ade-422-423-424-workshop-manual-abby.pdf

ADE 4 2 2 , 4 2 3 , 4 2 4 Workshop Manual

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IfllT in gto., D iese l dub

Works Workshop hop Manual Manual for ADE 422, 423,424

S * o Hl o i* * :

Begin in thru to secti tion 11

ENGINE REPAIR MANUAL ADE 420 SERIES

ATLANTIS DIESEL ENGINES (PTY) LTD AMENDMENT 7/90

P art No. 80530257 80530257 P ublished by the the P arts and Service De partment partment of Atlantis Diesel E ngines (Pty) Ltd.

W IfllT in gto., D iese l dub

Work Worksh shop op Manua Manuall for for ADE 422, 423,424 423,424

S e e Ho ie e :

Begin in thru to sect ction 11

FOREWORD T his manual is de signe d to be of as s istan ce to all perso nnel conce co nce rned with the ma intenance intena nce and overhaul of the ADE Diesel Engine. It presents a complete and detailed description of the Engine, together with precise instructions on the servicing and overhaul procedure, also a schedule covering technical data and dimensions which should be closely followed when overhauling any part of the E ngine, ngine, to to the M anufacturers standards. ADE 420 Series Engines have a left hand rotation when viewed from the rear. Throughout this manual, whenever L eft or R ight hand hand side o f the the engine is referred referred to, it is the the s ide of the engine when viewed from the flywheel end. E ffective maintena maintena nce can on ly be be carried carried o ut if if the personnel conce rned are fully conversa nt with the various components of the engine. Before maintenance operations are commenced, therefore, this manual should be carefully studied, and should at all times be kept where it will be needed in the workshop. Certain operations described in this manual require the use of special tools. These tools are ob tainable from G rundyTe chniform, full details are giv given en in Se ction 21 21. A S chool of I ns truction ruction is maintained maintained at ADE A tlan tlan tis tis where s taff employed employed by Dis tribut tributors ors and Operators of ADE powered applications are given instructions on diesel engine maintenance, with particular regard to the special characteristics of ADE Engines.

ENGINE PARTS W henever henever parts parts are ordered ordered for ADE E ngines ngines it is is es se ntial ntial that the the fulles t information information poss ible ible is given, always quote the engine number, type of application, part number and where possible the description.

R unning in Procedur P rocedure e It is not necessary to gradually runin a new engine and any prolonged light load running during the early life of the engine can in fact prove harmful to the bedding in of piston rings and liners.

CONTENTS TE C HNI C AL DATA

08

................................................................................................................................................

OPERATING AND MAINTENANCE SCHEDULE FAULT FINDING

11

......................................................................................................................

12

..................................................................................................................................................

PISTONS AND CONNECTING RODS

14

............................................................................................................

CAMSHAFT, TIMING CASE AND DRIVETIMING LUBRICATING SYSTEM AND SUMP

13

...............................................................................................................

CRANKSHAFT AND MAIN BEARINGS

FUEL SYSTEM

10

....................................................................................................................................................

CYLINDER BLOCK AND LINERS CYLINDER HEAD

09

............................................................................................

..............................................................

;................ 15

................................................................................................................

16

17

........................................................................................................................................................

ANCILLARY EQUIPMENT: COMPRESSOR, FLYWHEEL, TURBOCHARGER, EXHAUST BRAKE ALTERNATOR AND STARTER MOTOR, FAN BELT, POWER STEERING PUMP ........................... 18 COOLING SYSTEM LUBRICATING OILS

19

...............................................................................................................................................

20

..............................................................................................................................................

APPROVED SERVICE TOOLS

21

............................................................................................................................


Workshop Manual for ADE 422, 423,424

S e e Ho ie e :

Begin thru to section 1 1

SECTION 081

__________________________

Technical Data 422N

422T

422TI

423N

423T

423TI

424N

424T

424TI

Ratings to SABS 0131977 O utput kW/r/min

................................

Torque N.m/r/min Cubic capacity Bore mm

.............................

202/2300243/2300 276/2300 256/2300 300/2300

1022/12001402/12001550/12001278/12001687/1200 2000/1200 1388/1200 2236/1200 2400/1400 14,627 14,627

...................................

................................................

S troke mm

.............................................

.....................

14,627

18,277

18.277

18.277

21,937

21,937

21,937

128

128

128

128

128

128

128

128

128

142

142

142

142

142

142

142

142

142

8

8

8

10

10

10

12

12

12

16,9:1

16,25:1

16,25:1

16,9:1

16,25:1

16.25:1

2,8

2,6

2,6

2,8

2,6

2,6

No. of cylinders .................................... Compression ratio

368/2300 289/2300 412/2300 452/2300

16,9:116,25:116,25:1

C ompression tes t press ure MP a

2,8

2,6

2,6

Engine at operating temperature, readings taken at 180200 r/min. Minimum pressure 2,0 MPa. Difference between cylinders should not exceed 0,4 MPa. S tart of delivery __________________ Firing order

13°±0.515°±0,5 15°±0,5 1.5.7.2.6.3 4.8.

...................................

Engine Mass Kg .................................. (approximate figures depending on application) Idling speed

13°±0,5 15°±0.5

815

865

15°±0.5

1.6.5.10.2.7.3.8.4.9. 865

965

1020

13°±0,5 15°±0,5

15°±0,5

1.12.5.8.3.10.6.7.2.11.4 9

1020

1115

1165

1215

600 r/min

.............................

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e r c e d e s l ir in i» o r d e r » a n d v a l v e s e t

Cylinder Arrangement L e

Firing Orders:

LEp j

5

1

6

1

7

1

6

2

7

2

8

2

7

3

8

3

9

3

8

4

9

4

10

4

10

5

11

5

12

6

| F lywheel |

VS = 1,5,7,2,6,3,4,8 V 1 0 = 1,6,5,10,2,7,3,8,4,9 VI 2 = 1,12,5,8,3,10,6,7,2,11,4,9

Flywheel

Valve Set 6

7

8

9

If)

7 10

5 3 8

1 3

2

]

2 5 11

2 10

4

3

4 1 12

V alv es Rockiny, Set VK I'mnp Set V 10 linn}?

1

2

3

4

6 7

Set V 12 firing

6

8 9 5

5 6 4

9

11

12

8

7

Throughout the Workshop Manual, SI (International Metric Systems) units as approved by the South African Bureau of Standards (SABS) are used. All measurements are in mm unless otherwise indicated.

7/90

4 W lo rr in gtc Diesel Club

Workshop Manual for AD E 422, 423,424

Begin thruto section 11

_______________ SECTION

09-1 Operating and Maintenance

OPERATING AND MAINTENANCE P reparation before starting

Check the radiator coolant level. Check the engine sump oil level. (See "Oil specification for runningin after a major overhaul" below) (Refer to "Approved consumables & service intervals" bulletin for list of approved runningin oils) incorporated in section 9.

repeat cranking. When oil pressure is noted on the gauge, or the lowpressure light goes off, release the rack from the "no fuel" position to allow engine to start. Do not revup the engine immediately. If vehicle is fitted with keyoperated stop: Start engine and run at idling speed. Keep a check on engine oil pressure gauge. P ressure must be indicated after approx. 10 seconds.

ENGINE MAINTENANCE CATEGORIES

Ensure that there is fuel in the tank. Check that the battery is fully charged and that all electrical connections are properly made and all circuits are in order.

Category 1

Units operating under normal conditions, more than 100 000 km or 2000 hours annually, e.g. long haul operations.

S tarting and s topping the engine Category 2

Starting: Set accelerator half open and turn the starter switch. When the engine starts bring the accelerator to idle position and check the oil pressure. Do not engage the starter continuously for longer than 15 seconds. After an unsatisfactory starting attempt, allow the battery a 1530 seconds recovery time. P oints to note

Always ensure that the starter pinion has stopped rotating before reengaging the starter, as the ring gear or pinion may be damaged. Check the oil pressure gauge immediately after starting. S hould no oil pressure be registered, stop the engine immediately and investigate.

Units operating under normal conditions, up to 100 000 km or 2000 hours annually, e.g. medium to long haul operations.

C ategory 3

Units subject to severe operating conditions, e.g. extremely poor road conditions, heavy dust conditions, extreme climatic conditions (temperature and humidity), very short distances in traffic or construction operation. U nits operating up to 10 000 km or 200 hours annually, e.g. units operating under light loads or intermittent operating conditions, such as standby generator sets and emergency vehicles. However, when operating less than the recommended service intervals, the oil and oil filter should be changed once or twice a year, depending on the lubricating oil used. We recommend that maintenance and service be carried out according to hours of operation rather than mileage covered.

NORMAL SERVICE INTERVALS

Stopping: Relieve the load from the engine and gradually cut down engine speed to idle. Let it run for one minute then stop the engine.

Stopping (Turbocharged Engine) The stopping procedure is more critical for a turbocharged engine, due to the operational speeds reached by the turbocharger rotor assembly. Turning the engine off without allowing the engine to idle for at least three minutes after full load operation may damage the turbocharger bearings which rely on the engine oil pressure for positive lubrication.

Oil specification for running-in after a major engine overhaul.

Runningin oil must be used after either: a. Fitting new block assembly b. Fitting new pistonrings and liners c. Fitting new crankshaft bearings to a reground crankshaft. S tart-up procedure after major engine overhaul

Ensure that the oil filter bowl is primed with oil prior to cranking. Engine startup after fitting a new shortblock or major overhaul should be in such a way that oil pressure is noted before actual engine start (i.e. crank engine with startermotor and hold injection pump rack in "no fuel" position). However, crank only for 10 seconds then allow starter motor to cool for 60 seconds before

Recommended oil and filter change intervals

It is critical that the correct quality of oil is used when prescribing service intervals to ensure maximum life from your engine. While the quality of commercially available oils and the design of engines are being continually upgraded, the demands placed on them have also increased. Extensive testing has proved it necessary to specify different service intervals for the various quality oils.

APPROVED CONSUMABLES AND SERVICE INTERVALS

Details of approved lubricating oils, antifreeze/coolant inhibitors and powersteering oils are to be found in the latest issue of the ADE Approved Consumables and Service Intervals bulletin.

Service intervals based on fuel usage

Because of the high sulphur levels (>0,3%) in the fuels that are commercially available in South Africa and its degrading effects on the oils, It is necessary to limit the service intervals based on fuel throughput. For example a 366N engine having MultiSeries Super Plus S eries 3 Quality oil as listed on page 9 of our bulletin operating in long haul operations (i.e. Operating Category I) should be serviced at either 22 500 km, 450 hours or after 5 200 litres of fuel usage, whichever occurs first.

4 W la rr in gtc Diesel Club



OPE RATING AND MAINTENANCE 092 TABLE 1 - Service & calibration intervals of F.I.E.

Maintenance function

Engine type

Service interval

300/360 Series

400/440 incl.

152,236 & 354

420/440V

Service injectors

★ *

Renew injector nozzle Service and calibrate injection pump

* * *

Recommended S ervice & Calibration intervals for injection pumps and injectors.

*

max. km

max. hrs

Fuel lb

60 000

1 200

21 000

90 000

1 800

34 500

120 000

2 400

42 000

180 000

3 600

69 000

180 000

3 600

63 000

270 000

5 400

103 000

2. Check coolant level in the radiator 3. Service air cleaner dust bowl and prefilter if applicable.

As a general rule normal operating conditions apply to usages of 100 000 km or 2 000 hours per annum. For severe operating conditions such as forest, quarry, offroad mining, around town delivery, etc. the usages should be halved.

4. Check air cleaner restriction indicator, service filters If required. 5. Ensure there is ample fuel in the tank.

Injectors should be serviced at least once per annum, and fuel injection pumps at least once every second year. Service calibrations must be performed by authorised diesel equipment agencies, and pump testreports should be requested.

6. Ensure that the fuel tank cap/breather is unobstructed. 7. Ensure that the exterior of the sump is clean with an unobstructed airflow over the surface.

Predelivery Service 8. Ensure radiator fins have an unobstructed airflow. 1. Check general engine installation, i.e all pipes and hoses for tight sealing, condition and routing. 2. Open air cleaner and ensure that the element is positioned correctly and bolted down. 3. Check for fuel and oil leaks.

9. C heck oil pressure indicator.

Recommended Service/Maintenance Schedule

1. Change engine oil, drain oil while still hot. Dependent on oil change interval in accordance with chosen operating category.

4. Check oil level. 5. Check coolant level. 6. Check coolant for correct mixture, i.e antifreeze/anticorrosion agent and corrosion inhibitor.

2. Renew oil filter. Dependent on oil change interval in accordance with chosen operating category. 3. Renew fuel filters every 2nd oil change/service.. 4. Check air cleaner indicator, service filters if required.

7. C heck Vbelt tension. 8. C heck electrical equipment and connections.

5. Check all air cleaner intake ducts, hoses and clips etc. for serviceability and tightness.

9. C heck injection pump linkage for total movement.

6. Check that the intercooler is free from obstructions.

10. Check exhaust brake linkage and adjustment if fitted.

7. Check coolant hoses and hose clips for serviceabity and tightness.

11. Check that the fan has been fitted correctly. 8. Pressure test cooling system. 12. Start up, then check the oil pressure and coolant temperature gauges.

9. Ensure that the recommended corrosion inhibitor has been added to the cooling system.

13. C heck for any unusual noises. 10. Ensure that the radiator fins have an unobstructed airflow 14. While the engine is warming up check for oil and water leaks. 15. Check operation of visco fan (if fitted).

11. Tension all Vbelts and check for ageing. Replace defective Vbelts, Twin Vbelts must only be replaced in pairs. New belts must be retensioned after 1015 minutes of operation.

16. Run to operating temperature and check maximum r/min 12. Check exhaust system for damage or leaks. Daily Before Starting and after 810 Hours Operation 1. Check engine oil level and pressure upon startup (ensure machine is standing level).

13. Cpeck control linkage on injection pump and exhaust brake for correct function and adjustment, lubricate all joints. 14. Check all lines and hoses for tight sealing, chafing and leaks




OP ER ATING AND MAINTENANCE 093 15. Adjust valve clearance every second service. 16. Retighten all visible nuts and bolts on the engine and in particular at: a. Inlet and exhaust manifolds and ducts b. Exhaust flange c. Starter motor and alternator fitting d. nozzle holders e. Engine mount on cross member and engine support f. Bell housing bolts and nuts. 17. Check for fuel and oil leaks. 18. Check operation of oil pressure and temperature gauges. 19. Check battery electrolyte level. In summer and hot regions once a week. 20. Check battery terminals for tightness and condition.

ENGINE P RESE RVATION

When an engine is laidup for a prolonged period, it should be properly protected against corrosion. Preservation measures should be carried out in accordance with the different categories listed in the following sections.

1.0 General 2.0 Installed E ngines 2.1 Laid up for up to 12 months 2.2 Laid up for 12 to 36 months 2.3 Laid up for more than 36 months 3.0 Non-installed Engines 3.1 Laid up for up to 12 months 3.2 Laid up for 12 to 36 months 3.3 Laid up for more than 36 months

21. Check operation of visco fan (if fitted). 22. Check oil filler cap and dipstick for proper sealing P reparing Engine for operation

23. Inspect turbocharger turbine and compressor blades for damage, free rotation, end and side play.

Note:

 Renew coolant every 2nd year Attention: Satisfactory longterm operation of the air compressor depends on many varying factors. Therefore a specific service interval cannot be recommended. Dealers and Fleetowners should adopt service intervals which will suit their individual operating conditions.  Renew breather every 2nd year

1.0 General

An engine is classified as "laid up" when it has not operated for over one month. Laid up vehicles or engines should be stored in dry, well ventilated rooms, and must always be protected against direct moisture, e.g. rain or splash water. If this is not possible, laying up conditions are classified as extreme and the treatment specified for a given period should be increased, e.g. if an engine is to be laid up for up to 12 months it must receive the same treatment as an engine which is to be laid up for 12 to 36 months. 1.1

S pecification of fresh water

Sum of alkaline earth (water hardness) pH value at 20°C Contents of chlorine ions: Total contents of chlorides and sulphates

On any laid up engine all machined external unprotected surfaces, e.g. flywheels, Vbelt pulley grooves, etc. should be coated with a preserving agent or grease.

89,5  358 mg/litre

Vbelts must be slackened off and removed.

6,58,5 max. 100 mg/litre

All openings must be sealed airtight. This includes exhaust and air inlet ducts/cleaners on installed engines.

max. 200 mg/litre

Batteries must be disconnected in laid up vehicles and should be recharged outside the vehicle as required.

Full information on the quality of drinking water should be obtained from local departments of Water Affairs or local authorities. It is essential to protect your engine at all times against corrosion by the addition of anticorrosion/antifreeze additives (ethylene glycol with corrosion inhibitors) which among others, will meet the following demands:  adequate anticorrosion and cavitation protection for all components in the cooling system  lowering the freezing point  raising the boiling point. At no time should the coolant mixture exceed 55% by volume antifreeze/anticorrosion agent, as a higher percentage will reduce the antifreeze protection as well as lessen the heat dissipation. As corrosion inhibitors decompose during operation and the anticorrosion concentration is being reduced by topping up the cooling system with water, the frost protection must be checked regularly. Frost protection of 30°C corersponds with 40 to 45% (by volume) antifreeze/anticorrosion content in the coolant which may be determined by an optical or mechanical hydrometer, (30°C). The anticorrosion oil content in the coolant, i.e. 1% by volume, may be determined by a refractometer.

Only use approved products for mixture with the coolant as specified in the ADE Approved Consumables and Service Intervals bulletin (incorporated in this section) and at all times strictly adhere to the mixture specifications.

2.0 Installed Engines

These measures apply to all engines in vehicles, tractors and industrial engines. 2.1

Laid up for up to 12 months

2.1.1 NEW ENGINE S (distance covered up to 300 km or 6 hours of operation): The engines must be fitted to the maximum level with approved service products. Ambient temperatures must be taken into consideration when selecting SAE grades No further preservation measures are required. 2.1.2 USED ENGINES (distance covered more than 300 km or 6 hours of operation): Run engine until warm and drain engine oil. (Running in oil may remain in the engine). Renew oil filter cartridge. Fill with an approved runningin oil (anticorrosion engine oil). Fill or top up cooling system with the specified coolant mixture. Run the engine at medium speed for approx. 5 to 10 minutes until operating temperature is reached (coolant temperature 7579°C). Switch off the engine, fill the sump and the oil bath air filter (if fitted) to maximum level.




OP ER ATING AND MAINTENANC E 094

2.2

Laid up for 12 to 36 months

3.1

NE W ENGINES which have only been subjected to the

All the measures set out in sections 1.0 "General" and 2.1 "Installed engines, laid up for up to 12 months", must be carried out. In addition, the fuel system, the combustion chambers and the air compressor must be preserved in accordance with the following instructions.

runningin period at ADE do not require any additional preservation measures. Runningin oil may be left in the engines. Coolant must be completely drained. Remove the thermostats and insert one Chadpack Tablet (ADE part no. 3617 0072) into the housing. Refit the thermostats, close cover/outlet and ensure that the joints form a good seal. All engine openings must be sealed airtight.

Note: The procedure in this section should also be followed after less than 12 months in the case of sea shipments and in tropical areas. 2.2.1 P reservation of Fuel System:

Add approximately 10% runningin oil to diesel fuel and operate the engine with this mixture for approximately 5 to 10 minutes.

Note: Follow the instructions for sea shipments or tropical areas.

USED ENGINES must be treated in accordance with the measures set out in items 2.1.2 and 2.2.1 before being laid up or dismounted.

If a number of vehicle, tractor or industrialengines are to be preserved at the same time, the fuel and the runningin oil may be mixed in a separate container before feeding the solution into the fuel system via a threeway or fourway cock valve. This enables the concentration of oil in diesel fuel to be increased to 1520%.

Coolant must be drained completely and a Chadpack Tablet must be inserted in the thermostat housing. RE MANUFA CTUR ED ENGINE S must in all cases be preserved in accordance with section 2.2 in full.

2.2.2 Pres ervation o f Combus tion Chambers:

Oil may be sprayed into the combustion chambers via the injector ports after removal of the injectors, which may be immersed in oil for added protection. For best results the metered amount of oil must be in jected into the combustion chamber under pressure to ensure complete spraying of all areas. Upon completion of each cylinder (piston down), rotate the engine at least one full turn by hand.

3.2

3.3

Laid up for more than 36 months:

If the laying up period is extended for more than 36 months, preservation must be repeated every J 36 months (3 years) or 18 months in accordance with section 2.2 in full. If there is oil in the engine, this may be drained off at room temperature (approx. 20°C).

8-10ml

Note: Do not exceed the above amounts as this may lead to hydraulic lock and possible engine damage.

Refit all parts removed and ensure that seals and gaskets are in place. Reposition the injection pump governor controls to the operating position.

Laid up for 12 to 36 months:

The preservation measures set out in section 2.2 must be carried out in full.

Note: During the above operation the injection pump/governor control must be in the shutoff position. O il per c ylinde r

Laid up for up to 12 months :

It is not necessary to renew the oil filter cartridge.

4.0 PREP ARING THE ENGINE FOR OP ERATION 4.1

Remove sealing from all openings.

Note: Engines must not be started after the combustion chamber preservation has been carried out.

4.2

Remove preserving agent or grease from the grooves of Vbelt pulleys, flywheel and other unprotected surfaces.

2.2.3 P reservation o f Air C ompressors:

4.3

Reposition and tension Vbelts in accordance with instructions.

4.4

If not already installed, fit engine to machine.

4.5

Fill with approved lubricating and coolant service products or top up to maximum level.

Air compressor preservation should be done in con junction with the combustion chambers. A maximum of 5 cubic centimetres of runningin oil should be injected or poured into each cylinder via the compressor air intake after which ths engine must be rotated at least one half turn. 2.3

Laid up for more than 36 months

If the laying up period is extended for more than 36 months, preservation measures must be repeated every 3 years or 18 months in accordance with section 2.2 in full.

3.D NON INS TAL LE D ENGINE S

These measures cover new noninstalled engines, as well as remanufactured engines.

Note: Engines which have not received their first service must be filled with runningin oil, all others should be filled with approved operating oils. 4.6

Recharge and reconnect batteries.

4.7

Run engine to operating temperature (coolant temperature 7579°C) while monitoring pressures and temperatures.

W IfllTingto., Diesel dub

Workshop Manual for ADE 422, 423,424 S e e H nM ‘

B e g in thru to section 11

SECTION 101

__________________________

Fault Finding Fault Finding Chart FAULT

.

POSSIBLE CAUSE

S tarter motor turns engine too slowly

1. 2, 3. 4.

Will not start

5, 6, 7. 8. 9, 10, 12, 13, 14. 15, 16, 17, 18. 19, 20, 22, 31, 32, 33.

Difficult starting

5, 7, 8. 9. 10, 11, 12, 13, 14, 15, 16. 18, 19, 20, 21, 22, 24. 29, 31, 32, 33.

Lack of power

8,9,10,11,12, 13,14,18.19,20.21,22,23,24,25,26,27,31,32,33,60,62,63.

Misfiring

8, 9, 10, 12, 13, 14, 16. 18, 19, 20, 25, 26, 28, 29, 30, 32.

Excessive fuel consumption

11, 13, 14, 16, 18, 19, 20, 22, 23, 24, 25, 27, 28, 29, 31, 32, 33, 63.

Black exhaust

11, 13, 14, 16, 18, 19. 20, 22, 24, 25,27,28,29,31,32, 33,60.

Blue/W hite exhaust

4, 16. 18. 19. 20. 25, 27, 31, 33, 34. 35, 45. 56, 61.

Low oil pressure

4, 36, 37, 38. 39, 40, 42. 43, 44, 58.

