Perkins Engine 4-154 Service Manual

workshop manual

for

diesel

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engines

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•

4.154

PRINTED IN U.S.A.

workshop manual

for

4.154

diesel

©

Perkins

32500 Van Born Road P.O. Box 697 • Wayne, Michigan 48184 • U.S.A.

1976

Engines.

engines

Inc.

Publication No.

This publication supersedes the previous edition numbered

publication

Tills territories where

emission, noise, safety factors etc., then

tions, data and dimensions such a

nance) the local regulations when in use.

way

or

repairing an engine, it does

Published of

Perkins Engines Ltd., and printed

Abbey Printers, High Street, Spalding, Lines.

by

601

SEA

1076/1024

601SER1024.

is

written for world-wide

legal

requirements govern smoke

given

that, after servicing, (preventive mainte-

the Service Publications Department

must

use.

all

be

applied

not

contravene

in

England by

instruc-

In

in

PERKINS COMPANIES

AUSTRALIA

BRAZIL

Perkins Engines Division P.O.

Box 156, Dandenong, Victoria 3175, Australia.

Telephone: Motores Perkins

Cai.:a Postal 30.028, c Sao Paulo, Estado Telephone:

792-Q431.

443-1499. TeleK: 23715.

S.A.

Telex:

AA 30816.

Cables:

de

Cables:

'Perkoil'.

Sao Paulo, Brazil. 'Perkoil' Sao Paulo.

FRANCE

GERMANY

GREAT

BRITAIN

Moteurs Perkins S.A. 55 Boulevard Ornano, 93203 Saini-Denis, France. Telephone.

Perkins

8752 Kleinostheim, Postfach 12. Germany.

Telephone:

Perkins Engines Limited Peterborough, England

243-04:40.

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Telex.

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PEt

Telex·

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62251

4188869.

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SOUTH AFRICA

t,I.S.A.

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Telephone Johannesburg 725-5715.

Perkins

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Box

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S.pA

Telex·

ltd.

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Engines,

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Road

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Telephone: 528-61-67.

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lndustrija Motora Rakovica Patrijarha Dimltrija 7-13 Rakovica, Belgrade, Yugoslavia. Telephone: Cables:

Madras

Hiroshima 82-1111. Tela)(: 652-333.

Motor

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208

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(PABX-10

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SDF.

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S.A. (Division Zona

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2391s.

Cables:

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11341

YU

IMR.

Cables:

'Toyoko' Hiroshima.

Hyuildaimotor, SeouL

'Simpsons'

'Perkoilmex'.

Cables:

"Perki-e"

Madrid.

In addition to the above, there are Perkins Distributors in the majority throughout or

to one

the

world. For further details, apply to Perkins Engines Ltd., Peterborough.

of

the above companies.

of

countries

CONTENTS

General Information

Cylinder Head Pistons and Cylinder Block and Uners

Crankshaft and

Timing Case

Connecting Rods

Main

Bearings

and

Drive

Flywheel and Flywheel Housing

Timing

Lubricating System

Cooling System

Fuel System

Air

Cleaner Electrical System Exhauster Marine Engines Lubricating

Glossary

of

Oils

Terms

Approved Service Tools

Examples

of

Service Facilities

Index

3

SECTION A

SEcnON

SECTION C SECTION SECTION E

SECTION

SECTION G SECTION H SECTION J SECTION K SECTION SECTION M SECTION SECTION P

SECTION

Appendix Appendix Appendix Appendix Appendix

B

D

F

L

N

Q

FOREWORD

This Workshop Manual has been compiled for use

normal workshop therefore, have been omitted removal, dismantling, assembly

it

is

omitted from the text. Similarly, references

cleaning removal stood that these procedures will be carried follows that any open ports injection equipment, exposed by dismani:ling, will be blanked re-assembled, between the minimum and maximum dimensions which are Manufacturing Data and Dimensions for the relevant component parts quoted turing tolerance". This tolerance and its numerical value quality

If corresponding shaft have worn and place good workshop practice will ensure that consideration will be given to tion

Throughout this manual, whenever the

the

wheel end

joint

of

bum

in each

of

workmanship.

when carrying out a major overhaul it

in

the bush it may be necessary

the advisability

of

life that will involve labour costs at an early date.

engine is referred to, it

of

practice. Mention

faces, cleaning before inspection and re-assembly and

and scale have largely been omitted, it being under-

to

prevent the ingress

of

the sections in this manual

of

returning worn parts

the engine.

in order

or

of

is an expression

is

that

of to

refitting

high precision components, e.a. fuel

is

side

avoid repetition. Where the

of

foreign matter. The difference

necessary

of

that

the majority

to

renew the bush only, however,

"left"

as

viewed from

in

certain accepted practices

of

out

is

as

the accuracy

is

to

conjunction with

a part

is

straightforward

to

renewing joints,

where applicable.

off

until

given in the

known

as

"the

an aid

found that a bush and

of

service with an expecta-

or

"right"

manufac·

to

manufacture

of

the desired

wear has taken

hand side

the

rear

or

fly-

It

as

of

4

Unified

All proprietary American

The

block number

mation of would

Another where fuel engine for

Threads a

THREADS

ENGINE

immediately

should

or

both

be I 54 U 251.

possible,

injection

when

this

system

equipment

Pipe

ordering

letters

and

later

viewed

nd

used

Series.

NUMBE

he

quoted

parts.

and

system

be

pump

would

Engi

ne Numb

on

the

4.154

arc

R is

behind

standardised

from

located

in full

The

figures,

of

on

the the

be

GA

13870U500256D.

the

engine

rear. A typical

er

Location

engine

Unified

on

fuel

when

number

an

example

numb<!ring will,

on a pad

left

hand

excepting

Series

the

cylinder

pump.

seeking

of

near

side

and

This

infor-

consists

wh1ch

the

of

the

number

This

manual Department endeavour

contained but

due

turers

reserve

without

noti

is

of

is

made

herein

to

continuous

ce.

produced

Perkins

to

is correct

the

right

by

the

Service

Engines Limited

ensure

that

the

at the

to

alter

date

this

development the

Location

Publications

and

information

of

publication,

manufac-

specification

every

of

Engi

ne

Number

5

ENGINE

VIEWS

View of Front

Perkins engines are built to individu

suit the applications for which they are intended and

the engine views

particular specification.

Left Hand Side

do

not necessarily typify any

of

4.154 Engine

al

requirements to

6

View

of

Rear Right Hand Side

of

4.154 Engine

7

8

----9

10

~

e

-!'

<

.:::

•

'i

i

u

1

Cl>

.ii::

..

Q

i

u

.r

.§

!-<

....

Q

.t

>

1

]

~

_;

11

General Information

At

Type Bore (Nominal, see page Stroke Capacity Compression Ratio Combustion

Firing Order Valve

Automotive type Applications

Hydraulic Governor Maximum Torque

System

Tip Clearance

Section

GENERAL

ENGINE DATA

D.l.)

RATING DETAILS

INFORMATION

'A'

Four

Cylinder,

3.5 in (88,9 mm)

4.0 in (101

153.9 in

21.5:1 Indirect Injection, Ante-Chamber

(Perkins 1-3-4-2

0.012 in (0,30 mm) Cold

70

bhp

113 lbf ft ( 15.6 kgf

Four

Stroke, In-Line

,6

mm)

3

(2,523 litres)

.

"H"

type)

at 3,600 rev/ min

m)

at 2,000 rev/min

Agricultural type Applications

Mechanical Governor Maximum Torque

Intennittently Operated Industrial Applications

Mechanical Governor

Maximum Torque

Variable Speed Light Duty Industrial Applications

Hydraulic Governor Maximum Torque

Continuously Operated Industrial Applications

Mechanical Governor Minimum Governed

Note: The above ratings can vary according

Service Department, Perkins Engines, Ltd., Peterborough.

Speed

to

application.

62

bhp

113 lbf

bhp

62

113 lbf

70

bhp

ll3lbf

55

bhp

1800 rev/min

For

details

at 3,000 rev/min

ft

( 15,6 kgf m) at 2,000 rev/min

at 3000 rev/min

ft

( 15,6 kgf m) at 2,000 rev/min

at 3,600 rev/min

ft

(15,6 kgf

at 3,000 rev/min

of

m)

at 2,000 rev/min

individual ratings, apply

to

General Information

A2

APPROXIMATE ENGINE WEIGHTS DRY

Engines with standard basic components, i.e. fuel injection electrics.

lb Automotive Industrial Agricultural

of

Installed approximate weight

starter

motor,

air cleaner,

engines including all components, and flywheel, flywheel housing

but

without

Automotive Industrial Agricultural

clutch.

DE-RATING

Where engines are called upon The following table

a particular engine rating are not available.

is

given

to

operate in rarefied atmospheres occasioned

as

a general guide, which may be applied

430 400 430

lb

555 550 565

FOR

pump,

water and lubricating oil pumps, filters and

kg 195 180 195

kg

251

250 255

ALTITUDE

on

a percentage basis, where specific figures for

by

altitude,

or

they

should be de-rated.

backplate, fan,

Altitude

0 -

2,000

ft

(600 2,000 4,000 6,000 8,000

10,000 -

4,000 6,000

-

8,000

-

10,000 ft 12,000 ft

ft

ft ft

metre)

( 1200 metre)

(I

800

metre)

(2400

metre)

(3000

metre)

(3600metre)

Any necessary adjustments in this respect territory concerned. For or

to

Overseas Companies listed

any

further information apply

on

Page 2.

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

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

to

the fuel pump, should

to

Maximum Fuel Delivery

Measured at

,

..

. . . . .

be

carried

800

rev /min Pump Speed

No change

6% 12% 18% 24% 30%

out

by

De-ratilll

the

C.A.V. dealer for the

Service Department, Perkins Engines Ltd., Peterborough,

The

following wear limits indicate

serviced

or

replaced.

SERVICE WEAR LIMITS

the

condition when it is recommended

that

Generai Information

the

respective items should be

A3

Cylinder Head Bow

Maximum Bore Wear (when reboring Crankshaft Main and

Maximum Crankshaft End Float Valve

Stem

Diametrical Clearance Valve

H.ead

Rocker Clearance

Camshaft Camshaft End Float

Idler Gear End Float

Top

Max.

or

new liners are necessary)

to

Guide Bore

Thickness

Journals

Piston Ring

on

Big

End Journals

at

Outer

Shaft

Lift

Edge

RECOMMENDED

The following figures will apply

Component Cylinder Head Setscrews (also

Secure Rocker

Main Bearing Setscrews .............................................. .

Connecting Rod Nuts Connecting

Flywheel Setscrews .................................................... ..

Crankshaft Pulley Retaining

Power Take-off Pulley Setscrews ...............................

Camshaft Gear Setscrew .............................................. .

Idler Gear Hub Dynamo Alternator Pulley Atorniser Securing Lubricating Oil Filter Bowl Securing

Setscrews ......................................................... ..

Pump

Fuel

Shaft bracket) ................................... ...

Rod

Nuts (phosphated) ........................... ..

to

Pulley

Cylinder Block Nuts ....................... .

Nut

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

Nut

Drive Gear Securing Setscrews ................. ..

with

the

components lightly oiled before assembly.

(non

phosphated) ..................... .

Setscrews ...................... ..

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

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

Transverse Longitudinal 0.006 in (0,15 mm)

Ovality 0.0005 in Wear

Inlet Exhaust

Ovality and Wear 0.002 in (0,05 mm)

TORQUE

Screw

..

TENSIONS

Size

1/2 in 1/2 in 7/16 in 7/16 in 1/2

in

5/8

in

3/8 in

1/2 in

5/16 in 7/16 in 7/16 in 5/16 in

1/2 in 5/16

in

0.003 in (0,08 mm) concave

0.005 in (0,13 mm) convex

0.006 in (0,15 mm)

0.001 in (0,03 mm)

0.020 in (0,51 mm)

0.005 in (0,13 mm)

0.006 in (0,15 mm)

0.045 in

0.005 in (0,13 mm) O.Ql

O.Ql

0.008 in (0,20 mm)

lbfft

85 85

45

60

80

123 32 50 21

20

30 12

10 21

(O,Ql

mm)

(1,14

mm)

5 in (0,38 mm) 5 in (0,38 mm)

kgfm

11,7 11,7

6,2

8,3

11,1

17,0 4,5 6,9 2,9

2,8

4,15

1,7

l ,38

2,9

If

Connecting

Rod

Nuts are removed,

they

should

be

replaced

by

new ones.

•

General Information

A4

OPERATING INSTRUCTIONS

Starting the engine. If the weather or engine

tion

"R"

run position. Adjust the accelerator

position and engage the starter starter "heat engine starts release the starter switch

position.

Always be sure that the starter pinion and flywheel

have stopped rotating before re-engaging the starter

motor, otherwise the ring

To

A spring loaded

normal engine controls and functions by cutting off

the fuel at the fuel injection pump.

the knob and hold in this position until the engine

ceases the

experienced

stops "off"

and ensure the engine stop control

motor

start"

Stop

the engine

to

rotate. Ensure

"run"

rotilting; the switch can then be turned to the

position to switch

is

warm, turn switch

to

switch in a

position, see Fig.

stop

position, otherwise difficulty may be in

restarting the engine. When the engine

motor

<;lockwise

or

pinion may be damaged.

control

that

off

the electrical auxiliaries.

direction

A.l.

As

is

located near the

To

the control returns to

to

posi-

is

in

the

the the

to

the

as

the

"run"

the fully open

by turning

soon

to

operate, pull

At

oc.•~+

Cold Starting

stop

Switch on, ensuring the engine "run"

position. Turn on the fuel supply tap cold starting aid reservoir where fitted. Turn the starter switch for fifteen

With the accelerator the

starter switch to the by engaging start after twenty seconds, return the switch "heat" the starter position. should be released on

the off.

to

the

"heat"

to

twenty seconds.

the

starter motor.

position for

motor

As

cold starting reservoir (where fitted) turned

by switching to

soon.

as

to

position and hold it there

in

the

fully open position,

"heat

ten

seconds and then re-engage

the

engine starts,

the

"run"

control

start"

If

the engine does not

the

position, and

is

in the of

the

turn

to

the

start"

switch

the

tap

position, there-·

"heat

PREVENTIVE MAINTENANCE

General Information

AS

DAILY

level

of

Check Check level

vehicle or machine Check lubricating oil pressure (where gauge

In extreme dust conditions, empty dust bowl type air cleaner.

Under adverse agricultural conditions, clean chaff screens, radiators and centrifugal pre-filters.

4,000

MONTHS, whichever is the soonest. Drain and renew lubricating oil - Lubricating oil

meet

must specification in the appendix.

Renew element in lubricating oil filter. Empty Check fan belt tension -

3,000 rev/min the fan belt tension should monthly.

Clean water trap.

Check engine for oil and water leakage.

Where fitted, lubricate dynamo rear bush.

coolant.

of

lubricating oil in sump (make sure the

is

standing level).

MILES

dry

(6,000

the approved specification. See oil

air cleaner dust bowl.

km)

1~0

HOURS

For

engines rated at above

is

be

checked

fitted).

on

dry

or

The Kilometre conversions They are periods in Kilometres which should

of

in place

Operators above

application, therefore he should

maintenance for his engine with the schedule specified the engine

shorter periods also bearing in mind that on

low mileage work, the hours run are more applicable than the mileage covered.

Whilst maintenance,

3

local regulations concerning your vehicle or machine

and ensure that the engine regulations.

Running-in Procedure New

at full power or

20 hours. Neither should they be run without any load upon them. To assist in the initial bedding in such should be used at output after which it may be operated at full power.

Do

for an extended period, nor by running the engine at idling speeds with no load.

POST DELIVERY CHECKOVER

miles in relevant countries.

of

Preventative Maintenance schedule

by

or

as

not

4.154 engines are reminded that the

the manufacturer

is

fitted, and where necessary adapt the

we

have given specific periods for preventive

you

should have due regard for the

replacement engines should not be operated

output

piston rings, bearings, seals etc., the engine

for the first 500 miles (800 km) or 20 hours,

"run

about

in"

an engine by applying a small load

of

miles are

of

the application

is

operating within those

for the first 500 miles (800 km)

80%

of

not

accurate.

be used

is

c;ompare the routine

of

its maximum power

general in

to

which

stop-start

the moving parts

12,000 MILES (18,000 km)

MONTHS, whichever is Tractor and Industrial applications, renew the final

fuel filter element;

Check and adjust tappets.

Check hoses and clips.

Clean element not

indicated earlier)

24,000 MILES (36,000 .Ion) Vehicle

element.

72,000 MILES (108,000 Arrange for examination

equipment, i.e. Compressor/Exhauste"r, Starter Motor,

Dynamo etc.

Service atomisers.

of

dry type air cleaner,

Applications, renew the final fuel filter

km)

450

the

soonest.

900

HOURS

2,700 HOURS

and

service

HOURS

or

renew, (if

of

proprietary

or

12

After a customer has taken deliveryof his engine, a general checkover must be carried

500/1,000 miles

service and must include the retightening cylinder head setscrews in the correct sequence. With the engine thoroughly warmed through, the checkover comprises the following:-

Drain the lubricating oil sump and refill

1.

correct level with clean new engine oil (Do overfill).

Renew lubricating oil filter element (canister).

2.

Tighten the cylinder head setscrews in the

3. correct sequence (see torque

Reset the valve tip clearances

4.

mm) Check oil feed

5.

Check the tension

6. Check the tightness

7. screws, mountings, etc.

Start the engine and check for any fuel, coolant

8.

or

lubricating oil leaks.

Adjust idling speed

9.

(800/

1,600 km) or

of

80-85

(see page 8.5).

to

rockers.

fig.

lbf

of

the fan belt (see page K.2.)

if

necessary.

out

after the first

20/40

hours m

of

the

to

the

not

8.2)

and to the correct

ft (11,06-11,75 kgf m).

to

0.012 in (0,30

of

all

external nuts, set-

General Information A6

PRESERVATION

OF

LAID-UP ENGINE

Batteries

Where an application which

engine

is

to

able that some measure engine intervening period before operations are

menced.

It

is recommended, therefore,

procedure be adopted and applied immediately the

unit

is

I.

2. Run the engine until well warmed through.

3. Discard the paper element in the full flow

4. Clean

5. Fill the lubricating oil sump

be laid-up for several months, it

to

ensure

that

withdrawn from service.

Thoroughly clean all external parts engine.

Stop

the engine and drain the lubricating oil

sump.

cating oil filter, clean the filter bowl and fit a new element. Fill the filter bowl (where

sible) with a new oil

list

of

approved lubricating oils appears in the

appendix.

out

the engine breather pipe.

with clean new lubricating oil

as

grade,

referred

is

powered. by a Perkins

of

protectic.n be afforded the

it suffers no

to

in

ill

effect during the

that

the following

of

an approved grade. A

to

the correct level

of

(3)

above.

an approved

is

advis-

recom-

of

lubri-

pos-

the

(a) Remove the

engine and water, making sure the separators cov:ered.

(b) Recharge the

source

(c)

Screw home the vent plugs and clean the battery ture.

Clean the terminals and lightly smear

(d)

them with petroleum jelly.

(e)

Store in a cool, dry, dust-free place. no account should the battery where there

(f)- Recharge once a

rate

of

battery

top

of

supply.

removing all dust, dirt and mois-

is

charge,

or

up the cells with distilled

or

battery

a risk

batteries from the

that

the

top

separator guards are just

from a separate

of

freezing.

month

to

a state

edges

at

the

of

free gassing.

be

normal

of

On

left

Starters and Generators

Clean the terminals and lightly smear them with petroleum .ielly open, the protected against water falling

If

gener:ttor

the machine starter

is

and control panel must be

to

dire"ctly

stand in the

onto

them.

6. Carry

7. Drain water by opening all the drain taps

8. Remove the atomisers and spray into the

9. Replace the atomisers (using new

I

0. Remove the air cleaner and any air intake pipe

II.

12. Remove cylinder head cover. lubricate

out

cribed in the appropriate Fuel Pump section.

on the cylinder block and the radiator. ensure complete draining, remove the drain taps entirely and check that

the holes are reasonable drainage period, refit the taps open position.

cylinder bores oil, divided between all cylinders.

and slowly revolution.

which may be fitted between the air cleaner and air intake. orifice with waterproofed adhesive tape other

Remove the exhaust pipe, and seal orifice with adhesive tape as in

rocker assembly with engine oil and replace

cover.

attention

rotate

suitable medium.

to

the fuel

not

blocked by scale. After a

i pint (70 cm

the crankshaft one complete

Carefully seal the air intake

it

is

3

(I

pump

preferable

)

of

lubricating

joint

the

0) above.

as

both

in

washers)

or

some

manifold

des-

To

to

the

the the

Fuel Injection Pump

Drain all fuel oil from the fuel tanks and filters.

I.

Put into the fuel tank at least a gallon

the oils listed Inhibiting construction oil

is

inadequate, break the fuel feed line before the first filter and connect a small capacity auxiliary tank.

Prime the system as detailed

2.

Start

3.

4.

s.

the engine and run it until the oil has

circulated through the. injection

pipes and injectors, which will be after it has run light, at least fifteen minutes.

Stop

the engine.

Seal

the waterproofed adhesive tape of

water condensation during the lay-up period.

under

the

Fuel

of

about

air vent in the tank

"Recommended

System".

the

fuel

tank,

half maximum speed, for at

If,

because

this

on

page L.7.

or

filler cap with

to

reduce

of

one

Oils for

of

quantity

pump,

the

of

the

of

feed

risk

13. Remove the fan belt and retain this for refitting when

the

engine

is

to

be returned

to

service.

The proprietary brands mended for panies. They may world, to

the

purpose

not

but

suitable oils may be obtained

appropriate companies. The specification

of

oils listed are recom-

by

the

be available in all parts

should include the following:-

Viscosity: The viscosity should

centistokes likely

at

to

the

be experienced

Pour Point: Must be at least

not

lowest ambient temperature

on

l5°F

the lowest ambient temperature likely

on

experienced be lower be met during

The oils selected are calibrating

or

testing pumps.

restarting and should preferably

than

the lowest temperature likely to

the

lay-up period.

not

necessarily suitable for

respective oil com-

of

by

the

reference

be greater than 22

restarting.

(9°C) lower

than

to

be

General Information A 7

PREPARING THE ENGINE FOR RETURN SERVICE

When

the

engine

is

to

lowing procedure must be

1.

Thoroughly clean all external parts

observed:-

engine.

be returned

2. Carry

3. Ensure

out

cribed in

attention

the

Fuel Pump Section

that

the

cylinder block and rlJdiator

to

drain taps are correctly fitted in the closed position and fill the system with clean coolant. Check visually for leaks and remedy where necessary.

4.

Rotate freedom

the

water

of

the water pump seals.

pump

to

the

fuel pump

by hand

service,

on

Page A.8.

to

the

of

a!l

TO

fol-

the

des-

ensure

Caution

is

When oil be allowed

being drained from the system it must not

to

fall on electrical equipment.

RECOMMENDED OILS FOR INHIBITING THE FUEL SYSTEM

Lowest

Temperature

During

Lay-up

Esso

IL81S Esso·IL1047 Shell

Calibration

Shell

Calibration

Shell

Fusus

Shell

Fuses

In

Note: ture likely

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

..... • .................

Fluid

"C" (U.K.)

Fluid

"B"

"A"

•...................

"A"

R1476

(Overseas)

(Old

Type)

choosing a suitable oil

to

be met

by

the

engine during

.

••.•••

...

.....

the

25°F

(-4°C)

0°F

(-l8°C)"

0°F (-l8°C)

-70°F

(-57°C)

-l5°F

(-26°C)

25°F (-l4°C)

lowest tempera-

the

lay-up

period should be estimated, and the oil should be

that

the

such as,

or

lower

made

to been at least table for

temperature given in the table

than

restart

not

this estimate. No

the

en~ne

l5°F

(9 C) above

less

than

24

until

hours; otherwise there may

the

be difficulty in obtaining a free flow

attempt

temperature has

that

.Df

is

as low

should be

shown in the

fuel.

5. Refit the fan belt and adjust

to

the correct

tension.

6. Remove the cylinder head cover, lubricate the

rocker assembly with engine oil and replace the cover.

7. Remove the adhesive tape from

the

orifice and refit gauze

is

clean and if

with clean engine oil to

8.

Refit any air intake pipe between the air cleaner and

the

air intake

air cleaner. Ensure that the

it

is the oil bath type, fill the

whiCh

the

air intake

correct level.

may have been

removed during laying-up procedure.

9. Remove the adhesive tape from the exhaust the

manifold orifice and refit

exhaust pipe

using new joints.

10. Connect

fully charged and topped

the

battery

or

batteries

up

as

necessary with

into

circuit,

distilled water.

Starters and Dynamos

11. Wipe the grease from that

all connections are sound.

fitted with a Bendix

the

terminals and check

type

If

of

drive, which proves

the

starter is

sluggish in engagement when operated, the starter

motor

should be removed and the drive cleaned thoroughly in a suitable cleaning fluid. Lubricate with a little light engine oil before replacement.

12. Check the level and condition the

sump. Change the oil

the

engine in

the

normal manner checking

13.

oil in Start

for oil pressure and dynamo charge ately.

the

14. Whilst

temperature it running normally and

engine is attaining normal running

is

advisable

that

it is free from water,

fuel and lubricating oil leaks.

to

of

if

check

the

lubricating

necessary.

immedi-

that

it

is

General Information

D.P.A.

Distributor

Remove the adhesive tape from the fuel tank

1.

vent or filler cap.

Drain the fuel tank

2.

and condensed water, and refill the tank with fuel oil.

