Ade-422-423-424-workshop-manual-abby.pdf d6l4h

ADE

422 , 423 , 424

Workshop Manual

lX IfllTingto., Diesel dub

Workshop Manual for ADE 422, 423,424

S * o Hl o i* * :

B e g in thru to section 11

ENGINE REPAIR MANUAL ADE 420 SERIES

ATLANTIS DIESEL ENGINES (PTY) LTD AMENDMENT 7/90

Part No. 80530257 Published by the Parts and Service Department of Atlantis Diesel Engines (Pty) Ltd.

W IfllTingto., Diesel dub

Workshop Manual for ADE 422, 423,424

S e e Ho ie e :

B e g in thru to section 11

FOREW ORD T h is m anual is d e sig ne d to be o f a s s is ta n c e to a ll personnel co n ce rn e d w ith th e m a in te n a n c e and overhaul o f th e ADE D iesel Engine. It p re se n ts a c o m p le te and d e ta ile d d e s c rip tio n of th e Engine, to g e th e r w ith p recise in s tru c tio n s on the s e rv ic in g and overhaul procedure, a lso a sch e d u le co ve r­ ing te c h n ic a l d a ta and d im e n s io n s w h ic h s h o u ld be c lo s e ly fo llo w e d w hen o ve rh a u lin g any part o f th e Engine, to th e M a n u fa c tu re rs s ta n d a rd s. ADE 420 S eries E ngin es have a le ft hand ro ta tio n w hen view ed fro m th e rear. T h ro u g h o u t th is m an ua l, w henever L e ft o r R igh t hand sid e o f th e engine is referred to, it is th e side o f th e e ngine w hen view ed fro m th e fly w h e e l end. E ffe c tiv e m a in te n a n c e can o n ly be ca rrie d o u t if th e personne l co n ce rn e d are fu lly co n ve rsa n t w ith the v a rio u s c o m p o n e n ts o f th e engine. Before m a in te n a n ce o p e ra tio n s are co m m e n ce d , th e re fo re , th is m a nu al s h o u ld be c a re fu lly s tu d ie d , and sh o u ld at all tim e s be kept w here it w ill be needed in th e w o rksh o p . C e rtain o p e ra tio n s d e s c rib e d in th is m anual require th e use o f s p e c ia l to o ls . These to o ls are o b ta in a b le fro m G ru n d y-T e ch n ifo rm , fu ll d e ta ils are given in S e ctio n 21. A S ch o o l o f In s tru c tio n is m a in ta in e d at ADE A tla n tis w here s ta ff e m ployed by D is trib u to rs and O p e ra to rs o f ADE pow ered a p p lic a tio n s are given in s tru c tio n s on diesel engine m ain te n a n ce , w ith p a rtic u la r regard to the s p e c ia l c h a ra c te ris tic s of ADE Engines.

ENGINE PARTS W henever p a rts are ordered fo r ADE E ngines it is e s s e n tia l th a t th e fu lle s t in fo rm a tio n p o s s ib le is given, a lw a y s q u o te th e e n g in e num ber, typ e o f a p p lic a tio n , part n u m b e r and w here p o s s ib le th e d e s c rip tio n .

Running in Procedure It is n o t n e ce ssary to g ra d u a lly run-in a new e n gine and any pro lo n g e d lig h t load ru n n in g during th e early life o f th e e n g in e can in fa c t prove h a rm fu l to th e b e ddin g in o f p is to n rin g s and liners.

CONTENTS TECHNICAL DATA ................................................................................................................................................ 08 OPERATING AND MAINTENANCE SCHEDULE ............................................................................................09 FAULT FINDING .................................................................................................................................................... 10 CYLINDER BLOCK AND LINERS ......................................................................................................................11 CYLINDER HEAD .................................................................................................................................................. 12 PISTONS AND CONNECTING RODS ............................................................................................................... 13 CRANKSHAFT AND MAIN BEARINGS ............................................................................................................14 CAMSHAFT, TIMING CASE AND DRIVE-TIMING ..............................................................

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

LUBRICATING SYSTEM AND SUMP ................................................................................................................ 16 FUEL SYSTEM ........................................................................................................................................................17 A N C ILLA R Y EQUIPMENT: COMPRESSOR, FLYW HEEL, TURBOCHARGER, EXHAUST BRAKE ALTERNATOR AN D STARTER MOTOR, FAN BELT, POWER STEERING PUMP ........................... 18 COOLING SYSTEM ............................................................................................................................................... 19 LUBRICATING OILS ..............................................................................................................................................20 APPROVED SERVICE TOOLS ............................................................................................................................21

W IfllTingto., Diesel dub

Workshop Manual for ADE 422, 423,424

S e e Ho ie e :

B e g in thru to section 11

__________________________SECTION 08-1 Technical Data 422N

422T

422TI

423N

423T

423TI

424N

424T

424TI

Ratings to SABS 013-1977 O utput kW /r/min ................................

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

Torque N.m/r/min .............................

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

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

C ubic cap acity ...................................

14,627 14,627

14,627

18,277

18.277

18.277

21,937

21,937

21,937

Bore mm ................................................

128

128

128

128

128

128

128

128

128

Stroke mm .............................................

142

142

142

142

142

142

142

142

142

No. of c y lin d e rs ....................................

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

Com pression ratio .....................

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

Com pression test pressure MPa

2,8

2,6

2,6

Engine at operating temperature, readings taken at 180-200 r/min. M inim um pressure 2,0 MPa. Difference between cylinders should not exceed 0,4 MPa. S tart of d e liv e ry __________________

13°±0.515°±0,5 15°±0,5

Firing order ...................................

1.5.7.2.6.3 4.8.

Engine Mass Kg .................................. (approxim ate figu res depending on application) Idling s p e e d

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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A I ) K Sc M e r c e d e s lirin i» o r d e r » a n d v a lv e se t

Cylinder Arrangement 1

Le 6 1

LEp j

5

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 ly w h e e l |

Firing Orders: V S = 1,5,7,2,6,3,4,8 V10=

1,6,5,10,2,7,3,8,4,9

V I2 = 1,12,5,8,3,10,6,7,2,11,4,9

F ly w h e e l

Valve Set V alves Rockiny,

1

2

3

4

5

6

7

8

9

If)

Set VK I'mnp

8 9

5 6

7 10

3

Set V 10 linn}?

6 7

8

1 3

4 1

2 5

2

4

Set V 12 firing

6

5

4

3

2

]

12

11

10

9

11

12

8

7

Throughout the W orkshop Manual, SI (International Metric Systems) units as approved by the South A frican Bureau of Standards (SABS) are used. All measurements are in mm unless otherw ise indicated.

7/90

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Workshop Manual for ADE 422, 423,424

B e g in thru to section 11

_______________SECTION 09-1 O perating and M aintenance OPERATING AND MAINTENANCE Preparation 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. Pressure 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.

Starting and stopping 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. Points 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. Should no oil pressure be ed, 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.

Category 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. Units 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 emer­ gency 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 m ajor 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. Start-up procedure after m ajor 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 Series 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.

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Workshop Manual for ADE 422, 423,424

OPERATING AND MAINTENANCE 09-2 TABLE 1 - Service & calibration intervals o f 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 Service & 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 re­ quired. 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. Check 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-corro­ sion 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. Check V-belt tension. 8. Check electrical equipment and connections.

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

9. Check 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 tight­ ness.

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

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Workshop Manual for ADE 422, 423,424

OPERATING AND MAINTENANCE 09-3 15. Adjust valve clearance every second service. 16. Re-tighten all visible nuts and bolts on the engine and in par­ ticular 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 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 PRESERVATION

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 Engines 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 Preparing 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 compres­ sor depends on many varying factors. Therefore a specific ser­ vice interval cannot be recommended. Dealers and Fleet-owners should adopt service intervals which will suit their individual ope­ rating 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

Specification o f 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 unprotec­ ted 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 ex­ haust 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 anti­ freeze/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 anti­ corrosion 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.

O nly use approved products for m ixture w ith the coolant as specified in the ADE Approved Consumables and Service Intervals bulletin (incorporated in this section) and at all tim es stric tly adhere to the m ixture 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 m onths

2.1.1 NEW ENGINES (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. (Runningin oil may remain in the engine). Renew oil filter car­ tridge. Fill with an approved running-in oil (anti-corro­ sion 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 tempe­ rature 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.

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Workshop Manual for ADE 422, 423,424

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OPERATING AND MAINTENANCE 09-4

2.2

Laid up fo r 12 to 36 m onths

3.1

NEW 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 accor­ dance 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 in­ sert one Chadpack Tablet (ADE part no. 3617 0072) into the housing. Refit the thermostats, close cover/out­ let and ensure that the ts form a good seal. All en­ gine 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 Preservation o f 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 be­ fore feeding the solution into the fuel system via a three­ way or four-way cock valve. This enables the concen­ tration 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-MANUFACTURED ENGINES must in all cases be preserved in accordance with section 2.2 in full.

2.2.2 Preservation o f C om bustion 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 m onths: If the laying up period is extended for more than 36 months, preservation must be repeated every J36 months (3 years) or 18 months in accordance with sec­ tion 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 m onths: 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. Oil per cylinder

Laid up for up to 12 m onths:

It is not necessary to renew the oil filter cartridge.

4.0 PREPARING THE ENGINE FOR OPERATION 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 Preservation o f A ir Com pressors:

4.3

Reposition and tension V-belts in accordance with ins­ tructions.

4.4

If not already installed, fit engine to machine.

4.5

Fill with approved lubricating and coolant service pro­ ducts 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 in­ take after which ths engine must be rotated at least one half turn. 2.3

Laid up fo r m ore than 36 m onths 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 INSTALLED ENGINES 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 tempera­ ture 75-79°C) while monitoring pressures and tempera­ tures.

W IfllTingto., Diesel dub

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

B e g in th ru to se c tio n 11

__________________________SECTION 10-1 Fault Finding Fault Finding Chart FAULT

.

S tarter m otor turns engine too slow ly

POSSIBLE CAUSE 1. 2, 3. 4.

W ill not start

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

D ifficu lt 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 ,1 0 ,1 1 ,1 2 , 1 3 ,1 4 ,1 8 .1 9 ,2 0 .2 1 ,2 2 ,2 3 ,2 4 ,2 5 ,2 6 ,2 7 ,3 1 ,3 2 ,3 3 ,6 0 ,6 2 ,6 3 .

M isfiring

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

Excessive fuel consum ption

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, 2 5 ,2 7 ,2 8 ,2 9 ,3 1 ,3 2 , 3 3 ,6 0 .

B lu e/W h ite 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.

Erratic 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 .3 8 .4 1 .

O verheating

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

Excessive crankcase pressure

2 5 .3 1 ,3 3 , 3 4 ,4 5 , 55.

Poor com pression

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

Starts 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.

B attery capacity low. Bad electrical connections. Faulty starter motor. Incorrect grade of lubricating oil. S tarter m otor turns engine too slow ly Fuel tank em pty Faulty stop con tro l operation. Blocked fuel feed pipe. Faulty fuel lift pump. Choked fuel filter. R estriction in induction system. A ir in fuel system. Faulty fuel injection pump. Faulty atom isers o r incorrect type. Incorrect use of cold start equipm ent. Faulty cold starting equipm ent. Broken fuel injection pump drive. Incorrect fuel pump timing. Incorrect valve tim ing. Poor com pression. Blocked fuel tank vent Incorrect type o r grade of fuel. S ticking throttle or restricted m ovem ent. Exhaust pipe restriction C ylinder head gasket leaking. O verheating. Cold running. Incorrect tappet adjustment. S ticking valves Incorrect high pressure pipes. W orn cylin d e r 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.

Pitted valves and seats. Broken, worn o r sticking piston ring(s). W orn valve stems and guides. O verfull air cleaner or use of incorrect grade of oil Worn or damaged bearings. Insufficient oil in sump. Inaccurate gauge. O il pump worn. Pressure relief valve sticking open. Pressure relief valve sticking closed. Broken re lie f valve spring. Faulty suction pipe. Choked oil filter. Piston seizure /p ick up. Incorrect piston height. Damaged fan. Faulty engine m ounting (housing). Incorrectly aligned flyw heel housing or flywheel. Faulty therm ostat. R estriction in water jacket. Loose water pum p drive belts. Choked radiator. Faulty w ater pump. Choked breather pipe Damaged valve stem oil de flectors (if fitted). Coolant level too low. Blocked sump strainer. Broken valve spring. Damaged o r d irty turbocharger impeller. Leaking turbocharger oil seals. Leaking boost con tro l pipe. Leaking induction system.

W IfllTingto., Diesel dub

Workshop Manual for ADE 422, 423,424

S e c H nM ‘ B e g in th ru to se c tio n 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

C ylinder block Dowel pin H ollow pin Bolt Bolt C am shaft bearing Plug C am shaft Plug Seal Plug Seal Plug Seal Plug Seal Plug Plug Plug Plug Seal

21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

H ollow pin H ollo w pin Pin Ball Tube C onnector Seal Plug Seal Plug Seal Plug Seal Plug nut Seal Plug Seal Adapter Seal Cover

41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62

Seal Seal Gasket Spring washer Bolt “ O” Ring seals (bottom ) “ O ” Ring seal (top) Tombak seal Oil jet Seal Connector Transmitter Seal Transmitter Seal Breather Breather Seal Vent tube Hose Vent tube Clamp

7/90

4 l|' JdMMhgton Diesel dub

B eg in th ru to sectio n 11

Workshop Manual for ADE 422, 423,424

C Y L I N D E R B L O C K — 11-2

B o re fo r c y lin d e r lin e r fla n g e

“A”

154,0 153,9

F la n g e d e p th

“ B”

9.99 9.97

B o re fo r c y lin d e r lin e r f it

U p p e r fit/lo w e r f it

u p p e r“ C”

145.840 145.800

lo w e r “ D ”

144.540 144.500

o v a lity

m ax. 0.01

O v a lity fo r re p a ir

m ax. 0.08

D e v ia tio n o f fla n g e fa c e t o b lo c k fa c e

m a x . 0.02

C y lin d e r b lo c k le a k a g e te s t u n d e r w a te r w ith c o m p re s s e d a ir

150 kPa

C ra n k s h a ft b e a rin g b a s ic b o re

new

111.022 111.000

fo r re p a ir

111.040 110.970

P e rm is s ib le o v a lity

0.01

P e rm is s ib le ta p e r o f b o re

0.01

C a m s h a ft b e a rin g b a s ic b o re

76.030 76.000

R oughness o f upper jo in t surfaces

7/90

Rz 10^m — Rmax 16^m

W IfllTingto., Diesel dub

Workshop Manual for ADE 422, 423,424

S e e Ho ie e :

B e g in thru to section 11

CYLINDER BLOCK — 11-3

-c-

-—

—u

/

'

/

<

/

/

/

/

/

/ / / /

I

1

A

0 r CD|

-

A

■

■■■ -

) ------------- F

L in e r in s id e d ia m e te r “ A ”

128,010 127,990

F la n g e o u ts id e Dia. “ B ”

153,757 153,657

U p pe r f it d ia . “ C ”

145,800 145,778

Dia. o f ste p on lin e r s e a lin g fa ce “ D ”

142.0 141.8

O u ts id e d ia . “ E”

145.0 144.7

L o w e r f it d ia . “ F ”

144.475 144.451

F la n g e th ic k n e s s “ G ”

10.07 10.05

H e ig h t o f ste p above s e a lin g fa ce “ H ”

1.10 1.00

O v e ra ll le n g th " K ”

253.5 252.5

M ax. la te ra l ru n -o u t o f lin e r fla n g e “ a ” to c e n te rlin e

0.02

M ax. ru n -o u t be tw ee n lo w e r and u p p e r f it “ c ”

0.025

O v a lity o r ta p e r a t lo w e r f it “ F”

B e fo re fitm e n t Installed

m ax. 0.06 m ax. 0.04

P ro tru s io n above b lo c k fa c e

new fo r re p a ir

0.05 - 0.09 0.03 - 0.09

F la n g e s h im th ic k n e s s

fo r re p a ir

0.8/1.0/1.5

L in e r w e a r a t u p p e r re tu rn

0.06

S u rfa c e ro u g h n e s s o f ho n e d lin e r

R3z 3 - 5/ifn

4 W la rrin g tc Diesel Club

B e g in thru to section 11

Workshop Manual for ADE 422, 423,424

CYLINDER BLOCK — 11-4 TORQUE SPECIFICATIONS Main bearing cap bolts (see section 14)............................

M18 x 2

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

M12 x 1,5

Piston cooling nozzles/cam shaft spray nozzles Front oil seal cover bolts to cylinder block Tachograph cable nut to a d a p to r............. Blanking nut to rev. counter d r iv e ............ Crankcase breather to cylinder b lo c k ..... Engine m ounting-front to cylinder block . Adaptor for cooling system vent l i n e .....

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

Initia l torque Final torque Max, stretch length

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

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

1,5

Tightening torques for Standard bolts and nuts (normal and fine pitch) in N.m (Valid only if no other torque is specified).

Thread

8,8

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 2 0 x 1,5 M22 M22 x 1,5 M24 M24 x 2

8,6 21 23 42 46,5 73 76 114 128 178 190 245 280 350 390 465 520 600 660

C lassifica tion of Strength 10,9 12,9 11,8 29 32 58 65 100 105 165 178 250 270 355 390 490 550 660 730 850 910

300 N.m 90° — 100° 156 mm 80 N.m

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

Workshop Manual for ADE 422, 423,424

B e g in thru to section 11

CYLINDER BLO CK — 11-5 In tro d u c tio n The cylin d e r blocks of the ADE 420 Series Engines are made of grey cast iron w ith the sides extending below the cran ksha ft centre line. Interchangeable (Wet) cylinder liners are fitted, w hich once the cylinder head and pistons have been removed can ea sily be extracted. On replace­ m ent con sid erab le care should be exercised to ensure th a t the cylin d e r liners are corre ctly seated and sealed.

REM OVING AN D REPLACING CYLINDER LINERS R em oving 1. Mark cylin d e r liners and cylinde r block w ith paint, to ensure tha t the liners are returned to the o rigin al position. 2. Fit puller studs opposite to each o th er in to bolt holes in cylin d e r block. 3. Insert puller. Part num ber 40200433, in to cylinde r lin e r (fig. 1-11). 4. Open jaw s of puller to inner diam eter o f cylinder liner.

5. Fit of pu lle r on to studs, tig h te n nuts and screw dow n centre nut on pu lle r shaft. 6. Hold centre sh a ft o f p u lle r w ith a ring spanner and con tinu e tu rning centre nut p u llin g out liner from cylin d e r block (fig. 2-11). 7. Retract ja w s of puller. Unscrew stud s from cylin d e r block, and remove to g e th e r w ith puller.

8. L ift out cylin d e r liner from cylin d e r blo ck (fig. 3-11). 9. Remove O -rings from cylin d e r block and liner. 10. It is esse ntia l th a t the ou ter surface of the cylin d e r liner, together w ith the bores in the cylinder block are th o ro u g h ly cleaned before replacem ent.

Fig. 3-11

7/90

4 l|' JdNMhgton Diesel dub

Workshop Manual for ADE 422, 423,424

CYLINDER BLOCK — 11-6 REMOVING AND REPLACING CYLINDER LINERS Replacing 1. Insert new O-rings in to cylinde r liner bores in crankcase (dry). 2. Fit new O-ring in to upper recess of cleaned cylinder liner. 3. Apply approxim ately a 3mm dia bead of sealing com ­ pound onto seal (fig. 4-11).

Fig. 4-11 4. Apply a light coating of grease to the bottom o f the cylinder liner, outer surface. 5. Insert cylin d e r liner w hile rotating it 90° from the original fitte d po sitio n (fig. 5-11).

Fig. 5-11

6. Fit puller studs opposite to each other in to bolt holes in cylinder block (fig. 6-11). 7. Place steel disc on top of cylinder liner. 8. Fit of pu lle r onto studs, tig h te n nuts. Screw up nut on centre sha ft to back of puller .

Fig. 6-11

9. Using a ring spanner screw down centre shaft of puller, in sertin g cylin d e r liner. Tighten w ith torque wrench to 120 N.m and leave pressure applied for five m inutes (fig. 7-11). 10. Using a suita ble p la s tic knife, remove excess seal­ ing com pound forced out between cylinder block and liner. 11. Remove puller from cylinde r block.

Fig. 7-11

B e g in thru to section 11

W IfllTingto., Diesel dub

Workshop Manual for ADE 422, 423,424

S e e H nM ‘

B e g in th ru to s e c t i ° n 11

CYLINDER BLOCK 12. Measure the inside diam eter o f the cylinder liner at the bottom , using a suitable internal measuring instrum ent, at three points o ffset 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 w h ile fittin g the pistons, keep the liner under pre-load w ith tw o fa b ri­ cated sleeves (approx. 30 N.m). (fig. 9-11).

Im portant 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 rrin gtc Diesel Club

Workshop Manual for ADE 422, 423,424

CYLINDER BLOCK -

11-8

Note It is essential th a t when the cylin d e r liners have been removed or replaced, the liner protrusion is measured, to ensure correct sealing o f the cylin d e r liners. The correct s p e cifica tio n o f liner protrusion m ust be adhered to. The cylin d e r liner protrusion can be altered by the ad dition or sub tra ction o f shim s, w h ich can be obtained at your nearest ADE parts sto ckist.

MEASURING PROTRUSION OF CYLINDER LINER 1. Remove cylin d e r heads (See sectio n 12). 2. Place gauge plate Part num ber 40201953 on cylin d e r liner. Insert sho rt cylinde r head b o lts fitte d w ith spacers, and tig h te n to 50 N.m (fig. 10-11). Note: Check inside diam eter o f gauge plate prior to f it ­ m ent and if necessary m achine to 144 mm.

3. Place dial gauge holder on gauge plate and insert dial gauge, so tha t sensor probe rests on the cylinde r block w ith pre-load. Tighten dial gauge. Set dial gauge to “ O” on cylin d e r block, at each m easur­ ing point. M axim um tole ran ce between fo u r points, for each lin e r is 0,02 mm (fig. 11-11).

MACHINING CYLINDER LINER SHOULDER DEPTH 1. Remove pisto ns and cylin d e r liners. 2. Preparations Pack the bores in the cylin d e r block w ith clean rag or a su ita b le m aterial, as far up as possible in the m achining area, to pro te ct the cran ksha ft and bear­ ings against fa llin g sw arf and d irt. Cover all oil galleries p a rticularly the neighbouring cylinders, e.g. w ith a p la stic sheet. 3. Clean surface of cylinder block and bores for cylinder liners. 4. Determining liner shoulder depth: Shoulder o f cylinder liner dista nce (measured at 4 points, max. difference o f 4 m easuring po in ts per lin e r 0,02 mm). + T hickn ess o f shim - S pecified liner protrusion = S houlder depth.

Example (0.8 mm th ic k shim ) Liner sho ulder mean dista n ce 10,05 mm + m easured th ickn e ss of shim 0,80 mm -

S pecified liner protrusion

= Shoulder depth a = shoulder depth (fig. 12-11)

10,85 mm 0,09 m m 10,76 mm

B e g in thru to section 11

4 l|' JdNMhgton Diesel dub

Workshop Manual for ADE 422, 423,424

B e g in thru to section 11

CYLINDER BLOCK 5. Clean m ach in ing and c u ttin g tool (w ith com pressed air), prior to inserting tool. Give cutting tool and insert a lig h t coa ting o f o il (fig. 13-11).

