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CONTINENTAL DIESEL ENGINES

OPERATORS GUIDE &

REPAIR

WIS-CON TOTAL POWER CORP.

FOREWORD
Good operation anda plannedmaintenance program as outlined in this manual are vital in obtainingmaximum engineperformance andlong enginelife. Theinstructions on the following pages havebeenwritten with this in mind,to give the operatora better understanding of the various problems whichmayarise, andthe manner in whichtheseproblems can best be solved or avoided. Theoperatoris cautioned againstthe useof anyparts, other than genuine Wis-Con Total Power parts, for replacement or repair. Theseparts have beenengineered and tested for their particular job, andthe useof anyother parts may result in unsatisfactory performance andshort enginelife. Wis-Con Total Power distributors anddealers, because of their close factory relations, canrenderthe best andmost efficient service. THE LIFE OF YOURENGINEDEPENDS ON THE CAREIT RECEIVES. The MODEL, SPECIFICATION and SERIALNUMBER of your engine must be given when ordering parts. The MODEL and SPECIFICATION number are on the nameplate. The SERIAL NUMBER is stamped either on the crankcase or the engine’s identification tag. the MODEL, SPECIFICATION and SERIALNUMBER in the spaces provided below so hat it will be availablewhen ordering parts.

MODEL

SPECIFICATION

SERIAL

NUMBER

To insure promptandaccurateservice, the following informationmustalso be given: 1. State EXACTLY the quantity of eachpart andpart number. 2. State definitely whether parts are to be shipped by express, freight or parcelpost. 3. State the exactmailing address.

IMPORTANT
READ THESE INSTRUCTIONS CAREFULLY

All points of operationand maintenance havebeencoveredas carefully as possible, but if further information is required, sendinquiries to the factory for promptattention. When writing to the factory, ALWAYS GIVE THE MODEL,SPECIFICATIONAND SERIAL NUMBER of the engine referred to.

Startincj and Operatinq NewEncjines Careful breaking-in of a newengine will greatly increase its life and result in trouble-free operation. A factory test is not sufficient to establish the polishedbearingsurfaces, whichare so necessaryto the proper performance and long life of an engine. Thesecan only be obtained by running a newengine carefully and under reducedloads for a short time. ¯ Besure the engineis filled to the properlevel with a goodquality engineoil. ¯ For proper proceduresto follow when breaking-in a newengine, see ’Testing Rebuilt Engine’. Thevarious bearing surfaces in a newenginehavenot beenglazed, asthey will be with continued operation, and it is in this period of "running in" that special care mustbe exercised, otherwise the highly desired glaze will never be obtained. A newbearing surface that has once been damaged by carelessness will be ruined forever.

These changes can affect the servicegivento the product.illustrations and other itemscan change at anytime. contact Wis-Con Total Power. If a procedure. adjustments. or information. measurements. couldcause bodily injury or deathto youor other persons. Getthe complete andmost currentinformation beforestarting anyjob.Thereare many potential hazards for an untrainedmechanic andthere is no wayto label the engine againstall such hazards. service. you must satisfy yourself that it is safe for youandothers.if not heeded. tool.These warnings in the RepairManual andon the engineare identified by this symbol: Operations that may result only in enginedamage are identified in the RepairManual by this symbol: &CAUTION Wis-Con Total Powercannot anticipate every possible circumstancethat might involve a potential hazard.Memphis. Thespecifications.This RepairManual outlines basic recommended procedures.therefore. .Properrepair is importantto the safe andreliable operationof an engine. the warnings in this manual are not all inclusive. some of whichrequire special tools. pressures of operation. specificationsandillustrations in this manual are based on informationthat wasavailable at the time it waspublished. device orworkmethod not specifically recommended by Wis-Con Total Power is used. Tennessee. devicesor work methods. For parts. IMPORTANT: Theinformation. READ AND UNDERSTAND ALL SAFETY PRECAUTIONS AND WARNINGS BEFORE PERFORMING REPAIRS ON THIS ENGINE Warning labels havealso been put on the engines to provideinstructions andidentify specific hazards which. These labels identify hazardswhich maynot be apparent to a trained mechanic. Improper repair procedures canbe dangerous andcould result in injury or death. torques. You shouldalso ensure that the engine will not be damaged or made unsafeby the procedures you choose.

rings. Some of the dangers associated with servicing such items are generally mentionedin this manual. Always exercise caution wheneverworking with an engine or any associated system. / WARNING Someequipment and materials used in the overhaul or maintenanceof an engine such as machine tools.electrical equipment. solvents. Always observe safety precautions. Improper attire suchas loose clothing. hoses. soft shoesor bare feet couldbe hazardous and should be avoided whenservicing engines.compressed air. batteries./ WARNING Most sub-systemsused in conjunction with Wis-Con Total Powerindustrial engines including (but not limited to) radiators. service or repair your engine. electrical connections or other electrical components. pressurized systems. hot parts. clutches. electrical equipment.the appropriate handbooks and safety instructions provided by the manufacturer of the end item should alwaysbe consulted prior to the undertakingof any work on subsystemsattached to the engine. Always wear eye and hearing protection whenworking on or near engines. fuel lines or other fuel system components. / WARNING Read and observeall individual safety warningsas you use this manualto operate. 2 . These items are provided by the manufacturerof the end item in which the engine is used. to avoid any hazardsinherent to these sub-systems. transmissions. movingparts. Useor service of the engine(including the use of modifiedparts or materials) not in accordance with manufacturer’s specifications could damage your engine or cause personal injury.or fuel systems. hydraulic pumpsand generators. gasoline or other fuels maybe dangerousand can cause injury. are not supplied by Wis-ConTotal Power.however. fuel tanks. Injuries maybe causedby lack of care whenworking with. or near.fans. ties.

.......................................... SECTION 3 iLubrication ........................................................................................................................CONTENTS CONTINENTAL INDUSTRIAL ENGINES SECTION 1 General Information ..................................................................... Page 5 SECTION 2 Operating Instructions .................................................................................... Page 7 Page 13 Page 15 Page 21 Page 32 Page 34 Page 39 Page 61 Page 67 Page 69 Page 71 3 ............................................................................................ SECTION 4 Cooling System .................... SECTION 11 Limits &Clearance Data ............................................. SECTION 7 Preventive Maintenance .............................. SECTION 8 Engine Repair &Overhaul .................................................................................................................... SECTION 5 Fuel System .... SECTION 10 Torque Specifications ............................................................................................................ SECTION 6 Charging System ...................................................................... INDEX ....... SECTION 9 Trouble Shooting ....................

1 Bar 0. When ordering parts. INFORMATION FOR ORDERING PARTS specification number is listed.8 49. Thrust Main Brg.94) (2.8 .2 x 24.68 L .8 73 x 31. Oil Capacity Crankcase Filter Total Valve Clearance Intake Exhaust Water Capacity Engine Weight (Approx.60 PSI) 7 PSI 1-2 (2.94 x .8-4.88 x 1.36 .88 x . In most casesa Typical Nameplate .which lists the model andserial number.5:1 2.94 x .58 x 4.4.7 L .68 L 20.84 L 216 Kg ENGLISH 3 (3.014) (.06) (164) CID 20.0 L 191 Kg ENGLISH 2 (3.2 x 24.94) (2.25) (2.014) (.) TMD20 METRIC 3 91 x 103.2 2.94 x .73 L .94) (1. of Cylinders Bore & Stroke Displacement Compression Ratio Max.88 x .88 x .73 L .25) (2.65 L . Frt.88 x 1.8 .88 x .014) (.35 L 20.5:1 (40.5:1 (40 .94) (1.5:1 2.0 L 20.4.5 5.8 73 x 23.25) (2.1 Bar 0.5 Bar 1-3-2 73 x 23.94) (2.60 PSI) 7 PSI 1-3-2 (2.8 49.2 1.5 4.95 L 5. Rear Conn.88 x .018) (2.5:1 2.) TMD 27 METRIC 4 91 x t03.58 x 4. Main Brg.5 Bar 1-3-4-2 73 x 23.2 2.78 L .8 73 x 31.) pressure maybe experienced during cold starts.8 (2)73 x 23.58 x 4.8 49. Oil Pressure* Min.36 .) (With Accessories) *Higher oil TMD13 METRIC 2 91 x 103.94) (2.88 x .2 x 24.88 x . Thisdata is of vital importance in obtainingthe correct parts: always includethis information on yourparts order.46 2.018) (3.8 73 x 23.018) (3 Quarts) (475 LBS.95 L 4.36 .88 x 1.5 Bar 1-2 73 x 23. Rod Brg. Oil Pressure (Idling) Firing Order Main Brg.1 Bar 0.96) (6 Quarts) (1 Quart) (7 Quarts) (.46 3.96) (5 Quarts) (1 Quart) (6 Quarts) (.06) (123) CID 20.96) (4 Quarts) (1 Quart) (5 Quarts) (.88 x . refer to the enginename plate attached to side of the cylinderblock.95 L 6.46 2.1 Quarts) (420 LBS.6 L 253 Kg ENGLISH 4 (3.Industrial Diesel MODEL No. Main Brg.8 73 x 23.94) (2.8 Quarts) (557 LBS.8 73 x 31.5:1 (40-60 PSI) 7 PSI 1-3-4-2 (2.8 73 x 23.94) (1.5 3. Int.06) (82) CID 20.

General Information CONTINENTAL DIESEL ENGINE Continental Diesel Engines are Comet V combustion chamber indirect injection diesel engines. charge flow and burning characteristics to provide dependable and economical heavy duty service. OHV Design [ .of the intake manifold whereby each cylinder is fed with the air charge individually and is not influenced by other cylinders of the engine. Someof the principal design features are: 1. Individual Porting . CHOICE OF FUELS--Continental Industrial Diesel Engines have been tailored for heavy duty operation for use with #1 or #2 diesel fuel that meet a minimum cetane number of 45 (see fuel recommendations. resulting in minimumbore distortion for good oil control yet maintaining low heat rejection to the coolant. Individual Porting. The combustion chamber design has been tailored for the required turbulence.completely surround all ylinder bores to a depth sufficient to cover the hot piston ring travel. Water Jackets -. page 29).Section I . This is accomplished by casting the cylinder head with individual intake valve passages for each cylinder and connecting these passages to an intake manifold which also has individualized passages for each cylinder.

~linder HeadCover Rocker Arm ector Water Header -- Cylinder Head Intake Valve ~r Insert Piston dinder HeadGasket ChromeTop & Oil Rings Water Jacket PumpDriven G~ Connecting Rod Counterweighted Cra Gear Injection Heat Treated Alloy Stee Connecting Rod. Main Bearing Cap & Cylinder HeadBolts Pump Drive Gear Crankshaft Gear Oil Oil Pure Cross section of typicalWis-Con Continental Industrial Diesel .

Theentire aimin setting forth theseinstructions is to give youa benefit of the knowledge andexperience gainedover a long period of collaboration betweenEngineering Researchand Field Service. Sparks or flames neara battery could cause anexplosion or fire. This is a very important responsibility since the care and attention given the enginegoes a long wayin determining howlong a period it will operatesatisfactorily before havingto be shut down for repairs. Read andobserve safetywarnings on pages 1 and 2. Bodily injuryor death may resultto individuals during operation of anengine withinanyenclosure notadequately or properly ventilated.Section 2 Operating Instructions Theperson operating the engine naturally assumes responsibility for its care while it is being operated. Close water drain cock mon the side of the block.this maybe a pipe plug.) 2. (See Cooling System Section 4). Engine operation in anyenclosure requiresadequate and proper ventilation to avoid asphyxiationor other interruption of normal breathing. Bleedthe entire fuel system. provide air to mixwithfuel and to carry away heated air from thebuilding. Fill Fuel Tank-.Checkstorage battery terminals andall electrical connections. To supply sufficient air to cooltheengine.it must be thoroughly inspected for external damage and particular attention paid to the followingitems: 1. Battery acidcancause corrosive burns. Fill Crankcase with oil -. Read andobserve safetywarnings on pages 1 and 2.Usethe oil recommended for the ambienttemperature(see chart on page14). 3. Electrical Connections -. Always wear eye protection. STARTING THE ENGINE / WARNING Water DrainCock Fill radiator and water jacket with coolant. Detailedinstructions for bleeding the injection systems are given in section 5.Useof jumper cables or battery charging should be done only as directedby manufacturers’ safety instructions. (In some cases.See fuel recommendations on page 29. fuel systemmustbe bled to remove any air that mayhave become trapped in the system. 4. PREPARATION OF A NEW ENGINE FOR OPERATION Beforeplacing a new enginein operation. Radiator Coolant Inlet . WARN NG Stop engine before checking battery terminals or electricalconnections. The operating and preventive maintenance structions for the Diesel Enginesare simple and shouldbe followed without deviation. If theengine is new or rebuilt or if fuel filters have been serviced or any low pressure lines disconnected.

etc. manuallyenergize glow plugs for the appropriate time: either 7 seconds or 20 secondsdependingupon which type glow plugs are usedin the engine.then stop engineandrecheck oil level in crankcase -. turn switch to the "off" position andrepeatthe above steps.P. Engage glow plug preheat control and wait until the indicator light is off. Move switch to start position andstart engine. 1.The use of these fluids will causesevere internal engine damage and/or bodily injury. If enginedoesnot usean automatic preheat control. showrooms. 8. PowerTake-off IMPORTANT! Breaking in a new or rebuilt engine -. Adjust valve tappets to specified clearances. Engine should be operated long enoughto bring oil andwater temperature to normaloperating temperatu re. 38°C(100 7.). etc.then bring oil level to high markon dipstick.STARTlinG PROCEDUP~ 9. Thenopen throttle to abouthalf speed until the coolant reaches ° F. 2. If starting is not attemptedwithin 15 to 20 seconds. If the fuel pump is fitted with a mechanical shutoff. are started up for any reason. DisengagePowerTake-Off -. If they are stopped while still cold. 5.for peak performance and economical operation. they should be brought up to operating temperature in order to eliminate all condensation before stopping. 6.(if equipped) Starting engineunderload throwsoverloadon starter andbattery. Make sure electric shut-off is wiredto permit fuel flow when the starter switchis in the "start" and"run" positions. 1. condensation will settle on valvestems andguides. for a few minutesto circulate andwarm the oil.run it at idle for 5 minutes. 3. if enginestill doesnot start refer to trouble shootingsection 9. will bestuckby this rusting and sludging action. Adjust throttle to idle at 800to 1200 R. RELEASE Water Temperature Gauge 11.1 Bar (40 . If enginefails to start. CheckWater Temperature / WARNING Starting fluids or aids suchas ether or gasoline mustnot be used in a diesel engine air intake system. operation.M.4. be sure breatheror ventilation system is openso vapor can be expelled.60 PSI) * Higheroil pressure maybe experienced during cold starts.repeat the preheat sequence. move the control to full open. rings. . 4. and rust and sludgewill form.as well as other moving parts. Check Oil Pressure MODEL TMD OIL PRESSURE* 2. 10.8 . 8 WARM UP NEW ENGINES When newengines in distributors or dealers stock. Soon valves. CAUTION: After starting newengine-. 2. Read and observe safety warnings on pages 1 and2.Adjust idle speed to equipment manufacturer’s recommendation. the following adjustments should be made at end of first 50 hrs.

IDLINGENGINEslow engine downto low idle for about 5 minutes. after each operating period.STOPPING THE ENGINE 1. COLD WEATHER OPERATION Battery condition starting. If morethan a teacupful of water is drained off.M.) 2. 6. "FREQUENTREADINGSOF GAUGESHOULDBECOME A HABIT". before stopping-too rapid cooling down may cause distortion. move the control to full close. Injection pump warranty will be affected if pump failure results from water in the fuel. WATER FREEFUELis vitally important to the operationof your engineandfuel injection system. 8.the filter bowl should be drained daily until the amountof water so removedindicates that less frequent draining will be adequate to prevent water from enteringthe fuel injection pump. WHENENGINE IS OVERHEATED -donotadd water . This is formed by the piston combustion gases mixing with the fine oil mist in the crankcase and condensing on a cold surface. When the presenceof water in the fuel is suspected. 10. FOLLOW PREVENTIVE MAINTENANCE SCHEDULES RECOMMENDED-thiswill avoid troubles which might cause expensive breakdowns and maintain your engine for dependable and economicaloperation. 11. Moveswitch to off position. The multigrade lubricating oils 5W-20 and 10W-30 are ideal for cold starting with its reduced initial drag until warmed up. (A voltage regulator may limit it to a very low reading). the contaminated gases remain in gaseous form and the engine operates clean as long as breather system is kept clean--however temperatures below this will The oil used during cold weather should have a cold test below the lowest anticipated temperatures that will be encountered during its use. AMMETER-should register "Charging" at all times engineis rur~ning. CLEAN. Overheatingis detected by loss of coolant. This dew point is about 57°C (135°F. Sludge formation at low temperatures is a close second to dirt in causing engine damage and . Use a proper temperature range thermostat and warm engine up thoroughly.)-when crankcase temperatures are higher. If the fuel pump is fitted with a mechanicalshutoff. engine at idle for several minutes to cool.). 7. Higher temperatures are acceptable with pressurized systems. 5.should not exceed 508mm (20") water. CLEAN AND SERVICE AIR CLEANER-as recommended to maintain its efficiency. Adjust valve tappetsto specified clearances. Reduce engine Spe d to Idle.). the following adjustments should be made at end of first day’soperation. Disengage Power Take-Off 2. 2. 4.5 Bar (7 PSI) at idle (800-1200 R. BREAKING IN A NEW ORREBUILT ENGINE -for peak performanceand economical operation. MUFFLER RESTRICTION . Adjust idle speed to equipment manufacturer’s recommendation.if hot. the sourceof ingress mustbe foundor else the filter bowl must be drained at morefrequent intervals. when they assume the characteristics of the heavier oil.P. AVOID COLD--SLUDGECONDENSATION-by protecting unit to maintain crankcase temperature over 57°C (135°F. or cylinder head. 11 "MUSTS" FOR YOUR ENGINES 1. run 3. is very important for proper wear. Inspect mufflers periodically for restrictions to prevent burned valves. OIL PRESSUREshould be up to recommended pressure at operating speedand over 0. 4.allow engineto cool so as to prevent cracking the cylinder block. 9. WATERTEMPERATURE-normal operation 81°C-96°C (178-205°F. This condensation forms both a sulphuric and sulphurous acid which combines with the oil to becomea highly injurious sludge. 3. 1.