3. Fit a new filter element and oil flows free from air bubbles (see page L.8)

4. Air vent and prime the pump (see page L.7).

Pump

AS

to

remove any remaining oil

vent the filter until

NOTE:

If

the foregoing instructions are observed, the laying-up and returning to service should be carried out efficiently and without adverse affect on the engine. Perkins Engines Ltd., however, cannot accept liability for direct or consequential damage that might arise following periods

of

laying-up.

FROST

Precautions against damage if the engine weather either by adequately draining the water system or where this is not convenient, an anti-freeze of corrosion inhibitor may be used.

Should it be your policy

When draining a cooiing system, ensure that the

PRECAUTIONS

by

is

to be left exposed to inclement

reputable make and incorporating a suitable

damage by adding anti-freeze to the cooling system, is

advisable that the manufacturers mixture be contacted to ascertain whether their products are suitable for to ensure that their products will have no harmful effect on the cooling system generally. perience that the best results are obtained from anti-freeze which conforms to British Standard 3151 or has been tested in accordance with

5 to

give

at least

The coolant solution containing freeze manufactured to BS.3151 in water in a properly maintained engine should maintain its anti-freeze and anti-corrosive properties throughout the winter season and in general, a safe life ably be expected.

vehicle or machine

as

is

frost should

to

protect engines from frost

use

in Perkins Engines, also

good a result

25

of

12 months may reason-

on level ground.

be

taken

of

the relevant

It

is

our ex-

BS.5ll

7,

Clause

as

BS.315l.

per cent anti-

it

When

the engine

drained, but rotation by:-

(a) Locking

drain hole being blocked

(b) The locking of the seal through the freezing

globules of moisture between the seal and the

insert.

Operators are therefore advised to-take these tions when operating in temperatures below freezing point:

1.

Before starting the engine, by

hand, this will indicate if freezing has taken

place.

free any ice formation.

If

2.

3.

After an anti-freeze solution has been used, the cooling system should be thoroughly flushed in accordance with the anti-freeze manufacturer's instructions before refilling with normal coolant.

it is impossible

the engine should be filled with warm water. To

when all water has been drained, run the engine

for a few seconds at ing any moisture remaining in pump.

is

drained the water

of

the pump may be prevented

of

the impeller

If

freezing has taken place, this should

avoid this trouble. the operator should.

by

to

tum

1dung speed, thus

pump

ice due

tum

to

sediment.

the water pump

the

pump

is

also

the pump

precau-

by

hand,

<11Spers-

of

If

the foregoing action should be experienced, cannot be held responsible for any frost damage corrosion which may be incurred.

is

taken, no harmful effects

but

Perkins Engines Ltd.,

or

fault finding chart

General Information

A9

FauH

Low cranking speed

Will not start

Difficult starting Lack

of

power Misfiring Excessive fuel consumption Black exhaust Blue/white exhaust Low oil pressure Knocking Erratic running Vibration High

oil

pressure

Overheating

Excessive crankcase pressure

Poor compression Starts, and stops

Poulble

1,

5, 5, 8, 8,

Cause

2,

3,

4.

6,

7,

8,

9.

10.

12. 13, 14,

7.

8,

9,

10, 11, 12. 13,

9,

10,

1~

12, 13. 14. 18, 19,

9,

10. 12, 13, 14, 16. 18. 19. 11, 13, 14, 16, 18, 19, 11,

13,

14,

16.

18, 19,

4,

16.

18. 19,

20,

25, 27.

4,

36.

37, 38,

39,

40,

9,

14, 16. 18, 19,

7,

8,9,

10, 11,

13.

14,

20,

4,

38,

41.

12,

23. 25,

22, 26,

13. 26,

11, 13, 14, 16, 18. 19,

25,

31, 33, 34,

11,

19,

25, 28.

45,

29,

55. 31, 32.

10, 11, 12.

14.

20, 22, 20,f2.

31.

42, 43.

28.

14.

16.

29.

30, 33,

24, 25,

33,

15.

16. 17,

15, 16, 18. 19.

20, 21, 22. 20,

25, 26. 28. 29,

23.

24,

25, 27, 28,

24.

25, 27,

33.

34. 35.

44,

58.

29.

31.

33. 35,

20.

21. 23, 26,

45. 48, 49.

45,

47,

50, 51. 52, 53. 54. 57.

34.

46,

59.

KEY TO FAULT FINDING CHART

1.

Battery capacity low. 31. Worn cylinder bores.

2.

Bad electrical connections.

3.

Faulty starter motor.

4.

Incorrect grade of lubricating oil.

5.

Low cranking speed.

6.

Fuel tank empty.

7.

Faulty stop control operation.

8.

Blocked fuel feed pipe. 38. Inaccurate gauge.

9.

Faulty fuel lift pump.

10.

Choked fuel filter.

11.

Restriction in

12.

Air in fuel system.

13.

Faulty fuel injection pump.

14.

Faulty atomisers

15.

lncor'l-ect use of cold start equipment.

air

cleaner.

or

incorrect type.

16. Faulty cold starting equipment.

17. Broken fuel injection pump drive.

18.

Incorrect fuel pump timing.

19. Incorrect valve timing.

20.

Poor compression.

21.

Blocked fuel tank vent.

22.

Incorrect type or grade

23.

Sticking throttle or-restricted movement.

24.

Exhaust pipe restriction.

25.

Cylinder head gasket leaking. 55. Choked breather pipe.

26.

Overheating.

27.

Cold running. 57. Coolant level too low.

28.

Incorrect tappet adjustment.

29.

Sticking valves.

30.

Incorrect

h_igh

pressure pipes.

of

fuel.

32.

Pitted valves and seats.

33.

Broken, worn

34.

Worn valve stems and guides.

35.

Overfull air cleaner

36.

Worn

or

37.

Insufficient oil in sump.

39.

Oil pump worn.

40.

Pressure relief valve sticking open.

41.

Pressure. relief valve sticking closed.

42.

Broken relief valve spring.

43.

Faulty suction pipe.

44.

Choked oil filter.

45.

Piston seizure/pick up.

46.

Incorrect piston height.

47.

Damaged fan.

48.

Faulty engine mounting (Housing).

49.

Incorrectly aligned flywheel housing,

50.

Faulty thermostat.

51.

Restriction in water jacket.

damaged bearings.

52. Loose fan belt.

53.

Choked radiator.

54.

Faulty water pump.

56.

Damaged valve stem oil deflectors

58.

Blocked sump strainer. Broken valve spring.

59.

18,

19.

20. 22,

31, 32. 33.

20, 21, 22. 24, 29.

23.

24. 25, 26. 27. 30,

32.

29.

31.32.

28. 29.

31,

32,

45,

56.

36.

45, 46,

28. 29.

30. 33.

or

sticking piston ring/s.

or

use of incorrect grade of oil.

33.

59.

31. 32. 33.

31, 32.

33.

35,

45.

(if

33.

59.

or

flywheel.

fitted).

Section

Cylinder Head B 1

' ,

B

CYLINDER

The cylinder head

of

"cross flow" design with the exhaust and inlet

ing ports

on rod operated through the rocker gear mounted top cover which the right hand side a synthetic rubber oil deflecting seal, exhaust valves are provided with two springs retained by a hardened cap and split conical cotters. All valves

Cylinder

opposing sides. The overhead valves are push

of

the cylinder head, covered by a pressed steel

Head

is

a one piece high duty iron cast-

is

provided with a breather pipe fitted

of

the engine. Each inlet

both

CYLINDER HEAD DIMENSIONS

Overall depth Skimming allowance Pressure for Water Leak Test Valve seat angle Bore for Valve Guide Bore for Depth

of

Cylinder Head

Combustion Chamber Inserts

of

bore for Inserts

on

the

to

valve

has

inlet and

HEAD

operate in cast iron guides pressed into the head. The upper hemispherical in shape, being formed by an inserted machined plug containing a throat connecting the chamber to the cylinder. cylinder head through jets fishtail area in the combustion chamber inserts. The

cylinder head twenty setscrews, seven rocker shaft

part

of

the combustion chamber

Coolant is delivered

to

the valve bridge and

is

secured

to

the cylinder head.

3.248/3.252 in (82,5/82,6 mm) Nil 30 lbf/in2 (2.11 kgf/cm 45°

0.500/0.5()1

1.375/1.3766 in (34,92/34,96 mm)

0.425/0.4281 in (10,79/

in (12,7/12,73 mm)

to

the cylinder block by

of

which also secure the

2

)

10,87 mm)

to

is

the

Combustion Chamber Inserts

Outside diameter Clearance fit Combustion Chamber Insert thickness Height

Method

Valve Guides, Inlet

Outside diameter Interference fit Overall length Guide protrusion above Valve Guide bore diameter

of

Insert in relation

of

location

and Exhaust

of

Insert

Insert in Bore

to

of

Guide

of

Guide in Bore

Guide

Cylinder Head Top Face

Cylinder Head face

1.3724/1.374 in (34,86/34,9 mm)

0.001/0.0042 in (0,02/0,11 mm)

0.4252/0.426 in

0.001 in (0,02 mm) above,

0.0029 in (0,07 mm) below. By

Cylinder Block Face and Expansion Washer.

0.50125/0.50175 in (12,73/12,74 mm)

0.00025/0.00175 in (0,01/0,04 mm)

2.13 in (54,10 mm)

0.638/0;662 in ( 16,20/16,81 mm)

0.3145/0.3155 in (7,99/8,01 mm)

(10,80/ 10,82 mm)

Cylinder Head

Valves. Inlet

82

Valve

stem

Clearance

Valve head Valve face angle

depth

Valve Overall length

Sealing Arrangement

Valves, Exhaust

Valve stem C'learance fit Valve head Valve face angle

depth

Valve

Overall Sealing arrangement

Valve Springs Inner

Fitted Load at fitted length Free length

Valve Springs Outer

Fitted Load at Free length

diameter

fit

of

Valve

diameter

below Cylinder Head face

diameter

of

diameter

below Cylinder Head face

length

fitted

stem

of

Valve

Valve sten: in Guide

of

Valve

length

in Guide

(Production) (Service)

0.312/0.313

0.0015/0.0035

1.591/1.598

45°

0.029/0.041

0.060

in

(1,52

4.503/4.521 Synthetic

0.312/0.313

0.0015/0.0035

1.3937/1,4016

45°

0.027/0.040

0.060

4.503/4.5.21 in

in

Rubber

(I

,52

Nil

1.49 in (

28 ± 1.4

1.74 in

1.59 in

40±

1.8

37,84

lbf

(44,19

(40,38

2.0lbf(l8,1

r in

(45,97

(12,7

in (7

,92/7,95

in

(0,04/0,09

in

(40,41/40,59

in

(0,74/1,04

mm)

in (

114,38/114,83

Deflector

in (7 ,92/7,95

in

(0,04/0,09

in

(35,4/35,6

in

(0,69/1,02

mm)

(114,38/114,83

mm)

± 0,65 kgf)

mm)

± 0,91 kgf)

mm)

mm) mm)

mm)

mm) mm)

mm)

Rocker Levers

Rocker Outside Interference fit Inside

Rocker Shaft

Outside C'learance fit Lubrication

Push Rods

Overall length Outside

lever bore

diameter

of

diameter

of

Bush

of

Bush in bore

of

Bush

of

Shaft

Rocker

Lever Bush

(fitted)

on

Shaft

0.7188/0.7196

0.7199/0.7207

0.0003/0.0019

0.625/0.6258

0.6234/0.6244

0.0006/0.0024 No.

I Bracket

to

Rocker

8.5102/8.5412

0.247/0.25

Levers

in

(18,26/18,28

in

(18,29/18,30

in

(0,01/0,05

in

(15,87/15,89

in

(IS

,83/15,86

in

(0,01/0,06

through

(6,27/6,35

Shaft

in

(216,16/216,94

mm)

To Remove the Cylinder Head The following parts are bracketed

head which will have

to

be detached before the

cylinder head can be removed. Lubricating oil filler tube. Engine breather pipe.

to

Fuel pipe from lift pump rear covet plate

of

cylinder head). See Fig.

fuel filter (bracketed

Fuel filter.

to

the cylinder

B.l.

to

Cylinder· Head

BJ

Because the head be necessary

ROCKER ASSEMBLY is secured

by

the cylinder head securing setscrews, it will

to

adopt the following procedure.

to

the

Remove the two self-locking nuts from studs locating

in Nos. 1 and 7 rocker support brackets,- counting from the front. Loosen all the cylinder head setscrews in the reverse order to

that

shown

on

Fig. B.2. Remove the seven setscrews securing the rocker assembly. The rocker assembly can now be removed.

Valves

To remove the valve collets use a valve spring compressor and a suitable adaptor.

The valves are numbered original positions. the valve depths relative be contained within the limits quoted See Fig. B.3. Valve seat and valve angle both

inlet and exhaust valves.

If

servicing

to

ensure refitment

is

to

necessary, check that ·

the cylinder head face will

As

narrow a seat

on

Page B.2.

is

to

45° for

their

as

possible should be maintained. When refitting the valve assembly into the cylinder

head, take care inlet valve only

the rubber oil deflector

is

fitted

onto

the valve stem, open

on

the

that

end facing downwards, under the valve spring cap, see Fig.B.3.

Bl

82

VALVE SEAT INSERTS cannot be fitted

to

the

4.154 engine.

Valve

Guides

When renewing valve guides, remove the worn guides by

using a suitable dolly and press.

ment

of pull in, in continued until the guide of operation experienced in restarting.

new guides use a special tool with adaptor

but

of

care must be taken

the guide is commenced, the operation must be

is

fully home.

the guide into its location

is

completed, difficulty

Use

ensure correct guide protrusion

For

the replace-

that

when the pulling

If

is

of

the special stop will

as

quoted

the pulling

halted before the

is

likely

on

Page B 1,

to

be

see Fig. B.3.

83

Cylinder Head

84

Valve Springs

84

0

c

Check the specific lengths against the figures quoted on

8.2, fatigue.

overhaul

Rocker Shaft Assembly When

support brackets for re-assembly,

feed to the rockers cylinder head, and a drilling in the base support bracket locates with this hole,

Also note that the rocker shaft locating scallop

towards the front

Rocker Levers

If

rocker lever bushes are found replacement, rocker levers complete with bushes ready to fit are available.

Rocker level bushes are also available separately. With early engines, the oil hole in the bush should align with the oil hole in the rocker lever, but with later engines, after fitting the bush, it should be drilled with a 2 mm drill in line with the oil hole in

the rocker lever. With the latter operation, ensure that all machining swarf the rocker shaft.

valve

springs for pressures developed at

and for any signs

It

is

advisable to fit new springs when an

is

undertaken.

dismantling, take note

of

is

at the forward end

of

the shaft.

is

8.4.

The oil

of

Page 7.

Page

of of

No. l

the the

of

deterioration caused by

of

the order

see

Fig.

see

to

be in need

removed before assembling

is

BS

)

0·001in 0,02

O·OOZiin

n

m•

O,Olmm

above

-

n

DC

14-3

Combustion Chamber Inserts

To

·remove the inserts

through the atomiser bore and tap out.

To replace, locate the inserts

sion washers, turning whilst the engine

When

cylinder head face should be checked against the figures quoted on

Cylinder Head Distortion The limits for cylinder head bow are given in

SERVICE WEAR LIMITS on Page A.3. tion reveals a dimension in excess quoted, a replacement cylinder head as

no

allowance for skimming

Cylinder Head Gasket Fit a new gasket when replacing the cylinder head.

This

is

the cylinder block top face.

see

fitted, the height

fitted DRY, and

Fig.

Page

use

a short length

by

means

8.5,

to prevent the inserts from

is

in service.

of

the insert in relation

8.1,

see

Fig.

is

provided.

is

located by two dowels in

See Fig.

of

8.6.

If

of

is

recommended,

8.7.

of

bar

the expan-

to

the

examina-

the limits

86

Refitment

Before refitting the cylinder head, ensure that the oilway in the block clean. Examine the PUSH fit into their location.

The rocker assembly

and through Nos. I and 7 rocker support brackets and secured by two nuts. The rocker shaft positioned securing stud. (Take care that the oilway in the base

of

No. I support bracket corresponding oilway in the head. After fitting the cylinder head, replace the seven longest setscrews

through the support brackets into the head and secure finger tight.

Replace the remaining thirteen setscrews and tighten

them all progressively in the sequence shown in Fig. B.2, until a final torque kgf should

Retighten the two rocker assembly securing nuts.

Valve Oearances

The

cold at

following

(a) With the valves rocking on No. 4 cylinder (the

of

Cylinder Head

top

face and cylinder head is

RODS

for straightness, and

is

located by two studs in the cylinder head

by

the scallop which locates on the front

m)

is

achieved. This final torque tightening stage

be

repeated.

valve

tip clearance should be set with the engine

0.012 in (0,3 mm) procedure:-

period between the opening and the. closing clearance on No. 1 cylinder.

fitted before securing the head,

is

clean and aligns with the

of

80-851bfft

see

Fig. B.8, using the

of

the exhaust valve), set the

of

the inlet

(II,l-11,7

correctly

valve

Cylinder Head

(b) With the valves rocking on No. 2 cylinder, set

the clearance on No. 3 cylinder.

(c) With the valves rocking on No. I cylinder, set

the clearance on

(d) With the valves rocking on No. 3 cylinder, set

the clearance on No. 2 cylinder.

Atomisers

Refit the atomisers squarely into their locations using a new sealing washer, and ensure that the securing nuts are tightened evenly to a torque

(I

,4-1

,7

kgf m).

Engirie.Running Check Before fitting the top cover, start the engine and run

at a fast idle. Check for satisfactory oil pressure where a gauge

fitted. Check that lubricant is reaching the rocker assembly. Check for fuel, oil and coolant leaks.

When

the engine is thoroughly warmed through, shut

down

ap~

re-torque the cylinder head securing setscrews. clearances

Carry out this check again after

(800/I,600

When

the engine

to

0.012 in (0,30 mm).

km) or 20/40 hours in service.

No.4

is

cylinder.

cold,

re«:t

of I 0-12

the

500/1,000 miles

valve

BS

lbfft

tip

is

B1

B8

0·012in

0,30mm

clld

,,,

• • •

Sect1on

Pistons and Connecting Rods C I

C

PISTONS

The pistons are aluminium_alJoy, flat rings, and one scraper ring above the gudgeon one below

The gudgeon pins which are fully floating are located axially in

The gudgeon pins are off-set, so ensure

and connecting rods are correctly assembled by means of

the

rod

it.

the

numbers

big ends

manufactured

topped

pistons by circlips.

on the piston crowns and connecting as

described later in this section.

with

AND

from high silicon

three compression

that

piR

and

the pistons

PISTON AND ROD DIMENSIONS

Pistons

Pisto!l

Type Piston Height in relation Bore Diameter for Gudgeon Pin Transition fit

Compression Ring Groove Width top, 2nd and

Scraper Ring Groove Width

of

Pin in Bore

Rings

Compression, Compression, 2nd and Scraper, Scraper,

Compression Ring Width,

Ring Clearance in Grooves Scraper Ring Width, Ring Clearance in Groove

Scraper Ring Width,

Ring Clearance in Groove Compression Ring Gap, Compression Ring Gaps, 2nd and 3rd Scraper Ring Gap, Scraper Ring Gap,

top

4th 5th

to

3rd

top,

4th

5th

top

Cylinder Block

4th

and

5th

2nd and

3rd

CONNECTING

The

connecting rods are manufactured from

molybdenum alloy steel stampings with an

section shank. The big ends are split at

the

rod axis, with each cap secured by bolts. The big end bearing placeable thin wall aluminium-tin steel backed shell bearings, and backed

Top

Face 0.000/0.004/

3rd

bronze

Flat topped

1.2495/1.250

0.00024 interference (0,001/0,01 mm)

0.096/0.097

0.1895/0.1905

Chrome plated

Internally stepped Chrome plated, slotted Slotted

0.093/0.0938

0.0022/0.004

0.1868/0.1875

0.002/0.0038

0.1865/0.1875

0.002/0.004

0.014/0.019

0.011/0.016

0.014/0.019

0.011/0.016

in clearance/0.00046

RODS

the

small end bores are fitted

lined bushes.

in

(0,00/0,lO mm) above

in (31 ,74/31,75 mm)

in

(2,44/2,46 in

(4,81/4,84

or

Chrome

in

(2,36/2,38

in

(0,05/0,10

in (

4,74/4,76

in

(0,05/0,10

in

(4,74/4,76

in

(0,05/0,10

in

(0,35/0,48

in

(0,28/0,41

in

(0,35/0,48

in (0,28/0,41 mm)

ri$tht

two

boreS are fitted with re-

in

mm)

inlay

mm) mm)

mm)

mm) mm) mm)

mm)

"H"

an.llles

nuts and

with

steel

to

The Ring Gaps larger diameter bore. in diameter above

Gudgeon

Connecting

quoted

3.501

Pins

Type Outside Diameter Clearance fit

Rods Type

Big

End

Small End Connecting Length

of

Small End

above are

0.003

in (0.08

in

(88,93 mm).

in Small End Bush

Parent

Bore

Parent

Bore

Rod

Big

from centre line

End

a~

measured in a 3.501 in (88,93 mm) diameter bore.

mm)

should be added to the figures given for every 0.001 in

Fully floating

1.24976/1.24996

0.00054/0.00175

"H"

Section

Width

of

Big End

to

centre line

2.395/2.3955

1.375/1.376

1.361/1.363 in

6.8115/6.8135

in

(60,83/60,84

in

(34,92/34,95 (34,57/34,62

in

If

gaps are measured in a

(0,03

in (31 ,74/31,75 in

(0,01/0,04

(173,01/173,06

mm)

mm) mm) mm)

mm)

increase

Pistons and Connecting Rods C2

Connecting Rod End

Big

End Bolt Size Thread Type

of

Big End

Bolt

Float

Nut

0.0095/0.0131 7/16in(ll,ll U.N.F.

Self Locking

in

(0,24/0,33

mm)

Note: When

Connecting

Large and small

Big

End nuts are removed, they must be replaced

Rod

alignment

end

Connecting Rod bores must be square and parallel with

in (0,25 mm) measured 5 in ( 127 mm) each side the small

end

bush fitted, the limit

of±

0.010

II-~

.!:

~

~~

~·

~N

C:>O

+I +I

~

II

Small

End

Bushes

Cl

of

the axis

in (0,25 mm)

5in

127mm

-

by

of

the rod

is

reduced

5in

127mm

new ones.

on

to±

o e

- e

";g

'?N

i'jc:i

~~

each

other

within

the

test mandrel as shown in

0.0025

in

(0,06

mm).

-u

the

limits

Fig.

of±

C.

0.010

I.

With

Type Length

Out~ide

of

Small End Bush

Diameter

Interference Inside Diameter (finished bore in position

reaming)

Connecting Rod Bearings

Type Shell Width Outside Diameter

Inside Diameter Connecting Rod Bearing Running Clearance Steel Thickness Aluminium

Fit

Tin

Thickness

of

Bush

of

Bearings

in

Rod

Bearings

after

Steel Backed, Bronze lined

1.047/1.055 in

1.3785/1.380

0.0025/0.005

1.2505/1.25

Steel

backed,

1.1208/1.1280

2.3955 in (60,85

2.2504/2.2515

0.0014/0.003

0.0467/0.0582

0.0138/0.0256

(26,59/26,80

in

(35,01/35,05

in

(0,06/0,13

15

in

(31,

Aluminium

in

(28,47

mm)

in

(57

,16/57,19

in

(0,04/0,08

in

(I

,19/1,48

in

(0,35/0,65

76/31 ,79

/28.,65

Tin

mm)

lined

mm) mm)

mm)

mm) mm)

Remova1

of

Piston and Rods

Sump

On

some applications it will be found necessary

remove the engine from the chassis because the engine

support brackets are fastened The pistons and connecting rods are removed from

the cylinder block through the bores, see Fig. C.2.

Big

End Bearings

If

examination reveals renew big end bearings, they should be suitably marked

to

ensure ret'itment

to

the sump.

top

of

that

there is no necessity

to

their original positions.

the cylinder

to

Pistons and Connecting Rods C3

Gudge«,m To

the pistons, immerse the pistons in a warm liquid

I00-120°F (40-50°C), when the pins, after removal

of

Pistons and Rings

If

able dependant upon the condition

Production

Service Standard -

Cylinder bore -

Pins

facilitate the removal

the circlips, can

new pistons are to be fitted, three grades are avail-

Standard-

be

of

the gudgeon pins from

easily withdrawn.

of

the

liners.

Piston topping allowance tive to height above cylinder

top

face

is

block

in

(0,00/0,10 mm).

The piston and

will

of

limit Where engines have

conform regulation B.S.AU14Ia:I971, then pistons must topped tion limits.

3.5010/3.5020 in

piston height.

to

standard production

to

0.000/0.004

is

minimum topped

not

exceed the top

the smoke density

be

maintain produc-

used and

rela-

to

{88,93/88,95 mm)

Service

Cylinder bore -

(0, 76

0.030 in mm)

Oversize

Two pistons are available: one untapped the lation and one with minimum topping which will the

3.5310/3.5320 in

B.S.

top

limit

for topping

AU

14la:l971

of

piston height.

not

to

meet regu-

exceed

(89,69/89,71 mm)

The maximum permissible worn ring lift

piston ring with a new ring fitted mm).