Fig. 13-11

Pull up q u ick-a dju sting ring and guide c u ttin g tool in to holder. Insert c u ttin g tool so th a t centring ro lle r is on the side o f c u ttin g too l holder m arked w ith “ R” , and feed' threads on c u ttin g to o l face away from qu ick-a dju sting ring (fig. 15-11). Note 1: Remove protective pa in t on solenoid flange w ith thinners, p rio r to in itia l use (fig. 14-11). N ote 2: C e ntralise m achine on cylin d e r bore.

Fig. 14-11 6. C onnect pow er supply. Place m achine on cylin d e r bore to be m achined and sw itch on solenoid.

Fig. 15-11 7. Pull up qu ick-a dju sting ring w ith tw o hand. Hold qu ick-a dju sting ring w ith one hand, and push cu ttin g to o l w ith til cen tring ro lle r is on side w all o f cylin d e r block (fig. 16-11).

fing ers of each tw o fing ers of oth er hand un­ lin e r recess in

Note: C orrect he ig ht o f ce n trin g roller is adjusted w ith feed nut.

8. Move sw itch to position 2. This energises the solenoid ring and holds the m achine on the cylin d e r block.

Fig. 16-11

11-9

4 W la rrin g tc Diesel dub

Workshop Manual for ADE 422, 423,424

CYLINDER BLOCK — 11-10 9. Turn crank slo w ly clo ckw ise and check to see if the centring roller rests on surface around the entire c ir­ cum ference o f the liner recess, and the m achine has not moved (w ith sw itch in centre position). If the m achine has moved, turn crank clockw ise, and at the same tim e hold feed ring w ith tw o fingers. If centringroller loses co n ta ct w ith shoulder recess, turn crank anti-clockwise while at the same tim e holding the feed ring, u n til roller has co n ta ct on the entire c ir­ cum ference of sho ulder recess (fig. 17-11). Note: When centred correctly, the centring roller w ill have uniform all round and m achine w ill not move when s w itc h in g to “ O ".

Fig. 17-11 10. A fte r cen tring correctly, move sw itch to po sitio n 1. Pull up quick-a dju sting ring and push in cu ttin g tool un til cu tte r con tacts liner recess to be m achined, but not ag ainst side w all (fig. 18-11). 11. Turn crank and feed nut together clockw ise, until cut­ tin g to o l makes co n ta ct w ith liner recess seat. 12. L ift qu ick-a dju sting ring and push back cu ttin g tool, to po sitio n above the liner recess seat.

13. Unscrew alien cap screw s fo r vernier adjustm ent. Set vernier ring to " O " and tig h te n alien cap screw s (fig. 19-11). 14. A d ju st cu ttin g depth to 0,05 mm w ith feed nut. Note: G raduation of vernier = 0,01 mm.

15. Turn crank clockw ise, holding the feed ring w ith the other hand (fig. 20-11).

B e g in thru to section 11

W Iflfpingtoi, Diesel dub

Workshop Manual for ADE 422, 423,424

S e e H nM ‘

B e g in th ru to se c tio n 11

CYLINDER BLOCK — 11-11 N ote 1 M easure sh o u ld e r recess depth from surface of c u ttin g m ach in e a fte r each cut (0,05 mm) (fig. 21-11). N ote 2: The c u ttin g to o l is ground in such a w ay as to pre­ vent the desired diam eter being exceeded. In other words, the face o f the c u ttin g to o l runs on the lin e r recess diam eter, if there is resistance, release feed ring im m e d ia te ly and tu rn crank several tim es. O nly grind c u ttin g to o ls acco rding to d ra w in g s sup plied w ith m achine.

Fig. 21-11

Im portant The feed nut m ust not move w h ile tu rn in g the crank, as th is w ould change the depth settin g o f the c u ttin g too l. If necessary tig h te n screw located in feed nut (fig. 22-11).

Fig. 22-11

16. Pull back quick-adjusting ring w ith 2 fingers, and push back c u ttin g tool to sta rtin g p o sitio n ; set 0,05 mm c u ttin g depth w ith feed nut and co n tin u e c u ttin g procedure u n til desired depth is ob tain ed (fig. 23-11).

Fig. 23-11

N ote 1: Remove m achine a p p ro xim a te ly 0,3 mm before reaching desired sh o ulder recess depth, and recheck depth w ith a dial gauge. Recheck depth once again before fin a l m ach in ing , to make sure th a t the desired depth has been reached (fig. 24-11). Centre m ach in e a fte r each m easurem ent, (fig. 17-11).

Fig. 24-11

4 l|' JdNMhgton Diesel dub

Workshop Manual for ADE 422, 423,424

B e g in thru to section 11

k d r r i n g t o n D iesel t lu b

ADE 422, 423,424 Workshop Manual

S E C TIO N 12-1 Cylinder Head

C y lin d e r H ead 1 2 3 4 5 6 7

C ylind er head w ith valve guides Core plug Core plug S ealing ring B la nking plug Valve gu id e Valve seat in se rt-in le t

8 9 10 11 12 13 14 15 16

Valve seat in se rt exhaust G asket a sse m bly-cylin der head Hex b o lt Hex bo lt Hex bo lt C ylin d e r head gasket Rocker cover R ocker cover (w ith o il fille r) O il fille r cap

17 18 19 20 21 22 23 24 25

Sealing ring G asket Spring w asher B olt Nozzle ho ld er w ith nozzle Nozzle hold er In je cto r Sealing ring In je cto r secu rin g nut

BK ( a p H n g t o n D iesel Club

ADE 422, 423,424 Workshop Manual

C Y L IN D E R H E A D — 12-2

114.0

O verall h e ig h t o f c y lin d e r head

113.9 M in im u m c y lin d e r head h e ig h t a fte r m a c h in in g 1)

113.4

P e a k -to -v a lle y s u rfa c e fin is h o f m a tin g s u rfa c e in ^ m

0 -1 6

M ax. u n e v e n n e s s o f m a tin g s u rfa c e

0.015

M ax. p a ra lle l d e v ia tio n be tw ee n u p p e r and lo w e r s u rfa c e

0.1

In je c to r p ro tru s io n

1 .6—2.4

V alve head rece ss b e lo w m a tin g s u rfa c e

0 .7 -1 .1

1) C heck in je c to r p ro tru s io n a fte r m a c h in in g c y lin d e r head m a tin g s u rfa c e and, if necessary, c o rre c t w ith in je c to r washers.

M a c h in in g o f c y lin d e r head m a tin g su rfa ce In o rd e r to a tta in th e s p e c ifie d s u rfa c e fin is h a d h e re to th e fo llo w in g s p e c ific a tio n s w h en g rin d in g : S peed:

n

=

Feed:

u

=

C u ttin g v e lo c ity :

Vs =

1400 r/m in 9 2 0 m m /m in . 27 m /s e c .

The s p e c ifie d c u ttin g v e lo c ity is given by u s in g a se g m e n t g rin d in g w h e e l w ith a d ia m e te r o f 370 m m . W hen u sin g a d iffe re n t d ia m e te r (d e p e n d in g on m a c h in e type), th e speed m u s t be ch a n g e d so th a t th e re is no g re a te r v a ria tio n th a n ± 1 0 % fro m V s = 4 ? = 2 7 m /sec. “

1000 60

Im p o rta n t: S lo w e r fe e d o r m a n u a l fe e d w ill c h a n g e th e g r in d in g p a tte rn c o n s id e ra b ly a n d th e re w ill be no g u a ra n te e o f re a c h in g a s u rfa c e fin is h o f Rz = O to 16/u m. L e aka ge te s t u n d e r w a te r w ith c o m p re s s e d a ir

250 kPa

B a r r i n g t o n D iesel Club

ADE 422, 423,424 Workshop Manual C Y L I N D E R H E A D — 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 .0 7 -0 .1 1

0 .0 7 -0 .1 1

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

measured at O 49 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” stamp

7/90

BK ( a p H n g t o n D iesel Club

ADE 422, 423,424 Workshop Manual

C Y L I N D E R H E A D — 12-4

Diameter ‘‘a "

Distance “ b”

Inlet Valve Seat Insert

Exhaust 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 le vel**

4.65 4.50

4.05 3.90

30°

45°

0 . 7 - 1,1

0 .7 -1 ,1

measured at O 57 mm 0.01

measured at O 49 mm 0.01

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 o r new level Turbo Head with “ T” stamp

O ld Level V alves B re a kp o in ts ADE 420N — up t o ........ SA002748 N ADE 420T/TI — up to SA002902 N •■D" “ E” •B " “ C” Width Height Dia Seat Valve Centre Head Dia New Min New Max

“ F" Stem Dia

Dimen­ sions (mm)

“ A" Seat Angle

Inle t

30°

57,01 56,99

59,0 58,8

3,2 3,0

2,7

4,3 3.3

7

11,950 11,932

54

Exhaust

45°

49,01 48,99

51.1 50,9

2,7 2,5

2,2

4,5 3,5

5,5

11,940 11,922

IS HRC 54

“ F” Stem Dia

Stem Hardness

Stem Hardness HRC

N ew Level V alves B re a kp o in ts ADE 420N — ADE 420T/TI —

SA002749 N and UP SA002903 N and UP

Dimen­ sions (mm)

"A " Seat Angle

Inle t

30°

55,01 54,99

59,0 58,8

3.8 3,6

3,3

5,5 4,5

6,5

11,950 11,932

i54 HRC

E xhaust

45°

48,01 47,99

51,1 50,9

3,2 3,0

2,7

5,5 4,5

6,5

11,940 11,922

t54i

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

HRC

M ax. ru n o u t between valve seat and stem

0 .0 3

M ax. run ou t between valve head and stem

0 .2 0

M ax. v a lv e s e a t o v a lity

0.01

7/90

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ADE 422, 423,424 Workshop Manual C Y L IN D E R H E A D — 12-5

Valve Springs Engine M odel/ Spring A llo ca tio n

Spring

Inside Dia.

W ire 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 ± 1 5

33.1

720 ± 50

Relaxed Length

Pre-lc>aded Length Load N

Final .oaded Length Load N

420N in let and Exhaust valves and

O u te r'

420T/TI in let valves

Inner

22.8 + 0.2

3.0 ±0,025

65.5

46.3

143± 12

32.3

280 ± 20

O uter

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 ± 1 2

32.3

350 ± 20

420T/TI exhaust valves only

'O p tio n a l due to d iffe re n t suppliers

V alve g u id e p ro tru s io n . D im e n s io n “ D ” M ax. d e v ia tio n o f valve se a t to valve g u id e ce n tre

17.1 - 17.4 0.03

M ax. m is a lig n m e n t o f valve sea t to va lve g u id e m e a s u re d at

57 m m d ia . fo r in le t 49 m m dia. fo r e x h a u s t

0.01

7/90

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ADE 422, 423,424 Workshop Manual

C Y L I N D E R H E A D — 12-6

V alve C le a ra nce (m m ) — C old Engine MODEL

BREAKPOINTS

INLET VALVE

EXHAUST VALVE

ADE 422N

Up to SA 002762 M SA 002763 M and up

0,25 0,40

0,35 0,60

ADE 422T/TI

Up to SA 003441 P SA 003442 P and up

0,30 0,40

0,50 0,60

0,40

0,60

0,30 0,40

0,50 0,60

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

S till in e ffe ct To be advised * *

0,40

0,60

0,30 0,40

0,50 0,60

INLET VALVE Opens BTDC Closes ABDC

EXHAUST VALVE Opens BBDC Closes ATDC

S till in e ffe ct To be advised

** At new level since the firs t day o f m anufacture.

Valve T im in g 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 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 in e ffe ct To be advised —

ADE 424N ADE 424T/TI

S till in e ffe ct To be advised

** A t new level sin ce th e firs t day o f m anufacture.

7/90

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ADE 422, 423,424 Workshop Manual C Y L IN D E R H E A D — 12-7

TORQUE SPEC IFIC ATIO N S C ylinder head to cylin d e r block:

Single hexagon bo lts

M15 x 2

Duo hexagon bolts

Rocker sh a ft pedestal to cylin d e r h e a d ........................... Valve ad ju sting screw lo c k n u t ............................................. Rocker cover to cylin d e r h e a d ............................................. Inlet m an ifold to cylin d e r h e a d ........................................... Exhaust m an ifold to cylin d e r h e a d .................................... In je cto r securing nut to cylin d e r head (see sectio n 17) T urbocharger to exhaust m an ifold (see sectio n 18) B lanking plug to cylin d e r 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 m edium

I 7 -c,

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° -1 0 0 ° 10 N.m 60 N.m 120 N.m 180 N.m 9 0 °-1 0 0 ° 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

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ADE 422, 423,424 Workshop Manual

CYLINDER HEAD — 12-8 Introduction The ADE 420 Series Engines are fitte d w ith an in dividu al cylinde r head fo r each cylinder. As th is type of cylinde r head is the sam e throu gh ou t the 420 series o f engines, it makes for greater s tan dard isatio n and ease of service.

REMOVING AND REPLACING ROCKER COVER Removing 1. Unscrew and remove b o lts from rocker cover. L ift o ff cover (fig. 1-12). 2. Remove cover gasket.

Fig. 1-12

Replacing 1. F it new rocker cover gasket. 2. Replace rocker cover and tigh ten b o lts to 25 N.m (fig. 2 -12).

Fig. 2-12

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ADE 422, 423,424 Workshop Manual

C Y L IN D E R H E A D REMOVING CYLINDER HEAD Preparation 1. Drain engine coolant. 2. D isconnect in let pipe. 3. Remove exhaust m anifold

1. Using special ring spanner Part num ber 40200705, remove in je cto r pipes (fig. 3-12). 2. Remove rocker covers (see fig. 1-12).

3. Unscrew in je cto r pipes from in je ctio n pump, using special ring spanners 40200970 & 40200705 (fig. 4-12). 4. Pull fuel leak o ff pipes from injector.

5. Unscrew and remove rocker arm brackets (fig. 5-12). 6. Remove push rods.

Fig. 5-12

12-9

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ADE 422, 423,424 Workshop Manual

CYLINDER HEAD — 12-10

7.

Unscrew and rem ove c y lin d e r head b o lts (fig. 6-12).

Fig. 6-12

N o t e : C ylin d e r head b o lt underneath in je cto r, can be

loosened w ith special spanner 40200530, but it c an no t be rem oved from the c y lin d e r head (fig. 7-12). 8.

Remove c y lin d e r head.

N o t e : U nless the in je c to r has been rem oved, alw ays lay th e c y lin d e r head on its side to avoid dam age.

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ADE 422, 423,424 Workshop Manual

C Y L I N D E R H E A D — 12-11 REMOVING AND REPLACING VALVES

,

Removing 1. Place c y lin d e r head in to cla m p and secure. 2. A d ju st fo rk to diam e te r o f valve spring retainer. 3. Fit push rod in to eye o f lever and push down on valve spring retainer. Remove c o lle ts from valve stem (fig. 8 - 12). 4. Release push rod. Remove valve spring retainer and valve springs.

5. Pull valve stem seals from valve guides. 6. Remove c ylin d e r head from clam p and remove valves. 7. Remove spacers fo r valve springs (fig. 9-12).

R eplacing 1. L u bricate valve stem w ith engine o il and in sert in to valve guide. 2. Place c y lin d e r head in to cla m p and secure. 3. Fit spacers fo r valve springs. 4. Replace valve stem seals using special to o l Part num ber 40201555 (fig. 10-12).

5. F it inner and o u te r valve springs w ith clo se c o ils to w a rd s the c y lin d e r head. F it valve spring retainer. 6. F it push rod in to eye of lever and push down on valve spring retainer. Insert c ollets in grooves o f valve stem. Ensure th e c o lle ts are co rre ctly lo cated (fig. 11-12).

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ADE 422, 423,424 Workshop Manual

12-12

FITTING VALVE STEM SEALS 1. Lubricate valve stem s with engine oil and insert valves in to guides. 2. Place cylin d e r head in to clam p, and secure. 3. Using special to o l Part num ber 40201555, fit valve stem seal over valve (fig. 12-12).

4. Press valve stem seal onto valve guide. 5. Remove special too l and repeat procedure on second valve (fig. 13-12).

REMOVING AND REPLACING VALVE GUIDES 1. Clam p cylin d e r head. 2. Knock valve guides out o f cylinde r head, from the co m b u stio n side using special tool Part num ber 40200815. 3. M easure bore fo r valve guide in cylin d e r head and ream to next repair stage if required. 4. Coat new valve guide w ith graphite o il and knock in using special too l and spacer (fig. 14-12). 5. Use special reamer Part number 40200831 and ream valve guide inner diam eter to spe cifie d dim ension.

Fig. 14-12

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ADE 422, 423,424 Workshop Manual C Y L IN D E R H E A D -

REMOVING AND REPLACING VALVE SPRINGS Removing 1. Place cylin d e r head in to clam p and secure. 2. A d ju st fork to diam eter of valve spring retainer. 3. Fit push rod in to eye of lever and push down on valve spring retainer. Remove c o lle ts from valve stem (fig. 15-12).

Fig. 15-12

Replacing 1. Clean valve springs, and check spe cific values using a suita ble spring tester (fig. 16-12).

Fig. 16-12

2. Insert inner and outer valve springs w ith close co ils tow ards the cylin d e r head. F it valve spring retainer. 3. Fit push rod in to eye of lever and push down on valve spring retainer. Insert c o lle ts in to grooves of valve stem . Ensure the c o lle ts are corre ctly located (fig. 17-12).

Fig. 17-12

12-13

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C Y L IN D E R H E A D -

ADE 422, 423,424 Workshop Manual

12-1 4

G RINDING VALVES 1. Clean carb on d e p o s its from valve. 2. Check to see if valves can be re-used. Valve ends m ust not have surface dam age. C ollet grooves m ust not be w orn and chro m e c o a tin g on valve ste m s m u st be w ith o u t fla w s. A lw a ys replace bu rnt valves. 3. C h eck d im e n s io n s and run out of valves. Do not a tte m p t to stra ig h te n bent valve stem s. 4. S lig h t run o u t o f valve stem s can be corrected by g rin ­ din g the valve face. 5. Insert and cla m p the valve im m e d ia te ly behind the valve head to avoid vib ratio n when grind ing (fig 18-12).

6. Set co rre c t g rin d in g an g le on scale. 7. Move valve to w a rd s ro ta tin g grin d in g wheel at a s lo w feed rate u n til valve m akes c o n ta c t w ith g rin d in g w heel face. (fig. 19-12). 8. G rind fa ce o f valve w ith a lig h t feed u n til it is ground on its e n tire c ircu m fe re n ce .

Fig. 19-12

N o t e : A fte r grinding valve height “ D” m ust not be less than o u tlin e d in th e s p e c ific a tio n .

9. S ho uld it be necessary the valve stem face can be gro un d on a V -block m ounted on th e valve g rin d in g m ach in e (fig. 20-12).

Fig. 20-12

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ADE 422, 423,424 Workshop Manual

C Y L IN D E R H E A D REMOVING AND REPLACING ROCKER ARM Removing 1. C lam p ro cke r arm b ra cke t in a vice fitte d w ith s o ft jaw s. 2. U nscrew and rem ove lo c k n u t and valve a d ju s tin g screw (fig. 21-12).

3.

Remove rocke r arm c irc lip (fig. 22-12).

4. Rem ove th ru s t w asher and rocke r arm (fig. 23-12). 5. Clean all p a rts th o ro u g h ly and ch e ck fo r wear.

REPLACEMENT OF ROCKER ARMS 1.

F it rocke r arm s and th ru s t w asher to ro cke r arm bra cke t (fig. 24-12).

Fig. 24-12

12-15

B5C

B d t't'in g to »! D iesel Club

CYLINDER HEAD 2.

3.

ADE 422, 423,424 Workshop Manual

12-16

Insert c irc lip on rocker arm shaft (fig. 25-12).

Screw valve adjusting screw and locknut into rocker arm (fig. 26-12).

Fig. 26-12

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ADE 422, 423,424 Workshop Manual

C Y L IN D E R H E A D REPLACING CYLINDER HEAD 1. Clean cylin d e r head b o lt holes in cylin d e r block tho ro ug hly prior to replacing cylin d e r heads. It is par­ tic u la rly im portant to remove any w ater trapped in the b o lt holes. 2. Clean c y lin d e r head and cylin d e r blo ck faces.

3. Place new c y lin d e r head gasket over dow el sleeves in cylin d e r block face (fig. 27-12).

Fig. 27-12

1

4. Place c y lin d e r head ca re fu lly o n to cylin d e r head gasket. 5. M easure bo lts to ensure stretch lim it is not exceeded. 6. Give cylinde r head bo lts a light coating o f engine oil, insert b o lts and tig h te n in the sequence shown (fig. 28-12), acco rding to torque steps liste d under sp e c ific a tio n s . N o t e : The stre tch b o lts do not need to be re-torqued.

N o t e 1 : Use spe cia l spanner fo r b o lt underneath the fuel in jecto r. N o t e 2: If one of the bo lts has been tightened excessively, unscrew all 6 bo lts of the cylinde r head, check for stretch and tig h te n again beginning w ith step 1 (fig. 29-12).

Fig. 29-12

12-17

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ADE 422, 423,424 Workshop Manual

C Y LIN D E R H EAD — 12-18 6. Insert pushrods. 7. F it rocker arm bra cket and tig h te n b o lts o n ly fin g e r tig h t. A lig n rocke r arm s w ith valves and pushrods. 8. Tighten rocker arm bracket bo lts to 75 N.m (fig. 30-12).

9.

A d ju s t valve clearance.

10. R eplace rocker covers and tig h te n b o lts to sp e cifie d torque. 11. Fit fuel in je c to r pipes and tig h te n co n n e c tio n s on in ­ je c to r holder to 25 N.m (fig. 31-12).

Note: Hold in je ctio n pum p nuts w ith special spanner Part num ber 40200970. Tighten con ne ction s o f in je ctio n pum p td*25 N.m using c ro w fo o t socke t Part No 4020 0721. (fig. 32-12). 12.

C onnect fuel leak o ff pipe to in je cto rs.

N ote: C ylin d e r head b o lts need no lo ng er be retightened.

Fig. 32-12

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ADE 422, 423,424 Workshop Manual

C Y L I N D E R H E A D — 12-19 A D JU S T IN G V A LV E C LE A R A N C E (M e th o d ,1) Note: A d ju stm e n t o f valve clearance can be carried out w ith the engine Cold. 1. Remove rocker covers and gasket. (See page 12-2) 2. Fit special engine turning to o l Part num ber 40200093 (fig. 33-12), to tim in g case 8 x 20 mm b o lts, and turn engine in d irectio n o f rotation, until pisto n o f cylinder to be adjusted is at firin g TDC. Valves should be c lo s ­ ed, rocker arm s com pletely relaxed and push rods free to turn, (see fig. 34-12 to identify valves rocking in rela­ tio n to c y lin d e r firing).

Fig. 33-12

L o c a tio n o f c y lin d e rs ADE 420 S eries E n gine s V12

V12

V10

©

©

V10

VB

©

©

©

©

V8

©

©

©

©

©

©

©

©

©

©

©

©

©

©

©

©

©

©

©

©

©

©

©

©

Valves rocking no:

1 2 3

C ylin d e r Firing 422 se t no: 423 set no: 424 set no:

4 5 6

7

8

9 10 11 12

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

4 9

8

7

F irin g Order: ADE 422 1-5-7-2-6-3-4-8 ADE 423 1-6-5-10-2-7-3-8-4-9 ADE 424 1-12-5-8-3-10-6-7-2-11-4-9 Valve C learance cold

Refer to s p e c ific a tio n s in acco rda nce w ith breakpoints.