Be sure connections are clean and tight and that cables and wiring insulation are in good condition.replenish water and test for condition and state of charge. loosen the pressure cap to the first stop and let the pressure out o! the cooling system before removing the radiator cap. It is vitally important therefore to maintain oil and crankcase temperatures above 57°C (135°F. Alternator and regulator-run the engine and check the ammeter to be sure the alternator is charging and the regulator is functioning properly. ELECTRICAL SYSTEM A.Resulting in Burned Bearings and Stripped Pump Gears. 30). Read and observe safety warnings on pages 1 and 2.6" CLEAN ENGINE OPERATION 148. 1. Check and adjust alternator belt tension. which puts a heavy load on batteries.6" TO TEMPERATURES F / WARNING °. Battery . batteries run downand the engine is blamed for hard starting. High Temperature Operation--for every 5°C (10°F.check battery cables. Note:Some high altitude fuel delivery curve shaping can be performed on someSTANADYNE fuel injection pumps in the field (seepg. Read and observe safety ENGINE PREPARATIONFOR WINTER USE More than 90%of the hard starting complaints in cold weather are the direct result of inadequateattention to preparation for winter use and proper maintenar~ce. Wiring .) inlet air temperature-a powerloss of 1%results. per winter grade.5 LIQUID CONDENSATION S=udg=no.7" 10" 0" -17.3" ° 65. So.8" 45.ICE Sludge andFreezing of Oil Screens andPumps . Use of jumper cables or battery charging should be done only as directed by manufacturers’ safety instructions.4°C (85°F. / WARNING warnings on pages 1 and 2. LUBRICATION SYSTEM A. or clog the inlet strainer and cause bearing or oil pump failures. Putting your engine in proper condition and keeping it that way pays big dividends by reducing costly down time. loo’. 250 2oo’. Drain oil and changefilter. 37. 3. 10 A.) above29. Ringand ValveStickingand Burning of Bearings. Caution should be used when determining the proper seasonal grade lubricant to assist in cold weather starting. connections and other wiring. Sparks or flames near a battery could cause an explosion or fire.1" 93. Battery acid can cause corrosive burns. hoses and engine for water leaks.) the pump calibration should be modified to maintain an acceptable smoke level. invariably.result in injurious sludge formation. HighAltitudeOperation--if engine is to berun continuously at a highaltitude (above 5000 ft. Etching of Parts. ° 15o .) as shown the following chart: Use the checklist ready for winter. Addoil of the pro- types and B. 2. schedule to keep during the winter which follows to get your engine Then use the winter maintenance it in peak operating condition months. COOLING SYSTEM When sludging conditions prevail.9" 121. the oil should be examined daily and changed as it mayfreeze. 50" 32" o o Stop engine before checking battery terminals or electrical connections. Check radiator. There are several different manufacturers of transmissions and powertake-offs. Tighten hose clamps. An engine not properly prepared requires more cranking energy and time. 666 SNOW . repair leaks and install antifreeze to the level required for winter protection. Always wear eye protection. . Contact manufacturer for recommendations. Replace if required. CHECKLIST REACTIONS WITHIN ENGINE DURING CRANKCASE OPERATION c 176. If the coolant is hot or if the engine has been running.

3. 2. 7. Refer to SAEJ313 or your local fuel distributor for detailed information (see page30). Drain cooling systemcompletely. Fuel filters -. Check the fuel stop and throttle control for satisfactory operationandadjust as required. Fuel recommendations m the type of fuel to be used should be suitable for the ambient temperature to be expected. To insure against condensation in the fuel tank. 10 engine preservative oil which meetsMIL-L21260 Grade1 specification. This will avoid excessive sludgein the oil andreduce dilution of oil with rawfuel in the crankcase. 8. B. Bleedthe system as detailed in section 5. Servicedry type air cleaneras specified. Co WAR ilNG Starting fluids r aids uch as ether or gasoline must not be used in a diesel engine air intake system. Sealthe air ventin the tankor filler capwith waterproofedadhesivetape. EXHAUST SYSTEM A. 6. Read and observe safety warnings on pag s 1 and 2.operateit for at least an hour oncea week to get it thoroughly warm. particularly the primary stagefilter. 9. Run engine -. Be sure all hoses and clampsare properly seatedandtight. otherwisethis may freeze and stop the fuel flow. if supplied.removing all grease or ot~er foreign matter. Check instructions on the air cleaner decal.The use of these fluids will causesevere internal engine damage and/or bodily injury. Sealall openings air-tight -. FUELSYSTEM A.with adhesive tape that will not absorb or retain moisture. 11. Drain crankcase. PI:{EPA. WINTEI~ I~I~INTEN~CE 1. Contact Wis-Con Total Power for special starting aids for colder temperatures. 11 .After engine hascooled. Changeoil as recommended on page 14. Refill crankcase -. fill to capacity at the endof each operating period.With SAENo. Never wash a hot injection pump with cold waterwhile engine is running. 12.4. for proper operation and repair as required. 10. Stop engine-. 7. 5.Refill with about2 gallons of a 50-50mixtureof purewhite kerosene and SAE No.RAT[ON OF ~_JYG]]~I-E FOR SEJ~ONJ~L STOI:tAGE (90 DAYSTO 6 MONTHS) 1. 5. Checkthe rain cap. Normal starting using the glow plugs supplied as standard equipment should be accomplished down to--20°C (~4°F). Drain fuel tankandfilters -. B. INTAKE AIR SYSTEM A. Fill coolingsystem-With a solution containing a rust inhibitor.To thoroughly warm-upoil in crankcase. Start engine andrun it at half speed for 15 minutes when the oil will havecirculatedthrough the injection pump.mustbe checked moreoften.Anddrain crankcaseoil. 2. Cleanfuel m handled by a reliable source having a cetane number of 45 minimum. 4. 3. is a definite requirementfor easy starting and efficient operation. MISCELLANEOUS A. We cannot caution you too seriously about obtaining fuel from a reliable source. Performmaintenance in accordance with instruction manuals. Checkand adjust tappets. 10 engineoil. lines andinjectors. If unit is only usedfor short periodsanddoesnot get thoroughlywarm. Cleanexterior enginesurfaces -. to remove all the moisture and condensation separated from the fuel. 6.

NOTES 12 .

Failure to do so may result in engine damage dueto momentary oil starvationat start up. However. Refer to trouble shooting section for this information.Section 3 . Tappetsare lubricated by overhead oil return. A full flow oil filter is providedto remove dirt and foreign elementsfrom the oil. Theremovalof grit.Lubrication ENGINE LUBRICATION SYSTEM Continental industrial diesel engines havefull pressure lubrication to all main.the lubricating oil in internal-combustion engines becomescontaminated from the by-products of combustion: dirt. water. connecting rod and camshaft bearings as well as rocker arms and timing gears. OIL PUMP Onall engines. Oil PumpPick-up (Typical) OIL CHANGE FREQUENCY Engine oil does not "wear out". CAUTION: If the oil pressure is erratic or falls below these limits. (See suggested oil and filter change intervals on page 14. Note:Onengines equipped with remote oil filters. Higher oil pressure maybe experienced during cold starts.) 13 .a large capacity gerotor type oil pump is driven off the crankshaft and protected by a screened inlet. A by-pass valve maintains suitable oil pressure from idle to maximumspeed automatically. stop the engine IMMEDIATELY and find the cause of the trouble. 1 always fill theoil filter element withmotor oil priorto / installation. ~ TAPPET ~ R BEARINGS CAM ~ ~ / (( [~r GALLERY O~L BEARINGS PRRELIEFVALVE ~ CRANK& ROD BEARINGS PUMP OUMP Oil Filter Full-Flow Filter System Theschedulefor changing oil is directly dependent upon the operational environment: an extremely clean operation could go 100 hours while a dirty operation(foundry or cement factory) could be 50 hours or less.and the detergentsholding the carbon particles in suspension in the crankcase. Refer to page4 for complete oil pressurefigures. sludge and foreign particles causesfilter elements to clog and becomeineffective unless they are normally replaced every 100 hours or moreoften if conditions require. unburnedfuel entering the crankcase.

Continental industrial diesel engines operate in a wide range of service conditions and seasonal temperatures. Continuous Rating) andStandby 200 Hours Max. SF/CD .40 20W. 14 .g.A. The lubricating oil recommendation is based upon engine design. 10W .40 CD. 10W .40. long engine life.50. Lube oil analysisprograms are recommended in all applications for optimum engineperformance andlife. API SERVICE DESIGNATIONS Werecommend using oil described below for all Continentalindustrial diesel applications. type of service.exceedsengine manufacturer warranty requirements. High quality oils are required to assure maximum performance. 50 Hours 5W ~ Multi-Grade 15W-50have the the lighter oil characteristics ¯ 20 15W-50 ~ Oils such as SAE 5W-20 and SAE starting grade characteristics of and after warm up have the running of the heavier grade.40 SAE 15W .installation. 130 .40 20W. Sump Oil Temperature 210 .210°F (71 . and the atmospheric temperature prevailing.E. fuel systemand general engine conditions canall influence lubricant performance.LUBRICATION RECOMMENDATIONS Motor oils used for internal-combustion engine lubrication perform many useful functions including: Dissipating heat.Service Class D Service typical of industrial diesel engines operating under engine manufacturer’swarranties. Check your specification for accessories which mayrequire periodic lubrication. SE/CD . NOTE: 1. High detergent . sealing piston rings. S.Oil Classifications maybe used. SUGGESTED OIL ANDOIL FILTER CHANGE INTERVALS Continuous Dutyat Continuous Duty Rating Light DutyOperation (25% Max.30 "////////3 SA~ 10w F///////////////////////////////////~ SA~ ~0w~20 ~////////////////////////~ SA~ =0 V//////. so our recommendations are given for various types of service and ambient temperatures. ~o ~///////////////////~ ~ For engines in continuousduty oil viscosity should be based on sump oil temperature.71 °C) The Multi-Grade oil used should cover the single grade recommendation for the atmospheric temperature involved.Oil Classifications maybe used.250"F (99 . Standard Continental supplied starters and alternators have sealed bearings requiring no lubrication. preventing metal-to-metal contact wear and reducing power loss through friction.Oil Classifications maybe used. SG. The following SAE grades are general recommendations for Continental Industrial diesel eogines during changing seasonal atmospheric temperatures: AVERAGE AMBIENT TEMPERATURE AT WHICH ENGINE STARTING IS REQUIRED: °C °F -30 -20 -18 0 17 20 5 40 16 60 27 80 38+ 100 + "/////////////////////////////////////////~ ~///////////////////////~ SA~ ~0 y///////////////J SAE 20W .160"F (55 .40 SAE 10W.~ ~ SA~ ~w. Environmental.SAE 20 and SAE 30. SAE10W-30 covers SAE-10W.~9"C) SAE Grade 40 30 30 10W. SAEo20W. OIL BODYGRADES Theoil gradesavailable from the lightest (SAE5W) to the heaviest (SAE50) are: CLEAN DIRTY ENVIRONMENT ENVIRONMENT 100 Hours Max. Lube oil andfilter mustalways be changed after the first 50 hours of operation of a new or rebuilt engine. 15W.30.121°C) 160 .30.50 20 10W. and minimum cost of operation.40 SAE10W . 15W. e.

Coo ing System Thefunction of the cooling system is to prevent the temperaturesin the combustionchamber from damaging the engine and at the same time keepthe operatingtemperatures within safe limits. CAUTION: OVERHEATED ENGINE never pour cold water or coldanti-freeze into theradiator of anoverheated engine. passingalong and between the cylinder bores and is metered by the headgasket into and across the cylinder headto cool the pre-combustion chambers. However. The thermostat valve remainsclosed and only allowsthe coolant to circulate within the engine itself until normal operating temperaturesare reached.depending uponthe application. the rate of expansion being1/32 liter per liter (1/4 pint per gallon) when the temperature is raised from 4° to 81°C(40° to 180°F). When desired temperature is reached.whichcontrols the opening to the radiator or heat exchanger. This provides for both rapid and eventemperature increase of all engine parts during the warm-up . in order to prevent damage to valves.this systemmustbe kept from overheating. Keep engine running whileadding coolant. For example: If a 4 gallon coolingsystem is filled completely full ofwaterat4°C(40°F). however.in whichis mounted the positive shut-off thermostat. Like all liquids it expands when heated. period. as enginetemperatures mustbe brought up to andmaintained within satisfactory rangefor efficient operation.ectional View showing Coolant Passages in Head andBlock EXPANSION OF WATER Water has always been the most commonly used coolant for internal combustion enginesbecause it hasexcellent heat transfer ability andis readily obtained everywhere. This canleadoperators to believeengines are overheating when theyare actually operating normally. valve seats and guides. the coolant enters the radiator or heat exchanger. the chemicalcontent of the water is suchthat eventhe best of rust inhibitors will not protect the cooling system from the formationof rust andscale. There are instances wherethis corrosive elementhaseaten holes throughcast iron parts suchas water pumpimpellers and bodies. the coolant enters the thermostathousing. WATER FILTERS In some areas. Operation of engines in this temperature range is not harmful.Section 4 .Upon being discharged from the thermostathousing. Continental industrial diesel engines operate mostefficiently with coolant temperatures of 81°93°C (180°-200°F) and a thermostat and bypass system is usedto control thesetemperatures. whereit is cooledbefore reentry into the engine. while shutting off the by-passsystem. Thecoolant fromthe pump enters the front of the block. Upon leaving the cylinder head. Allow the engine to cooland avoid the danger of cracking the cylinderhead or block. COOLING SYSTEM All Continental industrial diesel engines have the coolant force-circulated by a water pump and use a thermostat and by-passsystemto control the temperature range.1 pintwill be lost through the radiator overflow pipe by the time the water temperature reaches 81°C (180°F). This condi15 . temperature gauges are not alwaysaccurateand maysometimes indicate higher thanactual temperature. Maintainingthe cooling system efficiency is imo portant. pistons and bearings. the thermostat valve opensallowing all the coolant to circulate throughboth the engineandradiator. IMPORTANT: Presentthermostats begin to openat 81°C (180°F)andare fully openat 94°C(202°F).

ANTI-FREEZES Water freezes at 0 °C (32 °F. For the eyes. immediately flush the eyes with water for several minutes.tion is caused by electrolysis taking place in the parts involved. Every 500 hours of operation the radiator and cooling system should be well cleaned and flushed with clean water. In standard radiator design fins are connected to the metal tubes to give an extended surface through which heat can be dissipated.23°Cto -34°C (-10° to-30°F circulated. Ratio Ethylene Glycol to water lto4 2to5 ltol CORROSION INHIBITORS / WARNING Corrosion inhibitor can cause damage to the eyes or skin. scale and rust on the cooling surfaces prevent normal heat transfer from . This pressure becomesless at higher altitudes and the reduced pressure causes water and other liquids to boil at a lower temperature. Operating conditions will determine the frequency of this service. It is important that these tubes be kept clean on the inside and the fins free of dirt on the outside so the maximum heat transfer can take place in the radiator. I! contact is made. will serve to keep the cooling surfaces of the core free of dirt and other particles. CLEANING COOLING SYSTEM Deposits of sludge. 0°to-12°C 12°C to. The correct proportion of anti-freeze is also important when the engine is to be operated under high ambient temperature conditions. When operating temperatures are below 0°C (32°F. in a direction opposite to that of the fan circulated air. Where the use of hard water cannot be avoided an approved water softener can be used.23oc (32°to 10°F / t+ 10°to. only soft clean water should be used in the cooling system. forms solid ice and expands about 9% in volume--which causes tremendous pressure and serious damage when allowed to freeze inside the cooling system.) under atmospheric pressure at sea level.). Read and observe safety warnings on pages 1 and 2. water filters should be incorporated in the assembly to remove these troublesome elements and offset the electrolytic action. simple to use and make cleaning and flushing necessary only after long periods of operation. Hard water will cause scale to form in the radiator and the engine water jackets and cause poor heat transfer. Permanent anti-freeze will also raise the boiling temperature of the coolant. Rust inhibitors for water are inexpensive. using compressed air. seek prompt medical attention. OPERATINGTEMPERATURE RANGE ANTI-FREEZE ETHYLENE GLYCOL (permanent type) Whenthere are no leaks add water only to makeup for eval~oration. Radiator Drain Water forms rust due to its natural tendency to combine chemically with iron and air in the system. Where these conditions exist. EFFECT OF ALTITUDE ON COOLING Water boils at 100°C (212 °F. RadiatorCoolant Inlet Blowing out between the fins of the radiator.) an anti-freeze liquid must be added which will lower the freezing point a safe margin below the anticipated temperature of outside air.10°F) . immediately wash skin with water. RADIATOR The radiator or heat exchanger consists of a series of metal tubes through which the coolant is 16 Wherever possible. In either event. The adC~ition of a corrosion inhibitor is not necessary if an anti-freeze containing a rust inhibitor is used.

as follows: 1. Put radiator cap on tight. Partly close the water pumpopening to fill the engine jacket with water before applying the air. corrective cleaning by reverse flow flushing will most effectively remove the heavy deposits of sludge. REVERSE FLOW FLUSHING Whenever a cooling system is badly rustclogged es indicated by overflow loss or abnormally high operating temperatures. 5. R v rse flush the radiator.repeat until the flushing stream runs out clear. The appearance of rust in the radiator or coolant is a warning that the corrosion inhibitor has lost its effectiveness and should be cleaned before adding fresh coolant. 7.the metal surfaces to the coolant and in time render the cooling system ineffective to properly maintain normal operating temperatures. the unit is defective and should be replaced. 17 Reverse Flushing Radiator . with 4. Dependable cleaning compounds should be used. rust and scale. 4. to avoid radiator damage. Before testing. If the valve can be pulled or pushedoff its seat with only a slight effort whencold or it does not seat properly. Follow the same procedure outlined above for the radiator by alternately filling the water jacket with water and blowing it out with air 5. 2. Shut off the air. 2. 3. again fill the radiator with water and apply air pressure. Clean and inspect radiator cap. Thermostat operation can be checked in the following method: 1. After cleaning and flushing. 2.g should be performed immediately after draining the cleaning solution. Clampthe flushing gun in the upper hose. The reverse flow flushin. Heat the water slowly and check temperature with a thermometer.5 Bar (80 PSI) until the flushing stream is clear. This is of prime importancebecausedifferent cleaners vary in concentration and chemical compositions. Clamp the flushing gun in the lower hose a hose clamp. Disconnent the hoses at the engine. Apply air pressure gradually. To Reverse flush the engine water Jacket 1. It is advisable to flush the radiator first. 6. Follow the procedure recommendedby the supplier. Turn on the water and let it fill the radiator. Hang thermostat by its frame in a container of water so that it does not touch the bottom. the system should be filled with an approved anti-freeze compoundcontaining a rust and corrosion inhibitor. 3. clean and examinethe thermostat. allOwing the engine to cool as much as possible. Removethe thermostat. WATER FLUSHING GUN AI~ CLOSED FLUSHING GUN AIR Reverse Flushing Engine -NEW HOSE TESTING THERMOSTAT HOSE Remove the water outlet elbow.

