Section 2000 BASIC ENGINE 0-155, D-179 3 D-206 1 0-239 3 D-246 9 D-268 9 D-310 9 0-358, DT-239, DT-358, DT402 Engines
J I Case A Tenneco Company
Printed in England
co Don 8-59030
November. 1987
SPECIFICATIONS Static Timing (Degrees BTDC) *
D-155
- 239 DT - 239
VAJV E/ PS *
0 246
O
VA/VE/PS
*
0-358
10
VAlVE/PS
824
18
383
10
724, 734
14
834
18
1055, 955
19
500C/E
12
824.744. S.U.
16
844
18
1056. 956
14/ 8/2.2
10
824. 834. 744 Crane
16
784/785
16/ 4/2.5
1630 A. 1730 A,
TD 7E, 100 E P.S.
12
84 Hydr.
16
1830 A
TB
453
53310
V/E 433, WE WE 433 Series II
8/ 8/2.5
DT-358
VANE
423, E-423
8 C. P.S.
12
2681T
16
531. 541. (8--ill)
14
2781T
16
Acer> 1 820 with
WE 533 Series II
10/ 8/2.5
125 GD/P.S.
S.D. b33
10
H 30 B. Galion Cr.
16
5033
12
AT - 540
18 18 18
1730B-1930B
18
Galion 102 Grader
16
8/ 8/2.5
DU-’2D
16
8/ 8/2.5
H-60
16
8
Series 200 ATk. M.T.
18
1046
16
1521 S
18
16/ 8/2.5
725 SP
14
16
H65B
17
H-3OBNice,
16
321.431
12
Ingersoll-Rand
16
844 S
5000/5500 W.R.
16/ 8/2.8
845
1130/1 230 TOE
12
620 B
VAlVE/PS
743, 745 S/833
16/ 8/2.8
510
14
574H.S.
16
TD-8CA
14/ 8/2.2
574 G.D.
12
884/885
4500 B T.C.
14
3654, 3654 S.U.
14
270 A
454 G.D./454 ItS.
14
3500 A G.D./H.S.
14
866 -- HS (Austr.)
16
464 GD/U.S.
14
674 G.D.
14
3964/3965
18
3654 S . U.
14
2500AG.D.
12
484. 248 IT 485
14/ 8/2.2
1258 u. TD-8B
SU-644-LD
14
Ser. II
2454 GD/U.S.
14
S.U. 644 H.D.
240A SM/U.S/CC.
14
3400 A G.D./H.S.
433
8/ 8/2.5 10/ 8/2.5
533/385
D-179 553
+
633/633 V
E SlI
0-268
-
VA/VE/PS
18 8
D-310
VA
3980
16
946 (2100 RPM)
16
515
16
946 (2200 RPM)
10
976, 986. 886 (U.S.)
18
686
14
S-8A.SlO
16
4WD-
766
10
Ii-60B,520A
16
14
3400 B S.M.
955
12
It-65C
16
2400 A GD/I -IS.
14
H.S./f.C.
431, 531
16
530A
16
Irrigation
14
684/685
16/ 8/2.8
H SO B
12
943
14
2574G.D.
12
DU-2D
16
953
250 A. SM.
12
0 1500 C
18
923
16
260 ATC SM./H.S.
18
616/622 H.S.
16
933
18
VAlVE/PS
Irrigation Unit
18
711 S.P Header Harv.
10
1420/782
554. 654. 644
12
2500 AH.S.
14
165C
221
14
2574 H.S.
14
696
14
650
16
TD-7CG.D.
12
250A H.S./T.C.
14
1 3820 A
14
3980 8/3984 B
20
12
856 XL
/8
9000 F. L.
14
630
18
12/ 8/2.8
833 V + [
/
715 Comb.
12
280 PH
20 16
Unit
506
D
- 206
100 G.D. 733/733 V
+
F SIt
12
-
14/ 8/2.8
18
-
8
8
18 -
16
474 G.D/H.S.
14
782 Couon Picker
16
1246
100 B Series II
10
786
10
1255
86 Ilydr.
--/10 16
3990
/8
584/585
121 8/2.8
TD-68
10
1400
100 B. 624
10
Irrigation Unit
25811
12
640(D-358)
16
624 (Mexico)
12
640 )DT 358)
20
VA = Machines with VA Injection Pump VIE = Machines with VIE Injection Pump PS = Plunger Stroke total stroke of injection plunger in mm with a tolerance of 0.02 mm (pumps without timing window only).