X

Fig. 34-12

X — F lyw hee l end

3. Insert fee ler gauge between rocker arm o f in let or ex­ haust valve. Valve cle ara nce is co rre ct when feeler blade can be pulled th ro u g h w ith s lig h t resistance. 4. If the cle ara nce requires ad ju stm e n t, in se rt screw driver and ring spanner and adjust in the norm al m an­ ner (fig. 35-12).

Fig. 35-12 5. Turn the engine to the next cylin d e r TDC firin g p o s i­ tio n each tim e, and set a ll the valves in firin g order sequence. 6. Replace rocke r covers, renew dam aged gaskets, tig h te n rocke r cover b o lts to 25 N.m (fig. 36-12). 7. Remove spe cia l turning to o l from tim in g case.

EK f t d r r in g t o n D iesel Club

ADE 422, 423,424 Workshop Manual

C Y L IN D E R H E A D — 12-20 A D J U S T IN G V A LV E C L E A R A N C E (M e th o d 2) 1. R em ove ro cke r cove rs and g a ske ts. (See page 12-2) 2. F it sp e cia l e n gine tu rn in g to o l Part nu m be r 40200093 (fig. 33-12). to tim in g ca se 8 x 20 m m b o lts, and tu rn e n gine in d ire c tio n o f ro ta tio n , u n til th e No. 1 c y lin d e r TDC m ark is a lig n e d w ith the edge o f th e in s p e c tio n hole. 3. C h eck to see if No. 1 c y lin d e r is at TDC, ro c k in g or firin g . (At TDC firin g bo th valves w ill be c lo se d and th e push rods w ill tu rn easily). The fo llo w in g valves can the n be a d ju ste d a t No. 1 firin g TDC:

L o c a tio n o f c y lin d e rs A D E 420 S e rie s E n g in e s E ngine V12

V12

V10

©

©

V10

V8

©

©

©

©

V8

©

©

©

©

©

©

©

©

©

©

©

©

©

©

©

©

©

©

©

©

©

©

©

©

422 & 422T 423 424

Engine 422 & 422T 423 424 Fig. 37-12

4. In se rt fe e le r gauge betw een ro c k e r arm o f in le t o r e xh a u st valve. Valve cle ara nce is c o rre c t w hen fe e le r b la d e can be pu lle d th ro u g h w ith s lig h t re sista n ce . 5. If th e cle a ra n ce re q u ire s a d ju s tm e n t, in s e rt scre w d riv e r and ring s p a n n e r and a d ju s t in the norm al m an ne r (fig. 38-12).

Fig. 38-12

6. R eplace ro cke r covers, renew dam ag ed g a ske ts, tig h te n ro c k e r co ve r b o lts to 25 N.m (fig. 39-12). 7. R em ove s p e c ia l tu rn in g to o l fro m tim in g case.

E xh a u st valve

1, 3, 4, 8 1;% 8, 9 1, 2S4, 7, 9, 11

1, 2, 5, 7 1, 2, 5, 6, 9, 10 1, 3, 5, 8, 9, 12

**

The fo llo w in g valves can be a d ju s te d at No. 1 R o cking TDC:

X X — F ly w h e e l end

In le t valve

In le t valve

E xha ust 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

-

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Club

ADE 422, 4 23 ,4 24 Workshop Manual

<*»

C Y L IN D E R H E A D CHECKING COMPRESSION PRESSURE

•

Preparation 1. Check Valve Clearance (see fig. 38-12). 2. Run engine u n til norm al operating tem perature is reached (70-95°C). 3. Remove in je c to r holder and injector.

Testing 1.

Insert in je c to r sealing ring (fig. 40-12).

2.

Insert ad ap to r in cylin d e r head and tig h te n lo catin g nut for in je c to r holder (fig. 41-12).

3. Screw com pression tester w ith extension on adaptor (fig. 42-12). 4. Check com pression pressure at an engine speed of ap pro xim ately 120 r/m in. (starter speed) w ith the th ro ttle in clo sed po sitio n. Turn engine un til te st in d ica to r stop s rising. Note: If com pression pressure is less than 2,0 MPa, or when the pressure d iffe re n ce between the cylinde rs are greater than 0,4 MPa, remove the cylinder heads to inspect valve seats and cylinde r bores. 5. Remove com pression te ste r and adapter. 6. Replace in jecto r, and sea lin g ring. Fig. 42-12

12-21

k d r r i n g t o n D iesel t lu b

ADE 422, 423,424 Workshop Manual

CYLIN D ER HEAD — 12-22

In le t M a n ifo ld 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

In le t m a n ifo ld In le t m a n ifo ld T h re a d e d in s e rt G a ske t S p rin g w a s h e r B o lt Cap H o se c lip Plug B ra cke t

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

B ra c k e t B ra c k e t B ra c k e t B ra c k e t B ra c k e t B ra c k e t T ra n sve rse m a n ifo ld G asket S p rin g w a s h e r B o lt

B a r r i n g t o n D iesel Club

ADE 422, 423,424 Workshop Manual

C Y L I N D E R H E A D — 12-2 3 REMOVING AND REPLACING INLET M ANIFO LD Removing 1. Unscrew and rem ove in je c to r pipes from ap pro pria te c y lin d e r head (fig. 43-12). 2. Rem ove transve rse in le t m a n ifo ld . 3. D etach and rem ove hose fro m a ir com p resso r. 4. U nscrew and rem ove in le t m a n ifo ld .

Replacing 1. F it in le t m a n ifo ld w ith new gasket and tig h te n to a to rq u e o f 25 N.m (fig. 44-12). 2. R eplace transve rse in le t m a n ifo ld . 3. Replace in je c to r pipe s and tig h te n to 25 N.m.

REMOVING AND REPLACING EXHAUST M ANIFO LD Rem oving 1. U nscrew and rem ove exh au st pipe from m a n ifo ld . 2. D isco n n e ct e xh a u st brake cylinde r. 3. Remove g a ske ts (fig. 45-12).

Replacing 1. R eplace e xh a u st m a n ifo ld fitte d w ith new gaskets. 2. R eplace m o u n tin g b o lts w ith sleeves and tig h te n to 50 N.m (fig. 46-12). 3. F it e xh a u st brake c y lin d e r and tig h te n b o lts to s p e c ifie d torque. 4. F it e xh a u st pipe to exh au st m a n ifo ld , and tig h te n b o lts to s p e c ifie d torque.

Fig. 46-12

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ADE 422, 423,424 Workshop Manual

■ _________S E C T IO N 13-1 P istons & C o n n ectin g Rods

P iston & C o n ne ctin g Rod 1 B earing s h e lls 2 C o n n e c tin g rod 3 G udgeon pin bush 4 C irc lip 5 G ud geo n pin 6 B ig end b o lt

7 P isto n 8 Sleeve 9 O il c o n tro l ring 10 2nd co m p re s s io n ring 11 Top co m p re s s io n ring

ADE 422, 423,424 Workshop Manual

ftd t't'in gto r. D iesel t lu b

PISTONS AND CONNECTING RODS -

13-2

Piston 46.009 G u d g e o n p in bore dia.

46.003 46.000 45.995

G u d geo n p in dia.

m a tin g s u rfa c e w ith p is to n a t TDC

+ 0,43 + 0,07

G u d g e o n p in /c o n ro d bu sh c le a ra n c e

0 .0 5 5 -0 .0 7 0

G u d g e o n p in /p is to n c le a ra n c e

0 .0 0 3 -0 .0 1 4

P is to n : N o m in a l d ia m e te r

128,0

D is ta n c e b e tw e e n p is to n c ro w n and c y lin d e r b lo c k

Piston Rings E n g in e

G ro o v e

1

2

G ap

P is to n Ring C la s s ific a tio n

S id e C le a ra n c e

K e y s to n e

-

0 .3 5 - 0 .5 0

0 .0 6 0 -0 .0 9 5

0 .3 5 - 0 .5 0

0 .0 3 0 - 0 .0 6 5

0 .2 5 - 0 .4 0

-

0 .3 5 - 0 .5 0

0 .0 6 0 -0 .0 9 5

0 .3 5 - 0 .5 0

0 .0 3 0 - 0 .0 6 5

0 .2 5 - 0 .4 0

’

M olybodenym coated

T , M olybodenym T a p e rfa c e cQated

420N 3

420T/TI

B e v e lle d w ith ru b b e rlin e d s p rin g

1

.. . K e y s to n e

2

T M olybodenym Ta an pe e rfa rfa cc e e cQate(J

3

M olybodenym ’ . coated

B eve lled w ith rub be rlin e d s p rin g

C onrod Bush In n e r dia.

46.065 46.055

O u te r dia.

50.700 50.670

W id th

3 8 .700 3 8 .200

LC B a r r i n g t o n Diesel Club

ADE 422, 4 2 3 ,4 2 4 Workshop Manual t PISTONS AN D C O N N EC TIN G 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 , 8 9 .5 6 4 '

0 g.

Rep. size 2

89.356 , 89.314

g 7g,

Rep. size 3

89.106 ( _ 1 00) 89.064 ' ’

Conrod Bearing Width

0 31.0 30.8

'

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

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

0.025

TORQUE S P EC IFIC ATIO N S C onnecting rod b o lt s ......................

M16 x 1,5

In itia l torque Final torque Max. stretch length

100 N.m 9 0 ° - 100° 68,5 mm

B a r r i n g t o n D iesel Club

ADE 422, 423,424 Workshop Manual

PISTONS AN D C O N N EC TIN G RODS -

13-4

In tro d u c tio n The 420 Series of Engines are fitte d w ith lig h t alloy p is­ tons. In all cases the top com pression ring is m ounted in a reinforced groove. The num ber o f pisto n rings fitte d depends on application. Pistons and connecting rods are rem ovable from the top of the cylin d e r block.

REM OVING PISTONS — C YLINDER HEAD AN D SUM P REMOVED R em oving 1. To avoid damage to the pisto n rings, remove carbon w ith a scraper from the top of the cylin d e r liner. 2. Unscrew and remove con ne cting rod bearing cap (fig. 1-13).

Note: Ensure that connecting rod bearing caps are marked for replacem ent to the same con ne cting rod (fig. 2-13).

3. Push out connecting rod and pisto n from below. 4. Clamp connecting rod and piston in a vice (fitted w ith so ft jaws), remove gudgeon pin circlip , and press out gudgeon pin, lift o ff pisto n (fig. 3-13).

Fig. 3-13

B a r r i n g t o n D iesel Club

ADE 422, 423,424 Workshop Manual PISTO N S A N D C O N N E C T IN G RODS — 13-5

R e p la c e m e n t 1. C lam p co n n e c tin g rod in a v ice (use p ro te ctive ja w s) so th a t the lo n g e st side o f the co n n e c tin g rod face s to w a rd s th e rig ht. Place the heated p isto n over the c o n n e c tin g rod w ith the arrow on th e p isto n crow n p o in tin g to w a rd th e rig ht. 2. Lubricate and insert gudgeon pin and replace c irc lip s (fig. 4-13).

3. Coat piston w ith engine oil. O ffset piston rings in rela­ tio n to each other. F it relaxed p is to n ring cla m p over p isto n , and co m p re ss to o u ts id e d ia m e te r o f pisto n, so th a t th e cla m p can s till move (fig. 5-13).

4. Inse rt bearing she ll in to co n n e c tin g rod. Ensure th a t the lo c a tin g ta b is fitte d c o rre c tly in th e co n n e c tin g rod. C oat bearing w ith engine o il (fig. 6-13).

5. L u b rica te bearing su rfa ce s o f c o n n e c tin g rod w ith en gine o il. 6. Insert p isto n in to c y lin d e r lin e r w ith arrow fa cin g in to w a rd s th e ce n tre (fig. 7-13) o f the engine. 7. Push p is to n in u n til c o n n e c tin g rod bearing rests on cra n k s h a ft jo u rn a l.

( d r H n g t o n D iesel Club

ADE 422, 423,424 Workshop Manual

PISTONS A N D C O N N EC TIN G RODS -

13-6

8. Insert bearing shell in to con ne cting rod cap. Ensure th a t the locating tab is fitte d corre ctly in the connecting rod cap. Coat bearing w ith engine oil (fig. 8-13).

9. Measure length o f big end bo lts (fig. 9-13). Note: Big end b o lts can s till be used as long as stretch does not exceed 68,5 mm.

10. Fit bearing cap and screw in bearing bolts finger tight. Note: Ensure th a t marks on bearing cap and connecting rod align (fig 10-13). 11. T ighten big end bo lts alte rna te ly in tw o steps to 100 N.m, using a torque wrench and then a fu th e r 90°.

Fig. 10-13

ftd t't'in gto r. D iesel Club

ADE 422, 423,424 Workshop Manual

PISTO NS A N D C O N N E C T IN G RODS M E A SU R IN G C O N N E C T IN G ROD BE AR IN G S N ote Bearing sh e lls fo r c o n n e ctin g rod bearings are delivered ready fo r in s ta lla tio n . No m a ch in in g o r s cra p ­ ing sho uld be perform ed on the bearings. 1. Clean bearing surface in con ne cting rod and bearing cap w ith clean rag. 2. Inse rt bearing she ll in to c o n n e ctin g rod cap. Ensure th a t the lo c a tin g ta b is fitte d c o rre c tly in the c o n n e ctin g rod cap (fig. 11-13).

3. Place bearing cap w ith shell in to c o n n e ctin g rod. Id e n tific a tio n num bers m ust be on the sam e side. 4. T igh te n big end b o lts to an in itia l torqu e o f 100 N.m in 2 steps and then to a final torque of 90° + 1 0 ° angle o f rotatio n. Note: H old co n n e ctin g rod in a vice (fitte d w ith so ft jaws, as clo se as po ssib le to the c o n n e ctin g rod bearing (fig. 12-13).

Fig. 12-13

13-7

( d r H n g to n Diesel Club

ADE 422, 423,424 Workshop Manual

PISTONS AND CONNECTING RODS — 13-8 5. Set a 50-100 mm internal measuring instrum ent to diameter of connecting rod big end bore using an out­ side m icrom eter (fig. 13-13).

6. Measure connecting rod big end bearing bore at three points (vertically and approxim ately 30° away from m atin g po in ts, using set 50-100 mm in te rna l m icrom eter (fig. 14-13). Note: M easurements specified in table m ust be adhered to. 7. Unscrew and remove bearing cap.

REPLACING PISTON RINGS 1. Set piston ring pliers Part number 40200307 to 128 mm diam eter w ith the adjusting screw (fig. 15-13). 2. Piston rings can be removed and replaced at th is setting.

Fig. 15-13

ir r in g io n Diesel

Club

ADE 422, 423,424 Workshop Manual

S e c tio n s:

14 a n d 15

_________________________ SECTION 14-1 Crankshaft & Main Bearings

C ra n ksh aft & M ain Bearings 1 2 3 4 5 6 7

Hub bolt V-belt pulley Hub Dust cover * Wear ring Crankshaft w ith counter balances Counter balance

8 9 10 11 12 13

Bolt Locating pin Crankshaft gear Spacer Spigot bearing Crankshaft bearing shells

B d r r in g t o n D iesel Club

A D E 422, 423,424 W orkshop Manual

C R A N K S H A FT AN D M AIN BEAR IN G S -

S e c tio n s:

14 an d

14-2

C ran k sh a ft Repair Size

Main Bearing Journal Dia.

Standard

Width of Thrust Bearing Journal

104000 103.980

Standard 1

103.900 ( 103.880

0,1)

Standard 2

103.750 , 103.730

0 25)

Rep size 1

103.500 ^ Q 5^ 103.480 ' '

ReP s iz e 2

^ H ^ (-° ,7 5 ) 103.230

Rep size 3

103 000 ( _ i,o) 102.980

38.062 /gj 38.000 ( 1

38.562 , 0 ,, 38.500 ( + ° ’5)

39.062 , 39.000 (

i

q.

Conrod Bearing Journal 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 ( 89.230 '

0,75)

1

’ ' § 9 ^2 9 (- 1 ,0 ) 88.980 ' '

C ra n k s h a ft jo u rn a l h a rd n e s s

HRC 53 ± 3

F or R e pa ir o n ly: C ra n k s h a ft jo u rn a l h a rd n e ss a t tw o th ird s o f c irc u m fe re n c e

M in .: HRC 46

M ax. c ra n k s h a ft jo u rn a l/c o n ro d jo u rn a l ta p e r

0.01

M ax. c ra n k s h a ft jo u rn a l/c o n ro d jo u rn a l o v a lity

0.01

M ax. c ra n k s h a ft ru n o u t w ith c ra n k s h a ft

0.06

ru n n in g o n o u te r c ra n k s h a ft b e a rin g jo u rn a ls M ax. ra d ia l ru n o u t o f fly w h e e l s p ig o t w ith c ra n k s h a ft ru n n in g on o u te r c ra n k s h a ft b e a rin g jo u rn a ls M ax. la te ra l ru n o u t o f fly w h e e l m o u n tin g s u rfa c e

.

c ra n k s h a ft ru n n in g on o u te r c ra n k s h a ft b e a rin g jo u rn a ls M ax. la te ra l ru n o u t o f th ru s t b e a rin g s u rfa c e M ax. im b a la n c e o f c ra n k s h a ft w ith c o u n te rb a la n c e w ith o u t fly w h e e l, ru n n in g on o u te r m a in b e a rin g s

0.02

0.02

0.02

60 cm g

R a dii on c ra n k s h a ft and c o n ro d b e a rin g jo u rn a ls

3 .5 -4 .0

R a d ii on th ru s t b e a rin g jo u rn a l

4.0

M ax. m is a lig n m e n t o f c o n ro d b e a rin g s to c ra n k s h a ft b e a rin g s in re fe re n c e to b e a rin g le n g th

S p ig o t d ia . fo r fly w h e e l

40

* *

0.01

61.959 61.940

15

BDC fcdriM hgton Diesel

Club

ADE 422, 423,424 Workshop Manual

S e c tio n s!

14 a n d 15

C R A N K S H A FT AND M AIN BEAR IN G S — 14-3

. Repair Size

C ra n k s h a ft Bearing Crankshaft Bearing Dia. Installed

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 ,7 5 ) 103.316

Rep size 3

103.112 , -1 ,0 ) 103.066 1

Max. bearing journal ovality Basic bore dia. in crankcase for crankshaft bearing

Thrust Bearing Width

37 -81 (Std) 37.74

3831 , + 0 5 ) 38.24^ '

38.81 / 38.74 (

,

0.02 for repair

111.040 110.970

new

111.022 111.000

Crankshaft end play (thrust bearing)

0.1 9 0 -0 .3 2 2

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

0.0 8 7 -0 .1 5 3 0.0 8 0 -0 .1 4 6

Main and Bigend journal surface finish

(Lapped)

Ra 0.2/im Rmax 2^m

TORQUE SPEC IFIC ATIO N S Counter balance bo lts to cran ksha ft .................................

M16 x 1,5

Pulley to hub/vibration d a m p e r........................................... Pulley hub/vibration dam per to c r a n k s h a ft...................... Main bearing cap bo lts (see sectio n 11) ..............

M8 M 1 6 x 1,5 M18 X 2

Main bearing cap side b o lt s .................................................

M12 x 1,5

In itia l torque Final torque Max. stretch length

In itia l torque Final torque Max. stretch length

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 b o lts prior to bearing cap side bolts.

7/90

BDC fcdriM hgton D iesel Club

A D E 422, 423,424 W orkshop Manual

CRANKSHAFT AND MAIN BEARINGS — 14-4 Introduction The crankshaft is forged, precision ground and ed 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 Sec­ tion 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 bear­ ing caps using bearing bolts (fig. 2-14). N o te : Mark bearing caps and bearing shells In correct sequence.

4. Screw guide mandrels Part 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.

N o te : 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. N o te : 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 tio n s:

14 an d

15

( d r H n g t o n D iesel Club

A D 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 fitte d w ith bearing s h e lls .‘En­ sure m arks on bearing caps correspond. 4. M easure m ain bearing b o lts for stre tch (fig. 5-14). N o t e : M ain bearing b o lts may be reused w ith a stre tch o f up to 156 mm.

5. T igh te n m ain bearing cap b o lts to an in itia l torque of 300 N.m in 3 stages and then to a fin a l torqu e of 9 0 ° + 10°. 6. Insert and tig h te n m ain bearing side b o lts to 80 N.m (fig. 6-14).

■

©

I I / /

Fig. 6-14

8. Measure crankshaft bearing bores at three points (ver­ tic a lly and a p p ro xim a te ly 30° away from the m atin g po in ts w ith the set 100-160 mm dial gauge (fig. 8-14).

N o t e : S pe cifie d values m ust be adhered to.

9. Unscrew b o lts and remove bearing caps.

"

'

“ ................ I

<

7. Set a 100-160 mm in te rna l m easuring in stru m e n t to standard diam e te r o f cran ksha ft bearing bore using an o u tsid e m icro m eter (fig. 7-14).

■

V

© X W /X F I

I I

A

L

BDC fcdriM hgton D iesel Club

A D E 422, 423,424 W orkshop Manual

C R A N K S H A F T AN D M AIN BEARING S — 14-6 REPLACING BEARING SH ELLS AND CRANKSHAFT 1. Clean o il ga lle rie s in crankcase w ith com pressed air applied from the oil pum p side. 2. Clean crankshaft, bearings and bearing lo catio ns thoroughly w ith clean rag. Clean oil galleries in crank­ sh a ft w ith a w ire brush and blow out w ith com pres­ sed air. 3. Check cran ksha ft bearing jo u rn a ls w ith a hardness te ste r (fig. 9-14). N o t e : A conversion table is supplied w ith the hardness

tester.

4. Insert bearing shells in to crankcase and bearing caps in correct order. Ensure th a t the locking tabs are cor­ re ctly located in cap and crankcase. N o t e : Align holes in bearing shells, w ith drilling s in crank­ case (fig. 10-14).

5. Lubricate bearing surfaces w ith engine oil.

Fig. 10-14

6. Screw guide m andrels Part num ber 40200077 in to front and rear of crankshaft. Place rope around m andrels and lift crankshaft. Lower cran ksha ft in to crankcase (fig. 11-14).

Fig. 11-14

N o t e : Ensure th a t tim in g m arks are lined up corre ctly (fig 12-14).

Fig. 12-14

S e c tio n s:

14 an d

15

BDC B a r r i n g t o n D iesel Club

A D E 422, 423,424 W orkshop Manual

7. Fit 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 bo lts may be reused w ith a stretch of up to 156 mm (see fig. 5-14).

Fig. 13-14

9. Tighten m ain bearing cap bolts to an in itia l torque of 300 N.m in 3 stages and then to a final torque of 9 0 ° + 10°. 10. Insert and tig h te n m ain bearing side b o lts to 80 N.m (fig. 14-14).

11. Fit suita ble dial gauge to crankcase and check end floa t o f cran ksha ft (fig. 15-14).

Fig. 15-14

S e c tio n s:

14 an d

15

BDC fcdriM hgton D iesel Club

A D E 422, 423,424 W orkshop Manual

C R A N K S H A FT AND M AIN BEARINGS — 14-8 C R AN K SH A FT GRINDING 1. Remove counter balance weights. Check to see if coun­ ter balances are marked prior to removal. If not, mark counter balance using a suitable punch to ensure cor­ rect installation. 2. Remove crankshaft tim in g gear. 3. Clean crankshaft and check for m isalignm ent, jo u r­ nal run out, hardness using special tool Part number 40200501 and cracks. C rankshafts show ing signs of cracking should be replaced. S traighten or if necessary replace bent crankshafts. If bearing jo u r­ nals do not meet sp e cifica tio n s or are found to be scored, the crankshaft should be ground to the next repair stage (see fig. 16-14). 4. It is essential to keep to the specified radii for the main bearing and crankpin journals.