Installing New Gasket 18 . Many operations use a pressure cap on the radiator to prevent overflow loss of coolant during normal operation. Assemble new water outlet elbow mounting gasket. however. Read and observe safety warnings on pages 1 and 2. This spring loaded valve in the cap closes the outlet to the overflow pipe of the radiator and thus seals the system.) or 120 (248 °F.3 or 1. PRESSURE CAP PRESSURECAP CONTACT Installing Thermostat SEAT FAN BELT TENSION Whentightening fan belts. the thermostat should be replaced. Under no circumstances should a pry bar be used on the alternator to obtain fan belt tension or damage to the bearings will result.200°F. loosen the alternator adjusting bolts and pull out on the alternator by hand until the belt is just snug. When a pressure cap is used an air tight cooling system is necessary with particular attention to tight connections and a radiator designed to withstand the extra pressure. Thermostat flange must seat in counterbore with gasket sealing contact between it and the outlet elbow. Most pressure valves open at 0. allowing steam and water to pass out the overflow pipe. so that pressure developing within the system raises the boiling point of the coolant and allows higher temperatures without overflow loss from boiling. Whenadjusted correctly the fan belt deflection on the long side should not exceed 13mm (1/2"). loosen the pressure cap to the first stop and let the pressure out of the cooling system before removingthe radiator cap.3. If the valve does not start to open at temperatures of 81 °-93°C (180°.) point is reached. the boiling point of the coolant at this pressure is 107°C(224 °F. Checking Thermostat Wheninstalling a new thermostat in the water header make sure that the temperature sensing unit goes in first or faces toward the cylinder head.) or if it opens well before the 81 °C (180 °F.0 Bar (41/2 or 15 PSI). RADIATOR PRESSURE CAP / Thermostat Open 85°C~ WARNING If the coolant is hot or if the engine has been running. When replacing the thermostat in" the water header be sure the counterbore is clean.) at sea level.

REMOVING WATER PUMP The water pump assembly can be removed from the engine as a unit for service or repair in the following manner: 1. 4. 4. Use puller to remove impeller (4) taking precautions to prevent damageto the casting. 2. Remove seal (5). 3.The water pump requires no attention other than bearing replacement when it shows excessive looseness or if a coolant leak develops which shows a damaged or badly worn seal that needs replacement. DISASSEMBLY OF WATER PUMP When replacement of any internal parts becomes necessary. Use puller to removefan hub (11) from shaft. there is a drain plug on the side of the cylinder block which drains which might be trapped in the base of completely right hand all coolant the block. 1. The inlet of the water pump is connected to the lower radiator connection and the outlet flow from the pumpis through integral passages cast in the block. Removefasteners holding the pump body to the front of the block and remove the pump assembly. Remove countersunk screws (1) holding cover (2) removing cover and gasket (3). Coolant Drain Removing Water Pump WATER PUMP The water pump is located on the front of the cylinder block and is driven by the fan belt from the crankshaft pulley. Loosen alternator so that fan belt can be slacked off enoughto slide over pulley. 3. Adjusting Fan Belt Tension CYLINDER BLOCK COOLANT DRAINS Whenthe cooling system is to be drained. 19 . Remove fan by taking out four cap screws. 2. No lubrication of the pump is required as the bearings are of the permanently sealed type and are packed with special lubrication for the life of the bearing. disassembly must be in the following sequence in order to prevent damageto the pump. Drain coolant.

Reassemble pump. Use thick soapsuds on both the seal and shaft when assembling in order to prevent damageto the seal. DO NOT ATTEMPT TO DRIVE WATER PUMP SHAFT (10) OUT THROUGH REAR OF HOUSING. 6. 4. ~ Please reference SPB88-374. Seal contact surfaces must be smooth and flat. 3. C!ark Water Pump 2O . The shaft must be supported during this operation to prevent damageto the seal and bushing. Pull out the alternator by hand. as bearing damage will result with a pry bar. Install fan belt and adjust belt tension to have 13mm (1/2") deflection on long side. The fan hub must be installed prior to replacing rear plate. REASSEMBLY AND INSTALLATION 1. 2.l Drive Shaft out in this direction Disassembling Water Pump 5. To do so will damage the housing beyond repair. 5. Mount pump assembly on block using a new housing gasket. Refill cooling system. replacing worn or failed parts. Removelock rings (7) holding bearing and shaft assembly in body after which shaft (10) can be forced out through the front with an arbor press or lead hammer. A light film of lubricant applied to the face of the seal will facilitate seating and sealing. The bushing should be replaced if scored or cut.

electric fuel pumps to transfer fuel fromthe fuel tank to the fuel injection pump. as fine particles of dirt in the fuel are extremely destructive to high-pressure pumps of any description. Fuel should flow and the pump should beginticking if it is operating properly. The injection systemof a diesel engineincludes an injection pumpassembly complete with governor. suchas suctionleaksat joints in the supplyline can cause erratic enginebehavior. with a container. etc.fuel supply pump. Various components are made with the utmost precision and maybe easily damaged when removed. Read andobserve safetywarnings on pages 1 and 2. All injection pumps should be calibrated and repaired at authorizedservice stations. This makes themextremely useful when bleeding the air from the fuel system. A brokenstreamwith bubbles anddribblesor no fuel at all indicatesthe fuel pump is probablybador that there are restrictions somewhere 21 .the correct pattern of sprayfor the combustionchamber. (See Bleeding the Fuel System.)Theydrawlittle battery currentandonly a slight drain is usuallyseen on the storagebattery during the bleeding process. Electric fuel pumps will operate withouthaving to crank the engine over. Beprepared. throughthe nozzles.check for voltageat the first wire connection closestto the electric fuel pump. It shouldbe bornein mindthat minor troubles. one for each cylinder. unless engine operation is seriously impaired and the cause of thedifficultyis directlytraceable to thepump unit.simplydisconnect the fuel inlet line fromthe fuel injection pump andturn the ignition switchon. A steadysolid stream of fuel indicatesthat the fuel pu mp is probably OKfor continueduse. Improper handling of fuel could result in an explosion orfire causing bodily injury to yourself or others.If you can’t hear or feel the fuel pump operating . When fuel pump trouble is suspected. unlessfactory trained personnel are available with the proper tools andtest equipment. If the pump is operating. These electric pumps are usually mountedto the crankcase fuel pumppad cover wherea mechanical fuel pump wouldnormally be mounted. high-pressuresteel lines connectingthe pump discharge outlets to the nozzles. Thefuel transfer pump drawsthe fuel from the supplytank. bad switches. Not the least of theseare the filtration elements.check for actual batteryvoltageto the unit before declaring it to be bad! Usinga Voltmeteror test light . but volumeor flow needs to be checked . Youcanactually feel the pump operating andhearit ticking if the work areais quite enough. If voltageis present at the fuel pump make one last test before declaring the pump bad! Loosen the fuel line fitting onthe inlet fuel line onthe injection pump. It is unlikely that the injection pump itself wouldrequire overhaul beforeit has several thousand hours of operation.The fuel injection pump places it underthe high pressurerequired for mechanical atomization. forces it through the filters anddelivers it to the injection pump. CAUTION: There should be notampering with the injectionpump assembly. distributes it in the propersequence to the various cylinders. This connection is usually foundat the fuel shut off solenoidon the fuel injection pump. convey andinject the fuel into the engine. meters it with great accuracy. Carelessor too frequent removalof elements of the fuel injection system for "inspection" or "cleaning" is generally far moreharmfulthan beneficial. broken wires.fuel filters. or removal of it for inspection. and nozzle holders and nozzle assemblies. dueto the danger that dirt will enter the exposed connections and the possibility of mishandling the equipment through lack of knowledge of its design and construction. commences the individual injections with fine precision in timing.Theareashould beproperly ventilated. If no voltage is present .always check that the pump is getting voltage from the ignition circuit and that the BLACK groundwire is intact beforedeclaringthe pump is bad! A "quick" test for voltageis to turn the ignition switch"on" andfeel the bodyof the pump. and producesuniformly.Secl "on Fuel System Thebasicpurpose of the fuel system is to store. ELECTRIC FUEL TRANSFER PUMP ManyContinental TMD Industrial engines use WARN NG Smoking or open flameshould be avoided any timethe fuel system is being repaired or serviced.checkthe equipment electrical circuit for blownfuses.to catchthe fuel as it comes out of the open line.

in the fuel circuit.loosen connection (B).Set the accelerator to the fully openposition and ensurethat the stop controlis in the "run"position. Note: If connection (A) is inaccessible due to the type of filter in use-. Tighten nuts. CAV--DPA Fuel System Schematic Note: Electrical equipment such as starters should be shielded duringbleeding to prevent fuel entry. Note: Electrical equipment such as startersshould be shieldedwith non-conductive material during the bleeding process to prevent damage fromfuel entry. Loosen the filter outlet (A). Turnthe ignition switchto the "on" position. Loosen the vent valvefitted on oneof the two hydraulic headlocking screws (C). (Refer to page8. they are most likely found to beeither plugged fuel filters or trash on the inlet side of the electric fuel pump. gearboxes.Crank engine until fuel free fromair flows. 1. this must bedone irrespective of theheight of thefilter in thesystem. andif the system shouldbe drainedafter havingrun outof fuel. lighten the housing vent screwandthen the governor vent screw. 22 TypicalSTANADYNE Fuel System Schematic . CAV-DPA Fuel System Before bleeding and venting the CAVmDPA fuel system ensurethat the outside of the vent screws and surroundingarea is thoroughlyclean to preventdirt and foreign matter entering the system. or the fuel injection pump inlet connection (B) whichever is the higher. Loosen anytwo injector high pressurepipe nutsatthe injector end. Start the engine. 3. be certain that all transmissions. Tighten connections. When fuel freefrom air flowsfromthevents. Tighten the connection. etc. Loosen the filter outlet connection (A) or the fuel injection pump inlet connection (B) whicheveris the higher and allowfuel to flow until free of air.after anysubsequent removal. 4. BLEEDING THE FUEL SYSTEM Bleeding is necessary on initial installation of the fuel injection system. Turn the ignition switchto the "on"position. If a wheeled vehicle is involved . andallow fuel to flow until free of air. 5. arein a neutral position before attempting to crank the engine. InjectionPump Vents (CAV--DPA) Note: Filters of thefourboss typemust alsobevented at the plugged boss. Also. There could alsobe anair leakin the fuel pick up line on the suction side of the pump causingthe pump to cavitate. andthe vent screw(D) on the governorhousing.becertainthat the wheels are"chocked" and the parking brake is set. If restrictionsaresuspected in the fuel circuit.) 6. 2. Energize the glow plugs. hydraulic controls. 2. Stanadyne Fuel System 1.

Toreplacethe filter element: 1.so the filter is onthe pressure side of the transfer pump. Thisallows the water. Todrain the waterfromthe filter. andno attemptshouldbe made to cleanthe element. Install newO-ring on the center stud. Snap the spring clampsinto position and bleed the fuel system. Discardthe dirty element. Always drain thewater from thefuelfilter withthe engine dead andelectric fuel pump off. Bleed the fuel system(refer t page22. (Reference page 23. It shouldbe replaced at the regularly scheduled periodic maintenance interval or if there is reason to believethat it is plugged. Lubethe newelement grommets with clean diesel fuel andpushinto place. Tightenthe drain plug. Not : Electrical equipment such as startersshould be shielded with non-conductive materialduringfilter replacing and priming to prevent fuel entry. Glow Plugs Stanadyne Fuel Filter Note: Thisfuel filter is not a water separator. FUEL FILTERS CleanFuel is a Mustin diesel operation. No attempt should be made to clean this type element.) 5.3. Loosen anytwoinjector high pressure pipe nuts at the injector end. newfilter elementin position and replace the bowl.Tighten centerstudto 6-8 lb. water shouldbe drained from the fuel filter approximately oncea week. Continental diesels are normally equipped with the filter installed between the fuel injection pump and the transferpump outlet. To replace the metal canister elementsimply releasethe two spring clamps andpull the old elementoff the filter bracket. Cleanthe inside of the bowl andcenter tube. Start the engine. Fit the newupperand lower sealing washers.Poor fuel quality andharshworkconditionscanshortenthe weekly drain interval to daily intervals.Extreme conditions mayrequire additional filters to provide longer filter change periods. (8-11Nm). Under normal conditions the element should be renewedevery 400 hours. 3. 5. Theperiod for changing the elementwill largely depend uponthe quality and condition of the fuel available.when clean fuel is not available. simplyloosen the drain plugat the bottom of the filter assembly 1/2 to 1 turn. which is heavier. 2. Stanadyne Fuel System. Under normalconditions. Remove filter bowl. Placethe Stanadyne FuelFilter (# TMD20FO0400) 23 . 4.(Refer to page8. If water contamination is anticipated. Leave the drain plugopen until water-free fuel is observed. andwith the ignition switch "on". Energize the glowplugs.Remove anddiscard the upperand lower elementsealing washers and O-ring from the center stud. This period shouldbe decreased if unavoidable contamination of the fuel is experienced. 4.an additionalprimary fuel filter andwaterseparator should be installed beforethe fuel transferpump. Not : It is bestto drainthewater after the engine has been at rest for awhile.) CAV-DPA Fuel Filter Thefuel filter is of the paperelement type. crankthe engineuntil fuel free from air flows.Setthe accelerator to the fully open position. It should be replaced whenperiodical maintenance is being carried out or if there is reason to believe that the elementis plugged. Tightenthe line nuts./ft. CAVmDPA fuel system).to separate and settle to the bottom of the filter.

1 BAR) TESTING Injectors should not be disassembled unlesstesting shows that cleaningor other service is needed. 2. Engineoverheating. Thelower acceptable limit figures for the service injectors are necessary dueto nozzle needleembedment andspring relaxation that takes placeafter a nozzlehasbeen put into use. with the engine running at a fast idle. Injectors that fail to meet the acceptable pressure limits should be adjusted by addingor subtracting . HeatShield & Injector. The high velocity f spray maypuncture the skin and cause blood poisoning.INJECTORS When replacing injectorsin the cylinderhead it is essential that a newheat shield washer be fitted between the nozzlecapandthe cylinder head. To performa compression test. This will dislodgesome light carbon build-up fromthe tip of the nozzleand may remove anyvery fine dirt particles in the nozzle cavities. STEP 1 : Set tester so that it will applypressure and then work the pump handle several sharp strokes. Theexterior of the injectors shouldbe rinsedwith cleaningsolution before testing. STANADYNEmstamped just under one of the bleedoff tubes. 5.depending upon the type system involved. **A serviceinjector is considered to be anyinjector that hasbeen in use or any injector that has beenreconditionedandno new parts wereinvolved. / WARNING Side View Tighteninjectors evenlyto 50-55LB-FT (70 Nm). because of different operatingpressures. Becarefulnot to flush anydebrisinto the open ports of the injector. This may get rid of anydebristhat has just entered the nozzleduring the removal andcleaning process.2-155. in turn. Thisallowsthe fuel to escape andnot enter the cylinder. Bodily injury may result duringthis operationif care is not exercised. Thenozzles are identified by verysmall lettering on the outsideof the nozzleas follows: CAV--stamped just abovethe large hex portion of the nozzle. connect it to the tester. It is impossible to adjust thesetting of theinjectorwith anydegree of accuracy without proper equipment. Smoky exhaust(black or white). Thereare manytesters on the market--follow the 24 Acceptable Pressure Limits New Injector=1900-2016 PSI (131-139 BAR) **Service Injector=1755-2016 PSI **Service Injector=1925-2250 PSI (121-139 BAR) (132. Theinjector least affecting the engineperformance shouldbe removed fromthe cylinder head andreconditioned or replaced. One company is CAV and the other is STANADYNE. STEP2: Nowwork the pumphandle slowly and observe the opening pressure. Increased fuel consumption. Usea special hydraulic injector tester equipped with a filter so that onlyclean oil enters the injector. After havingidentified the nozzle.Compare to the following chart.7-155. 4. Keep hands and face away from nozzle spray. Misfiring. Therefore it is recommended that adjustments and/orrepairsbe made only by authorized CAV or Stanadyne repair centers. CAUTION: Noattemptshouldbe made to adjust the injection pressure withouta proper testing pump and pressure gauge. turn it upside down andshake it. Read and observe safety warnings on pages 1 and 2.(Reference page 59. Knocking in one(or more)cylinders. Thefaulty injector or injectors may be locatedby loosening the line fitting nut oneach. determine the brandname of the fuel injector aboutto be tested. TMD engines currently use injectors made by two different companies. Beforetesting. Anydisassembly of the fuel injectors shouldbe done in an extremely clean workarea. Before testing eachinjector.1 BAR) *A newinjector is an injector with no engine "run time" onit. They look very much alike. 7. 6. ) Injector NozzleSide manufacturer’s instructions for correct andsafe operation of the test equipment chosen. CAV STANADYNE Acceptable Pressure Limits *New Injector=2150-2250 PSI (148. 3. Lossof power. Injectors shouldbe takenout only if engineis malfunctioning as outlined below: 1. but are nevermixed togetheron anyoneengine.

andincorporates no ball or roller bearings. Watch for dribble from the sprayorifice. Wideor non-uniform spraypatterns are questionable. Shimsshould be available from the CAV or STANADYNE service center which is performing the adjustment. Disconnect any low pressurefuel lines. POOR Typical CAV-DPA Fuel Injection Pump GOOD Nozzle Spray Patterns CAV-DPA INJECTION PUMP TheDPA distributor type fuel injection pump. Check that spraypattern is a "straight shot"or that it isn’t aimed off to oneside. Also. self-contained unit for multi-cylinderdiesel engines.This makes for a smoother running engine. Check the specification of your enginefor your particular fuel injection pump. This will save you muchtime during reinstallation of the pump if the pump is goingback onto the same engine. 26.shims.It is 25 STEP 4: Nowwork the pump handle rapidly (about 100 strokes per minute) and observethe spray pattern produced. DO NOT separatethe injection pump from the adaptor mounting plate unless absolutely necessary. checkthe nozzlespraypattern. Thenumber of workingparts remainsthe same irrespective of the number of enginecylinders the pump is required to serve. incorporating a sensitive all-speed governor. by the trained eye of the CAVor STANADYNE technician. Thepump is flange mounted to the engine. Thespray pattern should exit the injector in the formof a thin line o stream that gradually gets a little widerbeforedevel opinginto a small mist cloud out at the end. which indicatesabad seat. (SeeShort Method pg.) CheckingInjector Opening Pressure STEP 3: Oncethe pressure setting has been confirmed. Replaceany injector that cannot be adjustedto meet the above pressurelimit specifications.the "judgement call" should be made . Holdconstant pressure on the tester lever to maintainthe opening pressureof the nozzle. The extreme precision necessary canwell be appreciated since this cycle mustbe repeated thousands of time per minutewith virtually no variation in timing or amount of fuel injected. which indicates a leak between the holder and the valve bodylappedsurfaces. If in doubt. FUEL IN]ECTION PUMP Thefunctionof a diesel fuel injection pump is to accurately meteranddeliver fuel to a nozzlein each cylinder andto inject it at high pressure into the combustion chamber at precisely timedintervals. It is a relatively simpledesign.is a compact.gearsor highly stressed springs. linkagerods or electrical wires that need to come off to allow injection pump removalfrom the engine. Removal of the Fuel Injection Pump Remove all highpressure fuel lines beingcareful not to bendthem. look for leaksalongthe body of the nozzleholderitself. Not: It is always a good practice to haveall the injectors of anyoneengineset as nearlyalike as possible. Remove the three long bolts that go completely throughthe timing gear coverandremove the injection pump.