Knocking

9, 14, 16, 18, 19, 22. 26, 28, 29, 31, 33, 35, 36, 45, 46, 59.

E rratic running

7, 8, 9, 10, 11. 12, 13, 14, 16, 20, 21, 23, 26, 28, 29, 30, 33, 35, 45, 59.

Vibration

13, 14, 20, 23, 25, 26, 29, 30, 33, 45. 47. 48, 49.

High oil pressure

4.38.41.

Overheating

11, 13. 14. 16. 18, 19, 24, 25, 45, 50, 51, 52, 53, 54, 57.

Excessive crankcase pressure

25.31,33, 34,45, 55.

P oor compression

11. 19. 25, 28. 29. 31. 32, 33, 34, 46, 59.

S tarts and stops

10. 11. 12.

Key to Fault Finding Chart 1. 2. 3. 4 5 6. 7. 8 9 10. 11 12 13 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26 27. 28. 29. 30. 31.

Battery capac ity low. Bad electrical connections. F aulty starter motor. Inco rrect grade of lubricating oil. S tarter motor turns engine too slowly F uel tank empty F aulty stop control operation. Blocked fuel feed pipe. F aulty fuel lift pump. Choked fuel filter. R estriction in induction system. Air in fuel system. F aulty fuel injection pump. F aulty atomisers or incorrec t type. Inc orrect use of cold start equipment. F aulty cold starting equipment. Bro ken fuel injection pump drive. Inc orrect fuel pump timing. Inc orrect valve timing. P oor compression. Blocke d fuel tank vent Inc orrect type or grade of fuel. S ticking throttle or restricted movement. E xhaust pipe restriction C ylinder head gasket leaking. Overheating. Cold running. Inc orrect tappet adjustment. S ticking valves Incorrect high pressure pipes. Worn cylinder bores.

32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43 44. 45. 46. 47. 48. 49. 50. 51. 52. 53. 54. 55. 56. 57. 58. 59 60. 61. 62. 63.

P itted valves and seats. Broken, worn or s ticking piston ring(s). Worn valve stems and guides. Overfull air cleaner or use of incorrect grade of oil Worn or damaged bearings. Insufficient oil in sump. Inaccurate gauge. Oil pump worn. P ressure relief valve sticking open. P ressure relief valve sticking closed. Broken relief valve spring. F aulty suc tion pipe. C hoked oil filter. Piston seizure/pick up. Inco rrect piston height. Damaged fan. F aulty engine mounting (housing). Incorrectly aligned flywheel housing or flywheel. F aulty thermostat. R estriction in water jacket. Loose water pump drive belts. C hoked radiator. F aulty water pump. Choked breather pipe Damaged valve stem oil deflectors (if fitted). C oolant level too low. Bloc ked sump strainer. Broken valve spring. Damaged or dirty turbocha rger impeller. Leaking turbocharger oil seals. Leaking boost control pipe. Leaking induction system.



S e c H nM ‘ B e g in thru to section 11

SECTION 111 Cylinder Block

__________________________

Tombak Seal

Cylinder Block 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Cylinder block Dowel pin Hollow pin Bolt Bolt C amshaft bearing Plug C amshaft P lug Seal P lug Seal Plug Seal Plug Seal P lug P lug P lug P lug Seal

21 Hollow pin 22 Hollow pin 23 P in 24 Ball 25 Tube 26 C onnector 27 Seal 28 P lug 29 Seal 30 P lug 31 S eal 32 P lug 33 Seal 34 Plug nut 35 S eal 36 Plug 37 Seal 38 Adapter 39 S eal 40 Cover

41 Seal 42 S eal 43 Gasket 44 Spring washer 45 Bolt 46 “O” Ring seals (bottom) 47 “O ” Ring seal (top) 48 Tombak seal 49 Oil jet 50 Seal 51 Connector 52 Transmitter 53 Seal 54 Transmitter 55 Seal 56 Breather 57 Breather 58 Seal 59 Vent tube 60 Hose 61 Vent tube 62 Clamp

7/90

4 l|' JdMMhgton Diesel dub

Begin thru to section 11


CYLINDER BLOCK — 11-2

B ore fo r c ylinde r liner flange

“A ”

154,0 153,9

Flange depth

“B”

9.99 9.97

Bore for cylinder liner fit

Upper fit/lower fit

upper“C”

145.840 145.800

lower “D”

144.540 144.500

ovality

max. 0.01

O vality for repair

max. 0.08

Deviation of flange face to block face

max. 0.02

C ylinder block leakage test under water with c ompress ed air

150 kP a

C ranks haft bearing basic bore

new

111.022 111.000

for repair

111.040 110.970

P ermiss ible ovality

0.01

P ermissible taper of bore

0.01

C ams haft bearing basic bore

76.030 76.000

Roughness of upper joint surfaces

7/90

Rz 10^m — Rmax 16^m



S e e Ho ie e :

Begin thru to section 11

CYLINDER BLOCK — 113

—

-c-

— u

/ ' 0 r CD| <

/ /

/

/

1

A

/ / / /

I

/ /



A

■

■ ■ 

) ------------

-

F

Liner inside diameter “A ”

128,010 127,990

Flange outside Dia. “B”

153,757 153,657

Upper fit dia. “C ”

145,800 145,778

Dia. of step on liner sealing face “D”

142.0 141.8

Outside dia. “E”

145.0 144.7

Lower fit dia. “F”

144.475 144.451

Flange thickness “G”

10.07 10.05

Height of step above sealing face “H”

1.10 1.00

O verall length "K ”

253.5 252.5

Max. lateral runout of liner flange “a” to centerline

0.02

Max. runout between lower and upper fit “c”

0.025

O vality or taper at lower fit “ F”

Before fitme nt Installed

max. 0.06 max. 0.04

P rotrusion above block face

new for repair

0.05  0.09 0.03  0.09

Flange shim thicknes s

for repair

0.8/1.0/1.5

Liner wear at upper return

0.06

S urface roughness o f honed liner

R3z 3  5/ifn

4 W la rrin gtc Diesel Club



CYLINDER BLOCK — 114 TORQUE SP ECIF ICATIONS Main bearing cap bolts (see section 14)............................

M18 x 2

Main bearing cap side b o lts ................................................ Note: Tighten stretch bolts prior to bearing cap side bolts Blankoff Plugs ........................................................................

M12 x 1,5

300 N.m 90° — 100° 156 mm 80 N.m

M 14x 1,5 M 18x 1,5 M 26x 1,5 M 30x 1,5 M 14x 1,5 M8 M22 x 1,5 M 22x 1,5 M6 M12 M14 x 1,5

50 N.m 80 N.m 120 N.m 150 N.m 47 N.m 25 N.m 35 N.m 100 N.m 8 N.m 110 N.m 50 Nm

Piston cooling nozzles/camshaft spray nozzles Front oil seal cover bolts to cylinder block Tac hograph cable nut to ad ap tor............. Blanking nut to rev. counter drive ............ Crankcase breather to cylinder block ..... Engine mountingfront to cylinder block . Adaptor for coo ling system vent li n e .....

Initial torque Final torque Max, stretch length

T ightening torques for S tandard bo lts and nuts (normal and fine pitch) in N.m (Valid only if no other torque is specified).

Thread M6 M8 M8 x 1 M10 M10 x 1 M12 M12 x 1,5 M14 M14 x 1,5 M16 M16 x 1,5 M18 M18 x 1,5 M20 M 20x 1,5 M22 M22 x 1,5 M24 M24 x 2

C las sification of S trength 10,9 12,9 8,8 8,6 21 23 42 46,5 73 76 114 128 178 190 245 280 350 390 465 520 600 660

11,8 29 32 58 65 100 105 165 178 250 270 355 390 490 550 660 730 850 910

14,5 35,5 38 70 78 123 128 195 215 300 320 415 465 590 660 800 875 1000 1100

4 l|' JdNMhgton Diesel dub



CYLINDER BLOCK — 115 Introduction The cylinde r blocks of the ADE 420 S eries E ngines are made of grey cast iron with the sides extending below the crankshaft centre line. Interchangeable (Wet) cylinder liners are fitted, wh ich once the cylinder head and pistons have been removed can easily be extracted. On replacement considerable care should be exercised to ensure that the cylinder liners are correctly seated and sealed.

REMOVING AND REPLACING CYLINDER LINERS Removing 1. Mark cylinder liners and cylinder block with paint, to ensure that the liners are returned to the original position. 2. F it puller studs opp osite to each other into bolt holes in cylinder block. 3. Insert puller. P art number 40200433, into cylinder liner (fig. 111). 4. Open jaws of puller to inner diameter of cylinder liner.

5. F it support of puller onto studs, tighten nuts and screw down centre nut on puller shaft. 6. Hold cen tre shaft of puller with a ring spanner and continue turning centre nut pulling out liner from cylinder block (fig. 211). 7. R etract jaws o f puller. Uns crew support studs from cylinder block, and remove together with puller.

8. L ift out cylinder liner from cylinde r block (fig. 311). 9. Remove O rings from cylinder block and liner. 10. It is ess ential that the outer surface of the cylinder liner, together with the bores in the cylinder block are thoroughly cleaned before replacement.

Fig. 311

7/90



CYLINDER BLOCK — 116 REMOVING AND REPLACING CYLINDER LINERS Replacing 1. Insert new Orings into cylinder liner bores in crankcase (dry). 2. F it new Oring into upper recess of cleaned cylinde r liner. 3. Apply approximately a 3mm dia bead of sea ling compound onto seal (fig. 411).

Fig. 411 4. Apply a light coating o f grease to the bottom of the cylinder liner, outer surface. 5. I nsert cylinder liner while rotating it 90° from the original fitted position (fig. 511).

Fig. 511

6. Fit puller studs oppos ite to each other into bolt holes in cylinder block (fig. 611). 7. P lace steel disc on top of cylinder liner. 8. F it suppo rt of puller onto studs, tighten nuts. Screw up nut on centre shaft to back of puller support.

Fig. 611 9. Using a ring spanner screw down centre shaft of puller, inserting cylinder liner. Tighten with torque wrench to 120 N.m and leave pressure applied for five minutes (fig. 711). 10. Using a suitable pla stic knife, remove excess s ealing compound forced out between cylinder block and liner. 11. Remove puller from cylinder block.

Fig. 711




S e e H nM ‘

B e g in thru to sec t i° n 11

CYLINDER BLOCK 12. Meas ure the inside diameter of the cylinder liner at the bottom, using a suitable internal measuring instrument, at three points offset 60° to each other (fig. 811).

Note: If more than 0,04 mm deviation is measured, check seating of lower Oring seal.

13. To prevent the cylinder liner moving while fitting the pistons, keep the liner under preload with two fa bricated sleeves (approx. 30 N.m). (fig. 911).

Important If used pistons are replaced, it is essential to replace the top piston ring on all pistons removed.

Fig. 911

11-7

4 W lo rr in gtc Diesel Club


CYLINDER BLOCK 

118

Note It is essential that when the cylinder liners have been removed or replaced, the liner protrusion is measured, to ensure correct sealing of the cylinder liners. The correct specification of liner protrusion must be adhered to. The cylinder liner protrusion can be altered by the addition or subtraction of shims, which can be obtained at your nearest ADE parts stockist.

MEASURING PROTRUSION OF CYLINDER LINER 1. R emove cylin der heads (See section 12). 2. P lace gauge plate Part number 40201953 on cylinde r liner. Insert short cylinder head bolts fitted with spacers, and tighten to 50 N.m (fig. 1011). Note: Check inside diameter of gauge plate prior to fitment and if necessary machine to 144 mm.

3. P lace dial gauge holder on gauge plate and insert dial gauge, so that sensor probe rests on the cylinder block with preload. Tighten dial gauge. Set dial gauge to “O” on cylinder block, at each measuring point. Maximum tolerance between four points, for each liner is 0,02 mm (fig. 1111).

MACHINING CYLINDER LINER SHOULDER DEPTH 1. Remove pistons and cylinder liners. 2. P reparations Pack the bores in the cylinder block with clean rag or a suitable material, as far up as possible in the machining area, to protect the crankshaft and bearings against falling swarf and dirt. Cover all oil galleries particularly the neighbouring cylinders, e.g. with a plastic sheet. 3. Clean surface of cylinder block and bores for cylinder liners. 4. Determining liner shoulder depth: Shoulder of cylinder liner distance (measured at 4 points, max. differenc e of 4 measuring points per liner 0,02 mm). + Thickness of shim  S pecified liner protrusion = S houlder depth.

Example (0.8 mm thick shim) Liner shoulder mean distance 10,05 mm + measured thickn es s of shim 0,80 mm  S pecified liner protrusion

10,85 mm 0,09 mm

10,76 mm = S houlder depth a = shoulder depth (fig. 1211)





CYLINDER BLOCK  5. C lean machining and cu tting tool (with compressed air), prior to inserting tool. Give cutting tool and insert a light coating of oil (fig. 1311).

Fig. 1311

P ull up quick adjus ting ring and guide cu tting tool in to holder. Insert cutting tool so that centring roller is on the side of cu tting tool ho lder marked with “R ”, and feed' threads on cutting tool face away from quickadjusting ring (fig. 1511). Note 1: Remove protective paint on solenoid flange with thinners, prior to initial use (fig. 1411).

No te 2: Ce ntralise machine on c ylinder bore.

Fig. 1411 6. C onnect power supply. P lace machine on cylinde r bore to be machined and switch on solenoid.

F ig. 1511 7. P ull up quick adjus ting ring with two hand. Hold quicka djusting ring with one hand, and push cutting tool with til centring roller is on side wall of cylinder block (fig. 1611).

fingers of each two fingers of other hand unliner recess in

Note: C orrect height of cen tring roller is adjusted with feed nut.

8. Move switch to pos ition 2. This energises the solenoid ring and holds the machine on the cylinder block.

F ig. 1611

119

4 W la rr in gt c Diesel dub


CYLINDER BLOCK — 1110 9. Turn crank slowly cloc kwis e and chec k to see if the centring roller rests on surface around the entire circumference of the liner recess, and the machine has not moved (with switch in centre position). I f the machine has moved, turn crank clock wise, and at the same time hold feed ring with two fingers. If centring roller loses contact with shoulder recess, turn crank anticlockwise while at the same time holding the feed ring, until roller has contact on the entire circumference of shoulder recess (fig. 1711). Note: When centred correctly, the centring roller will have uniform contact all round and machine will not move when switching to “O".

Fig. 1711 10. A fter centring correctly, move switch to po sition 1. P ull up quickadju sting ring and push in cutting tool until cutter con tacts liner recess to be machined, but not against side wall (fig. 1811). 11. Turn crank and feed nut together cloc kwise , until cutting tool makes contact with liner recess seat. 12. L ift quick adjus ting ring and push back cutting tool, to position above the liner recess seat.

13. Unscrew alien cap screws for vernier adjustment. Set vernier ring to "O " and tighten a lien cap screws (fig. 1911). 14. A djus t cutting depth to 0,05 mm with feed nut. Note: G raduation of vernier = 0,01 mm.

15. Turn crank clockwis e, h olding the feed ring with the other hand (fig. 2011).


W Iflfpingtoi, Diese iesell dub

Workshop Manua nual fo for ADE 422, 422, 423, 423,42 4244

S e e H nM ‘

B e g in thru to section 11

CYLINDER BLOCK — 1111 Note 1 Measure shoulder recess depth from surface of cutting machine after each cut (0,05 mm) (fig. 2111).

tting too l is ground in suc h a way as to preNote 2: The cu tting vent the desired diameter being exceeded. In other words, the face of the cutting tool runs on the liner recess diameter, if there is resistance, release feed ring immediately and turn crank several times. Only grind cutting tools according to drawings supplied with machine.

F ig. 2111 2111

Important The feed nut mus t no t move wh ile turnin g the crank, as this would change the depth setting of the cutting tool. If necessary tighten screw located in feed nut (fig. 2211).

F ig. 2211 2211

16. 16. P ull back quicka djus ting ring ring with with 2 fingers, and push push back cutting tool to starting position; set 0,05 mm cutting depth with feed nut and continue cutting procedure until desired depth is obtained (fig. 2311).

F ig. 2311 2311

Note 1: Remove machine approximately 0,3 mm before reaching desired shoulder recess depth, and recheck depth with a dial gauge. Recheck depth once again before final machining, to make sure that the desired depth has been reached (fig. 2411). Centre machine after each measurement, (fig. 1711).

Fig. 2411

4 l | ' JdNMhgton JdNMhgton Diesel iesel dub


Begin in thruto secti tion 11

k d r r i n g t o n D ie ie se se l t l u b

ADE 422, 422, 423,424 Workshop Manual

SECTION 12-1 Cylinder Head

C ylinder ylinder Head 1 2 3 4 5 6 7

C ylinder ylinder head head with valv valve e guides guides Core plug Core plug S ealing ring ring Blanking plug Valve guide Valve seat insertinlet

8 9 10 11 12 13 14 15 16

Valve seat insert exhaust Gasket assemblycylinder head Hex bolt Hex H ex bolt bo lt Hex bolt Cylind er head gasket R ocker cover R ocker cover (with (with oil filler) Oil filler cap

17 18 19 20 21 22 23 24 25

S ealing ring Gasket Spring washer Bolt Nozz le holde r with nozzle Nozzle holder Injector Sealing ring Injector securing nut

BK ( a p H n g t o n D ie se l Club

ADE 422, 423,424 Workshop Manual

CYLINDER HEAD — 12-2

114.0

Overall height of cylinder head

113.9 M inimum cylinder head height after mac hining1)

113.4

P eaktovalley surface finish of ma ting s urface in ^ m

016

Max. unevenness of ma ting su rface

0.015

Max. parallel deviation between upper and lower surface

0.1

Injector protrusion

1.6—2.4

Valve head recess below mating surface

0.71.1

1) Check injector protrusion after machining cylinder head mating surface and, if necessary, correct with injector washers.

Machining of cylinder head mating surface In order to attain the specified surface finish adhere to the following specifications when grinding: S pe ed :

n

=

Feed:

u

=

C utting veloc ity:

Vs

=

1400 r/min 920 mm /min. 27 m/sec .

Th e s pe cifie d c uttin g ve loc ity is given by us ing a se gme nt gr ind ing whe el w ith a dia me ter o f 370 mm. W hen us ing a differe nt diame ter (depending on ma chine type), the s peed mus t be changed so that there is no grea ter variation th an ±1 0 % fr om V s = 4 ? =2 7 m/s ec . “

1000 60

Impo rtant: S lower feed o r manual feed will change the grinding pattern c ons iderably and there will be no guarantee of reaching a surface finish of Rz = O to 16/u m. Leakage test under water with compressed air

250 kPa

B a r r i n g t o n D i e s e l Club

ADE 422, 423,424 Workshop Manual CYLINDER HEAD — 12-3

Inlet Valve Seat Insert Repair 1 Standard Repair 2

Exhaust Valve Seat Insert Standard Repair 1 Repair 2

Basic bore “a” in cylinder head

60.030 60.00

60.230 60.200

60.430 60.400

53.030 53.000

53.230 53.200

53.430 53.400

Valve seat insert outside dia. “a1"

60.11 60.10

60.31 60.30

60.51 60.50

53.11 53.10

53.31 53.30

53.51 53.50

Valve seat insert interference fit in cylinder head Bore depth “ b” in cylinder head Valve seat insert height “e”

Dimension between cyl. head mating surface and valve seat insert face

0.070.11

0.070.11

12.6 12.5

12.8 12.7

13.0 12.9

12.6 12.5

12.8 12.7

13.0 12.9

previous level

8.9 8.8

9.1 9.0

9.3 9.2

9.7 9.6

9.9 9.8

10.1 10.0

new level *

8.4 8.3

8.6 8.5

8.8 8.7

9.2 9.1

9.4 9.3

9.6 9.5

previous level

3.8 3.6

3.0 2.8

new level *

4.3 4.1

3.5 3.3

45°

45°

—

1.8 1.6

measured at O 57 mm 0.01


Chamfer “c” Chamfer depth “d” Max. runout of valve seat to valve guide "F o r new level Turbo Head with “T” s tamp

7/90

BK ( a p H n g t o n D ie se l Club



Diameter ‘‘a"

Distance “b”

Inlet Valve Seat Insert

E xhaust Valve Seat Insert

previous level

57.01 56.99

49.01 48.99

new level**

55.01 54.99

48.01 47.99

previous level

4.05 3.90

3.55 3.40

new level**

4.65 4.50

4.05 3.90

30°

45°

0 .7  1,1

0.71,1

Valve seat angle “c” Distance between cylinder head mating surface and valve head face


Max. outofround of valve seat to valve guide


**F or new level Turbo Head with “T ” stamp

Old Level Valves Breakpoints

ADE 420N — upt o ........ SA002748 N ADE 420T/TI — up to SA 002902 N •■D" “E” •B " “C” Width Height Dia Seat Valve Centre Head Dia New Min New Max

Dimensions (mm)

“A" Seat Angle

Inlet

30°

57,01 56,99

59,0 58,8

3,2 4,3 2,7 3,0 3.3

E xhaust

45°

49,01 48,99

51.1 50,9

2,7 4,5 2,2 5,5 2,5 3,5

7

“F" Stem Dia

Stem Hardness

11,950 11,932

54

11,940 11,922

I54SHRC

“F” Stem Dia

Stem Hardness

HRC

New Level Valves Breakpoints

ADE 420N — ADE 420T/TI —

SA 002749 N and UP S A002903 N and UP

Dimensions (mm)

"A" Seat Angle

Inlet

30°

55,01 54,99

59,0 58,8

3.8 5,5 3,3 6,5 3,6 4,5

11,950 11,932

i54 HRC

E xhaust

45°

48,01 47,99

51,1 50,9

3,2 5,5 2,7 6,5 3,0 4,5

11,940 11,922

t54 i

“C” "D" “E" Dia Seat Valve Height Width Centre Head Dia New Min New Max

HRC

Max. runout between valve seat and stem

0.03

Max. runout between valve head and stem

0.20

Max. valve seat ovality

0.01

7/90



Valve Springs Engine Model/ Spring Allocation

Spring

Inside Dia.

Wire Dia.

32 ± 0.3

4.7 ±0.03

64

46.8

345 ± 15

32.8

740 ± 30

32 ±0.3

4.8 + 0.05

59

46.8

345 ±15

33.1

720 ± 50

Relaxed Length

Prelc>aded Length Load N

Final .oaded Length Load N

420N inlet and Exhaust valves and

Outer'

420T/TI inlet valves

Inner

22.8 + 0.2

3.0 ±0,025

65.5

46.3

143± 12

32.3

280 ± 20

Outer

33 ± 0.3

4.5 ± 0.03

68

46.8

355 ± 15

32.8

670 ± 30

Inner

22.8 ±0.2

3.2 ± 0.025

70

46.3

195 ±12

32.3

350 ± 20

420T/TI exhaust valves only

'O ptiona l due to different suppliers

Valve guide protrusion. Dimension “D” Max. deviation of valve seat to valve guide centre

17.1  17.4 0.03

Max. misalignment of valve seat to valve guide measured at

57 mm dia. for inlet 49 mm dia. for exhaust

0.01

7/90




Valve C learance (mm) (mm) — C old E ngine ngine MODEL

B R E A K P O IN T S

IN L E T V A L V E

EXHAUST VALVE

ADE 422N

Up to SA 002762 M S A 002763 M and up

0,25 0,40

0,35 0,60

A DE 422T/TI

Up to SA S A 00344 003441 1 P S A 003442 P and up

0,30 0,40

0,50 0,60

0,40

0,60

0,30 0,40

0,50 0,60

0,40

0,60

0,30 0,40 0,40

0,50 0,60 0,60

INLET VALVE Opens BTDC C loses ABDC

EXHAUST VALVE Opens Opens BBDC Closes ATDC

— ADE 423N A DE 423T/TI ADE 424N ADE 424T/TI

S till in e ffe c t T o be advis ed * *

S till in e ffe c t To be advised

** At new level since the first day of manufacture.

Valve Timing Degrees ENGINE MODEL

PRODUCTION BREAKPOINTS

ADE 422N

Up to SA 002762 M SA 002763 M and up

21,4° 16°

57,4° 42°

52,8° 57°

14,8° 13°

ADE 422T/TI

Up to SA S A 003441 003441 P SA 003442 P and up

13° 17°

27° 29°

55° 71°

13° 13°

16°

42°

57°

13°

13° 17°

27° 29°

55° 71°

13° 13°

16°

42°

57°

13°

13° 17°

27° 29°

55° 71°

13° 13

 ADE 423N ADE 423T/TI

S till till in effect To be advised —

ADE 424N ADE 424T/TI

S till till in effect To be advised


7/90

( d r H n g t o n D i es es e l Club


TO R QU E S P E C IF IC AT IO NS C ylinder head to cylinde r block:

S ingle hexagon hexagon bolts bolts

M15 x 2

Duo hexagon bolts

Rocker shaft pedestal to cylinder head ........................... Valve Valve adjusting adjusting screw loc kn ut ............................................. Rocker cover to cylinder head ............................................. Inlet manifold to cylinder head ........................................... Exhaust manifold to cylinder head ....................... ............. Injector securing nut to cylinder head (see section 17) T urbocharge r to exhaus t manifold (see s ection 18) Blanking plug to cylinder head ...........................................