5. Lap surface of journals after grinding. 6. Measure length of crankshaft 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 balances and tigh ten to an in itial torque of 100 N.m and a final torque of 90 + 10. N o t e : Marks on counter balances m ust be aligned w ith marks on crankshaft.

8. Clean oil galleries in crankshaft w ith a wire brush and blow out w ith com pressed air.

7/90

S e c tio n s:

14 an d

15

i r r i n g i o n D iesel Club

A D E 422, 423,424 W orkshop Manual

S e c tio n s:

14 an d

15

f t d f H n g t o n Diesel Club

ADE 422, 423,424 Workshop Manual

S e C t iO f lS !

14 a n d 15

C R AN KSH AFT AND MAIN BEARINGS — 14-10 R eplacing O il Seal 1. Coat outer surface of oil seal w ith a suitable sealing com pound. N o t e : Do not allow sealing com pound to com e in c ontact w ith the lip of the oil seal or the sealing surface o f the crankshaft.

2. Insert new oil seal in to housing and press or knock in so that the seal face is flush w ith the inside of the housing. Pack (fill) the area between the seal lip and dust lip w ith m ultipurpose grease. N o t e : cover w hile inserting o il seal in housing.

3. Fit new housing gasket over dow els in crankcase. 4. Lubricate wear sleeve for oil seal w ith engine oil. 5. Replace housing and housing bolts and tigh ten to a torque of 25 N.m (fig. 22-14).

_____

Fig. 22-14

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

7. Insert dust cover, fit pulley hub and vibration damper and tigh ten 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 Diesel Club

ADE 422, 423,424

workshop Manual

Sections: 14 and 15

C R AN KSH AFT AN D M AIN BEARINGS — 14-11 REPLACING W EAR RING ON C R A N KS H AFT R em oving 1. Fit special tool Part num ber 40249737 over wear ring on front of crankshaft, and push down adapter sleeve (fig. 25-14). 2. Pull o ff wear ring.

R eplacing 3. Heat new wear ring to approx 100°C. 4. Fit wear ring in to special tool Part num ber 40201801 and knock onto crankshaft (fig 26-14). 5. Coat surface of wear ring w ith engine oil.

REMOVING AN D REPLACING VIBR ATIO N DAMPER R em oving 1. Remove V-belts. 2. Remove fan w ith hub and pulley. 3. Unscrew and remove vib ratio n dam per or pulley hub (fig. 27-14).

R eplacin g 1. Fit vib ratio n dam per or hub, and tig h te n bo lts to a torque o f 200 N.m (fig. 28-14). 2. Replace engine fan w ith hub and pulley. 3. Fit and tension V-belts.

Fig. 28-14

BDC B a r r i n g t o n D iesel Club

A D E 422, 423,424 W orkshop Manual

S e c tio n s!

14 an d

__________________________ SE C TIO N 151 C am shaft, Tim ing Case and Drive Timing

C a m s h a ft 1 2

3 4 5 6 7 8 9 10

C am shaft Inlet valve Exhaust valve Valve spring inner Valve spring outer Spacer inner Spacer outer Spring retainer C o lle t Stem seal

11 12 13 14 15 16 17 18 19 20

Rocker sha ft and pedestal Ball Rocker arm A d ju stin g screw Locking nut T hrust washer C irclip Rocker sh a ft bolt Tappet Push rod

15

ADE 422, 423,424 Workshop Manual

B a r r i n g t o n Diesel Club

C A M SH AFT, TIM IN G CASE AND DRIVE-TIM ING -

S e c tio n s!

14 a n d 15

15-2

C a m s h a ft 69.940 69.910

J o u rn a l Dia. (in cl. th ru s t be a rin g )

H a rd n e ss

jo u rn a l cam

58-62 HRC

C a m s h a ft/b e a rin g c le a ra n c e

ra d ia l a xia l

0 .0 6 - 0 .1 5 6 0 .2 -0 .9

C a m s h a ft/th ru s t b e a rin g c le a ra n c e

ra d ia l

0 .1 3 - 0 .1 8

B a c k la s h c ra n k s h a ft/c a m s h a ft g e ar B a c k la s h In je c tio n p u m p /in te rm e d ia te /c a m g e a r

0 .1 1 8 -0 .2 4 2 0 .1 0 2 -0 .3 3 8

P e rm is s ib le ru n o u t c a m s h a ft jo u rn a ls (c a m s h a ft s u p p o rte d at o u te r jo u rn a ls )

0.05

P a ra lle l c a m /c a m s h a ft c e n tre lin e

0.005

C am and jo u rn a l s u rfa c e fin is h

Rz 3^m

C a m s h a ft Bearing 70 .090

C o lla r (th ru s t) b e a rin g

7 0 .070

B e a rin g in s id e dia. 70 .066 O th e rb e a rin g s

70 .000

B a s ic b o re fo r c a m s h a ft be a rin g

76.030 76.000

C a m s h a ft b e a rin g o u te r Dia.

76.100 76.070

M axim um Valve L ift w ith S p e c ifie d Valve C learance (mm) MODEL

BREAKPOINTS

INLET VALVE

EXHAUST VALVE

ADE 422N

Up to SA 002762 M SA 002763 M and up

13,76 1 1 ,9 5 -1 2 ,3 5

13,66 1 1 ,9 0 -1 2 ,3 0

ADE 422T/TI

Up to SA 003441 P SA 003442 P and up

11 ,5 0 -1 1 ,9 0 1 1 ,9 0 -1 2 ,3 0

1 3 ,1 0 -1 3 ,5 0 1 1 ,8 5 -1 2 ,2 5

**

11 ,9 5 -1 2 ,3 5

1 1 ,9 0 -1 2 ,3 0

11 ,5 0 -1 1 ,9 0 1 1 ,9 0 -1 2 ,3 0

1 3 ,1 0 -1 3 ,5 0 1 1 ,8 5 -1 2 ,2 5

1 1 ,9 5 -1 2 ,3 5

1 1 ,9 0 -1 2 ,3 0

11 ,5 0 -1 1 ,9 0 f l ,90 -1 2 ,3 0

13 ,1 0 -1 3 ,5 0 11 ,8 5 -1 2 ,2 5

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

S till in e ffe ct To be advised ** S till in e ffe ct To be advised

* At new level since the firs t day o f m anufacture.

BDC B a rrin g to n Dicscl Club

A D E 422, 423,424 W orkshop Manual

S e c tio n s!

14 an d

15

CAM SHAFT, TIM ING CASE AND DRIVE-TIMING — 15-3 Valve Travel at TDC w ith zero valve s e ttin g (mm) MODEL

BREAKPOINTS

INLET VALVE

EXHAUST VALVE

ADE 422N

Up to SA 002762 M SA 002763 M and up

0 ,5 0 -0 ,6 5 0,60 - 0,80

0,47 - 0,62 0 ,6 5 -0 ,8 5

ADE 422T/TI

Up to SA 003441 P SA 003442 P and up

0 ,4 0 -0 ,6 0 0 ,5 5 -0 ,7 5

0 ,5 5 -0 ,7 5 0,65 - 0,85

0 ,6 0 -0 ,8 0

0,65 - 0,85

0 ,4 0 -0 ,6 0 0 ,5 5 -0 ,7 5

0 ,5 5 -0 ,7 5 0,65 - 0,85

0,60 - 0,80

0 ,6 5 -0 ,8 5

0 ,4 0 -0 ,6 0 0 ,5 5 -0 ,7 5

0 ,5 5 -0 ,7 5 0,65 - 0,85

—

ADE 423N ADE 423T/TI

S till in e ffect To be advised —

ADE 424N ADE 424T/TI

S till in e ffect To be advised

** At new level since the firs t day o f m anufacture.

C am follow er O u te r S h a ft Dia.

Bore in C ra nkca se

S tan dard

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 le a ra n ce s h a ft/b o re

0 .0 3 5 -0 .0 7 7

Rockershaft/Rockerarm 28.052 28.000

B a sic bore rocke rarm

R ockerarm bush

O u te r Dia.

28 090

lnner Dia R o cke rsh a ft Dia.

24.980 24.967

C le a ra n c e s h a ft/b o re

0 .0 2 0 - 0 .0 5 4

TORQUE SPECIFICATIONS Tim ing device weights to cam shaft g e a r ....................

M10 Max. stretch length

Injector pump drive gear to tim in g d e v ic e ..................

M10 Max. stretch length

Injector pump driven gear to flange (see section 17) Tim ing/Flywheel Housing to cylinder block ................

Cover to tim ing housing (top), tightening sequence p. 15-6 Steering pump to tim in g housing (see section 18) Cam shaft thrust plate to tim ing housing ......................... Check plug for in jecto r pump tim in g m a rk s ................... Cover air com pressor opening to tim ing housing ......... Inspection cover for T.D.C. m a r k .......................................

M10 M10 M 1 2 x 1,5 M8 M8 -v M 2 6 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 80 N.m 100 N.m 25 N.m 25 N.m

7/90

A D E 422, 423,424 W orkshop M anual

C AM S H A FT, TIM IN G CASE AN D DRIVE-TIM ING -

15-4

In tro d u c tio n The cam shaft is forged and precision ground. It is sup­ ported by bearings, and driven by gears at the flyw heel end o f the engine. To gain access to the cam shaft, and tim in g gears it w ill be necessary to remove the flyw heel and tim in g case housing.

REM OVING AN D REPLACING TIM IN G CASE R em oving 1. D isconnect exhaust brake cylinde r from exhaust m anifold. 2. Remove oil pressure and return pipe from power steer­ ing pump. 3. Unscrew and remove coo la nt feed pipes to co m ­ pressor, (fig. 1-15).

4. Remove air intake hose and air pressure pipes from com pressor, (fig. 2-15). 5. Unscrew and remove fuel filte r from tim in g case.

Fig. 3-15

S e c tio n s:

14 an d 15

' B a r rin g to n »•«*«! Club

A D E 422, 423,424 W orkshop Manual

S e c tio n s:

14 an d

15

C A M S H A F T , T IM IN G CASE A N D DRIVE-TIM ING — 15-5 7.

Remove all sum p b o lts and lift o ff sum p, (fig. 4; 15)

Fig. 4-15

8. Remove flyw h ee l (See sectio n 18). 9. Unscrew and remove tim in g case m ounting bolts and lift o ff tim in g case (fig. 5-15).

R e p la c in g 1.

F it new gaskets (Right and Left) over do w e ll pins on tim in g case and trim ends to correct length, (fig. 6-15).

Fig. 6-15

2. F it tim in g case over do w e ll pins replace b o lts and tig h te n to 70 N.m, (fig. 7-15).

Fig. 7-15

A D E 422, 423,424 W orkshop M anual

CAMSHAFT, TIM ING CASE AND DRIVE-TIMING -

15-6

3. Replace sump and tighten bolts to 25 N.m. 4. Fit tim in g cover w ith new gasket and insert into correct position using special tool Part number 40200103 (fig. 8-15).

Fig. 8-15

5. Tighten tim ing cover bolts to 25 N.m in the sequence shown in (fig. 9-15). 6. Fit fuel filte r to tim in g cover and tighten bolts to 80 N.m.

Fig. 9-15

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

Fig. 10-15

9. Connect and tighten coolant feed pipes to com ­ pressor, (fig. 11-15). 10. Connect and tighten oil pressure and return pipes to power steering pump.

Fig. 11-15

S e c tio n s:

14 an d 15

fta r r in g to n Diesel Club

A D E 422, 423,424 W orkshop Manual

S e c tio n s:

14 an d

15

C A M S H A F T , T IM IN G CASE A N D DRIVE-TIM ING — 15-7 R EM O VIN G A N D REPLAC IN G C A M S H A F T In itia l P re p a ra tio n Remove engine. Remove rocke r cover, arm s and brackets, lift out pushrods (see S ectio n 12). Turn engine over and rem ove sump. Remove flyw h e e l (see S ection 18). Remove tim in g case (see page 15-2). Remove cra n ksh a ft (see S ection 14).

R em oving 1. Turn cran kcase up sid e down. 2. Ensure th a t the ca m fo llo w e rs are moved aw ay from the ca m s h a ft lobes. 3. Pull ca m sh a ft from drive gear end and slid e out, ta k ­ ing care not to dam age the bearings. 4. If w ork is to be perform ed on the ca m sh a ft bearings, it w ill be necessary to pu ll o ff the end blan king plug, using spe cia l to o l Part num ber 40202004 (fig. 12-15).

Fig. 12-15

R e p la cin g 1. Insert c a m sh a ft and slide in, ta kin g care not to dam age th e bearings (fig. 13-15).

Fig. 13-15

2. Ensure th a t the tim in g m arks on the c a m sh a ft and c ra n ksh a ft gears are corre ctly a lign ed (fig. 14-15). 3. Coat edges o f c am sh aft blanking plug w ith a suitable sealing com pound, and insert. Knock ca re fu lly home using a cop pe r or hide faced hammer.

Fig. 14-15

BDC fcdriM hgton D iesel Club

A D E 422, 423,424 W orkshop Manual

S e c tio n s:

14 an d

C A M S H A FT, TIM IN G CASE AN D DRIVE-TIMING — 15-8

1 2 3 4 5 6 Fig. 15-15

REM OVING AN D REPLACING C A M S H A FT BEAR IN G S In itia l p re p a ra tio n Remove engine. Remove rocker covers, arms and brackets, lift out push rods (see Section 12). Turn engine over and remove sump. Remove flyw heel, and tim in g housing. Remove cam sh aft blanking plug. Remove cam sh aft and crankshaft.

R em oving 1. B olt bearing flan ge (5) and cen tra lizing tube (7) onto crankcase using tw o M 1 0 x 25 mm bo lts (6) (fig. 15-15 and 16-15).

2.

G uide spind le tube (8) in to crankcase and insert tw o bearing holders (9) behind appropriate bearing.

N o t e : Insert bearing holder (9) in a reversed po sitio n to each other (fig. 17-15).

Fig. 17-15

Handle Sem i-shell Slot Lockpin Bearing flange Bolt

7 8 9 10 11 12

C entering tube Spindle tube Bearing holder Locks Locating ring C o lla r bearing

15

i r r i n g i o n D iesel Club

A D E 422, 423,424 W orkshop Manual

S e c tio n s:

14 an d

C A M S H A F T , T IM IN G CASE AN D D R IVE-TIM ING 3. Turn sp in d le tube u n til lo ckpin (4) engages in s lo t (3) o f sp in d le tube. 4. F it handle (1) on threa ds o f spind le tube (fig. 18-15).

Fig. 18-15

5. Insert bearing holder (9) in to cam sh aft bearing. Insert locks (10) in grooves behind bearing holder (9). Pull out ca m sh a ft bearing by tu rn in g handle (fig. 19-15).

N o t e : To reset bearing hold er (9) the sp in d le tu b e (8) f it ­ ted w ith a handle m ust be pulled o u t o f the crankcase.

Fig. 19-15

6. The co lla r bearing (12) w ill be pressed o u t tow ards the rear. T his w ill require co n n e ctin g the handle (1) w ith the bearing flan ge (5) throu gh the sem i-shell (2) (fig. 20-15). 7. Unscrew handle (1) and remove sp in d le tube (8) w ith bearing holders (9) and ca m sh a ft bearing bushes. U nscrew bearing fla n g e (5).

Fig. 20-15

R e p la ce m e n t 1. B olt bearing flan ge (5) and ce n tra lizin g tub e (7) on to crankcase, using tw o M10 x 25 mm bo lts (6) (fig. 15-15 and 16-15). 2. Insert cam shaft bearing bushes onto bearing holders (9) and lo ck (fig. 21-15). 3. G uide sp in d le tube (8) in to c a m sh a ft gallery and in ­ sert bearing ho ld er (9) w ith bearing bush in to a p p ro p ria te housing. Turn sp in d le tube (8) u n til lo ckpin (4) in bearing holder engages in groove (3) o f sp in d le tube.

Fig. 21-15

15

15-9

C f t a r r in g t o n D iesel Club

A D E 422, 423,424 W orkshop Manual

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

15-1 0

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

lo ca te s the o il d rillin g in the ca m sh a ft bush w ith the o il g a lle ry in th e crankcase. 4. Insert lo ck (10) o n to sp in d le tub e (8), fit handle and pull in bearing so th a t the oil d rillin g in the ca m s h a ft bush a lig n s w ith the o il g a lle ry in the cran kcase (fig. 22-15). N o t e : L u b rica te the o u tsid e o f the ca m s h a ft bushes w ith en gine o il p rio r to in sta lla tio n .

5. Insert lo c a tin g ring (1) (fig. 23-15) in th ru s t p o in t o f c o lla r bearing (12) when pulling in the inner c a m sh a ft bushes. N o t e : Because o f the considerable force required, no more than tw o bearings should be pulled in at once. To reset the bearing ho ld ers (9) th e sp in d le tube (8) w ith ha nd le m u st be pu lle d o u t o f the crankcase.

6. W hen lo ckin g c o lla r bearing on bearing hold er (12) ensure th a t the lower bore of the cam shaft bush faces to the rig h t o f the ce n tre line (fig. 24-15). 7. Rem ove bushes.

bearing

p u lle r and

m easure

ca m s h a ft

8. C heck th a t o il g a lle rie s and d rillin g s are clear.

Fig. 24-15

S e c tio n s:

14 an d

15

B D C

B a r r i n g t o n D iesel Club

A D E 422, 423,424 W orkshop Manual

S e c tio n s:

14 an d

C A M S H A F T , T IM IN G CASE A N D D R IVE-TIM IN G C H E C K IN G C A M S H A F T E N D -PLAY In itia l P re p a ra tio n s Rem ove T im in g case cover. Remove in je c tio n pum p.

C A M S H A F T EN D -P LAY 1. Push ca m s h a ft a g a in st the tim in g case. 2. A tta c h d ia l gauge to crankcase. Place d ia l gauge probe pin w ith pre-load on c a m s h a ft gear and set sca le to 0 (fig. 25-15).

F ig. 25-15

3.

Press cam sh aft gear against the dial gauge probe and read ca m s h a ft end play (fig. 26-15).

Fig. 26-15

15

15-11

R d f r in y t o n Diesel CCftjjIb

ADE 422, 423,424

C A M SH AFT, TIM IN G CASE AN D DRIVE-TIMING

workshop Manual — 15-12

C H EC KIN G VALVE LIFT 1. Remove rocker covers, (fig. 27-15). 2. A tta ch 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 approxi­ mately 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 INLET 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 read­ ing 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

BDC B a r r i n g t o n D iesel Club

A D E 422, 423,424 W orkshop Manual

S e c tio n s:

14 an d

15

CAMSHAFT, TIMING AND DRIVE TIMING — 15-13 CHECKING VALVE TRAVEL AT ZERO V ALVE 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 1 cylinder is in firing position and n o t 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. A tte n tio n ! Valves of No 1 cylinder should be in rocking posi­ tion, 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 iesel Club

A D E 422, 423,424 W orkshop Manual

CAM SHAFT, TIM ING AND DRIVE TIM ING — 15-14 20. Replace rocker cover and tighten bolts to specified tor­ que, (fig. 36-15).

19.

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

Fig 15-36

:

7/90

S e c tio n s:

14 an d

15

BDC B a r r i n g t o n D iesel Club

A D E 422, 423,424 W orkshop Manual

S e c tio n s!

14 an d

15

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

25 24

r

3 14

Z 05-6015

T im in g C a se 1

TIM IN G C A S E

14

2

OIL S E A L

15

PLUG

3

STUD

16

GASKET

SPR IN G W A SH ER

4

TH RU ST PLATE

17

GASKET

5

SCREW

18

SPR IN G W ATER

6

SPR IN G W A SH ER

19

BOLT

7

TH REA D ED IN SER T

20

BOLT

8

TH REA D ED IN SER T

21

C O V E R TIM IN G H O U S IN G

9

TH REA D ED IN SER T

22

T H REA D ED IN SE R T

10

COVER

23

SEAL

11

COVER

24

BRACKET

12

GASKET

25

BRACKET

13

BOLT

7/90

Bcc B a r r i n g t o n D iesel Club)

ADE 422, 423,424 Workshop Manual

Section 16 - Lubrication System

_________________ S E C T IO N 16-1 Lubricating S ystem and S um p

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

O il pum p a sse m b ly G ear G ear Driven G ear O il pum p a sse m b ly G ear G ear Cover Shim C irc lip In te rm e d ia te Gear

12 13 14 15 16 17 18 19 20 21 22

In te rm e d ia te gear B olt O il pipe F lan ge F lan ge H o lde r B olt H o lde r B olt C o n n e c tin g sh a ft Sleeve

23 24 25 26 27 28 29 30 31 32 33

C irc lip B o lt Flange B olt B olt S u c tio n pipe G asket B olt F ilte r pipe W asher B olt

B a rrin g to n Diesel Club

ADE 422, 423,424 Workshop Manual

Section 16 - Lubrication System

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

O il P u m p s Engine

Width of oil pump gears (nominal dim.)

Actual width o f gears eg.

1st pump

422N

422T/TI423N

423T/TI

424N

424T

J34

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 pum p 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/m in 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

O il P re s s u re R e lie f V a lv e 42 2N /T /T I; 4 2 3 N *

423T/TI; 4 2 4 N /T * *

B e lo w b re a k p o in t

550 kP a

750 kP a

A b o v e b re a k p o in t

650 kPa

650 kPa

E n g in e O p e n in g p re s s u re kPa:

* — SA 0 0 2 2 6 5 M * * _ SA 002424M

C a m s h a ft/P is to n C o o lin g F low C o n trol

P is to n o il s p ra y je t in n e r d ia .

C a m s h a ft o il s p ra y h o le s in n e r d ia .

7/90

N a tu ra l a s p ira te d 2.0 ------------------------------------------------------T u rb o c h a rg e d 2.3 1.0

BCC B ^ f r i n g t o n D iesel Club)

ADE 422, 423,424 Workshop Manual

Section 16 - Lubrication System

LU BR IC ATIN G SYSTEM AND SUMP -

16-3

Oil Filter By- Valve Spring for By

Inside Dia.

Wire

Relaxed

Length when

Length w ith

Opening

Gauge

Length

Pre-loaded

Final Load

Pressure of By-

Valve

(valve open)

Valve 13.5

2.25

53.6

42.1

77 N

31

153 N

230 - 300 kPa

Oil Pressure M in im u m o il pre ssu re — (s to p e n g in e im m e d ia te ly !)

600 r/m in

b e lo w 50 kPa

2.300 r/m in

250 kPa

Oil C a p a c ity D e p e n d in g on a p p lic a tio n

Model range 422N — 424T

TORQUE SPEC IFIC ATIO N S

SECTION 16

Oil pressure relief valve to f la n g e ...................................... O il pump to cylinde r b lo c k ................................................... O il pump cover to pump b o d y ............................................ S uctio n pipe to o il pump ...................................................... S uctio n pipe bracket to cylin d e r b lo c k ............................. Sump to cylinde r b lo c k ......................................... ................ O il pump to block (L H /R H ).................................... Sump drain plug ...................................................................... O il fille r neck to s u m p ............................................................ O il filte r bowl to filte r h e a d .................................................. O il coo le r to cooler h o u s in g ................................................. O il c o o le r/filte r head to cylinde r b lo c k ............................. Screw plug fo r filte r by v a lv e ...................................... O il fille r plug to filte r h e a d ................................................... O il drain plug filte r h e a d ....................................................... D ip stick tube adapter to sum p ........................................... D ip stick tube to a d a p to r ....................................................... Piston coo lin g/cam sh aft spray nozzles (see sectio n 11)

M8 M8 M8 M8 M8 M8 M8 M26 X M8 M12 x M8 M10 M 26x M26 x M18 x M14 x M16 x

1,5 1,5

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

a p p ro x. 23.0 - 32.5 (

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

B a r r i n g t o n D iesel Club

ADE 422, 423,424 Workshop Manual

LU B R IC A T IN G SYSTEM A N D SUM P — 16-4 IN TR O D U C TIO N L u b ric a tin g S yste m The ADE 420 series engines are sup plied w ith lu b rica tio n oil by a gear driven o il pum p, and th e o il is filte re d by a paper fu ll flo w elem ent. The oil cooler, c ra n ksh a ft, c o n ­ n e ctin g rods, ca m sh a ft, and rockers are ail pressure fed. The in je c tio n pum p, and a ir c om p resso r are also d ire c tly fed with engine oil. Relief and by - valves protect the sys­ tem against overload.

REMOVING AND REPLACING BREATHER R em oving 1. Unscrew clamp and pull off hose from breather. 2. Unscrew and remove breather from crankcase (fig. 1-16).

R e p la cin g 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 repair­ ing. Even slight damage e.g. dents in cover, could cause a faulure of the breather. A damaged breather should always be replaced.

7/90

Section 16 - Lubrication System

B a r r i n g t o n D iesel Club

ADE 422, 423,424 Workshop Manual

Section 16 - Lubrication System

LU BRICATING 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 springloaded 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 O IL PRESSURE SENDER UNIT R em oving 1. Unscrew wire connection to oil pressure sender unit. 2. Using a open spanner remove oil pressure sender unit, (fig. 5-16).

R e p lacin g 1. Screw in oil pressure sender unit fitted with a new seal­ ing washer, tighten and attach electrical connection (fig. 6-16).

R EM O VING AN D REPLACING SUMP R em oving 1. Drain engine oil. 2. Unscrew and remove o il fille r neck and d ip stick guide tube from sump. 3. Remove b o lts and sum p (fig. 7-16). 4. Clean sum p in te rio r and exterior.

t

7/90

B a r r i n g t o n D iesel Club

ADE 422, 423,424 Workshop Manual

LUBRICATING SYSTEM AND SUMP -

16-6

Replacement 1. F it new gasket to sump. 2. Replace sum p on crankcase and tig h te n bo its to 30 N.m (fig. 8-16). 3. Replace o il fille r neck and d ip s tic k guide tube. 4. Screw in and tig h te n o il drain plug to 80 N.m. 5. F ill sum p w ith oil.

REMOVING AND REPLACING OIL FILTER BY VALVE Removing 1. Unscrew drain plug on o il filte r bowl and drain oil. 2. Remove plug for by valve, lift out valve and spring, (fig. 9-16). 3. Check length and tension using a su ita b le spring tester.

Fig. 9-16

Replacing 1. Insert valve, spring, and plug in to o il filte r body, (fig. 10-16). Note: Use new sea lin g washer. 2. T ighten filte r plug to 60 N.m. 3. Replace oil filte r drain plug on filte r bowl, and tighten to 50 N.m 4. Ensure th a t the engine is in stop po sitio n. Turn the engine several tim es w ith the starter until oil pressure is ed on the gauge. Release stop c o n tro l and start the engine. 5. Check fo r oil leaks.

Section 16 - Lubrication System

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

ADE 422, 423,424 Workshop Manual

Section 16 - Lubrication System

LU B R IC A T IN G SYSTEM A N D SUMP REM O VIN G A N D REPLAC IN G O IL FILTER ELEM EN T R em oving 1. Unscrew drain plug on oil filte r bowl and drain oil. 2 . Remove cen tre bolt from oil filte r bowl, and remove to g e th e r w ith filte r ca rtrid g e , (fig. 11-16). 3. Remove filte r cartridge from bowl, and take off 0-ring.

R e p la cin g 1. F it new O-ring to filte r housing, (fig. 12-16). 2. Insert new o il filte r ca rtrid g e in to filte r bow l w ith co il spring to w a rd s the b o tto m o f the bowl.

3. Centre o il filte r bowl on filte r housing, o il drain plug fa cin g dow n, in sert cen tre b o lt and tig h te n to a to r­ que of 50 N.m (fig. 13-16) 4. Ensure th a t the engine is in sto p p o sitio n . Turn the engine several tim es w ith the starter u n til oil pressure is ed on the gauge. Release sto p co n tro l and s ta rt the engine. 5. Check fo r o il leaks.

16-7

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

ADE 422, 423,424 Workshop Manual

LU BR IC ATIN G SYSTEM AN D SUM P — 16-8 R EM O VING AN D R EPLAC IN G O IL PUMP R em oving 1. Drain engine oil. 2. Remove sum p (fig. 14-16). 3 Unscrew o il su ctio n pipe and o il pum p from c ra n k­ case.

R ep la cing 1. Replace o il pum p and su ctio n pipe, tig h te n b o lts to 35 N.m (fig 15-16). 2. F it sum p o n to crankcase (Fit new sum p gasket if necessary), and tig h te n b o lts to 25 N.m. 3. Replace o il drain plug, and tig h te n to 80 N.m. F ill sum p w ith oil.

D IS M A N T LIN G PR IM AR Y O IL PUMP D is m a n tlin g 1. Unscrew and remove suctio n pipe (fig. 16-16). N o t e : ADE 423T/TI engines have pumps with 3 x 2 8 mm gears. The following operations will in addition, also apply to this type of three gear oil pump.

2. Remove b o lts from oil pum p cover (fig. 17-16).

7/90

Section 16 - Lubrication System

Bcc B a rrin g to n Diesel Club)

ADE 422, 423,424 Workshop Manual

Section 16 - Lubrication System

LU B R IC A TIN G SYSTEM AN D SUMP 3. L ift out oil pum p driven gear from o il pum p Body (fig. 18-16).

Fig. 18-16 4.

Using a s u ita b le puller, rem o ved rive g e a r(fig . 19-16).

5.

Remove drive gear from oil pum p body (fig. 20-16).

16-9

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

ADE 422, 423,424 Workshop Manual

LU BR IC ATIN G SYSTEM AN D SUMP — 16-10 A S S E M B LIN G PRIM ARY O IL PUMP 1.

Insert driving gear w ith sha ft in to o il pum p body (fig. 21-16).

2.

Heat drive gear and drive or press on to drive sha ft (fig. 22-16).

Note: The gear should be fitte d so th a t the drive sha ft projects from the gear hub face by 0,5 mm.

3.

Insert driven gear and sha ft in to oil pump body, (see fig . 23-16).

4. Replace cover and bolts in oil pump body and tighten to 25 N.m (fig 24-16). 5. A tta ch a dial gauge to the o il pump body. 6. Place probe pin o t dial gauge on to end of o il pump sh a ft w ith pre-load. 7. Push oil pump sha ft down and set dial gauge to “ O” . 8. Push sh a ft or o il pump up, ag ainst dial gauge probe pin and read end play. Note: End play o f o il pump drive shaft should be 0,089 ± 0,039 mm.

Fig. 24-16

Section 16 - Lubrication System

BCC B a r r i n g t o n D iesel Club

ADE 422, 423,424 Workshop Manual

Section 16 - Lubrication System

B d P r in g to n D iesel Club

ADE 422, 423,424 Workshop Manual

LU BR IC ATIN G SYSTEM A N D SUMP -

16-12

6.

Using a su ita b le puller, remove drive gear (fig. 29-16).

7.

Remove drive gear and sha ft from o il pum p body (fig. 30-16).

A S S E M B LIN G SECO NDARY O IL PUMP 1.

Insert driving gear o f o il pum p in to pum p body (fig. 31-16).

2.

Heat drive gear fo r o il pump, and press on flush w ith end o f drive sh a ft (fig. 32-16).

Fig. 32-16

Section 16 - Lubrication System

BCC B a rrin g to n Diesel Club

ADE 422, 423,424 Workshop Manual

Section 16 - Lubrication System

LU B R IC A TIN G SYSTEM AN D SUM P 3. Insert driven gear and sha ft in to o il pum p ,body (fig. 33-16).

Fig. 33-16 4. Replace cover and b o lts in pum p body, and tig h te n to 25 N.m (fig. 34-16).

5. A tta c h a d ia l gauge to o il pum p body. 6. Place probe pin o f dial gauge o n to end o f o il pum p sha ft, w ith pre-load. 7. Push sh a ft o f o il pum p down, and set dial gauge to ■•

0" .

8. Push sh a ft o f o il pum p up, a g a in st dial gauge probe and read end play. 9. Fit o il in ta ke pipe w ith new gasket, and tig h te n b o lts to 25 N.m (fig. 35-16).

10. R eplace in te rm ed iate gear in oil pum p, and lock w ith c irc lip (fig. 36-16).

Fig. 36-16

16-13

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

ADE 422, 423,424 Workshop Manual

LU B R IC A T IN G SYSTEM A N D SU M P — 16-14 R E M O V IN G A N D R E P LA C IN G PRESSURE R ELIEF VALVE R em oving 1. Drain en gine oil. 2. Remove sum p (see fig. 7-16). 3. U nscrew pre ssure (fig. 37-16).

re lie f

valve

from

cra n kca se

R e p la c in g 1. Fit pressure re lie f valve o n to cran kcase and tig h te n b o lts to 35 N.m (fig. 38-16). 2. Replace sum p fitte d w ith new gasket, and tig h te n b o lts to 25 N.m. 3. F ill sum p w ith oil.

R EM O VING AN D REPLAC IN G O IL SPRAY JET R em o vin g 1. U nscrew ce n tre b o lt o f spray je t, and rem ove from cra n kca se (fig. 39-16).

R e p la c in g 1. Check align m en t o f o il spray je t w ith special to o l part num ber 40201937 (fig. 40-16). 2. Ensure th a t c a m s h a ft spray holes at spray je t base are free from o b s tru c tio n . 3. Check tha t fu ll m ovem ent o f the spray je t valve w ith in the cen tre b o lt is not re stricte d .

7/90

Section 16 - Lubrication System

B a r r i n g t o n D iesel Club

ADE 422, 423,424 Workshop Manual

Section 16 - Lubrication System

LU B R IC A TIN G SYSTEM A N D SUMP — 16-15 2.

Insert o il spray je t so th a t dow el pin engages w ith de tent in cra n kca se (arrow), and tig h te n to 47 N.m (fig. 41-16).

R E M O VIN G A N D R EP LAC IN G O IL COOLER R em oving 1. Unscrew c o o la n t drain plug from o il cooler, and drain co o la n t (fig. 42-16).

2. Remove b o lts holding oil cooler to c ylin d e r block, and rem ove c o o le r (fig. 43-16).

R e p la c in g 1. F it new ga sket to o il cooler. 2. Place oil coo le r on crankcase, insert bolts and tigh ten to 50 N.m (fig. 44-16). 3. Insert coolant drain plug in cooler housing and tigh ten to 50 N.m.

Fig. 44-16

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

ADE 422, 423,424 Workshop Manual

LU B R IC A TIN G SYSTEM AN D SUM P -

Section 16 - Lubrication System

16-16

D IS M A N T LIN G A N D A S S E M B LIN G OIL COOLER

D ism antling 1. Unscrew and remove filte r bowl and cartridge. 2. Remove o il filte r plug (fig. 45-16).

Fig. 45-16

3. Remove o il drain plug. 4. Remove o il coo le r m ou ntin g b o lts, and remove oil coo le r from housing (fig. 46-16). 5. Remove o il filte r by valve.

Fig. 46-16

A ssem bling 1.

S tick gasket for oil cooler on housing using a suitable sea la nt (fig. 47-16).

M

I

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

2. Replace o il co o le r and tig h te n b o lt to 25 N.m (fig. 48-16). 3. Insert co o la n t drain plug and tig h te n to 50 N.m.

Fig. 48-16

m

'

N ote: F it gasket w ith g ra ph ite surface fa cin g oil cooler.

-

—

^

X

BCC B a r r i n g t o n D iesel Club

ADE 422, 423,424 Workshop Manual

Section 16 - Lubrication System

LU BR IC ATIN G SYSTEM AN D SUMP — 16-17 4. Insert and tig h te n o il filte r plug to 60 N.m (fig. 49-,16).

5. Replace oil filte r by valve and tig h te n to 60 N.m (fig. 50-16). 6. Fit o il filte r bowl w ith o il filte r c artridge to filte r body, and tig h te n 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

B a r r i n g t o n D iesel Club

ADE 422, 423,424 Workshop Manual

LUBRICATING SYSTEM AND SUMP -

L U B R IC A T IO N 1. 2. 3. 4. 5. 6. 7. 8.

Section 16 - Lubrication System

16-18

CHART

Sump. Oil strainer. Oil pump. O il pressure relief valve. Oil cooler. Oil filter. F ilter by valve. Main oil gallery.

9. 10. 11. 12. 13. 14. . 15.

Injection pump. Oil pressure switch. Crankshaft. Rocker arm. Camshaft. Cam shaft spray and piston cooling jets. Combined in each bank of cylinders.

Bcc B a rrin g to n Diesel Club)

ADE 422, 423,424 Workshop Manual

Section 16 - Lubrication System

L U B R IC A T IN G SYSTEM A N D SU M P -

Oil C o o le r 1 2 3 4 5 6 7 8 9 10 11 12 13

Cover H e lico il insert H e lico il insert F ilte r bow l Seal Plug F ilte r ca rtrid g e Valve Spring Plug W asher W asher Plug

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

W asher Plug O-Ring W asher B olt O il co o le r G asket S pring W asher B olt ~ B olt G asket S pring w asher B olt ~

16-19

Bcc B a r r i n g t o n D iesel Club)

ADE 422, 423,424 Workshop Manual

L U B R IC A T IN G S Y S 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 O il cooler O il cooler Gasket Gasket

10 11 12 13 14 15 16 17

Bolt Bolt Bolt Cover Gasket Spring washer Bolt Bolt

Section 16 - Lubrication System

BbC

ftdrrincjtoh Diesel Cltlb

M e r c e d e s S e c t i o n :

a n d

A D E

F u e l

4 2 2 , 4 2 3 ,4 2 4

S y s t e m

W o rk sh o p M a n u al

“

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

M e r c e d e s

a n d

S e c t i o 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 la l

S y s t e 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

In je c tio n p u m p a n d Q o v e r n o r new used

In ie c to r p r e s s u r e

m in

P r e s s u r e d if f e r e n c e s b e t w e e n in je c to r s

17 5 M P a 16 5 M P a

C u rre n t 2 0 .0 — 2 0 .8 M P a m in . 1 7 .5 M P 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 i o n p u m p t o c y l i n d e r b l o c k ....................................................... I n j e c t o r s e c u r i n g n u t t o c y l i n d e r h e a d ....................................... I n j e 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 i l t e r h e a d ................................................................ F u e l filte r h e a d to s u p p o rt b r a c k e t .................. ......................... F u e l f i 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 in g I n l e t m a n i f o l d ....................... F u e l p ip e s to lif t p u m p , fu e l f ilte r a n d in je c tio n p u m p F u e l r e t u r n p i p e t o 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 l t e r b r a c k e t ............................................ F u e l s y s t e m b l e e d s c r e w ......................................................... I n j e c t o r n o z z l e t o n o z z l e h o l d e r ...................................................... in s p e c tio n h o le p lu g (t im in g c o v e r) s e e s e c tio n 1 5

7/90

M8 M 10 M 2 8 x 1 .5 M 1 4 x 1 .5 M8 M 1 2 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 s e l C lu b

M e r c e d e s S e c t i o n :

a n 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 la l

S y s t e m

FUEL SYSTEM - 17-3

3

4

LAYOUT OF FUEL INJECTOR PIPES

Etc

Bdfpihcjton Diesel Cltlb

M e r c e d e s S e c t i o n :

a n d

A D E

F u e l

4 2 2 , 4 2 3 ,4 2 4

S y s t e m

W o rk sh o p M a n u al

Etc

Bdfpihcjton Diesel Cltlb

M e r c e d e s S e c t i o n :

a n d

A D E

F u e l

4 2 2 , 4 2 3 ,4 2 4

S y s t e m

W o rk sh o p M a n u al

Etc

Bdfpihcjton Diesel Cltlb

M e r c e d e s S e c t i o n :

a n d

A D E

F u e l

4 2 2 , 4 2 3 ,4 2 4

S y s t e m

W o rk sh o p M a n u al

Etc

Bdfpihcjton Diesel Cltlb

M e r c e d e s S e c t i o n :

a n d

A D E

F u e l

4 2 2 , 4 2 3 ,4 2 4

S y s t e m

W o rk sh o p M a n u al

Etc

BdPPihcjton Diesel

C ltlb

M e r c e d e s S e c t i o n :

a n d

A D E

F u e l

4 2 2 , 4 2 3 ,4 2 4

S y s t e m

W o rk sh o p M a n u al

Etc

BdPPihcjton Diesel

C ltlb

M e r c e d e s S e c t i o n :

a n d

A D E

F u e l

4 2 2 , 4 2 3 ,4 2 4

S y s t e m

W o rk sh o p M a n u al

Etc

BdPPihcjton Diesel

C ltlb

M e r c e d e s S e c t i o n :

a n d

A D E

F u e l

4 2 2 , 4 2 3 ,4 2 4

S y s t e m

W o rk sh o p M a n u al

Etc

BdPPihcjton Diesel

C ltlb

M e r c e d e s S e c t i o n :

3

a n d

A D E

F u e l

4 2 2 , 4 2 3 ,4 2 4

W o rk sh o p M a n u al

S y s t e m

F ig

2 5 -1 7

F ig

2 6 -1 7

T u r n e n g in e to N o 1 c y lin d e r c o m p r e s s io n s tro k e to s ta rt o f d e liv e r y ( 1 3 ° o r 1 5 ° B T D C ) u s in g tu rn in g to o l T h e e n ­ g in e m u s t n o t b e tu r n e d b a c k . V a lv e s o f N o t c y lin d e r a r e c lo s e d a n d v a lv e s o f N o 6 c y lin d e r (A D E 4 2 2 ) a r e ro c k in g (fig . 2 7 -1 7 ) N o t e : C e r ta in in d u s tria l a p p lic a tio n s m a y b e fitte d w ith a p o in te r a n d m a r k o n th e v ib ra tio n d a m p e r , th is w ill o n ly b e fitte d s h o u ld th e n o r m a l m a r k in g o n th e fly w h e e l b e in a c c e s s ib le

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 iv e f a n g e s a u g n e d w i t h m a r k o n m ie c t i o n p u m p b o d y .

in s e t n e *

0

'm g m t o b o r e o f o il f e e d in i n je c t i o n

pump DOO> if'5 28-’7'

F,g 28-17

7/90

Etc

BdPPihcjton Diesel

C ltlb

M e r c e d e s S e c t i o n :

a n d

A D E

F u e l

4 2 2 , 4 2 3 ,4 2 4

S y s t e m

W o rk sh o p M a n u al

Etc

BdPPihcjton Diesel

C ltlb

M e r c e d e s S e c t i o n :

a n d

A D E

F u e l

4 2 2 , 4 2 3 ,4 2 4

S y s t e m

W o rk sh o p M a n u al

Etc

BdPPihcjton Diesel

C ltlb

M e r c e d e s S e c t i o n :

a n d

A D E

F u e l

4 2 2 , 4 2 3 ,4 2 4

S y s t e m

W o rk sh o p M a n u al

Etc

BdPPihcjton Diesel

C ltlb

M e r c e d e s S e c t i o n :

a n d

A D E

F u e l

4 2 2 , 4 2 3 ,4 2 4

S y s t e m

W o rk sh o p M a n u al

^13® & ar*H ngt°n Diesel Club

A D E 422, 423,424 W orkshop Manual

S e c tio n :

18 - V a rio u s

S E C T IO N 18-1

A ir C om pressor 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 DOWEL 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 COMPRESSOR -

A D E 422, 423,424 W orkshop Manual

S e c tio n :

18 - V a rio u s

18-2

Air Com pressor C ylin d e r

1

Bore

90

S tro ke

46

D is p la c e m e n t

292 cm 3

P ressure D elivery c a p a c ity (en gine a t 2.300 r/m in)

810 kP a /1000 kPa

a g a in s t

100 kPa

470 f/m in

810 kPa

400 f/m in

90.030

B o re d ia m e te r

90.000 89.950

P is to n d ia m e te r

89.910 0.08

P isto n cle a ra n ce

0 .1 0

P is to n re tru s io n fro m u p p e r

0.4

e d g e o f c y lin d e r lin e r

1 .2

2 0 .0 0 0

G u d geo n p in d ia m e te r

19.996 0 .0 2 0

G ud geo n pin c le a ra n c e in c o n ro d bush

0.037 0.003

G u d geo n pin c le a ra n c e in p is to n

0 .0 1 2

31.975

C ra n k s h a ft jo u rn a l d ia m e te r

31.959 P isto n ring gap

G roove 1 G roove 2 G roove 3

G roove 4

P is to n rin g s id e c le a ra n c e

0.35 0.55

0.25 0.40

G roove 1 G roove 2

0.520

G roove 3

0.052

G roove 4

Note:

C y lin d e r lin e rs and p is to n w ill be s u p p lie d m a tc h in g th e given to le ra n c e u n d e r one part num ber.

f t d r r i n g t o n D iesel Club

A D E 422, 423,424 W orkshop M anual

S e c tio n :

18 - V a rio u s

COMPRESSOR — 18-3

*

Air C o m p re s s o r (contd.) C o n ro d b ig end bore

36.016 36.000

C o n ro d b e a rin g

32.008 31.994

L e n g th o f c o n ro d fro m C L big e n d /s m a ll end b o re

105.00 104.95

W id th o f c o n ro d

s m a ll end

20.060 20.000

b ig end

19.935 19.883

TORQUE SP E C IFIC A TIO N S AIR COMPRESSOR F ittin g s — suctio n /p re ssu re pipe to c y lin d e r head ....... C om pressor drive gear to c a m s h a ft................................... Driven gear to a ir com p resso r cra n ksh a ft .......................

M 2 6 x 1,5 M10 M18 x 1,5

A ir com p resso r cylin d e r barrel to tim in g housing ......... C o nn ecting rod to cran ksha ft .............................................. Pressure valve to in te rm ed iate plate ................................. Interm e dia te plate to cylin d e r head ................................... C ylind er head to c y lin d e r barrel .......................................... Inner bearing cage to tim in g housing ............................... Inner bearing re taining plate to cage ............................... Steering pum p o r cover to tim in g housing ...................... B lanking plug s air com pressor c y lin d e r head ................

M8 M8 M6 M8 M8 M8 M8 M10 M22 x M 26x M14 x M 22x M 16x M8 M8

F ittin g — C o ola nt sup ply to cylin d e r barrel .................... F ittin g — C o ola nt return to cylin d e r head ....................... C o ola nt pipes to fittin g s ........................................................ A ir com p resso r blanking plate (tim in g h o u s in g )............ A ir com p resso r blan king plate c ra n k c a s e ........................

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

80 65 without special tool 360 with special tool 270 30 30 14 30 30 25 50 60 80 80 50 80 35 25 30

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 N.m N.m

160 50 50 35 55 140 80

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

ALTE R N ATO R A N D STARTER MOTOR A lte rn a to r su p p o rt bracket to cylin d e r b lo c k ................... S upport bracket to a lte r n a to r ............................................... A lte rn a to r a d ju stin g b o lt to sum p ...................................... A d ju stin g b o lt cla m p to a lte rn a to r ..................................... A lte rn a to r pu lle y re taining n u t ............................................. S tarter m otor to tim in g housing ..........................................

