Escolar Documentos
Profissional Documentos
Cultura Documentos
2000
BASIC ENGINE
0-155, D-179 3 D-206 1 0-239 3 D-246 9 D-268 9
D-310 9 0-358, DT-239, DT-358, DT402 Engines
453 10 824. 834. 744 Crane 16 784/785 16/ 4/2.5 1630 A. 1730 A,
18
V/E 433, WE 53310 TD 7E, 100 E P.S. 12 84 Hydr. 16 1830 A
WE 533 Series II 10/ 8/2.5 125 GD/P.S. 14 2781T 16 Acer> 1 820 with
18
S.D. b33 10 H 30 B. Galion Cr. 16 AT - 540
633/633 V + E SlI 14/ 8/2.2 574 G.D. 12 884/885 16/ 8/2.5 725 SP 14
-13-
INJECTION PUMP EP/VA VE
2. Position the engine on the compression stroke num- For static degrees of the engine, see "Technical
ber one cylinder (intake and exhaust valves are Data".
closed).
5. Read the graduation on the front pulley as outlined in
1. Remove central plug from distributor head and mount lIlust. 195.
dial indicator with extension (2), lIlust. 193 a. Rest
stylus of the indicator on the face of the distributor
plunger and pro-load approx. 3 mm.
Illust. 1 93b
lIlust. 193 a.
1 - Pointer on roller ring
1 - Dial indicator 2 - Scribe line on face cam
2 Extension (special tool 1329 159C1)
3 - Packing ring 6. With static timing correct, both pointers (Illust. 1 93b
and 1 94) must be in line with their respective
4. Slightly turn the crankshaft to and fro to find the bot- timing marks.
tom dead centre of the distributor plunger.
Note: On EP/VA pumps the face cam has a second
5. With the distributor plunger in BDC, zero the dial scribe line marked with letter "L". Do not use this scribe line
indicator, for adjustment.
-91-
INJECTION PUMP EP/VA VE
Removal
. I
Illust. 194
DC 10 2W
Must. 196
1
\2 3 1 Drive shaft nut
2 - Hub
Illust. 195 3 - Hub cap screws (three)
-91a-
INJECTION PUMP EP/VA - VE
Remove rectangular cover plate from the crankcase front Installing and Timing the Pump to the Engine
cover.
The engine must be in static timing position (first cylinder
on compression stroke and timing pointer lined up).
Remove nut (1) lllust. 196 and hub capscrews (3).
Proceed as follows:
1. Remove cover plates of the injection pump (Illust.
Note: Turn engine if necessary to place keyway in "up 1 93b) or mount dial indicator (lIlust. 1 93a). Remove
Position" (eleven oclock) to prevent the Woodruff-key cover plate of the front cover (lllust. 196).
from dropping into the oil pan, when the hub is removed.
/- Must. 199
CIW
Engine front plate 2 - Gasket
lllust. 197
Pulling hub from drive shaft 2. Apply liquid sealer to both sides of new gasket (2)
Illust. 199.
Remove gear with hub from the shaft, lIlust. 197.
3. Place woodruff-key into keyway of injection pump
Remove injection pump retainer nuts, using a special drive shaft.
wrench extension for loosening the inner nut, see Illust.
198, 4. Turn keyway in 11 oclock position and install the
pump.
Note: When removing the injection pump be sure mating
gears (pump drive gear - idler gear) are not disengaged Note. The following step 5 A. does not apply for DT-
to maintain the original timing. 402 engines equipped with water channel version (1)
Must. 200. On these engines position the pump as
shown in Must. 201, step 5 B.
,.
. $.
..
0 0
Illust. 200
lllust. 198 OT-402 engines
1 - Water channel, pump position according to
1 - Stud nuts (two) step 5 B
2 - Washers (two) 2 - Water pump carrier, injection pump postition
3 - Wrench, with extension (special tool 3055 700RT) according to step 5 A
INJECTION PUMP EP/VA - VE
SA. Positioning the pump so that washers (2) lIlust. If the engine is on number one compression at the
198 cover slotted holes of pump flange evenly, i. e. specified static timing and the injection pump is installed
the pump is level. with 1.0 mm plunger stroke the pump will be timed".
IN
1
Illust. 203
1 - Hub
2 - Hub retainer bolts, with washers
-z 3 - Keyway (in 11 oclock position)
-
7. Install hub (1) Illust. 203, use quality bolts (six lines
Illust. 204) and steel washers.
Must. 201
VE-Injection pump position on Tighten bolts (2) I [lust. 203 slightly.
DT-402 with (1) Illust. 200
F6 F-6
1 Stud 3 - Engine
2 - Slot 4 - Injection pump, VE
-
lllust. 204
lIlust. 202
2 1 3 4
1 - Injection pump drive gear
2 - Timing marks Must. 205
1 - Hub
Note: Since the idler gear is a walking gear, proper timing 2 - Hub retainer nut, with lock washer
alignment (2) Illust. 202 will not always be noted. 3 - Bolts, hub to gear
-93-
INJECTION PUMP EP/VA - VE
8. Install lock washer and nut (2) Illust. 205 Checking Injection Pump Timing with Dial Indicator
(pumps with timing window)
Block the engine and tighten nut (2), observe the dif-
ferent special torques for the respective nut size: )
Illust. 208
lIlust. 207
94 -
INJECTION PUMP EP/VA - VE
Note: (VE-pumps only). When connecting the fuel lines, The feed pumps is a diaphragm-type pump driven by the
make sure to use the fuel return valve (5) lllust. 211 on engine camshaft. It can also be operated manually on
the pump return port. hand lever (6) lIlust. 209 to fill the fuel system or for
venting purposes.
Fuel Feed Pump
14
lIlust. 209
_95-
INJECTION NOZZLE HOLDER
Installation <"
4j
A. Flange Mounted Holder
lllust. 211
Place the nozzle crabs into position and install the dish-
ed washers and crab bolts.
Illust. 210
Tighten the bolts (3) to specified torque.
1 - Nozzle holder seat capped up 2 - Nozzle holder
Connect the fuel supply pipes and the fuel return line
to the nozzle holders.
B. Crab Mounted Holder
Tighten pipe union nuts and fuel return hollow screws to
Clean sleeves in cylinder head and install nozzle holders specified torque, refer to "Special Nut and Bolt Torque
using new 0-rings. Data".
1111"I
TIMING GEAR TRAIN
Adjustment
78
A - B
AA BB
lllust 212
IlIust. 212 shows the gear train of a 6-cyl.-engine with Note: Marks on injection drive gear are for easy assem-
piston number one on compression bC. bly. It is not essential that the timing marks of injection
pump drive gear be aligned for proper timing.
The injection pump drive gear (3) is marked with num However, the following timing instructions should be used
bers 1 up to 6. to facilitate gear installation.
TIMING GEAR TRAIN
Illust. 212 a.
3 - Cylinder Engines
Engines with water channel A, use timing, mark 1.
Cylinder Engines
Engines with water channel A. use timing mark 2.
6 - Cylinder Engines
Engines with water channel A, use timing mark 5.
Engine: D 179 Application: 2400 A G. D., 2454 G. D., 4500 A, 454 G. 0., 3400 A G. 0.,
(Britain), 240A S.M./G.D. (Britain), 484 (xxx), 248 (xxx)
Timing Advance
Maximum fuel at rated load speed kg/h (Ibs/hr) ............................ 8.98 ( 19.8)
Minimum time sec/1000 ccm (sec/qt) * 337 (319
Fuel at 2100 rpm engine speed kg/h (lbs/hr)............................... 8.57 ( 18.9)
Minimum time sec/1 000 ccm (sec/qt) * 352 (333
Fuel at minimum overload speed kg/h (lbslhr) ............................. 6.26 ( 13.8)
Minimum time sec/1000 ccm (sec/qt) 483 (457
Fuel temperature at overflow line OC )0F) 47 (116.5)
* US qt
(NEZG 2836)
Engine power, fuel consumption and charging pump pressure + 3 %
5-19
Flow Bench Test Specifications
Correction of Control Specifications acc. to "Bosch" Test Instruction VDTWPP 161/4 or Pre-Adjusting Dimensions
see "Bosch" Repair Manual VDTWIP 161/4
Plunger Lift to Port Closure 0.3 ( 0.02 mm ( 0.04 mm)
Static Timing Alignment of the Pointer at 1 mm Plunger Stroke (ref. to Outlet A)
Delivery Difference
1. Control Specifications RPM
cu.cm./1000 Strokes
1.1 Injection Advance 600 3-4 mm
1.2 Charging Pump Pressure 600 0.4-0.45 MPa
cu.cm.
1.3 Full Load Delivery 800 65.5-66.5 2.5
1170 (30-40)
1080 66-69 (66.5-69.5)
800 (65-67) 55-100(40-110)
500 68 - 72(67 - 73)
Stop 1100 0
Idling Position Full 460-510
0
(4 40- 530)
375 (14-24)
Start 100 mm. 95 Opening Pressure
220(200) min. 95 20MPa
340 (360) max. 60
(NEZG 2775)
5-20
PERFORMANCE DATA
Engine: D-179 Application: 454 HS, 464 HS/GD, 240A HS/TC, 2400A HS, 2454 HS,
3400A HS/GD (U.S.), 4500B TC, 506
(NEZG 2835)
5-21
Flow Bench Test Specifications
Correction of Control Specifications acc. to "Bosch" Test Instruction VDTWPP 161/4 or Pie-Adjusting Dimensions
see "Bosch" Repair Manual VDTWIP 161/4
Plunger Lift to Port Closure 0.3 0.02 ( 0.04) mm
Static Timing Alignment of the Pointer at 1 mm Plunger Stroke (ref. to Outlet A)
Stop 1200 0
Idling Position Full 490-540
0
( 470 - 560)
400 (10.0-20.0)
Start 100 mm. 95 Opening
220 (200) mm. 95 Pressure
340 (360) less than 60 20 MPa
(NEZG 2776)
5-22