1st stage 2nd stage 3rd stage 4th stage Final Torque 1st stage 2nd stage 3rd stage 4th stage Final Torque Max. stretch length: short medium

I7 c, c ,/ ion iong M10_ > C M12 x 1 M8 M8 M10 Check during each service M22 x 1,5

X

10 N.m 50 N.m 100 N.m 140 N.m 90° 100° 10 N.m 60 N.m 120 N.m 180 N.m 90°100° 111 mm 146 mm 170 mm 75 N.m 50 N.m 25 N.m 25 N.m 50 N.m

100 N.m

7 /on /on



CYLINDER HEAD — 128 Introduction The ADE 420 420 Series E ngines are fitted fitted with an ind ividual cylinder head for each cylinder. As this type of cylinder head is the same throughout the 420 series of engines, it makes for greater standardisation and ease of service.

REMOVING AND REPLACING ROCKER COVER Removing 1. Unsc rew and remove remove bolts from rocker cover. cover. L ift off cover (fig. 112). 2. R emove cover cove r gasket. gaske t.

Fig. 112

Replacing 1. F it new rocker cover gasket. 2. R eplace rocker cover and tighten bo lts to 25 25 N.m (fig. 212).

Fig. 212



C Y L I ND E R H E A D -

REMOVING CYLINDER HEAD P reparation 1. D rain engine coolant. 2. Dis conn ect inlet pipe. 3. Remove exhaust manifold

1. U sing special ring spa nner P art number 40200705, remove injector pipes (fig. 312). 2. Remove rocke r covers (see fig. 112).

3. U nscrew injec tor pipes from injection pump, using special ring spanners 40200970 & 40200705 (fig. 412). 4. P ull fuel leak off pipes from injector.

5. Uns crew and remove rocker arm brack ets (fig. 512). 6. R emove push rods.

Fig. 512

12-9

k d r r i n g t o n D ie sel t l u b


CYLINDER HEAD — 1210

7.

Uns crew and remove cylind er head bo lts (fig. 612).

Fig. 612

N o t e : C ylinder head bo lt underne ath injector, can be

loosened with sp ecial spanne r 40200530, but it cann ot be removed from the cylinder head (fig. 712). 8.

R emove cylind er head.

N o t e : Unless the injector has been removed, always lay the cylinder head on its side to avoid damage.

kdrrington Diesel Club



RE MOVING AND RE P LACING VALVES

,

Removing 1. P lace cylind er head into clamp and secure. 2. A djus t fork to diameter of valve spring retainer. 3. F it push rod into eye of lever and push down on valve spring retainer. Remove collets from valve stem (fig. 8- 12). 4. Release pus h rod. R emove valve spring retainer and valve springs.

5. P ull valve stem se als from valve guides. 6. Remove cylin de r head from clamp and remove valves. 7. Remove spa cers for valve springs (fig. 912).

Replacing 1. L ubrica te valve stem with engine oil and insert into valve guide. 2. P lace cylinder head into clamp and secure. 3. F it spa cers for valve springs. 4. Replace valve stem sea ls using spec ial tool P art number 40201555 (fig. 1012).

5. F it inner and outer valve springs with c lose c oils towards the cylinder head. Fit valve spring retainer. 6. F it push rod into eye of lever and push down on valve spring retainer. Insert collets in grooves of valve stem. Ensure the collets are correctly located (fig. 1112).

( d r H n g t o n D i esel Club C Y L I N D ER H E A D -


12-12

FITTING VALVE STEM SEALS 1. Lubricate valve stems with engine oil and insert valves into guides. 2. P lace cylinder head into clamp, and secure. 3. Using s pec ial tool P art number 40201555, fit valve stem seal over valve (fig. 1212).

4. P ress valve stem seal onto valve guide. 5. Remove spec ial tool and repeat procedure on second valve (fig. 1312).

REMOVING AND REPLACING VALVE GUIDES 1. C lamp cylinder head. 2. K nock valve guides out of cylinde r head, from the combustion side using special tool Part number 40200815. 3. Mea sure bore for valve guide in cylinde r head and ream to next repair stage if required. 4. C oat new valve guide with graphite oil and knock in using special tool and spacer (fig. 1412). 5. Use spec ial reamer P art number 40200831 and ream valve guide inner diameter to specified dimension.

Fig. 1412

ftdt't'ingtor. Diesel Club


C Y L I N D ER H E A D -

REMOVING AND REPLACING VALVE SPRINGS Removing 1. P lace cylinder head into clamp and secure. 2. Ad just fork to diameter of valve spring retainer. 3. F it push rod into eye of lever and push down on valve spring retainer. Remove collets from valve stem (fig. 1512).

Fig. 1512

Replacing 1. Clean valve springs, and check spec ific values using a suitable spring tester (fig. 1612).

Fig. 1612

2. Insert inner and outer valve springs with clo se co ils towards the cylinde r head. F it valve spring retainer. 3. F it push rod into eye of lever and push down on valve spring retainer. Insert collets into grooves of valve stem. Ensure the collets are correctly located (fig. 1712).

Fig. 1712

12-13

( d r H n g t o n D i esel Club C Y L IN D E R H EA D -


1 2 -1 4

GRINDING VALVES 1. C lean carbon de pos its from valve. 2. C heck to see if valves can be reused. Valve ends mus t not have surface da mage. C ollet grooves must not be worn and chrome coating on valve stems must be without flaws. Always replace burnt valves. 3. C heck dimens ions and run out of valves. Do not attempt to straighten bent valve stems. 4. S light run out of valve stems can be corrected by grinding the valve face. 5. Ins ert and clamp the valve immedia tely behind the valve head to avoid vibration when grinding (fig 1812).

6. Set correct grinding angle on scale. 7. Move valve towards ro tating grinding wheel at a slow feed rate until valve makes contact with grinding wheel face. (fig. 1912). 8. G rind face of valve with a light feed un til it is ground on its entire circumference.

F ig. 1912

N o t e : A fter grinding valve height “D” must not be less than outlined in the specification.

9. S hould it be nec ess ary the valve stem face can be ground on a Vblock mounted on the valve grinding machine (fig. 2012).

Fig. 2012



CYLINDER HEAD -

REMOVING AND REPLACING ROCKER ARM Removing 1. C lamp rocker arm bracket in a vice fitted with s oft jaws. 2. Unscrew and remove locknut and valve adjusting screw (fig. 2112).

3. Re move rocke r arm circ lip (fig. 2212).

4. Re move thrus t was her and roc ker arm (fig. 2312). 5. C lean all parts thoro ughly and check for wear.

REPLACEMENT OF ROCKER ARMS 1.

F it rocker arms and thrust washer to rocker arm bracket (fig. 2412).

Fig. 2412

1 2-15

B5C

Bd t't'ingto»! Diesel Club

CY LINDER HEAD  2.

3.


1216

Insert circlip on rocke r arm shaft (fig. 2512).

S crew valve adjusting screw and locknut into rocker arm (fig. 2612).

Fig. 2612

( d r H n g t o n D i esel Club


C Y L I ND E R H E A D -

REPLACING CYLINDER HEAD 1. Clean cylinder head bolt holes in cylinder block thoroughly prior to replacing cylinder heads. It is particularly important to remove any water trapped in the bolt holes. 2. C lean cylinder head and cylinde r block faces.

3. P lace new cylin de r head gasket over dowel sleeves in cylinder block face (fig. 2712).

F ig. 2712

1

4. Place cylinder head carefully onto cylinder head gasket. 5. Measure bo lts to ensure stretch limit is not exceeded. 6. Give cylinder head bolts a light coating of engine oil, insert bolts and tighten in the sequence shown (fig. 2812), according to torque steps listed under specifications. N o t e : The stretch bo lts do not need to be retorqued.

N o t e 1 : Use special spanner for bolt underneath the fuel injector. N o t e 2: If one of the bolts has been tightened excessively,

unscrew all 6 bolts of the cylinder head, check for stretch and tighten again beginning w ith step 1 (fig. 2912).

F ig. 2912

12-17



CYLINDER HEAD — 1218 6. Insert pushrods. 7. F it rocker rocker arm brac ket and and tighte tighte n bo lts only finge finge r tight. Align rocker arms with valves and pushrods. 8. Tighten Tig hten rocker rocke r arm bracket bolts to 75 N.m (fig. (fig. 301 3012). 2).

9. A djust valve valve clearance. 10. R eplace rocker covers and tighten bo lts lts to spec ified ified torque. 11. F it fuel injector pipes and tighten conne ctions on in jec tor holder to 25 N .m (fig. 311 3112) 2)..

Note: Hold injection pump nuts with special spanner Part number 40200970. Tighten connections of injection pump td*25 N.m using crowfoot socket Part No 4020 0721. (fig. 3212).

12. 12.

C onnec t fuel leak off pipe to injec tors.

retightened. Note: C ylinder head bolts need no longer be retightened.

Fig. 3212

BK ftd rr in g to n Diesel Diesel Club



ADJ USTING VALVE CLE ARANCE (Method, Method,1 1) Note: Adjustment of valve clearance can be carried out with the engine Cold.

1. R emove rocker rocke r cove rs and gaske t. (See page 122) 122) 2. F it special engine turning tool P art number 4020 4020009 0093 3 (fig. 3312), to timing case 8 x 20 mm bolts, and turn engine in direction of rotation, until piston of cylinder to be adjusted is at firing TDC. Valves should be closed, rocker arms completely relaxed and push rods free to turn, (see fig. 3412 to identify valves rocking in relation to cylinder firing).

F ig. 3312 3312

Location of cylinders ADE 420 420 Series Series E ngines ngines V12

V12

V10

©

©

V10

VB

©

©

©

©

V8

©

©

©

©

©

©

©

©

©

©

©

©

©

©

©

©

©

©

©

©

©

©

©

©

X

Va lves roc king no:

12 3

Cylinder Firing 422 set no: 423 s et no: 424 s et no:

6 8 5 73 1 4 2 7 9 6 10 10 8 3 1 5 2 4 6 5 4 3 2 1 12 11 10 9

8

7

Refer to specifications in accordance with breakpoints.

F ig. 3412 3412

4. If the the clearanc e requires adjustment, inse rt screw driver and ring spanner and adjust in the normal manner (fig. 3512).

F ig. 3512 3512

7. R emove emove spec ial turning too too l from timing timing case.

9 10 11 12

Valve Clearance cold

3. Insert feeler gauge between rocker arm of inlet or exhaust valve. Valve clearance is correct when feeler blade can be pulled through with slight resistance.

6. Replace rocker covers, renew damaged gaskets, tighten rocker cover bolts to 25 N.m (fig. 3612).

7 8

F iring O rder: ADE 422 1572 157263 634 48 8 A DE 423 165102 165102738 73849 49 ADE AD E 424 112583106 1125831067211 721149 49

X — Flywheel end

5. Turn the the engine to to the next cylinder TDC firing po sition each time, and set all the valves in firing order sequence.

4 5 6

EK ftd rrin gt on Diese Diesell Club


CYLINDER HEAD — 1220 A D J U S T I N G V A L V E C L E A R A N C E ( M e th th od od 2) 2) 1. R emove rocker covers and gas kets. (See page 122 122)) 2. F it special engine turning tool P art number 4020 4020009 0093 3 (fig. 3312). to timing case 8 x 20 mm bolts, and turn engine in direction of rotation, rotation, until the the No. 1 cylinder TDC mark is a ligne d with the ed ge o f the ins pe ction hole. 3. C heck to to see if No. No. 1 cylinder is is at TDC, rocking or firing. (At TDC firing both valves will be closed and the push rods will turn easily).

Location of cylinders ADE 420 Series Engines

Th e fo llow ing valves can then be ad justed at N o. 1 firing TDC :

E ngine V12

V12

V10

©

©

V10

V8

©

©

©

©

V8

©

©

©

©

©

©

©

©

©

©

©

©

©

©

©

©

©

©

©

©

©

©

©

©

422 & 422T 423 424

Engine

422 & 422T 423 424 F ig. 3712 3712

4. Inse rt feeler gauge between roc ker arm of inlet or exhaust valve. Valve clearance is correct when feeler blade can be pulled through with slight resistance. 5. If the clearance requires adjustment, insert screw driver and ring spanner and adjust in the normal manner (fig. 3812).

Fig. 3812 6. Re place rocker covers, rrenew enew damaged gas kets, tighten rocker cover bolts to 25 N.m (fig. 3912). 7. R emove sp ecia l turning turning tool from timing timing case.

E xha us t valve

1, 2, 5, 7 1, 3, 4, 8 1, 2, 5, 6, 9, 10 1;% 8, 9 1, 2S4, 7, 9, 11 ** 1, 3, 5, 8, 9, 12

Th e fo llow ing valves can be adju sted at No. 1 R ocking TDC :

X X — Flywheel end

I n le t va lve

Inlet valve

E xhaust valve valve

2, 5, 6, 7 2, 3, 5, 6, 7, 10 3, 5, 6, 8, 10, 12

3, 4, 6, 8 3, 4, 7, 8 2, 4, 6, 7, 10, 11

- B a r r i n g * »* Die s el

Club

ADE 422, 423 ,424 Workshop Manual

<*»

C Y L I N D E R HE A D -

CHEC KING COMPRE SSION PRESSURE

•

P reparation 1. C heck Valve C learance (see fig. 3812). 2. Run engine until normal operating temperature is reached (7095°C). 3. Remove injec tor holder and injector.

Testing 1. Inse rt inje cto r se aling ring (fig. 4012).

2. Insert adap tor in cylinde r head and tighten loc ating nut for injector holder (fig. 4112).

3. S crew compres sion tester with extension on adaptor (fig. 4212). 4. Chec k compre ss ion press ure at an engine speed of approximately 120 r/min. (starter speed) with the throttle in closed position. Turn engine until test indicator stops rising. Note: If compression pressure is less than 2,0 MPa, or when the pressure difference between the cylinders are greater than 0,4 MPa, remove the cylinder heads to inspect valve seats and cylinder bores. 5. Remove comp ress ion tes ter and adapter. 6. R eplace injector, and sealing ring. Fig. 4212

12-21



CYLINDER HEAD — 1222

Inlet Ma nifold 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Inlet manifold Inlet manifold Threaded insert Gasket S pring washer Bolt Cap Hose clip Plug Bracket

11. 12. 13. 14. 15. 16. 17. 18. 19. 20.

Bracket Bracket Bracket Bracket Bracket Bracket Transverse manifold G ask et S pring washe r Bolt




REMOVING AND REPLACING INLET MANIFOLD Removing 1. Uns crew and remove inje ctor pipes from appro priate cylinder head (fig. 4312). 2. Remove transverse in let manifold. 3. Detach and remove hose from air compres sor. 4. U nscrew and remove inlet manifold.

Replacing 1. F it inlet manifold with new gasket and tighten to a torque of 25 N.m (fig. 4412). 2. R eplace transverse inlet manifold. 3. Re place injec tor pipes and tighten to 25 N.m.

REMOVING AND REPLACING EXHAUST MANIFOLD Removing 1. Uns crew and remove exhaust pipe from manifold. 2. Disc onne ct exhaust brake cylinder. 3. R emove gas kets (fig. 4512).

Replacing 1. R eplace exhaust manifold fitted w ith new gaskets. 2. R eplace mounting bolts with sleeves and tighten to 50 N.m (fig. 4612). 3. F it exhaust brake cylinder and tighten bolts to specified torque. 4. F it exhaus t pipe to exhaust manifold, and tighten bolts to specified torque.

F ig. 4612



■

_________

SECTION 13-1

Pistons & Connecting Rods

P iston & C onnecting R od 1 Bearing shells 2 C onne cting rod 3 G udgeon pin bush 4 C irclip 5 G udgeon pin 6 Big end bolt

7 P iston 8 S leeve 9 O il co ntrol ring 10 2nd com pres sion ring 11 Top com pres sion ring

ftdt't'ingtor. Diesel tlub


PISTONS AND CONNEC TING RODS 

132

Piston 46.009 Gudgeon pin bore dia.

46.003 46.000 45.995

Gudgeon pin dia.

mating surface with piston at TDC

+ 0,43 + 0,07

Gudgeon pin/conrod bush clearance

0.0550.070

Gudgeon pin/piston clearance

0.0030.014

P iston: N ominal diameter

128,0

Distance between piston crown and cylinder block

Piston Rings Engine

Groove

1

2

G ap

P iston Ring C lass ification

S ide C learance

Keystone ’



0.350.50

0.0600.095

0.350.50

0.0300.065

0.250.40



0.350.50

0.0600.095

0.350.50

0.0300.065

0.250.40

Molybodenym coated

T , Molybodenym T a pe rfa c e cQated

420N 3

1

420T/TI

2

3

Be velled with rubber lined spring .. . Keystone

Mo lybodenym ’ . coated

T e cQate(J Mo lybodenym T an ap e e rfa rfa c ce

Bevelled with rubber lined spring

Conrod Bush Inner dia.

46.065 46.055

O uter dia.

50.700 50.670

W idth

38.700 38.200

LC

B a r r i n g t o n Die se l Club

ADE 422, 4 23 ,42 4 Workshop Manual t

PISTONS AND CONNE CTING RODS 

133

Conrod and Conrod Bearing Conrod Bearing Dia. Installed

Repair Size

Standard

90.106 90.064

Standard 1

90.006 , 89.964

Standard 2

89 856 (  0,25) 89.814

Rep. size 1

89.606 , 0 g. 89.564' '

Rep. size 2

89.356 , 89.314

Rep. size 3

89.106 ( _ 1 00) 89.064 ' ’

Conrod Bearing Width

0 31.0 30.8

g 7g,

Conrod bearing basic bore dia.

95,022 95.000

Conrod bush basic bore dia.

50.630 50.600

Length of connecting rod between centre of big and small end

256.05 255.98 Big end

33.0 32.6

Small end

39.0 38.7

Connecting rod width at

Big end bearing clearance

radial

0.126 0.064

axial

0.500 0.240

Basic bore big/small end cylindrical tolerance

0.01

Max. permissible mass variation within one engine

60 gr

P ermissible deviation within 50 mm between centreline big end bore and centreline gudgeon pin

0.025

TO RQU E S P E C IF IC AT IO NS C onnecting rod bo lts ......................

M16 x 1,5

Initial torque Final torque Max. stretch length

100 N.m 9 0 ° 100° 68,5 mm




134

Introduction The 420 Series of E ngines are fitted with light a lloy pistons. In all cases the top compression ring is mounted in a reinforced groove. The number of piston rings fitted depends on application. P istons and con necting rods are removable from the top of the cylinder block.

REMOVING PISTONS — CYLINDER HEAD AND SUMP REMOVED Removing 1. To avoid damage to the piston rings, remove carbon with a scraper from the top of the cylinder liner. 2. Unscrew and remove connecting rod bearing cap (fig. 113).

Note: Ensure that connecting rod bearing caps are marked for replacement to the same connecting rod (fig. 213).

3. P ush out conn ecting rod and piston from below. 4. Clamp connecting rod and piston in a vice (fitted with so ft jaws), remove gudgeon pin circ lip, and press out gudgeon pin, lift off piston (fig. 313).

Fig. 313



PISTONS AND CONNECTING RODS — 135 Replacement 1. C lamp conn ecting rod in a vice (use protective jaws) so that the longest side of the connecting rod faces towards the right. P lace the heated piston over the connecting rod with the arrow on the piston crown pointing toward the right. 2. Lu bricate and insert gudgeon pin and replace circlips (fig. 413).

3. C oat piston with engine oil. O ffset piston rings in relation to each other. F it relaxed piston ring c lamp over piston, and compress to outside diameter of piston, so that the clamp can still move (fig. 513).

4. Insert bearing shell into connec ting rod. Ensure that the locating tab is fitted correctly in the connecting rod. Coat bearing with engine oil (fig. 613).

5. L ubricate bearing surface s of con nec ting rod with engine oil. 6. Insert piston into cylinde r liner with arrow facing in towards the centre (fig. 713) of the engine. 7. P ush piston in until con nec ting rod bearing rests on cranksha ft journal.




136

8. Insert bearing shell into conne cting rod cap. Ensure that the locating tab is fitted correctly in the connecting rod cap. Coat bearing with engine oil (fig. 813).

9. Measure len gth of big end bolts (fig. 913). Note: Big end bolts can still be used as long as stretch does not exceed 68,5 mm.

10. F it bearing cap and screw in bearing bolts finger tight. Note: Ensure that marks on bearing cap and connecting rod align (fig 1013). 11. Tighten big end bolts altern ately in two steps to 100 N.m, using a torque wrench and then a futher 90°.

F ig. 1013

ftdt't'ingtor. Diesel Club


PISTONS AND CONNE CTING RODS  MEASURING CONNECTING ROD BEARINGS Note Bearing shells for connecting rod bearings are delivered ready for installation. No machining or scraping should be performed on the bearings. 1. C lean bearing surface in con nec ting rod and bearing cap with clean rag. 2. Ins ert bearing shell into co nne cting rod cap. Ensure that the locating tab is fitted correctly in the connecting rod cap (fig. 1113).

3. Place bearing cap with shell into connecting rod. Identification numbers must be on the same side. 4. T ighten big end bolts to an initial torque o f 100 N.m in 2 steps and then to a final torque of 90° +10 ° angle of rotation. Note: Hold connecting rod in a vice (fitted with soft jaws, as close as possible to the connecting rod bearing (fig. 1213).

F ig. 1213

137

(d rH n g to n Diesel Club


PISTONS AND CONNECTING RODS — 138 5. Set a 50100 mm internal measuring instrument to diameter of connecting rod big end bore using an outside micrometer (fig. 1313).

6. Measure conne cting rod big end bearing bore at three points (vertically and approximately 30° away from mating points, using set 50100 mm internal micrometer (fig. 1413). Note: Measurements specified in table must be adhered to. 7. Uns crew and remove bearing cap.

REPLACING PISTON RINGS 1. Set piston ring pliers P art number 40200307 to 128 mm diameter with the adjusting screw (fig. 1513). 2. P iston rings can be removed and replaced at this setting.