The plungers are returned by pressure of the inflowing fuel andthis formsthe charging stroke. Fuel entering the pump through the maininlet connection is pressurized by a sliding vanetransfer pump carried on the rotor inside the hydraulic head. Besureto havethe enginemodelnumber. the rollers which operatethe plungersdo not follow the contourof the internal cam ring but contactthe cam lobesat points whichvary accordingto the degreeof plunger displacement. and fuel under injection pressure passes up the central bore of the rotor throughthe alignedports to oneof the injectors. uneven running and excessivesmoking. the inlet port is cut off and the single distributor port in the rotor registers with an outlet port in the hydraulichead. assembly. WORKINGPRINCIPLE The internal camring. DO NOT attempt to adjustthe timing without the pump mounting bolts securely torqued. The outward travel of the opposedpumping plungersis determined by the quantity of fuel metered. Fuel injection is effected by a single element havingtwin opposed plungerslocated within a transverseborein a central rotating member whichacts as a distributor and revolves in a stationary member known as the hydraulic head. Fuel is accurately metered to the pumping element. The single pumpingelement ensures uniform delivery of fuel to eachenginecylinder. Thepressure rise is controlledby a regulatingvalve assembly located in the pump end plate. Contact your Continental distributor for details. The fuel then flows through the passagesto the pumping elements. . This is the injection stroke. Thepump plungersare actuated by lobes on an internal camring. Thegovernorflyweight assembly is mounted on the drive shaft andis contained entirely within the pump body. normally has as many lobes as there are engine cylinders and operates the opposedpump plungersthrough cam rollers carried in shoes sliding in the rotor body. Installation procedures andtiming methods will vary depending on the make and modelof the Fuel Injection Pump in use. At the same timethe 26 plungers are forcedinwards by the rollers contacting the camlobes. Thecam lobes are contoured to providerelief of pressure in the injector lines attheend of the injection cycle. Therotor normally has as manyinlet ports as the engine has cylinders. specification number andserial number available when youcall.testing and adjustment of the DPA pump must be carried out by trained personnel. Pressure maintained within the pump housing prevents the entranceof dust.oil-tight. so that no additional lubrication system is required. TIMING OF INJECTION PUMP TO THE ENGINE WARNING Bodily injurymay resultduring thetiming operation of the fuel injection pump if the engine is running. The governorcontrol mechanism is enclosed in a housing mounted on the pump body. anda similar number of outlet ports in the hydraulic head. TheTMD engineis equipped with either a CAV-LUCAS injection pumpor a STANADYNE injection pump. Theinstallation andtiming procedure for the fuel injection pump will be separated into a ShortMethod and a Long Method. andduring operationall moving parts are lubricated by fuel oil underpressure. Look for nameplates or raisedletters onthe body of the pump for identification purposes. and gives accurate control of engine speed underall load conditions. Injection pumps mustbe installed on the engine in accuratealignmentandtimedto correct relation with the crankshaftfor properengineoperationwith maximum power and economy and to prevent complaints of hardstarting. this givesa sharpcut-off of fuel andprevents "dribble"at the nozzles. In consequence. overheating. and components which affect timing are designed with oneassembly position only to ensureprecision.and the high pressurechargesare distributed to the engine cylinders at the required timing intervals through ports in the rotor andthe hydraulichead. OVERHAULPROCEDURE Dismantling. Theplungersare forced inwards simultaneously as the rollers contact the diametrically opposed cam lobes. whichvaries in accordance with the setting of the metering valve. using specializedtools andtest apparatus. andeliminates havingto balancethe deliveries from eachof the high-pressure delivery lines. Linkage transmits the movement of the governor flyweightsto the control lever on the metering valve.Be sure of the kind of pump involvedbeforeattempting the installation and timing procedures that follow. Thepump rotor is driven by the enginethrougha pinned hub and gear. Asthe rotor turns. Mostpumps havean automatic device which varies the point of commencement of injection. If identificationof the pump is difficult. mountedin the pump housing. waterandother foreign matter. Theaccurate spacingof cam lobes anddelivery ports ensures the exactequalityof the timing interval betweeninjections. Theintegral governor is of the mechanical flyweight type. call your local distributor for assistance.

it can be reinstalled using the Short Method.Tighten screwsfinger tight. etc.CAV Thefollowing steps are for reinstalling and timing the original Fuel Injection Pump andAdaptor Plate onto the engine from which it was removed: 1. Note:Steps9 and10 maybe unnecessary if the injection pump wasneverloosened from or separated fromthe adapter mounting plate during removal of the pump fromthe engine. shut down cables. TheShortMethod is usedonly when the original injection pump. Holdthe gearin a soft jawedvise andtorque the three M8screwsto 20-25 FT. If an injection pump has beentested. Remove the 1/4" roundstock from the gear coverandre-install the screwplug andwasher. (34-40 Nm). Find a piece of roundstock approximately 1/ 4" in diameterand 5" to 6" long. 10. 6. Install a newO ring (P/N X07837) into the groove on the adaptor mountingplate. 5.Theinjection pump drive gearis the smallerof the twogearsvisible in the openingwherethe injection pump mounts to the engine. Insert the 1/4" roundstock throughthe gear cover andinto the . The COMPRESSION stroke is determined by looking for the single beveledtooth on the rear side of the injection pump drive gear while the engineis at TDC. Check that the three M8 bolts that fasten the injection pump to the adapter mountingplate are tight at 15-18FT. Install the adaptermounting plate onto the injection pump using the M8screws. linkage rods. 2. LBS. Torque the long M10 mounting bolts to 25-30 FT. LBS.(2734 Nm). Usuallytheseare hiddenby an access cover. 6. LBS. Install a newO ring (P/N X07837) into the groove on the adapter mounting plate. 7.The Long Methodmust be used any time a new or reconditioned injection pump is involved or any time a newor other than original adaptor mounting plate is used.(20-24Nm). 4. because this engine ° will run with the injection pump installed 180 out of time.If the beveled tooth is not visible in the opening. It is positioneddirectly in front of the injection pu. any time an injection pump is transferred from one engine to another. but no repairs werenecessary. 8. 7.CAV Thefollowingstepsare for installing andtiming a newor reconditionedor other than original Fuel Injection Pump: 1. Bleedthe fuel system(see page22). 8. 3. low pressure fuel lines. However. (27-34 Nm).it is nowconsidered to be "reconditioned" and the Long Methodmust be used.However. 11. simply rotate the crankshaft pulley one complete revolution clockwise and check for the beveledtooth again. 13. if repairs are necessary to the fuel injection pump. Also. Lightly lubricate the Oring with motoroil. Not : Some engines have DCmarkson the flywheel anda pointer pin fixed into the bell housing. it runs very poorly in that condition. 27 . Use three M8screws (P/N X22132)and lock washers for mounting the gear. This is very important. Guide the injection pump into position and install the three long M10 mounting bolts. Short Method . Check that the scribe markon the injection pump flange is matched up with the scribe mark on the injection pump adapter mounting plate. Grindor file off anyexisting scribe mark that maybe on the injection pump adaptormounting plate. 2. 4. Re-connect all electrical wires. Welding rod or brazing rod minus the flux worksgood here. Long Method . 9. Lightly lubricate the Oring with motoroil. (Gasket P/N TMD27B00300) 3. lock washers and nuts that secure the adaptor mounting plate to the engine. Install the high pressurefuel lines and torquethe fuel line nuts to 20-25FT. Note: Leave anytwoof the injector line nutsloose at the nozzles whichis part of Bleeding the Fuel system (see page 22). 5. 12. Install a new gasket to the front of the injection pump. The two marksshould look "as one" whenthe job is complete.mp gear. Remove the screw plug and washer located on the front side of the timing gearcover. TDC is when the notch on the front pulley lines up with the DCmarkon the pointer plate. LBS. 14. Install the injection pump gear along with alignment dowelpin onto the injection pump shaft. and lock washers. Rotate the crankshaft pulley clockwise (viewedfrom the front) until the notchon the ° degreeBeforeTopDead pulley is atthe 190-20 Center (BTDC) markon the pointer plate.adaptor mounting plate and crankcase are assembled together.flat washers.236" (6mm) deadendhole the injection pump gear. Rotate the crankshaft pulley clockwise (viewedfrom the front) until the #1 piston is TOP DEADCENTER (TDC) on the COMPRESSIONstroke. A newplate will haveno scribe mark.

16.Bell housing pointersare usually hiddenby an access cover. Mark Injection Pump Timing Mark 11. LBS. Then ° BTDC. 18. linkage rods. 15. Check that line "A"is still lined upwith the flat end of the snap ring. lock washers and nuts that secure the adaptor mountingplate to the engine. 12. Guidethe injection pump into position and install the three long M10 mounting bolts. Check that the engineis on the compression stroke by looking for the single beveled tooth on the rear side of the injection pump drive gear. low pressurefuel lines. because this engine ° will run with the injection pump installed 180 out of time.(2734 Nm). 17. shut down cables. rotate the body of the injection pump until it is. LBS. DO NOT attempt to adjustthe timing without the pump mounting bolts securely torqued.(34-40 Nm). WARNING Bodily injurymay resultduring thetiming operation of the fuel injection pump if the engine is running. it runs very poorly in that condition. TypicalCAV-DPA FuelInjectionPump Typical CAV-DPA Fuel Injection Pump (cut-a-way) 28 . Re-connect all electrical wires. Note: Leave anytwoof the injector line nutsloose at the nozzles whichis part of Bleeding the Fuel System (see page22). Torquethe three M8bolts that fasten the injection pump to the adaptormounting plate to 15-18 FT. LBS. This is very important. If it isn’t. (20-24 Nm). Remove the timing hole cover from the side of the injection pump housing. Torquethe M10 bolts to 25-30 FT. reset. stopping at 19°-20 Re-check that line "A" is still lined up with flat endof snapring. Install the timing hole coveronto the injection pumphousing.simply rotate the crankshaftclockwise onerevolutionandit will be visible. 19. rotate clockwise. 14.be certain that youare working with the BTDC marks. 13.Turn the injection pump gear until line "A" on the rotating shaft lines up with the flat endof the snapring (see below). Bleedthe fuel system(see page22). Restampthe pumpto adaptor mounting plate scribe marks. Install the high pressure fuel lines and torque the fuel line nuts to 20-25FT. If the beveledtooth is not visible in the opening. 9. If not. 10. Theinjection pump drive gear is the smaller of the two gears visible in the openingwherethe injection pump mountsto the engine. etc. Rotate the crankshaft counter clockwise about 1/4 turn (viewed from the front).Not: Some engines usemarks on the flywheel and a pointer pinfixedinto thebell housing. If this is the case. However.

Thepump is self-lubricated. 6. Thedistributor rotor incorporates two chargingports and a single axial bore with one discharge port to serviceall head outlets to the injection lines. distributor type pump.However. The metering valvecanbe closedto shut off fuel through solid linkage by an independently operated shut-off lever. Grindor file off anyexisting scribe mark that maybe on the injection pump adaptor mounting plate. Tightenscrews finger tight. there are numerous injection pump timing settings required to cover the manySTANADYNE applications. Lightly lubricate the Oring with motor oil. Short Method . As a result. 7.STANADYNE MODELDB2 INJECTION PUMP Themodel DB2 injection pump is describedas an opposed plunger. Thehydraulichead containsthe borein whichthe rotor revolves. Step 15) andthe corresponding locationof the front pulleytimingmark (Flywheel timing mark on some engines). inlet metered. becertainthat youareworking with thecorrectset of marks. the charging ports andthe head discharge fittings. transfer pump blades.STANADYNE --Installing andTiminga New or Reconditioned or other than original Fuel Injection Pump.these twomarks will line up. This method is identical to the STANADYN E Long Method that follows except that youomit the first (5) five steps when performingthe Short Method. SeeSPB 92-420 for the timingsetting required on yourparticularengine. 4. Check that the engine is on the compression 29 . Rotatethe crankshaftpulley clockwise(viewed fromthe front) until the notch onthe pulleyis atthe timing setting prescribedin SPB 92-420. Install a newO ring (P/N X07837) into the grooveon the adaptor mounting plate. Thedrive shaft engages the distributor rotor in the hydraulichead.distributor rotor. The most important point about timing the STANADYNE injection pump is the alignment of the internal timing marks(Ref. TheDB2 pump incorporates a single pumping chamber.STANADYNE --Re-installing andtiming the originalFuelInjection Pump andadaptor plate ontothe enginefromwhich it wasremoved. In most cases. The plungers are actuated toward each other simultaneously by an internal cam ring through rollers andshoes whichare carried in slots at the drive end of the rotor. Precisedistribution between cylinders.contains essentiallythe same number of partsregardless of the number of cylinders served. if thisis thecase. A newplate will haveno scribe mark. 8. the centrifugal force of the weights in their retainer is transmittedthrougha sleeveto the governor armand through a positive linkage to the metering valve. Theinjection pump is designed so that endthrust is against the faceof the transferpump pressure regulator. at the end of Step 15. Note: There are various types of STANADYNE fuel injection pumps used on the TMDengine. Various equipmentapplications having different speed ranges and load ranges are involved. 3. or by anelectrical solenoid. To determine the correct injection pumptiming for your particular engine.Thedrive endof the DB2 rotor incorporates two pumping plungers. Theendcapalso houses the fuel inlet strainer andtransfer pump pressureregulator. WARNING Bodily injurymay resultduring the timing operation of the fuel injection pump if the engine is running. Note:Thereis a chisel type scribe mark that is stamped into the injection pump mounting flangeand the adaptor mounting plate. 5.the metering valve bore. LBS. Long Method . Note:Some engines usemarks on the flywheelanda pointer pinfixed intothebell housing. don’t bealarmed if theymiss lining upby a smalldistance.refer to Service Parts Bulletin 92-420.positive displacement. Install the adaptor mounting plate onto the injection pump using the M8 screws. andgovernor. capableof close speedregulation. Use three M8screws(P/N X22132) and lock-washers for mounting the gear. Install a newgasket(P/NTM D27B00300) to the front of the injection pump.flat washers andlock washers. They are usedin the 2 cylinder.DO NOT attempt to adjustthe timing without the pump mounting boltssecurely torqued. 2. Install the injection pump gearalongwith alignment dowelpin onto the injection pump shaft. 3 cylinder and 4 cylinder engine models. Thehigh pressure injection lines to the nozzlesare fastenedto thesedischarge fittings. Thetransferpump at the rear of the rotor is of the positive displacement vanetype andis enclosedin the endcap. WorkingPrinciple Themainrotating components are the drive shaft. Thenumber of cam lobesnormallyequals the number of enginecylinders. The DB2pumpcontains its own mechanical governor. 1. inherent in the pump design. Theautomaticadvance is a hydraulic mechanism whichadvances or retards the pumping cycle. The face of the regulator assembly is compressed against the liner and distributor rotor and forms anend seal for the transfer pump. Holdthe gearin a soft jawed vise andtorquethe three M8screwsto 20-25 FT. Bell housing pointersareusuallyhidden by an access cover.andthe ability to presetfuel flow eliminates lengthy periods on the test stand. 9.(27-34 Nm).

youmust judgeas to whether the pump gear is one toothor more out of timeor if a minor rotation of the injection pump body will align the marks.Torque the threeM8 belts that fasten the injection pump to the adaptor plateto 15-18 It.page 31 . 12.repeat step12. testing andadjustment of the DB2 pump must be carried out by trained personnel. 1. The inherent self goveming feature of inlet metering is especially advantageous for such closegoveming control. lock washers and nuts that secure the adaptor mounting plateto the engine.because the pump gearis probably out of time. 11.) . Thesimplest method is to run the machine at maximum output at high altitude. Install the timingholecoverand gasket ontothe injection pump housing. Remove the timingholecoverfromthe side of the injection pump housing. Install the highpressure fuel lines and torque the fuel line nutsto 20-25 ft. 19. assembly. as shown. it runs verypoorly in that condition. Fuel Delivery CurveShaping for High Altitude use on Welder and Generator Set Pumps Maximum fuel delivery on welderandgenerator set pumps is adjustable to reduceexhaustsmoke under highaltitude conditions. (SeePage 23). the torquescrew may bebacked out to restorefull sealevel power. highidle mustbe readjusted. with the injection pump installed 180 However.Guide theinjection pump intoposition and install the threelongM10 mounting bolts. the DB2 canproduce stablegoverning at 3% regulation for welder or generator sets. the speed droopcontrol must beadjusted to providethe sharpest regulation possible withoutsurge or combustion instability. 14. . Re-check the timing marks after eliminatingthe backlash and playthat may bein thetiminggeartrain.Check the internal timing marks onceagainandadjust if needed. Re-connect all electrical wires. If the machine is returnedto operation at sealevel. 15. The setting may be done either onan injection pump test stand or by trial-and-error on a completemachine.stroke bylooking for thesinglebeveled tooth ontherear sideof theinjection pump drivegear. rotatethe body of theinjectionpump oneway or the otheruntil the marks line up.linkage rods.000feet.Turn theinjection pump gear until theinternaltiming marks are lined up. usingspecialized tools andtest apparatus.Thiscan beobtained at either1500 (50Hertz) or 1800 RPM (60Hertz). Turn theinjection pump gear until timing mark is aligned withthepointer. (SeeTorque Screw Location. 16. Thisis veryimportant because this engine will run ° out of time. After the proper droop setting is achieved. Ibs.The speed droop controlis used where theregulation is adjusted while thegenerator setis operating. Loosen the torque screw jamnut andturn the torquescrew in (clockwise) until exhaust smoke is reduced to acceptable levels. etc.If the marks are veryclosetogether.Thetwo marks should look like oneunbroken horizontalline.the injection pump drivegear is thesmaller of thetwogears visiblein the opening where the injectionpump mounts to the engine. Torque the M10 bolts to 25-30ft. 10. Ibs. Tuming the speed droop screw clockwise broadensregulation and reduces instability. STANADYNE DB2 INJECTION PUMP Welder or Generator Set Governor Normally. (27-34 Nm). If not. (34-40Nm). (See Below). Not ¯ Leave anytwoof the fuel line nutsloose at the nozzles whichis part of Bleeding the FuelSystem. Inspectthe internal timingmarks again. The extemal controlknob with aninternalscrew thread pitchsimilarto thegovernor spring pitchis adjusted to add or subtract activecoils. Retighten the jamnut. Asinglegovernor spring may alsobeselected which will regulate this droop adjustment range at beth1500 and 1800 RPM. TIMING MARK pressure fuel lines. Thisis done byrotatingthe crank pulleycounter clockwiseapproximately 1/4 turn (viewed fromthe front). Ibs. If thebeveled toothis not visible in the opening simply rotate the crankshaft one revolution clockwise and it will be. Then rotatethecrank pulleyclockwise until it is back to the prescribed timingposition. If the marks arefar apart. Bleedthe fuel system. Thus a single springmay allowa droop adjustment of approximately 2 to 5%. This is further aidedby the extremely low masses and resultinginertia forcesof the metering valveand govemor components. low 30 Speed droop governor control Only minor throttle levertrimming is necessary. 17. 13. (20-24 Nm). Overhaul Procedure Dismantling. Dudng initialset-upof awelderorgeneratorset. (SeePage 23). Noadjustment will normallybe requiredfor operationunder3. 18.

causing build up of deposits in energy cell and nozzle.whichcan be a cracked residual. abrasives.05°/o maximumby volume 10° below lowest anticipated operating temperature 30 minimim (A. DIESEL FUEL SPECIFICATIONS Continental Diesels have been designed and developed to use ONLY No.oorindicateScombustion.P. 2-D (heavyfuel) -. % causeL°wer smoke recoverYand p. or sulphur in excess of our recommendedspecifications can cause extensive damageto the injection pump and engine.I. in order of importance) RECOMMENDED LIMITS 50 desired 45 minimum 320 °F. (listed DIESEL FUEL CHARACTERISTICS Cetane Number Volatility: Initial Boiling Point 50% recovery 90% recovery End Point Distillation Recovery SU Viscosity 100 °F. maximum 700°F. 1-D (light fuel) and preferably No. Total Sulphur Corrosion (Copper) 3 Hours @ 212°F. Less smoke with fuel at low 50% and 90% Recovery Temperatures.5O/o maximum pass test . cloggedfilters.Contact your Continental distributor for details. The fuel not only supplies the energy for all the work done by the engine. Torque screw location Typical DR2Fuel Injection Pump FUEL RECOMMENDATIONS Diesel fuel selection.heavy oil fractions which Viscosity is a measure of flow resistance--the low limit minimizes leakage and lubrication and the higher 650 °F. Discoloration or pitting on polished shows same effect on engine parts. copper strip is abrasive and .I. the fuel injection system which operate with very close tolerances. Water in fuel causes corrosion. minimum 550 °F. 98o/o maximum limit insurespenetration andatomizations. causing pintle sticking and smoke.P.40 seconds . 31 . Amount of non-combustible material causes pump wear. a blend of preferably a straight-run distillate havingthe following characteristics: Refer to page 11 for seasonal fuel recommendations. Higher end points only partially burn. Degrees) . Gravity ~_~60 °F. (38 °C) Water and Sediment Pour Point A. Sulphurous acids corrode and increase engine wear.it also lubricates the parts of. Higher number--better To prevent premature vaporization during hot weather operation. handling and filtration is of great importance. Fuel that contains water. Ash Indicative of Ignition Starting and Idling.01% maximum by weight 31 rapid pumpwear and Fuel Oil must be in fluid to congealing wax. maximum EFFECT Quality. state to prevent clogging due Lower Gravity Fuels contain more heat Units/Gal.

