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Thermo King TK 2.44, Руководство по капитальному ремонту


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Table of Contents

Specifications  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Table of Contents  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
TK 2.44 & TK 3.66 Diesel Engine Specifications  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
TK 2.49 & TK 3.74 Diesel Engine Specifications  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
TK 3.88 Diesel Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
TK 3.95 Diesel Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Torque Values for TK 2.44 & TK 3.66 Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Torque Values for TK 2.49 & TK 3.74 Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Torque Values for TK 3.88 Engine  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Torque Values for TK 3.95 Engine  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

Engine Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  27

Table of Contents  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  27
Engine Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Inspection and Reconditioning  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

Table of Contents  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Inspection and Reconditioning  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

Camshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Connecting Rods. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Crankshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

Cylinder Head Assembly  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Valve Depth  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Valve Guides  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Valve Seat Replacement  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
Valve Seats. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Valve Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

Manifolds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
Oil Pressure Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Pistons  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Push Rods. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
Rocker Arm Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Timing Gears. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Water Pump  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  61
Wrist Pins  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

Engine Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

Table of Contents  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Engine Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65

Assembly Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
Assembly Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65

Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79

Table of Contents  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81

Содержание TK 2.44

Страница 1: ...Overhaul Manual TK 2 44 2 49 3 66 3 74 3 88 and 3 95 TK 8312 2 Rev 1 97 Copyright 1988 Thermo King Corp Minneapolis MN U S A Printed in U S A...

Страница 2: ...ment which has been so repaired or altered outside the manu facturer s plants as in the manufacturer s judgment to effect its stability No warranties express or implied including warranties of fitness...

Страница 3: ...Specifications 1 Engine Disassembly 2 Inspection and Reconditioning 3 Engine Assembly 4 Lubrication System 5 Fuel System 6 Electrical 7 Run In 8...

Страница 4: ...ssembly 29 Inspection and Reconditioning 39 Table of Contents 39 Inspection and Reconditioning 41 Camshaft 50 Connecting Rods 48 Crankshaft 45 Cylinder Block 41 Cylinder Head 51 Cylinder Head Assembly...

Страница 5: ...on Pump Timing 95 Individual Cylinder Timing 97 Timing Injection Pump To Engine 96 Maximum Speed Stop Screw Adjustment 87 Electrical 101 Table of Contents 101 Electrical 103 Fuel Solenoid 110 Fuel Sol...

Страница 6: ...K 2 49 TK 3 74 Diesel Engine Specifications 8 TK 3 88 Diesel Engine Specifications 13 TK 3 95 Diesel Engine Specifications 18 Torque Values for TK 2 44 TK 3 66 Engines 23 Torque Values for TK 2 49 TK...

Страница 7: ...ng 14 Degrees BTDC 14 Degrees BTDC Nozzle Injection Pressure 1707 psi 11768 kPa 1707 psi 11768 kPa Oil Pressure 18 5 psi 127 kPa Minimum 230 F 110 C 1600 rpm 18 5 psi 127 kPa Minimum 230 F 110 C 1600...

Страница 8: ...14 in 35 850 mm Middle 1 4138 1 4148 in 35 910 35 935 mm 1 4114 in 35 850 mm Flywheel End 1 4150 1 4157 in 35 940 35 960 mm 1 4114 in 35 850 mm Camshaft Bearing Inside Diameter Timing Gear End Bearing...

Страница 9: ...ter 7870 7874 in 19 991 20 000 mm 7864 in 19 975 mm Wrist Pin to Wrist Pin Bore Clearance 0 0007 in 0 017 mm 0018 in 0 045 mm Connecting Rod Wrist Pin Bushing Inside Diameter 7884 7889 in 20 025 20 03...

Страница 10: ...mm Timing Gears Timing Gear Lash Crankshaft Gear to Idler Gear 0016 0047 in 0 040 0 120 mm 0079 in 0 200 mm Crankshaft Gear to Oil Pump Gear 0043 0075 in 0 110 0 190 mm 0079 in 0 200 mm Idler Gear to...