Fig. 1513

irringion Diesel Club


_________________________

S e c t io n s :

14 an d 15

SECTION 14-1

Crankshaft & Main Bearings

C ranks haft & Main Bearings 1 2 3 4 5 6 7

Hub bolt Vbelt pulley Hub Dust cover * Wear ring C rankshaft with counter balances Counter balance

8 9 10 11 12 13

Bolt Locating pin C rankshaft gear Spacer S pigot bearing Crankshaft bearing shells

Bdrrington Diesel Club

A D E 4 22 , 4 23 ,4 24 W orksh op M anual

CR ANKS HAFT AND MAIN BEARINGS 

S e c t io n s :

1 4 a n d 15

142

Crankshaft Repair Size

Main Bearing J ournal Dia.

Standard

Width of Thrust Bearing J ournal

104000 103.980

Standard 1

103.900 ( 0,1) 103.880

Standard 2

103.750 , 103.730

38.062 /gj 38.000 ( 1

0 25)

Rep size 1

103.500 ^ Q 5^ 103.480 ' '

ReP size2

^H ^(°,7 5 )

Rep size 3

103 000 (_ i,o) 102.980

103.230

38.562 , 0 ,, 38.500 ( +° ’5)

39.062 , 39.000 (

i

q.

’ '

Conrod Bearing J ournal Dia.

Width of Conrod Bearing journal

90.000 ,q , j , 89.980 (S,d)

89 900 ( 0,1) 89.880 ' 89 750 ( 89.730 '

71.120 71.000

0,25) '

89 500 (0,5) 89.480 ' ' 89 250 ( 0,75) 1 89.230 ' § 9^29 (1 ,0) 88.980 ' '

C rankshaft journal hardness

HR C 53 ±3

F or Repair only: C ranks haft journal ha rdness at two thirds of circumferen ce

Min.: HRC 46

Max. crankshaft journal/conrod journal taper

0.01

Max. crankshaft journal/conrod journal ovality

0.01

Max. crankshaft runout with crankshaft

0.06

running on ou ter cranks haft bearing journals Max. radial runout of flywheel spigot with cranksha ft running on outer crankshaft bearing journals Max. lateral runout of flywhee l mou nting surface

.

crankshaft running on outer crankshaft bearing journals Max. lateral runout of thrus t bearing surface Max. imbalance of crankshaft with counterbalance without flywheel, running on outer main bearings

0.02

0.02

0.02

60 cmg

Radii on crankshaft and conrod bearing journals

3.54.0

R adii on thrust bearing journ al

4.0

Max. misalignme nt of con rod bea rings to cranks haft bearings in reference to bearing length

S pigot dia. for flywheel

4 0 * *

0.01

61.959 61.940

BDC fcdriM hgton Diesel Club


S e c t io n s !

14 an d 15

CRANKSHAFT AND MAIN BEARINGS — 143

.

C r a n k s h a f t B e a r in g Crankshaft Bearing Dia. Installed

Repair Size Standard

104.112 104.066

Standard 1

104.012 , 0,1) 103.966 '

Standard 2

103.862 ,  0,25) 103.816

Rep size 1

103.612 , 0,5) 103.566

Rep size 2

103.362 , 0,75) 103.316 103.112 , 1,0) 103.066 1

Rep size 3 Max. bearing journal ovality

Thrust Bearing Width

3781 (Std) 37.74

3831 , +05) 38.24^ '

38.81 / 38.74 (

,

0.02

Basic bore dia. in crankcase for crankshaft bearing

for repair

111.040 110.970

new

111.022 111.000

Crankshaft end play (thrust bearing)

0.1900.322

Radial clearance of crankshaft (Thrust Bearing) (Other Bearings)

0.0870.153 0.0800.146

Main and Bigend journal surface finish

(Lapped)

Ra 0.2/im Rmax 2^m

TO RQU E S P E C IF IC AT IO NS Counter balance bolts to crankshaft

.................................

M16 x 1,5

Pulley to hub/vibration damper........................................... Pulley hub/vibration damper to crankshaft...................... Main bearing cap bolts (see section 11) ..............

M8 M 16x 1,5 M18 X 2

Main bearing cap side b o lts .................................................

M12 x 1,5



100 N.m 9 0 ° 100° 84,5 mm 25 N.m 200 N.m 300 N.m 9 0 ° 100° 156 mm 80 N.m

Note: Tighten stretch bolts prior to bearing cap side bolts.

7/90



CRANKSHAFT AND MAIN BEARINGS — 144 Introduction The crankshaft is forged, precision ground and supported by steel backed shell bearings, with thrust washers at the flywheel end. Counterbalances are bolted to the crankshaft webs.

REMOVING AND REPLACING CRANKSHAlT AND BEARINGS Removing Vibration Damper, Hub and Pistons removed, (see Section 13). 1. Remove front oil seal housing (fig. 1 ■ 4). Fig. 114

2. Unscrew and remove side bolts of crankshaft main bearing caps. 3. Unscrew and remove Main Bearing Bolts, lift off bearing caps using bearing bolts (fig. 214). N o t e : Mark bearing caps and bearing shells In correct sequence.

4. Screw guide mandrels P art number 40200077 Into front and rear of crankshaft.

Fig. 214

5. Place a rope around mandrels and lift crankshaft from crankcase using a suitable hoist (fig. 314). 6. Remove main bearing shells from crankcase, check all parts for damage and wear.

Note: All main bearing shells are delivered ready for instal-

lation. No machining or scraping should be performed on the bearing shells. Thrust washers are supplied in various oversizes, the crankshaft must then be reground to the appropriate bearing shell width to maintain the specified crankshaft endfloat.

REPLACING AND CHECKING SHELL BEARINGS 1. Clean bearing surface in crankcase and bearing caps with clean rag. 2. Insert bearing shells into crankcase and bearing caps in correct order. Ensure that the locking tabs of the bearing shells are correctly located in cap and crankcase. Lubricate bearing shells with engine oil. Note: Bearing shells in crankcase have an oil deliveiy

hole which must be aligned with the adjacent hole in the crankcase (fig. 414).

S e c t io n s :

1 4 a n d 15


AD E 422, 423,424

workshop Manual

Sections: 14 and 15

C R A N K S H A F T A N D M A I N B E A R I N G S — 14-5 3. Replace bearing caps fitted w ith bearing she lls.‘Ensure marks on bearing caps correspond. 4. Me asure main be aring bo lts for stretch (fig. 514). N o t e : Main bearing bolts may be reused with a stretch of up to 156 mm.

5. T ighten main bearing cap bolts to an initia l torque of 300 N.m in 3 stages and then to a final torque of 90°+ 10°. 6. Inse rt and tighte n main bearing side b olts to 80 N.m (fig. 614).

■ ■

©

I

I

//

Fig. 614

8. Meas ure cran ksha ft bearing bores at three points (vertically and approximately 30° away from the mating points with the set 100160 mm dial gauge (fig. 814).

N o t e : S pecified values must be adhered to.

9. Uns crew bolts and remove bearing caps.

'

“ ....

...........

.

I

<

7. S et a 100160 mm interna l measuring ins trume nt to standard diameter of crankshaft bearing bore using an outside micrometer (fig. 714).

"

V

© X W /X F I

I I

A

L



CRANKSHAFT AND MAIN BEARINGS — 146 REPLACING BEARING SHELLS AND CRANKSHAFT 1. C lean oil galleries in crankca se with compress ed air applied from the oil pump side. 2. Clean crankshaft, bearings and bearing locations thoroughly with clean rag. Clean oil galleries in crankshaft with a wire brush and blow out with compressed air. 3. C heck cranks haft bearing journ als with a hardness tester (fig. 914). N o t e : A conversion table is supplied with the hardness

tester.

4. Insert bearing shells into crankcase and bearing caps in correct order. Ensure that the locking tabs are correctly located in cap and crankcase. N o t e : Align holes in bearing shells, with drillings in crankcase (fig. 1014).

5. L ubricate bearing surfaces with engine oil.

Fig. 1014

6. S crew guide mandrels P art number 40200077 into front and rear of cranks haft. P lace rope around mandrels and lift crankshaft. Lower crankshaft into crankcase (fig. 1114).

Fig. 1114

N o t e : Ensure that timing marks are lined up correctly (fig 1214).

Fig. 1214

S e c t io n s :

1 4 a n d 15

BDC B a r r i n g t o n D i es el Club


7. F it main bearing caps ensuring that marks on cap and crankcase align (fig. 1314). 8. Measure main bearing bolts for stretch (see fig. 514). N o t e : Main bearing bolts may be reused with a stretch

of up to 156 mm (see fig. 514).

Fig. 1314

9. Tighten main bearing cap bolts to an initial torque of 300 N.m in 3 stages and then to a final torque of 90°+ 10°. 10. Inse rt and tighten main bearing side bo lts to 80 N.m (fig. 1414).

11. F it suitable dial gauge to crankcas e and check end float of crankshaft (fig. 1514).

Fig. 1514

S e c t io n s :

1 4 a n d 15



CRANKSHAFT AND MAIN BEARINGS — 148 CRANKSHAFT GRINDING 1. Remove counter balance weights. C heck to see if counter balances are marked prior to removal. If not, mark counter balance using a suitable punch to ensure correct installation. 2. Remove cra nks haft timing gear. 3. Clean cranks haft and check for misalignment, jou rnal run out, hardness using special tool Part number 40200501 and cracks. C rankshafts sho wing signs of cracking s hould be replaced. S traighten or if necessary replace bent crankshafts. If bearing journals do not meet specifications or are found to be scored, the crankshaft should be ground to the next repair stage (see fig. 1614). 4. It is es se ntial to keep to the spe cified radii for the main bearing and crankpin journals.

5. Lap surface of journals a fter grinding. 6. Measure length of cranks haft counter balance bolts (fig. 1714). N o t e : Counter balance bolts may be reused if the stretch

limits are within specification. Remove counter balance weights. 7. Replace counter balanc es and tighten to an initial torque of 100 N.m and a final torque of 90 + 10. N o t e : Marks on counter balances must be aligned with marks on crankshaft.

8. Clean oil galleries in cranks haft with a wire brush and blow out with compressed air.

7 / 9 0

S e c t io n s :

1 4 a n d 15

i r r i n g i o n D ie se l Club

A D E 4 22, 4 23 ,4 24 W orksh op M anual

S e c t io n s :

1 4 a n d 15

f t d f H n g t o n D i e s e l Club

AD E 422, 423,424 Workshop Manual

SeCtiOflS!

14 an d 15

CRANKSHAFT AND MAIN BEARINGS — 1410 Replacing Oil Seal 1. Coat outer surface of oil s eal with a suitable sealing compound. N o t e : Do not allow sealing compound to come in contact with the lip of the oil seal or the sealing surface of the crankshaft.

2. Insert new oil seal into housing and press or knock in so that the seal face is flush with the inside of the housing. Pack (fill) the area between the seal lip and dust lip with multipurpose grease. N o t e : Support cover while inserting oil seal in housing.

3. F it new housing gas ket over dowels in crankcase. 4. Lubrica te wear sleeve for oil seal with engine oil. 5. Replace housing and housing bolts and tighten to a torque of 25 N.m (fig. 2214).

_____

Fig. 2214

6. Replace sump fitted with new gasket, insert bolts and tighten to a torque of 30 N.m (fig. 2314).

7. Insert dust cover, fit pulley hub and vibration damper and tighten to a torque of 200 N.m (fig. 2414). 8. Replace pulley and fan.

Fig. 2414

B a r r i n g t o n Die s el Club

ADE 422, 423,424

workshop Manual

Sections: 14 and 15

CRANKSHAFT AND MAIN BEARINGS — 1411 REPLACING WEAR RING ON CRANKSHAFT Removing 1. F it specia l tool P art number 40249737 over wear ring on front of crankshaft, and push down adapter sleeve (fig. 2514). 2. P ull off wear ring.

Replacing 3. Heat new wear ring to approx 100°C. 4. F it wear ring into spe cial tool P art number 40201801 and knock onto crankshaft (fig 2614). 5. C oat surface of wear ring with engine oil.

REMOVING AND REPLACING VIBRATION DAMPER Removing 1. Remove Vbe lts. 2. Remove fan with hub and pulley. 3. Uns crew and remove vibra tion damper or pulley hub (fig. 2714).

Replacing 1. F it vibration damper or hub, and tighten b olts to a torque of 200 N.m (fig. 2814). 2. Replace engine fan with hub and pulley. 3. F it and tens ion Vbelts.

Fig. 2814



__________________________

S e c t io n s !

1 4 a n d 15

SECTION 151

C a m s h a f t , T i m i n g C a s e an d Dr iv e T i m i n g

Camshaft 1 2

3 4 5 6 7 8 9 10

C amshaft Inlet valve E xha us t valve Valve spring inner Valve spring outer Spacer inner S p ac er o ute r Spring retainer Collet Stem seal

11 Rocker shaft and pedestal 12 Ball 13 R ocker arm 14 Adjusting screw 15 Locking nut 16 Thrust washer 17 Circlip 18 Rocker shaft bolt 19 Tappe t 20 P ush rod

B a r r i n g t o n D ie se l Club


CAM SHAF T, TIMING CASE AND DRIVETIMING 

S e c t io n s !

14 an d 15

152

Camshaft 69.940 69.910

J ou rna l Dia. (incl. thru s t bea ring)

Hardness

jou rna l cam

5862 HRC

C amshaft/bearing c learance

radial axial

0.060.15 6 0.20.9

C ams haft/thrust bearing clearance

radial

0.130.18

Backlash crankshaft/camshaft gear B acklash Injection pump/intermediate/camgear

0.1180.242 0.1020.338

P ermissible runout cam sha ft journa ls (cams haft suppo rted at outer journals)

0.05

P arallel cam /cam sha ft centreline

0.005

Cam and journal surface finish

Rz 3^m

Camshaft Bearing 70.090

C ollar (thrust) bearing

70.070

Bearing inside dia. 70.066 O therbearings

70.000

Basic bore for camshaft bearing

76.030 76.000

C ams haft bearing outer Dia.

76.100 76.070

M aximum Valve L ift with S pec ified V alve C learance (mm) MODEL

BREAKP OINTS

INLET VALVE

EXHAUST VALVE

ADE 422N


13,76 11,9512,35

13,66 11,9012,30

ADE 422T/TI

Up to SA 003441 P SA 003442 P and up

11,5011,90 11,9012,30

13,1013,50 11,8512,25

**

11,9512,35

11,9012,30

11,5011,90 11,9012,30

13,1013,50 11,8512,25

11,9512,35

11,9012,30

11,5011,90 f l ,90 12 ,30

13,1013,50 11,8512,25

ADE 423N ADE 423T/TI ADE 424N ADE 424T/TI

S till in effect To be advised ** S till in effect To be advised

* At new level since the first day of manufacture.

BDC B a rr in g to n Dicscl Club


S e c t io n s !

1 4 a n d 15

CAMSHAFT, TIMING CASE AND DRIVETIMING — 153 Valve Travel at TDC with zero valve setting (mm) MODEL

BREAKP OINTS

INLET VALVE

EXHAUST VALVE

ADE 422N


0,500,65 0,60  0,80

0,47  0,62 0,650,85

ADE 422T/TI

Up to SA 003441 P SA 003442 P and up

0,400,60 0,550,75

0,550,75 0,65  0,85

0,600,80

0,65  0,85

0,400,60 0,5 50 ,75

0,550,75 0,65  0,85

0,60  0,80

0,650,85

0,400,60 0,5 50 ,75

0,550,75 0,65  0,85

—


S till in effect To be advised —


S till in effect To be advised


Camfollower O uter S haft Dia.

Bore in C rankcase

S tandard

19.965 19.944

20.021 20.000

R epair 1 + 0.25

20.215 20.194

20.271 20.250

Repair 2 +0.50

20.465 20.444

20.521 20.500

C learance shaft/bore

0.0350.077

Rockershaft/Rockerarm 28.052 28.000

Basic bore rockerarm

Rockerarm bush

O uter Dia.

28 090

lnner Dia R ockershaft Dia.

24.980 24.967

C learance shaft/bore

0.0200.054

TO RQ UE S P E C IF IC AT IO NS Timing device weights to camsh aft g e a r....................

M10 Max. stretch length

Injector pump drive gear to timing device ..................

M10 Max. stretch length

Injector pump driven gear to flange (see section 17) Timing/Flywheel Hous ing to c ylinder block ................

Cover to timing housing (top), tightening sequence p. 156 Steering pump to timing housing (see section 18) Camshaft thrust plate to timing housing ......................... Check plug for injector pump timing marks ................... Cover air compressor opening to timing housing ......... Inspection cover for T.D.C. mark .......................................

M10 M10 M 12 x 1,5 M8 M8 v M 26 x 1,5 M38 x 1,5 M8 M8

(Short) (Long Bolts)

50 N.m 25,3 N.m 50 N.m 25,3 N.m 70 N.m 60 N.m 100 N.m 25 N.m 25 N.m 80N.m 100N.m 25 N.m 25N.m

7 / 9 0

A D E 4 22 , 4 23 ,4 24 W ork sh op M an ual

CAMS HAFT, TIMING CASE AND DRIVETIMING 

154

Introduction The c amsh aft is forged and precision ground. It is supported by bearings, and driven by gears at the flywheel end of the engine. To gain access to the camshaft, and timing gears it will be necessary to remove the flywheel and timing case housing.

REMOVING AND REPLACING TIM IN G CA SE Removing 1. Disconnect exhaust brake cylinder from exhaust manifold. 2. Remove oil pres sure and return pipe from power steering pump. 3. Unscrew and remove coolant feed pipes to compressor, (fig. 115).

4. Remove air intake hose and air pressure pipes from compressor, (fig. 215). 5. U nscrew and remove fuel filter from timing case.

Fig. 315

S e c t io n s :

1 4 a n d 15

' B ar rin g to n »•«*«! Club


S e c t io n s :

1 4 a n d 15

CAMSHAFT, TIMING CASE AND DRIVETIMING — 155 7.

Remove all sump bo lts and lift off sump, (fig. 4;15)

Fig. 415

8. Remove flywhe el (See se ction 18). 9. Unscrew and remove timing case mou nting bolts and lift off timing case (fig. 515).

Replacing 1.

F it new gas kets (Right and Left) over dow ell pins on timing case and trim ends to correct length, (fig. 615).

Fig. 615 2. F it timing cas e over dowe ll pins replace bo lts and tighten to 70 N.m, (fig. 715).

Fig. 715

A D E 4 22 , 4 23 ,4 24 W ork sh op M an ual

CAMSHAFT, TIMING CASE AND DRIVETIMING 

156

3. Replace sump and tighten bolts to 25 N.m. 4. F it timing cover with new gasket and insert into correct position using special tool Part number 40200103 (fig. 815).

Fig. 815

5. Tighten timing cover bolts to 25 N.m in the sequence shown in (fig. 915). 6. F it fuel filter to timing cover and tighten bo lts to 80 N.m.

Fig. 915

7. Replace air intake hose and air pressure pipe on compressor, (fig. 1015). 8. Replace and tighten engine brake cylinder on exhaust manifold.

Fig. 1015

9. C onnect and tighten coolant feed pipes to compressor, (fig. 1115). 10. C onnect and tighten oil pressure and return pipes to power steering pump.

Fig. 1115

S e c t io n s :

1 4 a n d 15

ftarrington Diesel Club


S e c t io n s :

1 4 a n d 15

CAMSHAFT, TIMING CASE AND DRIVETIMING — 157 REMOVING AND REPLACING CAMSHAFT Initial P reparation Remove engine. Remove rocker cover, arms and brackets, lift out push rods (see S ection 12). Turn engine over and remove sump. Remove flywhee l (see S ection 18). Remove timing case (see page 152). Remove cran ksh aft (see S ection 14).

Removing 1. Turn crankcase upside down. 2. E nsure that the cam follow ers are moved away from the camshaft lobes. 3. P ull cams haft from drive gear end and slide out, taking care not to damage the bearings. 4. If work is to be performed on the cam sh aft bearings, it will be necessary to pull off the end blanking plug, using spe cia l too l P art number 40202004 (fig. 1215).

F ig. 1215

Replacing 1. Inse rt ca ms haft and slide in, taking care not to damage the bearings (fig. 1315).

F ig. 1315

2. E nsure tha t the timing marks on the ca ms haft and crankshaft gears are correctly aligned (fig. 1415). 3. C oat edges of camsh aft blanking plug with a suitable sealing compound, and insert. Knock carefully home using a copper or hide faced hammer.

F ig. 1415



S e c t io n s :

1 4 a n d 15

CAMSHAFT, TIMING CASE AND DRIVETIMING — 158

1 2 3 4 5 6 Fig. 1515

REMOVING AND REPLACING CAMSHAFT BEARINGS Initial preparation Remove engine. Remove rocker covers, arms and brackets, lift out push rods (see S ection 12). Turn engine over and remove sump. Remove flywheel, and timing housing. Remove camshaft blanking plug. Remove camshaft and crankshaft.

Removing 1. Bolt bearing flang e (5) and centralizing tube (7) onto cran kcase using two M 10x 25 mm bolts (6) (fig. 1515 and 1615).

2. G uide sp indle tube (8) into crankcase and insert two bearing holders (9) behind appropriate bearing. N o t e : Insert bearing holder (9) in a reversed position to each other (fig. 1715).

Fig. 1715

Handle Semishell S lot Lockpin Bearing flange Bolt

7 8 9 10 11 12

Centering tube Spindle tube Bearing holder Locks Locating ring C ollar bearing

i r r i n g i o n D ie se l Club


S e c t io n s :

1 4 a n d 15

CAM SHAF T, TIMING CASE AND DRIVETIMING  3. Turn sp indle tube un til lockpin (4) engage s in slo t (3) of spindle tube. 4. F it handle (1) on thread s of sp indle tube (fig. 1815).

Fig. 1815

5. Inse rt bearing holder (9) into cams haft bearing. Insert locks (10) in grooves be hind bearing holde r (9). P ull out camshaft bearing by turning handle (fig. 1915). N o t e : To reset bearing holder (9) the s pindle tube (8) fit ted with a handle must be pulled out of the crankcase.

F ig. 1915

6. The co llar bearing (12) will be pressed ou t towards the rear. This will require connecting the handle (1) with the bearing flange (5) through the semishell (2) (fig. 2015). 7. Unscrew handle (1) and remove sp ind le tube (8) with bearing holders (9) and camshaft bearing bushes. Unscrew bearing flange (5).

F ig. 2015

R eplacement 1. B olt bearing flange (5) and centraliz ing tube (7) onto crankcase , using two M10 x 25 mm bolts (6) (fig. 1515 and 1615). 2. Insert cams haft bearing bushes onto bearing holders (9) and lock (fig. 2115). 3. G uide spind le tube (8) into cams haft gallery and insert bearing holder (9) with bearing bush into appropriate housing. Turn spindle tube (8) until lockpin (4) in bearing holder engages in groove (3) of spindle tube.

F ig. 2115

159

C f t a r r in g t o n D ie sel Club


C A M S H A F T , T IM I N G C A S E A N D D R I V E - T I M IN G -

1 5 -1 0

N o t e : Loc king the bearing holders on the spindle tube also

locates the oil drilling in the camshaft bush with the oil gallery in the crankcase. 4. Ins ert lock (10) onto s pindle tube (8), fit han dle and pull in bearing so that the oil drilling in the ca msh aft bush aligns with the oil gallery in the crankcase (fig. 2215). N o t e : Lubricate the outside of the camshaft bushes with engine oil prior to installation.

5. Ins ert loc ating ring (1) (fig. 2315) in thrus t poin t of collar bearing (12) when pulling in the inner camshaft bushes. N o t e : Because o f the considerable force required, no more than two bearings should be pulled in at once. To reset the bearing holders (9) the spindle tube (8) with handle must be pulled out of the crankcase.

6. W hen loc king c ollar bearing on bearing ho lder (12) ensure that the lower bore of the ca msha ft bush faces to the right of the centre line (fig. 2415). 7. Remove bearing puller and measure camshaft bushes. 8. C heck that oil galleries and drillings are clear.

