to g e th e r w ith valve stem seals.


VALVES

Dimen “A” “B” “C" “D” “E” , . p ,

sions Seat Dia Seat Valve Height Width Stem Stem Valve(mm) Angle Centre Head Dia New Min Dia Hardness Length

In le t 30° 40 42,942,7

2,82,6

2,1 4.33.3

8,950,8 ,9 3 5

— HRC 54

140,7140,3

Exhaust 4§? 34 36,1035,90

2,82,5

2,14,23,5

9,9409,925 t > rc54

140,714,03

Runout betw een va lve seat and stem 0,03

R unout betw een valve head and stem - 0,20

O va lity o f valve seat 0,01

VALVE ADJUSTMENT 360 Series 360 SeriesValve c lea rance (tem pera tu re m ax, 50°C) N C/T/TI

• In le t 0,40 0,40

Exhaust 0,60 0,60

VALVE TIMINGIn le t Open BTDC 15° 15°

C lose ABDC 45° 25°

E xhaust Open . BBDC 67°

OCOCO

C lose ATDC 13° 12°

ROCKtRSHAFT/ROCKER ARM :---------------------------- f—B asic bore rocke r arm 22,052

22,000

R ocker arm bushO uter dia.

Inner dia.

22,13022,100

20,02120,000

R o c k e r sh a ft d ia19,98019,967

arance sha ft/bore ; 0,020-0,054

^TORQUE SPECIFICATIONS

The fo llo w in g to rque s p e c ific a tio n s w ill app ly w ith the com ponen ts lig h tly o iled .

/ C y lin d e r head b o l t s .......................................................................................1st S tage: 60 N .m.(M ax im um s tre tch leng th 113mm) 2nd S tage: 90 N.m

3rd Stage: 120 - 130 N.m 4 tti S tage: 9 0 ° - ip o °

S crew p lugs to cy lin d e r h e a d .................................................................. , .M 2 4 x 1 ,5 ..70-150 N.m> ' M 3 0 x 1 ,5 ....... 100-200 N.min ie b to r p ro te c tio n sleeve to cy lin d e r head ...................... ..................M 1 4 x f ,5 .............. 50 N.mIn je c to r secu ring nu t to cy lin d e r h e a d ..........................................M 3 4 x 1,5 ..... ....... 70 N.mR ocker cove r to cy lin d e r h e a d .................................................................M 8 ..........................25 N.mva iye a d ju s tin g screw lock n u t ................................................................M 1 2 x 1 .................. 40 N.mR o flJ^ r sh a ft pedesta l to cy lin d e r h e a d ............................................... M 1 2 ........................100 N.mR ocker sh a ft lo ck screw to pedesta l ..................................................... M 6 ................... .......5 N.m

i/E xh a u s t m an ifo ld to cy lin d e r h e a d ..........................................................M 1 0 ............... ........60 N .m + 90°. In le t m an ifo ld to c y lin d e r h e a d ................................................................M 8 x 1 .................... 30 N .m' (Check at every service)ITyrbocharge r to exhaus t m an ifo ld 3 6 6 C /T m .......................................M 1 0 ........................50 N.m

3 6 4 C /T ..........................................M10 .........................30 N.mE xhaust flange to tu rbocha rge r ................................................................M 8 .........................30 N.mpressu re d u c t to tu rbocha rge r (V-clamp)«................................................................. ............. 6 N.m

WÊÈ, 360?i*rìèsS


REMOVAL OF ROCKER COVER

1. U nscrew and rem ove bo lts re ta in ing rocke r cover, (fig . 12-1).

Fig. 12-1

2. L ift o ff rocker cover, (fig. 12-2).

3. Remove gaske t from cy lin d e r head, (fig . 12-3).

Fig. 12-3

¡REMOVING CYLINDER HEAD

PreparationC lean the en tire upper ha lf o f th e eng ine, to prevent d ir t en te ring the cy lin d e r b o re s jjn d tappe t cham ber.

1. D ra in c o o la n t from rad ia to r and c y lin d e r block.

2. Remove fue l f ilte rs and if f itte d , power steering pump (fig . 12-4).

3. D isconnec t rad ia to r hoses and d ip s tic k gu ide tube.

4. D isconnec t and rem ove th e rm o s ta t hous ing.

F ig. 1 2 ^7


5. Remove rocker cover, see page 12-7.

6. Unscrew and remove clam ps reta in ing in jec to r pipes, (fig. 12-5).

7. D isconnect ou te r in je c to r p ipe co n n ec tio n s on cy lin d e r head, (fig. 12-6).

8. Using spec ia l to o l part num ber 40200705, unscrew and rem ove in je c to r p ipes, (fig. 12-7).

Fig. 12-7

9. U nscrew and rem ove fue l leak o ff p ipe, (fig. 12-8).


10. Remove in je c to r p ipes from cy lin d e r head.

11. U nscrew bo lts re ta in ing rocker assem bly, (fig. 12-9).

12. Remove rocker assem b ly (and co nnec ting n ip le 6 cy lin d e r only).

Fig. 12-9

13. L ift ou t pushrods. The pushrods shou ld be num bered to ensure rep lacem en t in the o rig ina l pos itio n s , (fig.12-10).

14. Remove in jecto r securing nuts, using specia l too l part num ber 40200873, (fig. 12-11).

15. Remove in je c to rs from c y lin d e r head, us ing im pact p u lle r part num ber 40201076, (fig. 12-12).

F ig. 12-12

LSerW*


Attention!16. S hou ld the in je c to rs not move using im pac t puller,

use spec ia l to o l part num ber 40201063, (tig. 12-13).

17. D isconnec t exhaust dow n pipe.

18. U nscrew bo lts and remove exhaust m an ifo ld , (if f i t ted w ith a tu rbocharge r, d isco n n ec t tu rboch a rg e r o il feed and dra in p ipes firs t), (fig. 12-14).

19. U nscrew bo lts and remove in le t m an ifo ld , (fig. 12-15).

20. U n sc re w sn d rem ove cy lin d e r head bo lts (in reverse tig h ten in '^ sequence), (fig. 12-16). See page 12-20.

ADE':S8£Ii*S*


21. Screw lif t in g handles, part num ber 40200747 in to cy linde r head and lif t o ff from cy linde r block. Remove lif t in g handles from cy lin d e r head, (fig. 12-17).

22. Remove cy lin d e r head gaske t, and c lean top of cy lin d e r b lock, (fig. 12-18).

Fig. 12-17

7>r i r— ir— \r-

Fig. 12-18

CHECKING VALVE RECESSION

1. P lace spec ia l to o l part num ber 40201351 on to the cy linder head w ith the probe o f the d ia l gauge resting on a valve head. Note reading on d ia l gauge and check the rem ainder o f the valves in th is m anner, ensure th a t read ings co rrespond w ith the sp e c ifica tio n s , (fig . 12-19).

REMOVING VALVES as follows:

2. A tta ch valve sp ring com pressor, Part No. 40200679, to exhaust m an ifo ld s tud , (fig. 12-20).

Fig. 12-20


3. Press dow n lever o f valve sp ring com presso r and rem ove co lle ts , (fig. 12-21).

4. Remove valve sp ring cap, valve, sp ring and valve sp ring sea ting w asher, (fig. 12-22).

5. Turn over cy lin d e r head and rem ove valves.

Attention! Before rem oving valves, ensure thay are numbered in the correct replacem ent sequence (fig. 12-23). Do not p in punch or s tam p num ber on the valves as th is m ay w eaken the valve head.

CHECKING VALVE STEM/GUIDE CLEARANCE

6. Insert valves so th a t the valve heads p ro trude by 10 m m. U sing a m agne tic based d ia l gauge, p lace the p robe aga ins t the ou te r d iam e te r o f the valve head. Zero the gauge w h ils t the valve Is pushed aga inst the probe. A fte r zero ing the gauge, push the valve away from the probe and no jp the reading (fig. 12-24). Th is p rocedure m ust be carried o u t on a ll valves. Check read ings aga in s t sp e c ifica tio n s .

Fig. 12-22

ADEI360'Series


VALVE FACING

1. Remove carbon dep os its from valves.

2. Check to see if valves can be re-used. Valve ends m ust have no su rface dam age. Valve c o lle t grooves m ust no t be w orn and ch rom ium p la tin g on valve stem s m ust be w ith o u t flaw s. B u rn t valves m ust a lw ays be rep laced.

3. Using V -b locks and a d ia l gauge, check run out o f valve stems. Do not a ttem pt to s tra igh ten bent valves, (fig. 12-25).

4. If no V -b locks and d ia l gauge is ava ilab le , a qu ick check can be m ade us ing a su ita b le s tra ig h t edge, (fig . 12-26).

Fig. 12-26

5. M inor va ria tio n s in to le ra n ce can be correc ted by refac ing on a valve grinder.

6. A d ju s t g rind ing ang le to 30° fo r in le t and 45° fo r ex haust, inse rt va lve and c lam p d ire c tly behind valve head to avoid v ib ra tio n (fig . 12-27).

7. Using a low feed rate g rind u n til valve face is c lean ly cu t a ll round.

8. The valve stem face can bp lig h tly ground, by locating the valve stem in the sp e c ia l a ttachem en t m ounted on the valve g rind ing m ach ine , (fig. 12-28).

ADE 360 Serïÿs


VALVE SEAT FACING

1. Place cy lin d e r head on w ooden b locks.

2. Insert valve seat fac ing too l and re-cut sea t to 30° for In le t and 45° fo r exhaust, (fig. 12-29).

Caution: Do not cu t valve seat d iam ete r above th e ir m axi: mum lim its , see s p e c ifica tio n s .

Note: As the rep lacem ent o f valve sea ts requ ires the use o f ce rta in spe c ia lise d equ ipm ent, we suggest th a t th is operation is carried out by an ADE approved engine recond itio n e r. If valve gu ides need to be rep laced new gu ides m ust be f it te d before valve seat re-facing.

REMOVING VALVES GUIDES

1. P lace cy lin d e r head under a hyd rau lic press.

2. Using su ita b le m andrel press ou t valve gu ides from cy lin d e r head, (fig. 12-30).

3. If necessary, ream valve guide parent-bore in cylinder head to next repa ir s tage us ing spec ia l to o l Part No. 40200750, (fig. 12-31).

REPLACING VALVE GUIDES

1. Coat new valve gu ide w ith g raph ited o il and pos ition in cy lin d e r head, (fig, 12-32).

ADE 360 Series


2. F it 1 7 -1 7 ,5 mm spacer from spec ia l to o l Part No. 40200556 over valve gu ide, (fig. 12-33).

3. Using m andrel o f specia l too l Part No. 40200556, press valve guide in to cylinder head to the specified ins ta lla tio n he igh t, (fig. 12-34) i.e. u n til flu sh w ith spacer.

4. F in ish inner d ia m e te r o f valve guide, us ing specia l ream er part num ber 40200828 (exhaust), 40209591 (in let), (fig . 12-35).

5. Using a spring tension tester, check valve springs and ensure they con fo rm to sp e c ifica tio n , (fig. 12-36). ■

"A/**/ <&> _/ ° f J

f f t i i f

s.

L '» 1 ® ) o

Pig. 12-35

A 0 E 360 Series


CHECKING CYLINDER HEAD

1. Using a s tra igh t edge, check surface o f cy linde r head fo r d is to rtio n a long its length, (fig. 12-37).

2. And across the cy linder head (fig. 12-38). If the cylinder head is found to be d is to rte d , it m ust be refaced to the requ ired su rface sp e c ific a tio n and he igh t.

N ote : Observe fuel in je c to r p ro trus ion when refac ing cy lin d e r head. Refer to p rocedure on page 12-19.

REPLACING VALVES

1. Insert valve stem o il seal item 3 (fig. 12-42) in to special to o l part num ber 40202253, (fig. 12-39).

2. Place o il seal on to top Of valve gu ide and press down as fa r as poss ib le , (fig. 12-40).

ADE 360 Series


3. L ibe ra lly o il valve s te m s item 1 (fig. 12-42) and insert va lves in to cy lin d e r head. Ensure th a t the valves are inserted in th e ir o rig ina l p o s itio n s , (fig. 12-41).

4. Fit valve spring seating washer (2), valve spring (4) and valve spring cap (5), (fig. 12-42).

5. A tta c h va lve s p rin g c o m p re s s o r pa rt num ber 40200679, to exhaust m an ifo ld s tud , (fig. 12-43).

6. Press down lever o f valve sp ring com presso r and in se rt valve co lle ts , item s 6, (fig. 12-42). Release lever and ensure th a t the c o lle ts are seated co rre c tly . The gap betw een th e co lle ts shou ld be id e n tica l, (fig. 12-44).

F ig. 12-41

Fig. 12-44

ADE 360 Series

CYLINDER HEAD 12-18

INJECTOR PROTECTION SLEEVES

W h e n o v e rh a u lin g th e c y lin d e r h e a d it is e s s e n tia l th a t all th e in jec to r p ro tec tio n s le e v e s a re re m o v e d an d e x a m in e d fo r co rros ion .

R em ovin g

1. U sin g s p e c ia l to o l p a rt n u m b e r 4 0 2 0 0 6 2 4 , u n screw an d re m o v e all in je c to r p ro tec tio n s le e v e s , (F ig . 1 2 -4 5 ) .

2 . E x a m in e o u te r s u rfa c e o f p ro tec tio n s le eve s fo r corrosion. B a d ly c o rro d ed s le e v e s m u s t b e rep la ced .

3. R e m o v e all in je c to r p ro tec tio n s le e v e O -r in g s e a ls from th e c y lin d e r h e a d . D O N O T R E -U S E . (F ig . 1 2 -4 6 ) .

R ep lacin g

1. A p p ly s ilicon g re a s e to n e w O -r in g s e a ls an d in sert into cy lin d e r h e a d , (F ig . 1 2 -4 7 ) .

2. L igh tly c o a t b o tto m s u rfa c e o f p ro tectio n s le e v e s w ith a silicon s e a lin g c o m p o u n d , (F ig . 1 2 -4 8 ) .

Fig . 1 2 -4 7 ____________________________________________

April ‘96

CYLINDER HEAD 12-19

3. In s e rt s le e v e s a n d tig h ten to th e sp ec ified to rq ue , using s p e c ia l to o l p a rt n u m b e r 4 0 2 0 0 6 2 4 , (F ig . 1 2 -4 9 ) .

C H E C K IN G F U E L IN J E C T O R P R O T R U S IO N

4. A tta c h a d ia l g a u g e w ith a m a g n e tic ba se , to th e cy lin d e r h e a d w ith th e p ro b e o f th e d ia l g a u g e resting on th e tip o f th e in jec to r n o zzle .

A t te n t io n : N o te re a d in g on d ia l g a u g e an d c h e c k th e re m a in d e r o f th e in jec tio n n o zz le s in th is m a n n e r, en su rin g th a t m e a s u re m e n ts c o rre s p o n d w ith th e sp ec ific a tio n s . T h e d e p th o f th e in jec to rs ca n b e a lte re d by fitting a th ic k e r o r th in n e r s e a lin g w a s h e r, (F ig . 1 2 -5 0 ) .

R E P L A C IN G C Y L IN D E R H E A D

E n s u re c y lin d e r h e a d a n d b lock fa c e s a re c lean .

1. U s in g c o m p re s s e d a ir, b lo w ou t bo lt ho les in top o f cy lin d e r b lock , (F ig . 1 2 -5 1 ) .

2 . P la c e n e w c y lin d e r h e a d g a s k e t in po sition, (F ig . 1 2 -5 2 )

F ig . 1 2 -4 9

Fig . 1 2 -5 0

F ig. 12 -5 1

i*Q O O C O O O O P o p e a O e

Fig. 12-52

April ‘96

CYLINDER HEAD 12-20

3. S c re w lifting h a n d le s , p a rt n u m b e r 4 0 2 0 0 7 4 7 , on to cy lin d er h e ad , a n d lift in to p o s itio n , (F ig . 1 2 -5 3 ) .

4. U n s c re w an d re m o v e lifting h a n d le s . L u b ric a te th re a d s an d grip a re a o f th e c y lin d e r h e a d bo lts , (F ig . 1 2 -5 4 :1 2 -5 5 ) in sert bo lts an d s c re w d o w n.

5. T ig h te n c y lin d e r h e a d bo lts in fo u r s ta g e s (s e e sp ec ific a tio n s ) by re fe rrin g to s e q u e n c e d ia g ra m be low . (F ig .1 2 -5 6 ) .

0 ® ® ® ® © ® @ ® ® ® 0

® © ® ® ® ^

ADE 366

ADE 364

n e i r=|■ I I » s

Fig. 1 2 -5 3

Fig . 1 2 -5 4

F ig. 1 2 -5 5

Fig. 12-56

April '96

CYLINDER HEAD 12-21

6. In s e rt pu sh ro d s , en su rin g th e y a re p laced in th e ir o rig ina l p o s itio n s , (F ig . 1 2 -5 7 ) .

7. R e p la c e ro c k e r sh a fts , in sert bolts bu t D O N O T tig h ten , (F ig . 1 2 -5 8 ) .

8. U s in g s p e c ia l to o l p a rt n u m b e r 4 0 2 0 2 1 8 5 , in sert co nn ectin g n ip p le b e tw e e n ro ck er sh afts , (F ig . 1 2 -5 9 ) . N o t req u ire d on A D E 3 6 4 .

9. T ig h te n ro c k e r s h a ft bo lts to th e sp ec ified to rq ue , (F ig .1 2 -6 0 ) .

F ig . 1 2 -5 7

Fig . 1 2 -5 8

l i l ie s

Fig. 1 2 -5 9

if

frTl FT) fFH fFPi I P » »5Fig. 12-60

April ‘96

CYLINDER HEAD 12-22

10. R e p la c e th e fu e l in jec to rs a n d tig h ten se cu rin g nu ts to th e s p ec ified to rq u e , us ing s p ec ia l to o l p a rt n u m b e r 4 0 2 0 0 8 7 3 , (F ig . 1 2 -6 1 ) .

11. R e -c o n n e c t u p p e r an d lo w e r in jec to r p ipes an d o u te r co n n ec tio n s . A tta c h fu e l le a k -o ff pipe.

N o te : S e a l o u te r c o n n e c tio n s w ith h y lo m a r or s u ita b le s e a la n t. T ig h te n a ll c o n n e c tio n s to th e s p ec ified to rq u e , us ing sp ec ia l too l p a rt n u m b e r 4 0 2 0 0 7 1 8 , (F ig . 1 2 -6 2 ) .

12. T ig h te n all fu e l le a k -o ff bo lts to th e s p ec ified to rq ue , (F ig . 1 2 -6 3 ) .

13. R e p la c e in le t m a n ifo ld fitted n e w g a s k e ts , an d tig h ten bo lts to th e s p e c ifie d to rq u e , (F ig . 1 2 -6 4 ) .

N o te : In le t m a n ifo ld m u s t b e fitted b e fo re e x h a u s t m a n i- fold.

April ‘96

CYLINDER HEAD 12-23

14. R e p la c e e x h a u s t m a n ifo ld w ith n e w g a ske t, and tu rb o c h a rg e r if fitted . T ig h te n all bo lts fro m th e m id d le ou tw a rd s , to th e s p e c if ie d to rq u e , (F ig . 1 2 -6 5 ) .

15. U s in g a n e w g a s k e t, a tta c h ex h a u s t do w n p ipe to m a n ifo ld , in sert bo lts an d tig h ten to th e sp ec ified to rq ue.

16 . F it ra d ia to r h o s e s a n d tig h ten clips, a ttach d ipstick g u id e tu b e .

17. R e p la c e fu e l filters , an d if fitted , p o w er s teerin g p u m p . R e -te n s io n V -b e lt . (F ig . 1 2 -6 6 ) .

VALVE CLEARANCE ADJUSTMENT ADE 364

1. In s e rt fe e le r g a u g e b e tw e e n v a lv e s tem an d ro ck er a rm . V a lv e c le a ra n c e is c o rre c t w h e n th e fe e le r g a u g e s lides th ro u g h w ith a s lig h t re s is ta n c e , (F ig . 1 2 -6 7 ) .

2 . If th e v a lv e c le a ra n c e req u ire s a d ju s tm e n t, re le a s e th e lo ck nut, a d ju s t v a lv e c le a ra n c e an d tig h ten th e lo ck nut w h ile h o ld in g th e a d ju s tin g screw .

D escr ip tion ADE 364ADE 366

E n g in e C rank shaft Intake v a lv e s Exh. v a lv e sp o s it io n o f to b e ad ju sted to b e ad ju stedcy lin d er No.1

36 4 N o .1 v a lv e rock ing 3 ,4 2 ,4

N o .1 v a lv e c lo sed 1 ,2 1 ,3

April ‘96

CYLINDER HEAD 12-24

V A L V E CLEARANCE ADJUSTM ENT ADE 366

1. In sert fe e le r g a u g e b e tw e e n v a lv e s te m an d ro ck er a rm . V a lv e c le a ra n c e is c o rre c t w h e n th e fe e le r g a u g e slides th ro u g h w ith a s ligh t res is ta n c e .

2. If th e v a lv e c le a ra n c e re q u ire s a d ju s tm e n t, re le a s e lock nut an d a d ju s t th e v a lv e c le a ra n c e . T ig h te n lo ck nut w h ile h o ld in g th e a d ju s tin g sc rew , (F ig . 1 2 -6 9 ) .

D escr ip tio n ADE 364ADE 366

E ngine C ranksh aft Intake v a lv e s Exh. v a lv e sp o s it io n o f to b e a d ju sted to b e ad ju stedcy lin d er No.1

3 6 6 N o . 1 v a lv e rock ing 3 ,5 ,6 2 ,4 ,6

N o. 1 v a lv e c lo sed 1 ,2 ,4 1 ,3 ,5

REPLACING ROCKER COVER

1. C h e c k s u rfa c e o f ro c k e r c o v e r fo r d a m a g e , (F ig . 1 2 -7 1 ).

2. F it n e w ro ck er c o v e r g a s k e t to cy lin d er h e ad , (F ig1 2 -7 2 ).

Fig. 12-72

April ‘96

CYLINDER HEAD 12-25

3. P la c e ro c k e r c o v e r in po sition , in sert bo lts an d tig h ten to th e s p ec ified to rq u e , (F ig . 1 2 -7 3 ) .

4 . R e p la c e th e rm o s ta t ho u s in g an d tig h ten bolts to th e

5. F ill ra d ia to r w ith co o la n t, s ta rt e n g in e an d run to o p e ra -

CHECKING COM PRESSION

1. R e m o v e ro ck er co ver.

2. C h e c k v a lv e c le a ra n c e , (s e e p a g e 1 2 -2 3 ).

3. R e p la c e ro c k e r co ver.

4. R u n e n g in e un til o p e ra tin g te m p e ra tu re is reach ed (7 0 -9 5 ) .

5 . E n s u re th a t th e b a tte ry is in a g o o d co nd ition .

6. R e m o v e ro c k e r co ver, in jec to rs an d s e a lin g w a s h e rs .

7. S e t in jec tio n p u m p co ntro l to s top position.

T estin g

1. In s e rt in je c to r s e a lin g w a s h e r , (F ig . 1 2 -7 4 ) .

2. In s e rt a d a p to r fo r th e c o m p re s s io n te s te r (p a r t n u m b e r 4 0 2 0 0 7 8 9 ) in th e c y lin d e r h e a d an d tig h ten w ith in jecto r

se cu rin g nut, (F ig . 1 2 -7 5 ) .

3. A tta c h c o m p re s s io n te s te r e x ten s io n to a d ap to r, (F ig .1 2 -7 6 ) .

4. C h e c k c o m p re s s io n a t an e n g in e s p eed o f a p p ro x im a te ly 1 8 0 -2 0 0 r /m in (s ta r te r s p e e d ) w ith th e th ro ttle in th e c lo s e d po sition . T u rn th e e n g in e until th e te s t in d ica to r sto p s ris ing. R e p e a t th is p ro c e d u re fo r a ll cylinders.

5. R e m o v e c o m p re s s io n te s te r an d a d ap te r.

6. R e p la c e s e a lin g w a s h e rs , in jectors an d lea k o ff pipes, tig h te n to th e s p e c ifie d to rq u e .

F ig . 1 2 -7 3

Fig. 1 2 -7 4

Fig. 1 2 -7 5

Fig. 12-76

April '96

CYLINDER HEAD 12-26

7. R e p la c e ro c k e r c o v e r an d tig h te n bo lts to th e sp ecified to rq u e , (F ig . 1 2 -7 7 ) .

April ‘96

SPECIAL TOOLS FOR THIS SECTIONOBTAINABLE FROM: GRUNDY-TECHNIFORM, BURMAN ROAD, DEAL PARTY ESTATE PORT ELIZABETH 6001 '


S p lit ring spanner for in je c to r pipes,(see fig . 12-7)

Part N um ber 40200705

S ocke t fo r in je c to r securing nuts(see fig . 12-11, 1 2 -6 1 )


Fuel in je c to r Im pact e x tra c to r (see fig . 12-12)


,c

E xtrac to r fo r in je c to rs (see fig . 12-13)


L ift in g hand les c y lin d e r head (see fig . 12-17, 12-53)


VALVE DEPTH GAUGE (see fig. 12-19)


ADE 360 Series


e n

o T ^

Valve sp ring com presso r (see fig . 12-43)

Part N um ber 40200679 40200682

Ream er fo r valve gu ide parent bore in cyl./head 13,5 x 15,5 mm (see fig . 12-31)


Valve gu ide rep lacem ent m andre l(see fig . 12-33, 12-34)


R eam er fo r exhaust valve gu ides (see fig . 12-35)Part N um ber 40200828

R eam er fo r in le t valve gu ides (see fig . 12-35)Part N um ber 40209591

Valve stem seal rep lac ing to o l (see fig . 12-40)


R em oving /R ep lac ing to o l for in je c to r p ro te c tio n sleeves (see fig . 12-45, 12-49)


P lie rs rocker sha ft co u p lin g bush (see fig . 12-59)

Part N um ber 40202185 ADE 366N/C/T/TI on ly

ADE 360 Series


C r o w fo o t r ing s c a n n e r R e m o v e '

R e p la c e m e n t o f m ie c to r p ipes

(see fig 12-62)

Part N u m b e r 40200718

A d a p to r fo r com press ion tester.(see fig. 12-75)

Part N u m b e r 40200789

Attention!As we recom m end th a t the rem oval and rep lacem en t o f valve sea ts shou ld on ly be carried ou t by an ADE Approved engine rebu ilder, the use o f these th ree spec ia l to o ls is not illu s tra te d in the text. These spec ia l to o ls are however ob ta inab le from G rundy-Techn ifo rm .

ADE 360 Series

_____________ SECTION 13Piston and Connecting Rods

CONTENTS OF SECTION 13

P a g e

IL L U S T R A T IO N .................................................................................................................................................................................................................................... 1 3 -2

IN T R O D U C T IO N ................................................................................................................................................................................................................................. 1 3 -3

S P E C IF IC A T IO N S .............................................................................................................................................................................................................................. 1 3 -3

R E M O V IN G P IS T O N S A N D C O N N E C T IN G R O D S ...................................................................................................................................................... 1 3 -5

R E M O V IN G P IS T O N R I N G S ....................................................................................................................................................................................................... 1 3 -6

C H E C K IN G B IG -E N D B E A R IN G S ............................................................................................................................................................................................ 1 3 -7

C H E C K IN G P IS T O N S A N D P IS T O N R IN G S .................................................................................................................................................................... 13 -11

R E P L A C IN G P IS T O N S A N D C O N N E C T IN G R O D S .................................................................................................................................................... 1 3 -1 3

S P E C IA L T O O L S ................................................................................................................................................................................ '...................... 1 3 -1 6

A p ril '96

Piston and Connecting Rods 13-2

1. S M A L L E N D B U S H2 . C O N N E C T IN G R O D3. C O N N E C T IN G R O D B O L T S4. B E A R IN G S H E L L S5. C IR C L IP S

6. C O M P R E S S IO N R IN G7. C O M P R E S S IO N R IN G8. O IL S C R A P E R R IN G9. P IS T O N

10. G U D G E O N P IN

April '96

PISTONS AND CONNECTING RODS 13-3

INTRODUCTION

T h e lig h t a llo y p is to n s used h a v e th e co m b u s tio n c h a m b e r ca s t in th e p iston crow n. T w o c o m p re s s io n an d o n e oil contro l ring a re fitted to th e p is to n s w ith th e to p c o m p re s s io n ring re ta in ed in an A l-fin b o n d ed insert. G u d g e o n pins a re tu b u la r to re d u c e w e ig h t a n d a re lo c a te d in th e p is to n s by circ lips. C o o lin g n o zz le s a re fitted to a s s is t w ith p is ton co o lin g of tu rb o c h a rg e d en g in e s .

F o rg e d s tee l c o n n e c tin g rods a re used w ith s e rra te d m a tin g su rfa c e s b e tw ee n th e c o n n ec tin g rod an d th e ca p to prov ide in c re a s e d rig id ity a n d to ex ten d b e a rin g life. T h e b ig -en d b e arin g sh ells a re stee l b a c k e d an d lined w ith a lu m in iu m /tin . T h e s m a ll-e n d bu sh is m a n u fa c tu re d fro m a h igh q u a lity p h o s p h o r b ro n ze an d s e a ts in an in te rfe re n c e fit in th e c o n n ec tin g rod

W ith th e c y lin d e r h e a d a n d s u m p re m o v e d , th e p is to ns ca n e a s ily b e w ith d ra w n fro m th e to p o f th e c y lin d e r block.

PISTONS AND CONNECTING RODS

R epair s t a g e s N om inal P iston d iam eter

C o m p ress io n h e ig h t ** B lock h e igh t

S ta n d a rd N /C /T /T I 9 7 ,5 6 2 ,8 0 to 6 2 ,8 6 3 5 8 ,8 2 to 3 5 9 ,0 7 (S T D )R e p 1 N + 0 ,5 R e b o re * 9 8 ,0 0 6 2 ,5 0 to 6 2 ,5 6 3 5 8 ,5 2 to 3 5 8 ,7 7 ( - 0 ,3 )R e p 1 n / c /t / t i 9 7 ,5R e p s ta g e 2 N /C /T /T I 9 7 ,5 6 2 ,2 0 to 6 2 ,2 6 3 5 8 ,2 2 to 3 5 8 ,4 7 ( - 0 ,6 )R e p s ta g e 3 N /C /T /T I 9 7 ,5 6 1 ,9 0 to 6 1 ,9 6 3 5 7 ,9 2 to 3 5 8 ,1 7 ( -0 ,9 )

1st re p a ir s ta g e fo r n a tu ra lly a s p ira te d o p tio n a l, i.e . e ith e r reb o re fo r o v e rs ize p is ton or fit s leeve . ■ m e a s u re m e n t fro m g u d g e o n pin c e n tre to p iston top .

*

M a x w e ig h t v a r ia tio n b e tw e e n p is to n s 2 0 g

G u d g e o n pin d ia m e te r 3 5 ,9 9 5 to 3 6 ,0 0 0

G u d g e o n pin b o re d ia m e te r 3 6 ,0 0 2 to 3 6 ,0 0 7

G u d g e o n pin to p is to n b o re c le a ra n c e 0 ,0 0 2 to 0 ,0 1 2

P is to n p ro tru s io n a t T D C to b lo ck s u rfa c e 0 ,1 7 0 to 0 ,5 8 0

N ote: T h e c o d e s B A 0 9 or B C 0 1 a p p e a r on th e p iston crow n s. T h e s e a re g rad in g c o d es fo r p ro d u c tio n only.

PISTON RINGS

360N/C/T/TI T ype S id e C learan ce G ap1 K e y s to n e 0 ,0 4 2 to 0 ,0 9 7 0 ,2 0 to 0 ,3 52 T a p e re d fa c e co m p re s s io n 0 ,0 6 0 to 0 ,0 9 5 0 ,2 0 to 0 ,3 53 O il co ntro l (s p rin g e x p a n d e r) 0 ,0 3 0 to 0 ,0 6 5 0 ,2 5 to 0 ,4 0

A tten tion : G a p a n d s id e c le a ra n c e a re e q u a l to a b o v e in a ll b o re re p a ir s tag e s .

April '96


C O N N E C T IN G R O D

R e p a ir s iz e C o n n e c t in g ro d b e a r in g d ia m e te r . in s ta l le d

C o n n e c t in g B ig e n d

ro d w id thS m a l l e n d

S ta n d a rd 6 0 ,0 5 6 to 6 0 ,0 9 5

3 7 ,7 3 0 to 3 7 ,8 3 0 3 5 ,5 to 3 5 ,6

S ta n d a rd 1 ( - 0 ,1 ) 5 9 ,9 5 6 to 5 9 ,9 9 5S ta n d a rd 2 ( - 0 ,2 5 ) 5 9 ,8 0 6 to 5 9 ,8 4 5R e p 1 ( - 0 ,5 ) 5 9 ,5 5 6 to 5 9 ,5 9 5R e p 2 ( - 0 ,7 5 ) 5 9 ,3 0 6 to 5 9 ,3 4 5R ep 3 ( - 1 ,0 ) 5 9 ,0 5 6 to 5 9 ,0 9 5

C o n n e c tin g rod big en d b a s ic b o re 6 5 ,0 0 0 to 6 5 ,0 1 9

T a p e r o f big en d b a s ic b o re 0 ,0 0 5

Big en d b e a rin g c le a ra n c e rad ia l 0 ,0 4 1 to 0 ,1 0 0ax ial 0 ,1 0 to 0 ,4 0

Leng th o f c o n n e c tin g rod b e tw e e n c e n tre s o f big en d an d s m a ll end 2 3 0 ,0 0 to 2 3 0 ,0 5

W e ig h t v a ria tio n b e tw e e n co n n e c tin g rods fo r re p a ir 4 0 g

M ax. p a ra lle l d e v ia tio n b e tw e e n c e n tre lin e o f big en d an d s m a ll end 0 ,0 1 0

Big en d b e a rin g crush 0 ,0 4 to 0 ,0 7

S M A L L E N D

S m a ll en d b a s ic b o re in c o n n e c tin g rod s ta n d a rd 3 9 ,0 0 0 to 3 9 ,0 2 5R ep 1 (1 -0 ,2 )_____________________________ 3 9 ,2 0 0 to 3 9 ,2 2 5

R e p 2 (+ 0 ,5 ) 3 9 ,5 0 0 to 3 9 ,5 2 5

S m a ll en d b u sh In n e r d ia m e te r in s ta lled_________________ 3 6 ,0 3 0 to 3 6 ,0 4 0

T a p e r /o v a lity to le ra n c e _________________ 0 ,0 0 2 _____________

In te rfe re n c e fit___________________________0 ,0 2 0 to 0 ,0 7 5

C le a ra n c e to g u d g eo n pin 0 ,0 3 0 to 0 ,0 4 5

T O R Q U E S P E C IF IC A T IO N S

C o n n e c tin g rod b o lts ..............................................................................................................1st s t a g e ..........................................4 0 -5 0 N m........................................................................................................................................................... F in a l.................................................... + 9 0 ° -1 0 0 °........................................................................................................................................................... S tre tch lim it.................................... 5 6 ,8 m m (M 1 2 )

P isto n co o lin g n o zz le s - up to e n g in e no. S A 0 7 0 9 0 0 V ..................................M 1 0 x 1 .............................................2 5 N mfro m .e n g in e no. S A 0 7 0 9 0 1 V .................................. M 1 0 x 1 .............................................1 5 -1 8 N m

April '96


(C y lin d e r h e ad an d s u m p re m o v a l)

R e m o v in g

1. U s in g a s u ita b le s c ra p e r, re m o v e ca rb o n d e p o s its from to p o f c y lin d e r b o re s , (F ig . 1 3 -1 ).

REMOVING PISTONS AND CONNECTING RODS

2. U n s c re w re ta in in g bo lts an d re m o v e p iston cooling n o zz le s , 3 6 0 C /T /T I , (F ig . 1 3 -2 ).

3 6 0 N e n g in e s h a v e c lo s in g p lugs in p la c e o f no zzles .

3. U n s c re w c o n n e c tin g rod bo lts an d re m o v e bearing c a p s , (F ig . 1 3 -3 ).

A t te n t io n ! B e a rin g c a p s a n d c o n n ec tin g rods a re m a rk e d as m a tc h e d p a irs (n o te n u m b e rs b e fo re a s s e m b ly ).

4 . R e m o v e p is to n s a n d co n n e c tin g rods fro m to p o f cy lin d e r b lock , (F ig . 1 3 -4 ) .

F ig . 13 -1

Fig. 13-4


5. R e m o v e b e a rin g s h e lls fro m ca p an d co n n e c tin g rods, if th e o ld b e a rin g s h e lls a re to b e used a g a in , m a rk sh e lls to e n s u re re p la c e m e n t in th e o rig in a l po sition, (F ig . 1 3 -5 ).

R em oval o f P isto n R in g s /P is to n from C on n ectin g R od s.