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

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

7/90

+m

D iesel Club COMPRESSOR -

A D E 422, 423,424 W orkshop Manual

18-4

In tro d u ctio n The ADE 420 S eries Engines are fitte d w ith a sin g le c y ­ lin d e r w a te r cooled W estin g h o u se air com pressor, m ounted on the tim in g housing and driven by gears. The com p resso r provides a ir fo r the use in the veh icle brak­ ing system , and the o p era tion of a n c illa ry air devices.

REMOVING, DISMANTLING, ASSEMBLING, AND REPLACING AIR COMPRESSOR D ism antling 1. U nscrew c o o la n t feed pipe from (fig. 1-18).

c y lin d e r head

Fig. 2-18 4. Remove tim in g case to p cover. 5. Remove end cover from tim in g case. 6 . Unscrew and remove cylinder head, w ith suction valve

(fig. 3-18).

Fig. 3-18

S e c tio n :

18 - V a rio u s

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

A D E 422, 423,424 W orkshop Manual

S e c tio n :

18 - V a rio u s

COMPRESSOR 7. Unscrew and remove cylinder barrel (fig. 4-18).

8 . Remove c irc lip s and push out gudgeon pin from

pisto n (fig. 5-18).

9. Remove connecting rod bearing bolts. L ift o ff bear­ ing cap, w ith bearing shells, and pull out connecting rod (fig. 6-18).

10. Unscrew and remove power steering pump, from end o f com pressor, and take o ff drive plate (fig. 7-18).

Fig. 7-18

18-5

^13® & ar*H ngt°n Diesel Club

A D E 422, 423,424 W orkshop Manual

S e c tio n :

COMPRESSOR — 18-6 11. Turn cran ksha ft toT D C , and insert lo cking tool, Part num ber 40201238 and b o lt down (fig. 8-18).

Fig. 8-18 12. Unscrew and remove drive gear using special tool, Part num ber 40201225. 13. Unscrew and remove cran ksha ft lo cking tool. 14. Lever out crankshaft from bearings, so that rear bear­ ing flange can be removed. Lift crankshaft out through top o f housing (fig. 9-18).

15. Remove bearing retaining plate (fig. 10-18). 16. Unscrew inner bearing cage bo lts from tim in g case.

Fig. 10-18 17. Using a suitable puller remove bearing and cage from tim in g case (fig. 11-18).

Fig. 11-18

*

18 - V a rio u s

^l3® & ar*H ngt°n Diesel Club

A D E 422, 423,424 W orkshop Manual

S e c tio n :

18 - V a rio u s

COMPRESSOR — 18-7 18. Using a special puller Part number 40201160 and sup­ port, Part num ber 40200585, pull bearing from cage (fig. 12-18).

Fig. 12-18 19. Knock or press bush from bearing flan ge using a suita ble d rift (fig. 13-18). 20. Unscrew and remove valve plate from cylin d e r head. 21. Remove exhaust valve retaining b o lts and remove valve.

Fig. 13-18

Assem bling 1. Check co n d itio n of exhaust valve and renew if necessary, the valve m ust not be scored or d isto rte d (fig. 14-18).

Fig. 14-18 2. Place exhaust valve on valve plate, curved surface facin g upwards. Insert bo lts and tig h te n to 14 N.m (fig. 15-18). F it valve plate to cylinder head, and tig h te n bo lts to 30 N.m.

Fig. 15-18

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A D E 422, 423,424 W orkshop Manual

COMPRESSOR — 18-8 3. K no ck bush in to bearing fla n g e w ith a s u ita b le d rift and ream to size 30,020 to 30,041 m m (fig. 16-18).

Note: Ensure th a t o il d rillin g s in bush and fla n g e are in a lign m en t.

4. Using a s u ita b le d rift kno ck bearing in to fro n t fla n g e (fig. 17-18).

5. Insert bearing flange in to tim in g case and locate w ith 2 b o lts (fig. 18-18).

6. K nock in bearing fla n g e w ith a s u ita b le d rift replace all b o lts and tig h te n to 25 N.m (fig. 19-18).

Fig. 19-18

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COMPRESSOR — 18-9 7. Insert bearing retaining plate, and bolts, tigh ten to 50 N.m (fig. 19-18). 8. Insert crankshaft, w ith balance w e igh ts facing upwards in to crankcase and knock in to bearing w ith a so ft hammer.

Fig. 20-18

9. Lubricate rear bearing bush, fit new O-ring to flange and insert in to crankcase ensuring th a t o il d rillin g s are in a llig nm e nt (arrowed) (fig. 21-18).

Fig. 21-18

10. Insert bolts in to bearing flange and tigh ten progres­ sively (fig. 22-18).

Fig. 22-18

11. Remove bolts from flange. 12. Insert locking tool, and bolt down. 13. Replace drive gear for com pressor (fig. 23-18).

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COMPRESSOR — 18-10 14. T igh te n drive gear b o lt to 270 N.m using spe cia l too l Part num ber 40201225 (fig. 24-18). Note: The fig u re o f 270 N.m is equal to 360 N.m w ith o u t using the spe cia l tool.

Fig. 24-18

15. Remove lo ckin g to o l (fig. 25-18). 16. Replace pow er steering pump and tig h te n b o lts to 60 N.m. 17. Insert c o n n e ctin g rod, beairings, bearing cap and bo lts. T igh te n b o lts to 30 f'i.m.

Fig. 25-18

18. Place pisto n over con ne cting rod and in sert gudgeon pin. 19. Insert c irc lip s and lo ck gudgeon pin (fig. 26-18).

Fig. 26-18

20. O ffset piston rings by 180° to each other. Using piston ring cla m p Part num ber 40201212, com p ress rin gs to o u te r dia m e te r o f pisto n, a llo w in g s lig h t m ovem ent o f clam p. 21. Insert p is to n in to c y lin d e r barrel, fitte d w ith new gasket, and push in. Remove ring cla m p (fig. 27-18).

Fig. 27-18

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COMPRESSOR 22. B olt on cylinde r barrel to tim in g case, and tig h te n to 25 N.m. 23. Place inlet valve plate over lo catin g pins on cylinder head (fig. 28-18). 24. Fit cylinde r head gasket, w ith the word “ TOP” fa c ­ ing in le t valve, over lo catin g pins on cylinde r head. 25. Replace cylinde r head and tigh ten b o lts to 30 N.m.

26. Replace and tig h te n b o lts o f tim in g case top cover to 25 N.m in sequence shown in (fig. 29-18). 27. Fit end cover of tim in g case and tigh ten bo lts to 25 N.m.

28. Reconnect a ir pressure feed pipe and in d u ctio n feed hose to cylinde r head (fig. 30-18).

Fig. 30-18 29. Reconnect co o la n t feed (fig. 31-18).

pipe to cylin d e r head

Fig. 31-18

18-11

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SEC TIO N 18-13 Flywheel

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

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FLYW HEEL — 18-14

Flywheel D ia m e te r fo r s ta rte r rin g gear

432.645 432.490

D ia m e te r fo r w e ar sle eve (Rear seal)

115.015 114.980

M a xim u m m a te ria l rem oval from c lu tc h su rfa ce

2.0

M ax. rad ia l ru n o u t m easured on w e ar sleeve lo c a tin g su rfa c e

0.05

M ax. ra d ia l ru n o u t m easured on s ta rte r rin g gear lo c a tin g su rfa ce

0.1

M ax. ra d ia l ru n o u t on c lu tc h lo c a tin g fla n g e

0.05

Max. la te ra l ru n o u t on c lu tc h fric tio n su rfa ce

0.1

TORQUE SPECIFICATION FLYW HEEL AND HOUSING Flywheel to crankshaft .................................................................

M16 x 1,5

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

7/90

Bolt length

Initial torque Final torque Initial torque Final torque 74 mm — max. 75 mm 80 mm — max. 81 mm 85 mm — Max. 86 mm

100 N.m 9 0 °— 100° 200— 220 N.m 9 0 °— 100°

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FLYWHEEL — 18-15

S tarter Ring Gear

R ing g e ar in s id e d ia m e te r

432.155 432.000

R ing gear c le a ra n ce

0 .3 3 5 -0 .6 4 5

In s ta lla tio n te m p e ra tu re fo r fittin g s ta rte r rin g gear

2 0 0 -2 3 0 ° C

M ax. la te ra l ru n o u t o f m o u n te d s ta rte r rin g gear

0.5

Ring gear w id th

(yellow colour)

18.6 18.4

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FLYW HEEL — 18-16 REMOVING AND REPLACING FLYWHEEL Removing 1. Loosen m ou ntin g b o lts on flyw heel. Unscrew tw o o p ­ po site b o lts, screw in guide m an dre ls Part num ber 40200077 (fig. 32-18).

2. Remove re m a in in g flyw h e e l b o lts, scre w in F lyw heel P o sitio n in g H andles Part num ber 40201982 and slide o ff flyw h e e l (fig. 33-18). 3. Remove g u id e m an dre ls and flyw h e e l p o s itio n in g handles. Clean and che ck flyw h e e l fo r dam age.

Replacing 1. Screw g u id e m an dre ls in to end o f cra n k s h a ft and flyw heel p o sitio n in g handles in to flyw heel (fig. 34-18). 2. Place flyw h e e l on m an dre ls and push in a g a in st end o f cra n ksh a ft.

Note: Ensure that locating dowel in crankshaft is aligned with hole in flywheel. 3. M easure le n g th o f flyw h ee l b o lts (fig. 35-18). Note: Flyw heel b o lts m ay s till be used if stre tch does not exceed 75 mm.

7/90

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FLYWHEEL — 18-17 4. L ig h tly o il threads o f flyw heel bolts, screw in tw o bolts, remove guide m andrels and flyw heel p o s itio n ­ ing handles. Replace rem aining flyw heel bolts. 5. Tighten flywheel bolts crossw ise to 100 N.m and then to a fu rth e r torque angle of 90° + 1 0 ° (fig. 36-18).

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

2. Heat new wear ring to approxim ately 150°C. 3. Insert new wear ring in to m andrel Part num ber 40200268 (rounder edge o f outside diam e te r facin g forward). Place m andrel on flyw heel and knock in to po sitio n (fig. 38-18).

REMOVING AND REPLACING SPIGOT BEARING Replacing spigot bearing 1. Using su ita b le d rift, kno ck out spigo t bearing from flyw h ee l (fig. 39-18).

Fig. 39-18

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2. Turn over flyw h ee l, insert new s p ig o t bearing and kno ck in to flyw h ee l (fig. 40-18).

Fig. 40-18

N ote: The s p ig o t bearing can be removed and replaced w ith the flyw h e e l in p o s itio n using p u lle r Part num ber 40200064. This requires rem oving the flyw h e e l m ou ntin g bo lts, and in se rtin g both guide m andrels. R eplace and tig h te n flyw h ee l b o lts to s p e c ific a tio n (fig. 41-18).

Fig. 41-18

M ACHINING FLYWHEEL O peration N ote I: To de te rm in e if the flyw h ee l can s till be m a ch in ­ ed, m easure the th ickn e ss o f the flyw h e e l and com pare the figures w ith spe cifica tion. If the m easurem ent is lower tha n the s p e c ifie d value, m inus m aterial rem oved, the flyw h e e l can no long er be used, and m u st be replaced. 1. To m achine, cla m p flyw h ee l in to a s u ita b le lathe, m ach in e and su rfa ce grind face (fig. 42-18). 2. Remove flyw h ee l and che ck once m ore for surface heat cracks. N ote II: If the flyw h e e l is s till cracked a fte r m ach in ing , and the cracks cannot be removed to retain spe cifica tions fo r flyw h ee l th ickn e ss, renew flyw h ee l. 3. Using com pressed air, clean sw arf from tapped holes fo r c lu tc h pressure plate atta ch m e n t. 4. R eplace flyw h ee l, and tig h te n b o lts to s p e c ific a tio n .

Fig. 42-18

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FLYWHEEL RENEWAL OF STARTER RING GEAR

'

Operation 1. Remove flyw heel (see page 18-16). 2. Place flywheel under a press. starter ring gear at several points, using s o f uniform height. 3. Rapidly heat starter ring gear w ith a w e lding torch, and press flyw heel from ring gear. 4. Check seating of ring gear on flywheel for score marks m achine if necessary to sp e cifica tio n s. Note I: Renew flyw heel if score m arks are excessive. 5. Heat new ring gear to spe cifie d tem perature (see spe cifica tions), and press on to flyw heel. N ote II: When fittin g new starter ring gear to flyw heel, make sure th a t the ring gear is pressed on squarely. Ring gears on w hich teeth are damaged, can be turned around and used again. Note III: In some instances where no drillings are provided for the bo lts holding the clu tch pressure plate, it w ill be necessary to d rill and tap the ring gear M 1 0 x1 5 m m (fig. 43-18). 6. When cooled, check flywheel and ring gear for run-out. 7. Replace flyw heel, (see page 18-16).

Fig. 43-18

18-19

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SECTIO N 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 Piston type seal rings Heat shield T hrust washer Spacer Bearing (Thrust) Seal carrier/Thrust washer O il d e fle cto r Rivet Data plate End plate Allan cap screw C om pressor wheel S haft nut C om pressor housing Springw asher and com pressor side clam ping segm ent

21 22 23 24

Bolt Turbine housing Nut & bolt S pringw asher and turbine side cla m pin g segm ent

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T U R B O C H A R G E R — 1 8 -2 2

9

T u rb o ch a rg e r and M a n ifo ld 1 2 3 4 5 6 7 8 9 10 11 12 13

7/90

Turbocharger Turbocharger Nut A ir intake manifold Air intake manifold Threaded insert Spring washer Gasket Bolt Bolt Plug Seal Plug

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

Air intake pipe Hose Hose Bracket Bolt Adapter Seal A ir transverse pipe Gasket Bolt Seal PLug Shield Bolt

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TURBOCHARGER — 18-23

T urbocharger C ross-section

TORQUE S PEC IFIC ATIO N TURBO CHARG ER O il return m anifold to tu rb o c h a rg e r................................... Securing nut fo r o il return fittin g to tim in g housing (side) O il return tube fittin g to tim in g housing ( to p ) ................ Inlet m an ifold to cylin d e r h e a d s ......................................... Turbocharger to exhaust m an ifold ..................................... O il supply pipe to tu rb o c h a rg e r.......................................... O il supply pipe to cylin d e r b lo c k ........................................ Heat shield to tim in g housing (42 2T )................................. Heat shield to oil return m an ifold (424T )......................... C onnecting m anifold to in let m an ifold LH-RH ............... Air transverse pipe .....................................................................

M8 M 2 6 x 1,5 M 2 6 x 1.5 M8 M10 M8 M 1 4 x 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

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Introduction The G arrett/AiR esearch Turbocharger for internal co m ­ bustion engine application com prises of a gas turbine and radial compressor, which utilize a com mon shaft. The tur­ bine and com pressor w heels are m ounted at opposite ends o f the shaft, w hich is enclosed and ed by the centre housing. The turbine and com pressor wheels are enclosed by cast housings attached to the centre housing. A fte r the engine is started, the flo w o f exhaused gases from the engine throu gh t the tu rbine housing and cause the sha ft assem bly to rotate. The com pressor wheel mounted at the opposite end of the shaft draws am­ bien t air in to the com pressor housing, com presses the air and delivers it to the engine. During operation, the turbocharger responds to the engine load dem ands by reacting to the flo w of exhaust gasses. As the power o f the engine increases, the flo w o f the exhaust also increases and the speed and ou tput of the ro ta tin g assem bly increases proportionately.

REMOVING AND REPLACING TURBOCHARGER Removing 1. Unscrew exhaust pipe from turbo cha rge r m anifold. 2. Unscrew air pipe from exhaust brake cylinder. 3. Remove o il feed and return pipes to turbocharger, (fig. 44-18).

4. Unscrew a ir intake hose clips (fig. 45-18).

Fig. 45-18

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TURBOCHARGER 5. Remove m an ifold between turbo cha rge r a n d 'co o le r (fig. 46-18). 6 . Unscrew turbo cha rge r from exhaust m an ifold and

remove.

Replacing Note: Prior to replacing turbocharger, the intake m anifold, and m an ifold flange ahead o f the com pressor, exhaust m anifold, and exhaust pipe, as w ell as oil feed and return pipes, m ust be inspected thoroughly fo r foreign particles, d irt and dam age. B lanking plugs on openings o f tu rb o ­ charger sho uld be removed sh o rtly before replacem ent. F ill bearing housing w ith clean engine oil throu gh o il in ­ let, before con ne cting o il feed pipes. Turn ro ta tin g parts by hand to give bearings a co a tin g o f oil. 1. Fit turbocharger w ith new gasket to exhaust manifold, and tig h te n bo lts to 50 N.m. 2. Replace and tig h te n m an ifold between turbo cha rge r and a ir coo le r (fig. 47-18).

3. C onnect o il feed and return pipes to turbocharger. 4. Replace a ir inlet hose clam ps and tigh ten (fig. 48-18). 5. Replace a ir in le t pipe to exhaust brake. 6 . A tta ch exhaust pipe to m an ifold and tig h te n b o lts to

sp e cifica tio n .

Fig. 48-18

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18-26

TURBOCHARGER TROUBLESHOOTING C o n d itio n

Possible Cause

C o rrection

U nusual exhaust gas d e n sity and pow er loss.

In s u ffic ie n t a ir and charge pressure to low.

C heck fla n g e and hose co n ­ n e ctio n s o f tu rbo cha rge r air pipe fo r leaks.

D irt on in sid e o f com p resso r housing.

Remove and clean com p resso r housing.

C logged a ir cleaner (excessive vacuum ahead o f com pressor, a lso o il leak on com p resso r side.)

Clean a ir cle an er o r replace filte r ca rtrid g e . Check intake. Check pipe behind tu rbo cha rge r fo r leaks.

Exhaust pipe behind tu rb o ­ charger, o r sile n ce r d irty o r damaged.

Clean or repair. Check opening o f engine brake valve.

Leaks at c o n n e ctio n s and fla n g e s o f air and exhaust pipes.

Check flan ge and hose con ne c­ tio n s, rep la cing gaskets if necessary.

R otor scrap in g due to excessive bearing play.

Remove pipes and che ck housing on tu rb in e and com pressor sides fo r sig n s o f scraping. Repair o r replace turbo cha rge r in case o f wear.

Unusual noise (e.g. w h istle)

C hecking Turbocharger in vehicle D isco n n e ct a ir in ta ke m an ifold. Turn rotor, che ckin g fo r easy and u n ifo rm running. If necessary turn back and fo rth several tim e s u n til ro to r is freed o f o il carbon deposits. The turb o ch a rg e r ro to r has g yro sco p ic s ta b iliz a tio n , and runs in fixe d bearings. To check, move ro to r.in and out. If there is no c o n ta c t on the tu rb in e or charger sides, th is m eans th a t the end play is corre ct. Move and turn th e ro to r up and down, if no scrap in g occurs, th e side play is a lso correct.

T urbocharger o il leaks The bearing ho using on all types o f tu rb o ch a rg e rs used on ADE engines are fitte d w ith oil c o n tro llin g piston type rings, to provide a seal between the oil and the air/exhaust gas. The fu n c tio n o f these seals is based on the pressure b u ilt up in th e com pressor housing. However there could be a vacuum at fa s t idle speed of w h ile co a stin g , w h ich would favour oil leakage and coating o f the inlet ports with o il. The am o un t o f o il lo st in th is way is extrem e ly low and has no, m easurable in flue nce on th e engines oil c o n su m p tio n .

F ittin g a R econditioned Turbocharger Prior to fittin g th e turbo cha rge r, the in le t and flanged m an ifold ahead o f the com pressor, the exhaust m an ifold and the exhaust pipe, as w e ll as the o il feed and return pipes, m ust be in spe cte d very th o ro u g h ly fo r d irt and dam age. Plugs on the op en ing s of th e turb o ch a rg e r should be removed only shortly before fitting . F ill the bear­ ing housing w ith clean engine oil through the o il inlet port before co n n e ctin g th e o il feed pipe. In d o in g so, turn the ro ta tin g parts by hand to give the bearings a coa t of oil.

If o il covered in le t po rts are found when servicing, there is no reason to remove the turb o ch a rg e r as long as an in sp e ctio n o f the turb o ch a rg e r did not show defects. A n o th e r cause fo r o il leaks cou ld be a dam aged (deform ed) or clo g g e d o il return pipe. The reduced cross s e ctio n size o f th e pipe w o u ld lead to an increase in flo w resistance, causing the oil level in the turbocharger to rise and o il to leak past the seals on the turbine and co m ­ pre ssor sides. In th is case clean o r replace the oil return pipe. '

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TURBOCHARGER — 18-27 CHECKING TURBOCHARGER M easuring Shaft End Play 1. Clamp turbocharger in a vice fitte d w ith soft jaw s (tur­ bine side facin g up). 2. Fit dial gauge in holder. 3. Place dial gauge m easuring tip on sh a ft end o f tu r­ bine wheel (fig. 49-18). 4. Push down turbine sha ft and set dial gauge to “ 0” . 5. Push turbine shaft up against dial gauge and read end play. M axim um perm itted end play = 0 ,1 6 mm.

M easuring Side Play Note: Side play is m easured only on tu rb in e side. 1. Push turbine wheel to one side, measure gap between turbine wheel and housing w ith a feeler gauge, note m easurem ent (fig. 50-18). 2. Push tu rb in e wheel in op po site directio n, measure gap at the sam e point w ith a feeler gauge, note m easurem ent. 3. The diffe re nce between the tw o m easurem ents is the clearance = 0,45 mm. Note: Measure at least tw o d iffe re n t points.

Fabricated Tool

Fig. 51-18

A K n u rle d s u rfa c e B A d a p te d to a v a ila b le ro to r

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TURBOCHARGER — 1828 DISMANTLING AND ASSEMBLING TURBOCHARGER D ism antling N ote: Clam p is self-m ade to draw ing on page 18-27. 1. M ark po sitio n of tu rb in e housing in relation to bear­ ing housing. 2. U nlock lo cking plates on cla m pin g segm ents of tu r­ bine housing (fig. 52-18).

Fig. 52-18

3. Unscrew b o lts from turbine housing and remove w ith cla m pin g segm ents and lock plates. 4. Using a soft faced hammer knock turbine housing and bearing housing apart (fig. 53-18). Note: Ensure th a t blades o f turbo cha rge r are not da m ag­ ed when rem oving housing.

Fig. 53-18

5. M ark p o s itio n o f bearing housing in relatio n to co m ­ pressor back plate and com pressor housing (fig. 54-18).

Fig. 54-18

6 . Unscrew com p resso r housing from back plate (fig.

55-18). 7. Loosen and remove com pressor housing from bear­ ing housing, w ith lig h t knocks from a so ft faced ham m er. Note: Ensure th a t blades of com p resso r are not dam ag­ ed when rem oving com p resso r housing.

Fig. 55-18

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TURBOCHARGER 8. Insert bearing housing in to clam p (self made), and unscrew com pressor sh a ft nut (fig. 56-18). Note: When unscrew ing sha ft nut, do not damage the sh a ft by tw is tin g . Alw ays use a T-socket spanner to unscrew sha ft nut, to avoid bending shaft.