In a worn cylinder bore, the piston ring gap should be

in

measured der and checked against the dimensions Page

C.l.

the unworn, clean portion

is

0.008

of

the

in

(0,20

the cylin-

quoted

top

on

C3

Pistons and

Connecting

Rods C4

Connecting Rods To

renew small by means new bushes, making sure

and rod small end align when fitted. Ream new bush to dimension squareness with big end bore. See ing

mnnecting

Assembly

If

H

i~

intended to utilise the existing pistons, ensure that they are relocated in their original positions relative to connecting rod and cylinder bores.

Heat the pistons il)sertwn

end

of

the gudgeon pin.

bushes, remove the worn bushes

a suitable press and dolly. Press in the

rod parallelism and twist.

in

liquid

that

the oil holes in the bush

quoted

to

J00-120°F

on

Page

C.2,

Page C.2, for check-

(40-50°C) for

out

the

ensuring

C4

is

given

on

Page

C.l,

they

piston.

beneath

see Fig.

are fitted

number

hom

on

On

It

will be

of

that

the the

the

The piston ring layout

for cross sectional diagram showing layout

C.4

rings, note the position rings.

Use

piston ring squce1.er when inserting the pistons

into

the cylinder bores.

Where piston rings are the. marked face rings

are marked

with the marked face Each connecting rod

the cylinder to which it belongs counting forward end pistons are camshaft opposite side assembly repeated assembling the caps appear noticed that each connecting rod assembly has its own assembly

on

is

"TOP",

of

the engine, (1,2,3,4,). When the

in

the bores, these numbers are

side

of

the

of

the connecting rod will be found an

number.

on

the connecting rod cap and when

the same side, see Fig. C'.6.

number.

of

the internally stepped

m>!rked

to the skirt

to

the crown

is

stamped with the

engine, see Fig. C.S.

These assembly numbers are

to

The

'"BTM", ensure of

ensure

rods, these numbers must

the piston. Where

that

of

the

letter

etched

of

C6

assembly number weight code.

When

refitting the connecting rod bearings, ensure that the locating tabs located in the machined recesses of the rod and see

Fig.

C.

7.

(A

to F)

is

the

connecting rod

of

the bearings are correctly

cap,

Pistons and Connecting Rods

CS

Lubricate the bearing surfaces and rod to the crankpin. Examine the securing bolts serviceability and renew if necessary. Renew the nuts and tighten evenly to a torque for non-phosphated nuts or 60 lbf phosphated nuts.

Piston height see

Page

See

Fig.

C.

C.S.

in

relation to cylinder block top

I can

be

checked with the piston at

of

fit

the connecting

45 lbf

ft

(8,3 kgf m) for

(6,2 kgf

T.D.C.

for

m)

face,

C7

cs

-----··----

The cylinder block crankcase in high

"dry"

type

The

crank

crankshaft axis.

case

duty

cylinder liners are fitted.

joint

Cylinder Block

Total

height

Bottom

Parent Bore diameter for Cylinder Liner

Cylinder Block recess Cylinder Block Recess Bore

Main Bearing Parent Bore

No. 1 Bore for Camshaft

No.2

Bore for Camshaft

No.3

Bore

No.4

Bore for Camshaft Cylinder Block Cylinder Block Crankshaft

Washer Recess

CYLINDER

is

cast integrally with

cast iron. Flanged cast iron

face does

Face

for

not

extend

below the

CYLINDER BLOCK AND LINER DIMENSIONS

of

Cylinder Block

depth

Camshaft

Tappet

diameter

Bore

from

for Liner Flange

diameter

Thrust

Section 0

BLOCK

the

Head Face

AND

Ventilation situated fitted

to

11.177/11.181

3.8125/3.8135

0.150/0.152

3.990/3.995

2.916/2.917

2.0472/2.0484

2.0374/2.0386

2.0275/2.0287

2.0177/2.0189

0.5625/0.56375

3.756/3.764

• •

LINERS

on

to

the right hand side

in in in (74,07{74,09

in

Cylinder Block

of

the

crankcase is by a

the cylinder head

in (28 in

(96,84/96,86 (3,81/3,86 (101,35/101,47

in

(52,0/52,03

in

(5 I ,75/5 I ,78

in

(5 I ,5/51,53

in

(5

I ,25/5 I ,28

in

(14,29/14,32

(95,4/95,6

of

3,9/284,0

mm)

and

top

the engine.

mm) mm)

mm)

Liners D 1

breather

cover, which

pipe

is

Cylinder Liners

Type Outside Interference fit

Cylinder Liner Finished Bore Cylinder Liner Flange Thickness Depth

Cylinder Liner Flange Diameter

Height Height

Clearance fit

diameter

Bore

of

Flange BELOW

Cylinder Block

of

Liner Collar ABOVE

of

Cylinder Block

Cylinder Block Recess

Collar ABOVE

of

Liner

of

Liner in Cylinder Block Parent

of

Liner Flange

Top

Face

I"'

Face

in

of

lange

of

Dry Interference

3.8145/3.8155

0.001/0.003

3.501/3.502

0.148/0.150

0.000/0.004

3.972/3.976

0.028/0.033

0.026/0.031

0.014/0.023

in in in (3,76/3,81

in in

in

Fit

in

(96,89/96,91

(0,02/0,08 (88,92/88,95

(0.00/0.10

(

100,0/101,0

(0,71/0,84

(0,66/0,79

(0,35/0,57

mm)

Cylinder Block and Liners

0·000/0·004 0,00/0,10

mm

In

0·021/0·031 1,66f0,19

02

mm

Cylinder Block The top face

In

up to a maximum is

necessary, the cylinder liner recess height should be lowered the cylinder block face (outside the gasket area) marked accordingly.

of

the cylinder block may be skimmed

of

0.020

in

(0,51

mm).

Where this

depth

by

the

same

and piston

amount,

and

01

----

/

/;

----

-"f:

Cylinder Liners

If

the

worn inside not exceed piston rings may be fitted.

If

examination

(89,10

mm) the liner can be bored (89,69/89,71 pistons fitted.

The limits for the flange recession, and liner collar protrusion may be checked

To

Renew Cylinder Liners

New

production Remove all liners should be pressed cate the outside diameter

oil. Press in the new liners until they are fully

collar

of of mm). Bore and finiSh the liners

3.501/3.502 finish

the liner should

the cylinder block by

of

22/32

diameter

0.006

in (0,15

reveals a worn condition

or

bore diameter dimensions in excess,

mm),

and

liners can be fitted

components

in

(88,92/88,95

micro in (0,56/0,81 microns).

of

the cylinder liner does

mm)

from

standard,

out

to

3.531/3.532

0.030

in

(0,76

mm)

on

Page

D.l,

from

the

out

from the

of

the new liner with clean

protrude

0.026/0.031 mm),

to

cylinder block.

bottom.

above

in

to

a dimension

and a final bore

of

see Fig.

the

new

3.508

oversiZe

Dl.

engine.

The

Lubri·

home.

The

top

face

(0,66/0,79

in in

of

• •

Section E

Crankshaft and Main B·earings

El

CRANKSHAFT

The crankshaft

with

steel and two centre webs. End float backed, aluminium tin replaceable thrust located

An timing gear crankshaft, located by a

oil

on

thrower

Crankshaft

is

integral balance weights

both

forged from chrome-molybdenum

sides

of

the centre main bearing.

flange

is

fitted to the forward end

provided

key.,

on

is

controlled by steel

at

CRANKSHAFT

Main

Journal Journal

Main Main

Journal

Main

Journal

Main

Journal Crankshaft Crankshaft Crankshaft Pin Fillet Radii Surface Finish, all Journals,

and Oil Seal Diameter Crankshaft Journals and Oil Seal Helix Diameter Oil Seal Helix Width Oil Seal Helix Depth

Crankshaft Flange Diameter Crankshaft Flange Width Spigot Bearing Recess

Spigot Bearing Recess Bore

Crankshaft End

Diameter Width No. I Width Nos. Width

No.3

Fillet Radii

Pin Diameter

Pin Width

Depth

Float

Pins Re-grind Undersizes

the front, rear

the rear end. A

2,

4 and 5

Pins

AND

washers

of

the

MAIN

Five main beurings are fitted, which are replaceable thin wall, aluminium tin lined, steel backed and retained by bearing are located by dowels and secured by steel setscrews.

BEARINGS

caps

of

AND MAIN BEARING DIMENSIONS

2.7485/2.749

1.391/1.421 in (35,4/36,1 mm)

1.4335/1.4415

1.4365/1.4385

9(64~5/32

2.2485(2.249

1.3725(1.3741 in l/8

9{64

16

micro

0.010,0.020

2.211/2.212

0.050/0.080

0.004/0.008

3.9985/3.9995

0.5

in

(12,7

0.875 in (22,22 mm)

1.2495/1.251

0.003/0.015

in

(3,2/3,57

in

max

and

in in in

mm)

in

(3,57/3,97

in

(69,81/69,82

in

(36,4/36,6

in

(36,49/36,54

(57,10(57,12

(34,86/34,9

(0,4

0.030

(56,16/56,18

(I

,27/2,03

(0,1/0,2

in

(10 l ,56/10

(31,74/31,77

(0,08/0,38

mml

mm)

microns max)

in

(0,25,

mm)

high

mm)

mm) mm)

mm)

I ,59 mm)

mm)

duty

cast iron which two

mm)

0,51 and

high tensile

0,76

mm)

Main

Bearings

Crankshaft

Type

Shell Width for all Journals Outside Diameter Inside Diameter Main Bearing Steel Thickness Aluminium

Thrust

Washers

Type Position in Engine Thrust

Washer Thickness

Thrust

Washer Thickness OfS

Thrust

Washer Diameter

of

Running

Tin

Thickness

of

Bearings

Clearance

STD

(I)

backed,

Steel

1.122/1.130

2.917 in

2.7515/2.753

0.0025/0.0045

0.0625

0.0197

Steel backed Aluminium Centre

0.0896/0.0915

0.0966/0.0985

3.744/3.756

Aluminium

in

(28

(60,84

in

(I

in

(0,50

Main Bearing

,5/28,7

mm)

in

(69,89/69,93

in

(0,06/0,

,59 mm) maximum

mm)

in

(2,26/2,32

in

(2,45/2,50

in (95,1{95,4 mm)

Tin

mm)

II

Tin

lined

mm)

mm) 1

mm) mm)

I

Crankshaft and

El

Main

Bearings E2

Crankshaft End

If

the thrust washers are to be renewed, remove the centre main bearing cap which provides the location for each washers. With the cap removed, the the washers are. accessible, see Figs.

The maximum permissible worn (0,51 mm). The fitting be used to bring the tion limits

Removal

Remove the timing case, see Page two rear main oil seal housing clamping setscrews before removing all main bearing caps, and mark the main bearings they are

Overhaul

The minimum permissible worn diameter

journals

journals 2.2475 in ovality for crank pins and main journals (0,01 mm).

Float

of

the two

quoted

of

Crankshaft

to

be replaced.

of

Standard Size Crankshaft

is

2.7475 in

bottom

of

oversize thrust washers can

end

flo:tt to within the produc-

on

Page

E.l.

their respective caps

(69,78

(57,08

mm),

mm).

halves

of

the

two

E.l

and E.2.

end-float

F.3.

and for the big end

Maximum permissible

thrust

top

halves

is

0.020

Release the

or

journals

of

the main

is

0.0005 in

of

in

if

The crankshaft can be reground

mmJ.'mm)"Undersize.

Crankshaft Rear

If

seals the following procedure should be With a half housing in a vice, and the seal recess

uppermost, settle approximately I in (25 mm)

seal, end

mm) beyond the half housing

Press the remainder from

Using a suitable

into

Fit manner.

To

Thoroughiy

all traces

0.020

in (-0,51 mm) and -

Oi~

Seal and

examination reveals the necessity

at

each

end,

into

of

the seal projects

the centre and working outwards.

position.

the

seal to

refit the assembly, proceed

clean

of

the old

the groove ensuring

of

th.e

round

the

other

the

joint

joint.

to-

Housing-

0.010/0.020 joint

seal

into

bar,

roll

half

housing in a similar

as

follows:-

and

butt

0.010

in (

0.030

to

adopted.

face.

position starting

and

press

faces, removing

-0,25

in ( -0,76

See Fig. E.3.

renew the oil

that

in (0,25/0,51

the

of

the

each

seal

E3

Crankshaft and Main Bearings E3

Lightly of

joint

aligned. Lightly

jointing

of Oil the crankshaft rear end around the oil

groove. Place engine and locate all setscrews and bearing cap face,

Tighten

lbf ft

Tighten the setscrews in the cylinder block and ing cap

Finally tighten lbf

Main

Each main bearing cap

cylinder block by the block serial stamped shaft.

coat

the

in position, ensuring

the rope seal with graphite grease.

(0,55--0,83

ft

(I

Bearing

side. See Fig. E.4.

the cylinder block and bearing cap side

joint

with jointing

coat

the

compound.

the

to a torque

,66 kgf m).

butt

the

clamping bolts

the

half housings in position

kgf m).

of

compound,

that

the

faces

of

Lubricate the exposed diameter

finger tight only.

12

clamping bolts

the half housings with

in

to a torque

lbf

ft

(I

,66 kgf m).

Caps

is

identified in relation

on

the

rear

of

the

bottom

and place the

securing .holes are

the cYlinder block

of

only

to.a

torque

number

face

on

which

the cam-

retum

on

4-6

bear-

of

to

the

12

E4

the

is

An arrow ward end

No. l cap an block. with corresponding

No.3 which carries easily identified.

No. 4 cap has no identification and numbers 1 and located, its position

No. to

carry the

therefore easily identified. To

positioned see Fig. over ing setscrews kgf m).

is cast

on

to

each cap indicating the for-

of

the engine

(counting

''A".

A corresponding

See Fig. E.4. No. 2 cap is stamped with a

has no Jetter,

5 cap is

the

2,

the

bottom

refit, ensure

the

crankshaft main

to a torque

to

ensure correct fi!ment.

from

the

front)

''A"

letter

stamped

but

is the

thrust washers and

but

as

is pre-determined.

rear main, and is drilled and

half

that

the

E.S,

centre

at

this stage these are already

of

the oil seal housing and

locating dowels are correctly and

the

journal.

of

80-85

is

is stamped

on

the

main bearing cap

cap is placed firmly

Tighten

lbf

stamped with

on

the

"B"

block.

is

therefore

is similar

ft

(II,

the

I-ll

to

tapped

secur-

is

,7

ES

Crankshaft

and

Main Bearings E4

Oil

Thrower Flange

E6

When refitting oil

thrower

lh<'

crankshaft before fitting

and

nankshaft

the

crankshaft,

t1ange, see Fig.

pulley.

Crankshaft Pulley

When fitting timing marks ahgn. See

screw to 123 Jbf

the

crankshaft pulley, ensure

on

the

Flg. E.7.

ft

(17,0 kgf m).

end

of

Tighten

do

not

omit

to

E.6,

onto

the

timing case cover

the

crankshaft

the pulley retaining set-

front

and

fit

end

that

pul!ey

the

of

the

E7

Crankshaft and

Main

Bearings

ES

F

c

0

i\

I

B

!\

,\

I

lA

l_

~

Crankshaft Regrind Data

0.010

in

Undersize

A 2.7385/2.739

(69,56/69,57 mm)

B 2.2385/2.239

(56,86/56,87 mm) C 1.4459 D 1.4416/1.4445

(36,61/36,69 mm) (36,74/36,82 mm) E 1.3806

1.4045 in (35,67 mm) maximum

F Rl 0.146/0.157

R2

0.126/0.142 in (3,20/3,61 mm)

Surface finish

Magnetic crack detection

limits

Maximum Run-out with the crankshaft mounted on the end main journals Independent readings:·

Crankshaft Pulley

Diameter T.I.R.

0.002 in (0,05 mm)

Journals

Number

Mounting

(0,25 mm)

in

(36,73 mm) maximum

in

(35,07 mm) maximum

in

(3, 71/3,99 nun)

of

crankpins, journals and fillet radii 8 micro inches (0,2 microns)

of

taper and out

Taper 0.00025 in Out

T.I.R.-

Run-out must not

1.

Number 0:003

A

i\

\

B

\(\

0.020 Undersize

2.7285/2.729 (69,30/69,32 mm)

2.2285/2.229 in (56,60/56,62 mm)

1.4466/1.4495

all all

D.C.

of

round for pins andjournals:-

(0,005 mm) (0,005 mm)

Rear

Oil

Diameter T.I.R.

0.002 in (0,05 mm)

be

2.

in

(0,08mm) 0.006

__!_.

in

(0,51 mm)

journals crankpins

_Flow-

Seal

opposed

Number

lj

in

2.5

3.

in

(0,15mm) 0.003 in (0,08mm)

~

A

l\

amps

of

c c

}\

/,lA

I II

Is

1/\(

0_

0.030 in (0,76 mm) Undersize

2.7185/2.719

{68,80/68,81 mm)

2.2185/2.219 (56,35/56,36 mm)

1.4516/1.4545

{36,87/36,94 mm)

A.C.

Round 0.00025

Flywheel Flange Diameter T.l.R.

0.002

in

Number 4.

in

Current-- 1300 amps

in

(0,05 mm)

It\~\

i

'

C.

L.A.

Number Mounting

E

__

5.

A

\(

Timing Case and Drive

Fl

Section

TIMING

A helical gear drive consisting driving cast iron camshaft and fuel

sion being made All gears are enclosed by an aluminium timing case

and cover. A timing timing case front cover, situated behind the crank-

shaft pulley which can locate into the back pulley piston.

The. cast iron camshaft with chill hardened cams

supported the cylinder block. All

lubricated

of

hardened steel crankshaft and idler gears

to

facilitate

See Fig. F.!".

in

four bearings in the right hand side

by

internal oilway drillings.

Camshaft

for

is

used,

fuel

pump

pin device

the

obtaining

the

timing gear train

pump

is

provided

of

T.D.C. No. I

gears, provi-

timing adjustment.

bearings are pressure

CAMSHAFT AND

CASE

on

the

of

the

of

TIMING

·F·

AND

is

GEAR DIMENSIONS

DRIVE

Journal Journal Journal

Journal Journal Journal Journal Journal Journal Journal Journal Journal

Cam Lift

Eccentricity Camshaft Camshaft

Oilway

for Rocker Lubrication

Camshaft Thrust Plate

Type Inside Diameter Thrust

Plate Thickness

Camshaft

Camshaft Gear

Inside Diameter

Transition

Length, No. I Diameter, No. I No. 1 Clearance Fit Length,

Diameter, No.2 Length, No. 3 Diameter, No. 3 Clearance Fit Length, Diameter, No.4

No.2

Clearance

No.4

Clearance Fit

of

Lift Spigot Diameter for Gear Spigot Width for

ot"

End

Float

of

fit

of

Gear

Fit

No.3

No.4

Pump

Cam

Thrust

Bore

Gear Boss

on

Camshaft Spigot

Plate

in (29,97 mm)

1.18

2.0437/2.0448

0.0024/0.0047 l.Oin(25,4mm)

2.0339/2.035

0.0024/0.0047

1.0

in

(25,4

2.0241/2.0252

0.0024/0.0047

1.0 in

(25,4

2.0 142/2.0

0.0024/0.0047

0.280/0.282

0.095/0.098

1.125 1/1.1257 in (28 ,58/28,59

0.2374/0.2401 Journal

No. I

Oil-impregnated Sintered

1.4

in

(35,5 mm)

0.233/0.2362

0.0012/0.0071

1.125/1.126 in

0.0007 interference/0.0009 in clearance

in (5 I in

(0,06/0,12

in

(51,66/5

in

(0,06/0,12

mm)

in

(51 ,41/5 I ,44

in

(0,06/0,12

mm)

!54

in

(5

I ,16/5 I ,19

in

(0,06/0,12

in (7

,11/7,16

in

(2,41/2,49 in

(6,03/6,10

in

(5,92/6,00

in

(0,03/0,18

(28,57/28,60

(0,018/0,023

,91/51,94

I ,69 mm)

mm) mm)

Iron

mm)

Timing Fuel

Case

Pump

Gear, Hub and

and

Drive

F2 Adaptor

Hydraulically Governed Engines

for

Inside Diameter

Drive Hub Spigot

Drive Hub Gear Clearance fll Adaptor Outside Diameter

Interference fit

Adaptor Inside Diameter Outside Diameter

Running

H1.1b

Drive

Fuel

Pump

Gear

for Mechanically

Governed Engines

Inside

Idler Gear and Hub

ldlt:r Gear Bore Diameter

Gear Bush Outside Diameter

Idler lnterferem;e

(!ear Bush Bore

Idler Outside Diameter

Clearan~e

Idler Gear Wtdth 1\ub

Wtdth

Idler Gear End Float

Cylinder BllKk

ldkr

Gear

Stu

and

Cylinder rulllng Dtameter

rran~itiun

of

Gear for

Fuel

Pump

Soi101ot

of

Gear

on

Hub Spigot

Parent Bore Diameter for Bushes

of

Bushes

(2)

of

Bushes

in

Parent Bore

of

Bushes

of

Clearance

End

Din

meter

fit

flt

llub

Cleamn~e

Blo~k

Ca~e

of

Spigot for Timing Case

fit

Hub

of

Drive Hub

Float

of

Gear for

of

Bush

in

of

Huh

of

Buslwd Gear

ldkr

Huh Bore

Sptgol

DiJmetn

ftl

of

Spigut m

Bore

Idler Huh Bore

of

Spigot

in

Bushes

Fuel

Puntp Spigot

Bore

on

Hub

for Block

riming Case Bore

!.7507/1.7516

1.7496/1.7503

0.0004/0.002

1.4063/1

1.40625/1.40725

0.0009/0.0013

1.2

50/1.25 16 in (31 ,75/31 ,79 mm)

1.248/1.249

0.001/0.0036

0.005/0.011

1.750/1.751 in

1.8898/1.8908

1.8915/1.8924

0.0007/0.0027

1.7327/1.7337

1.7303/1.7313

0.0014/0.0034

1.1320/1.1340in

1.140/1.144

0.006/0.012

1.732/1.733

1.731/1.732 in

0.000/0.002

2.3228/2.3240

2.3217/2.3229

0.000 1(0.0023

in

(44,47/44,49

in

(44,44/44,46

in

.4076 in (

(0,0 1/0,05 mm)

35

in

(0,02/0,03

in

(31 ,70/31,72 mm)

in

(0,02/0,09

in

(0,13/0,28

(44,45/44,47

in

(48,00/48,02

in

(48,04/48,07

in

(0,02/0,07

in

(44,01/44,04 in(43,95/43,97 in

(0,03/0,09

(28

in

(28,95/29,06

in

(0,15/0,30

in

(43,99/44,02 (43,97/43,99

in

(0,00/0,05

in

(58,99(59,03

in

(58,97/59,00

in

(0,00/0,06

,72/35,7 5

(35

,72/35,74

mm)

,75/28,80 rum)

mm) mm)

mm)

mm) mm)

mm)

mm) mm)

mm)

mm) mm)

mm)

mm) mm)

mm)

Crankshaft Gear

Inside Diameter

Crankshaft Spigot for Gear Diameter

Transition fit

Timing Gear Backlash

All

Gears

of

Gear

on

Shaft

1.2496/1.2505

in (31

,74/31,76

1.2494/ 1.250 in ( 31,73/31

0.0004 clearance

interference/0.00

0.004

in

(0,01/0,03

(0,10

mm)

minimum

II

,75

mm)

in

To

Remove the Timing Case

Timing Case and Drive F3

The timing case setscrews, and to prevent damage take great care when separating the case from the sump

joints

the

sump

If an

attempt

out

lowering the sump,

the idler gear Prior to removal

remove titning

On sary to remove the fuel following

Remove fuel Remove drive

adaptor now

Remove The

idler gear removal

the

gears

hydraulically governed engines, it will be neces-

housing. With the gear removed,

be

withdrawn.

exhauster

timing case

of

is

also

attached

or, lower the

joints

on

reassembling.

is

to

be made

hub.

crankshaft pulley, front cover and all

except

procedure:-

pump.

hub

is

hub.

the timing case. See Page

then

See Page of

timing case, it

the crankshaft gear.

locating circlip

unit

(if

located by a transitional fit

Hub removal may facilitate

to

the

to

the

sump

and completely renew

to

remove

it

is

advisable

F.4.

is

pump

drive

hub

through

fitted).

F.4.

sump

the

case with-

to

necessary to

the rear

the

by

two

joints

remove

using the

of

hub

can

on

the the

To

Refit

the

Timing Case

With the new ends tongue cylinder block, loosely locating by the setscrews, case to block and case to sump the timing case securing setscrews, the idler gear hub may now be fitted

With the fitted over its locating idler gear ing face

sump

cork

joint

of

the cork and

can

joints

sump

the

case

of

the

fitted, remove. the idler gear allowing a clean area between the

the

case where

locate.

Offer

the

timing case

sump

are correctly located. By adjustment

to

the cylinder block and case.

removed, "the timing case may be

to

block

timing case and crankcase are aligned, see

ensuring the cork and

hub,

setscrews ensure the

the

but

hub.

sump

to

sump

on

Pit

butt

joint

and

of

tighten-

bottom

Fig. F.2.

When fitting the seals, ensure the tongues located

On pump the

under

hydraulically governed engines, refit the fuel

drive

previous sub-section.

sump

joints

and

front

of

the

butt

end

hub

following the reverse procedure in

of

the cork.

the

and rear

sump

joints

cork

are

a

F2

~-

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

Timing Case and Drive

D·251/1J·SODin

1,35fl,l2"""

F4

Refit the timing gears ensuring that the timing marks

align.

Refit timing case cover using the crankshaft pulley

for

conect

To Renew the Front

Press

a suitable dolly area

Press in the new seal from the front

cover

mm) F.3.

location

out

the old seal from the timing case cover using

of

the

seal bore.

to

a dimension

from

the

of

oil seal and cover.