1. C la m p c o n n e c tin g rod a n d p is to n a s s e m b ly in a v ice, fitted w ith p ro te c tiv e ja w s , (F ig . 1 3 -6 ).

2. T u rn a d ju s tin g s c re w o f ring ex p a n d e r, p a rt n u m b e r 4 0 2 0 0 3 0 7 , to a p p ro x . 9 8 m m , (F ig . 1 3 -7 ).

3. R e m o v e p is to n rin g s a t th is s e ttin g , (F ig . 1 3 -8 ) .

Fig . 1 3 -6

Fig. 13-8

April '96


4 . R e m o v e c irc lip s fro m p iston , push ou t g u d g eo n pin an d re m o v e p is to n fro m co n n e c tin g rod, (F ig . 1 3 -9 ).

C h eck in g B ig End B ea r in g s

1. C le a n c o n n e c tin g rod a n d b e a rin g ca p s u rface , (F ig .1 3 -1 0 ) .

2. F it big en d b e a rin g ca p an d in sert bolts , (c a p an d c o n n e c tin g rod n u m b e rs a lig n e d ), (F ig . 1 3 -1 1 ) .

3. T ig h te n c o n n e c tin g rod bo lts to th e s p ec ified to rq u e , (F ig . 1 3 -1 2 ) .

F ig . 1 3 -9

Fig. 1 3 -1 0

Fig. 13 -1 1

III: A » i

Fig. 13-12

April '96


4. U s in g an in te rn a l m e a s u rin g in s tru m e n t c h e c k big end p a re n t b o re in th re e p laces , (F ig .1 3 -1 3 ) .

5. U s in g an in te rn a l m e a s u rin g in s tru m e n t c h e c k b o re o f th e s m a ll en d b u sh , (F ig . 1 3 -1 4 ) .

A t te n t io n ! If th e s m a ll en d bu sh in n er d ia m e te r do es not m e e t th e s p e c if ic a tio n , th e bu sh m u s t b e p res sed o u t and rep la ced . W ith th e s m a ll en d bu sh re m o v e d , c h e c k th e p a re n t b o re a n d , if n e c e s s a ry , m a c h in e to th e 1s t re p a ir s tage . S ta n d a rd a n d o v e rs iz e o u ts id e d ia m e te r s m a ll end bu sh es h a v e a n u n fin is h e d in n e r d ia m e te r w h ic h m u s t b e re a m e d to th e s p e c if ie d s ize a f te r in s ta lla tio n . W h e n fitting a n e w s m a ll end bush to th e co n ro d , a lu b ric a tin g h o le m u s t b e drilled a fte r th e bush is fitted . R e a m in g o f th e bu sh ca n n o w b e ca rried out.

6 . M o u n t th e c o n n e c tin g rod in an a lig n m e n t g a u g e and c h e c k fo r b e n d in g , (F ig . 1 3 -1 5 ) .

7. C h e c k fo r tw is tin g , (F ig . 1 3 -1 6 ) .

W A R N IN G ! U n d e r no c irc u m s ta n c e s sh ou ld an y a tte m p t be m a d e to s tra ig h te n a b e n t c o n n e c tin g rod. C o n n e c tin g rods th a t do n o t c o n fo rm to s p e c if ic a tio n s m u s t a lw a y s be rep la ced .

F ig .1 3 -1 3

Fig. 1 3 -1 4

■nu ra=

Fig. 13-16


8. U n s c re w c o n n e c tin g rod bo lts an d re m o v e bearing c a p s , (F ig .1 3 -1 7 ) .

9. F it b e a r in g sh e lls in to c o n n ec tin g rod an d b e arin g cap. E n s u re th a t th e lo ca tin g ta b s a re fitted co rrectly , (F ig .1 3 -1 8 ) .

10. F it b e a r in g c a p to th e c o n n ec tin g rod, (n u m b e rs on th e b e a rin g c a p a n d co n n e c tin g rod a lig n e d ). C la m p co n n e c tin g rod in a v ic e fitted w ith p ro te c tiv e ja w s , (F ig .1 3 -1 9 ) .

11. In s e rt bo lts a n d tig h te n to th e sp ec ified to rq u e , (F ig .1 3 -2 0 ) .

Fig. 13-20

April '96


12. U s in g an in te rn a l m e a s u rin g in s tru m e n t c h eck big end b e a rin g b o re in th re e p la c e s , (F ig , 1 3 -2 1 ) .

C h eck in g th e B earin g C rush

13 . M o u n t th e c o n n e c tin g rod in a v ic e fitted w ith so ft ja w s . F it th e b e a rin g s h e lls in to b e a rin g ca p an d co nn ecting rod. In s e rt bo lts an d tig h te n to th e s p ec ified to rq ue . A tta c h a d ia l g a u g e w ith a m a g n e tic b a s e to th e vice, w ith th e p ro b e res tin g on th e u n d e rs id e o f th e b earin g cap , a n d se t th e g a u g e to “0". L o o s en th e big end bolt n e a re s t to th e d ia l g a u g e , n o te th e re a d in g on th e g a u ge. T h e fig u re w ill re p re s e n t th e b e a rin g cru sh and sh ou ld b e c o m p a re d w ith th e sp ec ifica tio n ,(F ig . 1 3 -2 2 ) .

14. U n s c re w th e c o n n e c tin g rod bo lts an d us ing a v e rn ie r ga u g e , c h e c k bo lts fo r s tre tch , re fe r to sp ec ifica tio n s , (F ig . 1 3 -2 3 ) .

15. C o n n e c tin g rods a n d b e a rin g s h e lls sh o u ld b e m a rk e d to e n s u re re p la c e m e n t in th e o rig in a l po sition , (F ig ,1 3 -2 4 ) .c h e c k re m a in d e r o f c o n n e c tin g rods a s ab ove .

Fig. 13-24

April '96


B e fo re ch e c k in g p is to ns , p is ton rings an d g u d g eo n pins, en s u re th a t th e p is to n an d p iston ring g ro o ves a re c le an an d free o f c a rb o n d e p o s its . C a re sh ou ld b e ta k e n to en su re th a t th e p is to n ring g ro o v e s a re no t d a m a g e d du ring c lean in g .

A t te n t io n ! In a ll c a s e s p is to n s an d th e ir a s s o c ia te d gu d g eo n pins a re c o n s id e re d to b e m a tc h e d pa irs . W h e n d ism a n tlin g , th e s e ite m s m u s t b e m a rk e d , so th a t du ring a s s e m b ly th e m a rk in g s c o rre s p o n d , an d th e p arts a re re tu rn ed to th e ir o rig in a l po sition .

1. P is to n s an d ring s sh o u ld b e re m o v e d as d e ta ile d on p a g e 1 3 -8 .

2. W h e n c le a n , c h e c k p is to n s c a re fu lly b e fo re re -u se.

3. U s in g a n in te rn a l m e a s u rin g in s tru m en t, c h e c k th e g u d g e o n pin b o re in th e p iston , (F ig . 1 3 -2 5 ) an d

4. U s in g a m ic ro m e te r , c h e c k th e o u te r d ia m e te r o f th e g u d g e o n pin, (F ig . 1 3 -2 6 ) .

CHECKING PISTONS AND PISTON RINGS

5. In s e rt a p is to n ring in to th e cy lin d er b o re an d us ing a piston , pu sh th e ring s q u a re ly d o w n into th e cy lin d er b o re to a d e p th o f a p p ro x im a te ly 3 0 m m fro m th e top, (F ig . 1 3 -2 7

April ‘96


6 M e a s u re th e en d g a p o f th e p is ton ring an d re p e a t th is p ro c e d u re w ith th e re m a in in g rings. R ing g a p s m u s t be w ith in th e s p ec ified lim its , (F ig . 1 3 -2 8 ) .

N o te : W ith th e p is to n s re m o v e d a ca re fu l e x a m in a tio n should be m a d e o f th e c y lin d e r b o re fo r w e a r an d lo ca lis ed se izu re .

7. R e -f it p is to n s to c o n n e c tin g rods , c le a n c a rb o n an d oil d e p o s its fro m p is to n ring g ro o v e s . E n s u re th a t th e g ro o v e s a re no t d a m a g e d , (F ig . 1 3 -2 9 ) .

8. R e p la c e all p is to n ring s us ing ring e x p a n d e r, p a rt n u m b e r 4 0 2 0 0 3 0 7 , (F ig . 1 3 -3 0 ) .

9. C h e c k c le a ra n c e o f p is to n ring s in th e g ro o ves , re p la c e piston a n d /o r ring s th a t do no t c o n fo rm to s p e c if ic a tio ns , (F ig . 1 3 -3 1 ) .

F ig . 1 3 -2 9

April '96


R E P L A C IN G P IS T O N S , P IS T O N R IN G S A N D C O N N E C T IN G

R O D S

1. C la m p c o n n e c tin g rod in a v ic e fitted w ith p ro tec tive ja w s , w ith th e e lo n g a te d s id e to th e righ t (in jec tion p u m p s id e ) as in d ic a te d by arro w s . P la c e p iston on c o n n e c tin g rod, w ith th e a rro w on th e p iston crow n fa c in g fo rw a rd a s in d ic a te d , (F ig . 1 3 -3 2 ).

2 . In s e rt g u d g e o n pin an d s e c u re w ith circ lips, (F ig .1 3 -3 3 ) .

3. R e p la c e p is to n ring s, us ing ring e x p a n d e r part n u m b e r 4 0 2 0 0 3 0 7 , s ta g g e r p iston rings, w h ich m u s t ro ta te fre e ly in th e g ro o v e , 1 8 0 ° e a c h s id e o f th e gu d g eo n pin, (F ig . 1 3 -3 4 ) .

4. L u b ric a te p is ton ring s w ith e n g in e oil, (F ig . 1 3 -3 5 ) .

April ‘96

Fig. 1 3 -3 2

m u /©=

Fig. 1 3 -3 3

Fig. 1 3 -3 4

mu *e=

Fig. 13-35 ._____________________________________


5. P o s itio n ring s q u e e z e r o v e r p is to n rings a n d c o m p re s s so th a t th e s le e v e w ill ju s t m o v e (F ig . 1 3 -3 6 ) .

6 . L u b ric a te big en d b e a rin g s a n d c ra n k s h a ft jo u rn a l w ith e n g in e oil, (F ig . 1 3 -3 7 ) .

7. In s e rt c o n n e c tin g rod an d p iston into c y lin d e r bore, w ith a rro w on p is to n c ro w n po in tin g to w a rd s th e fron t o f th e en g in e , (F ig . 1 3 -3 8 ) .

8. P u sh p iston d o w n in to c y lin d e r b o re a n d g u id e th e co n nectin g rod un til th e big en d b e a rin g co n ta c ts th e c ra n k s h a ft jo u rn a l, (F ig . 1 3 -3 9 ) .

Fig. 13-39


9 L u b r ic a te big en d b e a rin g c a p w ith e n g in e oil, (F ig .1 3 -4 0 ) .

10 . F it m a tc h e d big en d b e a rin g ca p to co n n ec tin g rod and

in s e rt bo lts (F ig . 1 3 -4 1 ) .

11. T ig h te n big en d b e a rin g bo lts to th e sp ec ified to rq ue , (F ig . 1 3 -4 2 ) .

12. In s e rt p is ton co o lin g n o zz le s en su rin g th a t lo cating pin on n o z z le b o d y a lig n s w ith drillin g in oil ga lle ry , (A D E 3 6 0 C /T /T I on ly ), (F ig . 1 3 -4 3 ) , in sert bo lts an d tig h ten to s p e c if ie d to rq u e . ( In 3 6 0 N e n g in e s fit p lugs an d to rq u e to sp e c ific a tio n ).

Fig. 1 3 -4 2

April '96

SPECIAL TOOLS FOR SECTION 13

O B T A IN A B L E F R O M G R U N D Y T E C H N IF O R M , B U R M A N R O A D , D E A L P A R T Y E S T A T E , P O R T E L IZ A B E T H 6 0 0 1


April '96

_________SECTION 14Crankshaft and Main Bearings


P a g e

IL L U S T R A T IO N ..................................................................................................................................................................................; ................................................ 14 -2

IN T R O D U C T IO N ................................................................................................................................................................................................................................. 14 -3

S P E C IF IC A T IO N S .............................................................................................................................................................................................................................. 1 4 -3

R E M O V IN G V IB R A T IO N D A M P E R ......................................................................................................................................................................................... 14 -5

R E P L A C IN G V IB R A T IO N D A M P E R ........................................................................................................................................................................................ 1 4 -5

R E M O V A L O F C R A N K S H A F T .................................................................................................................................................................................................... 1 4 -6

G R IN D IN G C R A N K S H A F T ........................................................................................................................................................................................................... 14 -8

C H E C K IN G B E A R IN G A N D P A R E N T B O R E S ................................................................................................................................................................1 4 -1 0

C H E C K IN G B E A R IN G S A N D H O U S IN G ............................................................................................................................................................................. 1 4 -1 0

R E P L A C IN G R E A R M A IN B E A R IN G O IL S E A L .............................................................................................................................................................1 4 -1 3

R E P L A C IN G C R A N K S H A F T ........................................................................................................................................................................................................1 4 -1 6

S P E C IA L T O O L S F O R S E C T IO N 1 4 .................................................................................................................................................................................... 1 4 -1 9

A p ril '96

Crankshaft and Main Bearings 14-2

15

C R A N K S H A F T A S S E M B L Y

1 B E A R IN G R E T A IN E R2 S P IG O T B E A R IN G3 B O L T4 F L Y W H E E L5 B O L T6 B A L A N C E W E IG H T7 C R A N K S H A F T8 W O O D R U F F K E Y

9 C R A N K S H A F T G E A R10 S P A C E R11 V IB R A T IO N D A M P E R12 C E N T E R IN G R IN G13 P U L L E Y14 B O L T15 C R A N K S H A F T M A IN B E A R IN G S

April ‘96


INTRODUCTION

T h e c ra n k s h a ft is p rec is io n fo rg ed , induction h a rd en e d an d su pp orted by seven th re e -la y e r b e a rin g sh ells on A D E 3 6 0 a n d fiv e on A D E 3 6 4 . A th ru s t b e arin g is fitted to th e n u m b e r 4 m a in b earing . S e p a ra te an d d e ta c h a b le b a la n c e w eigh ts a re bo lted to th e c ra n k s h a ft.

SPECIFICATIONSCRANKSHAFT

R epair s iz e (d iam eter)

Main bearing journal dia.

Width for th ru st bearing

C onrod bearing journal d iam eter

W idth Dia for rear rop e sea l

S ta n d a rd 8 7 ,9 9 to 8 8 ,0 1 3 2 ,0 0 0 to 5 9 ,9 9 5 to 6 0 ,0 1 5 9 0 ,8 7 4S ta n d a rd 1 ( - 0 ,1 ) 8 7 ,8 9 to 8 7 ,9 1 3 2 ,0 6 2 5 9 ,8 9 5 to 5 9 ,9 1 5 3 7 ,9 3 toS ta n d a rd 2 ( - 0 ,2 5 ) 8 7 ,7 4 to 8 7 ,7 6 3 2 ,3 0 0 to 3 2 ,3 6 2 5 9 ,7 4 5 to 5 9 ,7 6 5 to 9 0 ,9 2 8R e p a ir 1 ( - 0 ,5 ) 8 7 ,4 9 to 8 7 ,5 1 (+ 0 ,3 ) or 5 9 ,4 9 5 to 5 9 ,5 1 5 3 8 ,1 3 9 0 ,5 5 4 to 9 0 ,5 0 8R e p a ir 2 ( - 0 ,7 5 ) 8 7 ,2 4 to 8 7 ,2 6 3 2 ,5 0 0 to 3 2 ,5 6 2 5 9 ,2 4 5 to 5 9 ,2 6 5 9 0 ,2 3 4 to 9 0 ,2 8 8R e p a ir 3 ( - 1 ,0 ) 8 6 ,9 9 to 8 7 ,0 1 (+ 0 ,5 ) 5 8 ,9 9 5 to 5 9 ,0 1 5M a in an d big en d jo u rn a l h a rd n e s s H R C 5 6 ± 3

M in jo u rn a l h a rd n e s s on a t le a s t 2 /3 o f c irc u m fe re n c e (fo r re p a ir o n ly )

H R C 4 6

M a x . m a in an d big en d jo u rn a l ta p e r 0 ,0 0 5

M a x . m a in an d big en d jo u rn a l o va lity 0 ,01

M a x . c ra n k s h a ft run ou t w ith c ra n k s h a ft tu rn in g on o u te r jo u rn a ls

4 cy lin d er jo u rn a l 3 6 cy lin d er jo u rn a l 4

0 ,110 ,1 5

P a ra lle lis m o f big en d jo u rn a ls to m a in jo u rn a ls 0 ,0 1

L a te ra l run ou t a t th ru s t fa c e s 0 ,0 2

M a x run o u t o f fly w h e e l fla n g e w ith c ra n k s h a ft tu rn in g on o u te r jo u rn a ls

L a te ra lR ad ia l

0 ,0 30 ,0 3

R a d ii on th ru s t b e a rin g jo u rn a l m in im u m 3 ,7 5

M a in b e a rin g c le a ra n c eE nd flo a t (th ru s t b e a rin g ) R a d ia l (th ru s t b e a rin g ) R a d ia l (o th e r m a in s )

0 ,1 9 0 -0 ,2 9 00 ,0 5 0 -0 ,1 0 80 ,0 4 2 -0 ,1 0 8

T o rq u e to tu rn c ra n k s h a ft w ith n e w s e a ls an d b e arin g s fitted 12 N m

R e a r c ra n k s h a ft s e a l (rp p e ty p e ) p rotrusion a fte r in s ta lla tio n 0 ,5 to 0 ,8

M a in /B ig en d jo u rn a l s u rfa c e fin ish (la p p e d ) R a 0 ,2 pm R. m a x 2 pm

M a x . im b a la n c e o f c ra n k s h a ft w ith co u n te rw e ig h ts (w ith o u t fly w h e e l) runn ing on o u te r m a in b e arin g s

3 0 c m p

April ‘96

CRANKSHAFT MAIN BEARINGS


Repair s iz e (d iam eter) Main bearing dia. in sta lled

T hrust b earing w idth

S ta n d a rd 8 8 ,0 5 2 to 8 8 ,0 9 8 Std.S td .1 & S td .2

3 1 ,7 4 to 3 1 ,8 1 (s td )S ta n d a rd 1 ( - 0 ,1 ) 8 7 ,9 5 2 to 8 7 ,9 9 8S ta n d a rd 2 ( - 0 ,2 5 ) 8 7 ,8 0 2 to 8 7 ,8 4 8

S td .2 & all re p a ir s tag e s

3 2 ,0 4 to 3 2 ,1 1

(+ 0 ,3 ) or

3 2 ,2 4 to 3 2 ,3 1

(+ 0 ,5

R e p a ir 1 ( - 0 ,5 ) 8 7 ,5 5 2 to 8 7 ,5 9 8

R e p a ir 2 ( - 0 ,7 5 ) 8 7 ,3 0 2 to 8 7 ,3 4 8

R e p a ir 3 ( - 1 ,0 ) 8 7 ,0 5 2 to 8 7 ,0 9 8


B a la n c e w e ig h t to c r a n k s h a f t M 1 2 x 1 ,5

F ly w h e e l to c r a n k s h a ft M 1 2 x 1 ,5

P u lle y to c ra n k s h a ft (k e y d r iv e n ) M 2 4 x 1 ,5P u lle y to c ra n k s h a ft (k e y d r iv e n ) M 2 4 x 1 ,5P u lle y to c ra n k s h a ft (c o n e e le m e n t d r iv e n ) M 2 4 x 1 ,5

M a in b e a rin g c a p bo lts - s ta n d a rd hex. b o lts ........................................M 1 5 x 2

M a in b e a rin g ca p b o lts - m u lti hex. bo lts o n ly ...................................... M 1 5 x 2

2 n d p u lley to v ib ra tio n d a m p e r .......................................................................................

V ib ra tio n d a m p e r to c r a n k s h a f t M 2 4 x 1 ,5

In i t ia l ................................................. 3 0 -4 0 N mF in a l ......................................... .........p lus 9 0 ° - 1 1 0 °M a x . stretch length 4 5 ,3 m m

In i t ia l ................................................. 3 0 -4 0 N mF in a l ......................................... ......... p lus 9 0 ° - 1 1 0 °M a x . stretch length 2 6 ,3 m m

(s h a n k e d b o lt ) .................... ........ 5 0 0 -6 0 0 N m(fu lly th re a d e d b o lt ) ................. 8 0 0 -9 0 0 N m(1 s t s t a g e ) ..................................... 8 0 0 -9 0 0 N m(2 n d s t a g e ) .......................... p lu s 4 5 ° - 5 5 °

In i t ia l ................................................. 8 0 -9 0 N mF in a l ......................................... .........p lus 9 0 ° - 1 0 0 °M ax. stretch le n g th .......... 1 2 3 m m

In i t ia l ................................................. 4 5 -5 5 N mF in a l ......................................... p lus 9 0 ° - 1 0 0 °

4 7 N m

......... 5 0 0 N m

April '96


R E M O V A L A N D R E P L A C E M E N T O F

C R A N K S H A F T V IB R A T IO N D A M P E R

R e m o v a l

1. S la c k e n V -b e lt a d ju s te r on a lte rn a to r an d re m o v e belts , (F ig . 1 4 -1 ).

2 U s in g s p e c ia l to o l p a rt n u m b e r 4 0 2 0 0 1 4 5 , re le a s e and

re m o v e c e n tre bo lt fro m c ra n k s h a ft, (F ig . 1 4 -2 ).

3 D ra w v ib ra tio n d a m p e r fro m c ra n k s h a ft us ing sp ec ia l to o l p a rt n u m b e r 4 0 2 0 0 0 1 9 , (F ig . 1 4 -3 ).

R e p la c e m e n t

1. If n e c e s s a ry h e a t v ib ra tio n d a m p e r to a p p ro x im a te ly 8 0 °C in a w a te r b a th , a n d s lid e on to c ran ksh a ft. E n s u re th a t th e w o o d ru ff key e n g a g e s g ro o ve in th e v ib ra tio n d a m p e r (a rro w s ), (F ig . 1 4 -4 ).

April '96


2. S c re w c e n tre bo lt in to c ra n k s h a ft an d tig h ten to th e sp ec ified to rq u e , (F ig . 1 4 -5 ) .

A t te n t io n ! U n d e r no c irc u m s ta n c e sh ou ld th e ce n tre bolt be tig h ten e d w ith an im p a c t w re n c h .

R E M O V A L O F C R A N K S H A F T

T h e fo llo w in g ite m s m u s t b e re m o v e d fro m th e engine: cy lin d er h e a d , s u m p , co n n e c tin g rods, p istons, fly w h e e l an d ho using , t im in g g e a r c a s e c o v e r an d oil p u m p .

1. U n s c re w tim in g g e a r re ta in in g bo lt fro m cran ksh a ft,(F ig . 1 4 -6 ) .

2 . U s in g s p e c ia l to o l, p a rt n u m b e r 4 0 2 0 0 0 1 9 , pull tim in g g e a r fro m c ra n k s h a ft, (F ig . 1 4 -7 ) .

3. R e m o v e lo w er h a lf o f t im in g g e a r c a se , (F ig . 1 4 -8 ).

Fig. 14-8


4 . U n s c re w m a in b e a rin g c a p bo lts an d lift o ff bearing c a p s , (F ig . 1 4 -9 ) .

5. L ift o u t c ra n k s h a ft fro m c ra n k c a s e , (F ig . 1 4 -1 0 ).

6 . R e m o v e all m a in b e a rin g sh e lls fro m c ra n k c a s e . If b e a rin g s h e lls a re to b e re -u s e d , th e y m u st b e m ark ed to e n s u re re p la c e m e n t in th e o rig ina l position , (F ig .1 4 -1 1 ) .

7. C le a n all parts , m e a s u re c ra n k s h a ft jo u rn a ls an d c o m p a re w ith sp e c if ic a tio n s , (F ig . 1 4 -1 2 ).

Fig. 1 4 -9

Fig. 1 4 -1 0

Fig. 14 -1 1

Fig. 14-12

April '96


8. C h e c k c ra n k s h a ft fo r m is a lig n m e n t, jo u rn a l run out (F ig . 1 4 -1 3 ) .

9. C h e c k all m a in b e a rin g c a p bo lts fo r s tre tch lim it, re fer to sp e c if ic a tio n s , (F ig . 1 4 -1 4 ) .

CRANKSHAFT GRINDING

1. M a rk c ra n k s h a ft b a la n c e w e ig h ts an d re m o v e from c ra n k s h a ft, (F ig . 1 4 -1 5 ) .

2. R e m o v e tim in g g e a r fro m c ra n k s h a ft, us ing sp ec ia l to o l p a rt n u m b e r 4 0 2 0 0 0 2 2 , (F ig . 1 4 -1 6 ) .

A ttention! W h e n g rin d in g th e c ra n k s h a ft it is e s sen tia l th a t th e radii o f th e b e a rin g jo u rn a ls a re m a in ta in e d .(S e e F ig . 1 4 -3 4 , p a g e 1 4 -1 3 ) .

Fig. 1 4 -1 3

F ig. 1 4 -1 4

Fig. 1 4 -1 5

Fig. 14-16

April '96

I

C h eck in g C rankshaft after G rinding

1. c h e c k an d c ra c k te s t c ra n k s h a ft, (F ig . 1 4 -1 7 )

2. C h e c k all b a la n c e w e ig h t bo lts fo r stretch lim its , re fer to th e sp e c if ic a tio n s , (F ig . 1 4 -1 8 ) .

A t te n t io n ! A ll c ra n k s h a ft b a la n c e w e ig h t bolts th a t exceed th e m a x im u m stre tch lim it m u s t b e rep la ced .

3. R e p la c e b a la n c e w e ig h ts , a lig n in g m a rk s on w e ig h ts w ith m a rk s on c ra n k s h a ft, (F ig . 1 4 -1 9 ).

4 . In s e rt b a la n c e w e ig h t bo lts an d tig h ten to th e sp ec ified 'to rq u e , (F ig . 1 4 -2 0 ) .


April '96


5. U s in g c o m p re s s e d a ir, b lo w out all g a lle r ie s in th e

c ra n k s h a ft to e n s u re th a t no m e ta l p a rtic les a re re ta ined w ith in th e d rillin gs , (F ig . 1 4 -2 1 ) .

6. R e p la c e c ra n k s h a ft t im in g g e a r us ing s p ec ia l tool, part n u m b e r 4 0 2 0 0 1 9 0 , (F ig . 1 4 -2 2 ) .

C h eck in g C ran kshaft B earin g and P arent B o res

A ttention! B e a rin g sh e lls a re su p p lied re a d y fo r fitting , in s ta n d a rd an d v a rio u s re p a ir s izes . N o a tte m p t sh ou ld be m a d e to a lte r th e p re -d e te rm in e d s ize .

1. T h o ro u g h ly c le a n an d v is u a lly in sp e c t co nd ition o f all m a in b e a rin g b o re s in c ra n k c a s e an d b earin g caps,(F ig . 1 4 -2 3 ) .

2 . R e p la c e m a in b e a rin g c a p s in s e rt bo lts an d tig h ten to th e s p e c ifie d to rq u e , (F ig . 1 4 -2 4 ) .

F ig . 14 -21

Fig. 1 4 -2 2

mi » =

Fig. 1 4 -2 3

Fig. 14-24

April '96


3. A d ju s t an in te rn a l m e a s u rin g in s tru m en t, (F ig . 1 4 -2 5 ) .

4. M e a s u re m a in b e a rin g p a re n t bo res in o n e d irec tion c o m p a re m e a s u re m e n ts w ith th e sp ec ifica tio n s , (F ig1 4 -2 6 ) .

A

5. R e m o v e m a in b e a rin g bo lts an d b e a rin g caps, (F ig .1 4 -2 7 ) .

6. In s e rt b e a rin g s h e lls into c ra n k c a s e an d b e arin g caps. E n s u re th a t lo ca tin g ta b s on b e arin g sh ells a re co rrec tly in s e rte d in c a p a n d c ra n k c a s e , (F ig . 1 4 -2 8 ) .

Fig. 1 4 -2 5

Fig. 1 4 -2 6

Fig. 14-28


A tte n t io n ! M a in b e a rin g sh e lls h a v e oil d rillin gs w h ich m u st line up w ith h o les in th e c ra n k c a s e , (F ig . 1 4 -2 9 ).

7. R e p la c e m a in b e a rin g c a p s w h ic h a re m a rk e d 1 to 7 fo r A D E 3 6 6 an d 1 to 5 fo r A D E 3 6 4 , w h ich m u st be fitted in th e c o rre c t p o s itio n s w ith th e n u m b e rs to

w a rd s th e fro n t o f th e en g in e , (F ig . 1 4 -3 0 ) .

8. In sert b e a rin g c a p bo lts an d tig h ten to th e sp ecified to rq u e , (F ig . 1 4 -3 1 ) .

9. A d ju s t/s e t an in te rn a l m e a s u rin g in s tru m en t, (F ig . 1 4 -3 2 ) .

F ig . 1 4 -2 9

F ig . 1 4 -3 0

Fig. 14 -31

Fig. 14-32

April ‘96


10. M e a s u re all m a in b earin g in s id e d ia m e te rs in th re e p laces , c o m p a re m e a s u re m e n ts w ith th e s p e c ific a tio ns , (F ig . 1 4 -3 3 ) .

11 S h o u ld th e c ra n k s h a ft h a v e been re -g ro u n d e x a m in e th e rad iu s (R ) to e n s u re th a t th e s p ec ifica tio n has been a d h e re d to , (F ig . 1 4 -3 4 ) .

12 . R e m o v e all m a in b e a rin g ca p s , (F ig . 1 4 -3 5 ) .

R E P L A C IN G R E A R M A IN B E A R IN G O IL S E A L

A tte n t io n ! T h e f itm e n t o f th e s e s e a ls m u s t be ca rried out w ith th e b e a rin g s h e lls re m o v e d fro m c ra n k c a s e an d bearing

cap.

1. W ith th e oil s e a l re m o v e d , T h o ro u g h ly c le a n both h a lv e s o f th e b e a rin g h o us ing , (F ig . 1 4 -3 6 ) .

Fig. 1 4 -3 3

Fig. 1 4 -3 4

F ig . 1 4 -3 5

Fig. 14-36

April ‘96


2. U s in g a p a ir o f long n o s e p liers , re m o v e th e oil sea l reta in in g p ins fro m th e se a l ho u s in g in c ra n k c a s e and b e a rin g cap , (F ig .1 4 -3 7 ) .

3. U s in g an a lu m in iu m drift, ta p n e w oil se a l re ta in in g pin in to c ra n k c a s e an d b e a rin g ca p se a l ho us ing , (F ig .1 4 -3 8 ) .

A t te n t io n ! D o no t d a m a g e th e tip o f th e re ta in in g pins.

4 . F it o n e h a lf o f th e n e w oil s e a l in to s p e c ia l to o l, pa rt n u m b e r 4 0 2 0 1 6 0 7 , (F ig . 1 4 -3 9 ) .

5. N e w s e a l m u s t fit e x a c tly in to s p e c ia l to o l. B oth en ds o f s e a l m u s t to u ch to o l h o lder, (F ig . 1 4 -4 0 ) .

Fig. 1 4 -3 7

Fig . 1 4 -3 8

Fig . 1 4 -3 9

Fig. 14-40


6. L o c a te s p e c ia l to o l, fitted w ith n e w oil s e a l on to th e c ra n k c a s e an d d r iv e th e se a l in to th e hous ing , (F ig .1 4 -4 1 ) .

7. In s e rt n e w h a lf s e a l fo r b e a rin g ca p into th e sp ecia l to o l an d d r iv e in to b e a rin g cap , (F ig . 1 4 -4 2 ) .

A ttention! N e w s e a l en d s m u s t p ro tru d e 0 ,5 m m a b o v e th e b e a rin g c a p an d c ra n k c a s e m a tin g s u rfa c e s or 0 ,8 m m w h en th e c ra n k s h a ft is re g ro u n d to th e next re p a ir s tag e . N o fib res sh o u ld b e tra p p e d b e tw e e n th e b e a rin g ca p an d th e c ra n k c a s e m a tin g s u rfa c e s .

8. C o a t th e s e a l in th e c ra n k c a s e an d b e arin g ca p w ith a h e a t re s is ta n t g re a s e , (F ig . 1 4 -4 3 ) .

9. A p p ly a s m a ll a m o u n t o f s ilico n e s e a la n t to th e g ro o ve s in th e re a r m a in b e a rin g cap . T h e en d s u rfa c e o f s e a ls m u s t no t b e co a te d w ith s e a la n t, (F ig . 1 4 -4 4 ).

A ttention! If th e b e a rin g ca p d o es no t h a v e groo ves , ap p ly s e a la n t to th e s u rfa c e s o f th e c a p an d th e c ra n k - case. S u rfa c e s to be c o a te d w ith s e a la n t m u st be fre e o f g rease .

Fig . 14 -41

Fig . 1 4 -4 3

Fig. 14-44

April '96


REPLACING THE CRANKSHAFT

1. L ib e ra lly c o a t th e b e a rin g s w ith en g in e oil, (F ig . 1 4 -4 5 ).

2 . L o w e r th e c ra n k s h a ft on to th e b e arin g s , (F ig . 1 4 -4 6 ).

3. R e p la c e all m a in b e a rin g c a p s m a rk e d 1 to 7 fo r A D E 3 6 6 or 1 to 5 fo r A D E 3 6 4 . T h e y m u s t b e fitted in th e c o rre c t p o s itio n w ith th e n u m b e rs to w a rd s th e fron t o f th e e n g in e , (F ig . 1 4 -4 7 ) .

4. C o a t th e th re a d s o f th e m a in b e a rin g bo lts w ith en g in e oil, (F ig . 1 4 -4 8 ) .

Fi<g. 1 4 -4 5

nB.iFig. 1 4 -4 6

Fig. 1 4 -4 7

Fig. 14-48

April '96


5. In s e rt bo lts an d tig h te n to th e sp ec ified to rq u e , (F ig .1 4 -4 9 ) .

6 . C h e c k th e to rq u e req u ire d to tu rn th e c ran ksh a ft, w ith n e w b e a rin g s an d oil s e a l fitted , re fe r to sp ec ifica tio n s , (F ig . 1 4 -5 0 ) .

A t te n t io n ! S h o u ld th e c ra n k s h a ft no t tu rn a t th e requ ired to rq u e , re m o v e re a r m a in b e a rin g c a p an d c h e c k co rrec t fitting o f th e oil se a l.

7. R e fit c a m s h a ft t im in g g e ar, lin ing up tim in g m ark s . In se rt bo lts a n d tig h te n to th e sp ec ified to rq u e , (F ig .1 4 -5 1 . S e e a ls o p a g e s 1 5 -1 2 an d 1 5 -1 3 .

8. M o u n t a d ia l g a u g e in d ic a to r on th e c ra n k c a s e and m e a s u re th e c ra n k s h a ft en d flo a t in a c c o rd a n c e w ith sp e c ific a tio n s , (F ig . 1 4 -5 2 ) .

Fig. 14-52

April '96


9. R e p la c e th e b o tto m h a lf o f th e tim in g c o v e r an d tig h ten th e bo lts to th e s p e c ifie d to rq u e , (F ig . 1 4 -5 3 ) .

April ‘96

CRANKSHAFT AND MAIN BEARINGS — 14-19

SPECIAL TOOLS FOR THIS SECTIONO B T A I N A B L E F R O M : G R U N D Y - T E C H N I F O R M . B U R M A N R O A D . D E A L P A R T Y E S T A T E . P O R T E L IZ A B E T H 6 0 0 1 .

3

1n

=7 =7 0 r n

Im p a c t s o c k e t s c a n n e r¡see fig. 14.-21Part N u m b e r 40200145

P u l le r fo r c a m s h a f t g e a r

(see fig. 14-71Part n u m b e r 40200019

C r a n k s h a f t h a rd n e s s te s te r

(see fig. 14-13)Part N u m b e r 40200501

C r a n k s h a f t gear re p la c e r

(see fig. 14-22)Part N u m b e r 40200190

Rear oil sea l re p lace r (see fig. 14-39)Part N u m b e r 40201607

P u l le r fo r v ib ra t io n d a m p e r

(see fig. 14-3)Part n u m b e r 40200019

A D E 360 S e r ie s

ADE 360 Series

________________SECTION 15Camshaft, Timing Case and Drive Timing


P a g e

IL L U S T R A T IO N ...................................................................................................................................................................................................................................... 1 5 -2

IN T R O D U C T IO N ....................................................................................................................................................................................................................................1 5 -3

S P E C IF IC A T IO N S ................................................................................................................!............................................................................................................... 1 5 -3

R E M O V IN G C A M S H A F T ..................................................................................................................................................................................................................1 5 -5

R E P L A C IN G C A M S H A F T ................................................................................................................................................................................................................ 1 5 -9

R E M O V IN G T IM IN G C O V E R O IL S E A L ............................................................................................................ 1 5 -1 4

R E P L A C IN G T IM IN G C O V E R O IL S E A L ................................................................................................. 1 5 -1 5

S P E C IA L T O O L S .................................................................................................................................................. 1 5 -1 7

Camshaft, Timing Case and Drive Timing 15-2

C A M S H A F T A N D T IM IN G G E A R S

1. C A M S H A F T2. T H R U S T W A S H E R3. F L Y -W E IG H T4 . P IN5. S P R IN G6 . C A M S H A F T G E A R

7. R E T A IN IN G B O L T8. B O L T9. R O L L E R

10. IN J E C T IO N P U M P D R IV E G E A R11. F E A T H E R K E Y

April ‘96


IN T R O D U C T IO N

T h e c a m s h a ft is p rec is io n fo rg ed an d in duc tion h a rd e n e d . It is su p p o rted by stee l b a cke d b ro n ze b e a rin g s an d g e a r driven fro m th e c ra n k s h a ft. A c c e s s to th e tim in g g e a rs ca n b e g a in e d by re m o v a l o f th e c ra n k s h a ft v ib ra tio n d a m p e r an d tim ing c a s e , w h ic h is s itu a te d a t th e fro n t o f th e en g in e .