8
786
18 /12
5208
/10
8581
DT-402 3994, 650 HO
-13-
16
VIE 16
953 ItS. 953 GB
16
1455
14
53OASH
16
-
INJECTION PUMP EP/VA General:
VE
6. Slowly turn the crankshaft in direction of the rotation until the dial indicator shows 1.0 mm travel of the distributor plunger.
This section consists of the following subsections: Checking Static Timing Removal Installing and Timing the Pump to the Engine Checking Timing with Dial Indicator
7. Read actual degrees of static timing on crankshaft pulley, see lIlust, 194 and 195, and compare with "Technical Data", 8. (Pumps without timing window only). Turn the engine to check the total plunger stroke and compare with timing specifications. If out by more than 0.02 mm repeat steps 4 - 8.
For all other service instructions refer to service Manual "Fuel System. Injection Pump and Turbocharger".
Checking Static Timing: B. Timing Window Method It is good practice to check static timing of the injection pump before removing it from the engine.
1. Shut oft fuel supply, 2. Remove lower cover plate of the pump. Illust. 193 b. 3. Position the engine on the compression stroke number one cylinder (intake and exhaust valves are closed). 4. Turn the crankshaft in direction of rotation until the timing pointer (1) Illust. 194 is in line with the specified timing mark (2) on the graduation.
Note: The dial indicator method A) may be used with all injection pumps, whereas Method B) is restricted to pumps with timing window: Illust. 193b. A. Dial Inidicator Method 1. Shut off fuel supply. 2. Position the engine on the compression stroke number one cylinder (intake and exhaust valves are closed).
For static degrees of the engine, see "Technical Data". 5. Read the graduation on the front pulley as outlined in lIlust. 195.
1. Remove central plug from distributor head and mount dial indicator with extension (2), lIlust. 193 a. Rest stylus of the indicator on the face of the distributor plunger and pro-load approx. 3 mm.
Illust. 1 93b lIlust. 193 a. 1 - Pointer on roller ring 2 - Scribe line on face cam
1 - Dial indicator 2 Extension (special tool 1329 159C1) 3 - Packing ring
6. With static timing correct, both pointers (Illust. 1 93b and 1 94) must be in line with their respective timing marks.
4. Slightly turn the crankshaft to and fro to find the bottom dead centre of the distributor plunger.
Note: On EP/VA pumps the face cam has a second scribe line marked with letter "L". Do not use this scribe line for adjustment.
5. With the distributor plunger in BDC, zero the dial indicator,
-91-
INJECTION PUMP EP/VA VE
Removal Thoroughly clean the left side of the engine to prevent dirt from entering the pump. Cap or plug all lines and ports as they are opened. Remove the injection pipes. Disconnect all lines from the pump.
.
I
Illust. 194 2 - Graduation on the front pulley
1 - Pointer
10
DC
1
2W Must. 196
\2
1 Drive shaft nut 2 - Hub 3 - Hub cap screws (three)
3 Illust. 195
One graduation mark = 2 0 1 - TDC mark
2
100 BTDC
3 20 BTDC
-91a-
INJECTION PUMP EP/VA - VE Remove rectangular cover plate from the crankcase front cover.
Installing and Timing the Pump to the Engine The engine must be in static timing position (first cylinder on compression stroke and timing pointer lined up).
Remove nut (1) lllust. 196 and hub capscrews (3).
Turn engine if necessary to place keyway in "up Position" (eleven o’clock) to prevent the Woodruff-key from dropping into the oil pan, when the hub is removed.
Note:
Proceed as follows: 1. Remove cover plates of the injection pump (Illust. 1 93b) or mount dial indicator (lIlust. 1 93a). Remove cover plate of the front cover (lllust. 196).