2.. SWITCH LOW OIL AMP WARNING FL1 I LIGHT ~ L.Charging System ~to W~RE l . for a limited time. DIAGRAM MURPHYSWITCH SWITCH HIGH WATER TEMPERATURE HOURMETER (OPTIONAL) IE~. It providesa sourceof current for starting the engine. It has two major functions: 1.. 32 ..~] I I . . 4 GLOWPLUG TYPICALPOWER UNIT WIRINGDIAGRAM STARTER The chargingcircuit consists primarily of an alternator. RECTI~ Y--4 "~\ =PUMP SOLENO. Wiring Wiring in the charging circuit should be carefully inspectedfor frayed insulation "or othe. Also inspect all connections to the alternator. ~l~l~ WIRING NOTE: ALL WIRING TO BE STRANDED. When analyzing the charging circuit..and replace any wiring that is defective. ~ . regulator and battery (including all ground connections). regulator. is an electrochemical device for converting chemical energyinto electrical energy. Battery Battery condition is very important for proper starting. battery and wiring.r damage. ~C #8 /// ABLE SOLID MOToRG FUSE I ~~ ~ ~ " ~CmT ~ I 5~ ~’~ ELAY ~ 2~ ~4 ~ I TR I OL CO~ UNIT~ I ment with connectors pointd°wn t WlREing GLOW PLUGS INDICATOR LAMP 2W MAX. The lead-acid storage battery. */ TO FUEL SHUT~OFF SOLENOID I OIL & WATER SW TCH ALL WIRE #16 AWGUNLESS OTHERWISENOTED SYMBOLS ----’~F INTERNAL GROUND PUSH ON CONNECTOR-PUSH ON CONNECTOR -FEMALE MALE (// ALTERNATOR (// ~ #8 AWG PUSH BOTTON ~ ~ ~’ /-- ONTACTOR L~c~:::::~T~h ~JL-~J NOT FURNISHED ’~ E~ll c= ~. used on automotive and industrial applications.DI~. and clean and tighten as required. It can. furnish current whenthe electrical demands of the unit exceed the output of the alternator.. ll=-]-~l~ U NO.Section E. the components should be checkedin the following order: II.

will cause severe damage to the units and/or wiring. Any attempt to do so may result in damage to the alternator./ WARNING Stop engine before checking batteryterminals or electrical connections. 4. 7. If it is necessary to solderanylead to a rectifi r lead. A "High" charge rate is normal for the first few minutes. Reconnect battery cable. Do not flash field or ground terminals of the regulator. With this construction.C. Always wear eyeprotection. the following steps should be observed during installation. Th field circuit must never be grounded. (positive to positive. wiring or other components of the charging system. use a pair of pliers as a heat dambetween the solder joint and the rectifier. Battery polarity should be checked with a voltmeter before connecting the battery. 2. and it can be assumed that this type regulator will outlive the other components in the charging system. Makesure regulator is of the same voltage and polarity as the alternator and battery. connectbattery to the regulator field terminal. Sparks or flames near a battery could cause an explosion or fire. Note: Whenservicing the charging system. Alternator The alternator differs from the conventional D. Disconnect the battery. The alternator must not be operated on open circuit with the rotor windingenergized. These cannot be adjusted or repaired.) IV. Each bearing is prelubricated which eliminates the need for periodic lubrication. between the alternator and the regulator. before connecting or disconnecting test instruments (except voltmeter) or before removing or replacing any unit or wiring. 8. 5. on this system. or circuits. No polarization is required. Read andobserve safetywarnings on pages 1 and2. generator. Start engine and observe ammeter. Disconnect battery cable at battery terminal. Do n t attempt to polariz the alternator. Precautions to be observed whentesting or servicing the alternator system: 1. shunt generator in that the armature is the stationary member and is called the stator: while the field is the rotating memberand is called the rotor. 3. 3. regulator. Grounding of the alternator output terminal maydamage the alternator and/or circuit and components. 7. Battery acidcancause corrosive burns. but will decrease as the battery recharges. its polarity must be connected correctly to prevent damageto the electrical system components.C. Reference always should be made to the manufacturer’s maintenance manuals for complete trouble shooting instructions. Refer to equipment manufacturer for battery recommendations. Grounding of the field terminal either at the alternator or regulator will damage the regulator. do not. Use of jumper cablesor battery charging shouldbe doneonly as directed by manufacturers’ safetyinstructions. Regulator Most regulators are fully transistorized and completely sealed. If a booster battery or fast chargeris used. 4. 1. Reversed battery connections maydamagethe rectifiers. 5. ammeteror accessories. 2. never remove a unit until tests have shown it to be defective. Connect alternator in accordance with the manufacturer’s instructions. To avoid damageto the regulator. III. 6. at any time. 6. Make sure the mounting area of the alternator and regulator base are clean and make a good tight connection. alternator. negative to negative. The comparatively small values of current supplied to the field may be conducted without difficulty through small brushes and rotating slip rings. generator of comparable electrical size and is equally as simple to service and test. Accidental grounding or shorting at the regulator. 33 . Other regulators are adjusted and repaired in accordance with the manufacturer’s instructions.C. 9. Alternating current is rectified (changed to direct current) by meansof diode rectifiers rather than mechanically with brushes coming into contact with the various segments of the rotating armature on the generator. The alternator is somewhatlighter and more compact in design than the conventional D. the higher current values involved in the armature or stator maybe conducted to the external circuit through fixed leads and connections rather than through the rotating commutator and brushes as in D. Installation of Regulatorfor Alternator To insure proper operation and to protect the alternator and regulator.

Never useair pressur that is more than 2 Bar(30 pounds persquare inch)and make sure theair line is equipped witha water flit r to prevent damage to parts. DRY TYPE REPLACEABLE AIR FILTER Dry type air filters are standardequipment on many enginesandit is mostimportantthat the dirt buildupin the cartridge doesnot reduce the air flow sufficient to cause a noticeableloss in power. indicating loose fuel. Clean cartridge by gently tapping flat on a smooth horizontal surface to loosen and remove the heavierdirt deposits.wear can be reducedby careful operation and a planned maintenanceprogram. fuel and oil and maintaining coolant operating temperaturesof 81 °-93°C (180°-200°F. however. OVERALLVISUAL INSPECTION OF ENGINE Lookfor evidence of fluid leakson floor. Thefollowing pages. In general. Themostefficient oil level is between the two dipstick levels. 50. oil or water connectionsmtighten if found.Visually inspect fan andbelt for condition and adjustment. In extremely dusty operationsthis may be onceor twice daily. 2. 4. whenoperating. . All moving parts in the engineare subjectto wear.). operating environment dictates the air cleaner service periods. 400 and 500 hour maintenance. CHECKRADIATOR Fill radiator with a clean 50/50water/anti-freeze mixture to normallevel maintaineddue to expansion 34 Wear protective glasses or a faceprotect r wh neverair hoses areused. IMPORTANT: Donot add oil until oil level approaches the lowmark--then add onlyenough to bringit to highlevel-NEVER above. Read and observe safetywarnings onpag s I and 2. Cleanfiller cap and areaaround spoutbeforefilling to prevententrance of dust into fuel system. but it is importantto usethe following guidelines: ¯ ALWAYS keep air pressure adjusted to less than 30 psi (2 Bar). They should normally be serviced every 50 hours in the following steps: (Extremeconditions will requiredaily cleaning. WAR ilNG Check Oil Levelof Engine 3.coveringDaily. FILL FUELTANK Fill fuel tankat endof day’soperation to prevent condensation forming in tank. Haphazard maintenance will only lead to faulty engineperformance and shortenenginelife. Donot operate the engine with oil below lowlevel mark. diesel engine operation demands carefulattentionto the cleanliness of air. have been worked out with our field servicedivision as "Minimum Requirements" to keep your engine in dependable operating condition. One basic type of air cleaneris normallyused-the dry replaceableelementtype. 250. the enginewill soonwear excessively if the air cleaner doesnot remove the dust before enteringthe cylinders. CHECKAIR CLEANER All engines.donot allowdirt to fall into ~eexposed carburetor. DAILY PREVENTIVE MAINTENANCE SCHEDULE 1. Replace thecartridge if in doubt! The cartridge can also be cleaned with compressed air. In dust protected areas the air cleaner should be serviced when changingoil. CAUTION: Donot damage the gasketsealingsurface or bend theouterscreen portion of thecartridge while cleaning.) Remove cover and cartridge after removing wing bolt . a definite maintenance program should be set-up and followed.Section 7 Prevenl:ive Maintenance In order to obtain maximum efficiency from your diesel engine. when heated. consume several thousand cubic feet of air per hour. Onany air cleaner. 5. Sincedusty air is full of abrasivematter. cylinder headand block. CHECKOIL LEVEL OF ENGINE Thedipstick indicates the high andlow oil level in the crankcase--make allowancefor additional oil drainage back into oil pan if engine has not been stopped15 minutes.

Dry type air cleaners are efficient only as long as top and bottom sealing edges are not damaged. Blow-by circulates into the intake manifold maintaining crankcase pressure within a narrow range regardless of operating speedor load. inside cover and mountingseat before installing element.4. morefrequent replacement will be required.such as dents or bends. Replace the cartridge if in doubt! Oftenin cleaning the cartridge it is tapped against surfacesthat are not flat. Also surface of air cleaner base and cover whereair cleaner cartridge seals. ¯ ALWAYS blow th cartridge clean from the inside out. Servicing of the PCVsystem is confined to checking the conditions of the hosesand connections. Under extremedust conditions. 35 .60 PSI) Higher oil pressuresmay be experienced during cold starts. NOTE: A 1/4 teaspoon of dust per hour can ruin an engine in one 8 hour day.¯ ALWAYS keepthe tip of the air nozzleor air hose at least 2 inches (50mm) from the paperportion of the cartridge. Replace immediately if bent. PCV SYSTEM All connectionsmustbe air tight. cartridge gasket surface.whichever occursfirst. thus damaging sealing edges. crushed or damaged. CHECKOIL PRESSURE ReplacingNewCartridge. Note oil pressure gaugewhich should indicate the following pressurerangeat full throttle anda minimum of 0.1 Bar (40. MODEL OIL PRESSURE TMD 2.5 Bar (7 pounds)pressure at idling speed. Place cartridge on mounting seat-make sure outer edgeof cartridge fits inside edgeof bottom plate.8. Replace cover and assemble wing bolt finger tight to insureair filter seal. must be clean and not damaged. Typical TeledyneContinental Motors PCV System Installation CAUTION: Do not wash or oil cartridge. The element should be replaced every 250 hoursor when servicing doesnot result in full powerrecovery. CleaningDry TypeAir Filter Wipeinside screen. CAUTION: Failure to comply with the above guidelines will damage the cartridge and lead to severe engine damage. if edges are damaged dirt will enter the engine.Regardless of howclean the paperis.

). then turn the engineover with the starter--In the belief they are doing a better job of crankcase cleaning.The best method is to drain the oil when the engineis thoroughly heatedmwhich will carry off mostof the sediment. Theschedule for changing oil is directly dependent upon the operational environment: an extremely clean operation could go 100 hours while a dirty operation(foundry or cement factory) could 50 hours or less. In doingthis. if required.250. Adddistilled water. Checkspecific gravity of each cell--which should be at least 1. CHECKFAN BELT TENSION Inspect wearcondition of fan belt. Some operators unwisely put kerosene in the crankcaseafter draining the engineoil. Sparks or flames neara batterycould cause anexplosion or fir .) is reduced60% -18°C (0°F. 3. Fan Belt Tension 5. In addition. kerosene is circulated through the oil pump. 4.) Be sure that no unfiltered air can enter the engine. Read and observe safety warnings onpages I and 2. Always weareye protection.5mm (3/8") abovethe separators. note alignmentand checkbelt tension whichshould allow not over 13mm (1/2") deflection on the long span. the frequency of oil changes and oil filter replacement is very important and should be madeat regular.) than 27°C (80@F. REPEATDAILY OPERATIONS OUTLINED Follow previous Instructions. Use of jumper cables or battery chargingshould bedone onlyasdirected bymanufacturers’ safety instructions. to raise level 9. CHECKBATTERY / WARNING Stop engine before checking batteryterminals r electrical connections. therefore. Checking Battery Particular attention shouldbe giventhe battery during cold weather. Thisis veryvaluable in correcting defectsin the early stages and preventingexpensive repairs or delays. SERVICE AIR CLEANER Cleanelementwith compressed air. Battery acidcancause corrosive burns. 36 . some of the kerosene will be trappedandremainto thin out the new oil. EVERY 50 HOURS 1.)---but yet the power requiredto crankthe engineis 2 1/2 timesgreater at -18°C(0°F. scheduled periods. (See Daily Instructions. 2. reducingits lubricating qualities. Do not put kerosene into the crankcase.Thecranking powerof a fully chargedbattery @27°C (80°F. the main oil header and the branches leading into the engine bearings--thereby washing away the protectiveoil film.NOTE ANY UNUSUAL NOISE Operatorsfamiliar with daily engineoperation soonbecome alert to anynoise not normallypresent. Thoroughlyclean the sealing surfaces before replacing new element and gasket. Replace the oil filter element everytime the oil is changed. CHANGECRANKCASE OIL Enginelife is dependent upon clean oil being circulated to all moving parts.

36ram (. ADJUST IDLE SPEED TO EQUIPMENT MANUFACTURERSRECOMMENDATION Repeatagain at end of 500 hours. Inspect control wires andconnections.) 7. 37 . REPEATDALLYAND 50-HOUR SCHEDULES Followprevious Instructions. IF DRY REPLACEABLE ELEMENT AIR CLEANERIS USED.018") Glow Plugs 4. REPEATDALLY AND 50-HOUR SCHEDULES Follow previous Instructions. EXHAUST 0. 2. DRAIN WATER FROM FUEL FILTERS(S) Note:Some fuel filters are not equipped with a water drain. Checkfan and accessorydrive belts. MODEL TMD INTAKE 0. FUEL SYSTEM (See fuel filters Replace fuel filter element. COOLINGSYSTEM Clean radiator core by blowing out with compressedair. otherwise any good commercialengine cleaner to washdownthe engine. 2.6. ADJUST VALVE TAPPET CLEARANCE Check and adjust intake and exhaust valve tappets to following clearancesat operating temperature.page 23) EVERY 250 HOURS Check all connections for leaks. FIRST 250 HOURSRECOMMEND ADJUSTING VALVE TAPPET CLEARANCE. CAUTION: Never allow cool water to comein contact with the fuel injection pump while the engine is running! Injection pump seizure mayresult. CHECKGLOWPLUGS Inspect glow plug wiring.46mm (. Inspect water pump and connectionsfor leaks. 1. REPEAT DALLYm 50 HOUR AND250 HOUR SCHEDULES. Inspect radiator mounting. 3. . Inspect mounting and gaskets. EVERY 400 HOURS 1. page23. EVERY 500 HOURS 1.014") 3. 2. SAFETY AND THERMALCONTROLS 4. CLEANEXTERIOROF ENGINE Use steamif available. REPLACEELEMENT. 5. (SeeFuel Filters.

NOTES 38 .

39 . page 24. Removerocker arm shaft assembly and push rods. Disconnect the injectors and leak-off lines at both the nozzle and pump connections. Grip the push rods and snap them sideways out of the tappet sockets as shownin the illustration. Place a protective cap over ends of injector for keeping openings clean. This will prevent an interference between the socket and the leak-off nipple. This will prevent any dirt or foreign matter from entering. Be sure to cut a relief in the inside of your socket for clearance. these should be included in your equipment. and cored passages for air. This method serves to break the hydraulic connection and permits lifting the push rods out and leaving the tappets in place. Many shop tools have been developed to save time and assure good workmanship. glow plugs. CYLINDER HEAD The cylinder head is the most important part of the engine assembly since it contains the complete combustion chamber including valves. Use only genuine Continental parts in Continental engines since years of development and testing have gone into these specifications to assure maximumlife and performance. fuel injection nozzles. 2. Remove injection nozzle assemblies.Engine Repair and Overhaul This section includes instructions for repairs and overhaul of the componentunits of Continental industrial diesel engines. Refer to fuel injection system for testing procedures. Disconnecting Injector Leak-off Line CAUTION:Always cover openings with protective caps at any time whenlines are disconnected. REMOVING THE CYLINDER HEAD 1. 3. exhaust and water flow.Section 8 . Provide a clean place to work and clean the engine exterior before you start disassembling-dirt causes engine failures. Remove cylinder head cover by removing the capscrews holding the cover to the cylinder head. Drain water from engine and disconnect radiator or heat exchanger hoses. Removing Push Rod from Ball Socket of Tappet 5. Socket relief clearance Caution should be used when replacing the fuel injectors to prevent loosening the injector leak-off nipples. 4.