S P E C IF IC A T IO N S

C a m s h a f t B e a r in g s

B e a rin g position S ta n d a rd3 6 4 3 6 6 J o u rn a l dia. B e a rin g ID— 1 5 5 ,9 4 1 to 5 5 ,9 6 0 5 6 ,0 0 0 to 5 6 ,0 3 01 2 5 5 ,6 9 1 to 5 5 ,7 1 0 5 5 ,7 4 0 to 5 5 ,7 7 02 3 5 5 ,4 4 1 to 5 5 ,4 6 0 5 5 ,4 9 0 to 5 5 ,5 2 03 4 5 5 ,1 9 1 to 5 5 ,2 1 0 5 5 ,2 4 0 to 5 5 ,2 7 0

C a m s h a ft lo b e a n d jo u rn a l s u rfa c e fin ish R z 3 p m

E c c e n tr ic - C o m p re s s o r d rive R a 0 ,2 pm ; R m a x 2 p m

B a s ic b o re fo r c a m s h a ft b e a rin g 6 0 ,0 0 0 to 6 0 ,0 3 0

C a m s h a ft b e a rin g O D 6 0 ,1 5 0 to 6 0 ,1 8 0

C a m s h a ft b e a rin g c le a ra n c e R a d ia l 0 ,0 3 0 to 0 ,0 7 9A x ia l 0 ,1 8 0 to 0 ,5 2 0

H a rd n e s s J o u rn a l 5 7 to 6 3 H rcC a m lo bes 5 7 to 6 3 H rc

R u n -o u t o f c a m s h a ft jo u rn a ls (c a m s h a ft s u p p o rted a t o u te r jo u rn a ls ) 0 ,0 2 5

B a c k la s h c ra n k s h a ft /c a m s h a ft g e a r, c a m s h a ft/in je c tio n p u m p g e a r 0 ,0 7 0 to 0 ,1 8 0

V a lv e tra v e l s p e c if ic a tio n s fo r c h eck in g 3 6 4 N , 3 6 6 NIn le t E x h a u s t

0 ,5 6 to 0 ,9 6 0 ,6 4 to 1 ,0 4

v a lv e tim in g a t T D C a n d "O" c le a ra n c e 3 6 6 C /T /T I, 3 6 4 C /T 0 ,5 8 to 0 ,9 8 0 ,6 1 to 1 ,01

M a x im u m v a lv e lift (w ith s p ec ified 3 6 4 N /C /T , 3 6 6 NIn le t E x h a u s t1 0 ,5 6 1 0 ,5 6

v a lv e c le a ra n c e ) 3 6 6 C /T /T I 1 0 ,1 6 1 0 ,5 6

April '96


Outer shaft dia. Bore in cylinder block

Standard 27,980 to 27,990 28,000 to 28,033

Repair stage 1 (+0,2) 28,180 to 28,190 28,200 to 28,233



Clearance shaft /bore 0,010 to 0,053


Timing degree pointer.............................................................. M6............................................8 Nm

Timing device to camshaft....................................................... M16 x 1,5................................. 300 Nm

Timing segment to camgear.................................................... M8............................................30 to 40 Nm (+90° to 100°)

Injection pump gear 364N/C/T, 366N.......................................M14 x 1,5..................................80 Nm366C/T/TI.................................................M18 x 1,5..................................105 Nm

Camshaft thrust plate to block.................................................M8 x 1.......................................35 Nm

Timing case to cylinder block...................................................M10..........................................65 Nm

Timing case cover to timing case.............................................M6............................................10 Nm*

April '96


1. Remove rocker cover, (refer to page 12-7).

2. Unscrew and remove rocker shaft, (refer to page 12-9).

3. Remove pushrods and mark to ensure replacement in the original position.

4. Unscrew and remove side cover, (Fig. 15-1).

REMOVING AND REPLACING THE CAMSHAFT

5. Lift out camfollowers, (Fig. 15-2), and number each in order to replace in the same position.

6. Drain engine oil and remove sump, (Fig. 15-3).

7. Unscrew and remove bolts retaining oil pump, lift out pump, (Fig. 15-4).

April ‘96


8. Slacken the V-belt adjuster on the alternator and remove the belts, (Fig. 15-5).

9. Using special tool, part number 4020 0145, unscrew and remove centre bolt retaining vibration damper, (Fig. 15-6).

10. Attach special puller, part number 4020 0019, to vibration damper and puli off, (Fig. 15-7).

11. Unscrew and remove bolts retaining the timing case cover and lift off, (Fig. 15-8).

April '96


12. Using a socket, unscrew and remove the Allen cap screw retaining the timing gear to the camshaft, (Fig.15-9).

13. Using special tool, part number 4020 0019, pull off timing gear from camshaft, (Fig. 15-10).

14. Remove shim and feather key from the camshaft, (Fig.15-11).

15. Unscrew bolts retaining the camshaft thrust plate and remove from the camshaft, (Fig. 15-12).

il

A V 1 O I

g. 15 -9

Fig. 15-12


16. If the engine is fitted with a crankcase mounted compressor remove the compressor cylinder head bolts together with the gasket, (Fig. 15-13).

17. Turn the piston of the compressor to TDC and pull off the cylinder barrel, (Fig. 15-14).

18. Remove the circlips retaining the gudgeon pin, push out and remove the piston, (Fig. 15-15).

19. Unscrew the nuts retaining the bearing cap to the connecting rod, (Fig. 15-16).

Fig. 15-13

Fig. 15-14

Fig. 15-15

Fig. 15-16

April '96


20. Remove connecting rod and bearing cap, (Fig. 15-17).

21. Pull out the camshaft from the cylinder block. Do not damage the camshaft bearings, (Fig. 15-18).

REPLACING

1. Carefully insert the camshaft into the cylinder block without damage to the camshaft bearings,(Fig. 15-19).

2. Fit thrust plate to camshaft, insert retaining bolts and tighten to the specified torque, (Fig. 15-20).

Fig. 15-19

April '96


3. Fit shim to camshaft, (Fig. 15-21)

4. Fit timing gear to camshaft; ensure that the marks on timing gear and crankshaft gear are aligned, (fFig.15-22).

5. Insert feather key, locating timing gear to camshaft, (Fig. 15-23).

6 Insert Allen cap screw into camshaft, (Fig. 15-24).

Fig. 15-21

Fig. 15-22

Fig. 15-23

Fig. 15-24

April '96


7. Tighten cap screw to the specified torque, (Fig. 15-25).

8. Replace timing case cover and align using special tool 4020 2198, (Fig. 15-26).

9. Insert bolts retaining the timing cover and tighten to the specified torque, (Fig. 15-27).

10. If necessary, heat the vibration damper to approximately 80°C in a water bath before sliding onto the crankshaft. Ensure that the woodruff key locates in the groove, (Fig. 15-28).

Fig. 15-25

Fig. 15-26

Fig. 15-27

Fig. 15-28

April '96


11. Screw centre bolt into crankshaft and tighten to the specified torque, (Fig. 15-29).

Attention! The centre bolt must not be tightened with an impact wrench

12. If the engine is fitted with a crankcase mounted compressor the crankshaft should be turned so that the lobe for the compressor connecting rod is at TDC. Replace bearing cap and connecting rod, (Fig. 15-30).

Note: When using belt driven compressors the oil supply hole in the eccentric is closed off with a jubilee clamp.

13. Tighten nuts to the specified torque, (Fig. 15-31).

14. Fit compressor piston to connecting rod, insert gudgeon pin and circlips, (Fig. 15-32).

■ni) a k

Fig. 15-29

Fig. 15-32

April '96


15. Lightly apply a suitable sealing compound to the base of the cylinder barrel.

16. With the special piston ring squeezer, part number 4020 1131, compress the piston rings, insert piston into the cylinder barrel, push the barrel down over the piston rings and remove the piston ring squeezer. Push the barrel fully home, (Fig. 15-33).

17. Replace the compressor cylinder head, fitted with a new gasket, insert bolts and tighten to the specified torque, (Fig. 15-34).

18. Replace the oil pump, insert the retaining bolts and tighten to the specified torque, (Fig. 15-35).

19. Using new gaskets, replace the sump, insert bolts and tighten to the specified torque, (Fig. 15-36).

Fig. 15-36

April '96


20. Insert cam followers in the same position from which they were removed, (Fig. 15-37).

21. Replace side cover, insert bolts and tighten to the specified torque, (Fig. 15-38).

22. Insert push rods in their original position, see page 12- 21 .

23. Replace the rocker shafts and insert the bolts but do not tighten.

24. Use special tool, part number 4020 3185 and insert the connecting nipple between the rocker shafts, see page 12-21.

25. Tighten the rocker shafts to the specified torque, see page 12-23.

26. Adjust the valve clearance, see page 12-23.

27. Replace the rocker cover with a new gasket, insert bolts and tighten to the specified torque, (Fig. 12-24).

REMOVING AND REPLACING THE TIMING COVER OIL SEAL

Timing cover removed from the engine.

Removing

1. Place the support ring of special tool, part number 4020 0200, under the front of the timing cover to prevent distortion when the oil seal is removed, (Fig.15-39).

2. Use the adapter ring and spacer of the special tool to press the oil seal from the housing, (Fig. 15-40).

Fig. 15-40


Replacing

1. Locate a new oil seal in front of the housing, (Fig.15-41).

2. Place a 12 mm distance piece inside the timing cover, behind the oil seal housing, (Fig. 15-42).

3. Place the spacer of the special tool on top of the oil seal, (Fig. 15-43).

4. Press the seal into the timing housing until it is flush with the inside edge of the timing cover and butts onto the distance piece, (Fig. 15-44).

Fig. 15-44


5. Section through timing case with the oil seal in place, (Fig. 15-45).

Note: When replacing the timing case oil seal it is essential to replace the wear ring on the crankshaft.

April '96

SPECIAL TOOLS FOR THIS SECTIONO B T A I N A B L E F R O M : G R U N D Y - T E C H N I F O R M . B U R M A N R O A D . D E A L P A R T Y E S T A T E . P O R T E L IZ A B E T H 6 0 0 1

CAMSHAFT, TIMING CASE AND DRIVE TIMING — 15-17

i m p a c t so ck e t s o a n n e r isee tig 15-6i

Part N u mD e r 40200145

P u lle r fo r cam sha ft gear, (see fig. 15-10)

Part N um ber 40200019.

P u lle r fo r v ib ra tion aam D er (see fig. 15-7)Part num ber 40200019

T im ing cover cen tra liz ing too l. ..(see fig. 15-26)


C om pressor p is ton ring squeezer use w ith p lie rs below ,(see fig. 15-33)


P liers fo r com pressor p is ton ring squeezer, (see fig. 15-33)


AMENDMENT 6/91

CAMSHAFT, TIMING CASE AND DRIVE TIMING — 15-18

Timing cover oil seal remover/ replacer,(see fig. 15-40).


Fabricate a 12 mm spacer x 100 mm dia., which is used as a distance piece under the timing case cover, when pressing in the seal, (see fig. 15-42).

AMENDMENT 6/91

_________SECTION 16Lubricating System and Sump


Page

IL L U S T R A T IO N ...................................................................................................................................................................................................................................... 1 6 -2

O IL F L O W C H A R T ............................................................................................................................................................................................................................... 1 6 -3

IN T R O D U C T IO N ....................................................................................................................................................................................................................................1 6 -4

S P E C IF IC A T IO N S .................................................................................................................................................................................................................................1 6 -4

R E M O V IN G T H E O IL C O O L E R ...................................................................................................................................................................................................1 6 -6

R E P L A C IN G T H E O IL C O O L E R ..................................................................................................................................................................................................1 6 -8

R E M O V IN G T H E O IL C O O L E R A D E 3 6 6 T ....................................................................................................................................................................... 1 6 -1 0

R E P L A C IN G T H E O IL C O O L E R A D E 3 6 6 T ....................................................................................................................................................................... 1 6 -1 2

R E M O V IN G T H E O IL F IL T E R E L E M E N T ............................................................................................................................................................................1 6 -1 5

R E P L A C IN G T H E O IL F IL T E R E L E M E N T .......................................................................................................................................................................... 1 6 -1 6

R E M O V IN G T H E O IL F IL T E R H E A D .................................................................................................................................................................................... 1 6 -1 7

R E P L A C IN G T H E O IL F IL T E R H E A D ...................................................................................................................................................................................1 6 -1 8

R E M O V IN G T H E O IL P U M P ........................................................................................................................................................................................................16 -21

A S S E M B L Y O F T H E O IL P U M P ................................................................................................................................................................................................1 6 -2 3

April '96

Lubricating System and Sump 16-2

OIL PUMP AND FILTER ASSEMBLY

1 OIL FILTER ELEMENT 17 STRAINER2 FILTER ELEMENT RETAINER 18 STRAINER RETAINING BOLT3 SEALING WASHER 19 OIL PUMP RETAINING BOLT4 WASHER 20 OIL PUMP BODY5 SEALING WASHER 21 OIL PUMP GEAR6 FILTER BOWL RETAINING BOLT 22 BY-PASS VALVE SCREW PLUG7 DRAINPLUG AND WASHER 23 WASHER8 GEAR SHAFT 24 BY-PASS VALVE SPRING9 OIL PUMP DRIVEN GEAR 25 BY-PASS VALVE

10 OIL PUMP DRIVE SHAFT 26 OIL FILTER HEAD11 OIL PUMP DRIVE GEAR 27 BANJO BOLT AND WASHER12 OIL PUMP DRIVE SHAFT/TACHO DRIVE 28 GASKET13 WOODRUFF KEY 29 INJECTION PUMP OIL FEED PIPE14 OIL PUMP COVER RETAINING BOLT 30 BANJO BOLT AND WASHER15 RELIEF VALVE 31 BLANKING PLUG16 OIL PUMP COVER PLATE 32 BLANKING PLUG AND WASHER

April '96


TYPICAL OIL FLOW - ADE 360 SERIES

Oil is drawn from the engine sump by a gear type pump, through a gauze strainer. The oil under pressure then flows between the oil pump body and drive shaft into a gallery, passing to the oil filter. From the oil filter, cleansed oil flows via an intersecting gallery to a plate type oil cooler. On the naturally aspirated engine, oil from the cooler enters the main oil gallery to the crankshaft, camshaft, rocker gear, etc.

The turbocharged engine oil flow differs from the naturally aspirated engine, in that the oil flowing from the main oil filter passes into an additional micro type filter, mounted on the outside of the oil cooler cover, before flowing into a large capacity fin type oil cooler, providing an increase in the cooling capacity. To assist with dissipation of the additional heat generated by the turbocharged engine, piston cooling nozzles are fitted to the main oil gallery, supplying a constant jet of cooling oil to the underside of the piston crowns. The turbocharger is fed under pressure from the main oil gallery, with a drain to the engine sump.

The ADE 364C/T/TI engine has a small finned cooler mounted integrally with the engine oil filter to assist with heat dissipation.

Note: The micro type oil filter mentioned above has since been removed on turbocharged engines built from mid 1995.

April '96


INTRODUCTION

A gea r ty p e p u m p s u p p lie s o il u n d e r p re ssu re th ro u g h a fu ll f lo w p a p e r ty p e o il f ilte r to th e c ra n k s h a ft, ca m s h a ft, co n n e c tin g rod b ig end b e a rin g s , ro c k e r sh a ft b e a rin g s , fu e l in je c to r p u m p and g o ve rno r. O il u n d e r p re ssu re is a lso fed to th e c ra n k c a s e m o u n te d a ir c o m p re s s o r and tu rb o c h a rg e r ( if fitte d ). P re ssu re re lie f and b y -p a ss v a lv e s p ro te c t th e sys te m a g a in s t o ve rlo a d .

OIL PUMP

SPECIFICATIONS

364N/C/T 366N

366C/T/TI

Width of pump gears 39,936 to 39,975 49,936 to 49,975

Axial play between gear face and housing 0,025 to 0,089 0,025 to 0,089

Clearance between teeth and housing 0,030 to 0,105 0,030 to 0,105

Outside dia. of pump gears 42,020 to 42,070 42,020 to 42,070

Inside dia. of pump driving gear 16,944 to 16,958 16,944 to 16,958

Inside dia. of pump driven gear 15,050 to 15,073 15,050 to 15,073

Diameter in housing for shaft of driven gear 15,000 to 15,018 15,000 to 15,018

Inside diameter of oil pump drive sprocket 16,944 to 16,958 16,944 to 16,958

A - Installation height between drive sprocket116,5 + 0,5

and pump housing flange when moving shaft in the indicated direction

- 0,3

B - Diameter of oil pump driving shaft 16,976 to 16,984 16,976 to 16,984

C - Diameter of oil pump driven gear shaft 15,028 to 15,039 15,028 to 15,039

D - Installation height of driven gear shaft 39,2 to 39,5 47,5 to 48,5

E - Installation height of drive gear to drive shaft 0,5 to 0,8 7,2 to 7,8

Pump speed364N/C/T

366N 366C/T/TI

Min. delivery rate (¿/min) with SAE 10 oil at 50°C and 400 kPa pressure

300 r/min1 400 r/min 45 58

April '96


OIL PRESSURE RELIEF VALVE____________________________________________________________I Opening pressure (kPa) 470 - 570

SPRING FOR PRESSURE RELIEF VALVEOD Wire dia. Unloaded Spring preload Spring final load

spring length Length Load Length Loadmm mm mm mm N mm N ,9,3 1,7 49,4 45,4 43,9 36,2 ! 145 :

OIL FILTER BY-PASS VALVE SPRINGOD Wire Unloaded Spring preload Spring final load Opening pressure

dia spring length Length Load Length Load of by-pass valvemm mm mm mm N mm N kPa16,5 1,5 66 31 42 to 48 21,0 57 160 - 250

OIL PRESSUREMinimum operating oil pressure (warm engine)

600 r/min 2800 r/min

80 kPa gauge pressure 280 kPa gauge pressure

Warning! Stop engine immediately when the oil pressure drops below the following values600 r/min 50 kPa gauge pressure

2800 r/min 250 kPa gauge pressure

OIL CAPACITYDepending on application 364N/C/T approximately 10 litres

366N/C/T/TI approximately 17,5 litres


Turbocharger oil drain to crankcase/sump (364C/T/TI)....Turbocharger oil supply from oil cooler cover (366C/T/TI)Turbocharger oil drain to sump (366C/T/TI).....................Oil supply to turbocharger................................................Oil drain from turbocharger..............................................Oil pressure gauge switch................................................Oil filter mounting............................................................Dipstick adapter...............................................................Sump drain plug..............................................................Dipstick tube to cylinder block..........................................Sump to cylinder block - Pressed steel............................

- Aluminium casting

Drain plug bush to sump.................Relief valve cap to oil pump cover....By-pass valve cap on oil filter'.........Banjo bolt to oil filter head...............Plug to oil filter head........................Plug to oil filter head (Aluminium).... Drain plug to filter head (Aluminium)Oil filter bowl to filter head...............Oil supply pipe to injector pump......Oil supply pipe to filter....................Suction pipe to oil pump cover........Oil pump cover to pump body.........Oil pump to cylinder block...............Oil cooler filter to cooler..................Oil cooler cover to cylinder block.....Oil cooler by-pass valve..................Oil cooler bolts (centre) 366N..........Cooler to cover 366C/T/TI...............

M 1 6 x 1 ,5 ........................................................ 4 0 N mM 1 4 x 1 ,5 ........................................................ 4 0 N mM 2 6 x 1 ,5 ........................................................ 7 0 N mM 8 ....................................................................... 3 5 N mM 8 ....................................................................... 3 5 N mM 1 4 x 1 ,5 ........................................................ 5 0 N mM 1 0 .................................................................... 5 0 N mM 1 4 x 1 ,5 ........................................................ 4 0 N mM 2 6 x 1 ,5 ........................................................ 8 0 N mM 1 6 x 1 ,5 ........................................................ 2 5 N mM 8 (S tu d s ) .................................................... 9 N mM 6 (B o lts ) ..................................................... 8 N mM 8 (S tu d s ) ..................................................... 2 5 N mM 6 (B o lts ) ....................................................... 15 N m- .......................................................................... 9 0 - 1 1 0 N mM 2 4 x 1 ,5 ........................................................ 2 0 N m (w ith L o ctite )M 2 4 x 1 ,5 ........................................................ 7 0 N mM 2 6 x 1 ,5 ........................................................ 6 0 N mM 1 0 x 1 .............................................................2 0 N mM 1 4 x 1 ,5 ........................................................ 3 5 N mM 1 0 x 1 .............................................................2 0 N mM 1 2 x 1 ,5 ........................................................ 4 5 N mM 1 0 x 1 .............................................................1 5 N mM 1 0 x 1 1 5 N mM 8 ....................................................................... 3 5 N mM 8 ....................................................................... 3 4 N mM 8 ....................................................................... 3 5 N mM 1 0 ....................................................................4 0 N mM 8 .......................................................................4 0 N mM 2 2 x 1 ,5 ........................................................ 6 5 N mM 8 ....................................................................... 3 0 N mM 8 ....................................................................... 3 5 N m

April ‘96


REMOVING AND DISMANTLING PLATE TYPE OIL COOLER 366N

1. R e m o v e s ta rte r m o to r.

2 . U n s c re w bo lts a n d re m o v e th e e x h a u s t m an ifo ld , (F ig . 1 6 -1 ) .

3. U n s c re w th e bo lts a n d re m o v e th e in le t m an ifo ld , (F ig . 1 6 -2 ) .

4 . U n s c re w a n d re m o v e th e oil p re s s u re g a u g e se n d e r unit, (F ig . 1 6 -3 ) .

5. R e m o v e b y - p a s s v a lv e fro m oil c o o le r c a s in g , (F ig . 1 6 -4 ).

April '96


6. U n s c re w and re m o v e a ll b o lts re ta in in g th e o il co o le r to th e c y lin d e r b lock , (F ig . 16-5).

7. Remove the oil cooler casing from the cylinder block, (Fig. 16-6).

8. Unscrew and remove bolts joining both halves of the oil cooler, (Fig. 16-7).

9. Dismantle the oil cooler halves, (Fig. 16-8).

M m >e=

Fig. 16-8___________________________________

April '96


ASSEMBLY AND REPLACEMENT OF OIL COOLER

1. Fit new gasket between oil cooler halves, (Fig. 16-9).

2. Insert bolts joining the oil cooler halves and tighten to the specified torque,(Fig. 16-10).

3. Replace oil pressure gauge sender unit and tighten the bolts to the specified torque, (Fig. 16-11).

4. Replace the by-pass valve and tighten the bolts to the specified torque, (Fig. 16-12).

¡ AN j T ' ~ , r - , J i f f

■ing. 16-9

Fig. 16-10

Fig. 16-12

April ‘96


5. F it a n e w g a s k e t b e tw e e n oil c o o le r cas in g an d cy lin d e r b lock.

6 . R e p la c e th e oil c o o le r to cy lin d er b lock , (F ig . 1 6 -1 3 ).

7 . In s e rt bo lts se c u rin g th e oil c o o le r to th e cy lin d er b lock an d tig h te n in c ro s s fa s h io n fro m th e c e n tre ou tw ard s , to th e s p e c ifie d to rq u e , (F ig . 1 6 -1 4 ) .

8. F it n e w g a s k e ts to th e in le t m a n ifo ld , in sert bo lts an d tig h ten to th e s p e c ifie d to rq u e , (F ig . 1 6 -1 5 ) .

9. F it n e w g a s k e ts to th e e x h a u s t m a n ifo ld , in sert bolts a n d tig h te n to th e s p e c ifie d to rq u e , (F ig . 1 6 -1 6 ) .

10 . R e p la c e th e s ta rte r m o to r.

11 . W ith th e e n g in e s to p c o n tro l se t to th e “O F F " po sition, tu rn th e e n g in e w ith th e s ta rte r m o to r until oil p res su re is re g is te re d on th e g a u g e .

12 . S ta r t th e e n g in e a n d a llo w to id le fo r s e vera l m inu tes; c h e c k all jo in ts fo r oil lea ks .

T ' ^

Fig. 1 6 -1 3

mu / © s

F ig . 1 6 -1 4

Fig. 1 6 -1 5

till A3=

Fig. 16-16

April '96


REMOVING OIL COOLER ADE 366T

1. Remove the starter motor.

2. Disconnect the oil feed and drain pipes to the turbocharger, (Fig. 16-17).

3. Unscrew bolts and remove the exhaust manifold, (Fig. 16-18).

4. Unscrew bolts and remove the inlet manifold, (Fig. 16-19).

5. Do not remove the oil cooler retainer bolts until the housing has been removed from the cylinder block, (Fig. 16-20).

April '96


6 U n s c re w an d re m o v e all bolts re ta in in g th e oil co o le r ho u s in g an d re m o v e fro m th e cy lin d er block, (F ig . 1 6 -2 1 ) .

7 . U n s c re w a n d re m o v e bo lts re ta in in g th e oil c o o le r e le m e n t to th e h o u s in g , (F ig . 1 6 -2 2 ) .

8. D e ta c h th e oil c o o le r e le m e n t fro m th e ho us ing , (F ig . 1 6 -2 3 ) .

9. U n s c re w th e c e n tre b o lt re ta in in g th e oil c o o le r filter e le m e n t to th e h o u s in g , (F ig . 1 6 -2 4 ) .

Fig. 16-22

April '96


10. L ift o f f th e f ilte r c o v e r and re m o ve th e f ilte r e lem ent, (F ig . 16 -25 ).

11. Unscrew and remove the oil pressure gauge sender unit, (Fig. 16-26).

12. Remove the by-pass valve from the oil cooler housing, (Fig. 16-27).

R E P L A C IN G

1. Replace the oil pressure gauge sender unit and tighten to the specified torque.

2. Replace the by-pass valve and tighten to the specified torque, (Fig. 16-28).

Fig. 16-25

Fig. 16-26

— I s s > mi /©=

Fig. 16-27

III! M s

Fig. 16-28

April '96


3. Fit a new O-ring to the oil cooler filter element cover, (Fig. 16-29).

4. Replace the oil cooler filter element.Note: The wide sealing face on the filter element goes towards the sealing surface of the oil cooler housing, (Fig. 16-30).

5. Replace the filter element cover, fitted with new O-ring, insert the retaining bolt and tighten to the specified torque, (Fig. 16-31).

6. Fit new gaskets between oil cooler element and housing, replace the cooler element and insert bolts, (Fig. 16-32).

Fig. 16-32

April '96


7. Tighten oil cooler retaining bolts to the specified torque, (Fig. 16-33)

8. Fit a new gasket between the cylinder block and the oil cooler housing.

9. Replace all bolts retaining the oil cooler housing to the cylinder block and tighten in cross fashion from the centre outwards to the specified torque, (Fig. 16-34).

10. Fit a new gasket to the inlet manifold, insert bolts and tighten to the specified torque, (Fig. 16-35).

11. Insert the exhaust manifold bolts and tighten to the specified torque, (Fig. 16-36).

Fig. 16-33

Fig. 16-34

Fig. 16-35

■ i l l » =

Fig. 16-36

April ‘96


12 . C o n n e c t oil fe e d an d d ra in p ip e to th e tu rb o ch arg er, a n d tig h te n to s p e c if ie d to rq u e (F ig . 1 6 -3 7 ) .

13 . R e p la c e th e s ta rte r m oto r.

14 . W ith th e e n g in e S to p co ntro l se t to th e “O F F " position tu rn th e e n g in e w ith th e s ta rte r m o to r until oil p res su re is re g is te re d on th e g a u g e .

15 . S ta r t th e e n g in e a n d a llo w to id le fo r s e vera l m inu tes . C h e c k a ll jo in ts fo r oil leaks.

R em ov in g th e Oil Filter E lem en t

1. U n s c re w a n d re m o v e th e filte r bow l d ra in plug an d a llo w oil to d ra in (F ig . 1 6 -3 8 ) .

2 . U n s c re w th e c e n tre b o lt re ta in in g th e filte r bow l to th e filte r h e a d , (F ig . 1 6 -3 9 ) .

3. R e m o v e th e oil filte r bow l an d th e filte r e le m e n t, (F ig . 1 6 -4 0 ) .

4 . C le a n filte r bow l, e le m e n t re ta in e r an d c e n tre bolt.

1

I

Fig. 1 6 -3 7 ___________

April '96


Replacing

1. F it a new O -r in g to th e filte r h e ad , (F ig , 16-41).

Insert a new filter element into the filter bowl, (Fig. 16-42).

Position the filter bowl to the centre of the filter head, insert bolt and tighten to the specified torque, (Fig. 16-43).

4. Replace the filter drain plug and tighten to the specified torque, (Fig. 16-44).

Attention! With the engine Stop control set to the “OFF" position, turn the engine with the starter motor until oil pressure is registered on the gauge.

5. Start the engine and allow to idle for several minutes. Check all joints for oil leaks.

2

3

April '96


REMOVING AND REPLACING THE OIL FILTER HEAD

Removing

1. Drain the filter bowl.

2. Remove the filter bowl and element, (Fig. 16-45).

3. Unscrew and remove the feed pipe to injection pump, (Fig. 16-46).

4. Unscrew and remove bolts retaining the filter head to the crankcase, (Fig. 16-47).

5. Remove the filter head from the crankcase.

Note: New level oil filter elements have integrated seal rings, and therefore the loose seal ring depicted in Fig. 16-47 will no longer be required.

6. Unscrew and remove the oil filter by-pass valve from the filter head, (Fig. 16-48).

Fig. 16-45

FicJ. 16-46

Fi.q. 16-47

mi » =

Fig. 16-48

April '96


7. R e m o v e th e oil f ilte r s e a l an d re ta in in g spring fro m th e filte r h e ad , (F ig . 1 6 -4 9 ) .

N o te : T h is s e a l is n o w in teg ra l p a rt o f th e oil filter a s s e m b ly .

8. T h o ro u g h ly c le a n all p a rts a n d b lo w out oil d rillin gs in th e h e a d w ith c o m p re s s e d a ir, (F ig . 1 6 -5 0 ) .

R e p la c in g

1. U s in g a sp rin g te s te r , c h e c k th e b y -p a s s v a lv e sp rin g te n s io n , re p la c e if re q u ire d , s e e s p e c ific a tio n s , (F ig .1 6 -5 1 ) .

Fig. 1 6 -4 9

Fig . 1 6 -5 0

llll A3 =

Fig. 1 6 -51

2 F it a n e w oil f ilte r s e a l a n d re ta in in g ring to th e filter h e ad , (F ig . 1 6 -5 2 ) .

m A»s

Fig. 16-52

April '96


3. U s e a n e w g a ske t, fit th e filte r h e ad to th e c ra n k c a s e an d in sert b o lts ,(F ig . 1 6 -5 3 )

Fig. 1 6 -5 3

4 . T ig h te n to th e s p e c ifie d to rq u e , (F ig . 1 6 -5 4 ) .

F ig . 1 6 -5 4

F it b y -p a s s v a lv e into th e filte r h e ad an d tig h ten th e s c re w p lug to th e s p e c ifie d to rq u e , (F ig . 1 6 -5 5 ) .

Fig. 1 6 -5 5

6 . C o n n e c t th e oil fe e d p ip e to th e in jection p u m p an d filte r h e a d , tig h te n th e s c re w p lug to th e sp ec ified to rq u e , (F ig . 1 6 -5 6 ) .

Attention! A b a n jo c o n n ec tio n w ith a s m a ll ho le is fitted to th e filte r h e ad ; th is a p p lie s a res tric tion to th e oil f lo w an d sh o u ld no t b e reverse d .

Fig. 16-56

April '96


7 F it a n e w O -r in g to th e filte r bow l, (F ig . 1 6 -5 7 ) .

8 . In sert a n e w oil f ilte r e le m e n t into th e filte r bow l, (F ig . 1 6 -5 8 ) .

9. F it th e filte r bow l an d e le m e n t to th e filte r h e a d , insert re ta in in g bo lt a n d tig h te n to th e s p e c if ie d to rq u e , (F ig .1 6 -5 9 ) .

10 . R e p la c e th e filte r bo w l d ra in p lug an d tig h te n to th e sp ec ified to rq u e , (F ig . 1 6 -6 0 ) .

11 . W ith th e e n g in e S to p c o n tro l s e t to th e “O F F " position , tu rn th e e n g in e w ith th e s ta rte r m o to r until oil p res su re is re g is te re d on th e g a u g e .

12 . S ta rt th e e n g in e a n d a llo w to id le fo r s e v e ra l m inu tes . C h e c k all jo in ts fo r oil leaks .

April '96


REMOVAL, STRIPPING, ASSEMBLY AND REPLACEMENT OF OIL PUMP

Removal

1. D ra in e n g in e oil an d re m o v e th e s u m p , (F ig . 1 6 -6 1 ) .

2 . R e m o v e oil p u m p re ta in in g bo lts , (F ig . 1 6 -6 2 ) .

3. P u ll o u t oil p u m p fro m c ra n k c a s e , (F ig . 1 6 -6 3 ) .

Stripping

1. C la m p th e oil p u m p in a v ic e fitted w ith so ft ja w s .

2. R e m o v e bo lts re ta in in g th e s tra in e r an d p ick -u p pipe, (F ig . 1 6 -6 4 ) .

3. R e m o v e th e p ic k -u p p ip e a n d s tra in e r fro m th e oil p u m p body .

Fig. 1 6 -61

F ig. 1 6 -6 2

Fig. 1 6 -6 3

Fig. 16-64

April '96


4 R e m o v e th e p re s s u re re lie f v a lv e , sp rin g an d piston fro m th e oil p u m p co ver, (F ig . 1 6 -6 5 ) .

5. U n s c re w an d re m o v e th e bo lts re ta in in g th e co ver p la te to th e oil p u m p b o dy , (F ig . 1 6 -6 6 ) .

6 . Lift o u t th e oil p u m p g e a r fro m th e oil p u m p body, (F ig .1 6 -6 7 ) .

7. P re ss th e oil p u m p s h a ft fro m th e d rive g e a r, (F ig .1 6 -6 8 ) .


8. R e m o v e th e oil p u m p d rive s h a ft fro m th e body, c o m p le te w ith g e ar, (F ig . 1 6 -6 9 ) .

9. P re s s oil p u m p d riv e s h a ft fro m th e g e ar, (F ig . 1 6 -7 0 ) .

10 . E x a m in e th e oil p u m p b o d y a n d g e a rs fo r s ig ns o f ex c e s s iv e w e a r, sc o rin g a n d lo c a lis e d se izu re . R e p la c e a ll fa u lty p a rts . S h o u ld th e oil p u m p b o d y or g e a rs s h o w s ig ns o f e x c e s s iv e w e a r th e c o m p le te oil pu m p m u s t b e rep la ced .

Assembly

1. P re s s g e a r on to th e oil p u m p d rive shaft, (F ig . 1 6 -7 1 ) .

2. C h e c k th e in s ta lla tio n h e ig h t o f th e g e a r to th e d rive sh a ft, (F ig . 1 6 -7 2 ) .

April '96


3. In sert th e oil p u m p d riv e s h a ft in to th e p u m p body, (F ig . 1 6 -7 3 ) .

4. P re s s th e he lica l g e a r on to th e s h a ft an d by us ing a v e rn ie r c h e c k th e d is ta n c e b e tw e e n th e g e a r an d th e p u m p fla n g e ; re fe r to s p e c if ic a tio n s fo r th e c o rre c t d is ta n c e , (F ig . 1 6 -7 4 ) .

5. In s e rt th e oil p u m p d rive n g e a r into th e p u m p body, (F ig . 1 6 -7 5 ) .

6 . C h e c k th e c le a ra n c e b e tw e e n th e o il p u m p g e a rs an d h o us ing , (F ig . 1 6 -7 6 ) .