CIW
/-
Must. 199 Engine front plate lllust. 197 Pulling hub from drive shaft
2 - Gasket
2. Apply liquid sealer to both sides of new gasket (2)
Illust. 199. Remove gear with hub from the shaft, lIlust. 197. Remove injection pump retainer nuts, using a special wrench extension for loosening the inner nut, see Illust. 198,
3. Place woodruff-key into keyway of injection pump drive shaft. 4. Turn keyway in 11 o’clock position and install the pump.
Note: When removing the injection pump be sure mating
gears (pump drive gear - idler gear) are not disengaged to maintain the original timing.
Note.’ The following step 5 A. does not apply for DT402 engines equipped with water channel version (1) Must. 200. On these engines position the pump as shown in Must. 201, step 5 B.
,.
. $. ..
0
0 lllust. 198
1 - Stud nuts (two) 2 - Washers (two) 3 - Wrench, with extension (special tool 3055 700RT)
Illust. 200 OT-402 engines 1 - Water channel, pump position according to step 5 B 2 - Water pump carrier, injection pump postition according to step 5 A
INJECTION PUMP EP/VA - VE SA. Positioning the pump so that washers (2) lIlust. 198 cover slotted holes of pump flange evenly, i. e. the pump is level.
If the engine is on number one compression at the specified static timing and the injection pump is installed with 1.0 mm plunger stroke the pump will be ’timed".
5 B. On DT-402 engines with water channel (1) I Ilust. 200 take care to tilt the injection pump toward the engine all the way within the play of the flange slots (2) lIlust. 201 before tightening.
However, if the complete timing gear train has been removed, the timing of the gear train must be reset as shown in lIlust. 212.
IN
I
1 Illust. 203 1 - Hub 2 - Hub retainer bolts, with washers 3 - Keyway (in 11 o’clock position)
-z -
7. Install hub (1) Illust. 203, use quality bolts (six lines Illust. 204) and steel washers.
Must. 201 VE-Injection pump position on DT-402 with (1) Illust. 200
Tighten bolts (2) I [lust. 203 slightly.
F6 F-6 3 - Engine 4 - Injection pump, VE
1 Stud 2 - Slot
6. Tighten stud nuts (1) Illust. 198 to specified torque.
-’ lllust. 204
1 lIlust. 202
2 1
1 - Injection pump drive gear 2 - Timing marks
Must. 205 1 - Hub 2 - Hub retainer nut, with lock washer 3 - Bolts, hub to gear
Note: Since the idler gear is a walking gear, proper timing alignment (2) Illust. 202 will not always be noted.
-93-
3
4
INJECTION PUMP EP/VA - VE 8. Install lock washer and nut (2) Illust. 205
Checking Injection Pump Timing with Dial Indicator (pumps with timing window)
Block the engine and tighten nut (2), observe the different special torques for the respective nut size: M - 12 = (19 mm spanner) 6 - 7 daNm M 14 = (22 mm spanner) 8.5-10 daNm
)
9. Loosen bolts (3).
Illust. 208 1 - Graduation marks, pulley 2 - Pointer shows degrees of timing as specified 3 - Pointer on roller ring 4 - Scribe line on face cam 5 - Extension (special tool) 6 - Dial indicator, shows 1.0 mm plunger stroke
Illust. 206 Adjusting the injection pump
If the position of timing pointer (1) lIlust. 207 is in doubt or if scribe mark on face cam cannot be clearly seen check pump timing with dial indicator, following method A. See also Illust. 1 93a
10. Turn the injection pump drive shaft until the pointer on the roller ring is in line with the scribe mark on the face cam lIlust. 207 or the dial indicator shows 1.0 mm plunger stroke, lIlust. 1 93a. At this point tighten the retainer bolts to specified torque. See "Special Bolt and Nut Torque Data". Finally turn the engine through a complete cycle and check to make sure that the timing of the front pulley at compression stroke coincides with that of the face cam lIlust. 207 or with the 1.0 mm plunger stroke shown on the indicator lIlust. 1 93a.
lIlust. 207 1 - Pointer on roller ring 2 - Scribe line on face cam
94 -
INJECTION PUMP EP/VA - VE Note: (VE-pumps only). When connecting the fuel lines, make sure to use the fuel return valve (5) lllust. 211 on the pump return port.