Using a C removethe valve rotors. Remove precombustion chamber inserts from cylinder head and place in a rack indicating the cylinder from which each was removed. Lift the cylinder headoff the engine and carry to a clean bench for further disassembly. Loosen and remove the capscrews holding the cylinder head to the block. Removeglow plugs. springs placing all parts type valve spring compressor.DISASSEMBLY OF CYLINDER HEAD 1. Injector with Protective Caps and Nozzle Removal 6. and oil seals on valve stems-in a container of solvent. Remove the valves and place them in order in a rack with holes numbered for both intake and exhaust so they will not be mixed in handling. retainers. Capping Injector Connections Removing Valve Springs 2. Valves in Rack 3. spring retainer locks. 4O Precombustion Chamber Inserts . Glow Plugs 7. 8.

be sure to go deep enough with the toot to clean up the bottom so that the insert will have full contact to carry away the heat. Newinsert installation must have a press fit.002"). Inspect carefully for cracks. See Limits and Clearance Section for maximum diameter permissible to determine actual amount it has increased. Grind the intake and exhaust valve seats in the head in accordance with instructions in the Valve Guide Data. Inspect carefully for cracks. clean and counterbore for 0. Removing Valve Guides from Combustion Chamber Side . Chill insert in container with dry ice for 20 minutes before assembling.010") larger insert using counterbore tool with correct fitting pilot. Clean the valve stem guides. Insert maythen be installed in the counterbore using a piloted driver and arbor press.038mm (. Replace all guides that are worn bell-mouthed or have increased 0. This assures it being seated firmly on the bottom of the counterbore. Continental does not recommend installing new inserts having the same outside diameter as the one removed. 41 VALVE SEAT INSERTS (IF SUPPLIED) 1. without the possibility of shearing the side walls. Use puller for removing faulty insert.CAUTION: Whenreplacing guides do not ream since theseare all pre-reamed before being ferrox coated--any further reaming will remove the coating. Total indicator reading of the run-out must not be more than 0. Check guides for wear by using a telescope gauge and 1" micrometer. page 42. The exhaust valve seat insert is held in place by a shrink fit. Whenrequired to replace with new insert. Inspect all exhaust valve inserts in the head and replace any that are loose. 3. Remove all valve guides when necessary by pressing them out from the combustion chamber side. Whenmachining the counterbore.0015) in diameter. 3. Before removing the arbor. page 42. 4. Clean the cylinder head thoroughly with a solvent or degreasing solution and blow it off with air pressure.05mm (.25mm (. indicate the seat. CleaningCombustion Pocket Clean insert and combustion pocket. VALVE GUIDES 1. removing lacquer or other deposits. 2. Usea pilot having a solid stem with a long taper. as all valve seats must be ground concentric and square with either new or worn valve stem guide holes. 5. Do not use tools that remove metal. Replace worn guides as required by pressing in new guides to the correct depth as given in the valve guide data. cracked or otherwise damaged. Remove all carbon from combustion areas using scraper and wire brush.

0 (1.VALVE GUIDE DATA Model TMD Intake A B C D E F G Valve Seat Angle Diameter of Seat Diameter of Choke Distance (From Bottom of Cylinder Head) Length of Guide Inside Diameter Guide Distance Intake to Exhaust 30 °15’ 39.4 (2.14) 43.50 (1.38) 8.0 (1.692 (.566) 35.0 (1.3432/.4 (2.38) 43.876) Exhaust 45° 15’ 33.319) 29.3422) 42 .0 (1.38) 8.717/8.3432/.692 (.3422) 47.65 (1.69) 60.69) 60.77 (1.717/8.

002") over the maximum allowable limits. also any of which valve stems are bent or worn more than 0. leaving at least 0. not.4mm (1/64") on either side where the blue does not show.002"). This should showa contact width of 1. coat the seat lightly with Prussian blue and drop the valve into position. cracked or burned.Checking ValveFacein "V" Blocks Grinding Valve Seat Check all refaced or new valves in V-blocks with indicator to determine if the contact face is true with the stem within 0. After the narrowed-down seat is brought within specifications. the seat in the ° stone to head may be narrowed by using a 15 reduce the outside diameter or using a 60° or 75° stone to increase the inside diameter.05mm (. If the contact is over 3. Reface or replace all valves.05mm (. oscillating it slightly to transfer the blue pattern to the valve face. the seat should be retouched lightly with the original stone to remove burrs or feathered edge.2mm (3/32") wide. 43 .62 to 3.2mm (1/16" to 3/32") and should fall well within the width of the valve face. Never allow valves to set downinside th seat. Checking for Proper Valve Seating AllowableHead Thickness of Refaced Valves All valves having less than 50% margin thickness (outer edge of valve head) after refacing has been completed must be replaced. Indicating Valve Seat VALVES Inspect valves for condition and replace any that are "necked". compare the refaced valve with a new valve. After the valves and seats have been refaced and reground. To check this dimension. repeat the refacing operation.

ValvePosition in Head "A poor valve grinding job cannot be correct d by valve lapping. This is perfectly normal due to expansion of the valve. it would look like this whencold. when compressed to the "valve open" or "valve closed" length." For example. do not lap valves in after Coat the valve stem with a light film of engine oil. Notice that the lapped area of the valve and the seat no longer match each other.RIGHT So remember. The thin line visible here shows where the valve lapped into its seat. Valve SpringTester Springs. grinding. VALVE SPRINGS Check all valve springs on a spring tester to make sure they meet specifications regarding weight and length. Keep in mind that the engine is now at rest and cold.. Nowyou can see that the effects of the lapping job are lost completely. must fall within the specifications shownon the Limits and Clearance chart when new. This illustration shows the samevalve only now it has reached normal operating temperature. after the valve has been hand lapped.. ValveAssembly 44 . and must not show more than 10% loss to re-use.

2. approximately 45 Installing Umbrella Seals ROCKER ARMS 1. PREPARING CYLINDER WALLS FOR RE. 2.20mm (. Please see Procedure 87-371. 3. retainer and retainer lock. 3. Inspect the rocker arm brackets for cracks or other damage. Replace all defective rocker arms or any having over 0.RINGING OR RE-BORING 1. To prevent damage to push rods. condition of valve contact surface and worn bores. replace after the cylinder head is installed. All intake and exhaust valves have umbrella seals. If the shaft has "shoulders" on it due to wear. Determine the original diameter of the cylinder barrel by checking this unwornareawith an inside micrometer or a dial bore gaugeat intervals of °. Clean the ring of carbon from aroundthe top of the cylinder bore formed above the travel of the top ring. re-ringing will suitable and if over 0. Examinerocker arms for cracks.008"). Inspect the rocker arm shaft for wear.008") re-boring recommended.005") clearance between shaft and arm. Replace rods that are faulty or excessively worn. Inspect push rods for bends or twist and examine the ball and cup ends for excessive wear. The maximumdifference in the above checks. Push Rod Inspection for Runout Ridge Reaming Top of Cylinder Bore 45 . VALVE PUSH RODS 1. Blow out oil holes with air. Ridge ream the cylinders to remove the unworn area at the top so that the new rings when assembled will not bump and distort both themselves and the piston lands.2.13mm (. Measuring Original Bore Diameter Above Ring Travel o Check in samemannerthe top of the ring travel area approximately 6mm (1/4") below the shoulder.20mm(. If less than 0. 2. indicates the amount of cylinder bore wear. Soak in boiling water for several minutes prior to installation. CHECKING BORE WEAR 1. Reassemble the valves and springs in the headwith the seal. replace.

) Insert hone in cylinder and expand to cylinder wall with slight tension. the cap can be reassembled and kept with its mating part.250. 2. Remove the excess carbon deposits from the top of the cylinder wall before beginning the glaze breaking operation. wet cylinder wall and stones with kerosene. It is important to remove the glaze on the cylinder bores by using a cylinder hone. Remove the cap screws holding the connecting rod caps to the rod. bright finish of 0.’ If the cylinder glaze is not removed. this is esp ciall¥ true whenchromerings are used. If this edge is not removed. with this finish the depressions in the surface tend to keep a supply of lubrication between the mating partsl This finish can be obtained by using 280 grit stones on the hone. remove this sharp edge with a piece of number 500 emerycloth. Upon completion of the honing operation. Use a hand drill and surface hone cylinder with a rapid up and down motion to produce a good crosshatch pattern. IMPORTANT: Stones must be used wet. in order to assure quick seating of the new pistion rings. every precaution must be taken to prevent damageto cylinder bores by the sharp corners and rough edges of the connecting rods. To get the correct cross hatch pattern with a cylinder hone.you will have no assurance as to when the rings will begin to function properly and control the oil. Push the pistons and connecting rods up through the top of the cylinder. Using a clean brush. Cover the entire crankshaft with a clean. Drain the crankcase and remove the oil pan. Apply kerosene continuously and increase tension on hone adjustment until a good pattern and finish is obtained. (This is to prevent loading the stones. 5. with an adjustable stone tension. Removing SharpEdgeAfter Honing e. use a top quality electric drill with a speed of 500 R. Keep applying keroseneduring honing to prevent stones from drying out and causing an incorrect honing pattern.Several good makes of ridge reamers are available which will reamthe top of the bore in direct relation to the worn area so that should the worn area be off center slightly there will be no partial ridge remaining.38 Micro Meters (10-15 micro inches). 4. A smooth.38 Micro Meters (10 to 15 micro inches) is desired.M. slightly oily cloth to prevent abrasives and dirt from getting on the crankshaft.P.25. Keepthe cap and bolts in numerical order so that when the pistons and rods are removed from the engine. carrying with them all the carbon and metal chips left from the cleaning and ridge reaming operation. The honing operation will produce a sharp edge at the bottom of the bores. .it can cause shaving of the piston skirts. or less and 280 grit stones. When doing this. Clean the loose abrasives from the stones by using kerosene and a wire brush. . 3.0. Honing Cylinders 46 The most desirable cylinder finish is 0. The following recommended: step by step procedure is a.

0 °C (68 °-70 °F). and replace any that exceed the allowable limits in our Limits and Clearance Data. PISTONS Check the pistons for excessive ring groove wear.08mm (. thoroughly wash the bores with soap. Checking Block for Cleanliness Checking Piston Fit in Bore 47 . Kerosene or other solvents will not remove the grit.) capacity. Rinse the block with clean. The cylinder walls and pistons must be perfectly clean and dry when fitting pistons in the cylinder bores. run a clean. Pistons should be fitted with the °block and piston at room temperature 20. The paper towel should comeout clean. dry paper towel through the bores. hot water and a stiff brush to remove all traces of grit.Desirable Crosshatch Pattern Obtained with a Cylinder Hone Oiling Bores After all honing operations are complete. This completes the honing operation. As soon as the bores have dried. lubricate with engine oil immediately to prevent rust. the of approx- When you have finished cleaning the block.5 kg (5 to 10#) Pull) TMDseries 0. If not.3 to 4.0 21. a half-inch thickness Chart. Cleaning Bores PISTON FIT ON STANDARDPISTONS (with 2.003") Checkthe piston fit in the bore using wide strip of feeler stock. of the specified in the Limits and Clearance feeler being attached to a small scale imately 7 kg (15 Lbs. clear water and dry with compressedair. the bores must be rewashed.

5 kg (5-10 pounds) on the scale. Using the arbor press. In any event. Heating them in hot water will facilitate assembly. 2. NEW BUSHINg OLD BUSHING Checking Connecting Rod for Twist and Alignment Pressing in Piston Pin Bushing This may be checked on a fixture with the piston pin assembledin the rod before assembling the piston. the large bore in the bearing end of the connectingrod. the piston pin will enter the piston very easily and can be tapped through the connecting rod and into place without distorting the piston. with the feeler inserted betweenthe piston and the cylinder midway betweenthe piston pin bosseswherethe diameter of the piston is the greatest.3-4. Checking Piston Pin Bushing for Wear The piston pin hole in the piston and the bushing in the connectingrod maybe honedto increasetheir diameterto obtain the desired fit as shownin our Limits and ClearanceChart.13mm (. an oversize piston pin may be obtained in 0. making sure they are fully seated in place. it maybe reamed first. PISTON PINS Checkthe bushing in the upper end of the connecting rod for wear. press out the old bushing and press in the new one making sure the oil supply holes line up--after which the bushing mustbe honedto obtain the correct fit of the pin in the bushingas shownon Limits and Clearance Chart. Notethat while the chart specifies a light press fit of the pin in the piston.003 or . When heated. If there is an excessof stock in the piston pin bushing.005") oversize. then honed. If wornandyou are using the original pistons. Checkthe fit of the piston whenit is approximately 50mm (2") down to the cylinder bore in an inverted position. the final operation should be donewith a honeto obtain the desired fit with better than 75%bearing area contact on the pin. The snap rings mustbe assembled in the grooves. The piston pin hole in the connecting rod must be parallel to and in plane with. Assemble the pistons on the connecting rod. there is a definite clearanceof the piston pin in the connectingrod. but regardlessof this preliminary 48 .08 or 0. PISTON AND CONNECTING ROD ASSEMBLY 1.When the correct fit is obtained you must be able to withdraw the feeler with a pull of 2. CONNECTING RODS Replace the bushing in the connecting rod if new pistons are used.

49 Checking Ring Clearance in Groove . check each ring in its respective groove to the limits specified in the manual. Oil Ring 2. since the diameter in line with the piston pin would be less at the top of the skirt than at the bottom. Pistons are cam and taper ground. PISTON RINGS Check the piston rings in the cylinder for gap. and this must be taken into consideration when checking alignment of the assembly. Prior to ring assembly check the ring grooves for nicks and burrs. RECOMMENDED METHOD OF INSTALLINGPISTON RINGS 1. from the top side so skirt will not be scratched. replace the rod. insert a piston in the cylinder bore in an inverted position and then insert each ring one at a time about 50mm (2") downin the bore.002") twist or out of squareness checked over a spread of approximately 100mm (4"). This is done by rotating each unassembledring around its groove to be sure of free action. The oil ring should be installed first on the piston. Prior to installing the rings on the piston. If ring to land clearance exceeds maximum serviceable limits. Installing Rings with RingExpander Tool Checking RingGap To do this. pistons must be replaced. If the ring does not have sufficient end gap clearance. file one end of the ring until sufficient clearance is obtained. Check the gap between the ends of the ring with a feeler gauge in accordance with specifications shown in the Limits and Clearance Chart.check the completed piston and rod assembly must be rechecked and there must not be more than 0.05mm (. If excessive.

Oil Piston and Rings 3. the compressor should be removed and rings checked for correct installation in the groove. removecamgear and injection pumpdrive gears. CAUTION: Somepiston rings are taper faced. -. Using a puller. Be sure to install pistons with notch or arrow in top toward the front of the engine. If any difficulty in tapping piston and ring assembly into the cylinder is encountered. Removescrews and remove gear cover. Removing Injection PumpDrive Gear CAUTION:The pistons have offset piston pins. To install the balance of the rings. Removethe crankshaft keys. Removethe oil pump and key by removing cap screws holding pumpto front of the engine. Start with the lowest ring first. When pistons are ready for installation in the cylinders.they must be replaced. Apply pressure on handles so ring is completely expanded. b. and inspect the bearing and crankshaft journals. Removing Crank Gear Install Tapered Rings with "Top" Side Up. a. use a ring tool with recess side up and place the ring in with the bottom side up. 50 . 5. 3. Position ring in the tool so the expanding fingers will fully engage both ends. gear and woodruff 4. oil generously. one at a time.CRANKSHAFT AND MAIN BEARINGS 1. scoring or actual wear. Pass the expanded ring and tool recessed side downover the piston to the proper groove. If there is any indication of flaking out. Using a puller. Remove each main bearing cap. 6. 2. Compressrings carefully using a good ring compressor and a light tap on the head of the piston will allow the assembly to go into the cylinder very easily. These are clearly marked "TOP" on the side to be up when assembled on piston. and some rings have the top side rharked with a color band or a PIP mark. removepulley from crankshaft. Removing CamGear with Puller 4.

Thelower mainbearingshells on some models. the head of this pin picksupthe bearing shell andforcesit out of the bore in the block. they should be removed and checkedfor thickness using a ball micrometer. notin theblock. If the visual inspectionappears satisfactory. Scored Bearing Due to Dirt or Lack of Oil operation will change their appearance completely.or oil to the bearings will becutoff. a very few hours of Removing MainBearing Appearance of a Good Bearing 7. The ungrooved bearing shell must be placed in thebearing cap. The bearing surface becomesa leaden gray in color and developsminutecraters.013mm (. Thethickness of the bearing shells is givenin the Limits andClearance Chart. Measuring Bearing Thickness 8.BEARINGS Tri-metal bearings whennew are smoothand highly polished. If visual inspectionof the crankshaft shows no indication of excessive wear or scoring.0005") beyond the maximum allowable tolerance the bearing shell mustbe replaced. are not. This appearance is a natural characteristic of this type bearingandin no wayindicatesfailure. the clearance of the bearingshould be checked. It may beinsertedin the oil hole of the crankshaftandas the crankshaftis turnedin a clockwise direction. 51 . Bearing Damage Dueto Corrosion CAUTION: The upper main bearing shells are grooved. To remove the upperhalf of the bearingshell use a special tool obtainableat mostparts houses. However. almost cellular in appearance. andif this thicknesshas been reducedmore than 0. which is a pin with anangular head.

// ~RS ~ET / ////. Standard crankshafts may be reground to decrease the diameter a maximum of 1. Tappets canthen be lifted out andlined up in sequence.8R(. which makes it possibleto pull the camshaft forwardout of the bearings.05mm (. there is a service camshaft bushing available as p/n F400G00222.// RIGHT WRONG WRONG . it should be removed and reground. L 52 AVOID SEE ~ SHARP ~INSUFFICIENT CHART BELOW .12") on all mains’ CrankshaftFillet Radii Checking Bearing Clearancewith Plastigage By placing the Plastigage on the crankshaft bearing surface and tightening the bearing and cap in place. 2.~ /////. method DO NOT TURN would destroy the If crankshaft is scored.0mm (.///-////.0R(. If the front camshaftjournal bore becomes wornbeyond limits.11") on all crankpins 3. Before shaft is reground. check the diameter of the camshaft journals to determine the next step. If clearance is equalto or greaterthan the amount indicatedunderwearlimits. Crankshafts must be nit mpered after regrinding. one at a time. Measure the camshaft bearing journals and bores. 3. the fillet radii mustbe within dimensional limits and must be perfectly blendedinto thrust and bearing surfaces. (See SPB89-389 for details. Check eachbearing.002") indicator reading. or wornenough so that new bearings will not fit with the required clearance. the width of the Plastigage after crushing will determinethe bearing clearance. CAUTION: When using this the crankshaft as that Plastigage.9.it mustbe checked for straightness and straigtened if necessary to be within 0././/.040").) 4.~. TMD 2. for installation in the same location unless inspection shows that they require replacement. by using a piece of Plastigage of a diameter specified to check certain clearances. Replacing Bearing 1. When reground. Remove the screws holding the camshaft thrust plate to the front of the cylinder block. Excess wearat these positions require replacement of the shaft.

more thanthat calls for replacement of the tappet. 1. Two or threesmall pits onthe contact faceis acceptable. Wornoil seals should be replaced in the following manner: l. Check the outsidediameter with a micrometer to determine if replacement is necessary because of wear.break edge "C" slightly on both cap and block to avoid cutting the seals during installation and coat seal edge "E". block clean all ACCEPTABLE NOTACCEPTABLE ValveTappetWear Comparison 2.Referto limits andclearance section. Remove rear bearing cap and filler assembly by using a puller.if carefully installed.CAUTION: When installing camshaftuse special care to prevent camshaft bumpingand loosening expansion plug at rear of crankcase causingan oil leak. The overhead valve engines have a good. REAR CRANKSHAFTOIL SEALS The overhead valve engines have the rear crankshaft oil seals incorporated in the combination rear main bearing cap and filler block.in this case. NOTE: This oil seal can be installed without removing the crankshaft. TAPPETS IMPORTANT: Installing rear oil seals correctly demands careful workmanship. c C D Installing Sealin Rear MainBearing Cap andFiller Block Filler BlockandSeal E 53 . trouble-free rear crankshaft oil seal -. Install crankshaft oil seals "A"--on engine block and main bearing cap. Inspecteach tappetcarefully. Before installing -. A damaged tappetcouldmean possibledamage to the camshaft. contacting the groove with sealing compound. 2. use only light greasein the seal grooveto assist sliding the seal in place. The rear crankshaft oil seal has a stiffener ring imbedded in the rubber and no metal retainer is required. Applypressureto the seal so that it will hug the crankshaft whichwill also help moving it in place. Removeold seals and thoroughly contact surfaces.Install seal with lip pointing towardengine.