Fig. 1 6 -7 3

c 0d■nil

Fig . 1 6 -7 4

Fig. 1 6 -7 5

iiiiaas

fig. 16-76

April '96


7. C h e c k th e c le a ra n c e b e tw ee n co v e r p la te an d gears, (F ig . 1 6 -7 7 ) .

8 . R e p la c e th e oil p u m p p la te , in sert bo lts an d tig h ten to th e s p e c ifie d to rq u e , (F ig . 1 6 -7 8 ) .

9 . F it oil re lie f v a lv e into th e oil p u m p co v e r p la te an d tig h te n to th e s p e c if ie d to rq u e , (F ig . 1 6 -7 9 ).

10 . P r im e th e oil p u m p w ith e n g in e oil.

11 . B o lt th e oil su c tio n p ip e a n d s tra in e r to th e oil pu m p b o d y a n d tig h te n to th e sp ec ified to rq u e , (F ig . 1 6 -8 0 ) .

Fig. 1 6 -7 7

Fig. 1 6 -7 8

Fig. 1 6 -7 9

■in /© =

^ 5 1

Fig. 16-80

April '96


12. F it th e s tra in e r to th e su ctio n p ipe, {F ig 1 6 -8 1 )

13 . In sert th e oil p u m p into th e c ra n k c a s e , re p la c e th e re ta in in g b o lts a n d tig h te n to th e s p ec ified to rq u e , (F ig .1 6 -8 2 ) .

F ig . 16 -8 1

F ig . 1 6 -8 2

14 . F it n e w s u m p g a s k e ts to th e c ra n k c a s e , (F ig . 1 6 -8 3 ) .

F ig . 1 6 -8 3

15 . R e p la c e th e s u m p , in s e rt th e b o lts a n d tig h te n to th e s p e c ifie d to rq u e , (F ig . 1 6 -8 4 ) .

16 . F ill th e s u m p w ith re c o m m e n d e d oil.

17 . W ith th e e n g in e S to p c o n tro l s e t to th e “O F F " position , tu rn th e e n g in e w ith th e s ta rte r m o to r until oil p res su re is re g is te re d on th e g a u g e .

18. S ta r t th e e n g in e a n d a llo w to id le fo r s e v e ra l m in u tes . C h e c k a ll jo in ts fo r oil lea ks .

Fig. 16-84

April ‘96

SECTION 17Fuel System


Page

ILLUSTRATION.......................................................................................................................................................................................... 17-2

INTRO DUCTION ........................................................................................................................................................................................ 17-3

SPECIFICATIONS..................................................................................................................................................................................... 17-3

REMOVING THE INJECTION PUM P.................................................................................................................................................. 17-4

REPLACING THE INJECTION PUM P .................................................................................................................................................. 17-5

SETTING “A" TYPE INJECTION PUMP TIMING .............................................................................................................................. 17-7

SETTING “MW ” TYPE INJECTION PUMP T IM IN G .......................................................................................................................... 17-10

REMOVAL AND REPLACEMENT OF FUEL INJECTORS.............................................................................................................. 17-13

TESTING THE INJECTOR FOR LEAKAGE.........................................................................................................................................17-15

TESTING THE NOZZLE OPENING AND INJECTION PRESSURE......................................................... 17-16 ’-16

JET SPRAY T E S T ..................................................................................................................................................................................... 17-16

DISMANTLING AND ASSEMBLY OF FUEL INJECTORS............................................................................................................... 17-16

ASSEMBLY OF THE NOZZLE . I I

SPECIAL TOOLS FOR SECTION 1 7 ................................................................................................................................................... 17-19

April '96

Fuel System 17-2

INJECTION SYSTEM

1 S E A L IN G W A S H E R 14 S E A L IN G W A S H E R2 B A N J O B O L T 15 IN J E C T O R A S S E M B L Y3 S P L IT S E A L 16 IN J E C T O R S E C U R IN G N U T4 IN J E C T O R P IP E S 17 N O Z Z L E5 C L A M P 18 C A P N U T6 C L A M P 19 S P A C E R7 S P R IN G W A S H E R 2 0 T H R U S T P IN8 S C R E W 21 S P R IN G9 “A" T Y P E IN J E C T IO N P U M P 22 S H IM

10 “M W " T Y P E IN J E C T IO N P U M P 23 S C R E W P L U G11 C L IP 2 4 S P L IT S E A L12 P A C K IN G 2 5 C O N N E C T O R13 C L A M P 2 6 L E A K -O F F P IP E

April ‘96

Fuel System 17-3

INTRODUCTION

T h e A D E 3 6 0 s e rie s o f e n g in e s a re fitted w ith tw o ty p e s o f B osch fuel in jection p u m p s . T h e su cce ss fu l “A" ty p e in jection p u m p is fitted to th e n a tu ra lly a s p ira te d en g in e , an d th e "M W " ty p e fuel in jection p u m p is used on th e tu rb o c h a rg e d en g in e . T h e “M W " fu el in jection p u m p , be ing o f a la rg e r and m o re rigid desig n , e n a b le s it to p ro v id e h ig h e r pressures, a llo w in g th e tu rb o c h a rg e d en g in e to d e ve lo p g re a te r p o w er an d a h ig h e r to rq u e

SPECIFICATIONS

FUEL SYSTEM

In jec tio n p u m p an d g o v e rn o r B O S C H

In jec tio n p re s s u re N e w 2 0 ,0 to 2 0 ,8 M P aU sed m in . 1 8 ,0 M P a

In jec tio n p u m p tim in g re fe r en g in e n u m b e r 3 6 4 N 1 9 ° B T D CD a ta p la te - o th e rw is e use 3 6 4 C /T /T I 1 5 ° B T D Ctim in g as lis ted 3 6 6 N 1 9 ° B T D C

3 6 6 C /T 1 6 ° B T D C3 6 6 T I - up to 1 5 0 k W 16° B T D C3 6 6 T I - a b o v e 1 5 0 k W 1 2 ° B T D C

F u el lift p u m p d e liv e ry p re s s u re 8 0 kP a

Id le s p eed 6 0 0 r/m in


In je c to r p ro tec tio n s le e v e .....................In je c to r se cu rin g n u t.................................In je c to r c a p nu t to n o zz le b o d y .........S tu d fo r in jec tion p u m p m o u n tin g ...In jec tio n p u m p g e a r to p u m p .............In je c to r p ip e nu ts to in jec tion p u m pIn je c to r p ip e nu ts to in je c to r ...............P re s s u re /R e tu rn p ip e a d a p te r to cyl

L e a k o ff p ip e to in je c to r s ......................S u p p ly an d re tu rn p ip e c o n n ec tio n s In jec tio n p u m p s u p p o rt...........................

D e liv e ry v a lv e ho lder:“A" ty p e p u m p ..............................................

* L o o s e n a fte r 1st, 2n d an d 3rd s tag e s

“M W " ty p e p u m p ...............................................8 m m n u t .................................................................

....................................................... M 1 4 x 1 ...............................................................5 0 N m

....................................................... M 3 4 x 1 ,5 .......................................................... 7 0 N m

....................................................... M 2 4 x 1 .5 .......................................................... 8 0 N m

....................................................... M 1 0 ...................................................................... 10 - 2 0 N m

....................................................... M 1 4 x 1 ,5 .......................................................... 8 0 N m

....................................................... M 1 2 x 1 ,5 .......................................................... 2 5 N m

........................................................M 1 4 x 1 ,5 .......................................................... 2 5 N mh e a d .......................................... M 2 2 x 1 ,5 10 N m....................................................... M 1 6 x 1 ,5 ............ 10 N m....................................................... M 8 x 1 ................................................................ 2 0 N m....................................................... M 1 4 x 1 .5 .......................................................... 3 5 N m....................................................... M 8 ......................................................................... 35 N m

....................................................... s ta g e 1 ...............................................................4 0 N m *s ta g e 2 ............................................................ 4 0 N m *s ta g e 3 ............................................................ 4 0 N m *F in a l to r q u e .................................................. 4 5 N m

50 - 60 Nm 12 - 16 Nm

April '96

Fuel System 17-4

REMOVING THE INJECTION PUMP

1 D e ta c h th e oil fille r p ip e or b re a th e r fro m th e tim in g c a s e ( if f it te d ) or re m o v e th e b lan k in g p lug, (F ig . 1 7 -1 ).

2. R e m o v e th e ro c k e r co ver, (F ig . 1 7 -2 ).

3. T u rn th e e n g in e in th e n o rm a l d irec tio n o f ro ta tion until th e N o. 1 p is ton is on c o m p re s s io n s tro ke an d th e m a rk on th e v ib ra tio n d a m p e r is in lin e w ith (F B ) p o in te r on th e tim in g c a s e , (F ig . 1 7 -3 ).

Attention! Never turn the engine in the reverse direction of rotation.

4. D is c o n n e c t th e fu e l filter, fu e l a n d oil feed p ipes to th e in jection p u m p , (F ig . 1 7 -4 ) .

F

Fi

Fi

g. 1 7 -2

Fig. 17-4

April ‘96

Fuel System 17-55. U s e s p e c ia l to o l, p a rt n u m b e r 4 0 2 0 0 7 0 5 , to un screw

a n d d e ta c h th e in je c to r p ip es fro m th e in jection p u m p , (F ig . 1 7 -5 ) .

6 . U n s c re w an d re m o v e nu ts re ta in in g th e in te rm e d ia te f la n g e o f th e in jec tio n p u m p to th e tim in g hous ing . F it p ro te c tiv e du st c a p s ,(F ig . 1 7 -6 )

7. L ift o ff th e in jec tio n p u m p , (F ig . 1 7 -7 ).

REPLACING THE INJECTION PUMP

1. T u rn th e e n g in e in th e n o rm a l d irec tio n o f ro ta tion until . N o . 1 p is to n is on c o m p re s s io n s tro ke. T h e m a rk on th e v ib ra tio n d a m p e r m u s t b e in lin e w ith th e (F B ) p o in te r on th e tim in g c a s e (F ig . 1 7 -8 )

Fig. 1 7 -7

April '96

Fig. 17-8

Fuel System 17-6

2. R e p la c e in jec tio n p u m p fla n g e g a ske t, in sert th e pu m p into th e tim in g ho u s in g an d e n s u re th a t th e m a rk on th e in jec tio n p u m p g e a r to o th lines up w ith th e a rro w in th e tim in g c a se , (F ig . 1 7 -9 0 ) .(R e fe r fig. 1 7 -1 6 oh p a g e 1 7 -7 ).

3. R e p la c e th e in jec tion p u m p re ta in in g nuts an d tig h ten to th e s p e c if ie d to rq u e (F ig . 1 7 -1 0 ) .

4. S e t s ta rt o f d e liv e ry (R e fe r to in jection p u m p tim in g Fig. 1 7 -1 4 )

5 A tta c h in jec to r p ip es to th e in jec tion p u m p . U s e specia l to o l p a rt N o . 4 0 2 0 0 7 1 8 to tig h ten all co n n ec tio n s to th e s p e c ifie d to rq u e , (F ig . 1 7 -1 1 )

6. A tta c h th e fu e l an d oil fe e d p ipes to th e in jection pu m p and tig h ten to th e s p e c ifie d to rq u e . R e p la c e th e b re a th e r p ipe or plug. (F ig . 1 7 -1 2 )

7 R e p la c e ro c k e r co ver.

F ig . 1 7 -9

F ig . 1 7 -1 0

Fig. 17 -11

Fig.17-12

April '96

SETTING “A" TYPE INJECTION PUMP TIMING

1. R e m o v e ro c k e r c o ver, (F ig . 1 7 -1 3 )

2 . T u rn e n g in e in th e d irec tio n o f ro ta tion until N o . 1 p is to n is on c o m p re s s io n s tro k e an d th e m a rk on th e v ib ra tio n d a m p e r is in lin e w ith th e p o in te r on th e tim in g c a se , (F ig . 1 7 -1 4 )

3. D e ta c h th e oil fille r p ip e or b re a th e r fro m th e tim in g c a s e ( if f it te d ) o r re m o v e th e b lan k in g p lug, (F ig .1 7 -1 5 ) .

4 . C h e c k to e n s u re th a t th e m a rk e d to o th on th e in jection p u m p g e a r is in lin e w ith th e p o in te r in th e tim in g g e a r co ver, (F ig . 1 7 -1 6 ) .

Fuel System 17-7

Fig. 1 7 -1 3

/ v N \

1 - - 1 m k

M ill « S

F ig. 1 7 -1 4

F ig .1 7 -1 5

Fig.17-16

April '96

Fuel System 17-85. D is c o n n e c t a ll in je c to r p ip es fro m th e in jec tion p u m p

using s p e c ia l to o l p a rt n u m b e r 4 0 2 0 0 7 0 5 . (F ig .1 7 - 17).

6. A tta c h P re s s u re L im itin g V a lv e s , s p ec ia l to o ls part n u m b e r 4 0 2 0 2 3 7 6 , to in jec tio n p u m p o u tle ts n u m b ers 2 to 6 . (R e f F ig . 1 7 -1 8 )

7 Pump Unit ( R e f f ig .1 7 -1 9 )

Item 1 Electric MotorItem 2 Gear PumpItem 3 Pressure Limiting ValveItem 4 Fuel Tank.Item 5 Return Line.Item 6 Test Line with Sightglass. Item 7 12v connection cablel Item 8 Connection line (supply) Item 9 Base plate tern 10 Relay box with switch

8 .D e ta c h fu e l su p p ly lin e a t p u m p an d c o n n e c t supp ly line (8 ) o f th e p u m p un it (R e f F ig 1 7 -2 0 )

9 D e ta c h fu e l re tu rn lin e (1 2 ) an d o v e rflo w v a lv e a t th e in jection p u m p an d s e a l b o re w ith a d u m m y p lu g .(1 3 ).

10. T o th e N o 1 o u tle t o f th e fu e l p u m p co n n e c t th e test line w ith s ig h tg la s s (R e f (6 )F ig . 1 7 -2 0 ) .

April '96

Fuel System 17-9

11 . T u rn th e c ra n k s h a ft in th e d irec tio n o f ro ta tio n until it is ap p ro x . h a lf a tu rn b e fo re T .D .C . o f th e N o. 1

c y !in d e r .(R e f. F ig 1 7 -2 1 )

12 . L o c k th e in jec tio n p u m p le v e r a t F u ll lo ad po sition

N o te :-B e fo re sw itch in g on th e T e s t P u m p U n it th e in jec tio n p u m p le v e r m u s t b e lo cked a t fu ll lo ad an d m u s t n o t b e m o v e d w h e n th e p u m p u n it is running . S w itc h on th e T e s t P u m p U n it on ly w h ile p e rfo rm in g m e a s u re m e n t

13 . S w itc h on th e T e s t P u m p U n it th en s lo w ly ro ta te th e c ra n k s h a ft in th e d irec tio n o f ro ta tio n an d o b serve th e fu e l je t in th e s ig h t g lass . - T h e e x a c t s ta rt o f d e liv e ry is re a c h e d w h e n th e fuel je t c h a n g e s from a ta p e re d je t s tre a m to a ch a in o f drops.

A = ‘ Fu ll * fu e l je t

B .= F u e l je t ta p e re d - s h o rtly b e fo re s ta rt o f d e live ry

C .= C h a in o f d ro p s = s ta rt o f d e live ry

1 4 .C h e c k s ta rt o f d e liv e ry m a rk in g b e tw e e n se ttin g p o in ter on tim in g c a s e a n d m a rk in g on v ib ra tio n d a m p e r o r belt pu lley . R e f. F ig . 1 7 -2 3 )

1 5 If it is n e c e s s a ry to c o rre c t th e s ta rt o f d e live ry o f th e in jec tio n p u m p , th e c ra n k s h a ft sh ou ld b e tu rn ed in d irec tio n o f ro ta tio n e x a c x tly to th e s ta rt o f de live ry m a rk in g o f se ttin g p o in te r w ith v ib ra tio n d a m p e r or be lt pulley .

16. S la c k e n th e nu ts (1 3 ) se cu rin g th e in jection p u m p . (R e f .F ig . 1 7 -2 4 )

N o te : -T h e in jec tio n p u m p le v e r m u s t b e lo cked a t full load an d m u s t no t b e m o v e d w h e n th e p u m p u n it is runn ing .

S w itc h on th e p u m p u in it on ly fo r p erfo rm in g m e a s u re m e n t o th e rw is e fu e l m a y g e t in to th e co m b u stio n c h a m b e r if th e n o z z le is lea k in g

April '96

1 7 .M o v e th e in jec tio n p u m p on th e s lo tted ho les fa r en o u g h to a c h ie v e e x a c t s ta rt o f d e liv e ry

Fuel System 17-10

8 .R e -tig h te n th e h e x .n u ts (1 3 ) o f in jection p u m p to s p ec ified to rq u e

19. R e p e a t te s tin g o f s ta rt o f d e liv e ry o p e ra tio n s 11 to 14 a b o v e

2 0 . R e m o v e th e P re s s u re lim itn g v a lv e an d th e te s t line fitted to no .1 c y lin d e r a n d re a s s e m b le in jection

p ip e s .R e f. F IG . 1 7 -2 6

2 1 .R e p la c e th e oil fille r p ip e / b re a th e r or b lan k in g plug to th e tim in g c a se . R e f. F ig . 1 7 -2 7 .

SETTING “ MW” TYPE INJECTION PUMP TIMING

Note:W ith th e fittin g o f th e “M W " in jec tio n p u m p to th e A D E 3 6 0 se rie s tu rb o c h a rg e d e n g in e th e t im in g p ro c e d u re has ch an g ed . It is no lo n g e r a d v is a b le to re m o v e th e de live ry v a lv e w h e n c a rry in g o u t th e sp ill t im in g . O n c e th e v a lv e has b e e n re m o v e d th e v a lv e s e a l co u ld b e d a m a g e d and c a u s e a le a k to d e v e lo p a t h igh pres su re .

1. R e m o v e ro c k e r co ver.

2 . T u rn th e e n g in e in th e d irec tio n o f ro ta tio n an d position No. 1 c y lin d e r on firin g s tro ke ± 4 5 d e g re e s b e fo re top d e ad ce n tre , (F ig . 1 7 -2 8 ) .

April '96

Fuel System 17-11

3. R e m o v e th e lo w p re s s u re p ip ing to an d fro m th e in jec tio n p u m p an d fuel filters . N o te position o f g a lle ry p re s s u re v a lv e N o . 1 an d fu e l su p p ly to g a lle ry N o. 2,(F ig . 1 7 -2 9 ) .

4. F it th e su p p ly p ip e fro m th e p re s s u re spill p u m p to th e fro n t en d o f th e in jection p u m p g a llery . F it a b lank ing plug to th e re a r en d o f th e g a lle ry .

(S p ill p u m p p a rt n u m b e r 4 0 2 0 2 3 6 3 or a lte rn a tiv e ly 4 0 2 0 -2 4 6 0 )

5. D is c o n n e c t a ll in je c to r p ipes an d th e re s p ec tive de liv e ry v a lv e u n io n s on th e in jec tion p u m p . F it p res su re re lie f v a lv e u n io n s , (F ig . 1 7 -3 1 ) .

6. C o n n e c t th e p re s s u re spill p u m p return p ipe w ith spill p ip e to th e No. 1 d e liv e ry v a lv e un ion , (F ig . 1 7 -3 2 ) .

7. M o v e th e a c c e le ra to r co ntro l le v e r on th e in jection p u m p to th e full s p eed po sition.

April '96

Fuel System 17-12

8. C o n n e c t th e p re s s u re sp ill p u m p to a s u ita b le p o w er supply; e n s u re th a t th e p u m p p re s s u re is approx. 2 5 0 0 k P a .

9. C o n tin u e tu rn in g th e e n g in e in th e n o rm a l d irec tio n o f ro ta tion until th e fu e l d is c h a rg e in th e g lass bow l c h a n ges fro m a ta p e re d je t s tre a m to a ch a in o f drops,(F ig . 1 7 -3 3 ) .

10. C h e c k th e tim in g m a rk s (F B ) on th e tim in g co ver and v ib ra tio n d a m p e r fo r a lig n m e n t, (F ig . 1 7 -3 4 ) .

11. If th e t im in g Is re ta rd e d lo o se n th e in jec tion pu m p

se cu rin g nu ts a n d m o v e th e to p o f th e in jec tion pu m p to w a rd s th e c y lin d e r b lo ck or a w a y fro m th e cy lind er block to a d v a n c e , (F ig . 1 7 -3 5 ) .

12. A fte r a d ju s tm e n t re -c h e c k th e tim in g by rep e a tin g o p e ra tio n s 2 to 9.

13. T ig h te n th e nu ts re ta in in g th e in jection p u m p to th e tim in g g e a r h o us ing , (F ig . 1 7 -3 6 ) .

April '96

Fuel System 17-13

14. R e m o v e th e b la n k in g plug an d high p re s s u re p ipe from th e te s t p u m p . R e c o n n e c t th e g a lle ry p re s s u re v a lv e an d th e lo w p re s s u re fe ed to th e p u m p an d tig h ten to

th e s p e c ifie d to rq u e .

15 . R e c o n n e c t th e in jec to r p ipes an d tig h ten th e bo ttom u n io n s to th e s p e c ifie d to rq u e , (F ig . 1 7 -3 7 )

16 . R e p la c e ro ck er cover.

REMOVAL AND REPLACEMENT OF FUEL INJECTORS

Removal

1. R e m o v e ro c k e r cover.

2 . U s e s p e c ia l to o l, p a rt n u m b e r 4 0 2 0 0 7 0 5 , an d u n screw th e p ip e s to th e fu e l in jector. P u sh th e in je c to r p ipe to

o n e s id e . D o no t b en d th e p ipe, F ig . 1 7 -3 8 ).

3. D is c o n n e c t th e fu e l le a k o ff p ipe, (F ig . 1 7 -3 9 ) .

4. R e m o v e th e in jec to r se cu rin g nu t w ith sp ec ia l tool 4 0 2 0 0 8 7 3 , (F ig . 1 7 -4 0 ) .

Fig. 17-40

April '96

Fuel System 17-14

5. U s e s p e c ia l to o l 4 0 2 0 1 0 7 6 to pull th e in jec to r out o f th e c y lin d e r h e a d , (F ig . 1 7 -4 1 ) .

6. If to o tig h t w ith d ra w th e in je c to r w ith s p e c ia l ex tracto r, p a rt n u m b e r 4 0 2 0 1 0 6 3 , (F ig . 1 7 -4 2 ) .K eep m a tc h e d w a s h e r w ith th e re s p e c tiv e in jector.

A t te n t io n ! S e e se c tio n 1 2 fo r re m o v a l an d re p la c e m e n t o f in jec to r p ro tec tio n s le e v e s

R e p la c e m e n t

1. In sert a n e w in je c to r s e a lin g w a s h e r into th e cy lind er h e ad , (F ig . 1 7 -4 3 ) .

N o te : T h e n e w s e a lin g w a s h e rs m u s t be th e s a m e s ize and th ic k n e s s a s th e o n es re m o v e d .

2. In sert in je c to r in to th e c y lin d e r h e ad an d lo ca te th e notch on th e in jec to r w ith th e g ro o v e in th e cy lin d er h e ad , (F ig . 1 7 -4 4 ) .

Fig. 17-44

April '96

Fuel System 17-15

3. R e p la c e th e in je c to r se cu rin g nut an d use a to rq u e w re n c h fitted w ith s p e c ia l to o l 4 0 2 0 0 8 7 3 to tig h ten to th e s p e c ifie d to rq u e , (F ig . 1 7 -4 5 )

4. R e p la c e th e fu e l le a k o ff p ip e fitted w ith n e w sea lin g w a s h e rs an d tig h te n to th e s p ec ified to rq u e , (F ig . 1 7 -4 6 )

5. R e p la c e th e p re s s u re p ip e to th e fuel in jec to r and use s p e c ia l to o l 4 0 2 0 0 7 1 8 to tig h ten to th e sp ecified to rq u e ,(F ig 1 7 -4 7 )

TESTING THE INJECTOR FOR LEAKAGE

1. W ith s p e c ia lis e d n o zz le c le an in g e q u ip m e n t ca re fu lly re m o v e c a rb o n d e p o s its fro m th e in jec to r n o zz le tip ho les , (F ig . 1 7 -4 8 )

April ‘96

Fuel System 17-16

2. A tta c h th e in jec to r to th e te s te r , (F ig . 1 7 -4 9 )

Attention ! O n ly u s e c le a n te s tin g flu id or filte red d iesel fuel for te s tin g pu rp o s es .

Note: C a re m u s t b e ta k e n du rin g te s tin g as th e sp ra y is un der c o n s id e ra b le p re s s u re an d w o u ld p e n e tra te th e skin o f h a n d s or fa c e

3. S lo w ly press d o w n th e p u m p te s te r le v e r until th e p res su reg a u g e sh o w s 2 0 0 k P a b e lo w o p en in g p re s s u re o f th e in jec to r n o zz le . T h e in jec to r is fa u lty if fu e l lea ks fro m th e n o zz le w ith in 10 se co n d s .

4 In all c a s e s o f s ie z u re o r le a k a g e d is m a n tle an d c le an th e in jector. T h e n o zz le m u s t b e re p la c e d if c a re fu l c le an in g

TESTING NOZZLE OPENING AND INJECTION PRESSURE

1. A tta c h in jec to r to te s te r.

2. S lo w ly a d v a n c e th e p u m p te s t le v e r ; n o te th e p res su re w h en th e in jec to r o p en s , (F ig . 1 7 -5 0 )

3. T h e in je c to r p re s s u re m a y b e a d ju s te d by ad d in g or rem o v in g s h im s on to p o f th e c o m p re s s io n sp rin g .

JET SPRAY TEST

1. T u rn o ff th e p re s s u re g a u g e .

2. O p e ra te th e h a n d p u m p le v e r (s e v e ra l b risk s tro kes ) .T h e in jection is c o rrec t w h e n all fo u r je ts sp ra y fin e an d even , (F ig1 7 -5 1 )

DISMANTLING AND ASSEMBLY OF FUEL INJECTORS

1. C la m p s p e c ia l in je c to r s u p p o rt 4 0 2 0 0 9 1 2 in a vice.

2. In sert th e in je c to r in to th e h o ld e r, (F ig . 1 7 -5 2 )

Fig. 1 7 -4 9

Fuel System 17-17

3. W ith s p e c ia l to o l 4 0 2 0 0 9 2 5 u n s c re w th e in jector n o zz le c a p nu t fro m th e in jec to r b o d y an d d is m a n tle th e in je c to r a s s e m b ly , (F ig . 1 7 -5 3 ) .

4. C a re fu lly re m o v e c a rb o n d e p o s its fro m in jec to r ho les , (F ig . 1 7 -5 4 )

5. D ip n e e d le v a lv e an d n o zz le b o d y into c le an d iesel fuel a n d c a ry o u t d ro p test, se e o p era tio n 6 be low .

6 . Lift n e e d le v a lv e by a p p ro x im a te ly o n e th ird o f its len g th fro m th e n o zz le body . R e le a s th e n e e d le v a lv e so th a t it re tu rn s to its s e a t u n d e r its ow n w e ig h t, (F ig .1 7 -5 5 )

If th e n e e d le v a lv e s ticks b e fo re reach in g th e s e a t , re p la c e th e c o m p le te n o zz le a s s e m b ly .

ASSEMBLY OF THE NOZZLE

1. In s e rt th e in je c to r b o d y into s p ec ia l ho ld ing too l 4 0 2 0 0 9 1 2 , (F ig . 1 7 -5 6 )

Fig. 1 7 -5 3

Fig. 1 7 -5 4

Fig. 1 7 -5 5

Fig. 17-56

April '96

Fuel System 17-18

2. In sert sh im (2 ), sp rin g (3 ), th ru s t pin (4 ), a d a p to r (5 ) in to th e in je c to r b o d y (1 ). In s e rt th e n e e d le v a lv e (6 ) in to th e n o zz le

(7 ). P la c e th e n o zz le on to th e a d a p to r (5 ), (F ig . 1 7 -5 7 )

3. T w o g u id e p ins a re fitted on bo th s id es o f th e a d a p te r. T h e g u id e p ins w h ic h lo c a te in th e co rresp o n d in g ho les in th e n o zz le h o ld e r a re in d iffe re n t position to th e tw o pins w h ich lo c a te th e n o zz le . In c o rre c t fitm e n t o f th e a d a p te r is th e re fo re im p o s s ib le . T h e a d a p te r fa c e w h ic h m a te s w ith th e n o zz le is c h a m fe re d a t th e ed g e , (F ig . 1 7 -5 8 ) .

4 . S c re w in jec to r c a p nu t (8 ) o n to th e in jec to r bo dy (1 ), (F ig . 1 7 59 ).

5. U s e s p e c ia l to o l 4 0 2 0 0 9 2 5 to tig h te n th e in jec to r ca p to th e sp ec ified to rq u e , (F ig . 1 7 -6 0 )

Fig. 1 7 -5 7

Fig 1 7 -5 8

Fig. 1 7 -5 9

Fig. 17-60

Fuel System 17-19


O B T A IN A B L E F R O M : G R U N D Y T E C H N IF O R M , B U R M A N R O A D , D E A L P A R K , P O R T E L IZ A B E T H 6 0 0 1 T E L : (0 4 1 ) 4 3 -2 2 9 9 , F A X : (0 4 1 ) 4 3 -2 2 2 4

S p lit ring s p a n n e r for in jec to r p ipes s e e fig. 1 7 -5 , 1 7 -1 8 p a rt n u m b e r 4 0 2 0 0 7 0 5

C ro w fo o t ring s p a n n e r for re m o v in g /re p la c in g in jec to r pipes s e e fig. 1 7 -1 1 , 1 7 -2 6 , 1 7 -4 7 p a rt n u m b e r 4 0 2 0 0 7 1 8

S pill p ipes e e fig. 1 7 -2 0p a rt n u m b e r 4 0 2 0 0 8 6 0

F u e l c o n ta in e r fo r ch eck in g s tarto f d e live rys e e fig. 1 7 -21p a rt n u m b e r 4 0 2 0 0 8 5 7

S o c k e t fo r in jec to r se cu rin g nutss e e fig. 1 7 -3 2p a rt n u m b e r 4 0 2 0 0 8 7 3

F u e l in jec to r im p a c t ex tra c to rs e e fig. 1 2 -1 2p a rt n u m b e r 4 0 2 0 1 0 7 6

April ‘96

Fuel System 17-20

E x tra c to r fo r in jectorss e e fig. 1 2 -1 3part n u m b e r 4 0 2 0 1 0 6 3

S u p p o rt fo r s trip p in g an d a s s e m b lin g in jec tors , s e e fig. 1 7 -4 4 p a rt n u m b e r 4 0 2 0 0 9 1 2

S p a n n e r fo r s trip p in g and a s s e m b lin g in jectors , 2 2 m m s e e fig. 1 7 -4 5 part n u m b e r 4 0 2 0 0 9 2 5

P re s s u re re lie f v a lv e (s e t o f 5 ) fo r b lan k in g o ff th e d e live ry v a lv e s e e fig. 1 7 -3 2 p a rt n u m b e r 4 0 2 0 2 3 7 6

P re s s u re sp ill tim in g p u m ps e e fig. 1 7 -3 3part n u m b e r 4 0 2 0 2 3 6 3

A lte rn a tiv e p art n u m b e r 4 0 2 0 2 4 6 0 J .S . B a rn e s tim in g un it a v a ila b le from : P ro -H y d Im p o rt & E xp o rt (P ty ) Ltd.111 T e n th R o a d , K ew J o h a n n e s b u rg

A p ril '96

SECTION 18A-1Turbocharger

CONTENTS OF SECTION 18A

P a g e

IL L U S T R A T IO N K K K T U R B O C H A R G E R ........................................................................................................................................................................1 8 A -2

IL L U S T R A T IO N G A R R E T T T U R B O C H A R G E R ...........................................................................................................................................................1 8 A -3

S P E C IF IC A T IO N S - K K K 8c G A R R E T T ................................................................................................................................................................................18 A -4

IN T R O D U C T IO N ................................................................................................................................................................................................................................ 1 8 A -5

R E M O V A L ............................................................................................................................................................................................................................................... 1 8 A -6

M E A S U R IN G T U R B O C H A R G E R S H A F T E N D P L A Y .................................................................................................................................................1 8 A -7

M E A S U R IN G T U R B O C H A R G E R S H A F T S ID E P L A Y ............................................................................................................................................... 1 8 A -8

D IS M A N T L IN G ......................................................................................................................................................................................................................1 8 A -9

A S S E M B L Y ......................' .................................................................................................................................................................................................... 1 8 A -1 5

R E P L A C E M E N T ...............................................................................................................................................................................................................................1 8 A -2 2

IN T E R C O O L E R ................................................................................................................................................................................................................................ 1 8 A -2 5

April ‘96

Turbocharger 18A-2

K K K T U R B O C H A R G E R

1 T U R B IN E W H E E L A N D S H A F T A S S E M B L Y2 S E A L IN G R IN G S3 H E A T S H IE L D4 C IR C U P5 B E A R IN G6 C IR C L IP7 B E A R IN G H O U S IN G8 C IR C L IP9 B E A R IN G

1 0 C IR C L IP11 T H R U S T W A S H E R

12 T H R U S T B E A R IN G1 3 O IL D E F L E C T O R1 4 S P A C E R1 5 S E A L C A R R IE R /T H R U S T W A S H E R16 S E A L IN G R IN G S17 O -R IN G18 E N D P L A T E19 S O C K E T C A P S C R E W2 0 C O M P R E S S O R R O T O R W H E E L21 C O M P R E S S O R R O T O R W H E E L

R E T A IN IN G L O C K N U T

April '96

Turbocharger 18A-3

Garrett AiResearch

1 C O M P R E S S O R R O T O R W H E E L R E T A IN IN G N U T 11 S P R IN G L O C A T IN G P IN S2 C O M P R E S S O R R O T O R W H E E L 12 B E A R IN G H O U S IN G3 E N D P L A T E 13 C IR C L IP4 O -R IN G 14 B E A R IN G5 S E A L IN G R IN G 15 C IR C L IP6 S E A L C A R R IE R /T H R U S T W A S H E R 16 H E A T S H IE L D7 C IR C L IP 17 L O C K P L A T E8 B E A R IN G 18 B O L T9 C IR C L IP 19 S E A L IN G R IN G

1 0 T H R U S T B E A R IN G 2 0 T U R B IN E W H E E L A S S E M B L Y

April '96

Turbocharger 18A-4

S P E C IF IC A T IO N S F O R K K K T U R B O C H A R G E R

R o to r s h a ft - en d p la y 0 15 m m m a xs id e p l a y 0 ,4 5 m m m ax.run o u t 0 ,0 0 7 m m m ax.


E nd p la te ............................................................ 8-10 N mC o m p re s s o r ro to r w h e e l re ta in in g n u t.......................................... 1s t.s ta g e .................................................................................................................... 1 0 N m

2 n d s t a g e ............................................................................. a n g le o f ro ta tio n +60°

T u rb in e h o u s in g to c e n tre h o u s in g .........................................................................................................................................................................................2 0 N mC o m p re s s o r h o u s in g to c e n tre h o u s in g ................................................................................................................................................................................. 7 N mO il re tu rn M 8 - 2 5 N mO il s u p p ly M 8 - 2 5 N mO il su p p ly b a n jo b o lt ........................................................................................................................................................................................................................40 N mT u rb o c h a rg e r to e x h a u s t m a n ifo ld .......................................................................................................................................................................................... 65 N m

S P E C IF IC A T IO N S F O R G A R R E T T T U R B O C H A R G E R

R o to r s h a f t - en d p la y 0 ,1 0 m m m ax .s id e p l a y 0 ,7 5 m m m ax .run o u t 0 ,0 0 7 m m m ax .


E n d p la te ..........................................................................................................................................................................................................................................8 - 1 0 N mC o m p re s s o r ro to r w h e e l re ta in in g n u t..........................................................1s t s t a g e ........................................................................in itia l to rq u e 2 N m

2 n d s t a g e ............................................................. a n g le o f ro ta tio n 9 0 °

T u rb in e h o u s in g to c e n tre h o u s in g .......................................................................................................................................................................... 1 1 , 5 - 1 5 N mC o m p re s s o r h o u s in g to c e n tre h o u s in g ................................................................................................................................................................1 1 , 5 - 1 5 N mO il r e tu rn ..............................................................................................................................................; M 8 - 2 5 N mO il s u p p ly M 8 - 2 5 N mO il su p p ly b a n jo b o lt ...................................... 4 0 N mT u rb o c h a rg e r to e x h a u s t m a n ifo ld .......................................................................................................................................................................................... 6 5 N m

April '96

Turbocharger 18A-5

INTRODUCTION

T u rbocharger

T h e G a rre tt /A iR e s e a rc h a n d K K K tu rb o c h a rg e rs fo r in ternal co m b u stio n en g in e a p p lic a tio n c o m p ris e s o f a tu rb in e an d a ra d ia l c o m p re s s o r w h ic h u tilise a c o m m o n sh aft. T h e tu rb in e an d c o m p re s s o r w h e e ls a re m o u n te d a t o p p o s ite en d s of th e sh aft. T h e s h a ft is e n c lo s e d a n d su p p o rted by fu lly flo a tin g b earin g s in a hous ing . T h e tu rb in e an d c o m p re s s o r w h e e ls a re en c lo s e d in c a s t ho u s in g s .