The feed pumps is a diaphragm-type pump driven by the engine camshaft. It can also be operated manually on hand lever (6) lIlust. 209 to fill the fuel system or for venting purposes.
Fuel Feed Pump A filter screen is installed in the feed pump to primarily filter the fuel from the fuel tank. When servicing the engine it is good practice to remove the filter screen. Use a soft brush and carefully clean in Diesel fuel, On reassembly make sure all parts seat properly to avoid leakage. Install a new feed pump if the diaphragm is damaged or the operating mechanism is defective. 4 Install plug (11) using liquid sealer.
10
Note: The fuel feed pump is attached to the crankcase side cover by means of an additional flange with two studs. To prevent dropping the flange into the crankcase on removal or installation, stud nuts should be cautiously removed and installed respectively.
5
13
14 lIlust. 209
_95-
INJECTION NOZZLE HOLDER <"
Installation
4j
A. Flange Mounted Holder Place the sealing 0-ring approx. 6 mm (24 in.) above the nozzle holder nut, them install the nozzle holder.
5\
) /2
Make sure the 0-ring is not twisted Tighten stud nuts or necked-down bolts in two steps to specified torque.
lllust. 211 .1
1 - Nozzle holder 2 - Crab 3 Bolt
4 - Fuel return line 5 - Return valve 6 Return line
Make sure hollow screws, show to the valve cover, Must. 211. Place the nozzle crabs into position and install the dished washers and crab bolts. Illust. 210 Tighten the bolts (3) to specified torque. 1 - Nozzle holder seat capped up
2 - Nozzle holder Connect the fuel supply pipes and the fuel return line to the nozzle holders.
B. Crab Mounted Holder Tighten pipe union nuts and fuel return hollow screws to specified torque, refer to "Special Nut and Bolt Torque Data".
Clean sleeves in cylinder head and install nozzle holders using new 0-rings.
1111"I
TIMING GEAR TRAIN Adjustment 78
A’’ ’ - B
BB
AA lllust 212 1 - Crankshaft pinion 2 Idler gear Injection pump drive gear 3 Camshaft drive gear 4 End play of idler gear = 5 0.20 0.33 mm (.0078 -.0130 in.)
IlIust. 212 shows the gear train of a 6-cyl.-engine with piston number one on compression bC.
On all engines the timing marks of gears (1) and (4) must be in line with the timing marks of the idler gear (2).
The injection pump drive gear (3) is marked with num bers 1 up to 6.
6 End play of camshaft = 0.09-0.44mm(.0035.fl173in.) 7 - Scribe mark on pump flange (displaced) 8 Front plate 9 Injection pump hub 10 Idler gear carrier
Note: Marks on injection drive gear are for easy assembly. It is not essential that the timing marks of injection pump drive gear be aligned for proper timing. If the engine is on number one compression at the specified static timing and the injection pump is installed with the injection plunger at 1.0 mm stroke. the pump will be timed. However, the following timing instructions should be used to facilitate gear installation.
TIMING GEAR TRAIN
Timing Instructions for Injection Pump Gear (3) IlIust. 212 (Part Numbers 3055 066 R3, 3056 885 R3, 3218 450 Ri)
Illust. 212 a.
3 - Cylinder Engines Engines with water channel A, use timing, mark 1. Engines with water pump carrier B, use timing mark 3. Cylinder Engines Engines with water channel A. use timing mark 2. Engines with water pump carrier B, use timing mark 4. 6 - Cylinder Engines Engines with water channel A, use timing mark 5. Engines with water pump carrier B, use timing mark 6.