This insert insures complete cure of the RTV. After the rear cap is in. Crankshaft Oil Sealin Block 3. Insert the capscrews and torque to 150-162 Nm (110-120Lb. inject RTVinto each side seal slot ’. Install Crankshaft. Dip the curing insert in clean water. apply a small bead of RTV material to the rear bearing capandfiller blockas shown. Force the RTVinto the channels until a steady flow comes out the corner chamfers. Applying RTV to Rear Filler Block 6. 7. Install curing insert until approximately 5/8" protrudesfrom slot. Allow to becometacky before assembling. Apply a light coat of cement(national oil seal or EC-847)to the butting ends of the crankshaft oil seal halves. (Seepage 60. place and torqued. Lightly coat the crankshaft contact edge of the seal with graphite grease to prevent damage prior to use. Dowel holes ~ with~~RTV ~/ Applying RTV to Rear Bearing Cap and Filler Block OIL PUMP The oil pumpis assembled to the front of the cylinder block and front main bearing cap and is held in place by capscrews. Installing RTV in Rear Filler BlockChannels 54 .) Install Curing Insert 8. Cut off flush with panrail. 5. Ft.’D" as shown in illustration. The pump is driven by a hardened key mounted in the crankshaft. Priorto installing oil pan.) ~-~-’~ Please see Pleasesee SPB 87-361.NOTE: Oil leakagewill occur if any voids are left along these slots. 4. Apply a light coating of RTVGasket Material to surface "B" and graphite grease to the oil seal lip. Carefully install the combinationrear bearing cap and filler block on to the dowels.

O-Rings When the pump is removed and disassembled.Nogasketsare usedin this assembly. (SeeSPB 88-379. TwoO-Ringsare required after S/N 88096321. Examine the pick-up screen for clogging or damage. Examine the O-Ringat the pump inlet. Oil PumpRemoval Engine oil pressure must be maintained to specificationfor satisfactoryengine life. The oil pumpmust be fully seated in the counterbore. 55 .issuedOctober.) NOTE: When replacing any oil pumps on engines built beforeS/N88096321. Install mounting capscrews and tighten to 20-24 Nm(15-18 Lb. Inspecting the key and keyway at the same time. If scored or wornbadly they must be replaced.Pr vious Oil Pump Impel ter (inn (Outer) ~Adapter ~/ashe r PIun ~ Sprlng Cap ~ O-Ring Current Oil Pump --E~ective S/N 88096321 Note: Refer to ServiceBulletin 88-379. If damaged. the oil suctiontubemust be replacedalso.1988. Timinggears shouldbe inspectedfor excessive wearand/or pitting andreplacedif necessary.) TIMING GEARS O-Ringat Pump Inlet 1. Ft. replace. examine the impellers. cover and cavity for wear.

Installing Injection Pump Drive Gear Checking Camshaft End Play InstallingCamshaft Gear 56 4. . NOTE: TMD20. atthe same 8me holding the camshaftforward with suitable bar throughthe fuel pump opening in the block so there is no possibility of the camshaft bumping the expansion plugat the rearend and forcingit outof position.This will break the threaded end off cast iron camshafts.8604usesa different cam gear and injectionpump drivegear set up. which assures you of the crankshaft and camshaft being in time. spec.2. Torquing Cam Gear Nut Check camshaft end play as shown in illustration. Examinethe camshaft thrust plate carefully for scoring and wear and if any indication of either shows.Forassembly inform ationsee SPB 87-372. a new thrust plate should be assembled. Refer to limits and clearance section for correct dimension. Camshaft Thrust Plate 3. Do not use impact wrench or over torque cam nut. Assemble the injeclJon pump drive gearwith key and cam gearto the camshaft by driving or pressing each on. CAUTION: NEVERUSE THE CAMSHAFT NUT TO PRESSTHE GEAR ONTOTHE CAMSHAFT. Assemble camshaft nut and torque to specification (see torque specifications section). Please reference SPB 87-372. Drive the crank gear on the shaft making sure that the marked teeth on the cam gear straddle the marked tooth on the crank gear. thuscausing anoil leak.

Mount an indicator on the flywheel housing and check the flywheel for runout. In both cases the maximum indicator reading must not be more than 0. The indicator should be set up so that it contacts the clutch face or the vertical surface of the clutch counterbore.008"). then turn the flywheel at least one full revolution at the same time holding against the crankshaft to offset the possibility of end play. End play should be between the 0. When assembled. Excessive runout of the flywheel. Using a dial indicator. at the same time holding against it to counteract end play.18mm (. check the crankshaft end play. No shims are required.20mm (. Special Capscrews Checking flywheel Housing Face 57 .0015") limits. is probably caused by dirt in or damageto counterbore locating the flywheel on the crankshaft flange.007") replace the flanged bearing. Caution: When checking runout remove glow plugs to allow engine to be turned over freely. AND FLYWHEEL HOUSING cap flywheel housing using special NOTE:Special capscrews having sealing bands are used in the upper holes to mountthe flywheel housing to the cylinder block. Re-locate the indicator to check the inside diameter of the counterbore. If the end play exceeds 0. mount the indicator on the flywheel so that it contacts the housing face and turn the crankshaft.0067") and 0.04mm(.Timing Gears Assembled Accordingto TimingMarks CRANKSHAFT END PLAY Checking FlywheelRun-Out The flywheel is machined and balanced so that the clutch face and locating counterbore will run true with its axis.008").20mm (. The maximum indicator reading must not exceed 0. These special capscrewsmust be used to prevent oil leakage. Flanged BearingControls Crankshaft EndPlay FLYWHEEL Install screws.17mm(. in either position. The crankshaft end play is controlled by the center flanged bearing.

In most cases.10mm (. or 0. we have outlined procedures for checking. smooth and flat. Checking Cylinder Head Flatness Lengthwise NOTE:The pistons have offset piston pins. INSTALLING HEAD 1. Make sure that gasket contact surfaces on the head and block are clean. the instructions have covered the reassembly of parts or subassemblies made up of several parts. use a good ring compressor and oil the bores thoroughly. locate them carefully in order to protect the bearing surfaces. If these limits are exceeded. REASSEMBLINGENGINE In the foregoing.076ram (. Installing Pistons Checking Housing Bore Once more. and tighten them to the torque specified. The samerunout limits prevail. replace the cylinder head. Checking Cylinder Head Flatness Crosswise 58 .004") low in the center lengthwise.Re-locate the indicator to contact the housing bore and check this in the same manner. Always lubricate the bearings with clean engine oil when assembling.003") crosswise or in localized low spots. A hammer handle may be used to bumpthe p!stons out of the ring compressor into the cylinder bore. repairing or replacing the many wearing parts in the engine. Be sure to install pistons with notch or arrow in top toward the front of the engine. Check flatness with straight edge and feeler gauge in three positions lengthwise and five crosswise. gradually decreasing towards the ends. The maximumpermissible is 0. When reassembling pistons and connecting rods. we call attention to care demanded to prevent connecting rods damagingthe cylinder bore finish and at the same time as they are assembled over the crank pin.

003") projection. The cylinder head capscrews require no sealant but should be installed with a very light coating of engine oil or lubriplate to reduce friction and insure proper clamp load and head Installing Glow Plugs Injector Nozzle Side NOTE:Always use new steel heatshield washers when installing injectors in cylinder head. 5. Install the injectors and glow plugs at this point. Side View Torquing Cylinder Head Capscrews Installing Heat Shield and Injector 59 . Tighten with torque wrench in recommended sequence to the correct torque shownin torque chart on page 68. Havingthe injectors and gl0w plugs in now.076mm (. by going over them two times before pulling them downto the final torque specification on the third round. I capscrew torque. Precombustion Insert Projection 3. which is precoated.75 CLASS 6G 6. Tap: M10x 1. Should these tapped holes need cleaning or reconditioning.2. lower the cylinder head assemblyevenly over the Iocator stud. Use new cylinder head gasket. 7.Insert projection in reference with cylinder head surface is flush to 0. thus no cementis required. Install precombustion chamber inserts. Before installing any headcap screwsin the block. be sure the threadsin the block andon the cap screws have been properly cleaned. making sure they are fully seated. care should be taken to use the proper tap. 4. Using a chain hoist. Replace the Iocator stud with the proper cylinder head capscrew.5 CLASS 6G M12x 1. eliminates the risk of dirt andforeign objects falling into the cylinder.

INSTALLING OIL PAN Beforeassembling the oil pan.In-Piece gasket matedal to plu~ holes. (Seepage54.) NOTES: 1. bead el Fonlt4n-Place gasketmetedalapplied to oil pan and filler block as shown OIL PAN Notes 1 and 2) Form-In-Piece Gasket g.0ram (.set tappets according to the following chart: MODEL TMD INTAKE 0.0~0) die.35) This urea ot Foam-in.018") 2.O mm(. make sure the contactsurfaces are flat andcleanof anygasket material or oil.014") EXHAUST 0. Read Labels.0~m (.36mm (. Parts must be assembledwithin 20 minutes after applying gasketmaterial. Tightenthe screws in accordance with limits prescribed in the torque chart--to avoidlooseness or overstressing. making certain theinsert is centrally located in sideslot Installcuring insert until approximately 5/8" protrudes from slot. The form-in-place gasketshould be appliedto the oil panandfiller blocks as shown here. Bottom View OII Pan Contact Face Typical RTV Oil Pan Application for the Diesel Overhead Valve Engine.238) deep from contact surfsce. Caution mustbe used in handling the gasket materials. 2. A form-in-placegasketmaterial is usedfor sealing the engineoil panto the crankcase.Place gasket must intersect vertical cs¥1tlee both sides IMPORTANTAfter assembly of the bearing cap to the crankcase. Cutoff flush withpan rail. When engine is completely assembled andfilled withproper oil (seelubrication section). 6O . MIn 6.46ram (. Sealant mustb~eed out chamfer at crankcase split line The twocuringinserts(pipe cleaners) included in the kit must beused asfellows: Dipthe curing insertin1:oa Con:airier of clean wa’~er and insertfull lengthinto bearing cap sideslot cavities filled with RTV material. fill bearing cap side capacity usingRTV andsyringe furnished in kit. Top View C}ankcesecontact face Rear Bearing Cap and Filler Block Form.

Operators should depend on their welldeveloped senses of feeling. 6 --Check brushes. Remember the cause is usually Simple. A good rule to follow in locating trouble is to never make more than one adjustment at a time--then locate the trouble by a process of elimination.with a generousamountof "Common Sense". A Preventive-Maintenance system including inspection. drive spring and mounting bolts. 2 -.Poor ground connection CORRECTION 1 --Recharge or replace battery. Engine operation in any enclosure requires adequate andproper ventilation to avoidasphyxiation or other interruptionof normal breathing. to supply sufficientair to coolthe engine. Read andobserve safetywarnings on pages 1 and2.Trouble Shooting / WARNING Any attempt to disassemble or repair fuel injection pumps must be made only by persons fully qualified and equipped. seeing and smelling and replace their sense of taste in this type of work -.rather than mysterious and complicated. Failure of a Diesel engine to perform satisfactorily is generally due to difficulties with the fuel supply system.Section 9. 3 --Inspect and tighten ground cable. 5 --Starting switch faulty 6 --Starting motor defective 7 --Internal engine seizure 61 . check for foreign objects in gears. commutator. 5 --Replace switch or relay. 4 --Clean and tighten connections.if unable to do this. 7 --Turn engine manually -.Inadequate battery capacity 3 -. hearing. rather than the injection pumpor nozzles. provide air to mix withfuel and to carryaway heated air from the building. lubrication and adjustment as recommendedin our Maintenance Section will prevent the greater portion of Diesel troubles. on top of piston or for piston seizure.Replace Battery. (A) Engine Won’t Turn Over 4 --Loose or faulty wiring connections. such as air leaks in the suction line due to loose connections or restrictions to fuel flow because of clogged filters. Following are listed some of the normal complaints encountered in routine operation of all Diesel engines--the probable causes and the recommended steps required to correct the difficulty: Bodily Injury or death may resultto individuals during operation of an engine withinanyenclosure not adequately or properly ventilated. COMPLAINTS PROBABLE CAUSE 1 --Dead or weak battery 2 -.

causing a scavenging effect in the pump distributor rotor and a void which cannot be recharged to a sufficient degree to provideopening pressure of fuel to the following injector.Crankingspeedlow 5 -.Lowatmospheric temperature WARNING Starting fluids or aids suchas ether or gasoline must not be usedin a diesel engine air intake system. as knowledge of this characteristicmightprovidea great saving in servicetimein such a given situation.Recharge or replacebattery.Use cold starting equipment -- (B) EngineTurns But Won’tStart 6 -.Wrong injection pump timing 7 -. the fuel rushesinto that cylinder with no restriction whatsoever. 6 n Retimepump to engineaccordingto recommedations. 2 -. Readand observesafety warnings on pagesI and 2. 3 -. 8 b Low compression 9 -.Theuseo( these fluids will cause severeinternal engine damage and/orbodily injury. 4 -. (c) Runs"Rough" With Excessive Vibration Note: A characteristic of a fuel injection pump is that if engine misfiringoccurs.Replace or correct.NoFuel Supplyto Pump 2 -. Please note this well.Disassemble andcleanprimary filter and replace secondary filter if clogged. 7 -. repairif necessary. Hence. check starter.Check connections and bleedFuel System.no combustion can take place. 62 .Refill with clean fuel or strain through chamois and bleedsystem.COMPLAINTS PROBABLE CAUSE 1 -.Glow plugsfaulty or inoperative 8 -. the cause mightbe an injector sticking open in the cylinder which immediately precedes that cylinder in the engine firing order.Air in FuelInjectionLines 3 ---Clogged or dirty filters 4 -.Seerecommendations in "G" 9 -.Water in Diesel Fuel CORRECTION 1 -. During injection to the cylinderwhich hasthe injector stickingin the open position. 5 n DrainFuel System . and it is traced to a certain cylinder in which no combustionis taking place.Fill FuelTank or open Shut-Off Valve.

7 mClean and Test Faulty Nozzle for pressure leakage and spray pattern. 1 --Lack of coolant. Remove. Keep engine speed up. 5 -.Check thermostat. Tighten hose connections and repair leaks as required. 4 -. 8 --Remove and have checked at an authorized service center. leakage and pattern.Poor fuel 1 --Wrong injection 2 --Air in fuel lines pump timing 3 --Clogged or dirty filters 4 --Restriction in air flow 5 --Poor fuel 6 -. and clean.Use Diesel engine fuel that meets specifications. tighten connections.COMPLAINTS PROBABLE CAUSE 1 --Misfiring cylinder or cylinders CORRECTION 1 --Loosen fuel line to injector one at a time--no noticeable change indicates that cylinder is misfiring. 3 --Clean Primary Filter and replace secondaryfilter if necessary. Reduce load.Clean and service air cleaner. 2 --Check connections and bleed fuel system.Injection nozzles faulty 8 --Injection pumpfaulty (13) Loss of Power 1 --Retime pump to engine according to recommendations. 6 -.Use recommendedDiesel Engine Fuel that meets specifications (See Pages11 & 29). Clean and test injector for pressure. 2 --Fan belts slipping 2 -3 -4 -5 -6 -- (E) Overheating 3 --Overloading the engine or in- 4 --Thermostats sticking operative 5 --Fuel injection timing wrong 6 --Back pressure in exhaust line Add water. 2 -. Inspect for restriction in muffler and exhaust system. 63 . 4 --Service Air Cleaner and Connections. (c) Runs "Rough" with Excessive Vibration 2 --Too low operating temperature--below 3 --Air in fuel lines 4 --Clogged air cleaner 165°F 5 --Engine idles too slowly 6 -.clean and check thermostats and replace if required.Poor Compression 7 -. Retime pump according to recommendation. 5 -. 6 m See "G" recommendations.Increase to recommended speed. Inspect belt condition and adjust tension.Check connections--Bleed fuel system. 3 -.

1 -. Replace gasketandtorque to Specification. 5 -.Check andreplaceanynot up to specifications.Cleanandgrind valves.Glow plugsnot usedat start-up (F) Excessive Smoke BLUE SMOKE -.Restriction in air supply 4 -. 2 -.Adjusttappetclearance to specifications.) 3 -. 4 -.Coolantleaks into combustion chamber 6 -.Leaky cylinder headgasket (G) Poor Compression (Under325#at 150 RPM) 3 -.Broken or weak valve springs 6 -. 2 -. 7 -.Reduce load.Check andcorrect if necessary.Overloading engine 3 -.Valvesholding open~ no tappet clearance 2 -.Replace 1 -. Reface or replaceas required.See (I) highoil consumption recommendation.Check thermostat.cleanandtest faulty nozzlefor pressure.Check thermostat -. 2 -. 5 -.Faultyinjectors CORREC~ON 3 --Poor fuel 4 -. (SeePages 11 & 29) 4 -.Energize glowplugsbeforestarting.Re-ring with recommended service kit.Piston rings wornor broken 7 -.Take pump to an authorized service center. 2 -. (See SPB 87-371-.Indicates High Oil Consumption 1 -.Wrong valve timing 4 -.Lowenginewater temperature 1 -. leakage andspraypattern.) 64 .Poor compression 5 -.Worn or stuckrings 2 -.Check thermostat. 3 -.Excessive fuel rate 2 -. 3 -. 6 -. valve stemor valve stemseal BLACK SMOKE 1 -.See"G" recommendations.If necessary rebore& replace pistons.increase enginetemperature.Lowenginewater temperature 3 m Worn valve guide. 3 ~ Clean air cleaner.Use Dieselfuel that meets specifications.Check headgasket.COMPLAINTS PROBABLE CAUSE WHITE SMOKE -. 4 -.Clean headandblock surfaces.MayIndicate Misfiring 1 mLowengine temperature 2 -.(SeeTorque Specification Section 10. 1 -.check for cylinder headwarpage.Worn pistons and bores 1 -.Burned or sticking valvesor incorrect valvetiming 5 -. 6 -.Cutout individualinjectorswith enginerunning -.