A fte r th e e n g in e is s ta rte d th e flo w o f e x h a u s t g a s fro m th e e n g in e p a sse s th ro u g h th e tu rb in e ho u s in g an d c a u s e s th e sh aft a s s e m b ly to ro ta te . T h e c o m p re s s o r w h e e l, m o u n ted a t th e o p p o s ite en d o f th e sh a ft, d ra w s a m b ie n t a ir into th e c o m p re s s o r h o u s in g , c o m p re s s e s th e a ir an d d e live rs it to th e en g in e.

D u rin g o p e ra tio n th e tu rb o c h a rg e r resp o n d s to th e e n g in e load d e m a n d s by reac tin g to th e e x h a u s t g a s en erg y . A s th e p o w e r o f th e e n g in e in c re a s e s , th e s p e e d a n d o u tp u t o f th e ro ta ting a s s e m b ly in c re a s e s p ro p o rtio n a te ly .

T h e re m o v a l a n d re p la c e m e n t p ro c e d u re illu s tra ted sh o w s a ty p ic a l in s ta lla tio n , w h ich m a y v a ry d e p e n d in g on sp ec ifica tio n .

C h eck in g a T u rb och arger in a V eh ic le

D is c o n n e c t th e in le t du c t an d tu rn th e rotor. E n s u re e a s y an d u n ifo rm runn ing . If n e c e s s a ry tu rn b a c k a n d fo rth se vera l t im e s un til th e ro to r is fre e o f oil an d ca rb o n depo sits .

T h e tu rb o c h a rg e r h a s g y ro s c o p ic s ta b ilisa tio n an d runs in flo a tin g bearin g s . T ry to m o v e th e ro to r in a n d out. T h e en d p lay is se t c o rre c tly if v e ry little or no p la y ca n be fe lt. M o v e an d tu rn th e ro to r up an d d o w n in e ith e r d irec tio n . T h e s id e p lay is ad ju s te d co rre c tly if no sc ra p in g o ccurs .

T urboch arger Oil L eak s

T h e b e a rin g h o u s in g s on a ll ty p e s o f tu rb o c h a rg e rs used on A D E en g in e s a re s e a le d w ith oil co n tro llin g rin g s to p ro v id e a se a l b e tw e e n th e oil a n d th e a ir /e x h a u s t g as . T h e fu n ctio n o f th e s e s e a ls is b a s e d on th e p re s s u re bu ild up in th e c o m p re s s o r h o u s in g . T h e re co u ld , ho w ev er, b e a v a c u u m a t high e n g in e R P M w h ile c o a s tin g w h ic h w o u ld fa v o u r oil le a k a g e a n d oil c o a tin g o f th e in le t port. T h e a m o u n t o f oil lost in th is w a y is e x tre m e ly lo w a n d h a s no m e a s u ra b le in flu e n ce on th e e n g in e 's oil c o n s u m p tio n .

T h e tu rb o c h a rg e r sh o u ld n o t b e re m o v e d if oil co vered ports a re fo un d du rin g a se rv ice , a s long a s a n in sp e ctio n o f th e tu rb o c h a rg e r d id n o t s h o w a n y d e fec ts .

A n o th e r c a u s e fo r oil le a k s co u ld b e a d a m a g e d (d e fo rm e d ) o r c lo g g ed oil re tu rn p ipe. T h e re d u c e d c ro s s -s e c tio n a l s ize of th e p ip e w o u ld le a d to a n in c re a s e in res is tan ce , ca u s in g th e oil level in th e tu rb o c h a rg e r to rise a n d oil to le a k p a s t th e s e a ls on th e tu rb in e a n d c o m p re s s o r s id es. In th is c a s e c le an o r re p la c e th e oil re tu rn p ipe.

Fitting a R eco n d itio n ed T urbocharger

P rio r to fittin g th e tu rb o c h a rg e r th e in le t an d fla n g e d m an ifo ld a h e a d o f th e c o m p re s s o r, th e e x h a u s t m a n ifo ld a n d ex h au s t pipe, a s w e ll a s th e oil fe e d a n d retu rn p ip es m u s t b e in sp ected th o ro u g h ly fo r d irt an d d a m a g e . T h e p lugs on th e tu rb o c h a rg e r o p e n in g s sh o u ld o n ly b e re m o v e d ju s t b e fo re fitting . T h e b e arin g h o u s in g m u s t b e filled w ith c le a n e n g in e oil th ro u g h th e oil in le t p o rt p rio r to co n n ec tin g th e oil fe e d p ipe. D u rin g filling tu rn th e m o v in g p a rts by h a n d to co a t th e b e a rin g s w ith oil.

April '96

Turbocharger 18A-6

R E M O V A L , O V E R H A U L A N D R E P L A C E M E N T

1. D is c o n n e c t th e oil fe e d p ip e to th e tu rb o c h a rg e r, (F ig . 1 8 A -1 ).

2 . R e m o v e th e oil fe e d re ta in in g b ra c k e t, if fitted , an d lo osen th e b o tto m b a n jo u n ion , (F ig . 1 8 A -2 ).

3. D is c o n n e c t th e oil d ra in p ip e fro m tu rb o c h a rg e r to s u m p , (F ig . 1 8 A -3 ).

4 . If a h e a ts h ie ld is fitted , u n s c re w th e re ta in in g nuts an d re m o v e , (F ig . 1 8 A -4 ).

i

Fig. 18A -1

Fig . 1 8 A -2

F ig . 1 8 A -3

Fig. 18A-4

April ‘96

Turbocharger 18A-7

5. P rio r to re m o v a l m a rk th e position o f th e ex h au s t e lb o w in re la tio n to th e tu rb o c h a rg e r body, (F ig . 1 8 A -5 ).

6 . R e m o v e th e e x h a u s t p ip e e lb o w fro m th e tu rb o c h a rger, (F ig . 1 8 A -6 ).

7. U n s c re w th e m o u n tin g nu ts o f th e tu rb o c h a rg e r an d re m o v e th e tu rb o c h a rg e r fro m th e e x h a u s t m an ifo ld , (F ig . 1 8 A -7 ).

M easu rin g th e tu rb o ch a rg er sh a ft en d play.

1. C la m p th e tu rb o c h a rg e r, tu rb in e en d up, in a v ic e fitte d w ith so ft ja w s .

2 . M o u n t a d ia l g a u g e fitted w ith a m a g n e tic b a s e on to th e tu rb o c h a rg e r h o u s in g . P la c e th e d ia l g a u g e prob e a t th e en d o f th e tu rb in e s h a ft a n d se t th e g a u g e to “0", (F ig . 1 8 A -8 ).

3. P u s h th e tu rb in e s h a ft a g a in s t th e d ia l g a u g e pro b e a n d n o te th e re a d in g . E n s u re th a t th e re a d in g ag re e s w ith sp e c if ic a tio n s .

Fig. 18A-8

April ‘96

Turbocharger 18A-8

M e a s u r in g t h e tu r b o c h a r g e r s h a f t s id e p la y

A tten tion ! T h e s id e p la y sh o u ld b e m e a s u re d a t th e tu rb in eend only.

1. P u sh th e tu rb in e w h e e l to o n e s id e an d m e a s u re th e g a p b e tw e e n th e b la d e s a n d th e ho u s in g w ith a fe e le r g a u g e . N o te c le a ra n c e . (F ig . 1 8 A -9 ).

2. P u sh th e tu rb in e w h e e l in th e o p p o s ite d irec tio n and m e a s u re th e g a p b e tw e e n th e b la d e s an d th e housing w ith a fe e le r g a u g e . N o te c le a ra n c e .

3. T h e s u m o f th e tw o re a d in g s d iv id e d b y tw o rep rese n ts th e a v e ra g e s id e p lay . C o m p a re w ith sp ec ifica tio n s .

A t te n t io n ! M e a s u re m e n ts sh o u ld b e m a d e a t tw o d iffe ren tpoints.

H O L D IN G T O O L S

120

K K K H O L D IN G T O O L

A K N U R L IN G F ig .1 8 A -1 0 B A D A P T E D T O A V A IL A B L E R O T O R

J__orvf I- 1

§ ^ p4—2ft

Fig. 18A-11 GARRETT HOLDING TOOL

April '96

Turbocharger 18A-9

D IS M A N T L IN G

1. P rio r to re m o v a l m a rk p o s itions o f th e tu rb in e an d c o m p re s s o r h o u s in g s in re la tio n to th e c e n tre ho us ing , (F ig . 1 8 A -1 2 ) .

2 . B en d d o w n th e lo ck in g p la tes a n d u n s c re w th e bolts ho ld in g th e tu rb in e a n d c o m p re s s o r h o u s in g s to th e c e n tre h o u s in g , (F ig . 1 8 A -1 3 ) .

A ttention! T ig h t h o u s in g s ca n b e re m o v e d w ith a ru b b er

o r h id e fa c e d h a m m e r.

3. U n s c re w a n d re m o v e th e bo lts an d locking p la tes fro m th e c o m p re s s o r h o u s in g , (F ig . 1 8 A -1 4 ) .

4 . R e m o v e th e c o m p re s s o r ho u s in g fro m th e c e n tre h o us ing , (F ig . 1 8 A -1 5 ) .

A tten tion ! T ig h t h o u s in g s ca n b e re m o v e d w ith a ru b b er fa c e d h a m m e r .

Fig. 18A-15

April ‘96

Turbocharger 18A-10

5 R e m o v e th e O -r in g fro m th e c o m p re s s o r ho us ing . (G a rre tt ) , (F ig 1 8 A -1 6 ) .

6 . U s in g s p e c ia l ho ld in g to o l m a d e to illu s tra tio n F ig . 1 8 A -1 0, 1 8 A -1 1, c la m p th e tu rb o c h a rg e r s h a ft an d u n s c re w th e c o m p re s s o r ro to r w h e e l re ta in in g nut, (F ig . 1 8 A -1 7 ) .

7. R e m o v e th e o u te r O -r in g fro m th e b a ck in g p la te , (F ig . 1 8 A -1 8 ) . (K K K -tu r b o s ) .

8. W ith a B o s ch h o t a ir b lo w e r o r s im ila r h e a t so urce, h e a t th e c o m p re s s o r ro to r w h e e l, (F ig . 1 8 A -1 9 ) .

A t te n t io n ! D o n o t h e a t th e c o m p re s s o r ro to r w h e e l w ith a w e ld in g to rch .

F ig . 1 8 A -1 6

aFig. 1 8 A -1 7

Fig . 1 8 A -1 8

Fig. 18A-19

April '96

Turbocharger 18A-11

9. L ift o ff th e c o m p re s s o r ro to r w h e e l fro m th e tu rb o rotor sh aft.R e m o v e re ta in in g a lie n ca p s c re w s fro m co p ress o r end p la te , (F ig . 1 8 a -2 0 ) .R e m o v e c o m p re s s o r end p la te from c e n tre ho u s in g

U n iq u e to KKK tu rb o ch a ra ers:

10 . L ift o u t th e s e a l c a rr ie r /th ru s t w a s h e r fro m th e c o m p re s s o r e n d p la te , (F ig . 1 8 A -2 1 ) .

11 . R e m o v e th e in n e r O -r in g fro m th e en d p la te , (F ig . 1 8 A -2 2 ) .

12 . R e m o v e th e oil d e fle c to r fro m th e c e n tre h o us ing , (F ig . 1 8 A -2 3 ) .

F ig . 1 8 A -2 2

Fig. 18A-23

April '96

Turbocharger 18A-12

13. R e m o v e th e th ru s t b e a rin g , (F ig . 1 8 A -2 4 ).

14 . R e m o v e th e s p a c e r s le e v e , (F ig . 1 8 A -2 5 ) .

15. R e m o v e th e th ru s t w a s h e r , (F ig . 1 8 A -2 6 ) .

U nique to GARRETT tu rb o ch a ra ers:

16 . R e m o v e th e O -r in g fro m th e c e n tre ho us ing , (F ig .1 8 A -2 7 ) .

F ig . 1 8 A -2 4

Fig . 1 8 A -2 5

■III ASS

Fig. 1 8 A -2 6

Fig. 18A-27

April '96

Turbocharger 18A-13

17 . L ift o u t th e th ru s t b e a rin g an d th ru s t w a s h e r fro m th e c e n tre h o u s in g , (F ig . 1 9 -2 8 ) .

18 . R e m o v e th e s e a l c a rr ie r /th ru s t w a s h e r fro m th e th ru st b e a rin g , (F ig . 1 8 A -2 9 )

19 . R e m o v e th e s e a lin g ring fro m th e s e a l ca rrie r/th ru s t w a s h e r , (F ig .1 8 A -3 0 )

All T u rb och araers:

2 0 . Lift o ff th e c e n tre h o u s in g fro m th e tu rb o ro to r shaft, (F ig . 1 8 A - 3 1 ).

F ig . 1 8 A -2 8

Fig. 18A-31

April '96

Turbocharger 18A-14

2 1 . R e m o v e th e h e a t sh ie ld fro m th e tu rb o ro to r shaft, (F ig . 1 8 A -3 2 ) .

2 2 . R e m o v e th e b o tto m s e a lin g ring s fro m th e tu rb o ro tor sh a ft, (F ig . 1 8 A -3 3 ) .

2 3 . R e m o v e th e tu rb o -ro to r s h a ft a s s e m b ly a n d th e ho ld ing to o l c la m p fro m th e v ic e .

2 4 . R e m o v e th e s e a lin g rin g s fro m th e s e a l ca rrie r, (F ig . 1 8 A -3 4 ) .

2 5 . R e m o v e th e c irc lips re ta in in g th e tu rb o ro to r b e arin g s fro m th e c e n tre h o u s in g , (F ig . 1 8 A -3 5 ) .

Fig. 18A-35

April '96

Turbocharger 18A-15

2 6 . L ift ou t th e b e a rin g s an d re m o v e th e in n er circlips, (F ig . 1 8 A -3 6 ) .

A t te n t io n ! A ll 'p a r ts sh o u ld n o w b e w a s h e d in a su itab le c le a n in g flu id. D o no t u s e a b ra s iv e c le an in g m eth o d s w h ic h m a y d a m a g e o r d e s tro y m a c h in e d su rfaces . T h o ro u g h ly c le a n th e tu rb in e en d oil c a v ity in th e cen tre h o u s in g . R e m o v e a ll c a rb o n is e d oil.C h e c k th e tu rb in e ho u s in g an d ro to r b la d e s fo r cracks, s c o re m a rk s a n d fo re ig n pa rtic les . C h e c k bo th ro tors fo r

b e n t o r d a m a g e d b la d e s a n d s e a l ring s fo r w e a r. R e p la c e all w o rn p arts . E x a m in e m a tin g su rfa c e s fo r th e s e a l rings in th e c e n tre h o u s in g a n d b a c k p la te . E x a m in e th e sea l g ro o v e s in th e s h a ft a n d s e a l c a rr ie r fo r w e a r.

A S S E M B L Y

1. P la c e tu rb o ro to r s h a ft on a s u ita b le V -b lo ck , leve l w ith th e b e a rin g p o in ts a n d c h e c k th e s h a ft fo r p a ra lle l ru n n in g 1 0 m m fro m th e en d o f th e th re a d s . R e fe r to th e s p e c if ic a tio n s fo r m a x im u m p e rm is s ib le run out, (F ig . 1 8 A -3 7 ) .

2 . F it th e in n e r c irc lips a n d b e a rin g s to th e ce n tre ho using, (F ig . 1 8 A -3 8 ) .

3. In s e rt th e o u te r b e a rin g c irc lip s in th e c e n tre hous ing , (F ig . 1 8 A -3 9 ) .

A t te n t io n ! A lw a y s u s e n e w c irc lips a fte r a n ov erh au l.

Fig. 18A-39

April ‘96

Turbocharger 18A-16

4. C la m p th e ro to r s h a ft in a v ice.

5. F it th e s e a lin g rings to th e b o tto m o f th e ro tor s h a ft an d lu b rica te , (F ig . 1 8 A -4 0 ) .

Fig. 1 8 A -4 0

6 . F it th e h e a t sh ie ld o v e r th e tu rb o ro to r sh aft, (F ig . 1 8 A -4 1 ).

F ig .1 8 A -4 1

7. F it th e c e n tre h o u s in g o v e r th e tu rb o ro to r sh a ft. D o not d a m a g e th e s e a lin g ring s, (F ig . 1 8 A -4 2 ) .

F ig . 1 8 A -4 2

U nique to KKK tu rb o ch a ra ers:

8. F it th e in n e r th ru s t w a s h e r , (F ig . 1 8 A -4 3 ) .

Ill: /©=

Fig. 18A-43

April '96

Turbocharger 18A-T7

9. R e p la c e th e s p a c e r, (F ig . 1 8 A -4 4 ) .

10 . F it th e th ru s t b e a rin g o v e r th e re ta in in g pins, (F ig

1 8 A -4 5 ) .

11 . In s e rt th e o il d e fle c to r, (F ig . 1 8 A -4 6 ) .

1 2 . F it a n e w in n e r O -r in g to th e en d p la te , (F ig .1 8 A -4 7 ).

Fig. 18A-47

April '96

Turbocharger 18A-18

13. R e p la ce a nd lu b ric a te th e s e a lin g rin gs on th e seal c a rr ie r an d f it in to th e end p la te , (F ig . 18A -48).

F ig . 1 8 A -4 8

14 . F it th e en d p la te to th e c e n tre h o u s in g , (F ig . 1 8 A -4 9 ) .

■wi'

Fig . 1 8 A -4 9

15. In sert th e c a p s c re w s re ta in in g th e en d p la te to th e c e n tre h o u s in g a n d tig h te n to th e s p ec ified to rq u e , (F ig . 1 8 A -5 0 ) .

U nique to GARRETT T u rb och araers:

16. L u b ric a te a n d re p la c e th e s e a lin g ring s on th e s e a l c a rr ie r /th ru s t w a s h e r (F ig . 1 8 A -5 1 ).

F ig . 1 8 A -5 0

A 3 =

Fig. 18A-51

April '96

Turbocharger 18A-19

17 . F it th e th ru s t b e a rin g to th e s e a l c a rrie r/th ru s t w a s h e r an d s lid e o v e r th e tu rb o ro to r shaft. A lig n th e th ru st b e a rin g w ith th e re ta in in g pins, (F ig . 1 8 A -5 2 ).

18 . R e p la c e th e O -r in g a t th e to p o f th e c e n tre ho using, (F ig . 1 8 A -5 3 ) .

19 . L in e up th e s e a lin g ring on th e s e a l c a rrie r/th ru s t w a s h e r a n d fit th e e n d p la te , (F ig . 1 8 A -5 4 )

2 0 . In s e rt th e b o lts fitted w ith th e lo ck p la te s into th e en d p la te , (F ig . 1 8 A -5 5 ) .

F ig . 1 8 A -5 2

F ig . 1 8 A -5 3

F ig . 1 8 A -5 4

Fig. 18A-55

April '96

Turbocharger 18A-20

2 1 . T ig h te n th e bo lts to th e s p e c ifie d to rq u e an d se cu re th e lo ck p la te s , (F ig . 1 8 A -5 6 ) .

A H t u r b o c h a r a e r s

2 2 . H e a t th e c o m p re s s o r w h e e l w ith a B o sch h o t a ir b lo w er o r a lte rn a tiv e h e a t so u rc e , (F ig . 1 8 A -5 7 ) .

A t te n t io n ! D o n o t h e a t th e c o m p re s s o r w h e e l w ith a w e ld in g to rch .

2 3 . F it th e c o m p re s s o r w h e e l to th e tu rb o ro to r sh aft, (F ig . 1 8 A -5 8 ) .

2 4 . R e p la c e th e o u te r O -r in g on th e en d p la te , a p p ly p e tro le u m je l ly to a s s is t, (F ig . 1 8 A -5 9 ) .

F ig . 1 8 A -5 7

Fig . 1 8 A -5 8

Fig. 18A-59

Turbocharger 18A-21

2 5 . R e p la c e th e c o m p re s s o r w h e e l re ta in in g lock nut and

tig h te n to th e s p e c ifie d to rq u e . D o not bend th e shaft, (F ig . 1 8 A -6 0 ) .

A t te n t io n ! A lw a y s u s e a n e w lo ck nut

2 6 . M o u n t th e c e n tre h o u s in g in a v ic e an d tu rn th e ro tor s h a ft b y h a n d to c h e c k fo r fre e runn ing , (F ig . 1 8 A -6 1 ).

2 7 . F it th e c o m p re s s o r ho u s in g to th e ce n tre ho us ing , (n o te sc rib ed a s s e m b ly m a rk s ). R e p la c e th e bo lts an d re ta in ing c la m p s a n d tig h te n to th e sp ec ified to rq u e , (F ig . 1 8 A -6 2 ) .

2 8 . F it th e tu rb in e h o u s in g to th e c e n tre ho us ing (n o te sc rib ed a s s e m b ly m a rk s ), (F ig . 1 8 A -6 3 ) .

N o te : O n G a r re tt tu rb o c h a rg e rs e n s u re th a t a n e w O -r in g is fitted in th e c o m p re s s o r ho us ing .

April ‘96

Turbocharger 18A-22

2 9 . R e p la c e th e bo lts an d c la m p s , tig h ten to th e sp ec ified to rq u e an d bend o v e r th e lo ckin g p la tes , (F ig . 1 8 A -6 4 ).

A t te n t io n ! A lw a y s fit n e w lo ckin g p lates .

30 . T u rn th e tu rb o ro to r s h a ft b y h a n d an d c h eck fo r free runn ing .

31 . L u b ric a te b e a rin g s in th e c e n tre ho u s in g w ith en g in e oil, (F ig . 1 8 A -6 5 ) .

R ep lacin g th e tu rb o ch a rg er

1. M o u n t th e tu rb o c h a rg e r o n to th e e x h a u s t m an ifo ld . E n s u re th a t th e m a tin g s u rfa c e s o f fla n g e d a re a s a re c le a n an d fre e o f b u rrs o r h igh sp o ts , (F ig . 1 8 A -6 6 ) .

2 . F it th e e x h a u s t p ip e e lb o w to th e tu rb o c h a rg e r (n o te sc rib ed a s s e m b ly m a rk s ), (F ig . 1 8 A -6 7 ) .

F ig . 1 8 A -6 4

■III /B s

Fig. 1 8 A -6 5

Fig . 1 8 A -6 6

III U s

(Fig. 18A-67

April '96

Turbocharger 18A-23

M o u n t th e h e a t sh ie ld , if fitted , to th e tu rb o studs an d s e c u re w ith n e w s e lf locking nuts, (F ig . 1 8 A -6 8 ).

F ig . 1 8 A -6 8

4. In s e rt th e b a n jo bo lt co n n e c tin g th e tu rb o fe e d p ipe to th e oil p re s s u re g a lle ry on th e c y lin d e r b lock an d tig h te n th e b o lt to th e s p ec ified to rq u e , (F ig . 1 8 A -6 9 )

Fig. 1 8 A -6 9

5. T ig h te n th e tu rb o oil fe e d p ip e re ta in in g b ra c k e t to th e s p e c ifie d to rq u e , (F ig . 1 8 A -7 0 ) .

F ig . 1 8 A -7 0

6 . U s e a n e w g a s k e t a n d re p la c e th e to p oil fe e d p ipe, in sert th e bo lts a n d tig h te n to th e sp ec ified to rq u e , (F ig . 1 8 A -7 1 ) .

Fig. 18A-71

April '96

Turbocharger 18A-24

April '96

Turbocharger 18A-25

INTERCOOLER

D e p e n d in g on a p p lic a tio n a n d /o r re q u ire m e n t th e A D E 3 6 0 series en g in es a re bu ilt to a c c e p t a c h a rg e a ir cooler ( In te rc o o le r), m o u n te d b e tw e e n th e tu rb o c h a rg e r c o m p re s s o r hous ing an d in le t m an ifo ld .T h e in te rc o o le r re s e m b le s a c o o la n t ra d ia to r co re (s e e fig 1 8 A -1 1 8 ). U n d e r lo ad , a ir is c o m p re s s e d an d fo rc ed v ia th e in te rc o o le r in to th e c o m b u s tio n a re a by th e tu rb o ch arg er. D u rin g co m p re s s io n by th e tu rb o c h a rg e r th e a ir h e a ts up and ex p a n d s , c o n s e q u e n tly b e c o m in g less d ense . By d irec tin g th e ho t a ir th ro u g h an in te rc o o le r s o m e h e a t is re m o v e d . T h e e x p a n s io n o f th e c h a rg e d a ir is th e re fo re red u ced , w h ich m e a n s m o re a ir w ill b e fo rc ed into th e c o m b u s tio n a re a , th e in c re a s e d d e n s ity o f th e c h a rg e d a ir (o x y g e n ) a llo w s fo r m o re fuel to b e in jec ted , an d c o n s e q u e n tly m o re p o w er w ill be d e v e lo p e d .

1 m m Exhaust

2 E SSjifl C harg e air

M ain ten an ce

1. K e e p th e c o o le r e x te rn a lly c le a n a n d fre e fro m ob struc tio n w h ich m a y a ffe c t th e a ir flo w .2 . C h a rg e a ir le a k s w ill resu lt in lo ss o f po w er, th ere fo re :

All in d u c tio n tu b in g a n d h o s e jo in ts m u s t b e kep t tight.E n s u re th a t a ll m o u n tin g s a re s e c u re to p re v e n t v ib ra tio n s w h ich m a y c ra c k th e in te rc o o le r tu b es .P e r io d ic a lly in sp e c t th e in te rc o o ie r tu b e s fo r ho les d u e to co rros ion o r im p a c t by d eb ris .

3. In th e e v e n t o f d u st o r fo re ig n ob jec ts en te rin g th e induction s y s tem a n d /o r tu rb o c h a rg e r c o m p re s s o r w h e e l fa ilure , c le a n th e in d u c tio n tu b in g /h o s e s to a n d fro m th e in terco o ier. D is m a n tle an d c le a n th e in te rco o ie r. S e a le d un its th a t c a n n o t b e c le a n e d p ro p e rly sh ou ld b e rep la ced .

April '96

SECTION 18BPower Steering Pump

CONTENTS OF SECTION 18B

P a g e

IL L U S T R A T IO N ........................................................................................................................................................................................................................................18B

IN T R O D U C T IO N ................................................................................................................................................................................................................................ 1 8 B -3

S P E C IF IC A T IO N S ............................................................................................................................................................................................................................. 1 8 B -3

F A U L T F IN D IN G ..................................................................................................................................................................................................................................1 8 B -4

R E M O V A L O F T H E P O W E R S T E E R IN G P U M P :..........................................................................................................................................1 8 B -5

Z .F . H IG H P R E S S U R E P U M P

D IS M A N T L IN G O F T H E R O T O R A N D C A M R IN G .......................................................................................................................................................1 8 B -6

R E M O V A L O F T H E D R IV E S H A F T ........................................................................................................................................................................................ 1 8 B -7

R E M O V A L O F F L O W A N D P R E S S U R E R E S T R IC T IO N V A L V E ........................................................................................................................ 1 8 B -8

D IS M A N T L IN G , IN S P E C T IO N A N D A S S E M B L Y O FF L O W A N D P R E S S U R E R E S T R IC T IO N V A L V E ..........................................................................................................................................................1 8 B -8

R E P L A C E M E N T O F F L O W A N D P R E S S U R E R E S T R IC T IO N V A L V E ...........................................................................................................1 8 B -9

P R E -A S S E M B L Y O F P U M P H O U S IN G .............................................................................................................................................................................. 1 8 B -9

A S S E M B L Y A N D R E P L A C E M E N T O F D R IV E S H A F T ........................................................................................................................................... 1 8 B -1 0

R E P L A C E M E N T O F D R IV E E N D F A C E P L A T E ..........................................................................................................................................................1 8B -11

R E P L A C E M E N T O F C A M R IN G A N D R O T O R .............................................................................................................................................................1 8B -11

R E P L A C E M E N T O F E N D F A C E P L A T E A N D C O V E R ...........................................................................................................................................1 8 B -1 2

V IC K E R S H IG H P R E S S U R E P U M P

D IS M A N T L IN G A N D R E M O V A L O F R O T O R A N D C A M R IN G ..........................................................................................................................1 8 B -1 3

R E M O V A L A N D D IS M A N T L IN G O F V O L U M E C O N T R O LA N D P R E S S U R E R E L IE F V A L V E ........................................................................................................................................................................................ 1 8 B -1 4

R E P L A C E M E N T O F D R IV E S H A F T A N D S E A L ..........................................................................................................................................................1 8 B -1 6

R E P L A C E M E N T O F R O T O R A N D C A M R IN G .............................................................................................................................................................1 8 B -1 7

R E P L A C IN G T H E P U M P .......................................... 1 8 B -1 8

SPECIAL TOOLS................................................................................................................................................................................. 18B-20

April '96

SECTION 18BPower Steering Pump

Z F -R O T A R Y P U M P T Y P E 7 6 7 3

1 N U T2 S P R IN G W A S H E R3 D R IV E S H A F T4 W O O D R U F F K E Y5 C IR C L IP6 B A L L B E A R IN G7 C IR C L IP8 S H A F T S E A L9 N E E D L E B E A R IN G

10 H O U S IN G11 B L A N K IN G P L U G12 S E A L IN G R IN G13 P H IL L IP S S C R E W14 ID E N T IF IC A T IO N P L A T E15 F IT T E D P IN16 O -R IN G

1 7 O -R IN G1 8 F R O N T P L A T E , D R IV E -E N D1 9 R O T O R2 0 V A N E21 C A M R IN G2 2 O -R IN G2 3 F R O N T P L A T E C O V E R -E N D2 4 S P R IN G2 5 O -R IN G2 6 C O V E R2 7 H O O K E D C IR C L IP2 8 T H R O T T L E IN S E R T2 9 V A L V E P IS T O N C O M P L E T E3 0 P R E S S U R E R IN G31 S E A L IN G R IN G3 2 B L A N K IN G P L U G

April '96

Power Steering Pump 18B-3


D e p e n d in g on a p p lic a tio n th e A D E 3 6 0 series en g in es can be fitted w ith e ith e r o f tw o ty p e s o f ro ta ry p o w e r s teering

p u m p s , bo th o f w h ic h o p e ra te a s fo llow s:

W h e n th e d rive s h a ft an d its ro to r a re tu rn ed , th e v a n e s a re gu ided in s lo ts an d be ing ra d ia lly m o b ile , a re p res sed a g a in s t th e g u id e p a rt o f th e c a m ring b y th e ac tio n o f ce n trifu g a l fo rc e an d oil p ressu re . T w o s u c c e s s iv e v a n e s a re c la s s e d as a cell (a to ta l o f 1 0 ). T h e ir la te ra l m o v e m e n t is res tric ted b y th e p re s s u re p la tes . E a c h ce ll d e liv e rs th e m a x im u m effec tive v o lu m e tw ic e p e r revo lu tio n . T h e su ctio n an d p re s s u re c h a m b e rs a re a rra n g e d so th a t th e h y d ra u lic an d ra d ia l fo rces ac tin g on th e ro to r w ill n e u tra lis e e a c h o ther. T h e co v e r en d fron t p la te an d th e d rive en d fro n t p la te a re p ro v id e d w ith four g ro o v e s so th a t th e p re s s u ris e d oil re a c h e s th e in tern a l fa c e o f th e p u m p v a n e s , w h ic h w ill th e n b e s u p p o rted by th e ce n trifu g a l fo rc e . F ro m th e p re s s u re c h a m b e r th e oil tra v e ls th ro u g h ho les to th e flo w restric tin g v a lv e , a n d by w a y o f a th ro ttle res tr ic tio n to th e p re s s u re line. T h e red u ced p res su re b eh in d th e th ro ttle restric tion is tra n s m itte d v ia ho les to th e s p rin g - lo a d e d en d o f th e flo w restric ting p iston an d th e re fo re on to th e re lie f va lve .

In c re a s in g th e s p e e d o r p u m p d e liv e ry w ill p ro d u c e a g ro w in g p res su re d rop b eh in d th e th ro ttle res tr ic to r an d a ls o a g a in s t th e sp rin g e n d o f th e v a lv e p is ton . W h e n th e h y d rau lic p o w e r (p re s s u re d iffe ren tia l t im e s p iston a r e a ) e x c e e d s th e spring fo rce , th e p is to n w ill m o v e to w a rd s th e sp rin g an d th e oil d e live red in e x cess w ill flo w th ro u g h th e n o w e x p o s ed ejectio n ho le in to th e su c tio n d u c t o f th e p u m p . A s a resu lt, an a lm o s t c o n s ta n t oil flo w fo r th e s teerin g g e a r is p ro v id e d th ro u g h o u t th e e n tire s p e e d ran g e .


P u lle y to p u m p s h a f t ....................................................................................................M 1 4 x 1 ,5 ................................................. 8 0 N mC o v e r to p u m p h o u s in g 3 5 to 4 0 N mP u m p b ra c k e t to fu e l filte r b r a c k e t ....................................................................... M 1 0 .............................................................. 4 0 N mA d ju s tin g b o lt to w a te r p u m p .................................................................................. M 1 0 ...............................................................4 0 N mA d ju s tin g b o lt to b ra c k e t.............................................................................................M 1 2 x 1 ,5 ................................................. 5 0 N m

V -belt te n s io n for 12 ,5 m m w id e b e lts

N e w V -b e l t .....................»..................................................................................... ..................................................................................... 4 0 to 4 5 k.qA fte r ru n -in p e r io d ...... *.................................................................................... ..................................................................................... 3 0 to 4 0 kgU s e d V -b e lt ........................................................................................................... ..................................................................................... 3 0 to 4 0 kg

April ‘96


V ic k e r s H ig h P r e s s u r e O il P u m p V T 2 7

F a u lt f in d in g

Problem Possible Cause RemedyP u m p is n o t d e l iv e r in g P u m p ru nn ing in w ro n g d irec tion C h a n g e d irec tio n o f ro ta tion

P u m p d rive s h a ft s h eared V -b e lt s lips o r is torn

R e m o v e th e p u m p to d e te rm in e th e e x te n t o f th e d a m a g e an d R e p la c e d a m a g e d parts

F lo w restric tion , v a lv e b inds D is m a n tle th e p u m p an d c le a n th e v a lv e . R e in sta ll v a lv e p is ton a n d c h e c k fo r e a s e o f o p era tio n . S lig h t roug h sp o ts ca n b e re m o v e d by lap p in g . D o no t g rin d o r c h a m fe r c o n tro l ed g es N o refin ish in g is p e rm itte d on v a lv e bo re . All p a rts m u s t b e c le a n e d prio r to a s s e m b ly . T h e s y s te m sh o u ld b e th o ro u g h ly flu s h e d a n d filled w ith c le a n oil.

V a n e s b ind in ro to r s lo ts R e m o v e th e p u m p an d c h e c k th e ro to r s lo ts fo r dirt, a b ra s iv e s a n d sw arf. C le a n ro to r an d v a n e s . D u rin g a s s e m b ly c h e c k th e v a n e s fo r e a s e o f o p eratio n .

O il v is c o s ity to o high. P u m p c a n n o t su ck

U s e oil o f c o rre c t v is co s ity .

In le t p ip es p a rtia lly b locked. D ra in th e oil fro m th e s y s te m . F lu sh all p ipes . Fill th e sy s tem w ith fresh oil in a c c o rd a n c e w ith rec o m m e n d a tio n s .

T a n k v e n t c lo g g ed .In le t filte r c o n ta m in a te d .

R e m o v e ta n k c o v e r a n d c le a n . C h e c k th e s y s te m filte r o r in ta k e filte r fo r c lo g g in g . If th e in ta k e filter is c lo g g ed , d ra in th e s y s te m , flu sh a n d refill.

E x c e s s iv e p u m p n o is e In ta k e p ip e p a rtia lly o r c o m p le te ly c lo g g ed . F ilte r c lo gg ed .

T h e p u m p sh o u ld b e a b le to s u c k w ith o u t res tric tion to p re v e n t ca v ita tio n . D ra in th e sy s tem , c le an th e in ta k e p ip e a n d filter. F ill up w ith re c o m m e n d e d oil.

L e a k in g in le t p ip e co nn ections . C h e c k by p o uring oil on co n n e c tio n s . N o te th e c h a n g e in p u m p no ise , tig h te n c o n n ec tio n s .

L e a k in g s h a ft sea ls . R e p la c e in a c c o rd a n c e w ith in s tru ctio n s

M is a lig n m e n t o f s h a ft co up ling . In sp e c t th e s h a ft b e a rin g a n d oil s e a l fo r p o ss ib le fa u lts , re p la c e a s n e c e s s a ry . R e a lig n sh aft.