Oil

and

press,

of

front

of

the

Seal (Front cover removed)

supporting

0.250/0.300

cover

the

of

the timing case

in (6,35/7,62

to

the

seal. See Fig.

cover

in

the

To Remove Idler Gear and Hub

Remove

Withdraw gear,

nuts

and retaining plate.

complete

with

bush

from

the

hub.

See

Fig. F.4.

The

idler gear

timing case,

difficulty be

removed.

hub,

may

be

is

experienced,

which

tapped

is

a transitional fit in

out

of

its location.

then

the

timin& case should

the

If

To

Refit

the

Idler

Gear

and

The

studs

securing

When refitting both

the

cylinder block and

F.S. Replace

correctly aligned. See Fig.

the

gear

the

hub,

on

hub

the

Hub

are slightly

ensure

hub

H.l.

off

centre.

that

the

oil drillings in

are clear. See Fig.

with

the

timing

marks

FS

Fit

the two (2,6-2,9

retaining plate, Fig.

new self locking

kgf m) Fig.

nuts

F.6.

F.6,

to a torque

No.2.

No. I and tighten

of

19-21

lbf

ft

Timing

Ca~

and Drive FS

Check the dimension maximum F.6.

NOTE: disturbed, removed to allow tate

To

Remove the Camshaft

Remove washer.

Draw the camshaft gear camshaft, see Fig.

To

Refit Remove the idler gear to facilitate timing.

Fit

the

and

enter

Draw the gear ing washer, screw and Jock with the tabwasher.

end

float

of

0.006/0.012

wear limit

If

the cylinder head assembly has

then

the

aligning

the

camshaft gear over the

into

to a torque

the

of

setscrew, tabwasher and retaining

F.

Camshaft Gear

keyway.

onto

tabwa&her and setscrew. Tighten the set-

the gear

in

is

0.015

the

rocker

camshaft

the

timing marks.

Gear

off

7,

the

of

its keyed location

using a puller, and adaptors.

camshaft by fitting the retain-

40-45

on

(0,15/0,30

in

(0,38

assembly should be

to

be

turned

key

of

lbf

ft

(6,2-6,9

the

h.ub

mm). The

mm).

not

the

camshaft

to

See Fig.

been

to

facili-

on

the

kgf m)

a

F6

NOTE:

facilitate

rocker disturbed.

Hvdraulically Governed

To

enable the camshaft to be

the

aligning

assembly

of

the

if

the cylinder head has

timing marks, remove the

Fuel

Pump Drive Assembly -

turned

not

Fig. fi.8.

To

Remove

Remove the three setscrews securing the gear fuel location.

To

Refit

Remove

Refit the

pump

the

fuel

gear and

the

Fuel

drive

hub,

Fuel

Pump

idler gear

pump

hub

are

Pump

Gear

and ease the gear from its

Gear

to

facilitate timing.

gear so

that

the

in

alignment as shown

timing marks

H.I.

to

in

to

been

the

on

Fig.

F8

Timing Case and Drive

F6

Refit idler gear and tjme engine. Check backlash

which should be

To

Fit

New Fuel Pump Gear

0.004/0.008

in

(0,10/0,20

mm).

In the event th1s

w1ll ensure correct fitmen\ fuel injection he

adopted.

Turn T.D.C., No. l piston being

Remove fuel

Replace idler gear ensuring that timing marks crankshaft gear, idler gear and camshaft gear coincide.

Turn

direction for m normal direction until No. l piston timing point (see

Remove fuel

governed pumps)

connection (hydraulically governed pumps) enabling the fuel

Then

on

line ally governed and mechanically governed pumps respectively) coincides with the squared fuel pump timing circlip.

Ensuring timing gears and fuel move, fit fuel injection pump gear and secure with three setscrews.

of

a new fuel pump gear being required,

be supplied

pump,

crankshaft until Nos. I and 4 pistons are

pump

nankshaft

about

pump

rotor

turn fuel

the

rotor

without

of

the following procedure should

gear and idler gear.

in

opposite direction

quarter

Page

L.l.).

inspection plate (mechanically

or

plate

to be seen.

pump

driving hub until the scribed

marked

timing marks and

the gear and timing

on

compression stroke.

of

a revolution.

embodying

"A"

or

"C"

pump

is

fuel return

(for

shaft

of

to

normal

Then

at its static

hydraulic-

end

of

do not

to

the

at

on

tum

the

F9

Turn

crankshaft back slightly and then forward again to No. fuel

Bring crankshaft up to T.D.C. for Nos. I and 4 pistons, No. and mark new fuel pump gear with a scribed line to coincide with the scribed line

driving hub: also

coincide with the single dot

When replacing a fuel governed engines,

timing gear backlash to within the limits prescribed on

F.7,

Adaptor

To

Remove the fuel injection Remove the drive hub locating circlip

rear

I piston

pump

Page

sub section headed

Remove

of

the

on

timing

is

I piston being

stamp

F.2.

For

Housing".

the

Fuel

adaptor

static timing point to check

correct.

on

its compression

on

two

dots

on

p·1mp gear

it

will be necessary to adjust the

method

Pump

housing, see Fig.

of

"To

Drive Hub

pump.

the fuel

on

the

idler gear.

on

adjustment, refit

the

F.9.

stroke

new gear

hydraulicaliy

see Page

Fuel

through

that

pump

to

Pump

the

With

the

gear removed, withdraw

the

hub. See Fig.

F.IO.

To

Refit

the

Fuel Pump Drive Hub

Following the reverse procedure, refit the hub.

Timing Case

and

Drive

F7

Remove Refit

sub-section.

To The

cylinder block and rear face fastening arrangement timing case and

To

on pump sections.

If

from gear. Remove the housing.

The bushes are an interference fit in the adaptor housing and can be replaced by using a suitable "dolly" of

the

idler gear

the

fuel pump gear

Remove

gain access

the

fitted, remove

adaptor

the

fuel

pump

inside of the timing case, remove the fuel

gear and drive hub; see

adaptor

housing

and· press. Fig. F

adapter housing showin.g

to

facilitate timing.

as

described in

Fuel Pump

adaptor

two

to

the

two

Adaptor

housing

is

by

three setscrews within the

setscrews

three

adaptor

exhauster unit, and oil feed pipe

to

exhauster. Remove the idler

remaining setscrews fastening

to

cylinder block, and remove

.II

Housing

is

of

shows view

secured

the timing case. The

to

the

cylinder block. F 10

securing setscrews

the

Jub.oil drain hole.

previous sub-

the

front face

to

the

To

Refit

the

Fuel

Pump

Adaptor

Replace the housing the

timing case, using a new

ing

that

it is properly located, see Fig. F .12.

Secure loosely with and timing case

GEAR/IDLER

BY

MANIPULATION ADAPTOR HOUSING. SECURING SETSCREWS UNTIL THE ADJUST-

MENT

IS

EFFECTED.

Refit

the

aligned, and circlip.

hub,

into

the

setscrews

BECAUSE

GEAR BACKLASH

DO

fuel

pump

Housing

its position at the rear

"0"

ring oil seal, ensur·

to

both

THE

OF

THE FUEL PUMP

NOT TIGHTEN THE

gear with timing marks

the

FUEL PUMP

IS

ADJUSTED

block

of

FJI

.

....

Fl2

Timing Case and Drive

F8

Refit the

teeth

the

idler gear, ensuring of

idler gear/fuel

that

pump

the

timing marks

gear align.

on

F13

TO ADJUST THE BACKLASH manipulate adaptor (0,10/0,20 to

Remove

gear and

Tighten housing securing setscrews within

case. Replace the gear and hub and circlip, and check

backlash again.

IF HAS

REPEAT

THE Mechanically Governed

Fig.

To

The gear is dowelled secured by three setscrews and spring washers.

Before removal idler gear.

housing until a figure

mm)

is

block setscrews.

the

hub.

THE TIGHTENING

ALTERED

THE PROCEDURE UNTIL

PRESCRIBED LIMITS.

obtained,

hub

locating circlip and withdraw

THE BACKLASH SETTING,

F.l3.

Remove

the

Fuel

of

Pump

the fuel

of

and tighten the housing

OF

SECURING SETSCREWS'

Fuel

Pump Drive Assembly

Gear

to

the fuel

pump

0.004/0.008

IT

IS

pump

gear, remove

the

timing

WITHIN

hub

the

and

the

in

~

To

Refit

the

Fuel

Pump

Gear

The

tightening

securing setscrews

the

Refit marks align.

Because adaptor IS

PROVIDED

torque

for

19-21

the fuel

lbf

ft

is

idler gear, making sure

of

the dowelled location

plate, NO ADJUSTMENT

FOR.

(2,6-2,9

Crankshaft Gear

The crankshaft gear is a transitional onto

the

crankshaft.

the the

then

the

rocker fuel lift

necessary, suitable puller.

To

Remove

Remove Remove

Camshaft

Should

this

can

assembly and pushrods.

pump.

its

be accomplished using a

and

Tappets

pump

drive gear

kgf m).

that

the

timing

of

the

fuel

FOR

fit,

removal became

pump

BACKLASH

and

is

keyed

Invert the engine, remove the sump and lubricating oil pump

Remove the front timing case cover, idler gear and camshaft gear. See Page F.3.

assembly, See Page J .3.

Timing

Case

and

Drive

F9

Remove the camshaft thrust pad secured cylinder block

Withdraw the camshaft, camshaft and exercising care and journals are not damaged, see Fig.

The tappets can be their locations, see Fig. 16.

To

Refit

Reposition the tappets in their locations, after

lubricating with clean engine oil.

Refit the camshaft into

the same Secure the camshaft thrust pad

with

two

Refit the camshaft

and F

.4

Refit the lubricating oil pump assembly, locating it

with screw and locking nut in the cylinder block. Refit the sump. Revert the engine

the cylinder head

by

two setscrews, See Fig.

taking

to

ensure

~emoved

the

Camshaft

care

as

setscrews and spring washers.

ensuring

and

used during its removal.

gear and idler gear, see Page F

that

the

to

its correct vertical position with

(if

fitted) uppermost.

by

Tappets

the

cylinder block exercising

to

timing

marks align.

the weight

F.IS.

lifting them

the cylinder block

F.l4.

that

to

the

of

the

the cams

out

of

F14

.S

Refit the fuel lift pump.

the

Refit

pushrods and rocker assembly. See Page

B.S

F16

• • •

Sect1on

Flywheel and Flywheel Housing G 1

G

FLYWHEEL

To Remove Six setscrews and plain washers secure the flywheel

the crankshaft flange. The setscrews are tightened a torque

To

facilitate safe flywheel removal, it is recommended that two diametrically opposed securing setscrews are removed and in their place, fit two suitably sized studs, fmger tight only. The remaining setscrews can now be removed and the flywheel withdrawn under control.

Flywheel Ring Gear

The ring gear When replacing the ring gear, the applied heat

new ring should not exceed Attention

edge

flywheel.

the

Flywheel

of

80

lbfft

(11,1 kgf m)

is

shrunk on the flywheel.

480°F

(250°C).

should

be

paid

to

the

chamfered "lead-in"

of

the ring gear, and its relative position

AND

to to

to

the

on

the

FLYWHEEL

Gl

HOUSING

To

Refit

the

Flywheel

The securing arrangement

is

by

flange which are the spacing

It

is

the crankshaft flange positioned diametrically site safely suspended whilst the securing setscrews are fitted. The studs can by the last two setscrews.

Flywheel Run-out The outside diameter

concentric within reading,

Flywheel Aligrunent

The alignment

the limit

of

flywheel radius from the crankshaft axis clock gauge plunger. this check, press the end float while turning the flywheel.

six setscrews and plain washen, into holes

not

equidistantly spaced. Fig.

of

the crankshaft flange tappings.

advisable to screw, finger tight only, two studs in

to

each other. This will enable the flywheel to

to

of

0.012 in

the crankshaft axis. See Fig. G.2.

of

the flywheel face should be within

0.001 in

the

of

flywheel

then

be removed and replaced

of

the flywheel should be

(0,30

(Outch

Face)

(0,03

mm) per inch

See Fig. G.2. When carrying

crankshaft one way

mm)

to

crankshaft

G.l

total

(25,4

to

indicator

take up

shows

oppO·

be

mm)

to

the

out

G2

"'"

Flywheel and Flywheel Housing G2

To

Remove the Flywheel Housing

G3

r:J

0

oQ

or m o to-?'""

0

Remove Unscrew the securing setscrews and

carefully

To

Ensure the free from burrs.

Fit

cylinder block sufficiently necessary.

With a clock gauge, check

flywheel housing bore and face are within listed

Diameter Housing Bore

Up

14lk 20 25ihto31

Any adjustments which may be necessary flywheel housing be carried block face.

the

flywheel and

to

dislodge if from

Refit the Flywheel Housing

that

the

mating face of

new dowels, see Fig. G.3 and secure housing

as

follows, see Fig. G.4.

to

14lk in

to

20~

~to

25'h in (511

rear face

of

(362

in(362

in(648

out

on the housing and

starter

motor.

the

mm)

to787

to

of

flywheel housing are clean and

to

that

Total Indicator Reading

to

511 mm)

to

648 mm)

mm)

within

the

tap

locating dowels.

the cylinder block and

allow for adjustment,

the

alignment

Maximum Allowance

0.006

in(0,15

0.008 in

0.010in(0,25

0.012 in (0,30 rnrn)

limits specified, must

not

on

the housing

to

of

the

limits

mm)

(0,20

rnm) mm)

to

bring

the

cylinder

if

If

the

dowels must be removed and

ments made, and/or oversize dowels fitted.

Tighten securing setscrews (4,5-5,0

bore concentricity needs adjustment,

the

cylinder block reamed in-line, and new

kgf m)

dowel holes in the flywheel housing

to

the

necessary adjust-

a torque of 32-36 lbf ft

the

• •

Section

H

TIMING

Timing HI

Because timing gears are fitted

is

unlikely

refitted

The removal

timing

Timing

When

marks are stamped gears are removed

original timing.

Timing

A timing pin

locates

Fig.

1 cylinder.

Befol-e

timing pin should be

To Re-set

It

is assumed

arid

the them remove the rocker shaft the

camshaft. However, it is important that securing brackets, and accordingly must

that

in

of

timing will alter unless

the

wrong position during an overhaul.

of

the cylinder head does

the

engine.

Marks

the

engine

is

assembled

on

the

gears, see Fig. H.'l.

it

is

not

difficult

on

the

into

the

F.

I is a simple method

any

attempt

to

the Original Timing

that

cylinder head

to

their correct position it will be necessary

on

the

4.154

the

cylinder head also secure

be

adopted:

front timing case cover which

back

of

the

of

is made

returned

the

timing gears have been removed

is

still secured. In order

to

release

engine some

the

on

the

4.154 engine,

the

gears are

not

affect

in

the

factory, timina

to

crankshaft pulley, see

finding T.D.C.

to

turn

to

the

its original position.

the

pressure from

of

the

following procedure

If

reset

to

on

engine

to

re-fit

to

remember

setscrews

rocker shaft

the

the the

No.

the

to

it

HI

the

Drain Remove Reduce

ing

the

cylinder block

the

atomisers.

the

pressure

setscrews

by

of

coolant.

on

the

cylinder head

I 1{3 flats

by

to

avoid distortion.

slacken-

Timing H2

Remove Turn

compression stroke. At this crankshaft spigot will be uppermost.

Fit

key and secure with setscrew and tab-washer.

Fit drive hub and secure with setscrews.

the

rocker shaft.

the

crankshaft until No. I piston

the camshaft gear

the fuel

pump

gear

to

is

point

its spigot, locating

the fuel

at

the keyway in the

pump

or

T.D.C.,

on

fuel

pump

on

the

Replace marks align as follows. The double gear to gear, and the single with the double dots pump gears, see Fig.

Secure the idler gear in position with the two lock

nuts For

pumps

Replace the rocker shaft, re-torque

see

cylinder block with coolant

Checking Valve Timing Turn

"overlap" closing inlet valve. At this point set No. clearance the just taken up. In this position Nos. I and 4 pistons should be correctly. pin

(flywheel) degrees

the

idler gear so

match

with the single

and retaining plate.

backlash adjustment (hydraulically governed

only) refer

Page B.S, replace

the engine until No. 4 cylinder valves are

position,

of

the exhaust valve and the opening

to

0.040

normal

direction

at

T.D.C., if the timing has been set

This can be checked by using

or

flywheel markings. A tolerance

dots

on

H

.I.

to

page

the

that

in

(I

,02 mm).

of

rotation

is

permi.SSible.

that

the appropriate timing

dots

on

dot

on

both

F.?.

is

on

the

idler gear

the

camshaft and fuel

the

atomisers and refill the

the period between the

I inlet valve tip

Turn

until the clearance

the idler

the crankshaft

to

cylinder head,

the

engine in

the

align

in

of

timing

of

the

2'h

is

H2

DC.I b

Should probably be due aligned.

When No. l inlet valve in original position before engine.

Fuel

With mechanically governed

on scribed line timing case,

the timing be incorrect

the

(0,30

mm) cold, and

to

the timing gears being incorrectly

timing has been set

to

the

Pump Timing Marks

the

pump

mounting

on

the

rear

see

Fig. H.2.

correct

return

flange should align with

of

then

do

not

figure which

the timing pin

attempting

pumps,

the

mounting

the

error

will

forget to re-set

is

0.012 to

its

to

turn

the

the scribed line

on

the the

plate

With hydraulically governed pumps, on

the

pump mounting flange should align with the

scribed line on

adaptor, see Fig. H.3.

To obtain access is

necessary

for hydraulically governed pumps, or the inspectiOn

cover on the side

governed pumps.

It

should

internal timing marks, the manufacturers' seals will

to

have removed only reseal when otherwise

the

mounting flange

to

be

remembered that

be broken. These seals should therefore

the

the fuel

remove the fuel return adaptor olate

of

by

authorised personnel who must

the

adaptor plate or cover

guarantee may become void.

the

pump

body

of

rotor

of

to

gain access

the

scribed line

the

fuel

markings, it

mechanically

to

is

replaced,

pump

these

be

Timing

H3

On the fuel number letter. A timing circlip pump appropriate scribed line with the sguared commencement

H.5.

To set the timing ciiclip, it pump

ciiclip by connecting No. 1 cylinder

marked pump Turn the rotation until circlip should now the appropriate letter

Checking Fuel Pump Timing

(Mechanically governed) Ensure

previously described.

Ensure that

mounting flange and adaptor plate align.

Position No. I piston at T.D.C. stroke. until No. 4 cylinder valves are rocking and pin engages in timing case.

pump

of

scribed lines, each one bearing an individual

body

from the engine and

"w"

up to 30 atm (31 kgf/cm2 or 440 lbf/in2).

pump

This can be obtained

rotor, inside the fuel pump, are a

is

which has

of

injection (static

on

the

by hand in the normal direction

it

"locks up". The squared end

be

timing circlip

the

scribed lines on

the

pulley. Screw timing pin back into

also positioned inside the

to

be

set so

on

end

pump

adjusted

on

the fuel

of

is

to

the

is

pump

the

circlip, it denotes

timing}-

necessary to remove

fix

the position

outlet

an atomiser tester and

so

that

pump

rotor.

correctly positioned as

on

the

by

turning

that

it

the

when the

rotor aligns

see Fig.

the

of

connection

aligns with

fuel pump

compression

the

of

the

engine timing

H3

The letter align with

Any discrepancy can be corrected fuel pump securing nuts and turning until

When normal direction T.D.C. then

Re-fit

"C"

on the fuel

the

straight edge

the

mark on the

the

timing is correct turn

of

re-fit

the

fuel

pump

of

the

circlip

rotor

is

in line with

rotation until No. I piston is at

springs and collets

inspection plate and re-seal.

rotor

should now

by

slackening

the

pump

the

engine in the

to

circlip.

the

body

valve.

the

Remove valves on No. 1 cylinder and allow the

crown

With a clock gauge at zero and in

stem H.4, of

rotation until

0.150 in (3,81 mm) down the cylinder bore. Then turn rotation the

clock indicates 0.125 in (3,17 mm) B.T.D.C. This

is

equivalent wheel B.T.D.C. and represents injection.

collets and valve springs from one

of

the

piston.

of

the

valve

resting

on

turn

the

engine AGAINST the normal direction

the

engine back again in

(to

take

up

to

18° angular movement

the

valve has moved approximately

the

timing gear backlash) until

the

valve

contact

piston crown see Fig.

the

normal direction

the

static point

of

to

rest on

with the

of

the

of

fly-

of

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

Timing H4

Checking Fuel Pump Timing

(Hydraulically governed)

H4

0

Ensure pumP timing circlip

is

correctly positioned

as

previously described.

Ensure

mounting

Position No. I piston at T.D.C. on

stroke. This can be obtained by turning the engine

until No. 4 cylinder valves are rocking and

that

engages

the

flange

in

scribed lines

and

adaptor

the

pulley. Screw timing

end plate align.

on

the

fuel

the

compression

the

back

pump

timing

into

timing case.

Remove

valves

the

With a clock gauge

stem H.4, of

0.230 tum take gauge indicates equivalent

B.T .D.C.

The

align

Any three

moving the flange.

the

colletS' and valve springs from

on

No. I cylinder and allow

crown

of

the

piston.

of

the

valve resting

turn

the

engine AGAINST the

rotation

fuel

until

in

the

engine

up

the

and

letter

with

discrepancy can

setscrews securing

the

pump

the

(5.84

mm)

back

timing gear backlash)

0.205 in (5,21

to

23°

angular

represents

"A"

on

the

straight edge

rotor

the

body

at

zero and in

on

the

piston

valve has moved

down

the

again in

the

fuel

be

approximate

and

cylinder bore.

the

normal

mm)

movement

static

pump

of

the

corrected

the

fuel

re-mark

the

one

valve

to

rest on

contact

normal

B.T.D.C. This

point

rotor

circlip, see Fig

by

pump

amount,

the

with

crown,

see Fig.

direction

approximately

direction

until

the

of

the

flywheel

of

injection.

should

slackening

gear,

or

pump

of

the

Then

(to

clock

now

H.5.

the

and move body

is

HS

the

timing

is

When

normal

T.D.C.

Re-fit

D

direction

then

the

fuel

re-fit

of

the

pump

correct

rotation

inspection

turn

the

until

springs and collets

No. I piston

plate

and

engine

to

the

re-seal.

in

the

is

valve.

at

Section

• •

J

Lubricating System

Jl

LUBRICATING

The

lubrication from a from filter to drillings through the to and timing gears. Drillings in oil

is

ends. directly

rotor

the

five main bearings. A feed

No. I main bearing

to

the four big end journals, from which oil splash

thrown

The

of

the

engine

is

type

oil

camshaft.

main oil gallery from which oil

up

to

lubP,cate

four

by

oilways from Nos.

pump

The

oil

the

main bearing housings

to

camshaft journals are lubricated

by

driven

is

delivered via a full flow

is

taken

lubricate

the

crankshaft distribute

the

cylinder bores and small

1,

AND t .OIL

full pressure feed

by

off

the

2,

4,

spiral gears

is

fed by

to

each

the

drilling

idler gear

and 5 crank-

t

hub

"""

shaft main bearings. An oil control porated oilway takes lubricant at a reduced pressure rocker shaft.

of

The oil pump which limits the maximum pressure, whilst filter incorporates a by-pass valve which prevents engine being starved become blocked

' "' ' '""" t

I

i i

SYSTEM

in No. 1 camshaft journal from which an

is

provided with a pressure relief valve

of

oil should the filter element

...,

.....

"'

...

feed is incor-

to

the

oil

the

Jl

...

,.

....

"'

Lubricating System

J2

LUBRICATING

Lubricating Oil Pressure

Sump

Capacity

Lubricating

Dipstick

Oil

Position

Pump

Type Number Number Method

Bore

of

Lobes-

of

Lobes -

of

Drive

in

Cylinder Block for Lubricating

Oil Pump Outside Diameter Clearance

Fit

of

Pump

Lubricating Oil Pump Clearances

Inner

Rotor

to

Outer

Rotor

End

Pump

Body Bore for Drive Shaft

Outside Diameter

Outer

to Pump Body

Float

of

Running Clearance

OIL

SYSTEM DATA AND PUMP OIMENSIONS

Inner

Rotor

Outer

Rotor

Lubricating Oil Pump Body

in

Bore

Rotor

Shaft

of

Shaft

in

Bore

30/60

lbf/in2 (2,1/4,2

at

maximum operating Varies according

Either side

speed and normal

temperature

to

of

application

engine

Rotor Four

Five Spiral Gear driven from

Camshaft

1.375./1.376 in

1.374/1.3746

0.0004/0.002

0.002/0.006

0.0052/0.010

0.001/0.005

0.625/0.626

0.623/0.6235

0.001S/0.003

(34,92/34,95

in

(34,90/34,91

in.(O,Ol/0,05 mm)

in (0,05/0,1 5 mm)

in

(0,13/0,25

in

(0,02/0,13

in

( 1

5,87/15,90

in

(I

5,82/15,84

in

(0,04/0,08

kgf/cm

mm)

2

)

mm)

Lubricating Oil Pump Drive Gear

Inside Diameter Outside Diameter Interference fit

of

Gear Bore

of

Gear

Drive Gear Backlash

Lubricating

Oil

Pump Relief Valve

Type Pressure

Setting

Relief Valve Bore Outside Diameter Clearance Length

of

Plunger Outside Diameter Spring,

Free Length

of

Plunger

of

Spring, Solid Length

Lubricating Oil Filter

Type Element By-pass Valve Type

of

Setting

Valve

Drive Shaft

on

Shaft

Plunger

in

Bore

Spring

0.4965/0.497

0.4983/0.4986

0.0013/0.0021

0.0155/0.019

in

(12,61J12,62 mm)

in

(12,66/12,67

in

(0,03/0.05

in

(0,39/0,48

Spring-Loaded Plunger

36/44lbf/in2

0.5605/0.5621

0.5585/0.5595

0.001/0.0036

0.78125

0.389/0.405

1.5625 in

0.812

in

(19,84

in

(39,69

(20,62

(2,53/3,10

in

(14,24/14,28

in

(14,18/14,21

in

(0,02/0,09

mm)

(9,88/10,29

mm)

Full Flow Paper Opens

between 8·12 Ibf/in2 (0,56/0,84

Spring-loaded ball

mm)

kgf/cm2)

mm) mm)

kgf/cm

2

)

L

Lubricating System J3

Removal

On some applications it will be found

cannot be removed unless the engine

supported,

engine bearers are secured

To Refit the

Prior

joints

fitted.