Страница 11: ...TK 3 66 Diesel Engine Specifications Rev 1 97 7 Starter No Load Test Voltage 11 volts Current 180 amps 11 volts Speed More than 3500 rpm 11 volts Commutator Outside Diameter 1 18 in 30 0 mm 1 14 in 2...

Страница 12: ...Degrees BTDC 14 Degrees BTDC Nozzle Injection Pressure 1707 psi 11768 kPa 1707 psi 11768 kPa Oil Pressure 18 5 psi 127 kPa Minimum 230 F 110 C 1600 rpm 18 5 psi 127 kPa Minimum 230 F 110 C 1600 rpm Va...

Страница 13: ...14 in 35 850 mm Middle 1 4138 1 4148 in 35 910 35 935 mm 1 4114 in 35 850 mm Flywheel End 1 4150 1 4157 in 35 940 35 960 mm 1 4114 in 35 850 mm Camshaft Bearing Inside Diameter Timing Gear End Bearing...

Страница 14: ...19 900 mm Wrist Pin to Wrist Pin Bore Clearance 0 0007 in 0 017 mm 0047 in 0 120 mm Connecting Rod Wrist Pin Bushing Inside Diameter 7884 7889 in 20 025 20 038 mm 7913 in 20 100 mm Wrist Pin to Wrist...

Страница 15: ...mm Timing Gears Timing Gear Lash Crankshaft Gear to Idler Gear 0016 0047 in 0 040 0 120 mm 0079 in 0 200 mm Crankshaft Gear to Oil Pump Gear 0043 0075 in 0 110 0 190 mm 0079 in 0 200 mm Idler Gear to...

Страница 16: ...TK 3 74 Diesel Engine Specifications Rev 1 97 12 Starter No Load Test Voltage 11 volts Current 180 amps 11 volts Speed More than 3500 rpm 11 volts Commutator Outside Diameter 1 18 in 30 0 mm 1 14 in...

Страница 17: ...m Valve Train Standard Dimensions Wear Limit Valve Spring Free Length 1 47 in 37 4 mm 1 33 in 33 7 mm Inclination 04 in 1 0 mm Valve Guide Inside Diameter Intake 2758 2764 in 7 005 7 020 mm 2787 in 7...

Страница 18: ...in 39 850 mm Middle 1 5713 1 5722 in 39 910 39 935 mm 1 5689 in 39 850 mm Flywheel End 1 5724 1 5732 in 39 940 39 960 mm 1 5689 in 39 850 mm Camshaft Bearing Inside Diameter Timing Gear End Bearing I...

Страница 19: ...8264 8268 in 20 991 21 000 mm 8258 in 20 975 mm Wrist Pin to Wrist Pin Bore Clearance 0 0007 in 0 018 mm 0018 in 0 045 mm Connecting Rod Wrist Pin Bushing Inside Diameter 8278 8283 in 21 025 21 038 m...

Страница 20: ...iming Gears Timing Gear Lash Crankshaft Gear to Idler Gear 0016 0047 in 0 040 0 120 mm 0079 in 0 200 mm Crankshaft Gear to Oil Pump Gear 0043 0075 in 0 110 0 190 mm 0079 in 0 200 mm Idler Gear to Cams...

Страница 21: ...3 88 Diesel Engine Specifications Rev 1 97 17 Starter No Load Test Voltage 11 volts Current 180 amps 11 volts Speed More than 3500 rpm 11 volts Commutator Outside Diameter 1 18 in 30 0 mm 1 14 in 29 0...

Страница 22: ...ndard Dimensions Wear Limit Valve Spring Free Length 1 47 in 37 4 mm 1 33 in 33 7 mm Inclination 04 in 1 0 mm Valve Guide Inside Diameter Intake 2758 2764 in 7 005 7 020 mm 2787 in 7 080 mm Exhaust 27...