Fig. 2415

S e c t io n s :

1 4 a n d 15

B D C



S e c t io n s :

1 4 a n d 15

CA MS HAFT , TIMING CASE AND DRIVETIMING  CHECKING CAMSHAFT ENDPLAY Initial P reparations Remove Timing case cover. Remove injection pump.

CAMSHAFT ENDPLAY 1. P ush cam sha ft agains t the timing case. 2. A ttac h dial gauge to crankcase. P lace dial gauge probe pin with preload on camshaft gear and set scale to 0 (fig. 2515).

F ig. 2515

3.

P ress cams haft gear agains t the dial gauge probe and read camshaft end play (fig. 2615).

Fig. 2615

1511

R d f r in y to n Die sel CCftjjIb

ADE 422, 423,424

workshop Manual

CAMSHAFT, TIMING CASE AND DRIVETIMING — 15-12 CHECKING VALVE LIFT 1. Remove rocker covers, (fig. 2715). 2. A ttac h engine turning tool. 3. A djust valve clearances . 4. Turn engine and set to TDC No 1 cylinder rocking. 5. Turn engine in reverse direction of rotation for approximately 90°, and note that the inlet valve is closing fully during this operation.

6. Attach a dial gauge to the cylinder head, with the probe placed on the inlet valve, and set gauge to “O ", (fig, 2815). N o t e : Adjust dial gauge to give sufficient preload to allow for valve lift.

7. Turn engine in the normal direction of rotation, and note reading on dial gauge when the needle stops, i.e. before it returns to "O ”. 8. Read off INL ET valve lift.

9. Reposition dial gauge, and place probe of dial gauge onto exhaust valve, and set to “ O”, (fig. 2915). 10. Turn engine in reverse direction of rotation and note reading on dial gauge, when the needle stops, i.e. before it returns to "O ”. 11. Read off measured EXHAUST valve lift.

Fig. 2915

12. Remove dial gauge, unscrew engine turning tool, and replace rocker cover and tighten to 25 N.m, (fig. 3015).

Sections: 14 and 15



S e c t io n s :

1 4 a n d 15

CAMSHAFT, TIMING AND DRIVE TIMING — 1513 CHECKING VALVE TRAV EL AT ZERO VALVE CLEARANCE 1.

,

Remove rocker cover of No 1 cylinder, (fig. 3115).

2. Fit engine turning tool to flywhell housing, (fig. 3215). 3. Turn engine in normal direction of rotation until TDC No 1 (OT1) mark on flywheel is reached. Attention! Check valve movement to ensure that No 1cylinder is in firing position and not in rocking position.

4. Set both vlaves of No 1 cylinder to “O ” clearance. 5. Turn engine 360° in normal direction of rotation until TDC No 1 (OT1) mark on flywheel is reached. Attention! Valves of No 1cylinder should be in rocking position, i.e. inlet valve starts opening and exhaust closing.

6. Mount dial indicator gauge on No 1 cylinder head.

7. Place dial gauge probe preloaded onto inlet valve spring retainer and set gauge to "O ” , (fig. 3315). 8. Turn engine back slowly until needle of dial gauge stop. 9. Note reading of inlet valve travel. 10. Remove dial gauge indicator from cylinder head. 11. Turn engine slowly in normal direction of rotation until piston of No 1 cylinder is once more at TDC, valves rocking. 12. Mount dial gauge indicator on No 1 Cylinder head.

13. Place dial gauge probe, preloaded onto exhaust valve spring retainer and set gauge to "O ”, (fig. 3415). 14. Turn engine in normal direction of rotation until needle of dial gauge stops. 15. Note reading of exhaust valve travel. 16. Compare both readings with the specifications. 17. Remove dial gauge from cylinder head. 18. Continue turning engine in normal direction of rotation until TDC No 1 (OT1) mark on flywheel is reached. Attention! No 1 cylinder and valves should be in firing position.

7/90

^

i r r i n g t o n D ie se l Club


CAMSHAFT, TIMING AND DRIVE TIMING — 1514 20. Replace rocker cover and tighten bolts to specified torque, (fig. 3615).

19.

Adjust clearances of both vlaves of No 1 cylinder, (fig. 3515).

Fig 1536

:

7 /90

S e c t io n s :

1 4 a n d 15



S e c t io n s !

1 4 a n d 15

C A M S H A F T , T IM I N G C A S E A N D D R I V E -T I M I N G — 1 5 -1 5

25 24

r

3 14

Z05-6015

T imin g C as e 1

T I M I N G C A SE

14

2

OIL S E A L

15

PLU G

3 4

STUD

16 17

GASKET

18

S PR IN G W A TE R

19

BOLT BOLT C O V ER T IM IN G H O U S IN G

5

THRUST PLATE SCREW

6 7

S P R IN G W A S H ER T H RE AD ED IN S E RT

SPRING WASHER

GASKET

8

T H RE AD ED IN SE RT

20 21

9

THREADED INSERT

22

THREADED INSERT

10

COVER

SEAL

11

COV ER

23 24

12

GASKET

25

BRACKET

13

BOLT

BRACKET

7/90

Bcc B a rr in g to n Diesel Club)


_________________

Section 16 - Lubrication Syste m

SECTION 16-1

Lubricating System and Sump

Oil Pump 1 2 3 4 5 6 7 8 9 10 11

O il pu mp a ss em bly G ear Gear Driven G ear Oil pump assembly Gear G ear C over S him C irclip Intermediate Gear

12 13 14 15 16 17 18 19 20 21 22

Intermediate gear B olt Oil pipe F lange F lange Holder Bolt H older B olt C onnecting shaft Sleeve

23 24 25 26 27 28 29 30 31 32 33

C irclip Bolt Flange Bolt Bolt S uction pipe G asket B olt F ilter pipe Washer Bolt


B arr in gt o n Diesel Club


L U B R I C A T I N G S Y S T E M A N D S U M P — 16-2

Oil Pumps Engine Width of oil pump gears (nominal dim.)

Actual width of gears eg.

1st pump

422N

422T/TI423N

423T/TI

424N

424T

J 34

43 ~

28

28 28

34 28

33.950 33.911

42.950 42.911

27.960 27.927

27.960 27.927

33.950 33.911

2nd pump 1st pump

34 and 43 mm pump

0.128 0.050

28 mm pump

0.106 0.040

End play between face and housing

Clearance between teeth and housing

0.122 0.030 >■

Outside dia. of oil pump gears

56.770 56.724

Inside dia. of oil pump gears

21.915 21.900

Dia. of oil pump shafts

21.940 21.930

Inside dia. of oil pump drive sprocket

21.915 21.900

Min. delivery rate f/min with SAE 10 oil at

29.4

37.0

51

50.0

54.4

at 1 700 r/min

—

—

155

—

—

at 2 400 r/min

138

175.0

—

227

251.5

at 600 r/min

50°C and 400 kPa

Oil Pressure Relief Valve 422N/T/TI; 423N*

423T/TI; 424N/T* *

Below breakpoint

550 kP a

750 kP a

Above breakpoint

650 kPa

650 kP a

E ngine O pening pressure kPa:

* — S A 002265M ** _ SA 002424M

Camshaft/Piston Cooling Flow Control Na tural as pirated P iston o il spray jet inner dia.

-------------------------------------------------------

T urb oc ha rge d C am sha ft oil spray holes inner dia.

7/90

2.0 2.3 1.0

BCC B ^ frin g to n Diesel Club)



LUBRICATING SYSTEM AND SUMP 

163

Oil Filter By-pass Valve Spring for Bypass

Inside Dia.

Wire

Relaxed

Length when

Length with

Opening

Gauge

Length

P reloaded (valve open)

Final Load

Pressure of ByPass

Valve

Valve 13.5

2.25

53.6

42.1

77 N

31

153 N

230  300 kPa

Oil Pressure Minimum oil pressure — (stop engine immediately!)

600 r/min

below 50 kP a

2.300 r/min

250 kP a

Oil Capacity De pending on ap plic ation

TO R QU E S P E C IF IC AT IO NS Oil pressure relief valve to fla n g e ...................................... Oil pump to cylinder b lo c k ................................................... Oil pump cover to pump b o d y ............................................ S uction pipe to oil pump ...................................................... Suction pipe bracket to cylinder block ............................. Sump to cylinder block ......................................... ................ Oil pump support to block (LH /R H) .................................... Sump drain plug ...................................................................... Oil filler neck to sump ............................................................ Oil filter bowl to filter head .................................................. Oil cooler to cooler housing ................................................. Oil cooler/filter head to cylinder block ............................. Screw plug for filter bypass valve ...................................... Oil filler plug to filter head ................................................... Oil drain plug filter head ....................................................... Dipstick tube adapter to sump ........................................... Dipstick tube to adaptor ....................................................... P iston cooling/c ams haft spray nozzles (see sec tion 11)

Model range 422N — 424T

approx. 23.0  32.5 (

SE CTIO N 16 M8 M8 M8 M8 M8 M8 M8 M26 X 1,5 M8 M12 x 1,5 M8 M10 M 26x 1,5 M26 x 1,5 M18 x 1,5 M14 x 1,5 M16 x 1,5

35 35 25 35 35 30 35 80 25 50 25 50 60 80 50 50 35

N.m N.m N.m N.m N.m N.m N.m N.m N.m N.m N.m N.m N.m N.m N.m N.m N.m



LUBRICATING SYSTEM AND SUMP — 164 INTRODUCTION Lubricating System The A DE 420 series engine s are supp lied w ith lub rication oil by a gear driven oil pump, and the oil is filtered by a paper full flow element. The oil cooler, crankshaft, connecting rods, camshaft, and rockers are ail pressure fed. The in jec tion pump, and air co mpres so r are also dire ctly fed with engine oil. Relief and by pass valves protect the system against overload.

REMOVING AND REPLACING BREATHER Removing 1. Unscrew clamp and pull off hose from breather. 2. Unscrew and remove breather from crankcase (fig. 116).

Replacing 1. Insert new Oring into breather, (fig. 216).

2. Fit breather over connection on crankcase (fig. 316). Note: Do not damage the breather while servicing or repairing. Even slight damage e.g. dents in cover, could cause a faulure of the breather. A damaged breather should always be replaced.

7/90





LUBRICATING SYSTEM AND SUMP — 165 3. Tighten clamp of breather to approximately 8 N.m,*(fig. 416). 4. Connect hose to breather and tighten clamp. N o t e : The vacuum in the crankcase is regulated by a spring

loaded rubber diaphragm fitted integrally with the breather. Ozone can cause cracks in the rubber diaphragm, through which the engine can take in unfiltered air. This will lead to premature engine wear. Always replace the breather when oil vapour is expelled through the vent on the top of the breather.

REMOVING AND REPLACING OIL PRESSURE SENDER UNIT Removing 1. Unscrew wire connection to oil pressure sender unit. 2. Using a open spanner remove oil pressure sender unit, (fig. 516).

Replacing 1. Screw in oil pressure sender unit fitted with a new sealing washer, tighten and attach electrical connection (fig. 616).

REMOVING AND REPLACING SUMP Removing 1. Drain engine oil. 2. Unscrew and remove oil filler neck and dips tick guide tube from sump. 3. Remove bo lts and sump (fig. 716). 4. Clean s ump interior and exterior.

t

7/90




166

Replacement 1. F it new gasket to sump. 2. R eplace sump on crankcas e and tighten boits to 30 N.m (fig. 816). 3. R eplace oil filler neck and dipstick gu ide tube. 4. S crew in and tighten o il drain plug to 80 N.m. 5. F ill sump with oil.

REMOVING AND REPLACING OIL FILTER BYPASS VALVE Removing 1. Uns crew drain plug on oil filte r bowl and drain oil. 2. Remove plug for bypass valve, lift out valve and spring, (fig. 916). 3. Check length and tension using a suitable spring tester.

Fig. 916

Replacing 1. Insert valve, spring, and plug into oil filte r body, (fig. 1016). Note: Use new sealing washer. 2. T ighten filter plug to 60 N.m. 3. Replace oil filter drain plug on filter bowl, and tighten to 50 N.m 4. E nsure that the engine is in stop pos ition. T urn the engine several times with the starter until oil pressure is registered on the gauge. Release stop control and start the engine. 5. C heck for oil leaks.


( a r H n g t o n D iesel (l u b



LUBRICATING SYSTEM AND SUMP  REMOVING AND REPLACING OIL FILTER ELEMENT Removing 1. Uns crew drain plug on oil filter bowl and drain oil. 2. Remove centre bolt from oil filter bowl, and remove together with filter cartridge, (fig. 1116). 3. Remove filter cartridge from bowl, and take off 0ring.

Replacing 1. F it new O ring to filte r housing, (fig. 1216). 2. Inse rt new oil filter cartridge into filter bowl with coil spring towards the bottom of the bowl.

3. C entre oil filter bowl on filter hous ing, oil drain plug facing down, insert centre bolt and tighten to a torque of 50 N.m (fig. 1316) 4. E nsure that the engine is in stop po sition. Turn the engine several times with the starter until oil pressure is registered on the gauge. Release stop control and start the engine. 5. Check for oil leaks.

167



LUBRICATING SYSTEM AND SUMP — 168 REMOVING AND REPLACING OIL PUMP Removing 1. Drain engine oil. 2. R emove sump (fig. 1416). 3 Uns crew oil suc tion pipe and oil pump from cra nkcase.

Replacing 1. R eplace oil pump and su ction pipe, tighten bo lts to 35 N.m (fig 1516). 2. F it sump onto crankcas e (Fit new sump gaske t if necessary), and tighten bolts to 25 N.m. 3. R eplace oil drain plug, and tighten to 80 N.m. F ill sump with oil.

DISMANTLING PRIMARY OIL PUMP Dismantling 1. Un screw and remove suction pipe (fig. 1616). N o t e : ADE 423T/TI engines have pumps with 3x28 mm gears. The following operations will in addition, also apply to this type of three gear oil pump.

2. Remove bo lts from oil pu mp cover (fig. 1716).

7/90





LUBRICATING SYSTEM AND SUMP  3. L ift out oil pump driven gear from oil pump Body (fig. 1816).

Fig. 1816 4.

Us ing a su itable puller, removedrive gear(fig. 1916).

5.

Remove drive gear from oil pump body (fig. 2016).

169



LUBRICATING SYSTEM AND SUMP — 1610 ASSEMBLING PRIMARY OIL PUMP 1.

Inse rt driving gear with sh aft into oil pump body (fig. 2116).

2. Heat drive gear and drive or press onto drive sha ft (fig. 2216). Note: The gear should be fitted so that the drive s haft projects from the gear hub face by 0,5 mm.

3. Ins ert driven gear and sh aft into oil pump body, (see fig. 2316).

4. R eplace cover and bolts in oil pump body and tighten to 25 N.m (fig 2416). 5. A ttac h a dial gauge to the oil pump body. 6. P lace probe pin ot dial gauge on to end of oil pump shaft with preload. 7. P ush oil pump shaft down and set dial gauge to “O” . 8. P ush sha ft or oil pump up, agains t dial gauge probe pin and read end play. Note: End play of oil pump drive shaft should be 0,089 ± 0,039 mm.

Fig. 2416


BCC B a r r i n g t o n D ie se l Club



B d P r i n g t o n D i e s e l Club



1612

6.

Us ing a su itable puller, remove drive gear (fig. 2916).

7.

Remove drive gear and sha ft from oil pump body (fig. 3016).

ASSEMBLING SECONDARY OIL PUMP 1.

Inse rt driving gear of oil pump into pump body (fig. 3116).

2.

Heat drive gear for oil pump, and press on flush with end of drive shaft (fig. 3216).

F ig. 3216


BCC B a rr in g to n Diesel Club



LUBRICATING SYSTEM AND SUMP  3. Inse rt driven gear and s haft into oil pump ,body (fig. 3316).

Fig. 3316 4. R eplace cover and bolts in pump body, and tighten to 25 N.m (fig. 3416).

5. A ttac h a dial ga uge to oil pump body. 6. P lace probe pin of dial gauge onto end of oil pump shaft, with preload. 7. P ush shaft of oil pump down, and set dial gauge to ■•

0" .

8. P ush sh aft of oil pump up, agains t dial gauge probe and read end play. 9. F it oil intake pipe with new gasket, and tighten bo lts to 25 N.m (fig. 3516).

10. R eplace intermediate gear in oil pump, and lock with circlip (fig. 3616).

F ig. 3616

1613



LUBRICATING SYSTEM AND SUMP — 1614 REMOVING AND REPLACING PRESSURE RELIEF VALVE R emoving 1. Drain engine oil. 2. Remove sump (see fig. 716). 3. Uns crew pres sure (fig. 3716).

relief valve from crankc ase

Replacing 1. F it pres sure relief valve on to crank cas e and tighten bolts to 35 N.m (fig. 3816). 2. R eplace sump fitted with new gasket, and tighten bolts to 25 N.m. 3. F ill sump with oil.

REMOVING AND R EPLACING OIL SPRAY J ET Removing 1. Un screw ce ntre bolt of spray jet, and remove from crankcase (fig. 3916).

Replacing 1. C heck alignme nt of oil spray jet with spec ial too l part number 40201937 (fig. 4016). 2. Ensure that cams haft spray holes at spray jet base are free from obstruction. 3. C heck that full movement of the spray jet valve within the centre bolt is not restricted.

7/90





LUBRICATING SYSTEM AND SUMP — 1615 2. Inse rt oil spray jet so tha t dowel pin engages with detent in crankcase (arrow), and tighten to 47 N.m (fig. 4116).

REMOVING AND REPLACING OIL COOLER Removing 1. Uns crew co ola nt drain plug from oil coo ler, and drain coolant (fig. 4216).

2. Remove bolts holding oil coo ler to cylinder block, and remove cooler (fig. 4316).

R eplacing 1. F it new gas ket to oil cooler. 2. P lace oil cooler on crankcase, insert bolts and tighten to 50 N.m (fig. 4416). 3. Insert coolant drain plug in cooler housing and tighten to 50 N.m.

Fig. 4416





1616

DISMANTLING AND ASSEMBLING OIL COOLER

Dismantling 1. Uns crew and remove filter bowl and cartridge. 2. Remove oil filte r plug (fig. 4516).

F ig. 4516

3. R emove oil drain plug. 4. Remove oil co oler mou nting bolts, and remove oil cooler from housing (fig. 4616). 5. Remove oil filte r bypass valve.

Fig. 4616

Assembling 1.

S tick gasket for oil cooler on housing using a suitable sealant (fig. 4716).

M

Note: F it gasket with graphite surface facing oil cooler.

I

m

'

^ V --------------------------------\_ / r Fig. 4716

2. Replace oil cooler and tighten bolt to 25 N.m (fig. 4816). 3. Inse rt coo lant drain plug and tighten to 50 N.m.

Fig. 4816

-

— ^ X

BCC B a r r i n g t o n D ie se l Club



LUBRICATING SYSTEM AND SUMP — 1617 4. Insert and tighten o il filte r plug to 60 N.m (fig. 49,16).

5. R eplace oil filter bypas s valve and tighten to 60 N.m (fig. 5016). 6. F it oil filter bowl with oil filter cartridge to filter body, and tighten to 50 N.m. Note: Remote mounted oil filters must be primed during filter changes, i.e. fill filter bowl with clean engine oil before fitting to the fitter head.

Fig. 5016

7/90




LUBRICATION


1618

CHART

1. Sump. 2. Oil strainer. 3. Oil pump. 4. Oil pressure relief valve. 5. Oil cooler. 6. Oil filter. 7. F ilter bypass valve. 8. Main oil gallery.

9. Inje ction pump. 10. Oil pressure switch. 11. Crankshaft. 12. Rocker arm. 13. Camshaft. 14. Camshaft spray and piston cooling jets. . 15. Combined in each bank of cylinders.





Oil Cooler 1 Cover 2 Helicoil insert 3 Helicoil insert 4 F ilter bowl 5 Seal 6 P lug 7 F ilter cartridge 8 Valve 9 Spring 10 P lug 11 Washer 12 Washer 13 P lug

14 Washer 15 P lug 16 ORing 17 Washer 18 Bolt 19 Oil cooler 20 Gasket 21 S pring W asher 22 Bolt ~ 23 Bolt 24 Gasket 25 Spring was her 26 Bolt ~

1619



L U B R I C A T IN G S YS T E M A N D S U M P -

16-20

Double Oil Cooler 1 2 3 4 5 6 7 a 9

Housing Seal Plug Seal Plug Oil cooler Oil cooler Gasket Gasket

10 11 12 13 14 15 16 17

Bolt B olt B olt Cover Gasket S pring washer B olt Bolt


BbC

ftdrrincjtoh Diesel Cltlb

M erc ed es S e c t io n :

an d

A D E

F u e l

4 2 2 , 4 2 3 ,4 2 4

S y s te m

W o rk sh o p M a n u a l

“

( a r r i n g t o n D ie se l C lu b

M erc ed es

an d

S e c t io n :

A D E

F u e l

4 2 2 , 4 2 3 ,4 2 4

W o r k s l' ° P M a m l a l

S y s te m

F U E L S Y S T E M — 172

Fuel System B O S C H P r e v io u s

I n je c ti o n p u m p a n d Q o v e r n o r new used

Iniector pressure

min

P r e s s u r e d if f e re n c e s b e t w e e n in jec to rs

17 5 M Pa 16 5 MP a

Current 20.0—20.8 MPa min. 17.5 MP a

1 .0 M P a

T O R Q U E S P E C IF IC A T IO N S D r i v e n g e a r to * i n j e c t i o n p u m p f l a n g e I n j e c t io n p u m p t o c y l in d e r b lo c k I n je c t o r s e c u r in g n u t t o c y l i n d e r h e a d I n je c t o r p i p e n u t s F u e l f i l t e r b o w l t o f il t e r h e a d F u e l f i l te r h e a d t o s u p p o r t b r a c k e t F u e l fi l t e r s u p p o r t b r a c k e t to : C o v e r o f t i m i n g h o u s i n g I n le t m a n i f o l d F u e l p i p e s t o l i f t p u m p , f u e l f il t e r a n d i n j e c t i o n p u m p F u e l r e tu r n p i p e to i n j e c t i o n p u m p F u e l r e t u r n p i p e t o f u e l f i lt e r b r a c k e t Fuel system bleed screw I n j e c t o r n o z z l e to n o z z l e h o l d e r ................................

.......................................................

.......................................

................................................................................................

................................................................

.................. .........................

.......................

................................................

............................................

.........................................................