Fit

by

the

housing

place, making sure

strips sit non-hardening jointing compound

tive seal.

Offer

setscrews

12-15

On some applications, back this case, apply final to ho\!sing.

of

Oil

Sump

that

or

removed from the chassis, because the

Oil

Sump

to

refitting

and new front and rear cork

the

new cork strips

the

timing case and cover at

rear main bearing cap and rear main oil seal

at

onto

the

and

lbf

of

the

avoid possible misalignment

the

the rear

the

sump

to

nuts

ft

(1,66-2,07

flywheel housing

to

the

sides

of

the

sump, new crankcase

dry

into

end,

pressing the strips firmly

that

the

sump joints. At these points, apply

its

and tighten

torque

butt

location, fit the retaining

kgf

m)

the

sump

to

joints

the

grooves formed

the

front end and

ends

of

to

make an effec-

them

to a

is fastened

by

four setscrews.

these setscrews first,

of

the

the sump

is

either

sump.

to

sump

must be

by

into

the

cork

torque

to

the

flywheel

J2

of

In

If

the

sump flywheel housing, apply a straight edge across the rear faces tightening.

To Remove the

Drain the oil and remove sump. Remove the

pipe flange Release

locating screw, see Fig. the

oil

To Dismande

Remove

J.2,

Fig.

strainer and Fig.

Remove

The relief valve plunger and spring can now be removed from

is being fitted prior

of

the

cylinder block

on

Pump

two

setscrews securing

to

the

cylinder block.

the

locking

pump.

the

delivery and suction pipes.

illustrates

the

end cover.

nut

J.6

the

on

Pump

the

J.3,

the

earlier

the

housing, see Fig.

and unscrew

current version.

and

to

and

No.

I,

which will release

Relief Valve

type

suction pipe and

J.4,

fitment

sump

the

oil delivery

the

No.

oil

I.

of

the-

before

pump

13

14

Lubricating System

J4

IS

Remove chamfer at

The gear can now be removed using a suitable puller.

Withdraw the shaft complete with inner

the

Examination

Relief

Refit the shaft and inner housing, followed by the the face which carries pump

The following dimensional checks can now be carried out,

Clearance between

the

one

pump body-.

and

Valve

body

first.

see Page J .2.

outer

end.

Re-Assembly

the

rotor,

noting

outer

the

chamfered edge enters

inner and

rotor

rotor,

outer

that

of

into

there

rotor

Oil

Pump

the

ensuring

rotor,

is

from

and

pump

that

the

see Fig.

J.S.

Clearance between End float of rotors. See Fig. The lubricating oil pump clearances given

are applicable affecting assembly must be fitted available.

Press the hard

Replace the relief valve spring and plunger location.

the

oil

up

against shoulder.

the

outer

rotor

and pump body.

J.6.

on

to

a new pump.

pump performance, a

as

If

individual

Page

wear

is

revealed

replaceq~ent

parts

are

pump drive gear onto the shaft until it

into

their

J.2,

not

a

is

•·•••/o-ou~

.•

o.G!JII.1h~

Refit the end cover, delivery and suction pipes, using new joints on the pipe ilanges.

To

Refit

the

Oil

Pump

Fit the lubricating oil pump in position, and locate with the securing screw. Lock lock-nut. flange

On some applications, a to

Refit the sump, see correct grade

When restarting and pipes engine revolutions, or alternaltively seconds with

Using a new joint, secure the delivery pipe

to

the

cylinder block.

No.4

main bearing housing.

of

oil, see Appendix.

to

prime with oil before speeding

the

sump

Page J.3, and refill with

the

engine, allow for

fuel pump

strainer

shut

the

screw with the

is

bracketed on

the

motor

off.

oil

for

the

pump

the

10/20

16

-------

Oil Filters

Ther.e are

two

types

of

oil filter used. Earlier engines

had a removable bowl and separate element whilst

current engines have a spin-on filter which consists

a canister which

Oil Filler -

Element Unscrew the setscrew

and remove. See Fig.

is

a combined

To

Remove and Replace the Filter

at

the

J.

7.

casing

bottom

and element.

of

the filter bowl

of

Replace the ft!ter element using new seals provided

and tighten setscrews

to

a torque

of

I 0

lbf

ft

(I

,4

kgf

m).

To Renew Spin-on Type

Unscrew

canister from ffiter head.

Oil

Filter Canister

See

Fig.

J.8.

Discard old canister

Oean

filter head

Using clean engine oil, liberally oil ment

canister.

top

seal

of

replace-

17

Lubricating System

JS

Fill new canister with clean lubricating oil allowing

time for the oil to filter through the element. Screw the replacement canister onto fllter until

touches head instructions given available tighten

Run engine

and

then

on

to

15

and

check for leaks.

tighten

the canister. Where a tool is

lbf

by

ft

(2,07 kgf

hand

as

m).

seal

just

per the

Oil FDter Headcasting

The headcasting

spring washers.

By-pass Valve A spring loaded ball type by-pass valve is

in

the

head casting

differential OP.erating pressure

-0,84

kgf/cm2).

is

secured

of

by

four setscrews

the

lubricating oil fdter with a

of

8-12

incor.porated

lbf/in2 {0,56

and

18

-----------------------"-

Section

COOLING

A centrifugal type water

of

the engine and belt driven from the crankshaft,

delivers coolant directly into a gallery cast in the

cylinder block. Coolant

head

through

in

the

combustion chamber inserts.

jets

pump,

mounted

is

delivered

to

the

valve bridge and fishtail area

to

on

the

front

0'iinder

• •

K

SYSTEM

Kl

Cooling System

Kl

Water

Pump

Thermostat

COOLING SYSTEM DATA AND WATER PUMP DIMENSIONS

Type

Engine water capllcity - less radiator

Typo

Outside Diameter Inside Diameter of-Pulley

Interference fit

Inside Diameter Outside Diameter Size and Clearance fit

Water Pump Impeller Bore

Outside Diameter

Interference fit Impeller Water Pump Seal, Counter

Typo

Opening Temperature Fully Travel at

to

Face

Open

Fully

of

Shaft for Pulley

Hub

of

Pulley Hub

of

Water Pump Pulley Assembly

of

Hub

of

Shaft for Impeller

of

Impeller

Pump Body Running Clearance

type

at

Open

Temperature

Bore

on

Shaft

for Pulley Assembly

Pulley

to

Hub

on

Shaft

Hub

Thermostatically-controlled, circulated

II

quarts) appiOximately,

Centrifugal

0.7873/0.7876

0.7849/0,7857 in

0.0016/0.0027

1.613/1.616

1.611/1,613

0.000/0.005 in (0,00/0,13 mm)

0.497/0.4975

0.498/0.499 0,0005/0.002

0.015/0.030 Synthetic Rubber - Carbon faced

Rotating Ceramic

by

Imperial pints (6.3 litres,

centrifugal type water pump.

in

(19,20/20,01 mm) (19,94/19,96

in (0.04/0,07 mm)

in

(40,97/41,05 mm)

in (40,92/40,97 mm)

in

(12,62/12,64

in(l2,65/12,67

in

(0,013/0,059

in

(0,38/0,76

water-cooled,

6.6

mm)

Wu

175"-

208°F

0.562 in (13,77 mm)

18l"F

(97 .5°C)

(79.5"-

83.5"C)

U.S.

Cooling System K2

K2

Fan Belt Adjust

lever setscrew, the lever bracket and to support bracket bolts.

Move the gene:rator

without undue on the longest unsupported length depress it

Tighten the generator adjusting lever setscrew and if

the tension

mounting bolts. When

the tension after a short period allow for bedding-in and initial stretch which common to new belts.

To

Remove Remove the four setscrews and

the fan and pulley and remove

On some applications a distance piece between

-to

Adjust

by

first slackening the generator adjusting

pressure, the thumb applied mid-way

approximately%in.(IO mm), see Fig. K.2.

is

still correct, tighten the remainder

a new belt

Remove

the

is

the

Water Pump

fan belt.

fan and pulley.

to

the generator support

so that the tension

fitted, it

is

advisable

of

running. This

tabwashers securing

both

components.

is

of

belt, can

to

such that

of

recheck

is

to

is

fitted

is

•

K3

Remove the water inlet pipe which

by

water pump

Disconnect Unscrew

water pump and remove, see Fig. K.3.

To

Dismantle Remove Remove the pulley hub

Press shaft complete with seals and impeller the

impeller end

1

0·004/0-D451n 0,10/1,14

mm

Remove the bearing retaining circlip from the hub

end

of

the pump body, see Figs. K.4 and and with a mandrel, press the two shaft bearings and distance piece

body. The impeller can now be removed from

using a suitable puller.

two setscrews and spring· washers.

the

Water Pump

the

setscrew and spring washers securing

the

Water Pump See

the

hub retaining circlip.

of

body.

out

By-Pass

by

means

through the front

1s

flanged

Hose

Fig.

K.4 and K.S.

of

a suitable puller.

K.S

of

the

to

out

No.

pump

shaft

the

of

I,

K4

Remove seal and counter face from shaft.

is

in

On some applications, the water pump body parts. The splitting apart

of

these two halves will

two

enable the shaft complete with impeller to be pressed out

of

the pump body.

Coo~g

System

K3

~-

Re-assemble

To Press

the bearings and distance piece onto the shaft and pack half to two thirds bearings, with

the Water

high melting point grease.

Pump.

See

Fig.

of

the space between the

K.S.

Press the shaft complete with bearings into the front of

the pump body and locate with the bearing retain-

ing

circlip. Supporting the shaft at the impeller end,

press the pulley hub

onto

the shaft, and fit the retaining circlip. The mechanical seal can now be fitted over the impeller end carbon

face

outwards, locating into a recess within

of

the shaft with the

the pump body,

is

The seal the ceramic face to the carbon face

Figs. K.4 and K.5.

followed by the ceramic counterface, with

of

the seal,

see

No.2.

Press the impeller onto the shaft until a clearance

0.015-0.030 in the impeller blades and

When

re-assembling a water pump trated in onto the shaft until a clearance (9,90/10,49 mm) the impeller to the joint face

-see

Fig.

Using a new joint, fasten the rear half

body

to

(0,38-0,76

the

Fig.

K.4, the impeller should

is

obtained from the front face

K.4.

the front half.

mm)

is

obtained between

pump body.

of

the type illus-

of

the water pump body

be

0.390/0.413

of

pressed

the pump

of

in

of

KS

0·015/t-0301n 0,31J0,71

mm.

A running clearance of0.004/0.045 in

(0,1

0/1

,l4mm) between the impeller blades and pump body should exist.

To Refit the Water Pump

Using a new joint and ensuring that

clean, refit the water pump, securing and spring washers to a torque

{1,66-2,07

kgf

m).

the

joint faces are

with

of

12-15

setS!7CWS

lbf

ft

Reconnect the by-pass hose.

the

Refit

using a new joint, and tighten the setscrews to a

torque

water inlet pipe

of

12-15

lbf ft

to

the water pump body,

(1

,66-2,07

kgf.m).

Refit the pulley and fan, secwing with four setscrews and tabwashers, tightening to

ft

(2,07-2,9

the

Refit

To-Remove

kgf m).

fan belt,

the

Thermostat

see

Page K.2.

a torque

Remove two setscrews securing the

of

19-21

top

lbf

water

connection.

the

Remove

thermostat,

see

Fig. K,6,

K6

Cooling System

K4

To

Test the Thennostat

Immerse the the

temperature

If

the temperature because no adjustment

thermostat

of

thermostat

range, see Page

in

the water.

does not

is

possible.

To Replace the Thennostat

A new joi:!t should be fitted housing and the water with

coolant,

check for leaks.

outlet

water

and

open

within

K.l,

fit a replacement,

between connection.

heat,

the

thermostat

On

checking

required

refilling

• • •

Section

L

Fuel System

Ll

A distributor type fuel injection horizontally at the rear hand side fuel

The fuel lift

Approved Fuel

Fuel

of

pump

the cylinder block, and

gear situated in

pump

Oil

United Kingdom United States

France India Germany Italy

Sweden Switzerland

oils available in Territories

of

the

timing case

the

timing case.

is

mounted

Specifications

on

FUEL

pump

is

mounted

on

is

the

right hand side

other

the

driven

by

FUEL

than those listed above which are

SYSTEM

left the

SYSTEM

BS.2869: 1967 VV-F-800a A.S.T.M./D975-66T

(J.O.

14/9/57

IS: 1460/1968 OIN-5160 CUNA

-Gas 630-01 SIS. 15 Federal Military 9140-335-1404

(1957)

54

of

the cylinder block and the camshaft. The atomisers are on the fuel contain pintle type nozzles.

pump

side

DATA

I (1967)

Oil

NC-

32 (1969)

Spec.

(1965)

to

an equivalent specification may be used.

is

driven

positioned vertically

of

the

Class

A.l

Grades

Nos. Gas Oil Grade

or

OF-A,

1-D

or

Fuel

Special or Grade A

by

an eccentric on

cylinder head, and

A.2

DF

-1

or

DF-2

2-D

Domestique

Fuel

Lift

Pump

Type Method Spring Colour Code

Delivery Pressure

Fuel Filter

Element Valve

type

Fuel Injection Pump

Manufacturer

Ty""

Pump

Rotation Timing letter, hydraulically governed Timing letter, mechanically

governed No. l Cylinder Outlet,

Static Timing

Hydraulically governed Mechanically

of

type

pump pump

Drive

governed

both

types

AC-DELCO, Eccentric Blue 5-

81bf/in2 (0,35-

Series F.H.

on

Camshaft

0,56 kgf/cm

Paper

Ball check valve

C.A.V. D.P.A. Clockwise viewed from drive end

'A'

·c·

'W'

Piston Displacement

0.205 in (5,21 mm)

0.125 in (3,17 mm)

2

)

Fuel System L2

Atomisen

Manufacturer

Atomiser Body

Atomiser Nozzle

Working Pressure Setting

lndentification Code Letter

Important Note

The

type

of

fuel

Reference

in service

Starting Aid

sho1.1,ld

Pressure

pump

and atomisers fitted

therefore

be made

Agricultural C.A.V.

BKB3SSD5247 BDN12SD6236

135 atm (139 kgf/cm2

or

ISO

atm

or 2200 lbf/in2)

BW

to

the

to

the

appropriate Parts Literature

4.154

1980 lbf/in2)

(ISS

kgf/cm2

engine may vary according

to

ensure correct replacements are fitted

Automotive

C.A.V.

BKB35SD5247

BDN4SD6:346

135 atm (l30.kgf/cm2

or 1980 lbf/in2)

ISO

atm (ISS kgf/cm2

or 2200 lbf/in2)

CJ

to

application and rating.

Ll

Manufacturer

Type

Voltage

Maximum Current Consumption Full Flow Rate

Height

of

Thermostart

reservoir above

C.A.V.

Thermostart - Type 357

12

volt

12.9 amps

4.3 - 4.9

(21°C)

4.5

at

ll.S

3

cm

/min

-IO.Oin(ll,4

volts

at

70°F

-2S,4cm)

Fuel Filter Element

Unscrew the clear, see together

Thoroughly

fluid. Do not use Gasoline (Petrol). Replace the sealing rings.

Place fill so against

Hold located and screwed horne.

Prime

the

centre

filter bowl securing setscrew located in

of

Fig.

with

clean

the

new element

with

clean fuel oil.

that

the

top

the

sealing ring

in

this position whilst

the

fuel

to

Remove and Replace the Fdter

the headcasting.

L.l,

and discard

the

fuel contained

the

in

Offer

rim

of

in

system

as detailed

Lower

the filter bowl

the

old

in

bowl in a suitable cleaning

the

tJ.lter

bowl

up

the

the element locates centrally

the

filter headcasting.

the

and partially

assembly squarelY

securing setscrew

on

Page L.7.

element

the

bowl.

is

Fuel

Lift

Pump

The lift return blue coloured diaphragm the actuated primer is

pump

is

valves which are opposite

diaphragm is

by

is

not

fitted

running.

fitted with a diaphragm,

by

an eccentric

to

operate

return

means

on

the

in

spring. Deflection

of

an operating arm

the

camshaft. A hand

pump

two

operation and a

when

the

non-

of

engine

Fuel System

L3

Testing

the

lift

Pump Fitted

to

the

En~ne

Disconnect the outlet fuel pipe. Rotate

the engine,

or

operate the hand priming lever. A spurt of fuel should emit from the outlet port once every two hand

priming lever

NOTE:

If

the engine one complete revolution

engine revolutions,

is

depressed.

or

every time the

the hand lever cannot be depressed, rotate

in

order

to

turn the eccentric on the camshaft from its maximum lift position.

To Remove the Lift Pump

Disconnect the fuel pipe, from the inlet and outlet

ports.

Remove

secure the pump the pump,

To

the

two nuts and spring washers which

See

Fi&.

Dismantle the

to

the cylinder block, and withdraw

L.2.

Lift

Pump

Before dismantling, make a file mark across the two

flanges

reas~mbled.

for location purposes when the pump

Remove the six cover screws and

is

being

separate the two main parts, then remove the diaphragm assembly from the lower half by turning the diaphragm through 90° in either direction.

The valves are using a screwdriver or other suitable tool.

casting

so

valves

into position using a suitable

casting around the valves

"staked-in", and can be prised out by

that

new valves can be correctly seated. Press

"dolly".

in

six places.

Clean the

Stake the

The rocker arm

ann

rocker with a soft mallet until the retainers are The rocker, pin, lever and return spring can now

pin can be removed by securing the

in a vice, and tapping the face

of

the body

dislodged.

be

examined for wear.

To

Re-assemble the

Fit the rocker arm assembly into the

Uft

Pump

bottom

half

of

the lift pump, Fit the rocker arm return spring making sure

Tap new stake over the open ends

Place the diaphragm the pull rod downwards, locating

that

it

seats properly.

retainers into the grooves in the casting, and

of

the grooves.

assembly over the spring, with

the

top

of

the

spring in the diaphragm protector washer. Position

so

the rod rocker arm link. assembly so that the notches with the rocker arm link and twist

that the notched blade locates intq the

Press downwards

on

the pull rod

it

through 90° in

the diaphragm

a!ign

either direction, this action will engage and retain the pull rod

in

the fork

of

the link.

----------·-----------------

Fuel System L4

When re-assembling the two pump halves, push

the

rocker arm towards the pump until the diaphragm level with the body flanges. The cover assembly can

the

now be olaced in oosition. with

aligned. Maintaining

the

pressure

on

the

file marks

rocker

arm,

fit the secunng screws and washers and tighten

evenly.

To Refit the Fuel

Ensure pump

enter the pump operating lever the

secure

that

mounting

block.

with

Uft

Pump

the

pump

face

is

Fit

the

pump

nuts

and spring washers.

flange and cylinder

clean, and using a new

onto

into

the

the mounting studs and

aperture in

block joint,

Fuel Injection Pump

IMPORTANT Unless proper test equipment and

trained technicians are available, adjustment

maintenance attempted.

To Remove

of

the fuel

the

Fuel Pump Hydraulically governed

pump

should

not

or

be

Disconnect the stop and throttle controls from the fuel pump and remove the return

springs.

is

Remove the fuel pump, and blank

high

and low pressure fuel pipes from the

off

all ports.

Remove the fuel pump securing nuts and plain and

spring washers and withdraw the fuel pump. See

Fig.

L.3.

To

Remove the Fuel Pump Mechanically governed

Disconnect the stop and

throttle

controls from the

fuel pump and remove the return springs. Remove the high and low

fuel pump and blank Remove the inspection cover from the timing

pressure fuel pipes from the

off

all ports.

case

front cover, and remove the three setscrews and spring washers securing the fuel pump pump, taking

care that they

do

gear

to

the

not drop into the

timing case. Remove the fuel pump securing nuts and plain and

spring washers and withdraw

the

fuel pump.

Fuel System

LS

The fuel pump gear will remain in mesh with the idler

gear, and will only drop timing case approximately

Precaution must be taken turned whilst the fuel

To

Refit

the

pump gear

Fuel Injection Pump Hydraulically

against the inside

1/8 in (3,17 mm).

that

the engine

is

unfastened.

of

is

the

not

governed. Fit a new fuel pump mounting flange

up the pump ensuring

is

shaft

correctly positioned

that

the master spline on the

joint,

and offer

to

engage with the

female spline within the fuel pump drive hub. When the splines are in correct alignment the pump

on

to

can be located

the mounting studs adaptor housing until the mounting flanges meet, the plain washers followed and

securing nuts can

Before tightening,

be

align the timing marks scribed on

the mounting flanges, see Refit the

high and low pressure fuel pipes, the control

by

fitted.

Fig. H.3.

the

spring washers

on

the

and

cables and springs. Fuel pump timing can be checked

as

detailed

Prime the fuel system

To

Refit

on

Page H.4.

the

Fuel Injection

as

described

on

Pump

Page

1.7.

Mechanically

governed

Maximum Speed Setting The maximum speed screw is set and sealed

not

be

manufacturers and must unless factory authority

is

ments should be carried out

altered in any way

first obtained. Any adjust-

by

experienced fuel pump technicians. The unauthorised removal seals

on

the pump may render the quarantee void.

When a fuel pump

is supplied

the governor maximum speed

as

a direct replacement,

is

set

figure only, and final adustment must

is

fitted

to

the pump

the engine. In order

to

a nominal

be

made after

to

establish

by

of

the

any

the correct setting which varies accordina to application, reference must be made symbol, stamped on the plate fastened

to

the settin& code

to

the pump

body.

For the purpose the last four

code

is

the maximum no load enJine speed. Warm the

of

setting the maximum speed stop,

fiaures shown

on

the fuel pump setting

engine and run up until this figure is reached; the maximum speed stop should

be set

at

this

then

figure.

Atomisers

Genernl

When replacing atomisers in the cylinder head

essential that a new, correct type copper washer is fitted between the nozzle cap and the cylinder head.

it

is

Fit

a new fuel pump motmting flange

up the pump, fitting it

to

the mounting studs

adaptor plate, Align the dowel location

joint,

on

and offer

on

the end

the

of the pump drive shaft with the dowel on tho pump gear. By manipulation remains in mesh with setscrews and spring washers, and tighten of

19-21lbf

ft

Refit the plain and pump mounting studs. Before tightening, timing marks back

of

Refit the

on

the

adaptor plate, see Fig. H.2.

high

control cables and

Fuel pump timing can

of

the gear and ensuring

that

the idler gear, refit the three

to

(2,07-2/}

kgf m).

spring washers and nuts

a torque

to

align the

the

pump mounting flange and the

and low pressure fuel pipes, the

springs,

be

checked

as

detailed on Page

it

the

H.3. Prime the fuel pump system

as

described

on

Page L.7.

Trouble

The first symptoms

into one

in Service

or

more

of

atomiser troubles usually fall

of

the following headings: Misfiring Knocking in one

or

more cylinders

Enaine overheating

of

Loss

power Smoky black exhaust Increased fuel consumption

The particular faulty determined atomiser "tick

by

in

turn, with the engine runnina at a fast

over".

If

atomJSer or atomisers may be

releasing the pipe union

nut

after slackening a pipe union

on each

nut

the

engine revolutions remain constant, this denotes a

to

faulty a

miser. The complete unit should

drawn from the cylinder head and known good serviceable unit

to

the correct code for

be

replaced

withby

the application. NOTE:

Care should

be

taken

to

prevent the hands face from coming into contact with atomiser spray, the workin& pressure will cause fuel oil

to

penetrate

the skin.

a

or

as

Fuel System L6

Maintenance

lA

Atomisers should be taken

regular intervals. Refer

out

to

for examination

Preventative Maintenance,

at

Page A.S. NO

ATTEMPT SHOULD THE PROPER GAUGE. SETTING

INJECTION

TESTING

IT

IS

OF ATOMISERS

IMPOSSIBLE TO ADJUST THE

BE

MADE

TO ADJUST

PRESSURE WITHOUT A

PUMP

AND

WITH

PRESSURE

ANY

DEGREE

OF ACCURACY WITHOUT PROPER EQUIPMENT. A perfect atomiser, when tested

through it in the open air sound

as

atomiser has been in

the fuel emerges from the holes. After the

"pinging" changes until the atomiser sounds likely

to

affect the running

D

\3

.B

Fuel

Pipes

The pipes should split

or

compressed otherwise leakage will result.

service for some time, the

to

a "crackling" sound.

"dead"

of

be

clean, the olives should not be

by

gives

pumping fuel

a short "pinging"

that its condition is

the engine.