Nozzles faulty 6 --Incorrect tappet clearance pumptim- 1 -. --Clean or replace spring. 2 aMaintain oil level between high and low marks on dip stick.Replace 10 --Replace 1 --Operating with low coolant temperature 2--Wrong fuel (J) Poor Fuel Economy 3 --Loss of power 4 --Incorrect injection ing 5 -. 5 --Clean and free up valve--check spring tension.Low oil level 2 --Oil pressure gauge or line faulty 3 --Oil too light--diluted 4 --Dirt in relief valve or broken spring 5 --Suction screen plugged 6 --Worn bearings 7 --Worn oil pump 8 --Pick-up tube O-ring damaged or missing CORRECTION --Add oil to dipstick level.46 (. 6 --Break in all new and rebuilt engines as recommended.Locate and repair. 7 --Re-ring with recommendedservice rings. w Replace (H) Low Oil Pressure 1 --Oil leaks 2 --Too high oil level maintained 3 --Incorrect grade of oil used High Oil Consumption 4 --Clogged crankcase breather 5 --Oil pressure too high--relief valve stuck 6 --Piston rings not properly run-in 7 --Worn.014) int. --Remove screen and clean in solvent. -. 8 --If necessary rebore & replace pistons 9 -.Follow "D" recommendations.36 (. 6 --Adjust tappets .Maintain 79. repair or replace pump. and . --Inspect lines and check with Master Gauge. --Change oil and follow recommendedlubrication.COMPLAINTS PROBABLE CAUSE 1 -.4 °C-85 °C (175°F-185°F) for maximum economy and performance. 3 --Use recommended type and SAEnumberof lubricating oil.018) exh. 5 --Cut out faulty injector--clean and test for pressure. 4--Clean thoroughly. leakage and spray pattern. broken or stuck piston rings and clogged oil control rings 8 --Worn pistons or bores 9 --Worn bearings and valve guides 10 --Intake valve seals 1 -. 3 -. (Reference page 60) 65 .Replace --Remove. 2--Use Diesel fuel that meets specifications. 4Follow recommended timing procedure.

6--Turn engine manually--if uanble to do so check for foreign object in combustion chamber or for piston or bearing seizure. Replace pin with oversize. dull knock when accelerating under load. 2 -. Refit new set of gears if loose or worn badly. Replace if necessary. 3 --Condition noted at idle or light load and disappears at full load. main bearings. Adjust to specifications.Checktappet clearance. tight-gears whine. 5--Drain system and refill with clean fuel or strain remaining fuel through chamois. replace piston pin or rings if necessary. Removenozzle.Reduce load or increase speed. MECHANICAL KNOCKS 1 --To locate knock 2 -.Main bearings 3--Connecting rod bearings 4 --Loose piston pin 5 --Broken piston ring or pin 6--Tappet noise 7 --Timing gear noise 1 --"Short out cylinders" by loosening fuel line to nozzle one at a time--if no change in sound. 5 --Sharp. 3. Check gear fit and examineteeth. Removepistons. 2 --Clogged or dirty filters--check lines for obstruction or break. Check and correct as in Para.No fuel 2 --Restriction in fuel flow CORRECTION 1 --Refill fuel tank and bleed fuel system. clean and adjust. (Reference page 60) 7 --Loose or worn-gears rattle.Bleed fuel system.Use only #2 diesel engine fuel oil for good performance and economy. 66 . Examine bearing lining for wear or excessive clearance. 4 --Replace transfer pump. check opening pressure. clicking noise that cannot be eliminated by shorting out.COMPLAINTS PROBABLE CAUSE 1 -.Follow recommended timing procedure. knock is not occurring in that cylinder. 4 --Sharp metallic rap at idling speed or when starting cold. 2. 3-. 2 --Heavy. 6 -. 7 --Repair or replace 3 --Air in fuel lines 4 --Transfer pumpfaulty 5 --Water in fuel (K) Sudden Stopping 6 --Internal engine seizure 7 --Faulty electrical shut-off on injection pump COMBUSTION KNOCKS(Excessive) 1 --"Lugging" (L) Engine Knocks and Noises 2 --Poor quality fuel 3 --Injection timed too early 4 -.Injection nozzle sticking 1 -.

DO NOT Torque beyondhigh limit.8).8/9. Brackets Camshaft Nuts (cast iron camshaft) Crankshaft Pulley Glow Plugs Nozzle To Holder Fuel Injection PumpDriven Gear To Fuel Injection Pump *Injector to Cylinder Head Rocker Cover High Pressure Fuel Lines 8 9.8 9.819.8 150-162 68-75 61-68 20-24 34-40 34-40 14-19 20-24 23-27 8-11 20-24 34-40 75-81 122-135 190-203 88-95 163-176 31-38 68-75 27-34 68-75 7 -8 27-34 head.8 8.9 12.8 8.8/9.Section 10-Torque Specifications NOTE: The following Torque Values are based on Phosphate Coated Fasteners (Class 10.8/9.8 8.8/9.9) and Black Oxide Coated Fasteners (Class 8.8/9.9 & 12.8/9.8 & 9. ITEM Connecting Rods CAUTIONHigh limit is maximum.8/9.8/9. 110-120 50-55 45-50 15-18 25-30 25-30 10-14 15-18 17-20 6-8 15-18 25-30 55-60 90-100 140-150 65-70 120-130 23-28 50-55 20-25 50-55 5-6 20-25 Accessories And Misc.9 8.8 8.8 and cylinder Always use a new steel heat shield washer between inlector 67 . Main Bearing Caps Flywheels Flywheel Housings Rear End Plates Manifolds (Seezpruf) Gear Covers Water Pump.8 8.8 8.8 8.8/9.8 8.9 12.8 8.8 8.FT.m LB. CYLINDER HEAD ENGINE SERIES TMD SEE CHART Page 68 TORQUE N.8/9.8 8.s Oil Pans (Sheet Steel) Oil Pump To Engine Rocker Shaft Supports THD SIZE MAT’L CLASS 3/8 SAE GR 8 61-68 45-50 M14 M10 M10 M8 M10 M10 M8 M8 M8 M6 M8 M10 M12 M14 M16 7/8 M16 M12 M22 5/16 M24 M8 M12 12.

9. PROPERTYCLASS MARKING BOLTS AND SCREWS: The property class symbols for metric bolts and screwsare given in table at right. N. . PROPERTY CLASS IDENTIFICATION SYMBOL BOLTS.NOTE: The Following Torque Values are to be used. STU DS: All metric studs used on TMD enginesare of property class 10.markingwill be at nut end.Lbs.8 N.m LB.8 9.Lbs.9 12.FT.m LB.Lbs." ColdTorquing Procedure Step 1.FT.8 9. Torquewith HandTorqueWrench to: ¢ TMD20 M10~ 12 9 10 I1 Screw Size (SH) M12 (HH) M10 (HH) M12 Ft. SCREWS AND STUDS 8. Torquewith HandTorqueWrench to: Screw Size (SH) M12 (HH) MIO (HH) M12 Ft. THD SIZE M6 M8 M 10 M 12 M 14 M 16 M20 Torque Value for specific part to be installed TORQUE (Phosphate Coated Fasteners) Class 8.9 STUDS SMALLER THAN M12 (~ -I’- 8.8 Class 9.9 CYLINDER HEAD TMD13 MIO--=.9 12.9 N-m LBoFT. 85-90 30-35 80-85 N-m 115-122 41-47 108-115 (HH) He x Head Ca p Screw NOTE:(SH) = Socket Head Cap Screw ® Torque all 68 ® cylinder @ head capscrews using the proper torquing sequence shown here. If marked.8 10.Lbs. 8-11 6-8 8-11 6-8 20-24 15-18 20-24 15-18 34-40 25-30 34-40 25-30 75-81 55-60 75-81 55-60 122-135 90-100 122-135 90-100 190-203 140-150 190-203 140-150 Class 10. the marking may be indented on the side of the head for hex head products. Retorque with Hand Torque Wrench (after enginereachesnormal operating temperature) to the followingvalues.in onesingle smooth motion: ScrewSize (S H) M (HH) alO (HH) M12 Ft. 30-35 10-15 25-30 N-m 41-47 14-20 34-41 TORQUE SEQUENCE Step 2.only if is not listed on preceding sheets. Alternatively. Marking shall be located on the top of the head. 60-65 20-25 55-60 N-m 81-88 27-34 75-81 Step 3.8 10. 95-100 35-40 90-95 N-m 129-136 47-54 122-129 Hot Retorquing Procedure TMD27 MI0---~15 14 11 I1~ 13 Step 4. Torquewith HandTorqueWrench in one single smooth motion: Screw Size (SH) M12 (HH) MIO (HH) M12 Ft.

0. Dia. Dia.008) VALVE SPRINGS Outside Dia.0006) (.64018.837 (1.0056) (. Dia.142 0.--Fin.0030/.150 52. Dia. Clearance Limits Disired Clearance "Wear Limits--Max.8708) (. Desired Stem Clear. ENGINE MODEL VALVE GUIDE (Intake & Exhaust) Length Outside Dia. Length--Valve Closed Load--Valve Closed "Wear Limits--Min.162 0. in Bushing Desired Pin Fit 71. *Wear Limits--Min.372) (1. 34.3376) ’) (44°45 (.65751.554 1. CI.178 (.3383) ’ ) (29°45 (.8740) (1.0973) (. Thickness "Wear Limits--Min.0037/.717/8.15 0.511147.0067/.6535) (52.2810.749/42.03810.025 (.7445) (1. *Wear Limits--Max. INTAKE Stem Dia.0607) (1.011/.0011) 0. Side Play Desired Side Play 30. Brg.0015) PISTON PIN Length Diameter "Wear Limits--Min.125 0. 8.013/0.7 28. Clearance Limits Desired Clearance C/S End Play 78.692 8.3409/.175/30.944 72.1259/1. of Brg.85 42. CI.00151. Thk.974172.0 24KgF 21.642 8. Hole E)ia.080/0.0978/.3447) *Wear Limits--Min.0005/0.294) (104.3394) (.1870) (2.484/2. 8.1248) (1.311 25.13910.096 0. Hole Dia. Bore in Block t~rg. Dia. Thk.00 2.--Crank Pin "Wear Limits--Min.775 (2 3/8) (.133/0.075/0.567/1.6820) Dia.0023) (.0038) (.425 42.0617/.17/0.091 0.344 0.0615) (.8#) (47.592 .7490) (1.459 72.053 (. Thickness *Wear Limits--Min.0029) Bush.1250/1.311 42.6875/1. TMD METRIC (ENGLISH) ENGINE MODEL CAMSHAFT Brg.0055/.Section 11.8695) (1. Stem.0716/3. Bore in Block "Wear Limits 25. Brg.0021) Bore--Inside Dia. Wgt. Seat Angle Stem Clearance--Limits *Wear Limits--Max. Dia. Desired Fit Bush.187 49. Desired Stem Clear. Length--Valve open Load--Valve open *Wear Limits--Min.625/47. of Main Brg.9978) (.0020) (.019/78.588 28.1255) (1.0035) (.0/70.575/28. Dia.212/49.04 (3.0019) (.324/25.20 (1.032 0.1245) (1. Seat Angle Stem Clearance Limits *Wear Limits--Max. 29°45 0.0070) CONNECTING RODS VALVES.575 .870511.089 0.795/2.6#) (93.3422) (.862/42.675 8.9355) (.9375/1. Dia.0612) (.5KgF 32.450/44.058 0. Journal Dia.8750/1.623 0. Min.571 28.006) (. "Wear Limits.0709) (.54KgF 42.471 2.9365) (1.9970/. Wgt.562 Light Push 28.0968) (2.683011.783) (1.598/28.918 0.0008 TAPPET Outside Dia.362 1. *Wear Limits--Max.336/44. "Wear Limits--Min. EXHAUST Stem Dia.028 0.13 (.8730/2.660/8.600 44. #1 #2 #3 Bore--Clearance Limits End Play 0.9986/. Pin CI.001) Under MinimumNewShaft Diameter 47.745511.9965) (.0036) (.375/52.88 47.0052/.073 (.750011.016 0. 44°45 0. Hole Dia.622 8.542 49.8718) (2.052 0.486 44.6865) VALVES.0031/. CI.723 (ENGLISH) (1.3#) (1.Limits and Clearance Data NOTE: Dimensions shown are for standard engines.4 16. 60.3402/.3432/.1269) (0.0012) (.09510.6565) (. Jr. Hole Dia.0620/2. #1 #2 #3 TMD METRIC 47.0049) (.5#) MAIN BEARINGS Dia.3402) (.364125.020 (2. Dia.5KgF (1.048 0.005) 69 .700/16.1880/1.

ENGINE MODEL PISTONS Cylinder Dia. *WearLimits--Cyl. Bore Piston Pin Hole Dia. Ring GrooveWidth--#1 Max. WearLimit Width Ring GrooveWidth #2-*Max Wear Limit Width #2-Ring GrooveWidth #3 *Max WearLimit Width Piston Fit-Feeler Gauge Lbs. Pull PISTON RINGS Ring Width--#1 *WearLimits--Min. Width Ring Width--#2 *WearLimits--Min. Width Ring Width #3 WearLimits--Min. Width Ring GapClear--#1 Ring GapClear--#2 Ring GapClear--#3 Ring Side Clear--#1 Ring Side Clear--#2 Ring Side Clear--#3 METRIC 91.039/91.000 0,20 28.583/28.578 2.560/2.540 2.611 2.06012.040 2.111 4.060/4.040 4.109 0.08 2.3-4.5Kg

TMD (ENGLISH) (3.584213.5827)

(.008)
(1.1253/1.1251 (mI0081.1000) (1.028) (.0811/.0803) (.0831) (.1598/.1591) (.1618) (.003)

(5-10#)

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

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

(.1546)
(.0161.026) (.016/.026) (,012/.024) (.0032/.0020) (.0032/.0020) (.0032/.0020)

NOTES

70

Index / WARNING

Read andobserve all individual safetywarnings as youusethis manual to operate, serviceor repair y ur engine.Seepages 1 and2.

Important Safety Notice and Warnings ................................................................................................

1 &2

Contents ............................................................................................................................... ~......................... 3 Industrial Cntinental Diesel Specifications .............................................................................................. SECTION 1 - General Information Continental Diesel Engine ..................................................................................................................... 4 5

SECTION 2 - Operating Instructions Preparation of a New Engine for Operation .......................................................................................... 7 Starting the Engine ................................................................................................................................ 7 Stopping the Engine ............................................................................................................................... 9 11 "Musts". ............................................................................................................................................. 9 Cold Weather Operation ........................................................................................................................ 9 Engine Preparation forWinter Use ...................................................................................................... 10 Preparation of Engine for Seasonal Storage ....................................................................................... 11 SECTION 3 - Lubrication Engine Lubrication System .................. : ............................................................................................... 13 OilPump ...............................................................................................................................................13 OilChange Frequency ......................................................................................................................... 13 Lubrication Recommendations ............................................................................................................ 14 SECTION 4 - Cooling System Cooling System .................................................................................................................................... Effect of Altitude on Cooling ................................................................................................................ Anti-Freezes ......................................................................................................................................... Cleaning Cooling System ..................................................................................................................... Testing Thermostat .............................................................................................................................. Radiator Pressure Cap ........................................................................................................................ Fan Belt Tension .................................................................................................................................. Water Pump ......................................................................................................................................... 15 16 16 16 17 18 18 19

SECTION 5 - Fuel System Electric Fuel Transfer Pump ................................................................................................................ 21 Bleeding the Fuel System .................................................................................................................... 22 Fuel Filters ...........................................................................................................................................23 Injectors ................................................................................................................................................ 24 Testing .................................................................................................................................................. 24 Fuel Injection Pump ............................................................................................................................. 25 Timing of Injection Pump to theEngine ............................................................................................... 26 Fuel Recommendations ....................................................................................................................... 31 SECTION6 - ChargingSystem Charging System .................................................................................................................................. 32 71

SECTION 7 - Pr ventive Maint nanc Daily Preventive Maintenance Schedule ............................................................................................. Dry Type Replaceable Air Filter........................................................................................................... PCV System ......................................................................................................................................... Check OilPressure .............................................................................................................................. 50- Hour Preventive Maintenance Schedule ...................................................................................... 250 - Hour Preventive Maintenance Schedule .................................................................................... 400 - Hour Preventive Maintenance Schedule .................................................................................... 500 - Hour Preventive Maintenance Schedule ....................................................................................

34 34 35 35 36 37 37 37

SECTION 8 - Engine Repair and Overhaul Cylinder Head ...................................................................................................................................... 39 Disassembly of Cylinder Head ............................................................................................................. 40 Valve Guides ........................................................................................................................................ 41 Valve Seat Inserts (if supplied) ............................................................................................................ 41 Valve Guide Data ................................................................................................................................. 42 Valves ................................................................................................................................................... 43 Valve Springs ....................................................................................................................................... 44 Rocker Arms ........................................................................................................................................ 45 Valve Push Rods .................................................................................................................................. 45 Checking Bore Wear ............................................................................................................................ 45 Preparing Cylinder Walls for Re-Ringing or Reboring ......................................................................... 45 Pistons .................................................................................................................................................. 47 Piston Pins ...........................................................................................................................................48 Connecting Rod ................................................................................................................................... 48 Piston and Connecting Rod Assembly ................................................................................................ 48 Piston Rings ......................................................................................................................................... 49 Recommended Method of Installing Piston Rings .............................................................................. 49 Crankshaft and Main Bearings ............................................................................................................ 50 Bearings ............................................................................................................................................... 50 Camshaft ..............................................................................................................................................52 Tappets ................................................................................................................................................ 53 Rear Crankshaft OilSeals ................................................................................................................... 53 OilPump ............................................................................................................................................... 54 Timing Gears ........................................................................................................................................ 55 Crankshaft End Play ............................................................................................................................ 57 Flywheel and Flywheel Housing .......................................................................................................... 57 Reassembling Engine .......................................................................................................................... 58 Installing Head ..................................................................................................................................... 58 Installing OilPan .................................................................................................................................. 60 SECTION 9 - Trouble Shooting Engine Won’t Turn Over ...................................................................................................................... 61 Engine Turns, butWon’t Start .............................................................................................................. 62 Runs "Rough" with Excessive Vibration .............................................................................................. 62 Loss ofPower ...................................................................................................................................... 63 Overheating .......................................................................................................................................... 63 Excessive Smoke ................................................................................................................................. 64 Poor Compression (under 325# at 150 RPM) ..................................................................................... 64 Low OilPressure .................................................................................................................................. 65 High OilConsumption .......................................................................................................................... 65 Poor Fuel Economy ............................................................................................................................. 65 Sudden Stopping .................................................................................................................................. 66 Engine Knocks and Noises .................................................................................................................. 66 SECTION 10- Torque Specifications ................................................................................................... SECTION 11- Limits and Clearance Data ........................................................................................... 67-68 69-70

72

NOTES .

NOTES .

WIS. Tennessee 38181 Phone: (901) 365-3600 TOLLFREE: 1-800-932-2858 TELEX:462-1058 (IT1") FAXNO: (901) 369-4050 EUROPEAN: Rue JosephDeflandre.SERVICEAND PARTS Available from your Authorized WlS-CON TOTAL POWER Service Center CALIFORNIA P~oposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer. Box 181160 Memphis.O. 13 B-4920 Chaudfontaine(Liege) Belgium Phone: (32) (41) 675320 TELEX: 42631 TDYTP B FAX NO: (32) (41) January/1993 TTP10148 .CON TOTALPOWER coRP. and other reproductive harm. birth defects. HEADQUARTERS: 3409 Democrat Road P.