......................................................

i n s p e c t i o n h o l e p l u g ( ti m i n g c o v e r) s e e s e c t i o n 1 5

7/90

M8 M 10 M 2 8 x 1 .5 M 1 4 x 1 .5 M8 M 12 x 1.5

35 50 70 25 20 80

N m N m N m N m N m N.m

M 12 M 14 M 14 M 16 M8 M 22

80 30 30 40 15 75

N.m N.m N m N.m N.m N.m

* x x x x

1 .5 1 .5 1 .5 1.5

x 1 .5

“

( a r r i n g t o n D ie se l C lu b


an d

A D E

F u e l

4 2 2 , 4 2 3 ,4 2 4

W o r k s l' ° P M a m l a l

S y s te m

FUEL SYSTEM - 17-3

3

4

LAYOUT OF FUEL INJECTOR PIPES

Etc

Bdf pih cjto n Diesel Cltlb


an d

A D E

F u e l

4 2 2 , 4 2 3 ,4 2 4

S y s te m


Etc



an d

A D E

F u e l

4 2 2 , 4 2 3 ,4 2 4

S y s te m


Etc



an d

A D E

F u e l

4 2 2 , 4 2 3 ,4 2 4

S y s te m


Etc



an d

A D E

F u e l

4 2 2 , 4 2 3 ,4 2 4

S y s te m


Etc

BdPPihcjton Diesel Cltlb


an d

A D E

F u e l

4 2 2 , 4 2 3 ,4 2 4

S y s te m


Etc



an d

A D E

F u e l

4 2 2 , 4 2 3 ,4 2 4

S y s te m


Etc



an d

A D E

F u e l

4 2 2 , 4 2 3 ,4 2 4

S y s te m


Etc



3

an d

A D E

F u e l

4 2 2 , 4 2 3 ,4 2 4


S y s te m

Fig

25-17

F ig

2617

T u r n e n g i n e t o N o 1 c y l i n d e r c o m p r e s s i o n s t r o k e to st a rt o f d e l iv e r y (1 3 ° o r 1 5 ° B T D C ) u s i n g t u r n i n g to o l T h e e n  g i n e m u s t n o t b e t u r n e d b a c k . V a lv e s o f N o t c y l i n d e r a r e c lo s e d a n d v a l v e s o f N o 6 c y l i n d e r ( A D E 4 2 2 ) a r e r o c k i n g (f i g . 2 7 - 1 7 ) N o t e : C e r t a i n i n d u s t r i a l a p p l i c a t io n s m a y b e f i t te d w i t h a p o i n t e r a n d m a r k o n t h e v i b r a t io n d a m p e r , t h i s w i ll o n l y b e f i tt e d s h o u l d t h e n o r m a l m a r k i n g o n t h e f l y w h e e l b e inaccessible

4

5

T u r n c a m s h a f t o f m i e c t i o n p u m p u n t il m a r k o n d r i v e f a n g e s a u g n e d w i th m a r k o n m i e c ti o n p u m p b o d y .

in se t n e*

0

' m g m t o b o r e o f o i l f e ed in i n j e c t io n

p u m pD O O >if'5 28-’7 '

F,g 2817

7 / 9 0

Etc



an d

A D E

F u e l

4 2 2 , 4 2 3 ,4 2 4

S y s te m


Etc



an d

A D E

F u e l

4 2 2 , 4 2 3 ,4 2 4

S y s te m


Etc



an d

A D E

F u e l

4 2 2 , 4 2 3 ,4 2 4

S y s te m


Etc



an d

A D E

F u e l

4 2 2 , 4 2 3 ,4 2 4

S y s te m


^13® &ar*Hngt°n Diesel Club


S e c t io n :

18 - V ariou s

SECTION 18-1

Air Compressor 1 2 5 6 7 8 9 10 11 12 13 14 15 17 18 21 22 23 24 25 26 27 28

DRIVE GEAR CRANKSHAFT BOLT BEARING BEARING RETAINING PLATE SCREW FLANGE BUSH SEALING RING CONNECTING ROD DOWE L BOLT BEARING SHELL CYLINDER LINER WITH PISTON CYLINDER LINER WITH PISTON PISTON RING PISTON RING PISTON RING GUDGEON PIN CIRCLIP PLUG SCREW CONNECTOR SEALING RING

29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48

GASKET SCREW SPRING WASHER CYLINDER HEAD GASKET VALVE VALVE PLATE VALVE PLATE HOLDER BOLT GASKET BOLT SPRING WASHER SCREW PLUG SEALING WASHER SCREW PLUG CONNECTION SEALING RING INTAKE PIPE NUT HOSE CLIP

^ a r r i n g t o n D iesel H u b C O M P R ES S O R -


S e c t io n :

18 - V ariou s

18-2

A i r C o m p r es s o r C ylinder

1

Bore

90

Stroke

46

Displacement

292 cm3

Pressure Delivery capacity (engine at 2.300 r/min)

810 kP a/1000 kP a

against

100 kP a

470 f/min

810 kPa

400 f/min

90.030

Bore diameter

90.000 89.950

P iston diameter

89.910 0.08

P iston clearance

0.10

P iston retrusion from upper

0.4

edgeof cylinderliner

1 .2

20.000

Gudgeon pin diameter

19.996 0.020

Gudgeon pin clearance in conrod bush

0.037 0.003

Gudgeon pin clearance in piston

0.012

31.975

C rankshaft journal diameter

P iston ring gap

31.959 Groove 1 Groove 2 Groove 3

Groove 4

P iston ring side clearance

0.35 0.55

0.25 0.40

Groove 1 G roove 2

0.520

Groove 3

0.052

Groove 4

Note:

C ylinder liners and piston will be supp lied matchin g the given toleranc e under one part number.

f t d r r i n g t o n Diesel Club


S e c t io n :

1 8 - V a r io u s

COMPRESSOR — 183

*

A i r C o m p r e s s o r (c o n t d .) C onrod big end bore

36.016 36.000

C onrod bearing

32.008 31.994

Length of conrod from CL big end/small end bore

105.00 104.95

W idth of conrod

small end

20.060 20.000

big end

19.935 19.883

TO R QU E S P E C IF IC AT IO NS AIR COMPRESSOR F ittings — suction/pressu re pipe to cylinder head ....... Compressor drive gear to camshaft................................... Driven gear to air compressor crankshaft .......................

M 26x 1,5 M10 M18 x 1,5

Air compressor cylinder barrel to timing housing ......... C onnec ting rod to cranks haft .............................................. P ressure valve to intermed iate plate ................................. Intermediate plate to cylinder head ................................... C ylinder head to cylinde r barrel .......................................... Inner bearing cage to timing housing ............................... Inner bearing retaining plate to cage ............................... S teering pump or cover to timing ho using ...................... Blanking plugs air compressor cylinder head ................

M8 M8 M6 M8 M8 M8 M8 M10 M22 x 1,5 M 26x 1,5 M14 x 1,5 M 22x 1,5 M 16x 1,5 M8 M8

F itting — C oolant supply to cylinder barrel .................... F itting — C oola nt return to cylinde r head ....................... Coolant pipes to fittings ........................................................ Air compressor blanking plate (timing housing) ............ Air compressor blanking plate crankcase ........................

80 N.m 65 N.m without special tool 360 N.m with special tool 270 N.m 30 N.m 30 N.m 14 N.m 30 N.m 30 N.m 25 N.m 50 N.m 60 N.m 80 N,m 80 N.m 50 N.m 80 N.m 35 N.m 25 N.m 30 N.m

ALTERNATOR AND STARTER MOTOR Alternator suppo rt bracket to cylinder bl o c k ................... Support bracket to alternator............................................... Alternator adjusting bolt to sump ...................................... Adjusting bolt clamp to alternator ..................................... A lternator pulley retaining n u t............................................. S tarter motor to timing hous ing

..........................................

M14 M10 M10 M 12x M 14x M24 x M 12x

1,5 1,5 1,5 1,5

160 50 50 35 55 140 80

N.m N.m N.m N.m N.m N.m N.m

7/90

+m

Diesel Club

C O M P R ES S O R -


18-4

Introduction The ADE 420 S eries E ngines are fitted with a s ingle cylinder water cooled Westinghouse air compressor, mounted on the timing housing and driven by gears. The compressor provides air for the use in the vehicle braking system, and the operation of ancillary air devices.

REMOVING, DISMANTLING, ASSEMBLING, AND REPLACING AIR COMPRESSOR Dismantling 1. Unscrew coolant feed pipe from cylinder head (fig. 118).

Fig. 218 4. R emove timing ca se top cover. 5. R emove end cover from timing case. 6

. Unscrew and remove cylinder head, with suction valve (fig. 318).

Fig. 318

S e c t io n :

18 - V ariou s

^ a r r i n g t o n D iesel H u b


S e c t io n :

18 - V ariou s

C O M P RE S SO R 7. Uns crew and remove cylinder barrel (fig. 418).

8

. R emove circlips and push out gudgeon pin from piston (fig. 518).

9. Remove connecting rod bearing bolts. L ift off bearing cap, with bearing shells, and pull out connecting rod (fig. 618).

10. Unscrew and remove power steering pump, from end of compressor, and take off drive plate (fig. 718).

Fig. 718

18-5



S e c t io n :

COMPRESSOR — 186 11. Turn cran ksh aft toTD C , and insert locking tool, Part number 40201238 and bolt down (fig. 818).

Fig. 818 12. Uns crew and remove drive gear using s pecia l tool, P art numbe r 40201225. 13. Uns crew and remove cran ksha ft loc king tool. 14. Lever out cranksha ft from bearings, so that rear bearing flange can be removed. Lift crankshaft out through top of housing (fig. 918).

15. Remove bearing retaining plate (fig. 1018). 16. Uns crew inner bearing cage bo lts from timing case.

Fig. 1018 17. Using a suitable puller remove bearing and cage from timing case (fig. 1118).

Fig. 1118

*

18 - V ariou s

^l3® &a r*H ngt°n Diesel Club


S e c t io n :

18 - V ariou s

COMPRESSOR — 187 18. Us ing a special puller Part number 40201160 and support, P art number 40200585, pull bearing from cage (fig. 1218).

Fig. 1218 19. Knock or press bush from bearing flange using a suitable drift (fig. 1318). 20. Unscrew and remove valve plate from cylind er head. 21. Remove exhaus t valve retaining bo lts and remove valve.

Fig. 1318

Assembling 1. Check condition of exhaust valve and renew if necessary, the valve must not be scored or distorted (fig. 1418).

Fig. 1418 2. P lace exhaust valve on valve plate, curved surfa ce facing upwards. Insert bolts and tighten to 14 N.m (fig. 1518). F it valve plate to cylinder head, and tighten bolts to 30 N.m.

Fig. 1518



COMPRESSOR — 188 3. K nock bush into bearing flange with a suitable drift and rea m to s ize 30,020 to 30,041 mm (fig. 1618).

Note: Ensure that oil drillings in bush and flange are in alignment.

4. Using a su itable drift knock bearing into front flange (fig. 1718).

5. Inse rt bearing flange into timing case and locate with 2 bolts (fig. 1818).

6. K nock in bearing flange with a su itable drift replace all bolts and tighten to 25 N.m (fig. 1918).

Fig. 1918

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S e c t io n :

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COMPRESSOR — 189 7. Insert bearing retaining plate, and bolts, tighten to 50 N.m (fig. 1918). 8. Insert crankshaft, with balance weights facing upwards into crankcase and knock into bearing with a soft hammer.

Fig. 2018

9. Lubricate rear bearing bush, fit new Oring to flange and insert into crankcase ensuring that oil drillings are in allignment (arrowed) (fig. 2118).

Fig. 2118

10. Insert bolts into bearing flange and tighten progres sively (fig. 2218).

Fig. 2218

11. Remove bolts from flange. 12. Insert locking tool, and bolt down. 13. R eplace drive gear for comp res so r (fig. 2318).



COMPRESSOR — 1810 14. T ighten drive gear bolt to 270 N.m using s pec ial tool P art numb er 40201225 (fig. 2418). Note: The figure of 270 N.m is equal to 360 N.m without using the special tool.

Fig. 2418

15. R emove locking too l (fig. 2518). 16. Re place power steering pump and tighten bo lts to 60 N.m. 17. Insert connecting rod, beairings, bearing cap and bolts. Tighten bolts to 30 f'i.m.

Fig. 2518

18. P lace piston over con nec ting rod and insert gudgeon pin. 19. Inse rt cir clip s and lock gudgeon pin (fig. 2618).

F ig. 2618

20. O ffset pis ton rings by 180° to each other. Us ing piston ring clamp Part number 40201212, compress rings to outer diameter of piston, allowing slight movement of clamp. 21. Insert piston into cylinder barrel, fitted with new gasket, and push in. Remove ring clamp (fig. 2718).

F ig. 2718

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80C fta rri n g to n Diesel Club


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COMPRESSOR  22. B olt on cylinder barrel to timing case, and tighten to 25 N.m. 23. P lace inlet valve plate over locating pins on cylinder head (fig. 2818). 24. F it cylinder head gasket, with the word “TOP ” fac ing inlet valve, over locating pins on cylinder head. 25. Replace c ylinder head and tighten b olts to 30 N.m.

26. Re place and tighten b olts of timing case top cover to 25 N.m in sequence shown in (fig. 2918). 27. F it end cover of timing c ase and tighten bolts to 25 N.m.

28. Re connect air pressure feed pipe and induction feed hose to cylinder head (fig. 3018).

F ig. 3018 29. R econnect coo lant feed pipe to cylinde r head (fig. 3118).

Fig. 3118

1811



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SECTION 18-13 Flywheel

Flywheel 1 RING GEAR 2 WEAR RING 3 FLYWHEEL 4 FLYWHEEL BOLT

^a rrin g to n Diesel H ub


Section:

18 - Va rious

FLYWHEEL — 1814

Flywheel Diameter for starter ring gear

432.645 432.490

Diameter for wear sleeve (Rear seal)

115.015 114.980

Maximum material removal from clutch surface

2.0

Max. radial runout measured on wear sleeve locating surface

0.05

Max. radial runout measured on starter ring gear locating surface

0.1

Max. radial runout on clutch locating flange

0.05

Max. lateral runout on clutch friction surface

0.1

TO RQU E S P E C IF IC AT IO N FLYWHEEL AND HOUSING Flywheel to c ranksha ft .................................................................

M16 x 1,5

New dual hexagon bolts Max. stretch length Flywheel (timing) housing to cylinder block (see section 15) Top cover to timing housing (see section 15)

7/90

Bolt length

Initial torque 100 N.m Final torque 90°— 100° 200—220 N.m Initial torque 90°— 100° Final torque 74 mm — max. 75 mm 80 mm — max. 81 mm 85 mm — Max. 86 mm

80C ^a rri n g to t» Diesel Club


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FLYWHEEL — 1815

Starter Ring Gear

Ring gear inside diameter

432.155 432.000

Ring gear clearance

0.3350.645

Installation temperature for fitting starter ring gear

200230° C

Max. lateral runout of mounted starter ring gear

0.5

Ring gear width

(yellow colour)

18.6 18.4

*3 ® B arrin gto n Diesel Club


FLYWHEEL — 1816 REMOVING AND REPLACING FLYWHEEL Removing 1. Loos en mounting bolts on flywheel. Unscrew two op posite bolts, screw in guide mandrels Part number 40200077 (fig. 3218).

2. R emove rema ining flywhee l bolts, sc rew in F lywheel P os itioning H andles P art number 40201982 and slide off flywheel (fig. 3318). 3. Remove guide mandrels and flywheel positioning handles. Clean and check flywheel for damage.

Replacing 1. Screw guide mandrels into end of crankshaft and flywheel pos itioning handles into flywhe el (fig. 3418). 2. P lace flywheel on mandrels and push in against end of crankshaft.

Note: Ensure that locating dowel in crankshaft is aligned with hole in flywheel. 3. M eas ure length of flywhee l bo lts (fig. 3518). Note: F lywheel bo lts may s till be used if stretch does no t exceed 75 mm.

7/90

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FLYWHEEL — 1817 4. L ightly oil threads o f flywheel bolts, screw in two bolts, remove guide mandrels and flywheel positioning handles. Replace remaining flywheel bolts. 5. Tighten flywheel bo lts cross wise to 100 N.m and then to a further torque angle of 90° +10° (fig. 3618).

REMOVING AND REPLACING WEAR RING ON FLYWHEEL Removing and Replacing 1. Using a suitable puller and support pad, pull wear ring from flywheel (fig. 3718).

2. H eat new wear ring to approxima tely 150°C. 3. Insert new wear ring into mandrel P art number 40200268 (rounder edge of outside diameter facing forward). P lace mandrel on flywheel and knock into position (fig. 3818).

REMOVING AND REPLACING SPIGOT BEARING Replacing spigot bearing 1. Using su itable drift, knock out spigo t bearing from flywheel (fig. 3918).

Fig. 3918


FLYWHE EL 


1818

2. Turn over flywheel, ins ert new sp igot bearing and knock into flywheel (fig. 4018).

Fig. 4018

Note: The sp igot bearing can be removed and replaced with the flywhee l in pos ition using pu ller Part number 40200064. This requires removing the flywheel mounting bolts, and inserting both guide mandrels. Replace and tighten flywheel bolts to specification (fig. 4118).

F ig. 4118

MACHINING FLYWHEEL Operation Note I: To determine if the flywheel can s till be m ac hined, measure the thickness of the flywheel and compare the figures with spe cification. If the measurement is lower

than the specified value, minus material removed, the flywheel can no longer be used, and must be replaced. 1. To machine, clamp flywheel into a suitable lathe, machine and surface grind face (fig. 4218). 2. Remove flywhee l and che ck once more for surface heat cracks. Note II: If the flywheel is still cracked after machining, and the cracks cannot be removed to retain specifications for flywheel thickness, renew flywheel.

3. Using compress ed air, clean swarf from tapped holes for clutch pressure plate attachment. 4. R eplace flywheel, and tighten bolts to spe cification.

F ig. 4218

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FLYWHEE L  RE NEWAL OF STARTER RING GEAR

'

Operation 1. Remove flywheel (see page 1816). 2. P lace flywheel under a press. Support starter ring gear at several points, using supports of uniform height. 3. R apidly heat starter ring gear with a welding torch, and press flywheel from ring gear. 4. Check seating of ring gear on flywheel for score marks machine if necessary to specifications. Note I: Renew flywheel if score marks are excessive.

5. Heat new ring gear to specified tempera ture (see specifications), and press onto flywheel. Note II: When fitting new starter ring gear to flywheel, make sure that the ring gear is pressed on squarely. Ring gears on which teeth are damaged, can be turned around and used again. Note III: In some instances where no drillings are provided for the bolts holding the clutch pressure plate, it will be necessary to drill and tap the ring gear M10x15mm (fig. 4318).

6. When cooled, check flywheel and ring gear for runout. 7. R eplace flywhe el, (see page 1816).

Fig. 4318

1819



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SECTION 18-21 Turbocharger

Turbocharger 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Bearing housing C irclip Bearing Oring Turbine wheel and shaft P iston type seal rings H eat shie ld T hrust washer Spacer B earing (Thrust) Seal carrier/Thrust washer O il defle ctor Rivet Data plate E nd plate Allan cap screw C ompress or wheel S haft nut C ompress or housing S pringwasher and compres sor side clamping segment

21 22 23 24

Bolt T urbine housing Nut & bolt S pringwashe r and turbine side clamping segment



T U R B O C H A R G E R — 18 -2 2

9

T urbocha rger and M an ifold 1 Turbocha rger 2 Turbocha rger 3 Nut 4 Air intake manifold 5 Air intake manifold 6 Threaded insert 7 Spring washer 8 Gasket 9 Bolt 10 Bolt 11 P lug 12 S eal 13 P lug

7/90

14 15 16 17 18 19 20 21 22 23 24 25 26 27

Air intake pipe Hose Hose Bracket B olt Adapter Seal Air transverse pipe G as ket B olt Seal P Lug Shield Bolt

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TU R BO C HA R G E R — 1823

Tu rbocharge r C ross sec tion

TO R QU E S P E C IF IC AT IO N TU R BO C HA R G E R Oil return manifold to turbocha rger................................... Securing nut for oil return fitting to timing housing (side) Oil return tube fitting to timing housing (top) ................ Inlet manifold to cylinder heads ......................................... T urbocharge r to exhaust manifold ..................................... Oil supply pipe to turbocharger.......................................... Oil supply pipe to cylinder bl o c k ........................................ Heat shield to timing housing (422T)................................. Heat shield to oil return manifold (424T)......................... C onnec ting manifold to inlet manifold LHRH ............... Air transverse pipe .....................................................................

M8 M26x 1,5 M 26x 1.5 M8 M10 M8 M 14x 1,5 M16 M8 M10 M8

25 30 120 25 50 25 25 150 25 50 25

N.m N.m N.m N.m N.m N.m N.m N.m N.m N.m N.m

7/on


TUR BOC HAR GE R 


1824

Introduction The G arrett/AiR ese arch T urbocharger for internal com bustion engine application comprises of a gas turbine and radial compressor, which utilize a common shaft. The turbine and compressor wheels are mounted at opposite ends of the shaft, which is enclosed and supported by the centre housing. The turbine and compress or wheels are enclosed by cas t housings attached to the centre housing. After the engine is started, the flow of exhaused gases from the engine pass throught the turbine housing and cause the shaft assembly to rotate. The compressor wheel mounted at the opposite end of the shaft draws ambient air into the compressor housing, compresses the air and delivers it to the engine. During operation, the turbocharger responds to the engine load demands by reacting to the flow of exhaust gasses. As the power of the engine increases, the flow of the exhaust also increases and the speed and output of the rotating assembly increases proportionately.

REMOVING AND REPLACING TURBOC HAR GE R Removing 1. Uns crew exhaust pipe from turboc harge r manifold. 2. Uns crew air pipe from exhaust brake cylinder. 3. Remove oil feed and return pipes to turbocharger, (fig. 4418).

4. Uns crew air intake hose clips (fig. 4518).

Fig. 4518

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TURBOCHAR GE R  5. Remove manifold between turboc harge r and 'coo ler (fig. 4618). 6.

Unscrew turbocharger from exhaust manifold and remove.

Replacing Note: P rior to replacing turbocharger, the intake manifold, and manifold flange ahead of the compressor, exhaust manifold, and exhaust pipe, as well as oil feed and return pipes, must be inspected thoroug hly for foreign particles, dirt and damage. Blanking plugs on openings of turbocharger should be removed shortly before replacement. F ill bearing housing with clean engine oil through oil inlet, before connecting oil feed pipes. Turn rotating parts by hand to give bearings a coating of oil.

1. F it turbocharge r with new gasket to exhaust manifold, and tighten bolts to 50 N.m. 2. R eplace and tighten manifold between turbocharge r and air cooler (fig. 4718).

3. C onnec t oil feed and return pipes to turbocha rger. 4. Replace air inlet hose cla mps and tighten (fig. 4818). 5. R eplace air inlet pipe to exhau st brake. 6

. Attach exhaus t pipe to man ifold and tighten bo lts to specification.

Fig. 4818

1825

B0C ^ a rr in g to n Diesel Club T U R B O C HA R G E R -


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18-26

TURBOCHARGER TROUBL ESHOOTING C ondition

P ossible Cause

C orrection

Unusual exhaust gas density and power loss.

Insufficient air and charge pressure to low.

Check flange and hose connections of turbocharger air pipe for leaks.

Dirt on inside of compressor housing.

Remove and clean compressor housing.

C logged air cleaner (excessive vacuum ahead of compressor, also oil leak on compressor side.)

Clean air cleaner or replace filter cartridge. Check intake. Check pipe behind turbocharger for leaks.

Exhaust pipe behind turbocharger, or silencer dirty or damaged.

Clean or repair. Check opening of engine brake valve.

Leaks at connections and flanges of air and exhaust pipes.

Check flange and hose connections, replacing gaskets if necessary.

R otor scraping due to excessive bearing play.

Remove pipes and check housing on turbine and compressor sides for signs of scraping. Repair or replace turbocharger in case of wear.

Unusual noise (e.g. whistle)

C hecking Turbocha rger in vehicle Disc onnec t air intake manifold. Turn rotor, chec king for easy and uniform running. If nec essary turn back and forth several times until rotor is freed of oil carbon deposits. Th e turboc harge r rotor has gyros cop ic stab ilization , and runs in fixed bearings. To check, move rotor.in and ou t. If there is no contact on the turbine or charger sides, this means that the end play is correct. Move and turn the rotor up and down, if no scraping occurs, the side play is also correct.

Turbocha rger o il leaks The bearing hous ing on all types o f turboc harge rs used on ADE engines are fitted with oil controlling piston type rings, to provide a seal between the oil and the air/exhaust gas. The function o f these s eals is based on the pressure built up in the compressor housing. However there could be a vacuum at fast idle speed of while coasting, which would favour oil leakage and coating of the inlet ports with oil. The amount of oil lost in this way is extremely low and has no, measurable influence on the engines oil consumption.