Fuel Rator Test Specifications
Application: 2400 A G. D., 2454 G. D., 4500 A, 454 G. 0., 3400 A G. 0., (Britain), 240A S.M./G.D. (Britain), 484 (xxx), 248 (xxx)
Engine: D 179
Injection Pump "Bosch" EP/VA31100H 1100 CR-62 (3 144 402 R91) Pump speed ....................................................1/2 engine speed Low idle speed - engine ............................................750 High idle speed - engine ............................................ max. 2455 Rated load speed - engine ..........................................2200 Minimum overload speed - engine .....................................1600 Max. torque daNm (ft.lbs) at 1600 engine rpm .............................18.3 Rated kW (HP) at engine rated load speed ................................38
Timing Advance Static timing - engine, degrees BTDC ...................................14 Total advance - engine, degrees BTDC ..................................25.9 Start to advance - engine rpm ........................................380 Pump advance at minimum overload engine speed (travel of advance piston) mm (inch) ....................................4.7 (.19) Full pump advance (travel of advance piston) mm (inch).......................5.4 (.21)
Charging Pump Pressure, at: Low idle, MPa (PSI) ...............................................0.29 (43) Minimum overload speed, MPa (PSI) ....................................0.50 (73) Rated load speed, MPa (PSI) .........................................0.57 (85) Max. permissible vacuum at inlet side of pump kPa (PSI) ......................20 (-2.9)
Fuel Ra tar Specifications Maximum fuel at rated load speed kg/h (Ibs/hr) ............................ Minimum time sec/1000 ccm (sec/qt) * Fuel at 2100 rpm engine speed kg/h (lbs/hr)............................... Minimum time sec/1 000 ccm (sec/qt) * Fuel at minimum overload speed kg/h (lbslhr) ............................. Minimum time sec/1000 ccm (sec/qt) Fuel temperature at overflow line OC )0F)
*
US qt
(NEZG 2836) Engine power, fuel consumption and charging pump pressure + 3 %
5-19
8.98 337 8.57 352 6.26 483 47
( 19.8) (319 ( 18.9) (333 ( 13.8) (457 (116.5)
Flow Bench Test Specifications
Engine: Rated Speed: 2200 RPM D 179 Application: 2400 A G.D., 2454 G.D., 4500 A, 454 G.D., 3400 A G.D. (Britain), 240 A S.M./G.D. (Britain), 484 (xxx), 248 (xxx) Injection Pump
BoschNo. EP/VA3/100H 1100 CR-62
I H CNo. 3 144 402 R91
Correction of Control Specifications acc. to "Bosch" Test Instruction VDTWPP 161/4 or Pre-Adjusting Dimensions see "Bosch" Repair Manual VDTWIP 161/4 Plunger Lift to Port Closure 0.3 (– 0.02 mm (– 0.04 mm) Static Timing Alignment of the Pointer at 1 mm Plunger Stroke (ref. to Outlet ’A’) Delivery Difference 1. Control Specifications RPM cu.cm./1000 Strokes 1.1 Injection Advance 600 3-4 mm 1.2 Charging Pump Pressure 600 0.4-0.45 MPa cu.cm. 1.3 Full Load Delivery 2.5 800 65.5-66.5 1.4 Idler-Governor Run-Out 375 16 22 1.5 Start 95 100 mm. 1.6 End-Governor Run-Out 1170 31 39 2. Check Data and in Brackets (Re-check Data) RPM 2.1 Injection Advance 160-300 (120-330) mm Begin 2.2 Charging Pump Pressure RPM 200 MPa 0.16-0.21 (0.14-0.23)
3 Opening P. 20 MPa
"
-
"
-
2.3 Feed Quantity Speed Lever End-Position
Feed Lever Full
RPM
600 (2,7-4.3) 600 (0.38-0.47)
cu.cm ./1000 Strokes
1190-1240 1170 1080 800 500
Idling Position
Stop Full
1100 460-510 (4 40- 530) 375
Start
100 220(200) 340 (360)
Shim thickness under advance piston spring Pre-load length of governor spring
5-20
0.61-0.66 (0.59-0.68)
Overflow Quantity cu.cm./10 sec.
10 0 (30-40) 66-69 (66.5-69.5) (65-67) 68 - 72(67 - 73)
55-100(40-110)
0 0 (14-24) mm. 95 min. 95 max. 60 2 mm 24.6 mm
(NEZG 2775)
820.970 (790-1000) End (5.2-5.9) 1100
Opening Pressure 20MPa
PERFORMANCE DATA Engine: D-179
Application: 454 HS, 464 HS/GD, 240A HS/TC, 2400A HS, 2454 HS, 3400A HS/GD (U.S.), 4500B TC, 506
Injection Pump: EP/VA31100H 1200 CR 61 (3 144 403 R91)
Pump speed ..........................................................