It

is

not

Ensure when fitting, that the pipe fits squarely at both

ends, and that the union nuts are not overtightened. When changing an atomiser always slacken the union nuts or remove the pipe completely. Never bend the pipe.

Starting Aid The

"Thermostart"

prised

of

a tubular valve body carried

which screws into the inlet manifold. The

is

surrounded

forms an ignitor coil. The

of

which the stem holds a ball valve

against its seating. The

starting aid, see Fig. L.4,

by

a heater coil, an extension

valve

body houses a needle,

ignitor end

in

a holder

valve

of

in

of

position

the unit has a

is

com-

body

which

perforated shield. Fuel oil from the reservoir enters through an adaptor.

When the unit position.

"heat"

body

is heated and expands, opening the ball valve

and permitting the

ised

by

switch

is cold, the ball valve is held

When

the coil is energised

switch, see Fig. A.

entry

the heat

is

turned

of

the valve body and when the

to

"heat

in

a closed

by

1.1sing

I,

or

button,

of

fuel. The fuel is vapour-

and

start"

or

both

the valve

buttons

the

are depressed, cranking the engine, air is drawn into the manifold. The vapour

sion and continues

When the coil

to

bum,.heating the inlet air.

is switched

and start" switch or

running,

rapidly cools

the

cold air entering the inlet manifold

the

valve body and the valve closes.

is i&nited

off

button

by

the coil exten-

by

releasina the

and the eDJine is

"heat

In

the

event

of reservoir feeding fuel primed, and cold start aid can be functionally checked ing

the

air cleaner and watching

it

is

being used.

The

starting aid dismantled. renewed.

difficult cold starting check

to

that

If

the

fuel

is

unit

the starting aid

is

reaching

a sealed unit and cannot be

ceases to function it must be

the

starting aid. The

starting aid whilst

that

by

is

fully

remov·

the

Fuel

System L 7

A worn valve will cause fuel

manifold consumption.

4.154 engines are fitted with efficient starting equipment, and any damage caused

Priming The air must be vented from the fuel system when·

ever any fuel pipes between injection pump and atomisers have been disconnected or when the system has been emptied

No the serious damage can be caused lack

In necessary before starting can be effected. Proceed as follows.

Slacken

housing(hydraulic Slacken the vent valve fitted on the head locking

screw

causing a smoky exhaust and excessive fuel

no

responsibility can

by

unauthorised starting aids.

the Fuel System

attempt fuel injection pump has

of

the

must be made

lubrication.

event

of

air entering

to

"bleed"

the

air vent valve

of

the

fuel injection pump see Fig. L.6,

the

IJlVernor) Fig.

to

leak into the inlet

be.

accepted for

the

fuel tank, fuel of

fuel.

to

start

the

been

filled and primed

to

the

fuel system, it will be

whole

on

top

L.6,

engine until

the pump through

of

the

fuel system

of

the govemor

No.

I.

No.2.

as

Operate lift pump until fuel, free from air bubbles rises from each. venting point.

Tighten the valves Head locking screw vent valve Fig. L.6, No. 2.

Governor housing vent valve, Fig. L.6,

Slacken inlet, Fig. L.6, the free from air bubbles, issues from around

The

Slacken the union nuts at the atomiser ends

two

Set

ensure position.

the

hand priming lever

in

the

following order.

the

union

nut

No.3,

lift pump. Retighten the union

fuel filter is self-bleeding.

of

the

high pressure pipes.

the

accelerator at the fully open position and

that

the

at

and operate

"stop"

see

Fig. L.S, on the

No.I.

the

fuel injection pump

the

priming lever of

nut

control

is

in

when fuel,

the

threads.

of

any

"run"

L6

Fuel System

L8

Turn both

the

engine

fuel pipes.

until

fuel, free from air, issues from

Tighten is ready for starting.

For and fuel filters procedure

Unscrew by two of tank).

Slacken screw on the side Slacken governor housing on the

When fuel, free from air bubbles issues from each vent point, order:-

Filter head venting screw. Head locking screw Governor vent screw

Slacken the pipe union

inlet, operate the priming lever on the fuel lift

and retighten when fuel, free from air bubbles issues

from around

the

unions

on

both

fuel pipes, and the engine

engines fitted with mechanical

the

fuel filter cover

the

priming lever

with

is

necessary.

vent screw on the hydraulic head locking

the

air vent screw near

tighten

the

air vent valves,

or

three turns,

(not

of

the fuel injection

the

fuel injection pump. Operate

of

the

fuel lift

the

connections in the following

on

the

fuel injecton

on

fuel injection pump.

nut

at the fuel injection

threads.

the

type

the

vent plug

return

pump.

fuel pumps

the

pipe

pump

the

top

pump.

following

on

top

to

the

body.

of

the

pump pump

Slacken the union

high pressure fuel pipes. Set the accelerator in

fully

open in the starter issues from all the fuel pipes. of

rotation reached, and the time will be speed bleeding battery engine at upwards conditions, the remaining air should be expelled in under

dischar~ed

Tighten ready for starting.

It

must carried connections must bubbles have disappeared. Unless care is taken this minutes

position and ensure

"run"

motor

may be necessary before this condition

of

rotation

operation

in a temperate

thirty

batteries may

the

be realised

out

operation,

of

priming, failure

nuts

at the atomiser ends

that

the

position.

until fuel oil, free from air bubbles

seconds. Cold conditions

unions on the fuel pipes and the ,engine

completely and

and this could take some

Rotate

Some

and

the

described above. A fully charged

or

warm climate will

of

280 rev/ min, and

take

longer.

that

this whole

be

no

made

until

to

start will occur.

stop control

the engine with

30

dependent

effectiveness

operation

action

all signs

to

60 seconds

upon

rotate

under or

partially

must

to tighten

four

of

these

of

with

to

the the

the

the the

the

be

air

five

is

• •

Section M

Air

Cleaner Ml

AIR

Genonl

Operating conditions play deciding aircleaner. Vehicle road Kingdom,

clean conditions minimal, require the air cleaner

regular intervals, as given

in

tion

revision

Senicing - Dry

Where kept ejector

An

fitted which element service

1

When an element discarded and replaced by a new one however,

new element removed, and loose dirt particles disposed gently tapping the element. Alternatively it can be

cleaned with a non-foaming detergent, subsequent life Some manufacturers incorporate a which protects against oil and soot conditions experienced in heavy traffic.

how

frequently

conditions

operating conditions which

in

air conditions, must

of

an

clean making sure

close,

18

in water

usually experienced

or

industrial engines operating in relatively

in

the

air cleaner maintenance schedule.

Type

automatic

but

do

gauge

is

pre-set

is

becomes contaminated, it should be

is

unavailable,

of

the

most

it

is necessary

or

machines operating

which

the

concentration

on

Page A.S.

incorporate

be

Air

Oeaners

dust

ejector

is fitted,

that

not

the

stick together.

important

in

to

be

Any

accompanied

lips

to

service on

the

of

serviced

alteration

a deteriora-

it

should be

of

the

pa.rt

normal

United

dust

rubber

restriction indicator can

to

necessary.

the element will be shortened.

indicate when a filter

the

element can be

"treated"

of but element,

CLEANER

iir

the

is

at

by

a

Ml

be

if

a

by

the

"'

Element

To remove

from the housing.

Depending should be taken entering the inlet manifold. Before

or cleaned clement, clean the inside

housing with a clean cloth.

Senricing - Dry Bowl (See Figs. M.l and M.2.)

Dust level should

(12,70 mm) from the slot in the dust cup baffle.

Depending

necessitate daily emptying

Check regularly for dead leaves

material

necessary.

Renewal

remove the element, release

the

clamp. The element can now be removed

on

the installation

to

prevent accumulated dirt from

Type

Air

not

be allowed

on

conditions

in the intake area. Tighten wing bolt if

tb.e

knurled nut and

of

the air filter, care

inserting

Qeaners

of

Fitted

to

build up

of

service this could

the dust bowl.

or

other foreign

the new

of

the fdter

with Dust

to

\4

in

• • •

M2~--------------~WL__,

Key

to

numbered annotations

1 - Body assembly.

2-

Element assembly.

3 - Nut and Gasket assembly.

4-

Clamp assembly.

5 - Baffle skirt.

6-

Cup assembly.

in

Figs.

• •

M I and

M.2.

Air

aeaner

M2

Restriction Indicator

If

a restriction indicator

the

transfer piping between air cleaner

in

is

fitted it should be located

engine manifold away from bends

It

will indicate·

service

the

by

element.

means

of

a visual signal when

Element Renewal

or

elbows.

outlet

and

to

Remove and assembly. Remove the baffle from dust cup by lifting it

the

clamp

drop

the dust bowl complete

by

out,

unscrewing

the

which gives access

pinchscrew,

with

interior

baffle of

to dust for removal. On horizontally mounted aircleaners

bowl

note the arrows

to

indicate correct positioning for reassembly.

Remove wing bolt situated at

on

the

bottom

rear

of

the

the dust

element,

and remove the element.

Optional Service Method

The dirty the following procedure

restored to give a limited period

However, it be replaced after six cleanings is

first:

Remove the element direct clean dry air at no more than kgf/crn the filter compound

air cleaner element can be cleaned, and

is

followed, it can be

of

is

recommended

as

2

)

up and down the pleats

that

or

described previously and

service life.

the element should

annually whichever

100 lbf/in2 (7

on

the

clean side

element. Immerse the element in a detergent air

as

instructed in the directions for use

by the manufacturers.

for

Allow the element to soak

Gently agitate element at end Bush

out

drrt.

at least

of

soaking

JO

minutes.,

penod

the the

if

,03

of

to

Rinse

the

loosened particles. Allow

unit with clean water

oven

dry,

but

a fan

or

air draft may be used

the

element

to

remove all

to

dry. Do

to

not

hasten

drying.

by

Inspect the dried element within the centre. Thin spots, pin holes

placing a bright light

or

the

slightest rupture will render the cartridge unfit for

further use.

ability. A

"treated" procedure described above the

element will be shortened.

Also examine the gasket for service-

If

damaged,

the

element must be replaced.

element can be cleaned using

but

the

subsequent life

the

of

Air

Oeaner

M3

Note:When replacing an air filter assembly, care

that

should be taken Owing

to

the

similar appearance

the correct assembly

horizontally mounted unit, it

other,

one with the

outlet

and displaced unit. However, and inlet ports

transposed, and the

engine would ensue. tion through necessary

to induction manifold the

interior

ducted

of

to

the area between

and incorrectly connect the inlet

trunking in

the

of

the

two

if connected incorrectly; damage to

If

ports

that

of

the engine

in

of

the

ensure

the filter element, and the inlet

of

the vertically and

is

possible

same manner as

positions

types

of

doubt,

a visual examina-

the filter assembly

outlet

is

the

element and filter

is

fitted.

to

replace

of

the

outlet

filter become

port

ducted

to

through

port

the

body.

Two-Stage Dry Type

Air

Oeaners with Multiple Filter

Elements

Extreme Heavy Duty.

This type

tion dust, and

of

air filter may be fitted where

is

designed

the

dust load within the air cleaner is

restriction indicator which red indicator flag which gradually trapped

by

the

When the flag reaches

See

Fig. M.3.

the

to

work

in

most reliable

heavy concentrations

m~thod

in

this type incorporates a

rises

applica-

of

.ascertaining

by

use

as

the

of

the

dirt

air cleaner increases the pressure drop.

the

top

position

it

locks in place, and the element should be changed. To re-set the

indicator push

the

Re-set

button.

is

M3

A furthe1 check system

is

tab placed through deflect

which

dust

immediately clouding

on

the

by

efficiency

a Dust-Sight. This incorporates a metal

directly in

against

the

air-stream, and a window

tab can be seen.

the

glass. When

inside

of

the air cleaner

The

of

the

cleaner and

tab will

window,

induction system are working correctly the window stays clean.

the trunking adjacent

This device, where fitted, will be found in

to

the

engine air intake or

manifold.

If

a restriction indicator

the replacement

of on a regular schedule basis, maintenance advised turers hand

book, only be based on the prevailing conditions the

application is working.

This

type

of

air cleaner incorporates a pre-cleaning

in

device removed from charges

which heavy dust particles are initially

the

into

the

engine exhaust gases via an aspirator. Pre-cleaned air then enters cleaning, before entering

or

other

device is

not

fitted,

the filter elements must be done

in

accordance with

the

vehicle

or

but

servicing of air cleanerS can

air entering

the

filter elements for final

the

engine air intake.

plant manufac-

the

filters and dis-

in

the

which

Air

Cleaner

M4

Element

Unclamp the pre-cleaner panel and move Pull

cartridge and replace with a new one.

Locate

Warning

Under no crrcumstances should petrol/gasoline be used for cleaning body,

Renewal

to

out

the dirty single unit, multiple element filter

the

pre-cleaner panel and re-clamp in place.

any

part, filter element or filter

of

the

air cleaner.

one side.

Section

• •

N

Electrical System

Nl

Alternator

Dynamo

Motor

Starter

Manufacturer Type Rotation Maximum output Maximum output Alternator Cut-in Alternator Cut-in Speed

Manufacturer Type

Rotation Output Dynamo Cut-in

Manufacturer

Type

Number Maximum current

Starter Cable Resistance

of

teeth

12

volt (hot)

12

volt (hot) ACS

Speed

on

Pinion

ELECTRICAL

II

AC

11

AC

AC5

SYSTEM

LucasorC.A.V.

llACorACS Clockwise viewed from drive end 43 amps at 13.5 volts 55

amps at 13.5 volts 1000 revjmin 1125 rev/min

LuOti

C40A, 2-pole, 2-brush, shunt wound, voltage control. Clockwise viewed from drive end

11

amps maximum I

OJ

SO

revjmin

Lucas M4S, CA45

10

800 amps or 1070 amps

0.0017 ohms

or

MSO

Nl

Key to

Wiring

Diagram

1-

12

Volt Battery.

2 -

Starter Relay

3-

Starter Motor.

4-

Ammeter.

S -

Auxilliary Heat/Start Switch. 6 - Thermostart. 7 -

ACS

89-

Alternator. Alternator Warnins lamp. 440 Regulator.

incorporating AC5 Altemotor.

N2

Key to

Wiring

Diagram

1 -

12

Volt Battery.

2 -

Starter Relay.

3

-Starter

4-

Ammeter.

S -

Auxilli.ary Heat/Start Switch.

6 - Thermostart.

7 - I lAC Alternator. 8

-Alternator

9 - 3A W

10-

II -4TR

Warnins

Field Isolating

Control Unit.

incorporating IJAC

Motor.

Warning Lamp.

Li&ht

Re.lay.

Altet't111tor.

Unit.

Electrical System N2

ALTERNATOR

Maintenance

Models

and I

ACS with

lAC

with

440

Regulator (See Fig.

4TR

Control Box (See Fig. N.2.)

GeneraJ The

alternator

manner

as a D.C. generator, namely, belt driven from

the crankshaft pulley, ability

to speeds, to cope demanded speeds owing ally in built up areas. weight,

output

As opposed to the ture windings the alternator has a stationary generating winding. When the inside the current battery

rectified by means

uni-directional flow The

alternator

·close limits by means

is

driven by the engine in the same

but

the advantage lies in its

provide higher maximum

with

by

modern to

increased density

for

output.

rotate

increased electrical load

equipment

Jt

is

DC

generator

inside a stationary field system,

rotating

stator,

(AC). This

the

output

is

produced

unsuitable for charging

which requires direct

of

diodes which convert it

to

the

battery.

voltage

output

of

a control hox which

output

and decreased road

of

traffic, especi-

also much lighter

in

which the arma-

field system inside a

rotor

is

current

(DC), so

is maintained within

transistorised and functions as fast switches.

N.l.)

at lower

rotates

alternating

the

it

is

fully

in

tO

alternator

The very little build-up

battery

the

charging system will normally require

attention,

of

dirt, and a check made if it fails to keep

but

it

should be

kept

free

charged.

from

(a) Regularly inspect the driving belt for wear and

correct tension. all belts

on

a multiple belt drive have equal

tension and are each

important

carrying their share

to

ensure

of

that

the

It

is

load. Slack belts will wear rapidly and cause slip which

wiU

not

drive the

alternator

at

the

required speed. Drive belts which are too tight

thrust

on

impose severe side bearings and ensure

that

shorten

the

alternator

their life. Periodically

the alternator

is

correctly aligned

to

the drive.

(b) Do not replace faulty belts individually in a

multi-belt system. A complete matched set

of

drive belts must always be used.

(c) Keep the

ed

is

ventilation slots and air spaces are clear and

alternator

in Kerosene

clean with a

or

cleaning fluid. Ensure

cloth

moisten-

that

unobstructed.

(d)

Remove regulator/control box housing, and ensure

any dirt accumulated

on

the

that

cooling air can pass freely over the casing.

Precautions

As

previously described the function regulator/control

as

one-way valves and the transistors in the

box operate as fast switches. Both

diode.~

in the alternator

are accurate and sensitive. They

do

but

because

temperature,

high to

prevent

(a)

DO engine in the immediately ruin the diodes

(b)

DO NOT disconnect a lead

not wear

out

they

and seldom require

are sensitive

to

voltage changes and

the following precautions are vital

them

from being

NOT disconnect the

is

running. This will cause a voltage surge

alternator

destroyed.

battery

charging system

or

transistors.

without

stopping the engine and turning all electrical

to

the

off

switches

(c)

DO NOT cause a

to

leads

to

lead wrong

connection immediately and or

diodes.

(d)

DO NOT connect a without

incorrect terminal. Always identify a

its correct terminal. A

checking for

position.

short

circuit by connecting

giving reverse

permanently

battery

into

correct

short

ruin transistors

polarity and

voltage.

(e)

DO NOT current

"flash"

flow. No

connections

matter

how brief the

to

the transistors may be ruined.

adjustment,

whilst the

that

will

first

circuit

polarity

the

will

system

check for

contact

or

Fault

Finding

The

ACS current warning light, cient evidence order. Therefore, no output tion

UNLESS:-

(a) The warning light fails

generator OR alternator

(b)

No charging

(c)

The

(d)

The

on

ACS

alternate~

indicated

or

that

is

either

as

shown

the

open

so designed

by

the extinguishing

on

the ammeter,

system

is

in proper working

circuit, voltage

checks should be performed

to

illuminate when the

and the switch

is

shown

indicating loss

fails

battery

is

stationary,

to

become extinguished when

is

running.

current

is

flat.

is

"boiling"

that

on

ammeter.

voltage control.

If

any

of

the above

indicated below

Connect a good quality moving coil voltmeter

(a)

0--50

volts range across the negative terminal, and terminals alternator moving coil the

alternator

battery

should

symptoms

should

marked

output

0-100

terminal be

occur,

the

be

followed.

battery

one

of

the three positive

LO, MED, HI. Disconnect

terminal.

amp

in

a charged condition.

Fit

ammeter

and

output

a good quality

a flow

is

or

current

the

installa-

is

procedure

or

regulator

in series

lead. The

of

the

suffi-

closed

the

of

with

(b) Close the warning light switch (master electric

(c)

(d)

(e) Increase engine speed momentarily

(f)

Any variance in

the

and befofe disconnecting any components.

The regulator

if found

and Warning

up

when switched

Warning Lamp does

out

and

output

on

switch should light up.

Switch fans, etc.

Start engine and

1.

2. The ammeter records a small charge

mum

tre

amperes for

With half speed, (engine speed switch connection selected for the positive sensing wire 26/28 on the appreciably.

Lamp does

Ammeter

when

dashboard) when the warning lamp

on

a I

0-15

for

The warning light should go

dependant on engine speed.

speed

wheJ.l

abouf

30

12

the

alternator running at approximately

off

electrical load. Depending on the

LO, MED

volts on 24 volt systems and

12

volt systems, then remain constant. At

same time the current reading should drop

the

foUowing precedure should be adopted

is

a sealed unit and

to

be faulty

''On".

Check all wiring connections at regulator, alternator and

Switch off, disconnect at regulator and connect it the

Switch on. lights up, the regulator

If

alternator

rulllling.

Check all regulator, alternator and

Switch at regulator and lator negative terminaL

Switch

If

faulty.

amperes load such

fifteen minutes.

run

at fast idle speed when

the charging current should

amperes for 24 volts, and 53

volt systems.

about

or

HI, tht; voltage should rise

above data could indicate a fault

it

must be replaced.

not

light

Check the bulb.

negative terminal.

lamp fails to light up, the

not

go

shows

no

battery

off,

on,

no

output,

output

is

If

no

fault

If

no fault

If

warning lamp

is

faulty.

connections.

If

no fault

disconnect

connect

and

run

alternator is faulty.

appears, regulator

as

lights,

out.

to

maxi-

1 ,500 rev/min)

13/14

volts

non-repairable

battery.

'F'

lead

to

is

faulty.

'F'

lead

to regu-

at fast idle.

is

to

Electrical System

Warning lamp does when

running

shows reduced

output

full

.,

...

not

go

and

output

onJy at maximum

out

Ammeter

with

.,

Warning lamp goes

Alternator delivers reduced output. maximum speed.

Warning

intennittently

needle oscillates is are switched in.

Batteries overcharging and

Ammeter indicates high full

Fault Finding

If

43 volts for

the failure may be due

wiring, and followed.

Test I Check the Field Isolating Relay Disconnect the earthed

from the alternator main 0-

nected cable. Link terminals 'C field relay. Reconnect the

master switch, start engine and run at charging speed. or

If

Full

lamp

fully charged

output

all

th.e

alternator does not produce its rated

12

60

DC

ammeter between the terminal and discon-

If

ammeter shows a charge the relay

its wiring and connections.

ammeter shows no charge, carry on with Test 2.

Test 2

Oteck

the

Alternator and Control Box

Leave the test ammeter connected, and disconnect

'F'

cables

together. Remove link from field relay terminals and ensure engine

Ammeter should indicate current values or indicates a faulty alternator. recorded, a faulty

and

they

and

run

more for

are connected

out

but

output

on

only

at

Alternator faulty. Remove from installation and apply open cuit diode check.

flashes

and

Ammeter

when

battery

and

no loads

Check for excessive resistance in regulator negative sensing lead.

If

no fault, regulator

the

time.

IJAC

volt and 23 volts for 24 volt circuit,

the

following procedure should be

'-'

from control unit and

at charging speed.

12

volt circuit. A zero

control

or

Check regulator positive

lead and its connection at regu-

lator. If no fault, regulator

to

any unit

battery

terminal and

output

terminal. Connect a I'

battery

to

'Cl'

If

satisfactory

unit

is

indicated.

is

faulty.

sensing

is

faulty.

output

or

the associated

the

and

'C2'

cable. Close the

is

join

and

'C2'.

of

35

or

low reading

output

cir-

cable

on the

faulty,

them

Start

amps

N3

of

is

EJectrical System

Test

3

or

Checking The

regulator CLOSED load. Also, checking must battery resistance ohm. remedied. zero or

24-30

battery

Adjusting

CIRCUIT,

or

be

in

to

control

of

Any

Connect a test

type)

scale

volts for

terminals,

the

resetting

the high resistance

N4

the

of

the 4 TR

when

system must be stabilised before

is

a well charged

complete

12-15

carried

unit

volts for

24

volt instal!ations,

and electrical load. Disconnect connect terminal earth approximately Start

\east eight minutes.

greater

this figure reading fied for

test

and

cable,

engine

than

with

the

ammeter

disconnected

and

switch

two

amps, such

and

run

ten

amps.,

is

reached.

the

appropriate

particular

at

If

the

continue

Then

control

Voltage Setting

control

the

unit

must

alternator

out,

and the

condition.

wiring,

note

about

to

circuit does

must

DC

voltmeter

12

the

reading

battery

between

cable.

Reconnect

on

an

electrical load

as

side and tail lights.

2000

charging

to

ensure

not

be

volt installations

earth

alternator

rev/min for

current

run

compare

setting limits,

umt

as

follows.

be set

is

under

battery

Check the

that

exceed 0.1

traced

(suppressed

between

with

cable and

battery

is

engine

the

voltmeter

as

on

the

and

the

no

main

of

still

until

speci-

at

Check

Warning Light Control

If

warning light does

"on"

or

volt

"off',

voltmeter

and

alternator)

ily, connect terminal

(12

Conne.ct leads

the

lights,

warning light

but

earth.

'E'

the

or

and

not

Reading should

be replaced. Fault

Diagnosis Procedure for

Alternator (a)

(b)

Fails

to

Check

driving

Apply Tests 1

Charge

belt

and

Low-Unsteady Charging (a)

Check

driving

belt

(b)

Check for high resistance

and

in the. circuit wiring

Check all

connections

function

system

between

14.0-15.0

'WL'

control

either

is

together.

11

by

charging satisfactor-

the

alternator be

7

(24

volt

If

warning lamp

is

faulty

AC.

remaining

"AL"

.0~

7.5

alternator)

and

should

for correct tension and wear.

2.

Rate

for

correct

at

tension battery

and

terminals

connection.

made

to

earth.

max

wear.

12V(37423)(37449)

(Part

No. marked

of

cover

If

Control

reading

priate limits

Adjustment

Stop

the mounting. meter

aduster. compound. the

alternator

Unit).

obtained

the

unit can be adjusted

of

Voltage Setting

engine

and

At

the

Carefully scrape away the sealing

Then

at chargmg

CLOCKWISE

ANTI.CLOCKWISE

required setting

Recheck

again

and

setting

is disconnect connections.

the

now

is

setting

slowly

correct,

test

If,

on

is

stable

remove

back

of

start

the

to

INCREASE

to

obtained.

by

stopping

"run-up"

meters

after

13.9

upper

DECRI:::ASE

and

adjustment, reading remains unchanged, trolled replacement

Test

manner,

4

must

then

be

the

fitted.