F itting a R econditioned T urbocharger P rior to fitting the turbocharger, the inlet and flanged manifold ahead of the compressor, the exhaust manifold and the exhaust pipe, as well as the oil feed and return pipes, must be inspected very thoroughly for dirt and damage. P lugs on the openings of the turbocharger sho uld be removed only shortly before fitting. F ill the bearing housing w ith clean engine o il through the oil inlet port before connecting the oil feed pipe. In doing so, turn the rotating parts by hand to give the bearings a coat of oil.

If oil covered inlet ports are found when servicing, there is no reason to remove the turbocharger as long as an inspection of the turbocharger did not show defects. Another cause for oil leaks could be a damaged (deformed) or clogged oil return pipe. The reduced cross sec tion size of the pipe would lead to an increase in flow resistance, cau sing the oil level in the turbocharger to rise and oil to leak past the seals on the turbine and compresso r sides. In this case clean or replace the oil return pipe. '

&ar*Hngt°n Diesel Club


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TURB OC HAR GE R — 1827 CHECKING TURBOCHARGER Measuring Shaft End Play 1. C lamp turbocharger in a vice fitted w ith soft jaws (turbine side facing up). 2. F it dial gaug e in holder. 3. P lace dial gauge measuring tip on sh aft end of turbine wheel (fig. 4918). 4. P ush down turbine sha ft and set dial gauge to “0” . 5. Push turbine shaft up agains t dial gauge and read end play. Maximum permitted end play =0,16 mm.

Measuring Side Play Note: Side play is measured only on turbine side.

1. P ush turbine wheel to one side, measure gap between turbine wheel and housing with a feeler gauge, note measurement (fig. 5018). 2. P ush turbine wheel in oppo site direction, measure gap at the same point with a feeler gauge, note measurement. 3. The differenc e between the two measurements is the clearance = 0,45 mm. Note: Measure at least two different points.

Fabricated Tool

Fig. 5118

A Knurled surface B Ada pted to available rotor



TURBOCHAR GE R — 1828 DISMANTLING AND ASSEMBLING TURBOCHAR GE R Dismantling Note: Clamp is selfmade to drawing on page 1827.

1. Mark pos ition of turbine hous ing in relation to bearing housing. 2. Unlock locking plates on clamping segments of turbine housing (fig. 5218).

F ig. 5218

3. Uns crew bolts from turbine hous ing and remove with clamping segments and lock plates. 4. Using a so ft faced hammer knock turbine hous ing and bearing housing apart (fig. 5318). Note: Ensure that blades of turbocharger are not damaged when removing housing.

Fig. 5318

5. Mark position of bearing housing in relation to com pressor back plate and compressor housing (fig. 5418).

Fig. 5418

6

. U nscrew compress or housing from back plate (fig. 5518).

7. Loos en and remove comp ress or housing from bearing housing, with light knocks from a soft faced hammer. Note: Ensure that blades of compressor are not damaged when removing compressor housing.

Fig. 5518

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TURB OC HAR GE R  8. Insert bearing ho using into clamp (self made), and unscrew compressor shaft nut (fig. 5618). Note: When unscrewing shaft nut, do not damage the shaft by twisting. Always use a Tsocket spanner to unscrew shaft nut, to avoid bending shaft.

9. Heat comp ress or wheel with suitable hot air blower (fig. 5718).

10. P ress sha ft from comp res so r wheel (fig. 5818). Note: The heat shield should be centred to avoid damage to piston ring seals and shielding.

11. Remove bearing hous ing and heat shield from shaft. 12. Unscrew compresso r back plate and remove with seal and Oring (fig. 5918).

Fig. 5918

1829



TURBOCHAR GE R — 1830 13. Remove oil deflec tor (4), spacer (3), thrust bearing (2), and thrust washer (1) (fig. 6018).

14. Remove compress or bearing from housing (fig. 6118).

15. Remove circ lips and turbine bearings from bearing housing (fig. 6218).

ASSEMBLING Note: Clean and check all parts for damage. Check housing and blades of turbine and compressor wheels for cracks, signs of foreign particles and scraping. Check piston ring type seals and grooves for wear.

1. Check turbocha rger rotor shaft for run out. P lace shaft on two Vblocks at height of bearings and measure runout 20 mm from end of rotor shaft, using a dial gauge. Maximum permissible runout = 0,007 mm, (fig. 6318).

Fig. 6318

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J f l r H n g t o n Diesel Club


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TUR BOC HAR GE R  2. Insert circlip in bearing housing, lubric ate turbine end bearing with engine oil, and insert with 2nd circlip (fig. 6418). Note: Insert circlips so that the rounded side faces bearing.

3. Turn bearing housing around and insert compress or end bearing with circlips.

4. Ins ert seal rings on to shaft, with gaps set at 180° in relation to each other (fig. 6518).

5. P lace heat shie ld over seal rings on rotor shaft (fig. 6618).

6. F it bearing housing over seal rings, so that the seal ring gap is at 90°, in relation to the oil inlet and outlet flanges (fig. 6718). Note: The heat shie ld s hould s till turn eas ily after fitting the bearing housing.

F ig. 6718

1831



TURBOCHAR GE R — 1832 7. Insert thrus t washer (1) and space r (3). Fit thrust bearing (2) with oil groove facing bearing housing, and dowel pin holes in alignment with dowel pins in bearing hou sing. F it oil deflec tor (4) (fig. 6818).

F ig. 6818 8. Lu bricate Oring with brake cylinder grease, and insert into compressor end plate (fig. 6918). 9. Insert seal rings onto seal carrier with gaps set at 180° in relation to each other. 10. F it seal carrier with seal rings into compres so r end plate, so that the piston ring gap is at 90°, in relation to the oil inlet and outlet flanges.

F ig. 6918

11. C oat se aling surface between bearing hous ing and compressor end plate, with a suitable sealing compound. 12. F it comp ress or end plate, lining up marks on bearing housing. Coat bolts with Loctite, insert and tighten to 8 N.m (fig. 7018).

F ig. 7018

13. F it O ring to compres so r end plate (fig. 7118).

F ig. 7118

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TUR BOC HARG ER — 1833 14. Heat compress or wheel to a maximum of 130°, and fit onto rotor shaft (fig. 7218).

15. C oat rotor sh aft nut with Lo ctite, and fit to shaft, tighten nut to 12 N.m (fig. 7318).

16. F it compressor housing, lining up marks on compress or end plate. Fit clamping segments, ins ert bolts, and tighten to 7 N.m (fig. 7418).

17. Attach turbine housing, lining up with marks on bearing housing. F it clamping segments, and lockplates. Insert bolts with high temperature grease, and tighten crosswise to 20 N.m. 18. Lo ck mounting bo lts (fig. 7518). 19. C heck turbocharger shaft for free running. Note: F ill bearing housing through oil inle t port with engine oil prior to operating turbocharger.

Fig. 7518

B0C ^ a rr in g to n Diesel Club EXHAUST BRAKE 


1834

Introduction Depending on application the ADE 420 Series Engines are fitted with an exhaust brake consisting o f a butterfly valve, which pivots on a spindle within the exhaust manifolds. The butterfly valves are s ituated at the flywheel end of each manifold. The butterfly valves are actuated by a pneumatically operated lever, which is secured to the butterfly valve spindles, where the spindles protrudes through the housing. When the footoperated exhaust brake valve (located on the floor of the cab, drivers side) is pressed, compressed air flows past the valve and enters an air operated cylinder. A piston, ins ide the cylinder and attached to the spind le levers, pushes the levers towards the rear of the vehicle and thus closes the butterfly valves. At the same time, the fuel supply to the injectors is cut off (ie the speed control lever moves to the stop position). The back pressure build up in the exhaust manifold exerts a braking effect via the transmission, to the wheels of the vehicle.

CHECKING EXHAUST BRAKE Checking exhaust brake adjustment 1. Uns crew and remove exhaust pipe from manifold. 2. Check to see if the engine brake retarder valve is wide open, and marks on engine brake shaft, and valve are in alignment (fig. 7618).

3. Operate engine brake and chec k to see if retarder flap is closed completely (fig. 7718).

REMOVING AND REPLACING EXHAUST BRAKE VALVE AND SHAFT Removing 1. Unscrew and remove exhaust pipe from manifold. 2. D isconn ect engine brake cylinder. 3. Uns crew and remove lever ope rating brake valve. 4. Remove spac er and brac ket (fig. 7818).

Fig. 7818

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EXHAUST BRAKE — 1835 5. Knock out engine brake shaft, and remove valve (fig. 7918).

Fig. 7918 6. Gently knock out shaft bushes from exhaust manifold, (fig. 8018).

Fig. 8018

Replacing 1. Knock new shaft bushes into exhaust manifold, so that the engine brake valve has an end play of 0,2 to 0,5 mm (fig. 8118).

Fig. 8118

2. Insert engine brake shaft through valve, so that marking on shaft is in alignment with engine brake valve, (fig. 8218).

Fig. 8218



EXHAUST BRAKE — 1836 3. F it stop brac ket over valve opera ting sha ft and insert spacer. 4. F it brake operating lever onto sha ft, so that with the valve fully open the brake cylinder can be fitted without tension (fig. 8318).

Fig. 8318

Note: Fine adjustment can be made on the brake cylinder. On turbocharged engines the stop of the valve operating lever must rest against the bracket, when the engine brake valve is fully open (fig. 8418).

5. T ighten clamp bolt of engine brake cylinde r so that the shaft has an end play of 0,2 to 0,5 mm. 6. F it engine brake cylinder. 7. Operate engine brake and check to see if the engine brake valve is fully closed. 8. Replace exhaust pipe, fitted with a new gasket, and securely tighten nuts.

REMOVING AND REPLACING STARTER MOTOR Removing 1. Disconnect battery. 2. D isco nnec t cables to starter motor. 3. U nsc rew and remove mounting n uts (fig. 8518). 4. Remove starter motor from below.

Replacing 1. F it starter motor onto studs from be low (fig. 8618). 2. R eplace nu ts and tighten to 80 N.m. 3. C onnect cables to starter motor. 4. C onnec t battery.

7/90

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SECTION 18-37 A l t er n at o r an d St ar t er M o t o r

SECTIONAL VIEW OF THE K 1 CLAWPOLE ALTERNATOR

B0C ^ d rri n g io n Diesel Club


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ALTERNATOR AND STARTER MOTOR — 1838 ALTERNATOR P recautions The diodes in the alternator function as oneway valves and the transistors in the regulator/control box operate as fast switches. Both are accurate and sensitive. They do not wear out and seldom require adjustment, but because they are sensitive to voltage changes and high temperature, the following precautions are vital to prevent them from being destroyed. (a) DO NOT disconnect the battery while the engine is running. This will cause a voltage surge in the alternator charging system that will immediately ruin the diodes or transistors. (b) DO NOT disc onnec t lead without first stopping the engine and turning all electrical switches to the off position. (c) DO NOT cause a short circuit by connecting leads to incorrect terminals. Always identify a lead to its correct terminal. A short circuit or wrong connection giving reverse polarity will immediately and permanently ruin transistors or diodes. (d) DO NOT co nnect a battery into the system without checking for correct polarity and voltage. (e) DO NOT “flash” connections to check for current flow. No matter how brief the contact the transistors may be ruined.

Maintenance The alternator charging system will normally require very little attention. It should be kept free from buildup of dirt, and a check made if it fails to keep the battery charged.

(a) R egularly inspect the driving belts for wear and correct tension. It is important to ensure that all belts on a multiple belt drive have equal tension and are each carrying their share of the load. Slack belts will wear rapidly and cause slip which will not drive the alternator at the required speed. Drive belts which are too tight impose severe side thrust on the alternator bearings and shorten their life. P eriodically ensure that the alternator is correctly aligned to the drive. (b) Do not replace fau lty belts individually in a multibelt system. A complete matched set of drive belts must always be used. (c) K eep the alternator clean with a cloth moistened in a suitable c leaning fluid. Ensure that ventilation slots and air spaces are clear and unobstructed. (d) Remove any dirt accumulated on the regulator/c ontrol box housing, and ensure that cooling air can pass freely over the casing.

Testing the Alternator in P osition F irst check the driving belt for condition and tension. The nominal hot outputs 6 000 r/min (alternator speed) are as follows:— 14V — 35A 28V — 28A 28V — 55A These figures may be exceeded s lightly when the a lternator is running cold. A dust proofed alternator can be fitted as an option, depending on application.

Trouble Shooting If a malfunction should develop in the current generating system, it must be kept in mind that trouble sources may exist in the battery, cables or other locations besides the alternator or regulator. The most common fault symptoms are listed in the chart below with probable causes and appropriate corrective measures:

Cause

Correction

Battery is dead or insufficiently charged: 1. Open circu it or con tact resistance in charging circuit

1. Remove open circu it or contact resistance

2. Defective battery

2. R eplace battery

3. Defective alterna tor

■ 3. Have alternator repaired in authorized workshop

4. Defective regulator

4. Replace regulator

5. VBelt too loose

5. Tighten VBelt

B0C B arr in gt o n

Club


S e c t io n :

18 - V ariou s

ALTE RNATO R A ND STARTER MOTOR — 1839 Charge indicator lamp does not burn with engine stopped and ignition on: 1. Ind icator bulb is burned out

1. R eplace with new bulb

2. Dead battery

2. R emove battery for cha rging

3. Defective battery

3. R eplace battery

4. Loos e or damaged cables

4. R eplace or tighten cables


5. R eplace regulator

6. S horted po sitive diode in the alternator

6. Have alternator repaired in authorized worksho p

7. Worn carbon brushes

7. R eplace brushes

8. Oxide layer on sliprings, or broken wire in rotor winding

8. Have alternator repaired

Charge indicator lamp continues to burn brightly during higher engine speeds: 1. C able D + /61 is s horted to ground

1. R epair or replace cable

2. D efective regulator

2. Replace regulator

3. Overvoltage protec tion device defective

3. R eplace overvoltage protec tion device

4. Defective rectifier, dirty sliprings , short in cable “DF " or in rotor winding

4. Have alterna tor repaired in authorized workshop.

Charge indicator lamp burns brightly with engine stopped, but on dims or glimmers with engine running: 1. P oor con nec tions (contact) resistance) in the charging circuit or in the cable to the charge indicator lamp

1. Remove con tact resistance


2. R eplace regulator

3. Defective alternator

3. Have altern ator repaired

Charge indicator lamp flickers: 1.

1.

R eplace regulator

C ontact regula tor may be inco rrectly adjusted or regulating resistor is burned out

STARTER MOTOR General S liding G ear S tarter Motor Type KB This s tarter motor, designed for large internal combustion engines, operates in two stages in order to protect the pinion and ring gear. The armature is fixedmounted in the driveend bearing plate and in the commutator end shield; the armature shaft is hollow and is designed to serve as the housing for a multidisc clutch on its drive end. This clutch housing is sealed on the end face by a cover on which a rolling or plain bearing is mounted to support the armature in the driveend bearing plate. On the commutator end the armature is supported in a plain bearing. A solenoid switch for the pinion and a control relay for the two switching stages are flanged to the commutator end shield. In this type of starter motor the pinion is shifted forward (sliding gear) by the solenoid switch acting through an engagement rod leading through the hollow armature shaft. The resistance, or opposing, winding located in the solenoid switch of the starter motor serves to adjust the starter motor torque when meshing. In order to prevent

oil, dirt, or dust penetrating into the inside of the starter motor, a radial loptype oil seal is fitted on the drive end bearing plate. The commutator end shield and the solenoid switch are enclosed by an end cover or a cover band. The drive spindle, on the spiral splines of which the multidisc clutch is mounted, is supported in a roller bearing in the driveend bearing plate and in a needle roller bearing in the armature shaft. The pinion is joined in a positive mechanical connection with the spindle by means of a feather key. The solen oid sw itch is de signed to drive the pinion forward in two stages. For this purpose it is fitted with a locking device, with a trigger, a stop plate, and a release lever. Th is type of starter mo tor is also fitted with a multidisc clutch between the armature and pinion, but in this case the clutch does not have an initial meshing stage.

* 9 ! B a r r i n g t o n D iesel C lub


ALTE RNATOR AND STARTER MOTOR 

1840

Maintenance Bas ic P oints When wo rk is performed on the electrical pa rts of the installed starter motor the danger of shortcircuits exists. F or this reason it is strongly recommended that be fore such work is started the ground cable be disconnected from the battery. Do not lay tools on the battery!

Brushes In those cases where the brushes are easily accessible, they should be checked from time to time to see that they are in good c on dition. A fter removal of the end cover or the cover band, the best procedure is to use a hook to lift the spring which presses the carbon brush against the com mutator (do not bend the spring to the side when doing this, and do no t lift the spring farther than neces sary); a check can then be made to see if the brush can move freely in its holder. The brushes and the brush holders must be free from dust, oil, and grease. If these parts are dirty or if they tend to stick, they should be cleaned with a clean cloth (because the threads c atch eas ily, do not use co tton waste or waste rag). Do not work on the bright rubbing surfaces of the brushes with emery paper, file, or knife. Clean the brush holder out well with dry compressed air. If a brush is broken, if the soldered connection has come open, or if the brush has become so worn that a danger exists that the spring or the shunt (pigtail) leading to the brush can contact the brush holder, the brush must be replaced. When installing the brush be sure that the spring is seated correctly on it. When the engine is given a major overhaul, the brushes should be replaced in any event. Every time the brushes are replaced the commutator should be turned down.

C ommutator T he c om mu tator sh ould have a s mo oth unifo rm s urfac e and must be free from oil and grease. Dirty commutators should be cleaned with a clean cloth (not with cotton waste). C omm utators that have become sc ored and out of round through use must be roughturned, the mica insulation undercut, and then precision turned in a suitably equipped workshop. In no case should o nly emery paper or a file be used to work on a commutator.

S e c t io n :

18 - V ariou s



S e c t io n :

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ALTERNATOR AND STARTER MOTOR — 1841 REMOVING AND REPLACING ALTERNATOR Removing 1. D isconn ect battery conne ctions. 2. Dis connec t elec trical connec tions to alternator. 3. Unsc rew lock nut of Vbelt adjuster and release tension (fig. 8718).

4. Unsc rew and remove alterna tor mounting bolts and lift off alternator (fig. 8818).

Replacing 1. F it alternator to mounting bracke ts and tigthen bo lts to 50 N.m (fig. 8918). 2. Insert bolt in Vbelt adjuster, on alternator.

3. F it Vbelt and tension, using s pecial too l (fig. 9018). Should this tool not be available, the Vbelt tension can be adjusted as follows : Without using undue pressure it should be possible to depress the Vbelt approximately 10 mm, with the thumb applying pressure at a po int midway between the water pump and alternator pulley. 4. Tighten Vbelt tens ione r lock nut.

Fig. 9018


RE PLACING VBELT 


1842

1. Uns crew lock nut of Vbelt adjuster, and release tension (fig. 9118). 2. L ift Vbelt from pulleys.

F ig. 9118

3. F it new Vbelt and tighten.

Note: See fig. 8918 for mounting bolt torque tensions.

4. Check Vbelt for correct tension using special tool (fig. 9218). Should this tool not be available, the Vbelt tension can be adjusted as follows: W ithout using undue pressure it should be possible to depress the V belt approximately 10 mm, with the thumb applying pressure a t a point midway between the water pump and alternator pulley.

S e c t io n :

18 - V ariou s

B0C ^ a rr in g to n Diesel Club


S e c t io n :

18 - V ariou s

SECTION 18-43

_________________

Power Steering Pump Introduction The ADE 420 Series E ngines are fitted with two types of Rotary, Power Steering Pumps, both of which operates as follows: When the drive sha ft and its rotor are turned, the vanes are guided in slots and being radially mobile are pressed against the guide path of the cam ring by the action of centrifugal force and oil pressure. Two successive vanes are classed as a cell (a total of 10), which are laterally restricted by the pressure plates. Each cell delivers the maximum effective cell volume twice per revolution. The suction and pressure chambers are arranged so that the hydraulic and radial forces acting on the rotor, will neutralize each other. The coverend front plate, and the drive end front plate are provided with 4 grooves so that the pressurized oil reaches the internal face o f the pump vanes, which will then be supported by the centrifugal force. From the pressure chamber the oil travels through holes to the flow restricting valve, and by the way of a throttle restriction to the pressure line. The reduced pressure behind the throttle restriction is transmitted via holes to the springloaded end of the flow restricting piston, and therefore to the relief valve. Increasing speed or pump delivery will produce a growing pressure drop behind the throttle restricter and also against the spring end of the valve piston. As soon as the hydraulic power (pressure differential times piston area) exceeds the spring force, the piston will move towards the spring, and the oil delivered in excess will flow through the now exposed ejection hole into the suction duct of the pump. As a result, an almost cons tant oil flow fo r the steering gear is provided throughout the entire speed range.

DISMANTLING Removal of Rotor and Cam Ring ZF High P ressure Vane P ump 7673 1. Loosen nut on drive shaft and pull off Vbelt pulley. 2. Pull out spring clip from groove in pump housing (fig. 9318).

Fig. 9318



POWER STEERING PUMP — 18-44 3.

Remove cover, compre ss ion spring and face plate from housing (fig. 9418).

4.

T ilt pump body and remove cam ring and rotor (fig. 9518).

R emoval of Drive S haft 5.

Remove circ lip (fig. 9618).

6. K nock drive s haft from hous ing (fig 9718).

Fig. 9718

S e c t io n :

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S e c t io n :

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POWER STEERING PUMP — 1845 7. Us ing a hide faced hammer knock drive end face plate from housing. ' 8. remove volume c ontrol valve. 9. Using a suitable punch knock needle bearing and shaft seal from housing (see fig. 9818). 10. Remove Orings from housing, remove fitted pin. Take Oring from drive end face plate.

11. The bearing can be pressed from drive sha ft after removing circlip (fig. 9918).

F ig. 9918

Removal of F low and P ressure R es triction Valve Z.F. High P ressure Vane P ump 7637 1. R emove blank ing plug from housing (fig. 10018). 2. Remove compression spring and valve completely from housing bore.

Dismantle, Inspection and Assembly of Flow and P ressure R es triction Valve 1. C heck pressure and flow res triction valve for score marks and wear. The flow control piston should not bind in housing bore. Check tolerance number on housing (on face end of valve bore) and on piston (Item 1) (fig . 10118).

F ig. 10118

^ a r r i n g t o n D iesel H u b P O W E R S T E E R IN G P U M P -


S e c t io n :

18 - V ariou s

1 8-4 6

2. Uns crew valve seat screw from press ure restriction valve (do not clamp in vice). Ensure that none of the washers, the ball, the spring guide and the co mpression springs are lost. The thickness of the washer is critical for the response range of the pressure relief valve. To prevent the possibility of damage, the washers available prior to dismantling must be replaced (fig. 10218). 3. Clean control valve and valve sc rew and blow out with compressed air. Reinsert compression spring, guide pin and ball. Scre w valve seat scre w into co ntrol piston together with previously installed washers and tighten.

1 VALVE PISTON 2 3 4 5 6

COMPRESS ION SPRING PRESSURE RELIEF VALVE SPRING GUIDE PIN VALVE BALL ADJ USTING WASHERS VALVE SEAT SCREW

7 COMPRESS ION SPRING VOLUME CONTROL VALVE 8 BLANKING SCREW WITH SEALING RING

Installation of Flow and Pressure Restriction Valve 4. F irst insert assembled valve piston with thin sha ft into bore. Ch eck fo r corre ct toleranc e (fig. 10318).

5. S lide compres sion s pring on valve piston and insert blanking plug into thread hole placing sealing washer underneath (fig. 10418).