Страница 23: ...9 in 39 850 mm Middle 1 5713 1 5722 in 39 910 39 935 mm 1 5689 in 39 850 mm Flywheel End 1 5724 1 5732 in 39 940 39 960 mm 1 5689 in 39 850 mm Camshaft Bearing Inside Diameter Timing Gear End Bearing...

Страница 24: ...00 mm 8228 in 20 900 mm Wrist Pin to Wrist Pin Bore Clearance 0 0007 in 0 017 mm 0047 in 0 120 mm Connecting Rod Wrist Pin Bushing Inside Diameter 8278 8283 in 21 025 21 038 mm 8307 in 21 100 mm Wrist...

Страница 25: ...iming Gears Timing Gear Lash Crankshaft Gear to Idler Gear 0016 0047 in 0 040 0 120 mm 0079 in 0 200 mm Crankshaft Gear to Oil Pump Gear 0043 0075 in 0 110 0 190 mm 0079 in 0 200 mm Idler Gear to Cams...

Страница 26: ...3 95 Diesel Engine Specifications Rev 1 97 22 Starter No Load Test Voltage 11 volts Current 180 amps 11 volts Speed More than 3500 rpm 11 volts Commutator Outside Diameter 1 18 in 30 0 mm 1 14 in 29 0...

Страница 27: ...5 3 5 Glow Plug 10x1 25 14 7 19 6 10 8 14 5 1 5 2 0 Idler Gear Shaft Mtg Bolt 6x1 9 8 11 8 7 2 8 7 1 0 1 2 Intake Manifold Mtg Bolt 6x1 9 8 11 8 7 2 8 7 1 0 1 2 Main Bearing Bolt 9x1 25 52 0 55 9 38...

Страница 28: ...5 3 5 Glow Plug 10x1 25 14 7 19 6 10 8 14 5 1 5 2 0 Idler Gear Shaft Mtg Bolt 6x1 9 8 11 8 7 2 8 7 1 0 1 2 Intake Manifold Mtg Bolt 6x1 9 8 11 8 7 2 8 7 1 0 1 2 Main Bearing Bolt 9x1 25 52 0 55 9 38...

Страница 29: ...low Plug 10x1 25 14 7 19 6 10 8 14 5 1 5 2 0 Idler Gear Shaft Mtg Bolt 6x1 9 8 11 8 7 2 8 7 1 0 1 2 Intake Manifold Mtg Bolt 6x1 9 8 11 8 7 2 8 7 1 0 1 2 Main Bearing Bolt 10x1 25 73 5 83 4 54 2 61 5...

Страница 30: ...low Plug 10x1 25 14 7 19 6 10 8 14 5 1 5 2 0 Idler Gear Shaft Mtg Bolt 6x1 9 8 11 8 7 2 8 7 1 0 1 2 Intake Manifold Mtg Bolt 6x1 9 8 11 8 7 2 8 7 1 0 1 2 Main Bearing Bolt 10x1 25 78 5 83 4 57 9 61 5...

Страница 31: ...27 Engine Disassembly 2 Table of Contents 27 Engine Disassembly 29...

Страница 32: ...rings and the existing timing marks and bearing cap marks Identical components in the valve train and the crankshaft assembly should be kept in order or marked This prevents mixing up these component...

Страница 33: ...Engine Disassembly Rev 1 97 30 TK 3 88 Rear View aea202 Crankcase Breather Hose Fuel Injection Line Valve Cover Exhaust Manifold Flywheel Oil Pan Starter Water Pump...

Страница 34: ...crankcase breather hose 5 Remove the fuel injection return lines 6 Remove the intake manifold Intake Manifold 7 Remove the fuel injection nozzles NOTE Removing the lift bracket from the cylinder head...

Страница 35: ...rings under these cap nuts and replace the O rings if necessary during assembly Valve Cover aea206 aea343 14 Remove the rocker arm assembly by removing the nuts and and bolt on three cylinder engines...