14.3

volts

edge

of

the

moulded

but

the

umt

outside

control

is

as

follows.

unit from its

a sealed

the

appro·

potentio-

engine, and while running

speed,

turn

the

adjuster slot

the

setting or

it

until

the

engine,

to

remount

charging speed.

the

then

control

restore original wiring

the

or

control

increases in

unit

is

faulty

voltmeter

an

uncon-

and

the

start

If

unit,

(c) Apply Test

Flat

Battery

(a) CHECK

2.

or

Low

condition

State

of

battery

Charge

with

hydrometer

and high rate discharge tester.

(b)

Check driving

(c) Check

open

when

battery

ld)

Check insufficient

abnormal electric loads

Excessive Charge

(a)

Apply

Noisy

Alternator

(a)

a

Alternator

(b)

Worn, frayed

(c)

Worn bearings, fully

belt

that

the

field isolating relay

master

will discharge

that

flat

or

alternator

Rate

to

Test

3.

loose

in

or

loose drive belt.

for correct tension

and

contacts

switch

through

low

is off, otherwise

rotor

battery

is

output

by

applying Test

winding.

not

caused b}

caused

a Fully Charged Battery

mounting

out

brackets.

of

alignment.

wear.

by

4.

Check

of

Alternator

Disconnect

ammeter

between disconnected and

switch

\eave

on engme alternator s:tme

and

time

for 3

output show

battery

the

cables.

on

the

or

run

at

approximately

should balance

a charge

Output

earth

cable, and

alternator

Reconnect

main

battery

connect terminal

earth

vehicle's full electrical load

4 minutes. Leave load

2000

the

to

the

battery.

rev/min.

load,

on,

and

test and

cable,

and

start

The

at

the

(d) (e)

(f)

Rotor Open

diodes, Loose

damaged

circuited,

or

stator

pulley.

or

pulley loose

or

short

on

shaft.

circuited rectified

,winding open-circuit.

Electrical

System

NS

Dynamo Models C40A

and

C40L

General The

C40A is a non-ventilated

to

fitted

applications such as agricultural machines,

unit.lt

wHI

be found

which operate under exposed service conditions. The

C40L

is

applications

a ventilated

such

dynamo

as

road vehicles, which operate·

and will be found

on

under cleaner and more normal conditions.

Both

types are shunt-wound two-pole two-brush

machines arranged

to

work

in

Conjunction with a compensated voltage control regulator unit. A ball bearing a

supports

porous

commutator The

output regulator unit and is of

the

battery equipment of

charge, the

the

battery

sufficient

tion

without

increase in

taken

by

lamps and

Whin

fitting a new

only

an authorised replacement. An incorrect replace-

ment

can result in damage to

Routine

Maintenance

the armature

bronze bush

end.

of

the

dynamo

dependent

and

in use. When

dynamo

is

fully charged, the

output

to keep the

any possibility

output

is given

other

control

at

the driving

the

is

on

the

loading

the

battery

gives a high

dynamo

battery

of

to

balance the current

accessories when

box,

it

the

dynamo.

rear supports

end

controlled

the state

of

is

output,

by

of

charge

the electrical

in a low

state whereas if gives

only

in good condi-

overcharging. An

in

use.

is

important

to

and

the

use

SeiVicing Testing in Position

to

Locate

Fault

in

Charging

Circuit.

1. Inspect the driving belt and adjust if necessary. Check the connections

2.

on

the

commutator

end

bracket. The larger connector carries the main

dynamo

output

and the

~maHer

connector,

the

field current.

off

3.

Switch

all lights and accessories, take

the cables from the terminals

of

the

off

dynamo

and connect the two terminals with a short

length

of

wire.

Start

4.

the engine and set to run

at

normal idling

speed. Clip the negative lead

5.

voltmeter. calibrated dynamo

termmal ami the

good earthing point

Gradually increase the engine speed, when the

6.

of

a moving coil type

0/20

pos1t1ve

on

the

yoke,

volts, to one

lead

to

voltmeter reading should rise rapidly and without meter reading to reach the engine

It

of rapidly and be Excessive sparking

fluctuation. Do

in

an

is

sufficient to run the

attempt

1.000 rev/min. wilhout

not

20

allow the volt-

volts, and do not race

to increase the voltage.

dynamo

If

the voltage does not rise

up to a speed

fluctuation the unit must

dismantled for internal examination.

at

the

commutator

in

the above test indicates a defective armature which should be replaced.

a

Lubrication Every

4,000

miles

(6,000

km)

or

ISO whichever 30

engine oil

commutator

Inspection

60,000

Every hours, the

is

the sooner, inject a few drops

into

end

of

dynamo

the hole marked

bearing housing.

Brush Gear

miles

(90,000

should be removed from the

km)

running hours

of

"OIL"

or

2,400

S.A.E. at

the

running

engine and the brushgear inspected by a competent electrician.

Belt

Adjustment

Every

4,000

miles

(6,000

km)

or whichever belt, and by

turning

taken

be

to avoid overtightemng time check Pull

to a torque

is

the

if

sooner, inspect

necessary adjust

the

dynamo

the

dynamo

of

15/20

on

pulley securing

lbf

150 running hours,

the

to

dynamo

take up any slackness

driving

its mounting. Care should

the

belt.

At

the same

nut

ft

(2,07/2,8

tightness.

kgf m).

Starter

Motor

Model M45G

General This

starter

return

motor

is

a four-pole, four-brush

earth

machine with series-parallel connected field

coils. A solenoid-operated pre-engaged drive assembly

carried main features

on

an extension

of

this type

of

the armature shaft.

of

drive are as

follows:-

(a) Positive pinion engagement preventing

the

pinion being

thrown

out

of

mesh

whilst starting.

(b)

Dual-purpose plate-clutch incorporated the

drive assembly giving over-speed and

over-load

(c)

Self-indexing pinion engagement flywheel begins

protection.

between

teeth

to

rotate.

to

ensure

the pinion and the

before the

starter

smooth

motor

is

The

in

Electrical System

N6

(d) Armature braking system

return to rest when the start released.

to

ensure rapid

button

The lamps do

is

2.

reading remains and the

motor

not steady

does

dim,

not

at

about

crank

the

voltmeter

12

volts,

engine.

Routine

(a) The

(b) After the

Sen-icing Testing in

Maintenance

starter maintenance inspection

motor

requires no routine

beyond

of

the electrical connection

the occasional

which must be clean and tight, the brush gear, and the

service for 2,400 sooner, remove the the engine and submit

commutator.

starter

60,000

motor

miles

has been

(90,000

running hours, whichever

starter

motor

11

to a thorough

bench inspection.

I.

Brush wear (this of Renew approaching,

the

amount

is

a fair mdication

of

work done).

brushes worn to,

5/16

in ( 7,9 mm)

in length. Brush

2.

spring ten•ion. Correct

swn

is

30/40

01

(0,85/1,13

Renew springs if tension has

dropped

3.

Sk1m badly

Check bearings for excessive side

4.

play

5. Check pinion movement.

6.

Clean and lubricate the indented

bearing using

below

25

commut~tor

worn.

of

armature shaft.

insid~;:

a

bentonite

the pinion sleeve

oz (0,71 kg).

if

it

is

pitted

based grease

this purpose.

7.

Clean and lubricate the

indenkd bronze bearing m the intermediate bracket.

Use

Ragosine 'Molypad' Molybdenised non-creep oil for this purpose.

Position

in

km) or

is

the

from

or

ten~

kg)

or

for

Conned to

voltmeter from solenoid terminal

starter

yoke

and ooerate

starter;

No volts indicated:

Poor

Jug

(a) (b) Bad

connections

earth

connection

(c) Broken starter lead,

at

battery

to

starter.

Full volts i.e. 12(14 volts indicated.

(a)

Faulty

solenoid switch.

(b)

Starter Model-

Open circuit

Motor

CA45

in

starter

- check brushes.

General Description

Designed for flange mounting, the motor has a uniform cylindrical shape with protrusions. This

is because the solenoid and main

CA45

no

switch assemblies are housed within the drive

shield,

around

(i.e. co-axially with)

the

annature

shaft. The essential feature

the Pinion alone moves axially to engage flywheel. There whole armature assembly,

Smooth

flywheel operation

Thus

engagement

is

constantly ensured by using two-stage

of

the nsk

the solenoid and switch mechanisms.

of

through faulty meshing,

construction,

In sections,

I.

into

which it can be easily dismantled.

The solenoid switch-gear and pinion assembly

of

the co-axiall

starter

the

is no longitudinal movement

as

in

the

axial types.

of

damage

the

starter

the pinion with

to

both

is

pinion and flywheel,

practically eliminated.

consists

of

the

three

is

housed in the drive end-shield.

'BAT',

starter

surface

end-

that,

engine

of

the

engine

main

Switch

the lamps.

If

the vehicle

on

with lighting, then connect a

battery

the starter

termin~ls

control

and watch for the following

before proceeding. Operate the

symptoms:-

1. The lamps dim drops

to

not

battery

earth

about

crank

the

(must be at least half-

battery

connection).

that

the engine

does

Check charged) and good cranking mally stiff.

is

not

0}20

(or

voltmeter reading

equipped

voltmeter across

6 volts), and the·

engine.

lugs (clean and a

Check by hand-

is

not

motor

abnor-

The

armature,

yoke,

2. The

3. Ready access

most likely

gear and

commutator

shaft and

commutator

pole-piece and field-coil assembly.

is possible

to

require

therefore,

adjustment,

to

such

assemblies.

assembly.

those parts

as

the

switch-

Starter Motor Model

MSO

General Description

The model M50 starter of

5 in ( 127,0 mm) nominal yoke diameter, and has a

21

slot armature.

motor

is a four

pole machine

Electrical System N7

It

is

essential grade as those always be used. four

fixing screws, assembling care must be taken coil and interconnectorleads, held by fixing screws. Before inserting brushes in their holders, it with compressed air moistened with petrol.

that

replacement brushes are the same

originally fitted. Genuine spares should

To

remove the brushes, unscrew the

one

to

each

brush.

to

reconnect the field

two

is

advisable

to

blow through

or

clean

them

the

with a

In

re-

of

the

holders

cloth

The drive screw

The function being engaged position being held started. The solenoid incorporates a switching arrangement which ensures develops its flywheel engagement has been achieved.

Testing

Ensure

Switch

If

the full brilliance, check tions to the action connection.

Difficulty in engine flywheel starter-shaft helices preventing free pinion movement. The fluid followed of

Aero Shell

is

of

type,

rotated

on

that

on

starter

of

shaft

pre-engaged, soleoid

incorporating a five roller clutch.

of

the

clutch

at high speeds

maximum

is

torque

the Vehicle

the

battery

the lamps and operate the

fails starter

the

starter

smooth

should be

by

6B

is in a charged

to

function,

the

switch and

and all external leads. Sluggish

can be caused

engagement

is

probably due

thoroughly

the application

or

its equivalent.

operated,

to prevent the armature

in

the

after

only when full pinion-

but

cleaned

event

the engine has

that

condition.

starter

the lights maintain

battery

by a poor

between

to

of

a small

push

of

the

two-~>tage

the

motor

button. connec-

or

faulty

starter

dirt

with

and

on

the

cleaning

quantity

commutator

The

or

dirt. Any trace

oil pressing a clean dry fluffless cloth against it, while armature

If

brushes and wrap a strip paper the abrasive side inwards. Rotate the armature hand until the surface moistened cloth.

If

gear

an authorised agent. Every

hours, whichever examination and service

the

commutator

(not

repair

etc.,

60,000

is

the

should be clean, entirely free from

of

such should be removed

hand

rotated.

is

dirty

or

emery cloth) round the

necessary to the

starter

miles,

of

is

must be exchanged

(90,000

is

the sooner, arrange for the

or

discoloured, tilt the

fine glass

even. Clean with a petrol

the

or

commutator,

commutator

km)

or

starter

motor.

by

carborundum

01

2400

with

by

or

switch

repaired by

running

Maintenance

Brush Gear and Commutator

Inspect the brushes are free in free for movement, and pulling gently brush and clean the sides

Be

sure

to retain the bedded (i.e. worn if

not,

paper firmly abrasive side outwards. With the brushes in position, rotate direction obtained. springs are they pressure

lip. The correct tension

their guides and

is

inclined

to

refit the brushes in their original positions

wrap a

the armature

of

rotation;

If

the brushes are worn

no

should be renewed. Check the

by

hooking a spring balance

at

intervals

by

easing back the brush springs

on

the

to

stick, temove

with

a petrol moistened cloth.

"bedding".

to

the

strip

of

very fine glass

around

longer providing effective pressure,

the

by

hand in the norntal working

until the correct

is

to

ensure

that

the

leads are quite

flexible connectiori.s.

The commutator

30/40

it

from

brushes should be well

commutator

periphery)

or

down

under

ozf

(0,85/1,13

carborundum

brush

so

brush

that

its holder

with

shape

that

the spring

they

If

but the

is

the

spring

kgf).

a

Description

H.l75

The sliding vane rotor.

type

unit,

exhauster

with

is

a high speed, rotary,

an eccentrically

• •

Section

P

EXHAUSTER

mounted

Exhauster

Pl

At all speeds, the

in

contact

force, assisted beneath No.

the eccentric

body.

the space between it and

and

rotation

compressed until the blade passed

Fig. P.S, No. 4 when the air,

surplus lubricating oil,

crankcase.

The

screwed

into

Mounting

The exhauster

case by

case cover,

exhauster

provided by

locating

P.2.

The exhauster

the back pump

the blades. When the

3,

the

As a blade passes

air

is

decreases the space and

pnit

into

the vacuum pipe and reservoir during operation.

four

into

gear.

rotor

blades Fig.

with

the

bore

by

spaces

between

mounting

drawn from the vacuum reservoir.

has an

the

inlet

is

mounted

setscrews entered

through

mounting

a dowel

the

exhauster

is

,sear driven through an aperture in

of

the

timing case, in train with the fuel

of

the

hydraulic action

of

the

is

oil

check valve Fig.

port

the

flange. A location

on

the

P.l,

No.2

the

body

by

rotor

the blades vary because

the

inlet port Fig.

following blade increases

discharged to

turns Fig. P

rotor

in the exhauster

the

discharge port

together

P.l.

to prevent oil from passing

on

the rear

into

timing case and into the

fuel

mounting

of

the front timing

pump

adaptor

flange. See Fig.

are

kept centrifugal of

the oil

I,

No. I

Further

air

is

then

with any

the

engine

No.

the timmg

is

also

body

.I,

of

PI

4,

Lubrication

Oil

is

fed

into

the

end cover Fig. P.S, pump

adaptor

an annular groove in

through

passes an oilway drilled

further

and a

cates

the

relieved

front

holes in the

through

through the slots in the is port.

exhauster housing. holes in

through

drilling from

bearing Fig. P.S,

rotor.

No.

the

rotor

a passage

through

I,

via a pipe from the fuel

From

rear bearing housing. The oil

the

bearing Fig. P.S,

the

length

the

shaft

At

the

rear end

into

a drilling

the

drilling, oil enters

of

the

centre oilway lubri-

No.2.

Oil also passes

communicating with

of

the air/oil discharge

No.3,

rotor

the

in

the

to

shaft

shaft, oil

P2

Exhauster

P2

P3

Servicing Every

houn;. Remove and dismantle the exhauster, and thoroughly

clean and inspect for wear and damage.

After removing clean with a solvent and brush.

Unscrew the nuts securing and remove.

It

tion, see Fig. P.3. Mark the the and union and remove the

In necessary circlip will release the gear from the splined shaft.

Before solvent. Clear the oilways in the compressed air.

Examine longitudinal ripples the

the

Exhauster

60,000

will be noted that the

rotor

order

body

miles

the

and withdraw. Unscrew the oil check valve

to remove

to

remove the gear. The removal

examination,

the

body

should be renewed.

Unit

(90,000

grease and dirt from

the

for <:racks, and the bore for

or

km)

or

the

end cover to the

end

cover has a dowel loca-

rotor

blades

copper

washers.

rotor

from the body

wash all parts in cleaning

hnes.

If

rotor

this

2400

the

exterior,

in

relation

it

and

body

condition

running

body

to

will be

of

the

with

exists,

rotor

The

beanngs, and if found be replaced.

Examine the check

rotor

Examine the oil check valve for damage, if necessary.

To

Lubricate all working parts prevent possible damage when the engine

and until oil flow commences.

Replace the

gear and secure with circlip.

Replace the before removal, see Fig. P.4.

Making sure removed, smear

with

cover and secure

The nameplate

should be a good running fit in the plain

rotor

that

the blades are a good' sliding fit in the

slots.

Reassemble

rotor

that

a suitable

to

be

worn,

the bearings should

and the blades for damage and

with

clean engine oil

into

the

exhauster

both

jointing

with

is

secured

blades in

all traces

sides

the

same position as

of

the

of

a new

compound,

setscrews and spring wasben;,

by

two

of

the setscrews.

body,

old

epd

refit

and

is

refit

joint

cover

replace

started

the

joint

the

end

to

are

P4

End float

0.0015/0.0035 in (0,04/0,09 mm).

of

rotor in the exhauster body should

be

Exhauster

P3

Rotate the rotor without binding after screws.

Screw the oil check valve and union, together with the copper washers and tighten.

Re-mount the exhauster unit

timing case, using a new

locating the exhauster

fuel pump adaptor body. Secure the exhauster unit

spring washers in the front timing case cover.

by

hand

to

ensure

tlghtenmg the ena cover set-

onto

joint

with sealing compound,

by

means

by

that

the rear face

of

the dowel in the

four setscrews and

it turns

of

the

PS

4.154 marine engine

General Data

Type

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

Bore (Nominal) Stroke

Cubic Capacity

Compression Ratio Combustion System Firing

Order Rotation (viewed Cooling System Fresh

Water Cylinder Head Maximum

Lubricating

Total Lubricating Oil Capacity

*Early 4.154M Lubricating

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

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

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

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

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

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

from

rear

of

engine)

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

Capacity

Water

Permissible Sea

Oil Pressure (engine)

Oil

sumps

Oil Pressure (gearbox)

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

Temperature

Sump

Capacity*

had a capacity

Water

Inlet Temperature

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

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

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

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

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

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

of

141MP

Section

······· . . . . . .

.

. .

·

..

...

.

pints.

8,0

litr,es ·

.

'0:

Cylinder, Four Stroke, In-Line

Four

3.5 in (88,9

4.0 in (101,6 mm)

153.9 in

21.5: Indirect Injection 1-J.-4-2 Left Indirect (Heat Exchanger) 25

pints 178°F (81°C) 100°F (37,8°C)

30/60

and

151MP

16.5

8.4

US

110/150 ing temperature and speed. sive speed may cause pressures

(14,06/17,58

mm)

3

(2,5231itres)

1

Hand Rotation

( 14,21itres)

lbf/in2 (2,1/4,2

normal operating temperature.

pints·

8,51itres · 9 US quarts

IMP

pints·

9,41itres · 9,9 US quarts

pints

lbf/in2 (7,73/10,55

2

kgf/cm

).

2

kgf/cm

Low

Marine

at

maximum speed

)

2

at

normal operat·

)

temperature

of

200/250

Engines

or

exces·

lbf

I in

Ql

2

Lubricating

Maximum

Installation

Engine

Engines can be

Battery Cable Resistance

Oil (gearbox) capacities Direct Drive Reduction

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

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

Permissible Engine

Angle

may

be installed

installed

ENGINE RATING

without

rev I

min

rev/min

Pump

Craft

without

rev I

rev/min

Craft

Gearbox

Service

Gearbox

min

General Pleasure

Gross

Output

62

bhp

at

3000

Nett

Shaft

Horsepower

at

bhp

Shaft

3000

Output

at

3000

Horsepower

at

3000

58 shp

Fuel Injection LJ51/750/1/3190

Commercial

Gross

62

Nett 54 shp

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

Compartment

at

angles between

on

the

level

but

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

with

Direct Drive Gearbox

Siming

Code

with

2:1 Reduction Gearbox

Temp

0°

and 10°

should

not

. . .

.....

front

operate

.

Level

3 pints ( 1,

4. 7

pints

end

up,

which

with

the

front

Not

to

ENGINE WEIGHTS

Marine Engine less Gearbox

6681b (299 kg)

Marine Engine

8031b

71

litres)

(2,36 litres)

allows

for a further

end

down.

exceed 0.0017

with

Including 2:1 Gearbox

(364

kg)

Inclined

2.2 pints ( 1,21itres)

4.5

pints (2,51 litres)

3°

rise underway.

OHM.

Flywheel Housing and Flywheel

but

Marine Engines Q2

Dimensions

-

26.29---------;

MODEL

WARNER

"V"

71

DRIVE

22

21

1

Sea

Water

P1pe

2 Fresh Water

from Pump to Heat Exchanger.

P1pe

from Eng:ne

3 Water Temperature Sender. 4

Lubricating Oil Dipstick.

5 Lubricating 6 Induction

7

Closed

011

A1r

C1rcu1t

Filler Cap.

Filter.

Breather Pipe

8 Atom1ser. 9 Lubricating Oil Filter Canister.

10

Fuel

011

11 12 13 14

Filter

Electrical Engme Stop Control Actuator. Gearbox Lubricating Gearbox Control Lever. Gearbox Lubncallng Oil Filler/Dipstick.

Oil

Pressure Sender {position).

20

19

18

to

Heat Exchanger.

Ma

rine Engines Q3

Engine

Views

Perkins engines are built to individual requirements to suit the applications are intended and these engine views do

particular specification.

any

17

16

IS

15

Reduction Gearbox.

16

Forward and Reverse Gearbox.

17

Flywheel Housing.

18

Flex1ble

19

20

21

22

23

24 25 26 27 28

Lubncating

Starter

Motor Lubncallng Lubncatmg Oil Sump. Eng1ne Sea

Water Pump Inlet. Fuel Sea

Water Pump. Engine Cold Starting Adaptor. Thermostat Housing.

.

01l

Sump Drain Plug.

Lubncatmg

InJeCtion

Pump.

Serial Number {position).

Oil

P1pes.

011

Pressure Sender.

for

which they

not

necessarily typify

29

Sea

Water Outlet.

Fresh

Water

30

31

Fresh Water Filler Cap. 32 Sea Water Inlet 33 Alternat 34 Alternator I Fresh

Fuel Lift Pump.

35

Fuel Lift Pump Pnming

36

37

Power Take-off Shaft.

Pipe

or.

r'l'1!Miil

to

Lubricating Oil Cooler.

to

Heat Exchanger.

Water

Pump Drive Belt.

L811er

.

29

30

31

32

3.

~-iit!t&l~II'J~~~~~=

38 Lubricating Oil 39 Lubricating 40 Neutral Switch {position).

41

Lubricating Oil Cooler.

42

Heat Exchanger/Exhaust Manifold Fresh Water Drain Plug.

43

Exhaust Manifold Flange.

44

Header

35

36

Sump

Oil Cooler Water Drain Plug

Tank/Heat

Drain Pump {position).

Exchanger/ Exhaust Manifold.

{or

tap).

Marine

Engines

Q4

Preventive

Maintenance

If a Perkins marine diesel engine

troublefree service,

in

accordance with the following Periodical

it

is

imperative that

is

to give long and

it

Daily

Check coolant level in header tank. Check sump oil level.

Check

engine and gearbox oil pressures {where gauge

fined).

Check gearbox oil level.

Every

150

hours or 3 months (whichever occurs

first)

Drain and renew engine lubricating oil Renew lubricating oil fitter canister Check both drive belt tensions.

Clean air intake gauze or screen. Check engine for leakage Clean

sedimenter

Every

occurs

Renew final fuel filter element. Check hoses and clips. Drain and clean fuel tank. Renew gearbox lubricating Service atomisers. Clleck and adjust valve tip clearances.

450

first).

/water

hours

or

of

trap.

12

oil

oil or water.

months

be

maintained

Attentions:-

(whichever

Every

Arrange for examination and service equipment, i.e. starter

2,

700

hours

motor, generator etc.

of

proprietary

Marine

Engines

QS

Gearboxes

BORG-WARNER 71CR

Filling

Transmission fluid Type

reaches the full mark on the dipstick. The unit should be

turned over

circuits.

Procedure

The oil level should

down

full mark on the dipstick. The dipstick assembly need

not

be

boxes have a plug type dipstick.

Oil

Capacities

at

idling

for

checking

and sufficient oil added

threaded into the

Typo

l1C&CR

1.523.

1

1.91

. 1

2.10 ; 1

2.57

:1

2.91 : 1

Inclined

71C&CR

1.523 : 1 : 1 2.7

1.91

2.10

:1

2.57:

1 2.7

2.91 : 1

Oil

Temperatures

Oil

pressure

110-

normal operating temperatures

73,8':'C). pressures may be obtained. A maximum transmission oil temperature

PROPELLER

(auxiliary

When yacht the propeller

With for exceeded:-

Direct Drive

At

low

of

200-

of

190°F (87 ,6°C) is recommended.

SHAFT

yacht

lnstallatlonal

oil operated reverse gears are used on auxiliary

installations care

with

the Borg-Warner gearbox

8 hours providing the following

1.5

1.9

2.1

2.5

2.9

"A"

should be added until

speed

for a

short

time to fill

oil level

be

checked immediately after shut-

to

bring the level

case

to determine

oil

Level

u.s.

Quorta

Imp.