9. Heat com pressor wheel w ith suita ble hot air blower (fig. 57-18).

10. Press sha ft from com pressor wheel (fig. 58-18). Note: The heat shield should be centred to avoid damage to piston ring seals and shielding.

11. Remove bearing housing and heat shield from shaft. 12. Unscrew com pressor back plate and remove with seal and O-ring (fig. 59-18).

Fig. 59-18

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TURBOCHARGER — 18-30 13. Remove o il d e flector (4), spacer (3), thrust bearing (2), and th ru st washer (1) (fig. 60-18).

14. Remove com pressor bearing from housing (fig. 61-18).

15. Remove c irc lip s and turbine bearings from bearing housing (fig. 62-18).

ASSEMBLING Note: Clean and check all parts fo r damage. Check hous­ ing and blades of tu rbine and com pressor w heels for cracks, signs of foreign p a rticle s and scraping. Check pisto n ring type seals and grooves fo r wear. 1. Check turbocharger rotor shaft for run out. Place shaft on tw o V-blocks at height of bearings and measure run-out 20 mm from end o f rotor shaft, using a dial gauge. M axim um perm issible run-out = 0,007 mm, (fig. 63-18).

Fig. 63-18

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TURBOCHARGER 2. Insert c irc lip in bearing housing, lu b rica te turbine end bearing w ith engine oil, and insert w ith 2nd circlip (fig. 64-18). N ote: Insert c irc lip s so th a t the rounded side faces bearing. 3. Turn bearing housing around and insert com pressor end bearing w ith circlip s.

4. Insert seal rings on to shaft, w ith gaps set at 180° in relation to each oth er (fig. 65-18).

5. Place heat shield over seal rings on rotor sha ft (fig. 66-18).

6. Fit bearing housing over seal rings, so th a t the seal ring gap is at 90°, in relation to the o il in let and ou tlet flan ge s (fig. 67-18). Note: The heat shield should s till turn easily a fte r fittin g the bearing housing.

Fig. 67-18

18-31

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TURBOCHARGER — 18-32 7. Insert th ru st washer (1) and spacer (3). F it th ru st bear­ ing (2) w ith oil groove facin g bearing housing, and dowel pin holes in alignm ent w ith dowel pins in bear­ ing housing. Fit o il d e fle cto r (4) (fig. 68-18).

Fig. 68-18

8. Lubricate O-ring w ith brake c y lin d e r grease, and in ­ sert in to com pressor end plate (fig. 69-18). 9. Insert seal rings on to seal carrier w ith gaps set at 180° in re la tio n to each other. 10. F it seal ca rrier w ith seal rings in to com p resso r end plate, so th a t the pisto n ring gap is at 90°, in relatio n to the o il in let and o u tle t flanges.

Fig. 69-18

11. C oat sea lin g surface between bearing housing and com p resso r end plate, w ith a su ita b le sealing com pound. 12. F it com p resso r end plate, lin in g up m arks on bear­ ing housing. Coat bolts w ith Loctite, insert and tighten to 8 N.m (fig. 70-18).

Fig. 70-18

13. Fit O-ring to com pressor end plate (fig. 71-18).

Fig. 71-18

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TURBOCHARGER — 18-33 14. Heat com pressor wheel to a maximum of 130°, and fit onto rotor shaft (fig. 72-18).

15. Coat rotor sha ft nut w ith Loctite, and fit to shaft, tigh ten nut to 12 N.m (fig. 73-18).

16. Fit com pressor housing, lining up marks on com ­ pressor end plate. Fit clam ping segments, insert bolts, and tigh ten to 7 N.m (fig. 74-18).

17. Attach turbine housing, lining up w ith marks on bear­ ing housing. Fit clam ping segm ents, and lockplates. Insert bolts with high temperature grease, and tighten crossw ise to 20 N.m. 18. Lock m ounting bolts (fig. 75-18). 19. Check turbocharger shaft for free running. Note: F ill bearing housing through oil in le t port w ith engine oil prior to operating turbocharger.

Fig. 75-18

B0C ^ a r r in g to n Diesel Club EXHAUST BRAKE -

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18-34

Introd u ction Depending on application the ADE 420 Series Engines are fitte d w ith an exhaust brake consisting of a butterfly valve, w h ich pivots on a spind le w ith in the exhaust m anifolds. The b u tte rfly valves are situated at the flywheel end of each m anifold. The bu tte rfly valves are actuated by a pneum atically operated lever, which is secured to the but­ terfly valve spindles, where the spindles protrudes through the housing. When the foot-operated exhaust brake valve (located on the flo o r o f the cab, drivers side) is pressed, co m ­ pressed air flow s past the valve and enters an air operated cylinder. A piston, inside the cylinder and attached to the spind le levers, pushes the levers tow ards the rear o f the vehicle and thus closes the b u tte rfly valves. At the same tim e, the fuel supply to the injectors is cut o ff (ie the speed con tro l lever moves to the stop position). The back pressure build up in the exhaust m anifold exerts a brak­ ing e ffe ct via the transm ission, to the wheels o f the vehicle.

CHECKING EXHAUST BRAKE Checking exhaust brake adjustm ent 1. Unscrew and remove exhaust pipe from m anifold. 2. Check to see if the engine brake retarder valve is wide open, and marks on engine brake shaft, and valve are in align m en t (fig. 76-18).

3. Operate engine brake and check to see if retarder flap is closed com p le te ly (fig. 77-18).

REMOVING AND REPLACING EXHAUST BRAKE VALVE AND SHAFT Removing 1. Unscrew and remove exhaust pipe from m anifold. 2. D isconnect engine brake cylinder. 3. Unscrew and remove lever operating brake valve. 4. Remove spacer and bracket (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

R eplacing 1. Knock new shaft bushes in to exhaust m anifold, 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 mark­ ing on shaft is in alignm ent w ith engine brake valve, (fig. 82-18).

Fig. 82-18

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EXHAUST BRAKE — 18-36 3. Fit stop bracket over valve operating sha ft and insert spacer. 4. F it brake op era ting lever onto shaft, so th a t w ith the valve fu lly open the brake cylin d e r can be fitte d w ith o u t te n sio n (fig. 83-18).

Fig. 83-18

Note: Fine adjustm ent can be made on the brake cylinder. On turbocharged engines the stop o f the valve operating lever m ust rest against the bracket, when the engine brake valve is fu lly open (fig. 84-18). 5. T ighten cla m p bolt o f engine brake cylin d e r so th a t the sh a ft has an end play of 0,2 to 0,5 mm. 6. F it engine brake cylinder. 7. O perate engine brake and check to see if the engine brake valve is fu lly closed. 8. Replace exhaust pipe, fitted with a new gasket, and securely tighten nuts.

R EM O VING AN D REPLACING STARTER MOTOR R em oving 1. D isconnect battery. 2. D isconnect cables to starter m otor. 3. Unscrew and remove m ounting nuts (fig. 85-18). 4. Remove s ta rte r m otor from below.

R eplacin g 1. Fit starter m o to r on to stud s from below (fig. 86-18). 2. Replace nuts and tig h te n to 80 N.m. 3. C onnect cab le s to s ta rte r m otor. 4. C onnect battery.

7/90

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SEC TIO N 18-37 A lternator and Starter M otor

SECTIONAL VIEW OF THE K 1 CLAW-POLE ALTERNATOR

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ALTERNATOR AND STARTER MOTOR — 18-38 ALTERNATOR Precautions The diodes in the alternator fun ction as one-way valves and the transisto rs in the regulator/control box operate as fast sw itches. Both are accurate and sensitive. They do not wear out and seldom require adjustm ent, but because they are sensitive to voltage changes and high temperature, the fo llo w in g precautions are vital to pre­ vent them from being destroyed. (a) DO NOT disconnect the battery w hile the engine is running. This w ill cause a voltage surge in the alte r­ nator charging system that w ill im m ediately ruin the diodes or transistors. (b) DO NOT disconnect lead w ith o u t firs t stopping the engine and turning all electrical sw itches to the off position. (c) DO NOT cause a short circu it by connecting leads to incorrect term inals. Always id e n tify a lead to its cor­ rect term inal. A short circu it or wrong connection giv­ ing reverse polarity w ill im m ediately and permanently ruin transisto rs or diodes. (d) DO NOT connect a battery in to the system w ithout checking for correct polarity and voltage. (e) DO NOT “ flash” connections to check for current flow. No m atter how brief the con tact the transisto rs may be ruined.

Maintenance The alternator charging system w ill norm ally require very little atten tion. It should be kept free from build-up of dirt, and a check made if it fa ils to keep the battery charged.

(a) Regularly inspect the driving belts for wear and cor­ rect tension. It is im portant to ensure that all belts on a m ultiple belt drive have equal tension and are each carrying the ir share of the load. Slack belts w ill wear rapidly and cause slip w hich w ill not drive the alter­ nator at the required speed. Drive belts w hich are too tigh t impose severe side thrust on the alternator bear­ ings and shorten their life. Periodically ensure that the alternator is correctly aligned to the drive. (b) Do not replace fa u lty belts individually in a m ulti-belt system. A com plete matched set of drive belts must always be used. (c) Keep the alternator clean w ith a cloth m oistened in a suitable cleaning fluid. Ensure that ventilation slots and air spaces are clear and unobstructed. (d) Remove any dirt accum ulated on the regulator/con­ trol box housing, and ensure that cooling air can freely over the casing.

Testing the A lternator in Position First check the driving belt for condition and tension. The nom inal hot outputs 6 000 r/min (alternator speed) are as fo llo w s :— 14V — 35A 28V — 28A 28V — 55A These figures may be exceeded slig h tly when the a lte r­ nator is running cold. A dust proofed alternator can be fitte d as an option, depending on application.

Trouble Shooting If a m alfunction should develop in the current generating system, it m ust 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 w ith probable causes and appropriate corrective measures:

Cause

Correction

Battery is dead or in su fficie n tly charged: 1. Open circ u it or con tact resistance in charging circu it

1. Remove open circ u it or resistance

2. Defective battery

2. Replace battery

3. Defective alternator

■3. Have alte rna to r repaired in authorized workshop

4. Defective regulator

4. Replace regulator

5. V-Belt too loose

5. Tighten V-Belt

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ALTERNATOR AND STARTER MOTOR — 18-39 Charge indicator lamp does not burn w ith engine stopped and ig n itio n on: 1. In d ica to r bu lb is burned out

1. Replace w ith new bulb

2. Dead battery

2. Remove battery fo r charging

3. Defective battery

3. Replace battery

4. Loose or dam aged cables

4. Replace or tig h te n cables

5. Defective regulator

5. Replace regulator

6. Shorted positive diode in the a lte rna to r

6. Have a lte rna to r repaired in authorized w orkshop

7. W orn carbon brushes

7. Replace brushes

8. O xide layer on slip-rings, or broken w ire in rotor w inding

8. Have a lte rn a to r repaired

Charge in d ica to r lam p con tinu es to burn b rig h tly during higher engine speeds: 1. Cable D + /61 is shorted to ground

1. Repair or replace cable

2. Defective regulator

2. Replace regulator

3. Over-voltage p ro te ction device defective

3. Replace over-voltage pro te ction device

4. Defective rectifier, d irty slip-rings, short in cable “ DF" or in rotor w inding

4. Have a lte rna to r repaired in authorized w orkshop.

Charge in d ica to r lamp burns b rig h tly w ith engine sto p ­ ped, but on dim s or glim m ers w ith engine running: 1. Poor con n e ctio n s () resistance) in the charg­ ing circu it or in the cable to the charge indicator lamp

1. Remove co n ta ct resistance

2. Defective regulator

2. Replace regulator

3. Defective a lte rna to r

3. Have a lte rna to r repaired

Charge in d ica to r lam p flickers: 1.

1.

Replace regulator

C o ntact reg ulator may be in correctly adjusted or regulating re sisto r is burned out

STARTER MOTOR General S liding Gear S tarter M otor Type KB This starter motor, designed for large internal com bustion engines, operates in tw o stages in order to protect the pinion and ring gear. The arm ature is fixed-m ounted in the drive-end bearing plate and in the com m u ta to r end shield; the arm ature sha ft is ho llo w and is designed to serve as the housing for a m ulti-disc c lu tch on its drive end. T his c lu tc h hous­ ing is sealed on the end face by a cover on w hich a ro l­ ling or plain bearing is m ounted to the arm ature in the drive-end bearing plate. On the com m utator end the arm ature is ed in a plain bearing. A solenoid sw itch for the pinion and a con tro l relay for the tw o s w it­ ching stages are flanged to the com m u ta tor end shield. In th is type o f s ta rte r m otor the pinion is sh ifte d forward (sliding gear) by the solenoid sw itch actin g through an engagem ent rod leading through the hollow arm ature shaft. The resistance, or opposing, winding located in the solenoid sw itch o f the starter m o to r serves to ad ju st the starter m otor torqu e when m eshing. In order to prevent

oil, d irt, or dust penetrating in to the inside o f the starter m otor, a radial lop-type oil seal is fitte d on the drive end bearing plate. The com m u ta tor end shield and the solenoid sw itch are enclosed by an end cover or a cover band. The drive spindle, on the spiral splines of w hich the m ulti­ disc c lu tc h is m ounted, is ed in a ro lle r bearing in the drive-end bearing plate and in a needle roller bear­ ing in the armature shaft. The pinion is ed in a positive m echanical con ne ction w ith the spind le by means of a fea th er key. The solenoid sw itch is designed to drive the pinion for­ ward in tw o stages. For this purpose it is fitted with a lock­ ing device, w ith a trigger, a stop plate, and a release lever. This type o f starter m otor is also fitte d w ith a m ulti-disc clu tch between the arm ature and pinion, but in th is case the clu tch does not have an in itia l m eshing stage.

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ALTERNATO R A N D STARTER MOTOR -

18-40

M a in te n a n ce B asic P oints W hen w o rk is p e rfo rm e d on th e e le c tric a l p a rts o f th e in ­ s ta lle d s ta rte r m o to r th e d a n g e r o f s h o rt-c irc u its e x is ts . F o r th is reason it is s tro n g ly re co m m e n d e d th a t b e fore such w o rk is s ta rte d th e ground c a b le be d is c o n n e c te d fro m th e b a tte ry. Do n o t lay to o ls on th e b a tte ry !

B rushes In th o s e ca se s w h ere th e bru sh e s are e a s ily a c c e s s ib le , the y sh o u ld be checked from tim e to tim e to see th a t they are in g o o d c o n d itio n . A fte r rem oval o f th e end co ve r or th e co ve r band, th e be st pro ce d u re is to use a ho ok to lift the s p rin g w h ich presses th e carbon brush a g a in st the c o m m u ta to r (do not bend th e s p rin g to th e sid e w h en d o ­ ing th is, and d o not lift th e spring fa rth e r th a n necessary); a ch e c k can th e n be m ade to see if th e b ru sh can m ove fre e ly in its holder. The brushes and the brush holders m ust be free from dust, o il, and grease. If th e s e pa rts are d irty o r if th e y te n d to s tic k , th e y sh o u ld be cleaned w ith a cle an c lo th (because the threads ca tch easily, do not use co tto n w a ste o r w aste rag). Do n o t w o rk on th e b rig h t ru b b in g s u rfa c e s o f the bru sh e s w ith em ery paper, file , o r kn ife . C lean th e brush h o ld e r o u t w e ll w ith d ry co m p re sse d air. If a brush is broken, if th e so lde red c o n n e c tio n has com e open, o r if th e bru sh has becom e so w o rn th a t a d a n g e r e x is ts th a t th e s p rin g o r the s h u n t (p ig ta il) le a d in g to th e bru sh can c o n ta c t th e brush holder, th e bru sh m u s t be replaced. W hen in s ta llin g the brush be sure tha t the spring is sea ted c o rre c tly on it. W hen th e e n g in e is given a m a jo r o ve rha ul, th e bru she s s h o u ld be re p la ce d in an y event. Every tim e th e bru she s are re p la ced th e c o m m u ta to r s h o u ld be tu rn e d dow n.

C o m m u ta to r T he c o m m u ta to r s h o u ld have a s m o o th u n ifo rm s u rfa c e and m u s t be fre e fro m o il and grease. D irty c o m m u ta to rs s h o u ld be cle a n e d w ith a cle a n c lo th (n o t w ith c o tto n w aste). C o m m u ta to rs th a t have be co m e sco re d and o u t o f rou nd th ro u g h use m u s t be ro u g h -tu rn e d , th e m ica in ­ s u la tio n un d e rcu t, and the n p re c is io n tu rn e d in a s u ita b ly e q u ip p e d w o rksh o p . In no case s h o u ld o n ly em ery pa pe r o r a file be used to w o rk on a c o m m u ta to r.

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ALTERNATOR AND STARTER MOTOR — 18-41 REMOVING AND REPLACING ALTERNATOR Removing 1. D isconnect battery connections. 2. D isconnect e le ctrica l con ne ction s to alternator. 3. Unscrew lock nut of V-belt adjuster and release ten­ sion (fig. 87-18).

4. Unscrew and remove alte rn a to r m ounting b o lts and lift o ff a lte rn a to r (fig. 88-18).

R ep la cing 1. Fit alternator to m ounting brackets and tigth en bolts to 50 N.m (fig. 89-18). 2. Insert b o lt in V-belt adjuster, on alternator.

3. F it V-belt and tension, using special to o l (fig. 90-18). Should th is too l not be available, the V-belt tension can be adjusted as fo llo w s: W ith o u t using undue pressure it should be possible to depress the V-belt ap pro xim ately 10 mm, w ith the th u m b applying pressure at a po in t m idw ay between the w ater pum p and a lte rna to r pulley. 4. Tighten V-belt te n sio n e r lock nut.

Fig. 90-18

80C fta r r in g to n Diesel Club

REPLACING V-BELT -

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18-42

1. Unscrew lock nut of V-belt adjuster, and release te n ­ sion (fig. 91-18). 2. L ift V-belt from pulleys.

Fig. 91-18

3. Fit new V-belt and tighten.

Note: See fig. 89-18 fo r m ounting b o lt torqu e ten sion s. 4. Check V-belt for correct tension using special tool (fig. 92-18). Should this tool not be available, the V-belt ten­ sion can be adjusted as fo llo w s: W ith o u t using un­ due pressure it should be possible to depress the Vbelt ap p ro xim a te ly 10 mm, w ith the thu m b applying pressure at a point m idw ay between the w a te r pum p and alte rn a to r pulley.

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SECTION 18-43 Power Steering Pump

Introduction The ADE 420 Series Engines are fitted w ith two types of Rotary, Power Steering Pumps, both of which operates as follows: When the drive shaft and its rotor are turned, the vanes are guided in slots and being radially m obile 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 o f 10), which are laterally restricted by the pressure plates. Each cell delivers the maximum effective cell volume tw ice per revolution. The suction and pressure chambers are arranged so that the hydraulic and radial forces acting on the rotor, w ill 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 of the pump vanes, which w ill then be ed 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 transm itted via holes to the springloaded end o f the flow restricting piston, and therefore to the relief valve. Increasing speed or pump delivery w ill produce a grow­ ing pressure drop behind the throttle restricter and also against the spring end of the valve piston. As soon as the hydraulic power (pressure differential tim es piston area) exceeds the spring force, the piston w ill 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 constant oil flow for the steering gear is provided throughout the entire speed range.

DISMANTLING Removal of Rotor and Cam Ring ZF High Pressure Vane Pump 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

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A D E 422, 423,424 W orkshop Manual

P O W E R S T E E R I N G P U M P — 18-44 3.

Remove cover, com pression spring and face plate from housing (fig. 94-18).

4.

T ilt pum p body and remove cam ring and rotor (fig. 95-18).

Removal of Drive Shaft 5.

Remove c irc lip (fig. 96-18).

6. Knock drive sh a ft from housing (fig 97-18).

Fig. 97-18

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POWER STEERING PUMP — 18-45 7. Using a hide faced ham mer knock drive end face plate from housing. ' 8. rem ove volum e co n tro l valve. 9. Using a s u ita b le punch knock needle bearing and sh a ft seal from ho using (see fig. 98-18). 10. Remove O-rings from housing, remove fitte d pin. Take O-ring from drive end face plate.

11. The bearing can be pressed from drive sh a ft a fte r rem oving c irc lip (fig. 99-18).

Fig. 99-18

Removal o f Flow and Pressure R e strictio n Valve Z.F. High Pressure Vane Pump 7637 1. Remove b lan king plug from housing (fig. 100-18). 2. Remove com p ressio n spring and valve co m p le te ly from ho using bore.

Dism antle, Insp e ction and A ssem bly of Flow and Pressure R estriction Valve 1. Check pressure and flo w re s tric tio n valve fo r score m arks and wear. The flo w co n tro l pisto n sho uld not bind in housing bore. C heck to le ra n ce num ber on housing (on face end o f valve bore) and on piston (Item 1) (fig. 101-18).

Fig. 101-18

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2. U nscrew valve seat screw from pressure re s tric tio n valve (do not cla m p in vice). Ensure th a t none o f the w ashers, the ball, the spring gu id e and the com p res­ sion sp rin g s are lost. The th ickn e ss o f the w asher is c ritic a l fo r the response range o f the pressure relief valve. To prevent the p o s s ib ility o f dam age, the w a she rs a va ila ble p rio r to d is m a n tlin g m ust be re­ placed (fig. 102-18). 3. Clean control valve and valve screw and blow out w ith com pressed air. R einsert com p ressio n spring, guide pin and ba ll. S crew valve seat screw in to c o n tro l piston tog ether w ith previously in sta lle d washers and tig h te n .

Installation of Flow and Pressure Restriction Valve 4. First insert assem bled valve piston w ith thin shaft into bore. C heck fo r co rre ct to le ra n ce (fig. 103-18).

5. S lide co m p re ssio n sp rin g on valve p is to n and in sert blanking plug in to thread hole placin g sealing washer unde rnea th (fig. 104-18).

1

VALVE PISTON

2 3 4 5 6

COMPRESSION SPRING PRESSURE RELIEF VALVE SPRING GUIDE PIN VALVE BALL ADJUSTING WASHERS VALVE SEAT SCREW

7 8

COMPRESSION SPRING VOLUME CONTROL VALVE BLANKING SCREW WITH SEALING RING

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POWER STEERING PUMP Pre-assem bly o f Pump H ousing

,

Note: Prior to assem bly, clean all parts, m oiste n s lig h tly w ith ATF o il and replace all sea lin g rin gs and O -rings. 1. Using a s u ita b le m andrel, press needle bearing in to h o using (fig. 105-18).....

. . . u n til face end o f needle bearing is 37,0 to 37,2 mm from fa ce end o f housing (fig. 106-18). Note: The needle bearing is in s ta lle d o n ly in pum ps w ith V-belt drive.

2. Press s h a ft seal in to housing w ith a m andrel. In sta ll seal w ith bearing grease between sea lin g lip s (fig. 107-18). 3. Using a so cke t spanner, screw bla n kin g plug in to pum p ho using and tig h te n . 4. Place O -ring in to bo tto m groove in housing.

5. Insert fitte d pin in to hole provided (fig. 108-18).

Fig. 108-18

18-47

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POWER STEERING PUMP — 18-48 A ssem bly and In sta lla tio n of Drive Shaft 6. Press ball bearing on drive sh a ft and replace c irc lip . F it key (fig. 109-18).

7. Insert preassembled drive shaft in to housing until ball bearing rests a g a in st housing flan ge (fig. 110-18).

8.

Insert c irc lip lo ca tin g ball bearing (fig. 111-18).

Replacem ent o f Drive End Face Plate 9. 10.