C o n ta in e r s e a l leak in g . R e p la c e th e c o n ta in e r c o v e r s e a l, tig h te n p ip e to ta n k co n n ec tio n s

April '96

Power Steering Pump 18B-5REMOVING AND REPLACING THE STEERING PUMP

R em o v in g th e pum p

1. L o o s en th e c la m p bo lt o f th e V -b e lt ad ju s ter, (F ig 1 8 B -1 ).

2 . S la c k e n o ff th e V -b e lt a d ju s te r fro m th e pu lley , (F ig . 1 8 B -2 ).

3. U n s c re w a n d re m o v e th e b o tto m p u m p m o u n tin g reta in in g bolt, (F ig . 1 8 B -3 ).

4 . C la m p th e p u m p d r iv e p u lley in a v ic e , fitted w ith so ft ja w s , u n s c re w th e p u lle y re ta in in g n u t a n d re m o v e th e pu lley , (F ig . 1 8 B -4 )

Fig 18B-1

Fig. 1 8 B -2

Fig. 1 8 B -3

Fig. 18B-4

April '96


5. U n s c re w th e bo lts re ta in in g th e m o u n tin g b ra c k e t to th e p u m p a n d re m o v e th e b ra c k e t, (F ig . 1 8 B -5 ).

DISMANTLING

R em oval o f R otor and C am R ing ZF High P r e ssu r e V an e P um p

1. R e m o v e th e c irc lip fro m th e g ro o v e in th e p u m p hous ing

(F ig . 1 8 B -6 ).

2. R e m o v e th e co ver, sp rin g a n d c o v e r en d p la te fro m th e

ho u s in g , (F ig . 1 8 B -7 ) .

3. T ilt th e p u m p b o d y a n d re m o v e c a m ring a n d rotor, (F ig . 1 8 B -8 ) .

Fig. 1 8 B -5

F ig. 1 8 B -7

Fig. 18B-8

April '96


R em o v in g th e d rive sh a ft

4 . R e m o v e th e circ lip , (F ig . 1 8 B -9 ).

5. W ith a R u b b e r o r p la s tic h a m m e r k n o ck th e d rive s h a ft fro m th e h o u s in g , (F ig . 1 8 B -1 0 ) .

6 . K n o c k th e d r iv e en d fa c e p la te fro m th e hous ing .

7. R e m o v e th e v o lu m e co ntro l v a lv e .

8. W ith a s u ita b le p u n c h k n o ck th e n e e d le b e a rin g an d d rive

s h a ft s e a l fro m th e h o u s in g , (F ig . 1 8 B -1 1 ) .

9. R e m o v e th e O -r in g s fro m th e ho u s in g , th e h o llo w pin an d d riv e en d fa c e p la te .

10 . A fte r re m o v in g th e c irc lip th e b earin g ca n b e p res sed fro m

th e d r iv e sh a ft, (F ig . 1 8 B -1 2 ) .

F ig . 1 8 B -9

Fig. 1 8 B -1 0

■in ra~

II M B S

Fig. 1 8 B -1 1

Fig. 18B-12

April '96


R e m o v in g th e F lo w a n d P r e s s u r e R e s t r ic t io n V a lv e

o f th e Z .F . H ig h P r e s s u r e V a n e P u m p

1. R e m o v e th e s c re w p lug fro m th e h o us ing , (F ig . 1 8 B -1 3 ).

2 . R e m o v e th e sp rin g a n d v a lv e p is to n fro m th e ho using bore

D ism an tlin g , In sp ec tio n and A sse m b ly o f th e F low and P r e s su r e R estr ic tio n V alve

1. C h e c k th e p re s s u re a n d flo w res tric tio n v a lv e fo r s c o re m a rk s an d w e a r. T h e f lo w co n tro l p is to n sh o u ld n o t b ind in th e ho u s in g b o re . C h e c k th e ite m n u m b e rs on th e ho us ing fa c e an d th e p iston to e n s u re m a tc h in g p arts a re used,(F ig . 1 8 B -1 4 ) .

2. U n s c re w th e v a lv e s e a t s c re w fro m th e p re s s u re restric tion v a lv e (d o n o t u s e a v ic e ). E n s u re th a t n o n e o f th e w a s h e rs , th e ba ll, th e sp rin g g u id e a n d c o m p re s s io n sp rin g s a re lost. T h e th ic k n e s s o f th e w a s h e r is critica l fo r th e re s p o n s e ra n g e o f th e p re s s u re re lie f v a lv e . N e w w a s h e rs m u s t b e fittedto p re v e n t th e p o s s ib ility o f d a m a g e , (F ig . 1 8 B -1 5 ) .

3. C le a n th e c o n tro l v a lv e an d th e v a lv e s c re w a n d b lo w ou t w ith

c o m p re s s e d air. R e in s e rt th e c o m p re s s io n sp rin g , g u id e pin an d ba ll. S c re w th e v a lv e ,s e a t s c re w in to th e co ntro l p iston, to g e th e r w ith th e p re v io u s ly in s ta lle d w a s h e rs .

Fig. 1 8 B -1 3

Fig. 1 8 B -1 5 ______________________________________________1 VALVE PISTON2 COMPRESSION SPRING PRESSURE RELIEF VALVE3 SPRING GUIDE PIN4 VALVE BALL5 ADJUSTING W ASHERS6 VALVE SEAT SCREW7 SPRING VOLUME CONTROL VALVE8 SCREW PLUG W ITH SEALING WASHER

April '96


R e p la c e m e n t o f F lo w a n d P r e s s u r e R e s t r ic t io n V a lv e

4 . In s e rt a s s e m b le d v a lv e p iston into th e bore. C h e c k for c o rre c t to le ra n c e , (F ig . 1 8 B -1 6 ) .

5 . S lid e th e c o m p re s s io n sp rin g o n to th e v a lv e p iston an d s c re w th e b la n k in g p lug in to th e th re a d h o le w ith th e se a lin g w a s h e r p la c e d u n d e rn e a th , (F ig . 1 8 B -1 7 ) .

P r e -a s s e m b ly o f P u m p H o u s in g

N o te : P rio r to a s s e m b ly c le a n all p a rts , m o is ten s ligh tly w ith A T F oil a n d re p la c e all s e a ls a n d O -rin g s .

1. W ith s u ita b le m a n d re l press th e n e e d le b e a rin g into th e

h o u s in g , (F ig . 1 8 B -1 8 ) .

T h e fa c e e n d o f th e n e e d le b e a rin g m u s t b e 3 7 ,0 to 3 7 ,2 m m fro m th e fa c e e n d o f th e ho u s in g , (F ig . 1 8 B -1 9 ) .

N o te : T h e n e e d le b e a rin g is in s ta lled o n ly in p u m p s w ith V -b e lt drive .

Fig. 18B-19


2. W ith a m a n d re l p res s th e s h a ft s e a l into th e ho using. F it th e s e a l w ith b e a rin g g re a s e b e tw ee n th e sea lin g lips, (F ig . 1 8 B -2 0 ) .

3. S c re w th e p lug in to th e h o u s in g an d tig h ten .

4. F it an O -r in g in to th e b o tto m g ro o v e o f th e ho us ing .

5. In sert a h o llo w pin in to th e h o le p ro v id ed , (F ig . 1 8 B -2 1 ) .

A sse m b ly and R e p la c e m e n t o f th e D rive S h aft

6 . P re s s th e ba ll b e a r in g o n th e d r iv e s h a ft a n d re p la c e th e circlip . F it th e w o o d ru ff key, (F ig . 1 8 B -2 2 ) .

7 . In sert th e p re -a s s e m b le d d r iv e s h a ft in to th e ho u s in g until th e ba ll b e a r in g res ts a g a in s t th e ho u s in g fla n g e ,(F ig . 1 8 B -2 3 ) .

LL| ig. 1 8 B -2 2

Fig. 18B-23

April '96


8. In sert th e circ lip re ta in in g th e ba ll b e arin g , (F ig . 1 8 B -2 4 )

R e p la cem en t o f th e D rive End F a ce P late

9. In s e rt th e O -r in g in to th e g ro o v e in th e n e c k o f th e

fa c e p la te .

10 . S lid e th e d r iv e en d p la te o n to th e h o llo w pin a n d press w ith th e n e c k in to th e h o u s in g , (F ig . 1 8 B -2 5 ) .

R e p la cem en t o f th e C am R ing and R otor

11 . In s e rt O -r in g (1 ) in to th e g ro o v e in th e hous ing , (F ig . 1 8 B -2 6 ) .

12 . In s e rt th e c a m ring . T h e s m a lle r h o le lo ca te s th e ho llow

pin. T h e c a s t h a lf a r ro w in d ic a te s th e d riv ing d irec tio n o f th e p u m p , (F ig . 1 8 B -2 7 ) .

April '96


13 . F it th e ro to r w ith th e s m o o th b o re on th e d rive shaft, (F ig . 1 8 B -2 8 )

14 . In sert th e te n v a n e s w ith th e ro u n d e d -o ff o u te r s u rfa c e s fa c in g th e c a m ring in to th e slo ts o f th e rotor, (F ig . 1 8 B -2 9 ) .

R ep la cem en t o f th e End F a ce P la te and C over

15 . F it th e c o v e r en d o n to th e c a m ring , a s sh ow n . T h e h o llo w pin fits in o n e o f th e s m a lle r ho les ,(F ig . 1 8 B -3 0 ) .

16 . In sert th e O -r in g , (F ig . 1 8 B -3 1 ) .

F ig . 1 8 B -2 8

Fig . 1 8 B -2 9

ii » =

Fig . 1 8 B -3 0

Fig. 18B-31

April '96


17 . In s e rt th e sp rin g in to th e b o re o f th e c o v e r en d plate. P o s itio n th e c o v e r w ith th e re c e s s in w ard s an d push in to th e h o u s in g until th e c irc lip ca n be in serted ,(F ig . 1 8 B -3 2 ) .

18. In s e rt th e flo w a n d p re s s u re res tric tio n va lve .

V ick ers High P r e ssu r e Oil P u m p VT27 D ism a n tlin g -R em o v a l o f R otor and C am Ring

1. R e m o v e th e s c re w s on th e p u m p ho u s in g to w h ich th e h o u s in g c o v e r is co n n e c te d ; re m o v e th e p u m p hous ing .

2 . R e m o v e th e sp rin g fro m th e th ru s t p la te . M a rk th e th ru s t p la te , c a m ring a n d h o u s in g c o v e r to e n s u re th e p arts a re co rre c tly a lig n e d on a s s e m b ly (re fe r to a rro w s ),(F ig . 1 8 B -3 3 )

3. R e m o v e th e th ru s t p la te fro m th e lo catin g p ins and ta k e o ff th e c a m ring, (F ig . 1 8 B -3 4 ) .

F ig . 1 8 B -3 3

1 O -R IN G 4 C A M R IN G2 T H R U S T P L A T E 5 O -R IN G3 S P R IN G 6 H O U S IN G C O V E R

2 T H R U S T P L A T E 6 H O U S IN G C O V E R4 C A M R IN G 7 M A R K IN G L IN E

April ‘96

4. R e m o v e ro tor w ith p u m p v a n e s fro m th e d rive sh aft sp lines , (F ig . 1 8 B -3 5 ) .


5. R e m o v e O -r in g s ite m s 1 & 5 , (F ig . 1 8 B -3 6 ) .

6 . R e m o v e th e v o lu m e co n tro l v a lv e .

7. C le a n all p a rts th o ro u g h ly a n d rinse.

Fig. 1 8 B -3 54 C A M R IN G A O IL IN F L O W F R O M6 H O U S IN G C O V E R S U P P L Y C O N T A IN E R7 M A R K IN G L IN E B H Y D R A U L IC O IL O U T 8 L O C A T IN G P IN F L O W O N C A M R IN G9 R O T O R C IN T A K E B O R E S

10 V A N E S

Fig. 1 8 B -3 61 O -R IN G 4 C A M R IN G2 T H R U S T P L A T E 5 O -R IN G3 S P R IN G 6 H O U S IN G C O V E R

R e m o v a l a n d D is m a n t l in g o f V o lu m e C o n tr o l a n d P r e s s u r e R e l ie f V a lv e

1. K n o c k h o llo w pin fro m th e p u m p ho us ing .

2. R e m o v e th e b la n k in g c o v e r o f th e v o lu m e contro l v a lv e a n d th e c o m p re s s io n sp rin g fro m th e p u m p h o u s in g , (F ig . 1 8 B -3 7 ) .

N o te : C a u tio n ! T h e c o m p re s s io n sp rin g m a y p u sh o ff th e b lan k in g c o v e r a n d th e v o lu m e c o n tro l v a lv e a fte r re m o v in g th e h o llo w pin. L o o s e n th e b la n k in g c o v e r w ith lig h t h a m m e r b low s if it sh o u ld re m a in in th e h o u s in g . D o no t d a m a g e th e v o lu m e c o n tro l v a lv e .

Fig . 1 8 B -3 71 B L A N K IN G C O V E R 4 V O L U M E C O N T R . V A L V E2 H O L L O W P IN 5 S P R IN G S3 O -R IN G 6 P U M P H O U S IN G

April '96


3. C la m p th e v o lu m e co ntro l v a lv e a t Its un grou nd end in a v ic e a n d u n s c re w th e v a lv e s c re w o f th e p ressure re lie f v a lv e . E n s u re th a t no a d ju s tin g sc rew s a re lost. R e m o v e th e v a lv e an d sp rin g fro m th e v o lu m e contro l v a lv e . (F ig . 1 8 B -3 8 ) .

4 . P rio r to re p la c e m e n t c h e c k th e g ro u n d s u rfa c e o f th e v o lu m e co ntro l v a lv e an d th e b o re in th e p u m p housing fo r w e a r an d d a m a g e . If th e s u rfa c e s a re sh o w in g score m a rk s re p la c e th e c o m p le te oil p u m p . N e v e r re p la c e th e v o lu m e c o n tro l v a lv e only.

F ig . 1 8 B -3 8

1 B L A N K IN G C O V E R W IT H O -R IN G2 V O L U M E C O N T R O L V A L V E3 S P R IN G F O R P R E S S U R E R E L IE F V A L V E4 V A L V E C O N E5 A D J U S T IN G W A S H E R6 V A L V E S C R E W7 S P R IN G F O R V O L U M E C O N T R O L V A L V E

S p e c ia l T ool

T o b e m a n u fa c tu re d , (F ig . 1 8 B -3 9 ) .

A IN S T A L L A T IO N T O O L B IN S T A L L A T IO N T O O L C IN S T A L L A T IO N S L E E V E

Fig.18B-39


R e p la c e m e n t o f D r iv e S h a f t a n d S e a l in g R in g

1. R e m o v e th e p u m p h o u s in g a n d press th e d rive sh aft fro m th e h o u s in g co ver. P a y a tte n tio n to th e shell h a lv e s ( ite m 1 0 ), (F ig . 1 8 B -4 0 ) .

2 . W ith a s c re w d r iv e r lift th e oil s e a l fro m th e hous ing cover.

3 . P la c e bo th sh e ll h a lv e s on th e d r iv e sh aft, th e n press th e d rive s h a ft in to th e h o u s in g co ver, (F ig . 1 8 B -4 1 ) .

N o te : T h e sh e ll h a lv e s d e te rm in e th e en d p lay o f th e d rive sh a ft w h ic h is 0 ,7 m m m a x . fo r n e w h igh p re s s u re oil p u m p s an d sh o u ld n o t b e m o re th a n 1 m m fo r used p u m p s .R e p la c e th e h igh p re s s u re oil p u m p if th e en d p la y is h igher.

4 . U s e th e in s ta lla tio n to o l to p re s s th e bu sh into th e hous ing , (F ig . 1 8 B -4 2 )

Fig. 1 8 B -4 01 O -R IN G 8 O -R IN G2 P U M P H O U S IN G 9 B E A R IN G B U S H3 T H R U S T P L A T E 1 0 S H E L L H A L F4 O IL G U ID E P L A T E 11 D R IV E S H A F T5 S P R IN G 12 B U S H6 C A M R IN G 13 O IL S E A L7 R O T O R W IT H P U M P V A N E S 1 4 H O U S IN G C O V E R

1 0 S H E L L H A L F11 D R IV E S H A F T1 4 H O U S IN G C O V E R

Fig. 1 8 B -4 2 1 2 B E A R IN G B U S H 14 H O U S IN G C O V E R B IN S T A L L A T IO N T O O L

.April '96


R e p la c e th e a s s e m b ly s le e v e on th e d rive s h a ft and w ith th e in s ta lla tio n to o l p ress th e oil sea l into th e ho u s in g , (F ig . 1 8 B -4 3 ) .

R e p la cem en t o f R otor and C am Ring

1. M o is te n a ll p a rts w ith A T F oil.

2 . In s ta ll v o lu m e c o n tro l v a lv e .

3. P la c e th e ro to r on th e d r iv e s h a ft so th a t th e co u n te rs u n k en d o f th e sp lin e d b o re fa c e s th e ho us ing cover.

4 . P la c e th e c a m ring on th e fitted p ins so th a t th e re s p e c tiv e m a rk in g s on th e h o u s in g c o ver an d on th e c a m ring a re a lig n e d , (F ig . 1 8 B -4 4 ) .

N o te : W h e n a n e w c a m ring is in s ta lled , it m u s t be p o s itio n e d so th a t th e h y d ra u lic oil b o re s a re a c c u ra te ly lo c a te d a b o v e th e re c e s s e s in th e ho u s in g cover,(ite m 4 & 5 F ig . 1 8 B -4 5 ) .

5. In s e rt p u m p v a n e s in to s lo ts o r ro to r so th a t th e ro u n d e d e n d s a re fa c in g o u tw a rd s to w a rd th e c a m ring.

6 . P o s itio n th e th ru s t p la te o v e r th e c a m ring, en surin g m a rk in g s a re a lig n e d ,

N o te : T h e o u tle t h o les fo r th e h y d ra u lic oil sh ou ld b e a b o ve th e h y d ra u lic oil b o re s ( ite m 5 ) o f th e c a m ring.

Fig. 1 8 B -4 3 11 D R IV E S H A F T13 O IL S E A L14 H O U S IN G C O V E R

C A S S E M B L Y S L E E V E A IN S T A L L A T IO N T O O L

Fig. 1 8 B -4 4 6 C A M R IN G

11 D R IV E S H A F T 1 4 H O U S IN G C O V E R

1 5 F IT T E D P IN16 M A R K IN G L IN E

Fig 1 8 B -4 5A O IL IN F L O W F R O M S U P P L Y C O N T A IN E R B H Y D R A U L IC O IL O U T F L O W F R O M C A M R IN G

R O T O R P U M P V A N EH Y D R A U L IC O IL U N D E R P U M P V A N E R E C E S S O N H O U S IN G F O R IN L E T O F H Y D R . O IL IN T O B O R EO IL B O R E 7 IN T A K E B O R E SC A M R IN G 8 D R IV E S H A F T

April ‘96


R e p la c in g th e P u m p

1. F it th e m o u n tin g b ra c k e t to th e p u m p , in sert bo lts an d tig h ten to th e s p e c if ie d to rq u e , (F ig . 1 8 B -4 6 ) .

2 . F it th e p u lle y to th e p u m p , c la m p th e p u lley in a v ic e fitted w ith so ft ja w s , re p la c e th e re ta in in g nu t an d tig h te n to th e s p e c if ie d to rq u e , (F ig . 1 8 B -4 7 ) .

3. F it th e p u m p to th e m o u n tin g in th e c y lin d e r b lock , in sert th e b o tto m re ta in in g bolt. D o no t tig h ten , (F ig . 1 8 B -4 8 ) .

4. F it th e V -b e lt to th e p u lley , (F ig . 1 8 B -4 9 ) .

Fig. 1 8 B -4 6

mi

F ig . 1 8 B -4 7

III!

F ig . 1 8 B -4 8

\ r ■im rasFig. 18B-49

April '96


5. In s e rt th e V -b e lt a d ju s te r c la m p bolt. D o no t tig hten , (F ig . 1 8 B -5 0 ) .

6 . U s e s p e c ia l to o l 4 0 2 0 2 3 2 1 an d a d ju s t th e V -b e lt ten s io n to 4 0 -5 0 kg (n e w b e lts ), run th e e n g in e fo r 1 0 -1 5 m in. a n d re -c h e c k th e te n s io n , w h ic h sh ou ld b e 3 0 -4 0 kg. A d ju s t to 3 0 -4 0 kg if th is fig u re is no t reach ed .P o s itio n th e te n s io n g a u g e on th e be lt w ith th e fla n g e p a ra lle l a g a in s t th e be lt ed g e . G ra d u a lly a p p ly p res su re to th e p re s s u re p a d . W h e n a “c lick” is h e a rd o r fe lt, stop an d re m o v e th e g a u g e . T u rn th e g a u g e s id e w a y s and ta k e a re a d in g a t th e sp o t w h e re th e in d ica to r a rm in te rs e c ts th e s c a le , (F ig . 1 8 B -5 1 ) .

7. T ig h te n th e lo ck nu t on th e V -b e lt ad ju s ter, (F ig . 1 8 B -5 2 ) .

8. T ig h te n th e c la m p bo lt on th e V -b e lt ad ju s ter, (F ig . 1 8 B -5 3 ) .

April '96

9. T ig h te n th e b o tto m p u m p re ta in in g bolt, (F ig . 1 8 B -5 4 ).


SPECIAL TOOLS FOR SECTION 18B

O B T A IN A B L E F R O M : G R U N D Y T E C H N IF O R M , B U R M A N R O A D , D E A L P A R K , P O R T E L IZ A B E T H 6 0 0 1

T E L : (0 4 1 ) 4 3 -2 2 9 9 , F A X : (0 4 1 ) 4 3 -2 2 2 4

. April ‘96

SECTION 18C-1Exhaust Brake

CONTENTS OF SECTION 18C

P a g e

IL L U S T R A T IO N ...................................................................................................................................................................................................................................1 8 C -2

IN T R O D U C T IO N ................................................................................................................................................................................................................................1 8 C -3

S P E C IF IC A T IO N S .............................................................................................................................................................................................................................1 8 C -3

R E M O V IN G T H E E X H A U S T B R A K E .....................................................................................................................................................................................1 8 C -4

R E P L A C IN G T H E E X H A U S T B R A K E .................................................................................................................................................................................. 1 8 C -5

C H E C K IN G E X H A U S T B R A K E S E T T IN G ......................................................................................................................................................................... 1 8 C -7

April '96

Exhaust Brake 18C-2

1 S H A F T A N D B U S H2 E X H A U S T B R A K E V A L V E3 V A L V E R E T A IN IN G N U T A N D B O L T4 B R A C K E T R E T A IN IN G B O L T5 S H A F T B U S H6 O P E R A T IN G A R M

7 N U T A N D B O L T8 N U T A N D W A S H E R9 O P E R A T IN G C Y L IN D E R

1 0 E X H A U S T B R A K E IN P O S IT IO N11 B R A C K E T1 2 E X H A U S T B R A K E B O D Y

April '96

Exhaust Brake 18C-3


D e p e n d in g on a p p lic a tio n , s o m e A D E 3 6 0 series e n g in es a re fitted w ith an e x h a u s t b ra k e co n s is tin g o f a b u tte rfly v a lv e pivo ting on a s p in d le w ith in a s e p a ra te ho us ing , s itu a ted in th e e x h a u s t s y s te m . T h e bu tte rfly v a lv e is a c tu a te d by a p n e u m a tic a lly o p e ra te d lever, w h ic h is s e cu red to th e bu tte rfly v a lv e sp ind le , w h e re th e s p in d le p ro tru d es th ro u g h th e

ho using .

W h e n a fo o t o p e ra te d e x h a u s t b ra k e v a lv e , lo ca te d on th e flo o r o f th e ca b (d riv e rs s id e ), is p res sed , c o m p re s s e d a ir flow s p a s t a v a lv e an d e n te rs an a ir o p e ra te d cy lind er. A p iston in s id e th e cy lin d er a tta c h e d to th e v a lv e s p in d le p u sh es th e lever fo rw a rd a n d th u s c lo s e s th e v a lv e . A t th e s a m e t im e th e fu el su p p ly to th e in jec tors is cu t o ff (i.e . th e s p eed co ntro l lever m o v e s to th e s to p po s itio n ).

T h e p re s s u re b u ilt-u p in th e e x h a u s t m a n ifo ld an d c o m b u stio n c h a m b e rs ex erts a b rak in g e ffe c t v ia th e tra n s m is s io n to th e w h e e ls o f th e ve h ic le .


C o n tro l le v e r c la m p b o l t .....................................C o n tro l le v e r s e c u rin g b o lt................................C le a ra n c e b e tw e e n v a lv e an d v a lv e bo dy

M 6 .............................................................. 8 ,5 N mM 1 0 ...........................................................4 2 N m

.......................................................................0 ,2 - 0 ,5 m m

April '96

Exhaust Brake 18C-4

R E M O V IN G A N D R E P L A C IN G T H E E X H A U S T B R A K EV A L V E , B U S H E S A N D S H A F T

R em ov in g

1. D is c o n n e c t th e in n e r a n d o u te r co ntro l lin kag e .

2 . D is c o n n e c t an d re m o v e th e e x h a u s t b ra k e b o d y fro m th e e x h a u s t d o w n p ipe.

3. M o u n t th e e x h a u s t b ra k e b o d y in a v ic e fitted w ith so ft ja w s . M a rk th e lo c a tio n o f th e e x h a u s t b ra k e v a lv e to th e co ntro l lev er, (F ig . 1 8 C -1 ) .

4 . R e m o v e th e e x h a u s t b ra k e c y lin d e r ba ll jo in t re ta in in g clip a n d le v e r o ff th e o p e ra tin g a rm , (F ig . 1 8 C -2 ) .

5. R e m o v e th e c la m p b o lt fro m th e o p e ra tin g a rm , (F ig . 1 8 C -3 ).

6 . R e m o v e th e o p e ra tin g a rm fro m th e sh a ft, (F ig . 1 8 C -4 ) .

Fig. 18C-4

Exhaust Brake 18C-5

April '96

Exhaust Brake 18C-6

2. In sert th e bo lt re ta in in g th e b ra k e v a lv e to th e s h a ft an d tig h ten to th e s p e c if ie d to rq u e , (F ig . 1 8 C -9 ) .

3. M e a s u re th e c le a ra n c e b e tw e e n th e ho u s in g an d th e b ra k e v a lv e w ith a fe e le r g a u g e , re fe r to sp ec ifica tio n . T h e c le a ra n c e c a n b e a lte re d b y m o v in g th e b ra k e v a lv e

s h a ft in o r ou t, (F ig . 1 8 C -1 0 ) .

4 . L ine up th e m a rk s a n d re p la c e th e co ntro l le v e r to th e b ra k e v a lv e sh a ft, (F ig . 1 8 C -1 1 ) .

5. In s e rt th e c o n tro l le v e r re ta in in g b o lt an d tig h te n to th e s p ec ified to rq u e , (F ig . 1 8 C -1 2 ) .

Exhaust Brake 18C-7

6 . R e p la c e th e e x h a u s t b ra k e c y lin d e r ba ll jo in t to th e o p era tin g a rm a n d in sert th e re ta in in g clip , (F ig . 1 8 C -1 3 ) .

C h eck in g th e E x h a u st B rake S e tt in g

1. D is c o n n e c t th e e x h a u s t p ip e fro m th e e x h a u s t b ra k e body.

2 . E n s u re th a t th e e x h a u s t b ra k e v a lv e is in th e fu lly op en po sitio n , (F ig . 1 8 C -1 4 ) .

3. O p e ra te th e e x h a u s t b ra k e a n d e n s u re th a t th e v a lv e fu lly

clo ses .

A d ju stin g th e E x h a u st B rake C ylinder L ength

1. R e m o v e th e o p e ra tin g lever.

2 . A d ju s t th e e x h a u s t b ra k e c y lin d e r len gth to 1 7 0 m m fro m th e c e n tre o f th e m o u n tin g b o lt to th e c e n tre o f th e ball jo in t h e a d , (F ig . 1 8 C -1 5

3. O p e n th e e x h a u s t b ra k e v a lv e fu lly an d re p la c e th e o p era tin g lever. P re -te n s io n th e c y lin d e r by 2 to 4 m m an d fit th e ball jo in t, (F ig . 1 8 C -1 6 ) .

4 . In s e rt th e b o lt in to th e o p e ra tin g le v e r a n d tig h te n to th e sp ec ified to rq u e .

5 . In s e rt th e lo ck in g c lip to th e ba ll jo in t.

6 . C o n n e c t th e e x h a u s t p ip e to th e e x h a u s t b ra k e body.

Fig . 1 8 C -1 3

Fig . 1 8 C -1 4

r----------------- 170mm-----------------

n= . . . ,is

Fig. 1 8 C -1 5

Fig. 18C-16

April '96

^ (aphitigioit Diesel Club

ADE 364 and ADE 366

Workshop ManualSection 18D - Flywheel

B arring ton D iesel C lub


______________________ SECTION 18DFlywheel

CONTENTS OF SECTION 18D

P a g e

IL L U S T R A T IO N ...................................................................................................................................................................................................................................1 8 D -2

IN T R O D U C T IO N ................................................................................................................................................................................................................................1 8 D -3

S P E C IF IC A T IO N S ............................................................................................................................................................................................................................. 1 8 D -3

R E M O V IN G T H E F L Y W H E E L ..................................................................................................................................................................... 1 8 D -4

R E P L A C IN G T H E F L Y W H E E L .................................................................................................................................................................................................1 8 D -5

R E M O V IN G A N D R E P L A C IN G T H E R IN G G E A R ........................................................................................................................................................1 8 D -6

R E M O V IN G A N D R E P L A C IN G T H E S P IG O T B E A R IN G ......................................................................................................................................... 1 8 D -8

S P E C IA L T O O L S ................................................................................................................................................................................................................................1 8 D -8

April '96

Flywheel 18D-2

1 S T A R T E R R IN G G E A R 4 B E A R IN G R E T A IN E R2 F L Y W H E E L 5 F L Y W H E E L R E T A IN IN G B O L T3 S P IG O T B E A R IN G

April '96

Flywheel 18D-3IN T R O D U C T IO N

M a n u fa c tu re d fro m high g ra d e g re y c a s t iron th e fly w h e e l is p rec is io n m a c h in e d an d b a la n c e d to fin e lim its T h e starterring g e a r is h e a t tre a te d an d s h ru n k on to th e flyw hee l. E ig h t stretch bo lts re ta in th e fly w h e e l to th e c ra n k s h a ft W h e nre m o v in g it is no t n e c e s s a ry to m a rk th e re la tiv e position o f th e fly w h e e l a s th e e ig h t bo lt ho les a re drilled ec cen trica lly , m a k in g in c o rre c t fittin g im p o ss ib le .

T h e fly w h e e l is th e s to re h o u s e o f e n e rg y an d is requ ired toa. p ro v id e e n e rg y fo r o p e ra tin g th e e n g in e b e tw ee n p o w er s tro kes, andb. to re d u c e th e v a ria tio n in th e ro ta tio n a l sp eed o f th e c ra n k s h a ft du ring th e e n g in e cycle

a s it tra n s m its p o w e r to th e d riven m a c h in e .


F L Y W H E E L

D ia m e te r fo r s ta rte r ring g e a r 3 3 5 ,3 9 0 to 3 3 5 ,5 3 0

D ia m e te r fo r m o u n tin g c ra n k s h a ft f la n g e 1 3 0 ,0 0 0 to 1 3 0 ,0 4 0

A x ia l ru n -o u t c ra n k s h a ft f la n g e 0,1

F ly w h e e l ru n -o u t m o u n te d to c ra n k s h a ft rad ia l 0 ,1la te ra l 0 ,1

Im b a la n c e o f fly w h e e l w ith ring g e a r 2 0 g e m

M a x im u m c lu tch s u rfa c e m a te r ia l re m o v a l 2 m m

C lu tch s u rfa c e fin ish R z 1 6 |jm

S T A R T E R R IN G G E A R

ID o f ring g e a r 3 3 4 ,6 9 0 to 3 3 4 ,8 3 0

R in g g e a r in te r fe re n c e fit 0 ,5 6 to 0 ,8 4

L a te ra l ru n -o u t o f m o u n te d s ta rte r ring g e a r 0 ,5 m m m ax .

S ta r te r ring g e a r m o u n te d a t a te m p e ra tu re o f 2 5 0 ° to 2 8 0 °


F ly w h e e l to c r a n k s h a f t M 1 2 x 1 ,5 .. . In it ia l..............................................................................................................................................F in a l ................................B o lt len g th 2 5 ,8 m m ..................................................................M a x . s tre tch len gtho r B o lt len g th 4 3 ,8 m m ............................................................ M a x . s tre tch len gth

Bell h o u s in g to r q u e .......................................................................................................................................................

3 0 - 4 0 N m 9 0 ° - 1 1 0 °2 6 .3 m m4 4 .3 m m 1 1 0 N m

April '96

Flywheel 18D-4

R E M O V A L A N D R E P L A C E M E N T

O F F L Y W H E E L A N D H O U S IN G

R e m o v a l

1. U n s c re w an d re m o v e th e bo lts re ta in in g th e fly w h e e l, (F ig . 1 8 D -1 ).

2 . L ift o ff th e fly w h e e l, (F ig . 1 8 D -2 ) .

3. U n s c re w th e fo u r bo lts re ta in in g th e fly w h e e l ho u s in g to th e c y lin d e r b lock , (F ig . 1 8 D -3 ) .

4. U n s c re w th e tw o o u te r bo lts , (F ig . 1 8 D -4 ).

Fig. 1 8 D -1

Fig . 1 8 D -2

F ig . 1 8 D -3

Fig. 18D-4

. April '96

Flywheel 18D-5

5. Lift o ff th e h o us ing , (F ig . 1 8 D -5 ).

R ep la cem en t

1. F it th e fly w h e e l h o u s in g to th e c y lin d e r b lock. R e p la c e an d tig h te n th e o u te r bo lts , F ig . 1 8 D -6 ).

2 . In sert th e fo u r in n e r bo lts , (F ig . 1 8 D -7 ).

3 . In s e rt th e tw o to p bo lts a n d tig h ten a ll bo lts to th e sp ec ified

to rq u e , (F ig . 1 8 D -8 ) .

F ig . 1 8 D -5

Fig . 1 8 D -6

Fig . 1 8 D -7

Fig. 18D-8

April '96

Flywheel 18D-6

4. R e p la c e th e fly w h e e l, in sert th e bo lts an d tig h ten to th e sp ec ified to rq u e , (F ig . 1 8 D -9 ) .

F ig . 1 8 D -9

R E M O V A L A N D R E P L A C E M E N T O F

S T A R T E R R IN G G E A R

R e m o v a l

1. R e m o v e th e fly w h e e l, (F ig . 1 8 D -1 0 ) .

Fig. 1 8 D -1 0

2 . P u n ch m a rk th e ring g e a r a n d drill tw o ho les into th e s id e o f th e g e ar. D o n o t drill th ro u g h th e ring g e a r a s th is w ill d a m a g e th e fly w h e e l, (F ig . 1 8 D -1 1 ) .

F'<r I 8 D - I I3. W ith a s h a rp ch ise l sp lit th e ring g e a r b e tw e e n th e drilled

h o les a n d re m o v e th e g e a r fro m th e fly w h e e l, (F ig . 1 8 D -1 2 ) .

A t te n t io n ! T h o ro u g h ly c le a n th e fly w h e e l an d fla n g e prio r to rep lac in g .

Fig. 18D-12

April '96

R ep lacin g

1. P la c e th e fly w h e e l on a fla t su rface .

2 . H e a t th e n e w ring g e a r to a p p ro x im a te ly 2 5 0 °C w ith a w e ld in g to rc h o r o th e r s u ita b le h e a t so urce, (fig . 1 8 D -1 3 ) .

3 . P la c e th e h e a te d ring on to th e fly w h e e l, (F ig . 1 8 D -1 4 ) .

4 . If n e c e s s a ry u s e a c o p p e r o r a lu m in iu m h a m m e r to fu lly lo c a te th e ring g e a r on th e fly w h e e l so th a t it s e a ts a g a in s t th e f la n g e s h o u ld er, (F ig . 1 8 D -1 5 ) .

5 . R e p la c e th e fly w h e e l an d tig h te n th e bo lts to th e sp ecified to rq u e , (F ig . 1 8 D -1 6 ) .

Flywheel 18D-7

Fig. 1 8 D -1 3

Fig . 1 8 D -1 4

Fig. 1 8 D -1 5

Fig. 18D-16

April ‘96

Flywheel 18D-8

R E M O V IN G A N D R E P L A C IN G T H E S P IG O T B E A R IN G

T h e fly w h e e l s p ig o t b e a rin g ca n b e e x tra c te d w ith th e fly w h e e l in p o s itio n o r re m o v e d fro m th e en g in e .

1. W ith s p e c ia l to o l 4 0 2 0 0 3 8 1 pull th e s p ig o t b e a rin g fro m th e h o u s in g , (F ig . 1 8 D -1 7 ) .