Страница 36: ...removed from either the top or the bottom of the block If the engine is turned upside down with the cylinder head off the lifters may fall out Removing Tappet aea210 aea211 20 Remove the starter moun...

Страница 37: ...cifi cations Check Timing Gear Lash 26 Remove the snap ring from the idler shaft and remove the thrust washer and the idler gear Note the timing marks on the timing gears The timing marks must be alig...

Страница 38: ...haft to avoid scratching or marring the camshaft bearings 30 Remove the oil pump Oil Pump aea217 aea218 31 Make sure the oil has been drained and remove the oil pan and the oil intake pipe NOTE Some e...

Страница 39: ...y can be placed in the same position when assem bled Identification Marks aea221 aea222 35 Remove the connecting rod caps Removing Connecting Rod Caps 36 Carefully remove the piston and connecting rod...

Страница 40: ...ar Main Bearing Cap 38 Carefully remove the crankshaft from the block aea225 NOTE The upper rear main bearing flywheel end has a thrust bearing on each side Make sure to remove these two thrust bearin...

Страница 41: ...Cylinder Block 41 Cylinder Head 51 Cylinder Head Assembly 56 Disassembly 52 Valve Depth 53 Valve Guides 52 Valves 53 Valve Seat Replacement 55 Valve Seats 54 Valve Springs 55 Manifolds 61 Oil Pressur...

Страница 42: ...an be completed by the time the rest of the engine is ready to assemble Cylinder Block 1 Inspect the cylinder block for cracks damage and dis tortion Use a straight edge and a feeler gauge to check th...

Страница 43: ...If the cylinders must be bored determine which over size pistons should be used Pistons are available in 010 and 020 in 0 25 and 0 50 mm oversizes NOTE If the 020 in 0 50 mm oversize is not large eno...

Страница 44: ...ss the cylinder sleeves into the block Place the pressing tool in the top end of the cylin der sleeve aea231 aea232 The bottom end of a cylinder sleeve has a slightly smaller outside diameter than the...

Страница 45: ...haft bearings do not have bearing inserts Measuring Front Camshaft Bearing Insert aea297 6 Measure the middle and rear camshaft bearings If the middle or rear camshaft bearings are larger than the wea...

Страница 46: ...p pet bores are larger than the wear limit refer to Specifi cations the block must be replaced Normally very little if any wear occurs in the tappet bores Small scratches or nicks should be cleaned up...

Страница 47: ...Specifications for the suggested out side diameter of undersized rod journals NOTE The most accurate method of determining the outside diameter of the undersized rod journals is to install the rod cap...

Страница 48: ...f a vise will put small nicks in the connect ing rod These nicks raise the stress on the connecting rod and can cause the connecting rod to break while the engine is running 3 Remove the carbon from t...

Страница 49: ...t pin and the connect ing rod bushing can be checked by oiling the wrist pin and inserting it into the connecting rod bushing The fit should be snug and it should take a slight push to move aea246 the...

Страница 50: ...t and parallelism The service limit for both twist and parallelism is 003 in per 4 in 0 08 mm per 100 mm If the twist or parallelism exceeds the wear limit straighten or replace the rod 7 Measure the...

Страница 51: ...e idler gear bushing To replace the bushing press the old bushing out of the idler gear and press the new bushing into the idler gear Measuring Idler Gear Bushing 3 Measure the outside diameter of the...

Страница 52: ...the clearance exceeds the wear limit refer to Specifications replace the thrust plate and check the aea254 aea255 clearance again If the clearance still exceeds the wear limit after replacing the thru...

Страница 53: ...has accumulated many hours of running time it is advisable to replace the valve guides because they usually show significant wear after numerous hours of service Because the valve seat grinding proce...

Страница 54: ...he valve seat or both may need replacement If the valve depth is over the wear limit after grinding the valve or the valve seat the valve the valve seat or both must be replaced To check the valve dep...