1/2 engine speed
Engine speed: low idle
.....................................................
1 /min
700-800
high idle .....................................................
1 /min
2710
rated load ....................................................
1 /min
2400
minimum overload
1 /min
1600
..............................................
Rated power at rated load speed
.........................................
Max. torque at minimum overload speed .................................. Torquerise
kW
daNm
........................................................
Static timing - engine ......................................... Start to advance - engine speed
Total advance - engine ........................................ Pump advance at minimum overload speed
18.5
%
degrees BTDC
.......................................
39
1/min
degrees BTDC
14 650 27.9
.................................. mm
3.1
Full pump advance at rated load speed ..................................... mm
6.3
Charging pump pressure at: low idle
.......................................................kPa
248
minimum overload speed ............................................kPa
448
rated load speed ..................................................kPa
675
Max. permissible vacuum at inlet side of pump ................................kPa
- 20
Fuel rator specifications: Fuel consumption at: rated load speed .................................................
kg/h
time......................................................... s/I 1 00/min below rated speed ..........................................
kg/h
time......................................................... s/I minimum overload speed ...........................................
kg/h
time......................................................... s/I Turbocharger, boost pressure at rated speed .................................. kPa
Engine power, fuel consumption and charging pump pressure + 3 % (NEZG 2835)
5-21
9.7 314 9.3 328 6.9 440
Flow Bench Test Specifications
Engine: Application:
Rated Speed: 24001rn/n D-179 454 H.S., 464 H.S./G.D., 240A H.S./T.C., 2400A H.S., 2454 H.S., 3400A H.S./G.D. (U.S.), 4500B, T.C., 506 BoschNo. EP/VA3/100H1200CR61
IHCNo. 3 144 403 R91
Injection Pump
Correction of Control Specifications acc. to "Bosch" Test Instruction VDTWPP 161/4 or Pie-Adjusting Dimensions see "Bosch" Repair Manual VDTWIP 161/4 Plunger Lift to Port Closure 0.3 – 0.02 (– 0.04) mm Alignment of the Pointer at 1 mm Plunger Stroke (ref. to Outlet ’A’) Static Timing Delivery Difference 1 . Control Specifications 1/mm. cm-_/_1000_Strokes 3.9 - 4.9 mm 800 1.1 Injection Advance 480 - 530 kPa 1.2 Charging Pump Pressure 800 cm3 68 -69 2.5 800 1.3 Full Load Delivery 1000 Strokes 400 12 - 18 " 3 1.4 Idler-Governor Run-Out " Opening P. 20 MPa mm. 95 100 1.5 Start 34 -42 1250 1.6 End-Governor Run-Out 2. Check Data and in Brackets (R e-chec k Data ) 800 200-350 (170-380) 980-1130(950-1160) 2.1 Injection Advance 11mm. Begin mm (3.6-5.2) End (6.0-6.7) 200 800 1200 2.2 Charging Pump Pressure 1/mm. kPa (460-550) 630-680 (610-700) 160-210 (140-230) 2.3 Feed Quantity . Delivery Overflow Quantity Feed Lever Speed Lever mm. cm 3 / 1000 Strokes cm3 / 10 sec. Full End-Position 1290-1340 10.0 0. (1275-1355) 1250 (33.0-43.0) 1150 69.0-72.0 (68.5-72.5) (67.5-69.5) 800 55-100 (40-110) 500 67.0-71.0 (66.0-72.0)
I
Idling Position
Stop Full
Start
1200 490-540 ( 470 - 560) 400 100 220 (200) 340 (360)
1.6 mm 24.6 mm
1: Shim thickness under advance piston spring 2: Pre-load length of governor spring
(NEZG 2776)
5-22
0 0 (10.0-20.0) mm. 95 mm. 95 less than 60
Opening Pressure 20 MPa