2 . In sert th e b e a rin g in to th e h o u s in g a n d d rive into p lace w ith a s u ita b le drift, (F ig . 1 8 D -1 8 ) .

A t te n t io n ! T h e sp ig o t b e a rin g is s e a le d an d d o es not req u ire g rea s in g .

S P E C IA L T O O L S F O R S E C T IO N 1 8 D

O B T A IN A B L E F R O M : G R U N D Y T E C H N IF O R M , B U R M A N R O A D , D E A L P A R K , P O R T E L IZ A B E T H 6 0 0 1 TE L : (0 4 1 ) 4 3 -2 2 9 9 , F A X : (0 4 1 ) 4 3 -2 2 2 4

April ‘96

Alternator and Starter Motor

CONTENTS OF SECTION 18E

SECTION 18E-1

P a g e

IN T R O D U C T IO N ................................................................................................................................................................................................................................ 1 8 E -2

T O R Q U E S P E C IF IC A T IO N S ..................................................................................................................................................................................................... 1 8 E -2

A L T E R N A T O R - S E C T IO N A L V IE W ..................................................................................................................................................................................... 1 8 -3

P R E C A U T IO N S ................................................................................................................................................................................................................................... 1 8 E -4

M A IN T E N A N C E ................................................................................................................................................................................................................................... 1 8 E -4

T E S T IN G T H E A L T E R N A T O R IN P O S IT IO N ..................................................................................................................................................................1 8 E -4

T R O U B L E S H O O T IN G ...................................................................................................................................................................................................................1 8 E -4

S T A R T E R M O T O R

G E N E R A L ...............................................................................................................................................................................................................................................1 8 E -5

R O U T IN E M A IN T E N A N C E ..........................................................................................................................................................................................................1 8 E -5

S E R V IC IN G - T E S T IN G IN P O S IT IO N ..............................................................................................................................................................................1 8 E -6

April '96

Alternator and Starter Motor 18E-2

INTRODUCTION

A lternator

A lte rn a to rs u s ed on th e 3 6 0 s e rie s en g in e s a re o f th e c la w p o le ty p e w h ich ra n g e fro m 1 4 V -5 5 A to 1 4 V -9 0 A an d 2 8 V -2 8 A to 2 8 V -5 5 A . T h e s e a lte rn a to rs a re fitted w ith e ith e r o n e o r tw o drive pu lleys, d e p en d in g on ap p lic a tio n .

Starter M otor

S ta rte r m o to rs fitted to th e 3 6 0 s e rie s e n g in e s a re o f th e fo u r pole, fo u r brush ea rth re tu rn ty p e w ith se rie s pa ra lle l c o n n ec te d fie ld co ils . T h e s e s ta rte r m o to rs ra n g e fro m 1 2 V -3 k W to 1 2 V -3 ,5 k W an d 2 4 V ~ 4 k W to 2 4 V - 4 ,5 k W d e p en d in g

on a p p lic a tio n .


ALTERNATOR AND STARTER MOTOR

S ta r te r to fly w h e e l h o u s in g ........A lte rn a to r to b r a c k e t .....................A d ju s tin g bo lt to c y lin d e r b lo ckA d ju s tin g bo lt c la m p .....................P u lle y to a lte rn a to r .........................P u lle y to a lte rn a to r .........................

.M 1 0 ............................................................ 6 0 N m,M 1 2 x 1 , 5 ...............................................6 0 N m.M 1 0 ............................................................ 4 0 N m.M 1 2 ............................................................ 3 5 N m.M 1 4 x 1 , 5 ...............................................6 0 N m.M 1 6 x 1 , 5 ...............................................8 0 N m

April ‘96


S E C T IO N A L V IE W O F T H E K 1 C L A W -P O L E A L T E R N A T O R

April '96


A L T E R N A T O R

P reca u tio n s

T h e d io d e s in th e a lte rn a to r fu n c tio n a s o n e -w a y va lves . T h e tra n s is to rs in th e re g u la to r/c o n tro l box o p e ra te as fa s t sw itch es . B oth a re a c c u ra te an d se n s itive .

T h e y do n o t w e a r ou t an d s e ld o m req u ire ad ju s tm e n t, but b e c a u s e th e y a re s e n s itiv e to v o lta g e c h a n g e s an d high te m p e ra tu re th e fo llo w in g p re c a u tio n s a re v ita l to p reven t th e m fro m be in g d e stro y ed :

a. D O N O T d is c o n n e c t th e b a tte ry w h ile th e en g in e is runn ing . T h is w ill c a u s e a v o lta g e su rg e in th e a lte rn a to r c h a rg in g s y s te m w h ic h w ill im m e d ia te ly ruin th e d io d e s o r tra n s is to rs .

b. D O N O T d is c o n n e c t th e lea d w ith o u t firs t s to p p in g th e e n g in e a n d tu rn in g all e le c tr ic a l sw itch es to th e o ff po sition.

c. D O N O T c a u s e a s h o rt c ircu it b y c o n n ec tin g le a d s to in co rre c t te rm in a ls . A lw a y s firs t id en tify a lead to its

c o rrec t te rm in a l. A s h o rt c ircu it o r w ro n g co n n ectio n g iv ing re v e rs e p o la r ity w ill im m e d ia te ly an d p e rm a n e n tly ruin tra n s is to rs o r d io d es .

d. D O N O T c o n n e c t a b a tte ry to th e s y s te m w ith o u t prio r c h eck in g fo r c o rre c t p o la r ity a n d v o lta g e .

e. D O N O T “flash " c o n n e c tio n s to c h e c k fo r c u rren t flow . N o m a tte r h o w b rie f th e c o n ta c t, th e tra n s is to rs m a y b e ru in ed .

M ain ten an ce

T h e a lte rn a to r c h a rg in g s y s te m w ill n o rm a lly req u ire ve ry little a tte n tio n , bu t it sh o u ld b e k e p t fre e fro m d irt and ch eck s sh o u ld b e m a d e if th e a lte rn a to r fa ils to ke ep th e b a tte ry c h a rg e d .

a. In sp e c t th e V -b e lts reg u la rly fo r w e a r an d c o rrec t te n sion. It is im p o rta n t to e n s u re th a t all V -b e lts on a m u ltip le d rive h a v e eq u a l te n s io n an d a re e a c h ca rry in g th e ir s h a re o f th e lo ad . S la c k d rive belts w ill w e a r ra pid ly an d c a u s e slip w h ich w ill no t d rive th e a lte rn a to r at th e req u ired sp eed . V -b e lts w h ich a re to o tig h t im po se s e v e re s id e th ru s t on th e a lte rn a to r b e arin g s and sh orten th e ir life. E n s u re p e rio d ic a lly th a t th e a lte rn a to r is co rrec tly a lig n e d to th e drive.

b. D o no t re p la c e fa u lty V -b e lts in d iv id u a lly in a m u lti be lt sy s tem . A c o m p le te m a tc h e d se t o f V -b e lts m u st a lw a y s b e used.

c. K eep th e a lte rn a to r c le a n w ith a c lo th m o is te n e d w ith a s u ita b le c le a n in g flu id . E n s u re th a t v e n tila tio n slots an d a ir s p a c e s a re c le a r an d un o b stru c ted .

d. R e m o v e a n y d irt a c c u m u la te d on th e re g u la to r/co n tro l box ho us ing . E n s u re th a t co o lin g a ir c a n p a ss free ly o v er th e cas ing .

T estin g th e a lternator in p o sitio n

F irs t c h e c k th e V -b e lts fo r co n d itio n an d te n s io n . T h e n o m in a l ho t o u tp u ts a t 6 0 0 0 r /m in (a lte rn a to r s p e e d ) a re as fo llow s:

1 4 V - 3 5 A

2 8 V - 2 8 A

T h e s e fig u res m a y b e e x c e e d e d s ligh tly w h e n th e a lte rn a to r is runn ing cold.

A d u st p ro o fed a lte rn a to r ca n b e fitted as an op tio n , d e p en d in g on ap p lic a tio n .

T rouble S h o o tin g

If a m a lfu n c tio n sh o u ld d e v e lo p in th e c u rren t g e n e ra tin g s y s te m it m u st b e ke p t in m in d th a t tro u b le s o u rc e s m a y ex ist in th e b a tte ry , c a b le s o r o th e r lo c a tio n s b e s id e s th e a lte rn a to r or regu la to r. T h e m o s t c o m m o n fa u lt s y m p to m s a re lis ted in th e c h a rt b e lo w w ith p ro b a b le c a u s e s an d a p p ro p ria te c o rrec tive m easu re s :

P rob lem - C a u se C orrection

B attery is d ea d or in su ffic ien tly ch arged ; R e c h a rg e b a tte ry

1. O p e n c ircu it o r c o n ta c t re s is ta n c e in ch arg in g c ircu it R e m o v e o p en c ircu it o r c o n ta c t re s is ta n c e

2. D e fe c tiv e b a tte ry R e p la c e b a tte ry

3. D e fe c tiv e a lte rn a to r H a v e a lte rn a to r rep a ire d in a u th o ris e d w o rk s h o p

4 . D e fe c tiv e re g u la to r R e p la c e re g u la to r

5. V -b e lt lo o s e T ig h te n V -b e lt

April '96


P rob lem - C a u se ________________________________________

C harge in d icator lam p d o e s n ot burn w ith th e e n g in e s to p p e d and th e ign ition on .

1. In d ic a to r bu lb is b u rn ed ou t

2. D e a d b a tte ry

3. D e fe c tiv e b a tte ry

4 . L o o s e o r d a m a g e d ca b le s

5. D e fe c tiv e re g u la to r

6. S h o rte d p o s itiv e d io d e in th e a lte rn a to r

7. W o r n c a rb o n b ru s h es

8. O x id e la y e r on slip rings or b ro k en w ire in ro tor

w in d in g

C h arge in d ica tor lam p c o n t in u e s to burn brightly during h igh er e n g in e s p e e d s

1. C a b le D + /6 1 is sh o rted to grou nd

2. D e fe c tiv e re g u la to r

3. O v e r v o lta g e p ro tec tio n d e v ic e d e fe c tiv e

4. D e fe c tiv e rec tifie r, d irty s lip ring s, sh o rt in c a b le “D F ” o r in ro to r w in d in g

C h arge in d ica tor lam p bu rn s brightly w ith e n g in e s to p p e d , but o n ly d im s or g lim m er s w ith e n g in e running:

1. P o o r c o n n e c tio n s (c o n ta c t re s is ta n c e ) in th e ch a rg ing c ircu it or in th e c a b le to th e c h a rg e in d ic a to r la m p

2 . D e fe c tiv e re g u la to r

3. D e fe c tiv e a lte rn a to r

C h arge in d ica tor lam p flick ers

1. C o n ta c t re g u la to r m a y b e in co rre c tly a d ju s te d or re g u la tin g re s is to r is b u rn ed ou t

STARTER MOTOR

G en eral

T h is s ta rte r m o to r is a fo u r po le , fo u r brush e a rth return m a c h in e w ith s e rie s p a ra lle l c o n n e c te d fie ld coils.

A s o le n o id o p e ra te d p re -e n g a g e d d rive a s s e m b ly is c a rrie d on an e x te n s io n o f th e a rm a tu re sh aft. T h e m a in fe a tu re s o f th is ty p e o f d rive a re a s fo llow s:

a. P o s itiv e p in ion e n g a g e m e n t p rev en tin g th e pin ion being th ro w n o u t o f m e s h w h ile s tarting .

b. A n o v e rru n n in g c lu tch is in co rp o ra ted in th e d rive a s s e m b ly g iv in g o v e rs p e e d a n d o v e rlo a d p rotection .

Correction

R e p la c e w ith a n e w bulb

C h a rg e b a tte ry

R e p la c e b a tte ry

R e p la c e o f tig h ten ca b le s

R e p la c e reg u la to r

H a v e a lte rn a to r re p a ire d by a u th o ris e d w o rk s h o p

R e p la c e b rushes

H a v e a lte rn a to r rep a ire d

R e p a ir o r re p la c e c a b le


R e p la c e o v e r v o lta g e pro tec tio n d e v ic e

H a v e a lte rn a to r rep a ire d by a u th o ris e d w o rk s h o p

R e m o v e c o n ta c t re s is ta n c e


H a v e a lte rn a to r rep a ire d


c. S e lf-in d ex in g p in ion to e n s u re sm o o th e n g a g e m e n t b e tw ee n th e p in ion a n d th e ring g e a r te e th b e fo re th e s ta rte r m o to r beg in s to ro ta te .

d. A rm a tu re b rak in g s y s te m to e n s u re rap id retu rn to rest w h e n th e s ta rte r bu tto n is re le a s e d .

Routine Maintenance

a. T h e s ta rte r m o to r req u ire s no ro u tin e m a in te n a n c e b eyo nd th e o c c a s io n a l in spectio n o f th e e le c tr ic a l co n nectio ns , brush g e a r an d th e c o m m u ta to r, w h ich m u st b e c le a n an d tight.

April ‘96


b. A fte r th e s ta rte r m o to r h a s been in se rv ice fo r so m e tim e , re m o v e th e s ta rte r m o to r fro m th e en g in e , su b m it it to a th o ro u g h b e n ch in sp ectio n .

1. B rush w e a r (th is is a fa ir in d ica tio n o f th e a m o u n t of w o rk d o n e ), re n e w b ru s h es w o rn to or a p p ro ac h in g 7 ,9 m m length .

2. B rush sp rin g te n s io n : C o rre c t te n s io n is 0 ,8 5 - 1 ,1 3 N, re n e w sp rin g s if te n s io n h a s d ro p p e d b e lo w 0 ,7 1 N.

3. S k im c o m m u ta to r if it is p itted or b a d ly w o rn .

4. C h e c k b e a rin g s fo r e x c e s s iv e s id e p la y on a rm a tu re shaft.

5. C h e c k p in io n m o v e m e n t.

6. C le a n a n d lu b ric a te p in ion s le e v e b earing .

7. C le a n a n d lu b ric a te d r iv e en d b ra c k e t bush.

m in a ls b e fo re p ro ceed in g . O p e ra te th e s ta rte r co ntro l andw atch for th e fo llow ing s y m p to m s:

1. T h e la m p s d im (o r th e v o ltm e te r re a d in g dro p s to ab o u t 6 vo its ) an d th e m o to r d o es not tu rn th e en g in e. C h e c k th e b a tte ry (m u s t be a t le a s t h a lf-c h a rg e d ) and b a tte ry posts (c le a n an d go od e a rth c o n n e c tio n )

2. L a m p s do not d im , th e v o ltm e te r read in g re m a in s s te a d y a t a b o u t 1 2 vo lts , an d th e m o to r d o es no t turn th e en g in e . C o n n e c t v o ltm e te r b e tw e e n so len o id te r m in a l an d s ta rte r yoke, th e n o p e ra te s tarte r. N o vo lts in d ica ted

C a u ses:

a. P o o r post co n n ec tio n a t b a tte ry .

b. B ad ea rth co n n ectio n .

c. B ro ken s ta rte r lea d , b a tte ry to s ta rte r

Fu ll vo lts , i.e . 1 2 /1 4 vo lts in d ica ted :

S erv ic in g - T estin g in P o s it io n - S y m p to m s a. F a u lty so len o id sw itch .

S w itch on th e lights . If th e v e h ic le is not e q u ip p e d w ith b. O p e n c ircu it in s ta rte r - c h e c k brushes , lighting c o n n e c t a 0 /2 0 v o ltm e te r a c ro s s th e b a tte ry te r-

C ut-aw ay v iew o f pre e n g a g e d drive starting m otor w ith o u ter -w ed g e roller ty p e overrunn ing c lu tch .

April '96

Diesel Club

ADE 364 and ADE 366

Workshop ManualSection 18 F - Compressor and Vacuum Pump

B arring ton D iesel C hib


SECTION 18F-1Compressor/Vacuum Pump

CONTENTS OF SECTION 18F

P a g e

IL L U S T R A T IO N - C A M S H A F T D R IV E N C O M P R E S S O R ..........................................................................................................................................1 8 F -2

IN T R O D U C T IO N ................................................................................................................................................................................................................................ 1 8 F -3

S P E C IF IC A T IO N S ............................................................................................................................................................................................................................. 1 8 F -3

T O R Q U E S P E C IF IC A T IO N S ......................................................................................................................................................................................................1 8 F -4

M E A S U R IN G T H E B E A R IN G C L E A R A N C E ..................................................................................................................................................................... 1 8 F -5

D IS M A N T L IN G T H E C Y L IN D E R H E A D ................................................................................................................................................................................1 8 F -7

R E -A S S E M B L Y O F T H E C Y L IN D E R H E A D ..................................................................................................................................................................... 1 8 F -8

S P E C IA L T O O L S F O R T H IS S E C T IO N .............................................................................................................................................................................. 1 8 F -9

B E L T -D R IV E N C O M P R E S S O R .............................................................................................................................................................................................1 8 F -1 0

B E L T D R IV E N C O M P R E S S O R - D IS A S S E M B L Y .................................................................................................................................................... 18 F -1 1

B E L T D R IV E N C O M P R E S S O R -A S S E M B L Y ............................................................................................................................................................. 1 8 F -1 3

S P E C IA L T O O L S ............................................................................................................................................................................................................................. 1 8 F -1 7

April '96

Compressor/Vacuum Pump 18F-2(C am sh aft driven)

N o te : W h e n belt driven co m p re s s o rs a re used th e oil h o le in th e lo b e o f th e c a m s h a ft, used fo r driving th e co m p re sso r, is c lo sed w ith a J u b ile e

c la m p . T o p rev en t oil loss during en g in e re -c o n d itio n in g en su reth a t th e c la m p is in position.

AIR COMPRESSOR

1 C Y L IN D E R B A R R E L2 B E A R IN G S H E L L3 B E A R IN G S H E L L4 C O N N E C T IN G R O D5 C O N N E C T IN G R O D B O L T6 N U T7 B O L T8 C IR C L IP

.9 G U D G E O N P IN1 0 P IS T O N R IN G11 S M A L L E N D B U S H

1 2 P IS T O N1 3 S C R A P E R R IN G1 4 P IS T O N R IN G1 5 V A L V E1 6 V A L V E1 7 G A S K E T1 8 S E A L IN G W A S H E R1 9 IN L E T P IP E2 0 U N IO N21 S E A L IN G W A S H E R2 2 C Y L IN D E R H E A D

April ‘96

Compressor/Vacuum Pump 18F-3


A ir c o m p re s s o rs a re used in v e h ic le s y s te m s to p ro v id e c o m p re ssed a ir used fo r b rak in g an d th e o p era tio n o f a n c illa ry air e q u ip m e n t. T h e s e c o m p re s s o rs h a v e a s in g le rec ip ro catin g p iston an d a re a ir cooled . T h e c o m p re s s o rs h a v e a o n e -p ie c e c y lin d e r h e a d , w ith th e in le t v a lv e p arts sc rew ed into th e h ead and th e d e live ry v a lv e s re ta in ed by a locknut. T h e piston runs in a re p la c e a b le c y lin d e r b a rre l w h ich is m o u n te d d irec tly onto th e en g in e c ra n k c a s e an d s e a le d w ith a g a s k e t a t th e

c y lin d e r h e ad .

D u rin g th e d o w n s tro k e o f th e p iston a pa rtia l v a c u u m is c re a te d a b o v e th e p iston, w h ich u n s e a ts th e in le t v a lv e a llow in g a ir to e n te r th e c y lin d e r a b o v e th e p iston. O n th e up stroke, th e a ir p res su re u n d e r th e v a lv e , p lus th e e ffo rt o f th e inlet v a lv e sp rin g c lo ses th e in le t v a lv e an d th en o p en s th e de live ry v a lv e , th e a ir u n d e r c o m p re s s io n is th e n d is c h a rg e d into a reservo ir. A t th e s ta rt o f th e do w n s tro ke th e d e live ry v a lv e c lo ses an d th e c y c le is re p e a te d . T h e c o m p re s s o r fe e d s a ir into a re s e rv o ir fitted w ith an u n lo a d e r v a lv e to m a in ta in co n s ta n t p ressure .

T h e a ir c o m p re s s o r a s s e m b ly ca n b e c h a n g e d to a v a c u u m p u m p by s im p ly tu rn in g th e c y lin d e r h e ad .

A IR C O M P R E S S O R /V A C U U M P U M P

C y lin d e r ........................................................................................................................................................................................1B o re .................................................................................................................................................................................................9 4 m mS tr o k e ............................................................................................................................................................................................ 3 0 m mD is p la c e m e n t............................................................................................................................................................................2 0 8 c m 3B o re d ia m e te r .......................................................................................................................................................................... 9 3 ,9 8 5 - 9 4 ,0 1 5 m mP is to n d ia m e te r ........................................................................................................................................................................9 3 ,8 5 0 - 9 3 ,8 8 0 m mP isto n c le a r a n c e .....................................................................................................................................................................0 ,0 6 8 - 0 ,0 9 2 m mP is to n p ro tru s io n .....................................................................................................................................................................0 ,2 5 0 - 0 ,7 0 0 m m

G u d g e o n pin d ia m e te r .................................................................................................................................1 6 ,0 1 2 - 1 6 , 0 1 5 m mB o re in p is to n ....................................................................................................................1 6 ,0 1 8 - 1 6 ,0 2 2 m mC le a ra n c e in p is to n ........................................................................................................ + 0 ,0 0 3 to + 0 ,0 1 0 m mC le a ra n c e in s m a ll en d b u s h ....................................................................................0 ,0 1 0 - 0 ,0 2 3 m m

C o n n e c tin g rod B ig en d b a s ic b o re ...........................................................................................................3 5 ,0 0 0 - 3 5 ,0 1 6 m mS m a ll en d b a s ic b o re ....................................................................................................1 9 ,0 0 0 - 1 9 ,0 2 1 m mS m a ll en d bu sh o u te r d ia ........................................................................................... 1 9 ,0 3 5 - 1 9 ,0 4 8 m mS m a ll en d bu sh in n er d ia ...........................................................................................1 6 ,0 2 5 - 1 6 ,0 3 5 m mS m a ll en d bu sh in te rfe re n c e f i t ............................................................................. 0 ,0 1 4 - 0 ,0 4 8 m mB ig en d b e a rin g c le a ra n c e r a d ia i.........................................................0 ,0 2 0 - 0 ,0 6 6 m m

a x ia l ......................................................... 0 ,0 6 5 - 0 ,3 1 7 m mW id th o f s m a ll e n d ........................................................................................................2 7 ,8 8 3 - 2 7 ,9 3 5 m mW id th o f big e n d ..............................................................................................................2 7 ,8 8 3 - 2 7 ,9 3 5 m mL e n g th o f co n n ec tin g rod (c e n tre to c e n tre ) ....................................................9 6 ,9 5 0 - 9 7 ,0 0 0 m mB ig en d b e a r in g /s m a ll en d bush, p a ra lle l w ith in .............................................0 ,0 1 m m

P is to n rin g s (a ll) G a p ........................................................................................................................................... 0 ,2 5 - 0 ,4 0 m mS id e c le a r a n c e ................................................................................................................ 0 ,0 2 0 - 0 ,0 5 5 m m

April '96


C O N N E C T IN G R O D B E A R IN G A N D C R A N K P IN D IA M E T E R S

S ta g e s C a m s h a f t jo u r n a l d ia . B e a r in g in n e r d ia .

S ta n d a rd 3 1 ,9 8 4 to 3 2 ,0 0 0 3 2 ,0 2 0 to 3 2 ,0 5 0

S ta n d a rd 1 ( - 0 , 1 ) 3 1 ,8 8 4 to 3 1 ,9 0 0 3 1 ,9 2 0 to 3 1 ,9 5 0

R e p a ir s ta g e 1 ( - 0 ,2 5 ) 3 1 ,7 3 4 to 3 1 ,7 5 0 3 1 ,7 7 0 to 3 1 ,8 0 0

R e p a ir s ta g e 2 ( - 0 ,5 ) 3 1 ,4 8 4 to 3 1 ,5 0 0 3 1 ,5 2 0 to 3 1 ,5 5 0

R e p a ir s ta g e 3 ( - 0 ,7 5 3 1 ,2 3 4 to 3 1 ,2 5 0 3 1 ,2 7 0 to 3 1 ,3 0 0

C A P A C IT Y

A ir c o m p re s s o r a t 2 8 0 0 r /m in . .D e liv e ry a g a in s t.

M a x im u m o p e ra tin g p re s s u re ..

V A C U U M P U M P

1 0 0 k P a - 1 4 0 £ /m in

8 1 0 k P a - 1 3 0 ¿ /m in

8 1 0 k P a

T a n k c a p a c i ty E n g in e s p e e d T im e (s e c ) V a c u u m (m m H g )

6 1 6 0 0 r /m in 3 0 6 2 52 8 0 0 r /m in 3 0 7 0 0

201 6 0 0 r /m in 3 0 4 5 02 8 0 0 r/m in 3 0 6 7 5


A IR C O M P R E S S O R /V A C U U M P U M P

C a p to c o n n e c tin g ro d ................................................................................................. M 6 ................................................................. 1 5 N mE x h a u s t v a lv e to c y lin d e r h e a d ..............................................................................M 6 ................................................................. 1 0 N mIn let v a lv e to c y lin d e r h e a d .......................................................................................M 4 0 x 1 , 5 ................................................. 1 8 0 N mC y lin d e r h e a d b a rre l to c r a n k c a s e .......................................................................M 8 ................................................................. 3 5 N m

B E L T -D R IV E N C O M P R E S S O R

C y lin d e r lin e r to c ra n k c a s e .............................................................................................................................................................. 2 2 N mC y lin d e r h e a d to c y lin d e r l in e r ....................................................................................................................................................... 3 0 N mP u lle y n u t ....................................................................................................................................................................................................1 0 0 N m

April ‘96


M e a s u r in g b e a r in g c le a r a n c e s

A t te n t io n ! S e e p a g e 1 5 -8 fo r re m o v a l o f th e c o m p re s s o r from

th e e n g in e

1. C la m p th e c o n n ec tin g rod in a v ic e fitted w ith so ft ja w s a n d re m o v e th e b e a rin g cap , (F ig . 1 8 F -1 ) .

2 . R e m o v e th e b e a rin g sh e lls fro m th e co n n ec tin g rod an d cap , (F ig . 1 8 F -2 ) .

3 . F it th e b e a rin g c a p to th e c o n n ec tin g rod, in sert th e bo lts an d tig h te n to th e s p e c if ie d to rq u e , (F ig . 1 8 F -3 ) .

4 . S e t a n in te rn a l m e a s u rin g in s tru m en t, (F ig . 1 8 F -4 ) .

F ig . 18 F -1

April ‘96


5. M e a s u re th e b ig -e n d b a s ic b o re in th e ve rtic a l position, (F ig . 1 8 F -5 ) .

6 . M e a s u re th e b o re o f th e co n n e c tin g rod s m a ll end bush, (F ig . 1 8 F -6 ) .

7 . U n s c re w th e b e a rin g bo lts a n d re m o v e th e b ig -e n d b earin g cap , (F ig . 1 8 F -7 ) .

8. In sert th e b ig -e n d b e a rin g sh e lls , fit th e c a p to th e co nn ecting rod, in s e rt th e b o lts a n d tig h te n to th e sp ec ified to rq u e ,(F ig . 1 8 F -8 ) .

Fig. 1 8 F -5

Fi.q. 1 8 F -6

F ig . 1 8 F -7

Fig. 18F-8

April '96


9. M e a s u re th e b ig -e n d b e arin g in s id e d ia m e te r in th re e p laces , (F ig . 1 8 F -9 ) .

10 . R e m o v e th e b ig -e n d b e a rin g c a p an d co n n ectin g rod fro m th e v ice.

M e a s u re th e c a m s h a ft ec c e n tric lo b e to d e te rm in e th e c le a ra n c e a fte r o b ta in in g th e b e a rin g I.D .

D ism an tlin g th e cy lin d er head

1. R e m o v e th e n u t re ta in in g th e cy lin d er head, (F ig . 1 8 F -1 0 ) .

2 . R e m o v e a n d d is m a n tle th e d e liv e ry v a lv e , (F ig . 1 8 F -1 1 )

3. U n s c re w th e in le t v a lv e fro m th e cy lin d er h e ad , using s p e c ia l to o l 4 0 2 0 1 7 3 3 , (F ig . 1 8 F -1 2 ).

F ig . 1 8 F -1 0

Fig. 1 8 F -1 1

Fig. 18F-12


R e a s s e m b ly o f t h e c y l in d e r h e a d

1 M o u n t th e c y lin d e r h e a d in a v ice , in sert th e d e live ry v a lv e into th e c y lin d e r h e a d an d tig h te n th e re ta in in g nut to th e s p e c ifie d to rq u e , (F ig . 1 8 F -1 3 ).

2 . T u rn o v e r th e c y lin d e r h e a d a n d in sert th e su ctio n v a lv e as fo llow s: 1 v a lv e s e a t, 2 v a lv e d isk , 3 sp rin g w a s h e rs ,4 su ctio n v a lv e nut, (F ig . 1 8 F -1 4 ) .

N o te : T h e su c tio n v a lv e nu ts 4 A a n d 4 B a re a lte rn a te fittings req u irin g th e u s e o f tw o d iffe re n t s p e c ia l to o ls fo r re m o v a l an d re p la c e m e n t. R e fe r to s p e c ia l to o ls lis t p a g e 1 8 F -9 .

3. T ig h te n th e su ctio n v a lv e n u t to th e sp ec ified to rq u e , using s p ec ia l to o ls 4 0 2 0 1 7 3 3 o r 4 0 2 0 2 3 3 4 , (F ig . 1 8 F -1 5 ).

A t te n t io n ! S e e p a g e 1 5 -1 2 fo r re p la c e m e n t o f c o m p re s s o r to

en g in e

4 . In sert a n e w g a s k e t, re p la c e th e c y lin d e r h e a d , in sert th e re ta in in g bo lts a n d tig h te n to th e s p ec ified to rq u e ,(F ig . 1 8 F -1 6 ) .

N o te : 0 ,6 5 a n d 0 ,9 m m g a s k e t d e p e n d in g on p iston pro tru sio n .

Fig. 18F-16

April '96


5. C o n n e c t th e a ir in le t an d d e live ry p ipes, (F ig . 1 8 F -1 7 ).

SPECIAL TOOLS

O B T A IN A B L E F R O M : G R U N D Y -T E C H N IF O R M , B U R M A N R O A D , D E A L P A R T Y E S T A T E , P O R T E L IZ A B E T H 6 0 0 1

0( V

\ v

■‘Z

J ¡L

S o c k e t fo r re m o v a l/re p la c e m e n t o f c o m p re s s o r v a lv e . (T y p e A ). (S e e F ig . 1 8 F -1 2 , I8 F -1 5 )

P a r t n u m b e r 4 0 2 0 1 7 3 3 .

€> f s r *

\ / /

/ j L 0 ^

S o c k e t fo r re m o v a l/re p la c e m e n t o f c o m p re s s o r v a lv e , (T y p e B). (S e e F ig . 1 8 F -1 2 , I8 F -1 5 )

P a r t n u m b e r 4 0 2 0 2 3 3 4 .

April '96

Belt-driven Compressor 18F-10

1 1

BELT-DRIVEN C O M PRESSO R

1 C O M P R E S S O R P U L L E Y R E T A IN IN G N U T A N D W A S H E R 16 C Y L IN D E R H E A D R E T A IN IN G B O L T S2 C O M P R E S S O R P U L L E Y 17 C Y L IN D E R H E A D B O L T F L A T W A S H E R S3 P IS T O N W IT H C O N N E C T IN G R O D 18 C Y L IN D E R H E A D G A S K E T4 C O N N E C T IN G R O D C A P 19 V A L V E P L A T E5 C O N N E C T IN G R O D C A P B O L T S 2 0 V A L V E P L A T E R E T A IN IN G S C R E W6 C R A N K S H A F T B U S H H O U S IN G 21 IN L E T V A L V E7 S T E E R IN G P U M P D R IV E W A S H E R 2 2 E X H A U S T V A L V E R E T A IN E R8 C R A N K S H A F T 2 3 E X H A U S T V A L V E9 C R A N K C A S E 2 4 E X H A U S T V A L V E R E T A IN IN G S C R E W S A N D

10 C R A N K C A S E M O U N T IN G B O L T S W IT H F L A T W A S H E R S W A S H E R S11 O IL IN L E T B A N J O B O L T A N D H O U S IN G 2 5 C Y L IN D E R S L E E V E12 C R A N K S H A F T B E A R IN G 2 6 C Y L IN D E R S L E E V E R E T A IN IN G S C R E W S13 C R A N K S H A F T B E A R IN G R E T A IN IN G C L IP A N D W A S H E R S14 C R A N K S H A F T S E A L H O U S IN G 2 7 C O M P R E S S O R M O U N T C A S T IN G B R A C K E T

15 C Y L IN D E R H E A D W IT H O IL D R A IN A N D ID L E R P U L L E Y

April '96


D IS A S S E M B L Y

1. L o o s e n th e p u lley fa s te n in g nut, (F ig . 1 8 F -1 8 ).

2 . P u ll o ff th e pu lley , (F ig 1 8 F -1 9 ) .

3. U n s c re w an d re m o v e th e c y lin d e r h e ad , (F ig . 1 8 F -2 0 ).

4 . R e m o v e th e v a lv e p la te w ith su c tio n v a lv e an d d e liv e ry v a lv e , (F ig . 1 8 F -2 1 ) .

Fig. 18F-21

April '96


5. R e m o v e th e c y lin d e r lin er re ta in in g nuts an d pull th e liner fro m th e p iston , (F ig . 1 8 F -2 2 ) .

6 . R e m o v e th e lo ck in g ring fo r th e p is ton pin, (F ig . 1 8 F -2 3 ).

7 . P u sh o u t th e p is ton an d d e ta c h fro m th e co n n ectin g rod, (F ig . 1 8 F -2 4 ) .

8. U n s c re w th e h o u s in g c o v e r b o lts a n d re m o v e th e hous ing

co ver, (F ig . 1 8 F -2 5 ) .

Fig. 18F-25

April '96


9. D e ta c h th e co nrod fro m th e c ra n k s h a ft an d re m o v e th e c ra n k s h a ft, (F ig . 1 8 F -2 6 ) .

10 . R e m o v e th e s h a ft s e a lin g ring fro m th e b e arin g cap , (F ig . 1 8 F -2 7 ) .

11 . R e m o v e th e p is to n ring s w ith s p ec ia l to o l 4 0 2 0 0 3 0 7 (p is to n ring p lie rs ), (F ig . 1 8 -2 8 ) .

ASSEM BLY

1. In s e rt s h a ft s e a lin g ring in to th e b e a rin g cap , (F ig . 1 8 F -2 9 ) .

F ig . 1 8 F -2 6

Fig. 1 8 F -2 7

Fig. 1 8 F -2 8

m W i

Fig. 18F-29

April ‘96

2. M o u n t O -r in g on b e a rin g cap . (F ig . 1 8 F -3 0 ).


3. A s s e m b le c o n n e c tin g rod to th e c ra n k s h a ft a n d install th e c ra n k s h a ft, (F ig . 1 8 F -3 1 ) .

4 . M o u n t th e b e a rin g c a p , (F ig . 1 8 F -3 2 )

N o te : R e c e s s in m o u n tin g bo ss in u p w a rd position .

5. M o u n t p is to n ring s , (F ig . 1 8 F -3 3 ) . U s e p isto n ring pliers p a rt no. 4 0 2 0 0 3 0 7 .

Fig. 1 8 F -3 0

Fig. 1 8 F -3 1

Fig. 1 8 F -3 2

, — ii fasFig. 18F-33

April '96


6 . P o s itio n th e p isto n w ith rings o v e r th e co n n ectin g rod a n d in sert th e p is to n pin, (F ig . 1 8 F -3 4 ).

7. M o u n t th e re ta in in g ring s fo r th e p iston pin, (F ig . 1 8 F -3 5 ) .

8 . M o u n t th e g a s k e t fo r th e c y lin d e r liner.

9 . U s e th e p is to n ring s q u e e z e r to bring th e p iston ring d ia m e te r to p is to n d ia m e te r a n d m o u n t th e cy lin d er liner, (F ig . 1 8 F -3 6 ) .

U s e c o m p re s s o r p is to n ring s q u e e z e r 4 0 2 0 11 31 to g e th e r w ith p lie rs 4 0 2 0 1 1 4 4 .

1 0 . F it th e c y lin d e r lin e r o v e r th e m o u n tin g studs an d tig h ten th e nu ts to 2 2 N m , (F ig . 1 8 F -3 7 ) .

Fig. 1 8 F -3 4

Fig. 1 8 F -3 5

ill'A M

Fig. 1 8 F -3 6

Fig. 18F-37

April '96


11. P la c e th e g a s k e t an d h e a d a s s e m b ly on th e cy lin d er liner, (F ig . 1 8 F -3 8 ).

N o te : G u id e pin o f th e v a lv e p la te m u s t lo c a te into a p p ro p ria te ho les a t th e to p o f th e c y lin d e r liner.