S e c t io n :

18 - V ariou s

POWER STEER ING PUMP  P reassembly of P ump Housing

,

Note: P rior to asse mbly, clean all parts, moisten s lightly with ATF oil and replace all sealing rings and Orings. 1. Us ing a su itable mandrel, press needle bearing into housing (fig. 10518).....

... until face end of needle bearing is 37,0 to 37,2 mm from face end of housing (fig. 10618). Note: The needle bearing is installed only in pumps with Vbelt drive.

2. P ress shaft seal into housing with a mandrel. Install seal with bearing grease between sealing lips (fig. 10718). 3. Using a socket spanner, screw blanking plug into pump housing and tighten. 4. P lace Oring into bottom groove in housing.

5. I nse rt fitted pin into hole provided (fig. 10818).

F ig. 10818

1847



POWER STEERING PUMP — 1848 Assembly and Installation of Drive Shaft 6. P ress ball bearing on drive sh aft and replace circlip. F it key (fig. 10918).

7. Inse rt preass embled drive sha ft into housing until ball bearing rests against housing flange (fig. 11018).

8.

Inse rt cir clip loca ting ball bearing (fig. 11118).

R eplacement of Drive End Face P late 9. 10.

Inse rt Oring into groove in neck of face plate. S lide face plate on pin as shown and press with neck into housing (fig. 11218).

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POWER STEERING PUMP — 1849 Installation of Cam Ring and Rotor 11. Ins ert Oring (1) into groove in housing (fig. 11318).

12. Insert cam ring. The sma ller hole holds the hollow pin and the two larger ones are above the ducts of the face plate. The cast, half arrow points towards driving direction of pump (see fig. 11418).

Fig. 11418

13. F it rotor with s mooth bore on drive shaft (fig. 11518).

14. Insert the ten vanes with the roundedo ff outer surfaces facing the cam ring, into slots of rotor (fig. 11618).

Fig. 11618



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POWER STEERING PUMP — 1850 R eplacement of E nd Face P late and Cover 15. F it face p late on cam ring as shown. The pin is in one of the two smaller holes (fig. 11718).

16. Inse rt Oring (1) (fig. 11818).

17. I nse rt comp ress ion spring into bore of face plate. P os ition cover with recess inwards and push into hous ing u ntil the circ lip can be inserted (fig. 11918). 18. Inse rt flow and press ure restriction valve.

Vickers High Pressure Oil Pump VT27 DismantlingR emoval of R otor and Cam R ing 1. Remove screws on pump hous ing to which ho using cover is connected, and remove pump housing. 2. Remove compre ss ion spring from thru st plate. Mark thrust plate, cam ring and housing cover together (refer to arrow) (fig. 12018).

1

O-RING

4

CAM RING

2

THRUST PLATE

3

COMPRESSION SPRING

5 6

O-RING HOUSING COVER


S e c t io n :


18 - V ariou s

POWER STEERING PUMP — 1851 3. R emoving thrus t plate from fitted pins and take off cam ring (fig. 12118). •

F ig. 12118 2

THRUST PLATE

6

HOUSING COVER

4

CAM RING

7

MARKING LINE

4. Remove rotor with pump vanes from drivesha ft spline (fig. 12218).

F ig. 12218 4

CAM RING

6

HOUSING COVER

7

M A RK ING LINE

3

FITTED PIN

9

RO TO R

10

VANES

a.

OIL INFLOW FROM SUPPLY CONTAINER

b.

HYDRAULIC OIL OUTFLOW ON CAM RING

c.

INTAK E B O R E S

5. Remove Oring from ho using cove r (Item 1 & 5) (fig 12318). 6. Remove volume co ntrol valve. 7. C lean all parts thorou ghly and rinse.

1

O-RING

4

CAM RING

2

THRUST PLATE

5

O-RING

3

COMPRESSION SPRING

6

HOUSING COVER



S e c t io n :

18 - V ariou s

POWER STEERING PUMP — 1852 R emoval and D isma ntling of Volume C ontrol and P ressure R elief Valve 1. K nock locking pin from pump housing. 2. Remove blanking co ver of volume co ntrol valve, and compression spring from pump housing (fig. 12418). N o t e : C aution! The compres sion s pring may push off the blanking co ver and the colume co ntrol valve after removing the loc king pin. If the blanking cover remains in hous ing, loosen by applying light hammer blows against cover. Be sure not to damage the volume control valve.

1

BLANKING COVER

4

VOLUME CONTROL VALVE

2

LOCKING PIN

5

COMPRESSION SPRINGS

3

O-RING

6

PUMP HOUSING

3. C lamp volume co ntrol valve at its unground end in a vice and unscrew valve screw of pressure relief valve. Ensure that no adjusting screws are lost. Remove valve cone and compression spring from volume co ntrol valve (fig. 12518). 4. P rior to replacement, chec k ground surface of volume co ntrol valve and bore in pump housing for wear and damage. If the surfaces are showing score marks, replace complete oil pump. Never replace volume control valve only.

Special Tool S elfmade (fig. 12618).

A

INSTALLA TION TOOL

B

INSTALLAT ION TOOL

C

INSTALLA TION SLEEVE

F ig. 12518 •

- *ODj

1

B L A N K I N G C O V E R W I TH O - R I N G

2

VOLUME CONTR OL VALVE

3

C O M P R E S S I O N S P R I N G F O R P R E S S U R E R E L I E F V A LV E

4

VALVE CON E

5

ADJUSTING WASHER

6

VALVE SCREW

7

C O M P R E S S I O N S P R I N G F O R V O L U M E C O N T R O L VA L VE


S e c t io n :


18 - V ariou s

POWER STEERING PUMP 

1853

R eplaceme nt of Drive Sha ft and Se aling Ring

w /M m t 1. P ress drive from ho using cover, paying attention to shell halves (Item 10) (fig. 12718).

14--------------R

2. L ift oil seal from hous ing cover using a screw driver.

-

13

Fig

12

tl

10

9

\\/

i — ty

8

7

6

8

12718

1 ORING 2 PUMP HOUSING 3 THRUST PLATE 4 OIL GUIDE PLATE 5 COMPRESSION SPRING 6 CAM RING 7 ROTOR WITH PUMP VANE

3. P lace both shell halves on drive shaft, then press drive shaft into housing cover (fig. 12818). N o t e : The shell halves determine the end play of the drive shaft, which is maximum 0,7 mm for new high pressure oil pumps and sho uld not be more than 1 mm for used pumps. Replace high pressure oil pump, if end play is higher.

Fig. 12818 10

SHELL HALF

11

DRIVE SH AF T

14

HOUSING COVER

4. P ress bearing bush with installa tion tool into housing cover (fig. 12918).

Fig. 12018 12

BEARING BUSH

14

HOUSING COVER

B

INSTALLATION TOOL

8 9 10 11 12 13 14

ORING BEARING BUSH SHELL HALF DRIVE SHAFT BEARING BUSH OIL SEAL HOUSING COVER



S e c t io n :

18 - V ariou s

POWER STEERING PUMP — 1854 5. R eplace assembly sleeve on drive shaft and press oil seal into housing cover with installation tool (fig. 13018).

13

OIL SEA L

14

HOUSING COVER

A

INSTALLATION TOOL

Installation of Rotor and Cam Ring 1. Mois ten all parts with ATF oil. 2. Install volume control valve. 3. P lace rotor on drive shaft so that the countersunk end of the splined bore faces housing cover. 4. P lace cam ring on fitted pins so that the respective markings on the housing cover and on the cam ring are in alignment (fig. 13118).

11

DRIVE SH AF T

14

HOUSING COVER

16

MARKING LINE

a Note: When a new cam ring is installed, position it so that the hydraulic oil bores are located accurately above the recesses in the housing cover (Item 4 & 5, fig. 13218). 5. Insert pump vanes into slots of rotor so that the rounded ends are facing outwards toward the cam ring. 6. P osition thrus t plate on cam ring and fitted pins lin ing up markings (fig. 13218). N o t e : The outlet holes for the hydraulic oil sho uld be above the hydraulic oil bores of the cam ring (Item 5).

a

OIL INFLOW FROM SUPPL Y CONTAINER

b

HYDRAULIC OIL OUTF LOW ON CAM RING

1

ROTOR

2

PUMP VANE

3

HYDRAULIC OIL UNDER PUMP VANE

4

R E C E S S O N H O U S I N G F O R I N L E T O F H Y D R A U L IC O I L

5

INTO HYDRAULIC OIL BORE HYDRAULIC OIL BORE

7

INTAKE BOR ES

6

CAM RING

8

DRIVE SHA FT

TO RQU E S P E C IF IC AT IO NS POWER STEERING PUMP Steering pump to timing housing .

M10

60 N.m

1 ^ 5$ B a r r i n g t o n D ie se l Club


Se ct io n s:

19 thru 21 (E N D )

SECTION 19-1 Cooling System

Water Pump 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

Water pump S haft C arbon ring seal Impeller Sleeve C eramic ring C irclip Hub Gasket Spring washer Bolt R epair kit R epair kit Thermostat Seal P ulley P ulley Bolt Spring washer

20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38

Pipe P ipe Co upling nut Ferrule Clamp Nut Lockwasher Bolt Water outlet Water inlet Bolt Gasket Bolt Bolt Spring washer O utlet adapter Gasket Spring washer Bolt


COOLING SYSTEM 


Se ct io n s:

19 thru 21 (E N D )

192

Cooling System S tan da rd V ers ion

Special application

S tarts to open at °C

79 + 2

71 ±2

S troke in mm

min 8

min 8

F ully open at °C

94

85

T he rmo sta t

Coolant Pump S pecifications and pump illustration can alter depending on application

S haft dia.

15,039 15,028

Dim. „A '! Impeller bore

Bearing dia.

15,018 15,000 54,994 54,981

Dim. ,,B’ Housing bore

P ulley sh aft dia.

54,970 54,940 25,061 25,048

Dim. „C ” P ulley flang e bore

Dim. „D "

Distance impeller to housing

Dim. ,,E"

F lange dia. for pulley location

25,021 25,000 1 ,0 - 1,4

55.970 55.940

Max. runout between “C” and “E”

0.03

Lateral runout of pulley flange at radius 52

0.02



Se ct io n s:

19 thru 21 (E N D )

COOLING SYSTEM 

193

TORQUE SP E CIF IC AT IONS Water pump to cylinder b lo c k ............................................... P ulley to wa terpump ................................................................ C oolant drain plug on optional oil co o le r........................ C ooling fan to hub (solid fan ) ............................................... Visco fan to hub/vibration damper...................................... C oolant outlet to water p um p ............................................... Fan guard to engine mounting/sump ................................. Fan guard to bracket............................................................... Inlet to water pump (Depending on application) ............

FAN RETAINING BOLTS (DIN933) — TIGHT E NING TOR QUE BOLT DIA

M8 M8 M10 M10

QUALITY

8,8 10,9 8,8 10,9

TOR QUE

23 30 42 58

N.m N.m N.m N.m

M8 M8 M12 X 1,5 M8 M8 M8 M10 M10 ( M10 [ M8

25 25 50 30 30 25 50 50 50 25

N.m N.m N.m N.m N.m N.m N.m N .m N.m N.m



COOLING SYSTEM — 194 Introduction The circ ulatio n of the c oo lant is ass isted by an impeller type water pump mounted on the front of the cylinder block, and driven by a Vbelt from the crank sha ft. Co oling by a finned radiator (water/air) or heat exchange (water/water). Automatic temperature control by two thermostats connected in parallel.

REMOVING AND REPLACING THERMOSTAT Removing 1. Dis conn ect coolant hose from thermos tat housing, and remove. 2. Unscrew and remove the rmos tat cover (fig. 119).

Fig. 119

3. Remove therm os tat from housing (fig. 219).

Replacing 1. Inse rt thermo stat in housing. 2. F it new Oring to thermos tat housing (fig. 319). 3. F it new gasket to thermo stat cover and replace, tighten bolts to 25 N.m. 4. R eplace and tighten clip s of coola nt hose.

Fig. 319

Se ct io n s:

19 thru 21 (E N D )

B0C B a r r i n g t o n D i es el Cl ub


Se ct io n s:

19 thru 21 (E N D )

COOLING SYSTEM  CHECKING THERMOSTAT Attach thermostat to a piece of wire and hang In a tank filled with boiling water. The main valve of the thermostat must be fully open after six to eight minutes (approximately 8 mm). Checking for start of opening. 1. Attach thermos tat to a piece of wire and hang in a tank filled with water. 2. Using a suitable source, heat water. IMPORTANT! From approximately 8°C below start of opening temperature (depending on version), the heating speed must not exceed 10 to 2° per minute. S tir water so as to produce a uniform temperature.

Note: Never use a welding torch or soldering iron to heat the thermostat.

REMOVAL AND R EP LACEMENT OF WATER PUMP Removal 1. If filled with antifreeze or an inhibitor, drain co olant into a clean container. Disconnect and remove water pump hoses. 2. Loosen lock nut on Vbelt adjuster and release tension. 3. R emove Vbelt. 4. Unscrew and remove mounting bo lts for water pump, lift off water pump. 5. Remove old gasket, and clean surface of water pump and cylinder block.

Replacing 1. Replace water pump, fitted with new gasket, insert bolts and tighten to specified torque. 2. Check Vbelt for correct tension using special tool (fig. 419). S hould this tool not be available, the V belt tension can be adjusted as follows: Without using undue pressure it should be possible to depress the V belt approximately 10 mm, with the thumb applying pressure at a point midway between the water pump and alternator pulley. 3. Replace water pump hoses and tighten hose clamps. 4. F ill radiator with coolant. Note: Add 1% radiator inhibitor (anticorrosion oil) throughout the year.

Fig. 419

195



COOLING SYSTEM — 196 DISMANTLING AND ASSEMBLING WATER PUMP Dismantling 1. Unscrew and remove thermostat housing cover, remove thermostats (fig. 519).

Fig. 619

3. Using a suitable puller, remove drive flange from water pump shaft (fig. 719).

F ig. 719

4. Remove circ lip from water pump shaft housing (fig. 819).

Fig. 819

Se ct io n s:

19 thru 21 (E N D )

B0C B a r r i n g t o n D ie se l Club


Se ct io n s:

19 thru 21 (E N D )

COOLING SYSTEM  5. P ress water pump sha ft and bearing from water pump housing (fig. 919).

6. Knock carbon ring seal from water pump body. 7. Remove ceramic ring and rubber sleeve from impeller, (fig. 1019).

Assembling 1. F it new carbo n ring seal in water pump body, using special too l, P art number 40202020 (fig. 1119).

2. P ress new water pump bearing into water pump housing (fig. 1219).

197



Se ct io n s:

19 thru 21 (E N D )

COOLING SYSTEM — 198 3.

Insert circlip into water pump bearing housing (tig. 1319).

4. P ress drive flange onto water pump sha ft (fig. 1419).

—^

1

'

Fig. 1419

5. Inse rt new cera mic ring and rubber sleeve into impeller (fig. 1519).

6. P ress water pump impeller onto water pump bearing shaft, leaving a clearanc e of 1 + 0,4 mm between impeller and water pump body (fig. 1619).

Fig. 1619

/ / x

P

--------

BDC

B d r r i n g t o n D ie se l Club


Se ct io n s:

19 thru 21 (E N D )

COOLING SYSTEM  7.

R eplace pulley and tighten bolts to 25 N.m (fig. 1719).

8.

Ins ert thermo stats , with new sea ls into water pump housing, and replace thermostat cover (fig. 1819).

Fig. 1819

Page 19-10 blank

199

»»cscl Club


S e ct io n s:

19 thru 21 (E N D )

Page 19-10 blank

SECTION 19-11 Visco Fan

Representation of Basic Fan Model 1

A LL EN C AP S CR EW

2

COVER , COMP LETE

3

COVER GASKET

4

ALLEN CAP SCREW

5

PRIMARY DISC

6

S P A C E R R I NG

7

BEARING

8

SEALING RING

9

BODY WITH BLADE

10

LOCKING DEVICE

11

COUNTER SUNK SCREW

12

FLANGED SHAF T

Page 19-12blank

BDC

Bdrrington Diesel Club


Some ADE 420 Series Engines are fitted with a thermostatica lly controlled viscous drive fan, which is mounted on the water pump hub, and driven by the Vb elt from the crankshaft. The visco us drive fan does not have a rigid co nne ction of the water pump pulley. A driven member which is fitted to the pulley can move within a chamber of the fan with a small clearance. On reaching a predetermined temperature the thermostat opens allowing oil to enter the chamber, as a result of the friction created by the oil within the fan chamber, the non driven body of the fan will turn thus driving the fan.

F illing Capacities S ilicon Oil Vis cos ity +) cS t

Qty. cm3

T 18 I

12.500 12.500 12.500 12.500 12.500 12.500 12.500

35 35 30 42 42 42 42

T 18 II T 18 II KW

12.500 12.500 12.500

42 45 40

T 21 II T 21 II K W

12.500 16.500 12.500 16.500 12.500 16.500 16.500

42 45 45 45 45 45 45

T 21 II D

16.500 12.500 12.500

42 42 42

Fan Model

C hecking and locking viscous drive fan

If there is an abnormal rise in coolant temperature, the following check should be carried out. When the engine is cold, the viscous silicon fluid flows back into the thermostat chamber. With the engine at operating temperature, it should therefore be difficult to turn the fan by hand. S tart up the cold engine, and allow it to run for 12 minutes at medium speed, then switch off the engine. The fan must now rotate easily when moved by hand, this is due to the fact that the s ilicon fluid has been thrown to the outside of the chamber, and since it is controlled by the thermostat, it cannot flow back when the engine is still cold. Check whether the viscous drive fan engages properly when the engine is warm. With the vehicle stationery, cover the radiator, start engine and allow it to run at medium speed until the water temperature has risen to 9095°C. Remove the radiator covering. The thermostat is now heated by the hot air from the radiator allowing silicon fluid to flow into the fan chamber. The fan speed sho uld increase within a few minutes (increasing fan noise), and the water temperature should return to normal operating temperature. If the engine is now switched off, it should be difficult to turn the fan by hand as the oil is s till in the fan chamber. In the event of failure of the viscous fan drive, the device can be locked. The locking device at the rear end of the fan serves to couple the fan rigidly to the pulley. To do this, unsc rew the lo cking nut (fig. 1819) up to the lock stop, then turn the fan slowly by hand until the pin of the locking device is felt to snap into place, aided by the spring pressure. T he visco us drive fan can be us ed for a limited period when in the locked cond ition. P rolonged opera tion in this con dition is no t advisable, the fan should be exchanged as soon as poss ible at your nearest A tlantis Diesel E ngine, parts stockist.

Note:

The vis co us drive fan s hould always be transpo rted a nd stored in a vertical position (as fitted to the engine) to prevent the silicon oil from running out.

19 thru 21 (E N D )

SECTION 1913 Visco Fan

Page 19-12 blank

Introduction

S e ct io n s:

F ig. 1819



Se ct io n s:

19 thru 21 (E N D )

SECTION 201 Lubricating Oils

VISCOSITY GRADES Ambient Air

SAE Grades

Tempe rature

30

20

o 0 10

O CM I

5

£

o

0

5 10

15

20

I

1

o in CO

CM

$

o

o i

$

o CM

I

o

CM

I o CM in

*At prolonge d ambie nt tempe rature above 20°C S AE 40 can be used.

DUE TO CONTINUOUS DEVELOPMENT, ATL ANTIS DIESEL ENGINES ARE CONSTANTL Y REVISING THEIR OIL RECOMMENDATIONS. TO OBTAIN THE LATEST OIL RECOMMENDATIONS, PLEASE REFER TO OUR SERVICE BULLETINS, OR CONSULT YOUR NEAREST OIL COMPANY FOR THEIR ADVICE.

1 ^ 5$ 5$ B a r r i n g t o n D ie ie se se l Club

ADE 422, 422, 423,4 423,424 24 Wor Worksho kshopp Man Manual ual

Se ct io n s:

19 thru 21 (E N D )

SECTION 21-1 A p p r o v e d S e r v i c e T o o l s Distributed by: GrundyTechniform (Pty) Ltd, Bruman R oad, Deal Party Estate, P ort Elizabeth E lizabeth 6001 6001

Tool

Tool No.

Engine turning tool

4020 0093

Crow foot socket for cylinder head bolts 17 mm

4020 0530

Ring spanner for injection pump pipe connec tions tions

4020 0970

Ring spanner for injector pipes

4020 0705

Castleated socket for removal and replacement of injector securing nut (pipes in place)

4020 1047

Castleated socket for removal and replacement of injector (pipes removed)

Injector dismantling socket

4020 1050 I

T

&V/

4020 0938

B0C B a r r i n g t o n D i es es el el Cl Cl ub ub


Se ct io n s:

19 thru 21 (E N D )

A P P R O V E D S E R V I C E T O O L S — 21 -2

Tool

Tool No.

Valve stem seal installer

4024 0778

Drive tool Flywheel wear ring

4020 0268

Drive tool Crankshaft front wear ring

4020 1801

Drive tool removal/replacement timing case oil seal

4020 0116

Drive tool Flywheel spigot bearing

4020 0064

/ T '\ Drive tool Crankshaft front cover oil seal

ll

'

RBHBV

»

4020 0129

P uller for 4020 1160 & 4020 1652

4020 0585

P uller for 4020 1665

4020 0598

Valve guide reamer 11.99 mm

4020 0831

1 ^5 ^ 5 $ ( d r H n g t o n Di D ie se se l d u b


Se ct io n s:

19 thru 21 (E N D )

APPROVED SERVICE TOOLS — 213

Tool

’

Tool No.

C rankshaft hardness hardness tester

4020 0501

Drive tool for compressor roller bearing in timing gear case

4020 1199

Drive tool for bush in compressor bearing flange.

7'< •'*(< Wr< < ' rJ \ '< ' r< \T < r< '<

i l l l i

4020 1209

Camshaft blanking plug puller

4020 2004

Oil spray jet alignment tool

4020 1937

(illustration of old type jet)

7 (^ T D Flywheel positioning handles

4020 1982

7/on

Bt*r*r*'n 3 to n »»cscl Club


S e ct io n s:

19 thru 21 (E N D )

A P P R O V E D S E R V I C E T O O L S — 21- 4

Tool

Tool No.

Connecting rod pull through handle

4020 1995

C rankshaft front wear ring remover

4024 9737

Measuring tool for cylinder Liner protrution

4020 1953

T iming case cover assembly tool

4020 0103

Locking tool for compressor

4020 1238

C r~

Check tool for injection pump .

1 ]

4020 1186

*

.....

Wrench for compressor drive gear bolt

Valve stem seal guide

7/90

4020 1225

u

.i

..... 

4020 1555



Se ct io n s:

19 thru 21 (E N D )

APPROVED SERVICE TOOLS — 215

Tool No.

Tool

C rowfoot socket for injector pipes

4020 0721

Support for injector nozzle holder

4020 0912

Connection for compression tester

n i

|

to

4020 0792

Cylinder liner removal/replacer

4020 0433

Universal Dial guage holder

4020 0446

P iston ring remover/ replacing pliers

4020 0307

P ilot mandrels for removal and replacement of flywheel

P iston ring compressor clamp

(iuuiL...

I

...ZB 4020 0077

buul---------

.(..JIB)

4020 1212



Se ct io n s:

19 thru 21 (E N D )

A P P R O V E D S E R V I C E T O O L S — 21- 6

Tool No.

Tool

Fuel lift pump tester

4020 1115

E xtractor for pilot bearing 25,5  30 mm

4020 1652

E xtractor for compressor bearing

4020 1160

E xtractor for valve seat insert 47 —56 mm

4020 1665

Injector impact extractor

4020 1076

c1 Water pump tool

5S? •a

n

5 MB»

4020 2295

ade-422-423-424-workshop-manual-abby.pdf

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