Страница 55: ...the valves in their respective valve seats and check the valve depth of each Replace any valve that has a valve depth over the wear limit Valve Seats 1 Inspect the valve seats for any major damage tha...

Страница 56: ...ly across from each other Allow the valve seat insert to cool and contract for 3 to 5 minutes Pry the valve seat insert out of the cylinder head with a small pry bar 2 Clean any carbon or other foreig...

Страница 57: ...alve stems prevents them from seizing to the new valve stem seals 3 Install the valve springs The end of a valve spring that has less pitch this end is wound tighter and may have some paint on it shou...

Страница 58: ...f the valve seat and the valve face The valve seat should appear smooth and be an even gray color The valve face should show a smooth even gray ring where it contacts the valve seat Repeat the lapping...

Страница 59: ...rm bush ing If a rocker arm bushing is larger than the wear limit refer to Specifications or shows significant damage replace the bushing or the rocker arm 6 Replace the rocker arm bushing by pressing...

Страница 60: ...et aea383 aea278 2 Measure the outside diameter of each tappet Replace any tappets that are smaller than the wear limit refer to Specifications Oil Pump 1 Remove the rotor plate and inspect the oil pu...

Страница 61: ...ter of rotor shaft from the diameter of the rotor shaft bore to obtain the rotor shaft clear ance Refer to Specifications for the standard dimen sion The wear limit is 0079 in 0 200 mm If the rotor sh...

Страница 62: ...is leaking out of the weep hole the mechanical seal is leaking and the water pump must be replaced Water Pump and Thermostat Assembly aea283 aea284 2 Check the water pump bearing If the water pump sha...

Страница 63: ...63 Engine Assembly 4 Table of Contents 63 Engine Assembly 65 Assembly Precautions 65 Assembly Procedure 65...

Страница 64: ...in the correct order the engine may require some disassembly to install these parts properly 6 Check all the assembly tolerances such as bearing clearance end play and gear lash carefully Neglecting...

Страница 65: ...aps The lower main bearing inserts are plain and identical 7 Place the lower thrust bearings in position on each side of the rear main bearing cap The lower thrust bearings each have a tab on the bott...

Страница 66: ...ing Cap Bolts 10 Remove the main bearing caps and check the plasti gauge to determine the clearance of each main bearing Refer to Specifications for the recommended main bearing clearance 11 Lubricate...

Страница 67: ...in its respective cylinder Level the ring in the cylinder with a piston and check the end gap with a feeler gauge If the end gap is not correct refer to Specifications check to make sure that the cyli...

Страница 68: ...with the wrist pin Ring Alignment 23 Oil each cylinder piston piston ring wrist pin and rod bushing with engine oil 24 Use a ring compressor to install each piston assembly The swirl chamber on top o...

Страница 69: ...cting rod The standard dimension is 008 to 016 in 0 20 to 0 40 mm 31 Place new O rings on the front of the engine block and make sure the dowel pins are in place Front of Engine Block 32 Place a thin...

Страница 70: ...he B between the teeth on the camshaft gear The injection pump gear tooth marked with a C should line up with the C between the teeth on the idler gear aea306 aea307 40 Place the thrust washer and the...

Страница 71: ...et 45 Place the cylinder head on top of the block and the head gasket Make sure to align the head with the dowel pins 46 Install the cylinder head bolts Torque the cylinder head bolts in two or three...

Страница 72: ...t and bolt one turn at a time to evenly apply the valve spring pressure to the rocker arm assembly Make sure the valve adjustment screws all seat properly in the sockets on the ends of the push rods w...

Страница 73: ...ch rocker arm bushing and from the hole in each rocker arm at a fairly good rate but there should be no large streams of oil from any of the rocker arms or bushings h Turn the engine over several time...

Страница 74: ...aea320 aea321 4 Install the oil intake pipe Install Oil Intake Pipe 5 Place a thin layer of sealant on the sealing sur face of the oil pan cover and place the oil pan cover in position on the oil pan...