12 . M o u n t c y lin d e r h e a d w ith g a s k e t a n d tig h ten th e bo lts to 3 0 N m , (F ig . 1 8 F -3 9 ) .

13 . M o u n t p u lley to th e c o m p re s s o r a n d tig h te n th e nu t to 1 0 0 N m , F ig . 1 8 F -4 0 ) .

Fig. 1 8 F -3 8

Fig . 1 8 F -3 9

F ig . 1 8 F -4 0

April '96


S P E C IA L T O O L S

O B T A IN A B L E F R O M : G R U N D Y T E C H N IF O R M , B U R M A N R O A D , D E A L P A R K , P O R T E L IZ A B E T H 6 0 0 1 T E L : (0 4 1 ) 4 3 -2 2 9 9 , F A X : (0 4 1 ) 4 3 -2 2 2 4

:> *P is to n ring pliers p a rt n u m b e r 4 0 2 0 0 3 0 7

C o m p re s s o r p iston ring s q u e e z e r u s e w ith p liers b e lo w p a rt n u m b e r 4 0 2 0 1131

A P lie rs fo r c o m p re s s o r p is ton ring s q u e e ze r

p a rt n u m b e r 4 0 2 0 1 1 4 4

April '96

Diesel Club

ADE 364 and ADE 366

Workshop ManualSection 19 - Cooling System

B arring ton D iesel C lub

_______________________ SECTION 19Cooling System


Page

IL L U S T R A T IO N ...................................................................................................................................................................................................................................... 1 9 -2

IN T R O D U C T IO N ....................................................................................................................................................................................................................................1 9 -3

S P E C IF IC A T IO N S .................................................................................................................................................................................................................................1 9 -3

R E M O V IN G T H E W A T E R P U M P ................................................................................................................................................................................................ 1 9 -5

D IS M A N T L IN G ........................................................................................................................................................................................................................................1 9 -6

A S S E M B L Y ............................................................................................................................................................................................................................................... 1 9 -9

T H E R M O S T A T A N D H O U S IN G ................................................................................................................................................................................................ 1 9 -1 5

R E M O V IN G / R E P L A C IN G T H E T H E R M O S T A T H O U S IN G ...................................................................................................................................1 9 -1 6

T H E R M O S T A T T E S T ................................................................................................................................................................................................ 1 9 -1 9

V IS C O F A N ..................................................................................................... : ..................................................................................................................................... 19 -21

IN T R O D U C T IO N ............................................................................................................................................................................................ 1 9 -2 2

S P E C IF IC A T IO N S ............................................................................................ 1 9 -2 2

O V E R H A U L IN G V IS C O F A N ......................................................................................................................................................................................................1 9 -2 3

D IS M A N T L IN G ..................................................................................................................................................................................................................................... 1 9 -2 3

A S S E M B L Y ............................................................................................................................................................................................................................................ 1 9 -2 5

S P E C IA L F A B R IC A T E D T O O L S ...............................................................................................................................................................................................1 9 -2 9

S P E C IA L T O O L S .................................................................................................................................................................................................................................19 -31

April '96

Cooling System 19-2

360 SERIES WATER PUMP

1. IM P E L L E R2. C A R B O N S E A L A S S E M B L Y3. W A T E R P U M P H O U S IN G4 . S E A L5. B E A R IN G6 . S H A F T7 . B E A R IN G8 . O -R IN G9. S E A L

10 . B E A R IN G C A R R IE R11 . C O U P L IN G F L A N G E /P U L L E Y C O U P L IN G F L A N G E

April '96

Cooling System 19-3


T h e w a te r p u m p is o f th e im p e lle r ty p e a n d driven by V -b e lts fro m th e c ra n k s h a ft. It is a s e a le d un it, filled w ith a sp ecia l h igh m e ltin g p o in t g re a s e d u rin g a s s e m b ly a n d req u ire s no fu rth e r a tten tio n du ring its life tim e .

A th e rm o s ta t h o u s in g is m o u n te d to th e c y lin d e r b lo ck w h ich is jo in e d to th e w a te r p u m p b y a c o n n e c tin g tu b e a n d se a led

by O -r in g s .


C O O L IN G S Y S T E M

T h e r m o s ta t S ta n d a r d O p t io n a l

S ta r ts o p e n in g a t 7 9 ± 2 ° C 71 + 2 °C

M a in v a lv e S tro k e m m F u lly o p en a t

8 m m 8 m m 9 4 ° C 8 5 °C

B y p a s s v a lv e c lo s e d a t 9 1 °C 8 2 ° C

M a x . o p e ra tin g te m p e ra tu re 9 5 ° C 9 5 °C

C o o la n t c a p a c ity (e n g in e o n ly ) 11< 11^

W A T E R P U M P

Im p e lle r s h a ft d ia m e te r 1 5 ,0 2 8 to 1 5 ,0 3 9

F o r la rg e b e a rin g 2 9 ,9 9 6 to 3 0 ,0 0 9

F o r s m a ll b e a r in g 1 6 ,9 9 7 to 1 7 ,0 0 8

F o r h u b 2 9 ,0 4 1 to 2 9 ,0 5 4

B o re in h u b d ia 2 9 ,0 0 0 to 2 9 ,0 2 1

H u b d ia . fo r fro n t s e a l 4 1 ,8 4 0 to 4 2 ,0 0 0

B o re d ia . in im p e lle r 1 5 ,0 0 0 to 1 5 ,0 1 8

P re s s in g im p e lle r o n w a te r p u m p s h a ft Im p e lle r f la n g e flu sh w ith hous ing M a x . ± 0 ,1 m m

L u b ric a tio n o f w a te r p u m p G re a s e ap p ro x . 8 0 gr

April ‘96

Cooling System 19-4

A tte n t io n : W h e n in s ta llin g a n e x c h a n g e en g in e , e n s u re th a t th e s p a c e r ring fitted b e tw e e n th e w a te r p u m p a n d th e fa n is o f th e s a m e th ic k n e s s a s in th e re m o v e d en g in e . I f n e c e s s a ry re p la c e th e s p a c e r ring so th a t th e d is ta n c e o f 2 5 to 3 0 m m b e tw ee n th e ra d ia to r a n d th e fa n is re ta in e d .

W A T E R P U M P

A W a te r p u m p s h a ft B H u bC B e a rin g c a rr ie r D O -r in gE L a rg e ba ll b e a rin g F S m a ll ba ll b e arin g G R e a r s e a l H C a rb o n se a l J Im p e lle r

K D is ta n c e im p e lle r a n d ho us ing : 0 , 5 +0 / ^ 0 3

.1 1 9 ± 0 ,5

364N/C/T

T O R Q U E S P E C IF IC A T IO N

W a te r p u m p to c y lin d e r b lo c k ................................................................................. M 1 0 ............................................................ 5 0 N mC o o la n t d ra in p lu g to c y lin d e r b lo c k ...................................................................M 1 8 x 1 , 5 ................................................5 0 -6 0 N mT e m p e ra tu re g a u g e p ro b e ......................................................................................... M 1 4 x 1 , 5 ................................................2 0 N mT h e rm o s ta t h o u s in g c o v e r ........................................................................................M 6 ................................................................2 5 N mW a te r ja c k e t c o v e r to c y lin d e r b lo c k (3 6 4 N /C /T ) ......................................... M 8 ............................................................... 3 5 N mW a te r p u m p b e a rin g c a r r ie r .................................................................................... M 6 x 3 0 .................................................... 1 5 N mC a p s c re w /s p a c e r to w a te rp u m p s h a f t ............................................................... M 1 4 x 1 , 5 ...............................................1 4 0 N m(L u b ric a te th re a d s w ith e n g in e o il)

F A N R E T A IN IN G B O L T S (D IN 9 3 3 ) - T IG H T E N IN G T O R Q U E

B o lt d ia . Q u a l i ty _________________________T o r q u e

M 8 8 .8 2 5 N m

M 8 1 0 .9 3 5 N m

M 1 0 8 .8 5 0 N m

M 1 0 1 0 .9 6 0 N m

April ‘96

Cooling System 19-5

Removing the water pump

1. D ra in ra d ia to r .

2 . D is c o n n e c t u p p e r ra d ia to r ho se .

3 . D is c o n n e c t lo w e r ra d ia to r hose.

4 . L o o s e n b o tto m a lte rn a to r re ta in in g bo lt, (F ig . 1 9 -1 ) .

5 . S la c k e n o f f a d ju s te r a n d re m o v e th e V -b e lt.

6 . R e m o v e th e th e rm o s ta t ho us ing .

7 . If a p o w e r s te e r in g p u m p is fitted , lo o sen th e a d ju s te r c la m p in g bo lt, (F ig . 1 9 -2 ) .

8 . S la c k e n o f f th e a d ju s te r a n d re m o v e th e V -b e lt , (F ig . 1 9 -3 ).

9 . U n s c re w a n d re m o v e th e bo lts re ta in in g th e V -b e lt pu lley o r th e c a p b o lt re ta in in g th e fa n to th e w a te r p u m p shaft. R e m o v e p u lle y o r fa n , (F ig . 1 9 -4 ) .

F ig . 19 -1

F ig . 1 9 -2

F ig . 1 9 -3

Fig. 19-4

April '96

Cooling System 19-6

10 . S la c k e n th e th e rm o s ta t h o u s in g re ta in in g bolts . U n s c re w a n d re m o v e th e b o lts re ta in in g th e w a te r p u m p to th e c y lin d e r b lock . R e m o v e w a te r p u m p an d g a s k e t, (F ig . 1 9 -5 ) .

Dismantling

1. W ith a s u ita b le p u lle r re m o v e th e h u b fro m th e w a te r p u m p s h a ft, (F ig . 1 9 -6 ) .

2 . U n s c re w th e b o lts re ta in in g th e fro n t b e a rin g ca rrie r, (F ig . 1 9 -7 ) . .

3 . L ift o ff th e b e a rin g c a rr ie r , (F ig . 1 9 -8 ) .

F ig . 1 9 -5

F ig . 1 9 -6

F ig . 1 9 -7

Fig. 19-8

April ‘96

4 . W ith s p e c ia l to o l 4 0 2 0 2 3 0 5 ta p th e o ld s e a l fro m th e sea l c a rrie r, (F ig . 1 9 -9 )

5 . R e m o v e th e O -r in g fro m th e to p o f th e fro n t b e arin g , (F ig . 1 9 -1 0 )

6 . R e m o v e th e b o lts fro m th e fron t, (F ig . 1 9 -1 1 ) .

7 . R e m o v e th e bo lts fro m th e b a c k p la te a n d d e ta c h th e b a c k p la te fro m th e p u m p b o dy , (F ig . 1 9 -1 2 ) .

Cooling System 19-7

Fig. 1 9 -9

Fig . 1 9 -1 0

F ig . 1 9 -1 1

Fig. 19-12

April ‘96

Cooling System 19-8

8. M o u n t th e w a te r p u m p b o d y u n d e r a p res s a n d w ith a s u ita b le m a n d re l re m o v e th e s h a ft c o m p le te w ith b e a rin g s fro m th e w a te r p u m p bo dy , (F ig . 1 9 -1 3 ) .

9. L ift o u t th e im p e lle r fro m th e re a r o f th e w a te r p u m p body, (F ig . 1 9 -1 4 ) .

10 . G e n tly k n o c k o u t th e re a r s e a l fro m th e w a te r p u m p body, (F ig . 1 9 -1 5 ) .

11 . P re s s th e la rg e b e a r in g f r o m th e sh a ft, (F ig . 1 9 -1 6 ) ,

F ig . 1 9 -1 3

F ig . 1 9 -1 4

F ig . 1 9 -1 5

Fig. 19-16

April '96

Cooling System 19-9

12 . R e m o v e th e s m a ll b e a r in g s fro m th e w a te r p u m p shaft, (F ig . 1 9 -1 7 ) .

Assembly

1. T h o ro u g h ly c le a n th e w a te r p u m p . E x a m in e th e b o d y fo r co rro s io n , c ra c k s a n d w e a r. R e p la c e th e w a te r p u m p c o m p le te ly if a n y p a rt sh o w s e x c e s s iv e w e a r.

2 . U s e s p e c ia l to o l 4 0 2 0 2 3 5 0 to in s e rt th e re a r s e a l in to th e w a te r p u m p b o dy , (F ig . 1 9 -1 8 ) .

3 . U s e s p e c ia l to o l 4 0 2 0 2 2 9 5 a n d in s e rt th e ca rb o n sea l a s s e m b ly in to th e h o u s in g , (F ig . 1 9 -1 9 ) .

4 . P a c k b o th b e a r in g s w ith m u lti-p u rp o s e g re a s e .

5. P re s s th e s m a ll b e a r in g o n to th e w a te r p u m p sh aft, (F ig . 1 9 -2 0 ) .

F ig . 1 9 -1 7

F: ig. 1 9 -1 8

. V ■ V / m ----------------------------------

: ig. 1 9 -1 9

Fig. 19-20

Aoril '96

Cooling System 19-10

6 . P re s s th e la rg e b e a rin g o n to th e w a te r p u m p sh aft, (F ig . 1 9 -2 1 ) .

7 . U s e s p e c ia l to o l 4 0 2 0 2 3 1 8 a n d re p la c e th e s e a l in th e s e a l c a rrie r, (F ig . 1 9 -2 2 )

8 . P la c e th e s e a l c a rr ie r o v e r th e w a te r p u m p s h a ft a n d press th e h u b o n to th e s h a ft a s fa r a s it w ill go , (F ig . 1 9 -2 3 )

9. F ill th e s p a c e b e tw e e n th e b e a rin g s w ith m u lti-p u rp o s e g re a s e , (F ig . 1 9 -2 4 ) .

F ig . 1 9 -2 1

F ig . 1 9 -2 2

F ig . 1 9 -2 3

Fig. 19-24

April '96

1 0 . F it O -r in g o v e r th e la rg e b e arin g , (F ig . 1 9 -2 5 ) .

11 . P re s s th e w a te r p u m p s h a ft w ith b e a rin g s in to th e w a te r p u m p b o dy , (F ig . 1 9 -2 6 ) .

1 2 . In s e rt th e b o lts in to th e s e a l c a rr ie r an d tig h te n to th e s p e c if ie d to rq u e , (F ig . 1 9 -2 7 ) .

13 . P re s s th e im p e lle r o n to th e w a te r p u m p s h a ft a s fa r a s th e s p e c if ie d c le a ra n c e b e tw e e n th e im p e lle r a n d th e w a te r p u m p b o dy . U s e a fe e le r g a u g e to c h e c k th e c le a ra n c e , (F ig . 1 9 -2 8 ) .


F ig . 1 9 -2 5

F ig . 1 9 -2 6

F ig . 1 9 -2 7

Fig. 19-28

April '96


14 . R e p la c e th e w a te r p u m p b a c k p la te w ith a n e w g a s k e t an d in s e rt th e fro n t a n d re a r bo lts , (F ig . 1 9 -2 9 ) .

15 . T ig h te n a ll b o lts to th e s p e c ifie d to rq u e , F ig . 1 9 3 0 ).

16 . R e p la c e th e w a te r p u m p a n d in s e rt th e bo lts re ta in in g th e p u m p to th e c y lin d e r b lo c k a n d tig h te n to th e sp ec ified to rq u e . F it th e th e rm o s ta t h o u s in g to th e c y lin d e r b lock w ith a n e w g a s k e t a n d tig h te n th e b o lts to th e sp ec ified to rq u e , (F ig . 1 9 -3 1 ) .

17 . In s e rt a lie n c a p bo lt in to th e c e n tre h u b a n d tig h te n to th e s p e c ifie d to rq u e . If f itted w ith a fa n , in sert th e bo lts re ta in in g th e fa n to th e h u b a n d tig h te n to th e s p ec ified to rq u e ,(F ig . 1 9 -3 2 ) .

F ig . 1 9 -2 9

F ig . 1 9 -3 0

F ig . 1 9 -3 1

Fig. 19-32

April '96

1 8 . W ith te n s io n g a u g e (s p e c ia l to o l) 4 0 2 0 2 3 2 1 a d ju s t th e V -b e lt te n s io n to 4 0 -4 5 kg (n e w be lts ), run th e e n g in e fo r 1 0 -1 5 m in u te s a n d re -c h e c k th e te n s io n , w h ic h sh o u ld b e 3 0 -4 0 kg. I f th is is n o t re a c h e d a d ju s t th e te n s io n to 3 0 -4 0 kg. P o s itio n th e te n s io n g a u g e on th e b e lt w ith th e f la n g e p a ra lle l to th e be lt e d g e . G ra d u a lly a p p ly p re s s u re to th e p re s s u re pad. W h e n a c lick is h e a rd o r fe lt, s to p a n d re m o v e th e g au g e . T a k e a n a c c u ra te re a d in g a t th e s p o t w h e re th e in d ica to r a rm in te rs e c ts th e s c a le , (F ig . 1 9 -3 3 ) .

19 . W h e n th e c o rre c t V -b e lt te n s io n s h a v e been ob ta in ed , lo ck th e s te e r in g p u m p V -b e lt a d ju s te r b o lt ( if fitted ), (F ig . 1 9 -3 4 ) .

2 0 . T ig h te n th e a lte rn a to r V -b e lt a d ju s te r nu ts, (F ig . 1 9 -3 5 ).

2 1 . T ig h te n th e b o tto m a lte rn a to r m o u n tin g bolt, (F ig . 1 9 -3 6 ) .


April '96


2 2 . T ig h te n th e s te e r in g p u m p m o u n tin g bo lt, (F ig . 1 9 -3 7 ) .

2 3 . C o n n e c t th e u p p e r a n d lo w e r ra d ia tio n h o ses , fill th e ra d ia to r w ith c o o la n t to w h ic h th e c o rre c t a m o u n t o f a p p ro v e d c o rro s io n in h ib ito r h a s b e e n ad d e d .

2 4 . S ta r t th e e n g in e , a llo w to re a c h n o rm a l ru n n in g te m p e ra tu re a n d c h e c k fo r c o o la n t le a k s .

A t te n t io n t N e v e r fo rc e a V -b e lt o n to th e p u lley b y us ing a lever. T h e V -b e lt m a y b e d a m a g e d a n d th u s c a u s in g a n e a rly fa ilu re . T h e a d ju s te r sh o u ld b e fu lly re le a s e d a n d th e V -b e lt tu rn ed o n to th e p u lle y b y h a n d . I f o n e b e lt in a s e t re q u ire s re p la c e m e n t a lw a y s in s ta ll a m a tc h e d pa ir. If o n ly o n e b e lt is re p la c e d it w ill b e c a rry in g a ll th e lo a d , w h ic h w ill le a d to e a rly fa ilu re .

F ig . 1 9 -3 7

April '96

Cooling System - Thermostat and Housing 19-15

CAMSHAFT AND TIMING GEARS

1 B O L T S2 C O O L A N T O U T L E T3 O -R IN G4 T H E R M O S T A T5 T H E R M O S T A T H O U S IN G

6 O -R IN G S7 C O N N E C T IN G T U B E8 G A S K E T9 W A S H E R

1 0 T E M P E R A T U R E S E N D E R U N IT

Aprii '96


REMOVING/REPLACING THERMOSTAT AND HOUSING

Removing

1. U n s c re w th e b o lts re ta in in g th e c o o la n t o u tle t to th e th e rm o s ta t h o u s in g , (F ig . 1 9 -3 8 ) .

2 . L ift o ff th e c o o la n t o u tle t, (F ig . 1 9 -3 9 ) .

3 . W ith a s u ita b le s c re w d r iv e r lift th e th e rm o s ta t fro m th e h o u s in g .

4 . R e m o v e th e O -r in g fro m th e th e rm o s ta t body , (F ig . 1 9 -4 1 ) .

F ig . 1 9 -3 8

F ig. 1 9 -3 9

F ig . 1 9 -4 0

Fig. 19-41

April ‘96


5 . U n s c re w a n d re m o v e th e bo lts re ta in in g th e th e rm o s ta t h o u s in g to th e c y lin d e r h e a d , (F ig . 1 9 -4 2 ) .

6 . R e m o v e th e th e rm o s ta t h o u s in g a n d g a s k e t fro m th e cy lin d er h e a d

7 . P u ll o u t th e c o n n e c tin g tu b e fro m th e th e rm o s ta t hous ing , (F ig . 1 9 -4 4 ) .

8 . R e m o v e a n d d is c a rd th e O -r in g s fro m th e co n n ec tin g tu b e , (F ig . 1 9 -4 5 ) .

N o te : P r io r to re p la c in g th e th e rm o s ta t ca rry o u t th e th e rm o s ta t te s t a s d e s c rib e d on p a g e 1 9 -1 9 .

F ig . 1 9 -4 2

Fig . 1 9 -4 3

-ig . 1 9 -4 4

Fig. 19-45

April ‘96


Replacing

1. F it n e w O -r in g s to th e c o n n e c tin g tu b e , (F ig . 1 9 -4 6 ) .

2 . A p p ly a lig h t c o a t o f s ilico n g re a s e to th e O -r in g s an d in s e rt th e c o n n e c tin g tu b e in to th e to p o f th e w a te r p u m p h o u s in g , (F ig . 1 9 -4 7 ) .

3 . F it th e th e rm o s ta t h o u s in g to th e co n n e c tin g tu b e , in sert a n e w g a s k e t b e tw e e n th e h o u s in g a n d th e c y lin d e r h e ad a n d in s e rt re ta in in g b o lts , (F ig . 1 9 -4 8 ) .

4 . T ig h te n th e re ta in in g b o lts to th e s p ec ified to rq u e , (F ig . 1 9 -4 9 ) .

F ig . 1 9 -4 6

F ig . 1 9 -4 7

F ig . 1 9 -4 8

Fig. 19-49

April '96


5. In s e rt th e th e rm o s ta t w ith a n e w O -r in g in to th e hous ing , (F ig . 1 9 -5 0 ) .

6 . R e p la c e th e c o o la n t o u tle t, in sert bo lts a n d tig h ten to th e s p e c ifie d to rq u e , (F ig . 1 9 -5 1

THERMOSTAT TEST

Preparation

1. R e m o v e th e th e rm o s ta t fro m th e h o us ing , (S e e p a g e 1 9 -1 6 ) .

2 . In s e rt a len g th o f co tto n th re a d b e tw e e n th e v a lv e an d th e th e rm o s ta t b o dy , s u ita b le to s u s p e n d th e th e rm o s ta t in th e c o n ta in e r, (F ig . 1 9 -5 2 ) .

3. S u s p e n d th e th e rm o s ta t in a c o n ta in e r filled w ith w a te r a n d in s e rt a th e rm o m e te r . E n s u re th a t th e rm o s ta t an d th e rm o m e te r a r e s u s p e n d e d a t th e s a m e lev e l, (F ig . 1 9 -5 3 ) .

F ig . 1 9 -5 0

F ig . 1 9 -5 1

F ig . 1 9 -5 2

Fig. 19-53

April '96


Check for Thermostat Opening Temperature

1. H e a t th e c o n ta in e r to a te m p e ra tu re o f 7 1 °C . A t th is te m p e ra tu re th e th e rm o s ta t sh o u ld d rop o ff th e co tton th re a d , (F ig . 1 9 -5 4 ) .

Full Open Check

2 . C o n tin u e to h e a t th e c o n ta in e r, w ith th e th e rm o s ta t res tin g a t th e b o tto m , to a te m p e ra tu re o f 8 2 °C . T h e T h e rm o s ta t s h o u ld n o w b e fu lly o p e n , (F ig . 1 9 -5 5 ) .

Checking for Length of Travel

3. R e m o v e th e th e rm o s ta t fro m th e c o n ta in e r. M e a s u re th e d is ta n c e b e tw e e n th e b y -p a s s v a lv e a n d th e lo w e r su p p o rt b ra c k e t o f th e th e rm o s ta t bo dy . A llo w th e th e rm o s ta t to cool a n d re tu rn to its c lo s e d p o s ition . A g a in m e a s u re th e d is ta n c e a n d s u b tra c t fro m th e p re v io u s ly o b ta in e d d im e n s ion. T h e re s u lt is th e len g th o f tra v e l, (F ig . 1 9 -5 6 ) .

A t te n t io n ! If th e th e rm o s ta t fa ils to re a c h m e a s u re m e n ts as p e r s p e c if ic a tio n s o r a n y o f th e o th e r ch ecks , it m u s t b e re p la c e d .

April '96

Cooling System - Visco Fan 19-21

B A S IC V IS C O F A N

1 C O V E R 8 S E A L2 G A S K E T 9 B E A R IN G3 D IS K D R IV E 1 0 C IR C L IP4 F A N B O D Y 11 S P A C E R5 F L A N G E D S H A F T 1 2 S P A C E R6 S C R E W 1 3 C A P S C R E W7 L O C K IN G D E V IC E

Visco Fan 19-22


D e p e n d in g on a p p lic a tio n 3 6 0 s e rie s en g in e s a re fitted w ith a th e rm o s ta tic a lly c o n tro lled v is c o u s d rive fa n , w h ic h is m o u n te d on th e w a te r p u m p h u b a n d d rive n b y V -b e lts fro m th e c ran ksh a ft.T h e v is c o u s d r iv e fa n d o e s n o t h a v e a rig id c o n n ec tio n to th e w a te r p u m p pu lley . A d rive co n n e c tio n , fitted to th e pu lley , ca n m o v e w ith in a c h a m b e r o f th e fa n w ith a s m a ll c le a ra n c e . O n reach in g a p re d e te rm in e d te m p e ra tu re th e th e rm o s ta t o p en s, a llo w in g oil to e n te r th e c h a m b e r . A s a resu lt o f th e fric tion c re a te d by th e oil w ith in th e fa n c h a m b e r , th e no ndriven b o d y o f th e fa n w ill tu rn th u s d riv in g th e fan .

C h e c k in g a n d lo c k in g v is c o u s d r iv e fa n

If th e re is a n a b n o rm a l r is e in c o o la n t te m p e ra tu re c h e c k w h e th e r th e v is c o u s d r iv e fa n e n g a g e s pro p erly w h e n th e e n g in e is w a rm . W ith th e v e h ic le s ta tio n a ry , c o v e r th e rad ia to r. S ta r t th e e n g in e a n d a llo w to run a t m e d iu m s p e e d un til th e w a te r te m p e ra tu re is 9 0 - 9 5 °C . R e m o v e th e ra d ia to r c o ver. T h e th e rm o s ta t is n o w h e a te d b y th e h o t a ir fro m th e ra d ia to r a n d op en , a llo w in g s ilicon flu id to flo w in to th e fa n c h a m b e r , th e re b y d riv in g th e fa n .

In th e e v e n t o f a fa ilu re o f th e v is c o u s fa n d r iv e th e d e v ic e c a n b e lo cked . T h e lo ck in g d e v ic e a t th e re a r e n d o f th e fa n s e rv e s to c o u p le th e fa n r ig id ly to th e pu lley .

T o c o u p le th e fa n u n s c re w th e lo ck in g nu t (F ig . 1 9 -2 6 ) up to th e lo ck sto p , th e n tu rn th e fa n s lo w ly by h a n d un til th e pin o f h e lo ck in g d e v ic e is fe lt to s n a p into p la c e a id e d by th e sp rin g p re s s u re .

T h e v is c o u s d r iv e fa n c a n b e u s e d fo r a lim ite d p e rio d on ly in th e lo cked co n d itio n . E x te n d e d o p e ra tio n in th is co n d itio n is n o t a d v is a b le . T h e fa n sh o u ld b e o v e rh a u le d

a s so o n a s p o ss ib le .

N o te : T h e v is c o u s fa n d r iv e sh o u ld a lw a y s b e tra n s p o rte d an d s to red in a v e rtic a l p o s itio n (a s fitted to th e e n g in e ) to p re v e n t th e s ilico n flu id fro m ru n n in g ou t. W h e n o v e rh a u lin g th e fa n it is e s s e n tia l to e n s u re th a t o n ly th e re c o m m e n d e d s ilico n flu id is u s e d . D o no t u s e m in e ra l b a s e d o il. T h e fa n w ill n o t o p e ra te co rrec tly , ca u s in g o v e rh e a tin g a n d s e rio u s d a m a g e to th e e n g in e .

V IS C O F A N

A D E N o . C a p a c ity S i l ic o n N o .7 6 2 0 0 5 0 4 3 9 c m 3 3 8 0 8 0 7 2 0

V is c o s i t y o f O il

S il ic o n V is c o s i t y3 8 0 8 0 7 2 0 1 2 ,5 0 c S t

T o rq u e s

D riv e d isc b o lts ..........................M 6 ...................... 1 0 - 1 3 N m.............................................................M 8 ...................... 2 8 , 5 - 3 3 N mT h e rm o s ta t c o v e r ..................................................... 1 0 - 1 3 N m

Fig. 19-57


O V E R H A U L IN G T H E V IS C O F A N

D is m a n t l in g

P rio r to d is m a n tlin g th e v is c o fa n th o ro u g h ly c le a n th e o u ts id e w ith a s u ita b le c le a n in g flu id .

1 . S e c u re th e fa n in a v ic e fitted w ith so ft ja w s ,(F ig . 1 9 -5 8 ) .

2 . R e m o v e th e th e rm o s ta t c o v e r re ta in in g s c re w s w ith a 5 m m A lle n k e y , (F ig . 1 9 -5 9 ) .

3 . in s e rt tw o M 8 b o lts in th e th re a d e d h o les in th e th e rm o s ta t c o ver, (F ig . 1 9 -6 0 ) .

4 . S c re w d o w n th e b o lts to lift o ff th e th e rm o s ta t co ver. T h e th e rm o s ta t is p re -s e t a n d m u s t n o t b e d is m a n tle d .

5 . L o o s e n a n d re m o v e th e d r iv e d isk re ta in in g sc rew s w ith a n in h e x s o cke t, (F ig . 1 9 -6 1 ) .

A t te n t io n ! T h e s e s c re w s a re se c u re d w ith L o c tite an d m a y b e d iffic u lt to lo o se n . T h e s c re w s c a n b e lo o se n ed by lightly ta p p in g th e en d o f th e s o c k e t w re n c h .

F ig . 1 9 -5 8

F ig . 1 9 -5 9

F ig . 1 9 -6 0

Fig. 19-61

April '96

6 . L ift o u t th e d r iv e d is k fro m th e fa n b o dy , (F ig . 1 9 -6 2 ) .

Visco Fan 19-24

7 . C a re fu lly re m o v e th e th e rm o s ta t c o v e r g a s k e t fro m th e fa n b o dy , (F ig . 1 9 -6 3 ) .

8 . P la c e s u p p o rt ( i t e m i p a g e 1 9 -3 0 ) u n d e r th e fa n bo dy a n d u s e a m a n d re l ( ite m 2 p a g e 1 9 -3 0 ) to p res s ou t th e d riv e s h a ft, (F ig . 1 9 -6 4 ) .

9. R e m o v e th e s p a c e r ring , (F ig . 1 9 -6 5 ) .

F ig . 1 9 -6 2

F ig . 1 9 -6 3

F ig . 1 9 -6 4

Fig. 19-65

April ‘96

1 0 . L ift o u t th e s e a l, (F ig . 1 9 -6 6 ) .

11 . R e m o v e th e c irc lip , (F ig . 1 9 -6 7 ) .

12 . T u rn th e fa n b o d y o v e r a n d us ing a s le e v e ( ite m 4 p a g e 1 9 -3 0 ) p res s o u t th e b e arin g , (F ig . 1 9 -6 8 ) .

13 . T h o ro u g h ly c le a n th e ho u s in g w ith a s u ita b le c le a n in g flu id .

14 . In s p e c t th e fa n b o d y fo r a n y d a m a g e .

A s s e m b ly

1. U s e th e s le e v e a n d s u p p o rt ( ite m s 3 a n d 1 p a g e 1 9 -2 9 ) a n d fit th e b e a rin g s , (F ig . 1 9 -6 9 ) .

A t te n t io n ! N e w b e a rin g s a n d fa n m u s t b e u sed w h e n rea s s e m b lin g th e fa n .

2 . R e m o v e th e s u p p o rt fro m u n d e r th e fa n an d fit th e d rive s h a ft in to p lace .

3. U s in g th e s le e v e p re s s th e d r iv e s h a ft in to th e hous ing , (F ig . 1 9 -6 9 ) .


F ig . 1 9 -6 6

Fig . 1 9 -6 7

F ig . 1 9 -6 8

Fig. 19 69

April '96

Visco Fan 19-26

4 . S e c u re th e fa n in a v ic e fitte d w ith so ft ja w s , (F ig . 1 9 -7 0 ) .

5 . F it th e c irc lip , (F ig . 1 9 -7 1 ) .

6 . G r e a s e th e s e a l lip s w ith a s u ita b le g re a s e a n d re p la c e th e

s e a l, (F ig . 1 9 -7 2 ) .

7 . W ith a p la s tic o r ru b b e r h a m m e r re p la c e th e s p a c e r ring, (F ig . 1 9 -7 3 ) . .

A t te n t io n ! T a p e r o f s p a c e r to p o in t to w a rd s d r iv e d isk.

F ig . 1 9 -7 0

Fig . 1 9 -7 1

F ig . 1 9 -7 2

Fig. 19-73

April ‘96

8 . C a re fu lly re p la c e th e d r iv e d is k into th e fa n body, (F ig . 1 9 -7 4 ) .

9. C le a n th e d r iv e d is k s c re w th re a d s a n d in sert th e screw s w ith L o ctite , (F ig . 1 9 -7 5 ) .

10 . T o rq u e th e s c re w s u s ing an In h e x so cke t, (F ig . 1 9 -7 6 ).

11 . U s e a s y rin g e filled w ith s ilicon o il (s e e sp ec ifica tio n s fo r q u a n tity a n d b ra n d ) to fill th e c e n tre o f th e ho us ing , (F ig . 1 9 -7 7 ) .


F ig . 1 9 -7 4

F ig . 1 9 -7 5

F ig . 1 9 -7 6

Fig. 19-77

April '96

Visco Fan 19-28

12 . T h o ro u g h ly c le a n th e th e rm o s ta t c o v e r w ith a s u ita b le

c le a n in g flu id , (F ig . 1 9 -7 8 ) .

13 . F it a n e w g a s k e t in to th e fa n h o u s in g , (F ig . 1 9 -7 9 ) .

14 . R e p la c e th e th e rm o s ta t c o v e r w ith tw o M 8 bo lts in th e th re a d e d h o les , (F ig . 1 9 -8 0 ) .

15 . T ig h te n th e A lle n c a p s c re w s w ith a 5 m m A lle n key so cke t, (F ig . 1 9 -8 1 ) .

A t te n t io n ! A lw a y s s to re th e fa n in a n u p rig h t position .

F ig . 1 9 -7 8

F ig . 1 9 -7 9

F ig . 1 9 -8 0

Fig. 19-81

April '96

Cooling System - Visco Fan 19-29Special tools for Visco Fan

These tools must be self fabricated

( Ite m 1 )S u p p o rt fo r re m o v in g b e a rin g s a n d d r iv e flan g e .

( Ite m 2 )M a n d re l fo r re m o v in g fla n g e d sh aft.

~L3 5

100

( Ite m 3 )S le e v e fo r in s ta llin g th e d r iv e fla n g e .

April '96

Visco Fan 19-30

( Ite m 4 )S le e v e fo r re m o v in g th e b e a rin g s .

( Ite m 5 )S le e v e fo r in s ta llin g th e d r iv e fla n g e .

(Ite m 6 )S u p p o rt fo r th e fa n b o d y , fo r in s ta lla tio n o f b e arin g s .

( Ite m 7 )S u p p o rt fo r th e fa n b o d y , fo r in s ta lla tio n o f b e arin g s .

April '96



O B T A IN A B L E F R O M : G R U N D Y T E C H N IF O R M , B U R M A N R O A D , D E A L P A R K , P O R T E L IZ A B E T H 6 0 0 1

T E L : (0 4 1 ) 4 3 -2 2 9 9 , F A X : (0 4 1 ) 4 3 -2 2 2 4

W a te r p u m p fro n t sea l R e m o v e m a n d re l,

P a r t N o . 4 0 2 0 2 3 0 5

W a te r p u m p fro n t s e a l re p la c in g m a n d re l,

P a r t N o . 4 0 2 0 2 3 1 8

C a rb o n a s s e m b ly s e a l re p la c in g to o l,

P a r t N o . 4 0 2 0 2 2 9 5

W a te r p u m p In n e r lip ty p e s e a l re p la c in g m a n d re l

P a r t N o . 4 0 2 0 2 3 5 0

V -b e lt te n s io n in g g a u g e ,

P a r t N o . 4 0 2 0 2 3 2 1

April ‘96

D i e s e l Club

ADE 364 and ADE 366

End of Workshop Manual

B arrington Ehesel C lub

Documents

ENGINE REPAIR MANUAL ADE 360 SERIES - Barrington Diesel Club · The 360 Series are direct injection, water-cooled four-stroke diesel engines. The cylinders are arranged in line and