Insert O-ring in to groove in neck o f fa ce plate. S lide face plate on pin as shown and press w ith neck in to ho using (fig. 112-18).

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POWER STEERING PUMP — 18-49 Insta lla tio n of Cam Ring and Rotor 11. Insert O-ring (1) in to groove in housing (fig. 113-18).

12. Insert cam ring. The sm aller hole holds the hollow pin and the tw o larger ones are above the du cts of the face plate. The cast, half arrow po in ts tow ards driv­ ing d irectio n of pum p (see fig. 114-18).

Fig. 114-18

13. Fit rotor w ith sm ooth bore on drive sha ft (fig. 115-18).

14. Insert the ten vanes w ith the rounded-off ou ter sur­ faces facin g the cam ring, in to slo ts of rotor (fig. 116-18).

Fig. 116-18

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POW ER STEERING PUMP — 18-50 R e p la ce m e n t o f End Face P late and C over 15. F it face plate on cam ring as shown. The pin is in one o f the tw o sm a lle r holes (fig. 117-18).

16. Insert O -ring (1) (fig. 118-18).

17. Insert com p ressio n spring in to bore of face plate. P osition cover w ith recess inw ards and push in to housing u n til the c irc lip can be inserted (fig. 119-18). 18. Insert flo w and pressure re strictio n valve.

V ic k e rs H igh P ressure O il P um p VT27 D ism a n tlin g -R e m o v a l o f R o to r and Cam Ring 1. Remove screw s on pum p housing to w h ich housing cover is connected, and remove pum p housing. 2. Remove com p ressio n spring from th ru s t plate. Mark th ru s t plate, cam ring and housing cover tog e th e r (refer to arrow) (fig. 120-18).

1

O -R IN G

4

CAM RING

2

TH R U ST PLATE

5

O -R IN G

3

C O M PR ESSIO N SPR IN G

6

HO USIN G COV ER

80C fta r r in g to n Diesel Club

S e c tio n :

A D E 422, 423,424 W orkshop Manual

18 - V a rio u s

POWER STEERING PUMP — 18-51 3. Rem oving th ru s t plate from fitte d pins and take o ff cam ring (fig. 121-18). •

Fig. 121-18 2

TH RUST PLATE

6

H O U SIN G COVER

4

CAM RING

7

M A R K IN G LINE

4. Remove rotor w ith pump vanes from drive-shaft spline (fig. 122-18).

Fig. 122-18 4

CAM RING

6

H O U SIN G C O V ER

7

M A RKIN G LINE

3

F I T T E D PIN

9

ROTOR

10

VANES

a.

O IL INFLO W FR OM S U P P L Y C ONTAIN ER

b.

H Y D R A U L I C O IL O U T F L O W O N C A M RI NG

c.

INTAKE B O R E S

5. Remove O-ring from housing cover (Item 1 & 5) (fig 123-18). 6. Remove volum e con tro l valve. 7. Clean all pa rts th o ro u g h ly and rinse.

1

O -R IN G

4

CAM RING

2

TH RU ST PLATE

5

O -R IN G

3

C O M PR E SSIO N SPR IN G

6

HO USIN G C OV ER

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A D E 422, 423,424 W orkshop Manual

S e c tio n :

18 - V a rio u s

POWER STEERING PUMP — 18-52 R em oval and D is m a n tlin g o f V o lum e C o n tro l a nd P ressure R elief Valve 1. Knock locking pin from pum p housing. 2. Remove blanking cover o f volum e con tro l valve, and com pression spring from pum p housing (fig. 124-18). N o t e : C aution! The com pression spring may push o ff the blanking cover and the c olum e c on tro l valve after rem ov­ ing the locking pin. If the blanking cover rem ains in hous­ ing, loosen by applying light hammer blows against cover. Be sure not to dam age the volum e c o n tro l valve.

1

B LA N K IN G C O V ER

4

V O L U M E C O N T R O L VA LV E

2

L O C K I N G PIN

5

COM PRESSION SPR IN G S

3

O -R IN G

6

PUMP HOUSIN G

3. Clam p volum e con tro l valve at its unground end in a vice and unscrew valve screw o f pressure relief valve. Ensure th a t no a d ju sting screw s are lost. Remove valve cone and com pression spring from volume con­ tro l valve (fig. 125-18). 4. Prior to replacement, check ground surface of volume c on tro l valve and bore in pum p housing fo r wear and damage. If the surfaces are show ing score marks, replace complete o il pump. Never replace volume con­ tro l valve only.

Fig. 125-18 •

S pe cia l Tool Self-m ade (fig. 126-18).

A

INSTALLATION TOOL

B

INSTALLATION TOOL

C

INSTALLATION SLEEVE

1

B L A N K I N G C O V E R WITH O -R IN G

2

VO LUM E C O N T R O L VALVE

- *ODj

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 VA LV E

4

VALVE C O N E

5

A D JU STIN G W A SH ER

6

VALVE S C R E W

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 V A LV E

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S e c tio n :

A D E 422, 423,424 W orkshop Manual

18 - V a rio u s

POWER STEERING PUMP -

18-53

R e p la ce m e n t o f Drive S h a ft and S e a lin g Ring

w /M m t 1. Press drive from housing cover, paying a tte n tio n to shell halves (Item 10) (fig. 127-18).

14

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

R

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

-

13

Fig

12

tl

10

9

8

\\/

i — ty

7

6

8

127-18

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

3. Place both shell halves on drive shaft, then press drive sh a ft in to housing cover (fig. 128-18). N o t e : The shell halves determ ine the end play of the drive sha ft, w h ich is m axim um 0,7 mm for new high pressure o il pum ps and should not be more than 1 mm fo r used pum ps. Replace high pressure o il pump, if end play is higher.

Fig. 128-18 10

S H E L L HALF

11

DRIVE S H A F T

14

HO USIN G C OV ER

4. Press bearing bush w ith in s ta lla tio n to o l in to hous­ ing cover (fig. 129-18).

Fig. 120-18 12

BEA RING BU SH

14

HO USIN G CO V ER

B

INSTALLATION TO O L

8 O-RING 9 BEARING BUSH 10 SHELL HALF 11 DRIVE SHAFT 12 BEARING BUSH 13 OIL SEAL 14 HOUSING COVER

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A D E 422, 423,424 W orkshop Manual

18 - V a rio u s

POWER STEERING PUMP — 18-54 5. Replace assem bly sleeve on drive shaft and press o il seal in to housing cover w ith in sta lla tio n too l (fig. 130-18).

13

O IL S E A L

14

H O U SIN G C O V ER

A

INST ALLAT IO N TO O L

In s ta lla tio n o f R o to r and Cam Ring 1. M oisten all parts w ith ATF oil. 2. Install volum e con tro l valve. 3. Place rotor on drive shaft so that the countersunk end of the spline d bore faces housing cover. 4. Place cam ring on fitte d pins so th a t the respective m arkings on the housing cover and on the cam ring are in alig n m e n t (fig. 131-18).

11

DRIVE S H A F T

14

H O USIN G C O V ER

16

M A R K I N G LI NE

a Note: When a new cam ring is installed, position it so that the hyd rau lic o il 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 round­ ed ends are facin g ou tw ard s tow ard the cam ring. 6. P osition th ru s t plate on cam ring and fitte d pins lin ­ ing up m arkings (fig. 132-18). N o t e : The o u tle t holes for the hyd rau lic oil should be above the hydraulic o il bores o f the cam ring (Item 5).

a

O IL I N F L O W F R O M S U P P L Y C O N T A I N E R

b

H Y D R A U L I C O IL O U T F L O W O N C A M RI NG

1

ROTOR

2

PUMP VANE

3

H Y D R A U L I C O IL U N D E R P U M P V A N E

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 I C O IL IN T O H Y D R A U L I C O IL B O R E

5

H Y D R A U L I C O IL B O R E

7

INTAKE B O R E S

6

CAM RING

8

DRIVE S H A F T

TORQUE S PEC IFIC ATIO N S POWER STEERING PUMP Steering pump to tim in g housing .

M10

60 N.m

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S e c tio n s:

1 9 th ru 2 1 ( E N D )

S E C TIO N 19-1 C ooling System

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

W ater pump S haft Carbon ring seal Im peller Sleeve C eram ic ring C irclip Hub Gasket Spring w asher B olt Repair k it Repair kit Therm ostat Seal Pulley Pulley Bolt Spring washer

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

Pipe Pipe C oup lin g nut Ferrule Clam p Nut Lockw asher B olt W ater o u tle t W ater in let B olt Gasket B olt B olt Spring washer O utlet adapter G asket Spring w asher Bolt

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COOLING SYSTEM -

ADE 422, 423,424 Workshop Manual

S e c tio n s:

1 9 th ru 2 1 ( E N D )

19-2

Cooling System T h e rm o s ta t

S ta n d a rd V e rs io n

S p e c ia l a p p lic a tio n

S ta rts to o p en at °C

79 + 2

71 ± 2

S tro k e in mm

m in 8

m in 8

F u lly o p en a t °C

94

85

Coolant Pump S p e cifica tio n s and pum p illu s tra tio n can alte r depending on a p p lica tio n

S h a ft dia.

15,039 15,028

Dim. „ A '! Im p e lle r bore

B e a rin g dia.

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

Dim. ,,B’ H o u s in g bore

P ulle y s h a ft dia.

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

Dim. „ C ” P ulle y fla n g e bore

Dim. „ D "

D is ta n c e im p e lle r to h o u sin g

Dim. ,,E"

Flange dia. fo r pulley location

25,021 25,000

1 ,0 - 1,4 55.970 55.940

M ax. ru n o u t b e tw e e n “ C ” and “ E”

0.03

L a te ra l ru n o u t o f p u lle y fla n g e a t ra d iu s 52

0.02

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COOLING SYSTEM -

19-3

TORQUE SPECIFICATIONS W ater pum p to c y lin d e r b lo c k ............................................... P ulley to w a te r p u m p ................................................................ C o o la n t d ra in plug on o p tio n a l oil c o o le r ........................ C o o lin g fan to hub (solid f a n ) ............................................... V is c o fan to h u b /vib ra tio n d a m p e r ...................................... C o o la n t o u tle t to w a te r p u m p ............................................... Fan guard to e n gine m o u n tin g /s u m p ................................. Fan guard to b r a c k e t ............................................................... Inle t to w a te r pum p (Depending on a p p lic a tio n ) ............

FAN RETAINING BOLTS (DIN933) — TIGHTENING TORQUE BOLT DIA M8 M8 M10 M10

QUALITY 8,8 10,9 8,8 10,9

TORQUE 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

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ADE 422, 423,424 Workshop Manual

COOLING SYSTEM — 19-4 Introd u ction The c irc u la tio n o f the co o la n t is assisted by an im peller type w ater pum p m ounted on the fro n t o f the cylin d e r block, and driven by a V-belt from the crankshaft. C ool­ ing by a finn ed rad ia to r (water/air) or heat exchange (water/water). A utom atic tem perature control by tw o ther­ m o sta ts connected in parallel.

REMOVING AND REPLACING THERMOSTAT Removing 1. D isconnect coo la nt hose from th e rm o sta t housing, and remove. 2. Unscrew and remove the rm o stat cover (fig. 1-19).

Fig. 1-19

3. Remove th e rm o sta t from housing (fig. 2-19).

Replacing 1. Insert th e rm o sta t in housing. 2. Fit new O-ring to the rm o stat housing (fig. 3-19). 3. Fit new gasket to the rm o stat cover and replace, tig h te n b o lts to 25 N.m. 4. Replace and tig h te n c lip s of co o la n t hose.

Fig. 3-19

S e c tio n s:

1 9 th ru 2 1 ( E N D )

B0C B a r r i n g t o n D iesel Club

ADE 422, 423,424 Workshop Manual

S e c tio n s:

1 9 th ru 2 1 ( E N D )

COOLING SYSTEM CHECKING THERMOSTAT A ttach therm ostat to a piece of wire and hang In a tank filled with boiling water. The main valve of the therm ostat must be fully open after six to eight minutes (approximate­ ly 8 m m ). Checking for start of opening. 1. A ttach therm ostat to a piece of wire and hang in a tank fille d w ith water. 2. Using a suitable source, heat water. IMPORTANT! From approxim ately 8°C below start of opening temperature (depending on version), the heating speed m ust not exceed 10 to 2° per m inute. S tir w ater so as to produce a uniform temperature.

Note: Never use a welding torch or soldering iron to heat the therm ostat.

REMOVAL AND REPLACEMENT OF WATER PUMP Removal 1. If fille d w ith anti-freeze or an inhibitor, drain coolant into a clean container. Disconnect and remove water pump hoses. 2. Loosen lock nut on V-belt adjuster and release tension. 3. Remove V-belt. 4. Unscrew and remove mounting bolts for water pump, lift o ff water pump. 5. Remove old gasket, and clean surface of water pump and cylinder block.

Replacing 1. Replace water pump, fitte d w ith new gasket, insert bolts and tighten to specified torque. 2. Check V-belt for correct tension using special tool (fig. 4-19). Should th is tool not be available, the V-belt ten­ sion can be adjusted as follow s: W ithou t using un­ due pressure it should be possible to depress the Vbelt approxim ately 10 mm, with the thum b 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 w ith coolant. Note: Add 1% radiator in hib itor (anti-corrosion oil) throughout the year.

Fig. 4-19

19-5

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COOLING SYSTEM — 19-6 DISMANTLING AND ASSEMBLING WATER PUMP D ism antling 1. Unscrew and remove the rm o stat housing cover, rem ove th e rm o sta ts (fig. 5-19).

Fig. 6-19

3.

Using a suitable puller, remove drive flange from water pum p sh a ft (fig. 7-19).

Fig. 7-19

4.

Remove c irc lip from w ater pum p sh a ft housing (fig. 8-19).

Fig. 8-19

S e c tio n s:

1 9 th ru 2 1 ( E N D )

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S e c tio n s:

1 9 th ru 2 1 ( E N D )

COOLING SYSTEM 5.

Press water pum p shaft and bearing from water pump housing (fig. 9-19).

6. Knock carbon ring seal from w ater pump body. 7. Remove ceram ic ring and rubber sleeve from impeller, (fig. 10-19).

Assem bling 1. Fit new carbon ring seal in w ater pump body, using special too l, Part num ber 40202020 (fig. 11-19).

2. Press new w ater pump bearing into water pump hous­ ing (fig. 12-19).

19-7

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S e c tio n s:

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COOLING SYSTEM — 19-8 3.

Insert c irc lip in to water pump bearing housing (tig. 13-19).

—^

4. Press drive flange onto w ater pump shaft (fig. 14-19).

1

'

Fig. 14-19

5. Insert new ceram ic ring and rubber sleeve in to im ­ peller (fig. 15-19).

6. Press w ater pump im peller on to w ater pump bearing shaft, leaving a clearance of 1 + 0,4 mm between im­ peller and w ater pump body (fig. 16-19).

Fig. 16-19

//x

P

--------

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S e c tio n s:

1 9 th ru 2 1 ( E N D )

COOLING SYSTEM 7.

Replace pulley and tigh ten bolts to 25 N.m (fig. 17-19).

8.

Insert th e rm o sta ts, w ith new seals in to w a te r pum p housing, and replace th e rm o sta t cover (fig. 18-19).

Fig. 18-19

Page 19-10 blank

19-9

» » c sc l Club

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S e c tio n s:

1 9 th ru 2 1 ( E N D )

Page 19-10 blank

SECTION 19-11 Visco Fan

R e p r e se n ta tio n o f B a s ic F an M o d el 1

A LLEN C A P SC R E W

2

C O V ER , C O M P L E T E

3

C O V ER G A S K E T

4

A LLEN C A P SC R E W

5

PRIM ARY D ISC

6

S P A C E R RING

7

BEA R IN G

8

S E A L IN G RIN G

9

BO DY WITH BLA D E

10

LO C K IN G D EVICE

11

C O U N T E R S U N K SC R E W

12

FLA NGED SH A FT

Page 19-12blank

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Some ADE 420 Series Engines are fitte d w ith a th e rm o ­ s ta tic a lly c o n tro lle d v isco u s drive fan, w h ich is m ounted on th e w ater pum p hub, and driven by the V -belt from the cran ksha ft. The visco u s drive fan does not have a rig id co n n e ctio n o f the w a te r pum p pulley. A driven m em ber w h ich is f it ­ ted to the pu lle y can move w ith in a cham ber o f the fan w ith a sm all clearance. On reaching a predeterm ined tem pe rature th e th e rm o sta t opens a llo w in g o il to enter the cham ber, as a resu lt o f the fric tio n created by th e oil w ith in the fan cham ber, the non driven body o f the fan w ill turn thus driving the fan.

Filling Capacities S ilicon Oil Fan M odel

V iscosity + ) cS t

Qty. cm 3

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 KW

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

C hecking and lo c k in g visco us drive fan If there is an abnorm al rise in co o la n t tem perature, the fo llo w in g check should be carried out. W hen the engine is cold, th e visco us s ilic o n flu id flo w s back in to the th e rm o sta t cham ber. W ith the engine at o p era ting tem perature, it sho uld the re fore be d iffic u lt to turn the fan by hand. Start up the cold engine, and allow it to run for 1-2 m inutes at m edium speed, then sw itch o ff the engine. The fan m ust now rotate e a sily when m oved by hand, th is is due to the fa c t th a t the s ilic o n flu id has been throw n to the ou tside o f the cham ber, and sin ce it is co n tro lle d by the th e r­ m ostat, it ca n n o t flo w back when the engine is s till cold. C heck w h ethe r the visco us drive fan engages properly when the engine is warm . W ith the veh icle statio nery, cover the radiator, start engine and a llo w it to run at m edium speed u n til the w a te r tem perature has risen to 90-95°C. Remove the ra d ia to r covering. The th e rm o sta t is now heated by the hot air from the ra d ia to r a llo w in g s ilic o n flu id to flo w in to the fan cham ber. The fan speed should increase w ith in a few m in utes (in creasing fan noise), and the w a te r tem pe rature s hould return to norm al op era ting tem perature. If the engine is now sw itch e d off, it should be d iffic u lt to turn the fan by hand as the o il is s till in the fan cham ber. In the event of fa ilu re o f the visco us fan drive, the device can be locked. The lo cking device at the rear end o f the fan serves to cou ple the fan rig id ly to th e pulley. To do th is, unscrew the lo ckin g nut (fig. 18-19) up to the lo ck stop, then tu rn the fan slo w ly by hand u n til th e pin o f the lo cking device is fe lt to snap in to place, aided by the spring pressure. The visco us drive fan can be used fo r a lim ite d period when in the locked co n d itio n . Prolonged operation in th is c o n d itio n is not advisable, the fan should be exchanged as soon as possible at your nearest A tla n tis Diesel Engine, parts sto ckist.

Note: The visco u s drive fan should alw ays be transp orted and stored in a vertical position (as fitte d to the engine) to pre­ vent the s ilic o n o il from running out.

1 9 th ru 2 1 ( E N D )

SECTION 19-13 V isco Fan

Page 19-12 blank

In tro d u ctio n

S e c tio n s:

Fig. 18-19

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SECTION 20-1 Lubricating O ils

VISCOSITY GRADES A m b ie n t A ir SAE G rades

T e m p e ra tu re

30

20

o 0 10

O CM I

5

£

o

0

5

10 15

20

I

o

1

CO I

o

CM

in

o i

$

o

CM

$

o

CM

I o

CM in

*A t prolonged am b ie n t tem pe rature above 20°C SAE 40 can be used.

DUE TO CONTINUOUS DEVELOPMENT, ATLANTIS DIESEL ENGINES ARE CONSTANTLY REVISING THEIR OIL RECOMMENDATIONS. TO OBTAIN THE LATEST OIL RECOMMENDATIONS, PLEASE REFER TO OUR SERVICE BULLETINS, OR CONSULT YOUR NEAREST OIL COMPANY FOR THEIR ADVICE.

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SECTIO N 21-1 Approved Service Tools D istributed by: G rundy-Techniform (Pty) Ltd, Bruman Road, Deal Party Estate, Port Elizabeth 6001

Tool

Tool No.

Engine turning tool

4020 0093

Crow foo t socket for cylinder head bolts 17 mm

4020 0530

Ring spanner for in je ctio n pump pipe connections

4020 0970

Ring spanner for in jecto r pipes

4020 0705

Castleated socket for removal and replacem ent o f in je cto r securing nut (pipes in place)

4020 1047

Castleated socket for removal and replacem ent o f in jecto r (pipes removed)

Inje ctor dism an tling socket

4020 1050 I

T

&V/

4020 0938

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A P P R O V E D S E R V IC E T O O L S — 21-2

Tool

Tool No.

Valve stem seal in sta lle r

4024 0778

Drive tool Flywheel wear ring

4020 0268

Drive tool Crankshaft front wear ring

4020 1801

Drive tool removal/replacem ent tim in g case o il seal

4020 0116

Drive tool Flywheel spigo t bearing

4020 0064

/ T'\ Drive tool Crankshaft front cover o il seal

ll

'

RBHBV

»

4020 0129

Puller for 4020 1160 & 4020 1652

4020 0585

Puller for 4020 1665

4020 0598

Valve guide reamer 11.99 mm

4020 0831

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S e c tio n s:

1 9 th ru 2 1 ( E N D )

APPROVED SERVICE TOOLS — 21-3

Tool

’

Tool No.

C rankshaft 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'<\ '<•'*(' <\ T<Wr <'<'

i l l l i

4020 1209

Cam shaft blanking plug puller

4020 2004

O il spray je t alignm ent tool

4020 1937

(illustration of old type jet)

7 (^T D Flywheel positioning handles

4020 1982

7/on

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A P P R O V E D S E R V IC E T O O L S — 21-4

Tool

Tool No.

C onnecting rod pull through handle

4020 1995

C rankshaft front w ear ring remover

4024 9737

M easuring tool for cylinder Liner p ro tru tion

4020 1953

T im ing case cover assem bly tool

4020 0103

Locking tool for com pressor

4020 1238

C r~

Check too l fo r in jectio n pum p .

1 ]

4020 1186

*

.....

W rench fo r com pressor drive gear b o lt

Valve stem seal guide

7/90

4020 1225

u

.i

..... -

4020 1555

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S e c tio n s:

1 9 th ru 2 1 ( E N D )

APPROVED SERVICE TO O LS — 21-5

Tool No.

Tool

C ro w fo o t socke t for in je c to r pipes

4020 0721

S upport fo r in je c to r nozzle holder

4020 0912

C o nn ection for com p ressio n tester

n i

|

to

4020 0792

C ylind er liner rem oval/replacer

4020 0433

Universal Dial guage holder

4020 0446

P iston ring remover/ rep la cing pliers

4020 0307

P ilot m andrels for rem oval and replacem ent of flyw h ee l

Piston ring com pressor cla m p

(iuuiL...

I ...ZB 4020 0077

buul---------

. (..J I B )

4020 1212

B0C B a r r i n g t o n D iesel Club

ADE 422, 423,424 Workshop Manual

S e c tio n s:

1 9 th ru 2 1 ( E N D )

A P P R O V E D S E R V IC E T O O L S — 21-6

Tool No.

Tool

Fuel lift pum p tester

4020 1115

E xtractor for p ilo t bearing 25,5 - 30 mm

4020 1652

E xtractor fo r com pressor bearing

4020 1160

E xtractor for valve seat insert 47 —56 mm

4020 1665

In je cto r im pact extracto r

4020 1076

Water pump tool

c5 1S ? •a

n

5 MB»

4020 2295

I ^

fydppihgton Diesel Club

End of Workshop Manual