Страница 75: ...ing flange in position on the rear of the block and make sure to align the dowel pins 65 Install and tighten the mounting bolts for the starter mounting flange NOTE The bolts at the bottom of the star...

Страница 76: ...s and torque them to 10 8 to 14 5 ft lb 14 7 to 19 6 N m 76 Install the glow plug connector 77 Place a nozzle gasket a nozzle protector and another nozzle gasket in each opening for the fuel injection...

Страница 77: ...9 Install the intake manifold with a new gasket 80 Install the fuel return lines 81 Install the crankcase breather hose 82 Install the fuel injection lines 83 Install the exhaust manifold with a new g...

Страница 78: ...79 Lubrication System 5 Table of Contents 79 Lubrication System 81...

Страница 79: ...gear shaft lubricates the idler gear bush ing the idler gear and the other timing gears before return ing to the oil pan The oil that flows to the fuel injection pump returns to the oil pan after lubr...

Страница 80: ...t Inspection 93 Delivery Valve 93 Fuel Control Rack And Pinions 94 Plunger Barrel Seal 93 Plunger and Plunger Barrel 93 Plunger Guide Assembly 94 Springs 94 Removal 91 Fuel Limit Screw Adjustment 88 I...

Страница 81: ...e 1 Fuel Tank 2 Prefilter Optional 3 Electric Fuel Pump 4 Fuel Filter 5 Injection Pump 6 Injection Nozzles The fuel is drawn from the fuel tank through the prefilter if used to the electric fuel pump...

Страница 82: ...all possible precautions must be taken to keep dirt from entering the system All fuel lines must be capped when disconnected The work should be done in a relatively clean area and the work should be...

Страница 83: ...c fuel pump The engine must be turned over with the starter 6 Tighten the injection lines and start the engine Maximum Speed Stop Screw Adjustment NOTE The maximum speed stop screw is covered with an...

Страница 84: ...governor housing which faces toward the flywheel The fuel limit screw is set when the injection pump is cali brated at the factory and SHOULD NOT be adjusted unless there is reason to believe someone...

Страница 85: ...nut is turned out toward the cap nut enough to allow adjustment 3 Remove the inspection plate from the side of the injec tion pump housing Remove Inspection Plate 4 Remove the 20 wire from the reset...

Страница 86: ...crew This will throw the adjustment off Tensioner Lever and Governor Lever Tensioner Lever Start Spring and Governor Lever aea341 aea342 9 Turn the fuel limit screw in or out to align the scribe mark...

Страница 87: ...ate 2 Remove the clip and disconnect the governor link from the fuel control rack aea344 3 Remove the nuts from the four studs on top of injection pump 4 Center the fuel control rack and remove the in...

Страница 88: ...keep the plunger shims with their respective plunger guides Plunger and Associated Components 4 Remove the fuel control rack 5 Remove the delivery valve spring holder the delivery valve spring the del...

Страница 89: ...p to an angle of approximately 60 degrees The plunger should slide smoothly into the plunger barrel c Repeat this test several times and turn the plunger about a quarter of a turn each time d Replace...

Страница 90: ...l control rack if it is bent or damaged or if the gear teeth show excessive wear aea352 Replace the fuel control pinions if the gear teeth show excessive wear or damage Assembly NOTE The steps in this...

Страница 91: ...e plunger guide stopper pin 16 Torque the delivery valve spring retainers to 29 to 32 ft lb 39 to 43 mm Installation 1 Center the fuel control rack and place the fuel injection pump in the injection p...

Страница 92: ...e 1 Rotate the engine in the normal direction of rotation counterclockwise from the flywheel end until the number 1 cylinder is at top dead center of the compres sion stroke a Remove the valve cover a...

Страница 93: ...roce dure for timing the injection pump to the engine but do not adjust the timing Check the timing of the other cylinders after checking the number 1 cylinder The injection timing mark for each cylin...

Страница 94: ...e aea358 Acceptable Spray Pattern Unacceptable Spray Patterns 3 Open the pressure gauge valve and check the opening pressure by pushing the hand lever completely down several times a The injection noz...

Страница 95: ...f any wear or damage is evident 7 Inspect the spring Replace the spring if it is bent scratched or rusted 8 Use a nozzle cleaning tool kit to clean the nozzle valve and seat set a Clean the carbon off...

Страница 96: ...s not slide smoothly into the nozzle seat NOTE A new nozzle valve and seat set should be thoroughly cleaned and tested before being installed 10 Assemble the injection nozzle and torque the nozzle nut...

Страница 97: ...rical 103 Fuel Solenoid 110 Fuel Solenoid Replacement 110 Glow Plugs 103 Starter 103 Assembly 108 Disassembly 103 Major Component Inspection 105 Gears and Bearings 107 Pinion Assembly 107 Starter Moto...

Страница 98: ...avy duty contacts and it extends the pinion gear to engage the ring gear on the engine s flywheel The pinion assembly includes an over running clutch that allows the pinion gear to turn freely if the...

Страница 99: ...Remove the two screws from the pinion housing and separate the pinion housing from the starter solenoid Make sure to keep track of the solenoid spring and the steel ball that are located between the s...

Страница 100: ...ositive brush holders should have infinite resis tance to the brush ring plate The negative brush holders should have continuity to the brush ring plate b Check the brushes Replace the brushes if they...

Страница 101: ...rmature a To check the bearings turn them by hand Replace the bearings if they are rough or seem loose aea372 aea373 b Visually check the armature Replace the armature if there is any sign of thrown s...

Страница 102: ...r leads on each pair of commutator bars that are directly opposite each other The ammeter will show no current in an open coil and lower than normal current in a shorted coil Replace the armature if a...

Страница 103: ...he starter solenoid does not energize replace it c Disconnect the jumper wire from the C terminal on the starter solenoid The starter solenoid should remain energized If the start solenoid does not re...

Страница 104: ...r a Place the armature in the stator b Make sure the negative brushes are in the locked position and place the brush ring on the commuta tor c Place the positive brushes in the brush holders d Move th...

Страница 105: ...e CH pin in the fuel solenoid connector The resistance of the pull in coil should be 0 2 to 0 3 ohms If the resistance of the pull in coil is not in this range replace the fuel solenoid 3 Test the hol...

Страница 106: ...end of the fuel injection pump Make sure the O ring is positioned cor rectly during installation to avoid damage and leaks 6 Install the new fuel solenoid 7 Turn the unit off and make sure to connect...

Страница 107: ...e 8 Table of Contents 113 Run In 115 Compression Test 118 Dynamometer Run In Procedure 115 Run In Procedure Without Dynamometer 115 Valve Clearance Adjustment 115 Three Cylinder Procedure 117 Two Cyli...

Страница 108: ...leaks CAUTION DO NOT run a newly rebuilt engine with out a load for a long period of time This can cause the engine s oil consumption to be higher than normal 2 Mount the engine in a unit and run the...

Страница 109: ...ber 1 cylinder with a feeler gauge Refer to Specifica tions for the recommended valve clearance aea381 5 Adjust the valves if necessary by loosening the lock nut and turning the adjustment screw unti...

Страница 110: ...he fly wheel timing marks is 1 2 3 but the firing order is 1 3 2 The reason for this is that the engine fires every 240 degrees of crankshaft rotation Therefore when adjusting the valves check the num...

Страница 111: ...he exhaust stroke Rotate the engine 360 degrees to place the number 3 cylinder at top dead center of the com pression stroke 9 Check and adjust both valves for the number 3 cylinder 10 Rotate the engi...

Страница 112: ...of fuel into the cylinders during the test If a cylinder fires during the test the resulting pressure will destroy the test equipment The manufacturer of the test equipment disclaims all responsibilit...

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