Pints

1.8 3.0 1.71

2.5

1.3

4.2 2.36

4.2

2.2 1.2

2.7 4.5 2.56

4.5

2.7

4.5

4.5 2.56

2.7

and

150 lbf/in2 (7,73-

temperature

250

lbf/in2 (14,06-

TRAILING

must

the engine

4.5

Pressures

of

150

or

be exercised

or

engines

it

is permissible

shaft

10,55 kgf/crn')

- 185°F

excessive speeds,

17,58

when

out

speeds are

1,500rev/min 1,000rev/min

to

level. Later

Utros

2.36

2.56

(.66,55

kgf/cm

trailing

of

use.

to

790

rev/min

715

rev/min

600

rev/min

520

rev/min

all

the

trail

not

it

at

Transmissions incorporating reduction gear means

of

stopping the transmission prolonged or continuous freewheeling. This is because the engine, being stopped, does in the gearbox. The box therefore is lubricated.

Propeller shaft brakes are available and the boat builder

or

stern gear specialist should be contacted for further

details.

Cooling

A centrifugal the engine and belt driven from the crankshaft, delivers coolant directly into the cylinder block and head.

When the thermostat

through the combined heat exchanger/exhaust manifold/header tank unit. circulated through a dual engine and gearbox tubular lubricating fresh water pump.

An

external by-pass arrangement allows the fresh water

to

circulate

allows

Sea

water is circulated through the heat exchanger

by

means expelled overboard or system.

Sea

Water

The

sea

heat exchanger and is bracket mounted on

cover.

case The pump is belt driven from the crankshaft pulley. The pump is self priming

-

2

!

when been laid

To

Remove

Uncouple the inlet and outlet connections. Unscrew the

of the pump

freed

To

Refit

Secure the pump the removal as described above.

In

order

bracket securing nuts slack, lever the pump

belt and maintain the tension

the have been tightened.

Check drive damage the

Recheck after a

type

oil cooler before returning

within

the thermostat

of

a self-priming vane type pump before being

Pump

water pump is used in conjunction

first commencing service or after the engine has

up

for

the

two

to

of

the drive belt and lifted off.

the

Sea

to

tension the drive belt, leave the

that

sufficient tension is present to prevent the

from

slipping

pump

System

water pump, mounted on the

valve lifts, water is then passed

Following this, the fresh water is

the engine until the temp8f"ature

to

open.

into

any considerable period.

Sea

Water

nuts and bolts

the bracket. The pump can

Water

to

the bracket in the reverse manner

but

shaft bearings,

short

period

not

a water injected exhaust

but

it

is advisable

Pump

which

Pump

until

not

overtight which could

of

running.

must

output

shaft

drive the oil

not

being properly

to

the engine

with

to

the timing

to

attach the

pump

to

the securing

have from

pump

front

the

prime

body

now

tighten

nuts

of

it

be

to

---------------------------------------------------------·

Marine Engines Q6

To

Dismantle

Remove the end cover fiKed

six slotted screws and remove the

the

Sea

Water

Pump

to

the water pump body by

rubber

impeller and

wear plate.

Remove the

pulley

A suitable press shaft

The cam in the

by removing the single securing setscrew.

Remove the rubber seal in the impeller housing and ring and seal in the bearing housing.

If

wear

plate

reversed.

sary

to

emery paper.

rotation tained the

pump

To

Reassemble

The reverse order to the procedure above should be adopted for the reassembly of the

Care should be taken that

the blades all lay

the

rotation

When

coated alternative.

When

the top surface, rear face and securing setscrew hole with

a suitable JOinting

It

is possible to

Cautionary

Because the must laid-up and the engine unused water grease

Fresh

The mounted driven

To

Remove

Slacken the

four

the pulley to pulley hub and remove the pulley.

Loosen the rubber hose by-pass rubber hose (situated behind the

Remove the five setscrews and spring washers securing

water

the and

joint

To

Refit

Use a

nut

securing the pulley

from

the

shaft.

may

be used

together

or

with

the

water

pump

impeller housing

indications

water

In

remove the

of

the impeller,

by

turning coupling

of

the rubber impeller

with

refitting the cam in the impeller hous1ng.

are apparent on

pump

end plate,

the case of the

stamped

This

will

remove the arrows

but

the eng1ne and

the

Sea

when

1n

the same direction relative

the

pump

i.e. blades trailing.

MARFAK

fit

2HD

compound.

the cam

to

end

this rotation can be ascer-

Water

replacing the rubber impeller

1s

grease

the housing one

and

to

press

out

bearing.

may

then be detached

the

both

of

plate it may be

instructions

noting

Pump

sea

water

being

fitted.

or

glycerine

draw

the impeller

impeller wear

these may be

by

showing

the

rotation

pump.

it

Note

water

pump

contains a rubber impeller

not

be run

in a dry

pump

should be packed

or

coated

with

Water

Pump

water

pump

on the

front

from

the crankshaft.

the

water

setscrews and spring washers securing the

connection

pump

to the cylinder

may

now

the

Fresh

new

JOint.

condition.

glycerine.

for

the closed circuit cooling is

of

the cylinder block and

Fresh

Water

pump/generator

from

alternator)

be removed.

Water

Ensure that the

If

for

any

with

Pump

drive

connection.

the

block.

Pump

joint

the

length

MARFAK

pump

The

faces are clean.

craft

of

belt. Remove

Loosen the

inlet pipe

water

off

neces·

means

must

as

way

only.

is

to

time

is

pump

the

"0"

the

be an

coat

be

the

2HD

belt

of

to

Refit the it

Reconnect the by-pass and the refitted and the generator adjusting lever setscrew and bolts.

Move when the the crankshaft approximately

Secure the alternator

adjusting lever setscrew and check to ensure

tension is correct.

To

Remove the pulley hub retaining circlip and

able

Separate the

by removing the

Press the shaft, complete of

Remove the bearing retaining circlip hub the the

Remove the impeller puller.

To

See exploded

Press the bearings and distance piece and pack bearings

Press the shaft complete the

it

clip,

Supporting pulley hub

Smear the outside suitable over the impeller end towards recess

Fit the ceramic ceramic face

Fig. K.4

Press the impeller

0.390/0.413 rear face front

Using a

clean, with

lbf

should and the inside

Fig. K.4. (basic manual).

pump

to

the cylinder

with

spring washers and setscrews.

pulley. The

the generator so that the belt is tightened,

Dismantle

tool,

the back or impeller end of the

end of the

two

front

Re-assemble

pump

see Fig.

within

face

fit

six

/ft ( 1,66/2,07

A running clearance

water

pump/generator

belt tensioned

thumb

is

applied

pulley and generator,

3/8

in (10

the

Fresh

pull the hub

two

halves of the

Six

nuts and spring washers.

pump

shaft bearings and distance piece

of

the

body.

the

view

on

half

to

two

with

high melting

body

and locate

K.4

No. 1 (basic

the shaft

onto

the shaft,

of

gap-filling

the rear of the

No.2

of

new

the rear

nuts

now

compound

the

pump

counter

is

to

the carbon face of the seal, see

(bar.ic manual).

onto

in

(9,90/10,49

the

front

the impeller, joint

and ensuring

half

and spring washers and

kgf

I m).

be obtained

of

the rear

block

front

water

inlet hoses. Refit

by

to

the stretch of belt between

it

mml.

support

off

body

from

Water

thirds

at

the brass case

of

body.

half

of

bracket bolts and the

Water

Pump

the shaft.

water

with

seals and impeller,

body.

from

and

with

the shaft using a suitable

Pump

page

11

(basic

of

the space between the

point

grease.

with

bearings

with

the bearing retaining cir-

manual).

the impeller end, press

fitting

the retaining circlip.

of

which

may the shaft pump.

face over the shaft so

the shaft

see

the

0.004/0.045 in (0,10/1, between

with

The seal locates

until

mmJ

is obtained between the

of

the

pump

Fig. K.4. (basic manual I.

that

the

water

pump

the impeller blades

half

of

the

face, securing

drive belt may be

slackening the

support

can be depressed

a mandrel, press

into

the carbon face

tighten

pump

bracket

that

with

a suit-

pump

body

the

front

from

out

manual)

onto

the

shaft

the

front

the seal

a clearance

now

body

joint body

with

be

fitted

into

that

and

faces are

securing

to

12/15

14

body,

that

the

out

or

of

the

of

the

mm)

see

a

Fresh water heat exchanger

I

Marine Engines Q7

'-

..

A.$

p

ffixhaust

1 Header tank 1

..

l

Engine Block

manifold

Head

l

..

~-

f

1

FRESH

Engine

~ILC

OOLERS

""

~

Gearbox

WATER SYSTEM

Sea water inlet

To water injected exhaust overboard

SEAWATER

or

CIRCUIT

Marine Engines Q8

Heat

Exchanger

(Refer

The heat exchanger unit is combined manifold and header tank as a single assembly.

The function water in the closed circuit achieved by passing the small bore tubes and guiding the heated fresh water, piped from the engine, over the tubes number is also contained in the heat exchanger/header tank assembly, the water acts manifold gas passages.

In order sary

To

Remove the fresh water filler cap, unscrew the water drain plug or open the tap, if fined, and drain the water.

Loosen the both the end covers.

This drawn

to

Engine

of

brass baffles. Because the exhaust manifold

to

clean a choked-up tube stack

to

remove the assembly from the engine.

Remove

two

ends

of

will expose the tube stack which may

out

from

vievvs,

of

the heat exchanger is

the

Tube

hose clips securing the end covers at

the heat exchanger assembly and remove

within

page

03)

with

sea

water through a series

as

a cooling media

Stack

the header tank.

with

to

cool the fresh

water. This is

with

it

the exhaust

the aid

of

for

the

is

not

neces-

now

of

be

Cleaning

If the tube stack is badly choked the best method cleaning is boiling caustic soda solution.

This The outside these are in the closed circuit.

The inside through them, are more likely to require cleaning.

If the inside

require using caust1c soda, they can be cleaned by

pushing a length tubes in the opposite direction

Care should be taken, the tubes,

to

will loosen

of

not

place the assembly in a hot, preferably

all

foreign matter adhering

the tubes should be relatively clean

the tubes, which have salt water passing

the tubes are

of

to

damage the tube walls.

1/8

when

not

so badly choked as

in

(3,

18

mm) rod

to

the

pushing the rod through

flow

of

to

water.

the unit.

down

of

as

to

the

Thermostat

The thermostat is situated in a housing attached front

of

the cylinder head and its function is

the engine coolant temperature.

To

Remove

Drain the fresh water coolant

moving the filler cap and removing the drain

header

block can be drained by removing the drain the right hand side lubricating

Remove the

nection situated on the top at

the

forward

The

top

thermostat

the

tank/heat

oil/gearbox

two

end

water

connection may

lifted

Thermostat

from

the system

from

the

top

of

the header tank

plug

from

the

bottom

exchanger assembly. The cylinder

of

the block, at the rear behind the

oil cooler.

setscrews securing the

of

the thermostat housing

of

the cylinder head.

now

out

of its location.

top

be removed and the

to

the

to

control

by

re-

rear

of

the

plug

from

water con-

To

Test

the

Thermostat

If

it

is suspected

correctly

Immerse the thermostat in a suitable container filled with perature at frequent when the thermostat valve opens check that the tem-

perature

a

is stamped on the thermostat.

If the thermostat does should be made

To

Clean the stat in its location making sure

correctly.

Using a

the and spring washers

Refill the closed circuit cooling system through the

Water

Slacken the

adjusting lever.

Slacken the adjusting lever

curing setscrew.

Slacken the

alternator.

Sideways movement

adjustment lever should

With

nator away

tensioned. Tighten the adjusting lever

and test the tension in the following manner.

The tension should be adjusted so that,

pressure, the

(10 mm)

midway along the longest unsupported length

belt (between the alternator pulley and crankshaft

pulley).

When the correct tension has been achieved, the alter-

nator

tightened

housing setscrew.

Incorrect adjustment

failure. If the adjustment is will duced which could lead

the alternator

If alternator bearings in

New

When a

and readjusted after a short period

the initial stretch

it

water and gradually heat. Check the water tem-

of

Replace

two

new

top

water connection and secure

Pump

the belt in position over the pulleys, pull the alter-

with

to

bonom

occur. The efficiency

the adjustment is

early failure.

Belts

new

that

the thermostat is

may

be tested in the following manner.

1ntervals

the water corresponds

to

adjust it. Replace

the

Thermostat

joint faces thoroughly. Place the thermo-

joint

and suitable jointing compound

to

a torque

filler s1tuated on the

Belt

Adjustment

nut

and bolt securing the alternator

bottom

from

belt can be depressed approximately

followed by the adjusting lever

support bracket

of

the cylinder block until the drive belt is

the thumb applying pressure

support

of

would

also be reduced.

will be overloaded

driving belt is

common

with

not

function properly

of

241bf/ft

top

to

thermostat housing se-

the alternator, limited by the

now

be possible.

bracket

the belt can result in eventual

too

nut

of

the water pump will be re-

to

overheating. The

tight

the

fitted

to

new

not

a thermometer and

with

the figure which

it

with a new

that

it

with

(3,32

with

fresh water

of

the header tank.

nut

and

to

alternator

without

and bolt should be

to

too

slack belt slip

water

which

it

should be checked

of

running

belts.

operating

no

a«efT1)t

unit.

is seated

fit

setscrews

kgf/m).

to

the

bolt

to

nut

undue

3/8

in

at a point

of

the

thermostat

output

of

pump and

will

result

to

take

up

To

Remove

(Refer

If

a sump drain pump is fitted it will have to

as

follows: -

Unscrew the union securing the drain pump sump. The cooler support bracket with now

be removed to enable the pump assembly to

drawn out Care

should be exercised when withdrawing the drain pump suction damage to the pipe.

Drain plug at bottom

Loosen the

the cooler from the bottom ouUet of the heat exchanger

the outlet from the cooler to the pipe taking the

and coolant back

The

flexible lubricating oil pipes may now

nected from the cooler. Four nuts and bolts,

bottom secure the

support bracket; their

cooler body

the

Engine/Gearbox Oil Cooler

to

Engine views, page

clamp which secures the pump body to the

of

the sump.

pipe

from

out

off

the fresh water coolant by removing the drain

rear

of the cooler body.

clips from the

to

the fresh water pump.

to

be detached.

hoses

two

clamp holding the cooler body to the

removal will enable the clamp and

03).

be

removed

two

nuts and bolts may

of

the sump to prevent

connecting the inlet

be

at the top and two at the

to

the

be

discon·

to

Marine

Engines Q9

To

Clean

the

Oil Cooler

BEK"'.aUse dismantle the oil cooler.

However, ing medium blockage caused by foreign bodies is likely.

If traces of oil by dipping the unit sene

Prepare a

tainer and immerse the cooler

of its integral construction it

because only fresh water

it

is necessary

or paraffin and drying thoroughly.

solution

to

clean the unit, firstly remove

of

caustic

soda

in

is

used

in

a container

in

hot

it.

not possible

as

the cool-

of

water in a con-

to

un~

all

kero-

r-------------------------

Lubricating

Lubricating oils should meet the requirements

or

Mll-L-2104C. The lubricating oils

cosity index

Some

of

80.

of these oils are listed below. Any

able.

Company

B.P. Ltd.

Brand

Vanellus M lOW Vanellus M

Castrol Ltd.

Castroi/Deusol Castroi/Deusol CAB

Castroi/Deusol

Castrol/Deusol

Deusol A X Super

A.

Duckham & Co.

Mobil

Oil

Co. Ltd.

Shell

Ltd.

Fleetol

0

Fleetol Fleetol

Farmadcol

Delvac

Delvac Rotella

Rotella

Motor

for

use

other

MIL-L-46152

HDX

Oil

Multi

V

Multi

lite

HDX

1200

Series 1210

Special

TX

Oils

of

the U.S. Ordnance Specifications

in Perkins Diesel engines should

have a minimum

oils which meet these specifications are also suit-

S.A.E. Designation

3QOF

QOF

1-lSOC)

to

30°F

(-10C)

CR

B 10W

5W/20

CAB 10W/30

CAB

10

10W/30

10W

(-10C)

to

SOOF

(270C)

20W

20W-50 20W-50

20

10W/30

20W/50

20W/40

20 20W/50 20W/50

10W/30

20

1220

lOW/30 20W/20

20W/40

MIL-L-46152

Over

SQOF

30

10W/30 20W/50 20W/40

30 20W/50 20W/50

10W/30

30

1230

lOW/30

30 20W/40

Vis-

(270C)

Company

Brand

B.P. Ltd Vanellus C3 Castrol Ltd.

Castroi/Deusol

Deusol RX Super

Agricastrol

Agricastrol Agricastrol

A. Duckham & Co. Ltd. Fleetol 3

Farmadcol 3

Esso Petroleum Co. Ltd. Mobil Oil Co. Ltd.

Essolube

Delvac

Shell Rimula CT

Rotella

Rotella TX

Where oils

previous specification

to

the

MIL-L-46152

Ml

L-L-21

or

MIL-L-2104C specification are

048

may continue

vice.

The.above specifications are subject

to

MIL-L-2104C

CR

HOD

MP

0-3HP

1300 Series

TX

alteration

without

OILS

QOF

(-1SOC)

JOOF

lOW

D

to

lOW

10W

3/10 3/10

10W

1310

10W lOW

be used providing

notice.

to

I-10C)

S.A.

E.

Designation

3QOF

(-lOC)

to

SQOF

(270C)

20W/20

20

20W/40

20 20W/30 20W/40

3/20 3/20

20/W 1320

20W/20 20W/20 20W/40

not

available, then oils

they

give satisfactory ser-

Over

SQOF

20W/40 20W/30

20W/40

1330

20W/40

I27°C)

30 30

30

3/30 3/30

30

30 30

to

the

Abbreviations ofTechnicaJ Tenns Applicable to Service Literature

Where it

down

A glossary

is

found

in British

of

TERM

ampere atmosphere

brake

horse

British

Thermal

centimetre

Cubic

centimetre

cubic

inch

foot

pounds gallon gallons

per gramme gramme hour

inch

kilogramme kilogramme

kilogrammes kilometre litre

mile

millimetre

miles

minute

ounce

pint pound

pound

pounds pounds revolutions second (time) shaft horse square square inch ton tonne volt yard

minute

per

gallon

per

hour

feet per

square inch per

power

centimetre

(I

000

necessary

Standards

such

terms

power

Unit

per

minute

metre

(torque)

per

square

(torque)

minute

kg)

to

use abbreviations in Service

Publications

with

their

{work)

centimetre

1991.

British

Literature

Standard

equivalent is given

GLOSSARY OF TERMS

BRITISH

STANDARD

A

•tm

bhp

Btu em em'

in'

ft

ft lbf/min g•l gal/min

g

gf

h

in

kg

kgf m

1

kgf/cm

km

I

mile

mm

mile/gal

mile/h

min

"'

pi

lh

lbf

lbf ft

2

lbf/in rev/min

'

•hp

em'

in'

ton

I

v

yd

the

units

and

symbols

below

for reference purposes.

REMARKS

or

ampere

similarly for millimetre, etc. similarly for

similarly for

when when

or

inch

similarly for gramme,

or

litre

similarly for similarly for kilometre,

when referring when referring

similarly for

similarly for millimetre, similarly for

if confusion

foot,

pint, referring referring

if

confusion

if

confusion

pint,

ton,

foot,

etc.

litre, etc.

to

gramme mass.

to

gramme force.

litre,

to

pound

to

pound

etc.

yard,

adopted

may

arise.

etc.

may

arise.

etc.

mass. force.

etc.

are those laid

arise.

--------~~~--~~----------

APPROVED SERVICE TOOLS

Available from

as~

8

V.

L.

Churchill & Co. Ltd., Oaventry, Northamptonshire,

~______,a

Tool No.

PD.1D

PD.10-1A

P0.1D-2

VALVE. GUIDE REMOVER AND

REPLACER

ADAPTOR

A

pair

nuts. Suitable for

The necessary adaptors below

ADAPTOR FOR PD.1D

A 20.5

to replace valve guides to a set height.

(MAIN

TOOL)

FOR

of

mm

P0.1D

puller bars fitted with knurled

distance

Should also

(W,"l

J(f'

and

distance

I"

guides.

piece from the

be

piece

uaed.

used

NN11

All Types

All Typea

....

4.107

4.108

4NF,

England.

41

PD.1D-4

P0.1D-5

P0.1D-6

PD.1D·7

ADAPTOR

A 15

used to replace

height.

ADAPTOR A 22.5 mm to replace valva guides to a sat height.

ADAPTOR

A 15

to replace valve guides to a set height.

ADAPTOR A

11!.5 used height.

FOR

PD.10

mm

(19/32")

valVe

FOR

PD.10

U"l

distance

FOR

{19/32")

FOR

(21132")

P0.1D

PD.1D

mm

to replace valve

distance piece

guldn

to a

set

piece used

distance piece used

distance place

guid

..

to a

aet

P3.1<M

3.152

4.192

4.203

,_,..

6.305

V8.510

(Early)

6.354

Attar engine

8522198 general.

M/F. 883981

Horizontal Turbo

8430754

1!.372

•.

154

No.

41

Tool No.

Descrlpdon

AppllceUon

()

PD.10-8

No.8

PD.418

P0.130A

SHORT VALVE GUIDE REPLACER/ ADAPTOR 20

mm (0.787")

PISTON RING SQUEEZER

PISTON HEIGHT GAUGE

A simple method piston height.

FUEL PUMP ALLEN SCREW KEY

Assists. access to the otherwise inaccessible screws on

AND VALVE DEPTH

of

quickly checking

D.PA

pump

V8.510 (Current) V8.540

All

Types

All Types

4.99

4.107

4.108

4.192

4.203

--------

PD.137

P0.138

P0.140

PD.140·1

VALVE GUIDE REAMER

015"

0/size

VALVE GUIDE REAMER

030'"

0/size

CAMSHAFT BUSH/THRUST COLLAR REMOVER

ADAPTOR FOR P0.140

4.236

4.212

4.248

4.236

4.212

4.248

V8.510 V8.540

6.354 Series

6.372

V8.510 V8.540

Tool No.

Description

Appllc.llon

~

I

~

cc=J!]=J

~

p

PD.14G-2

PD.14t

PD.143 VALVE SEAT RETAINING CUTTER V8.510

PD.143·1 ADAPTOR

FUEL PUMP THRUST COLLAR 6.354 Series

REMOVER/REPLACER ADAPTORS

TIMING COVER OIL SEAL REPLACER Used with 550 Driver Handle

AND

ROLLER HANDLE

Use with the appropriate valve seat

cutter

pilot

FOR

P0.143 V8.510

6.372

V8.510

V8.5-iO

V8.540

-~

\\•.

) I l'i

)

,,1,

'

~;;::_

G)

®

G)

~

PD.145

LC.173 INJECTOR SLEEVE EXPANDER

(top)

PD.146 cast iron head to give watertight seal

(bottom}

PD.t47

PD.150A CYLINDER LINER

CRANKSHAFT REAR OIL SEAL All engines wilh REPLACER ADAPTOR

(UP

TYPE SEAL)

Expands the copper sleeve into the

prior to

CRANKSHAFT REPLACER lip type seal. (UP

REPLACER (MAIN TOOL) For Field Service replacement of

single liners. Not advised overhaul. For this

with a

injector

TYPE SEAL}

hydraulic ram unit.

fitting.

REAR

REMOVER/ All types

work

OIL SEAL

for

complete

use adaptors

51" lip

T8.354-3

All

engines with

type seal.

4"

Tool

No.

O.acrlptton

Appllc.Uan

PD.150.1B

PD.15(}5

PD.150·6A

PD.150.7A

ADAPTORS FOR PD.150 Suitable

3.87" dia. Removal and replacement.

ADAPTORS

Suitable Removal and replacement

ADAPTORS FOR PD.150

Used

ADAPTORS U$ed

lor

cylinders

FOR

for cylinders

for

removal and replacement.

FOR

for

removal and replacement.

of

PD.150

of

PD.f50

3.6" dia. and

3.125" dia.

3.152

4.203 A4.212

4.236

6.305

6.354 Series

4.107

4.108

V8.510 VB.540

4.248

6.372

PD.150.10

1556

PD.155-1

PD.155-4A

ADAPTORS

Used to remove and replace cylinder liners

block.

BASIC The cruciform head with multiple holes at

different centres is used with

adaptors

ADAPTORS

Used to remove water pump Also suitable Gears on 4.236. 6.354 and 4.154.

ADAPTORS FOR PD.155A

Used to remove Oil Pump Gear.

FOR

PD.150

with crankshaft in

PUllER

listed below.

FOR

PD.155A

to remove Camshaft

or

out

of the

pulleys.

4.154

All types

3.144

4.203

4.192

3.152

Tool No.

Dncrlptlon

Application

MF.200.26

~QP

~

~~

~

336-101

@

33&-102

WA.TER Used

CON

ARBOR ADAPTOR Used

ARBOR ADAPTOR A4.212

Us~d

PUMP OVERHAUL KIT All engines except

with 370 Taper Base and Press. V8.510

ROD

JIG & 336 MASTER ARBOR All types

with

335 4.107

with

335

V8.540

4.99

4.108

A4.248 A4.270 A4.300 A4

318

4.236

8.354

8.372 V8.510 V8.540

-

~

6118B

PD.6118-1 ADAPTOR FOR 8118B 4.99

P0.6118-3 ADAPTOR FOR 61186 3.144

P0.8118-4 ADAPTOR

VALVE SPRING COMPRESSOR All types

4.107

4.108

4.154

3.152

-4.192

4.203

4.270

4.300

V8.510 V8.540

FOR 6118B

4.236

6.354

4.212

4.2-48

~

Perkins Engine 4-154 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual