D155, D179, D206, D239, D268, D310, D358, DT239, DT358 ......Diesel Engines Covered D155, D179, D206...

Serv

ice

Man

ual

Service Manual

THIS IS A MANUAL PRODUCED BY JENSALES INC. WITHOUT THE AUTHORIZATION OF INTERNATIONAL HARVESTER OR IT’S SUCCESSORS. INTERNATIONAL HARVESTER AND IT’S SUCCESSORS

ARE NOT RESPONSIBLE FOR THE QUALITY OR ACCURACY OF THIS MANUAL.

TRADE MARKS AND TRADE NAMES CONTAINED AND USED HEREIN ARE THOSE OF OTHERS, AND ARE USED HERE IN A DESCRIPTIVE SENSE TO REFER TO THE PRODUCTS OF OTHERS.

D155, D179, D206, D239, D268, D310, D358, DT239,

DT358 & DT402 Diesel Engines

IH-S-ENG D155

http://www.jensales.com/products/international-harvester-service-manual-ih-s-eng-d155.html

Diesel Engines CoveredD155, D179, D206D239, D246, D268

DT239, DT358, DT402

Models of Equipment with this engine.385 Hydro 84685 Hydro 86

375 WindRow 100C385 100E454 125C464 125E484 165

544 (RC) 250A TLB544 Utility 260A TLB

554 270A TLB574 280A584 500-C Crawler585 500-E624 510 Front End Loader644 510B664 510C674 515684 515C685 520B686 2400A/B706 2405B

715 Combine 2410B724 2412B744 2500A/B756 2505B784 2510B824 2514B826 3400A844 3500A

844s 3514884 3820A

1420 Axial Flow Combine 4500A Fork Lift1620 Axial Flow Combine 4500B Fork Lift

3088 90003288 S-8A

D268 4 Cyl TD-7CD239 TD-7ED268 TD-8C

D310 6Cyl TD-8ED358 6Cyl


Shop Man

0·15511191206 0·23912461268 0·3101358 OT ·239/358/402 DIESEL ENGINES

Compiled and Reproduced From Originals by Jensales Inc.

CGES-310-1


Longitudinal and Cross Section

Technical Data

Service Tools

Special Nut and Bolt Torque Data

Identification o f different Bolts

Valve Lever Assembly

TABLE OF CONTENTS

Camshaft. Idler Gear, Tappets and Push Rods

Cylinder Head, Valves and Valve Guides

Intake Manifold

Exhaust Manifold

Crankcase Front Cover and Front Plate

Crankcase, Oil Pan, Flywheel Housing

Crankshaft, V -Belt Pulley

Balancer

Flywheel w ith Ring Gear

Piston, Cylinder Sleeves and Connecting Rods

Oil Pump

Water Pump

Thermostat and Coolant Manifold

Fuel System

Fuel Injection Pump (VAl

Fuel Injection Pump (VE)

Injection Nozzle and Holder

Fuel Filters

Feed Pump

Injection Pipes

Venting the Fuel System

Tuning-Up

Checks Run-in Schedule

Handing over the Engine

Alternators

Generator and Regulators

Starting Motor

Turbocharger

CG ES-3'0- ' PR INTED IN UNITED STAT ES OF AMER ICA


.... 1

3

6

8

10

11 ,. 21

33

34

35

37

44

61

67

70

81

86

90

.2 94

125

172 17. 180

180

180

181

187

190

190

191

20. 218

234


II

INDEX

A Page .... Alternators and Regulators 191 Injection Nozzles 172 Alternators Operating Instructions 192 Injection Pipes 180 Alternators Trouble Shooting 197 Alternators Servicing "G , " 198 INJE CTION PUMP (VA) 94 Alternators Servicing "K'" 205 Operation 95 B Checks and Adjustments 99

Servicing and Tools 106 Balancer 61

Removal 110 Balancer Drive Gear 53

Disassembly 110 Balance Weights 55 Installation 183

Static Timing 183 Bearing Inserts 50 Timing with Dial Indicator 185 Blow-by Values • Bolt and Nut Identification 10 INJECTION PUMP (VE) 125

C Operation 130 Testing and Adjustments 161

Camshaft and Idler Gear ,. Servicing 135 Connecting Rods and Pistons 70 Tools 169 Crankcase Front Cover 35 Removal 126 Crankcase and Oil Pan 37 Disassembly 137 Crankcase Coonterbore Resurfacing 41 Installation 126 Crankcase Pressure Chart 4 Static Timing 126 Crankshaft. Regrinding Instruction 48 Timing with Dial Indicator 129 Crankshaft and V-belt Pulley 44 Aneroid 154 Cylinder Head 21 Cylinder Sleeves 70 M Cylinder Sleeve Protrusion 40/74

0 Manifold, Coolant 90 Manifold, Exhaust 34 Manifold, Intake 33 Data, Engines 1 Main Bearing Bolt Identification 10 Data, Special Nut and Bolt Torque 8 Main Bearing Caps 37 Delivery Valves (VA) 98

Delivery Valves (VEl 138 N

E Nozzles and Holders 172

Electrical Equipment 190 Nozzle Holder Sleeves 29 Engine, Checks 187 Engine, Data 3 0 Engine, Longitudinal and Cross Section 1 Engine, Handing over 190

Oil Pan 37 F Oil Pump 81

Oil Seal, Front 35 F" 84 Oil $eal, Rear 51 Flywheel 67 Flywheel Housing 37 P Fuel Feed Pump 180 Fuel Filters 179 Pistons and Connecting Rods 70 Fuel System 92

G R

Generators and Regulators 209 Run-in Schedule 190

CGES-Jl0-l PRINTED IN UNITED STATES OF AMERICA

Compiled and Reproduced From Originals by Jensales Inc_


s Special Nut and Bolt Torque Data Starting Motor (JO) Starting Motor (JF) Starting Motor Troubleshooting Static Timing Chart

T

Tools, Engine Technical Data, Engines Thermostat Timing Gear Train Tuning-Up Turbocharger Turbocharger, Troubleshooting

INDEX - Continued

..... 8

218 232 224

5

6 1

00 181 181 234 243

v

Valve l ever Assembly Valves and Valve Guides Valve Lash Valve TIming V-Belt Pullev Venting the Fuel System Vibration Damper Voltage Regulator. Alternator Voltage Regulator, Generator

w

Water Pump

CGES·31O· ' PRINTED IN UNITED STATES OF AMERICA


III

..... 10 21

185 187 58

180 58

195 212

86


1 - Piston r ings 2 - Piston, 3-ring type 3 - Cylinder sleeve 4 - Connecting rod 5 - a·ring 6 - Valve lever 7 - Valve, exhaust 8 - Valve seal 9 - Valve stem guide

10 - Valve seat insert, exhaust 11 - Valve push rod 12 - Valve tappet 13 - Camshaft 14 - Oil pan 15 - Balancer

LONGITUDINAL SECTION OF ENGINE (4-Cylinder Engine)

Blust. 1 Ref. Nos. apply equally to IlJust. 1 and 2

16 - Oil suction Screen 17 - Oil drain plug 18 - Oil pipe 19 - Oil pump 20 - Idler gear 21 - V-.belt pulley 22 - Vibration damper (if used) 23 - Idler gear carrier 24 - Water pump 25 - Thrust bearing. crankshaft 26 - Rear oil seal retainer 27 - Flywheel ring gear 28 - Flywheel 29 - Nozzle holder 30 - Heating pipe

CGES-31Q-l

31 - Manifold. intake 32 - Front plate, crankcase 33 - Gear. injection pump 34 - Starting motor 35 - Filter, fuel 36 - Oil filler neck 37 - Oil filter 38 - Oil filter socket 39 - Oil pressure switch 40 - Breather 41 - Feed pump, fue l (if $0 equipped) 42 - Manifold, exhaust 43 - Thermostat (short coolant manifold)

PRINTED IN UNITED STATES OF AMERICA

Compiled and Reproduced From Originals by Jensales Inc_


2

ENGINE

p.155 -179 ·206 DT-239

-246 ·268 -310 / DT·358 T-402

CYLINDER

3 3

• • • 4 6 6 6

CROSS SECTION OF ENGINE (4-CYlinder Engine)

1lIust.2

BORE STROKE

mm In'" mm In'"

98.' 3.875 111.1 4.375 98.' 3.875 128.5 5.059 98.' 3.875 111.1 4.375 98.' 3.875 128.5 5.059 98.' 3.875 128.5 5.059

100 3.937 139.7 5.500 98.4 3.875 11 1.1 4.375 98.4 3.875 128.5 5.059

100 3.937 139.7 5.500

CG ES·31 0·1 PRINTED IN UNITED STATES OF AMERICA

DISPLACEMENT

Litre Cubic Inch

2.54 155 2.94 17. 3.38 206 3.92 23. '.03 246 4.40 268 5.06 310 5.87 358 6.59 402


DIMENSION '~A'_'

mm Inch

424.18 16.70 458.72 18.06 424.18 16.70 458.72 18.06 458 .72 18.06 464.32 18.28 424. 18 16 .70 458.72 18.06 464.32 18.28


TYPE

Direction of rotation, facing flywheel ComprHSion ratio

Compression at starting speed, MPa (PSI) Firing order

0-155, 0-179 0 - 206,0-239,O-246,O-268,DT -239 0 - 310,0-358, OT -358, DT -402

Valve clearance. engine hot

COOLI NG SYSTEM

Most favOf'able operating temperature

AIR SYSTEM

Max. permissible restriction before servicing the air deaner

LUBRICATING SYSTEM

Oil pressure at rated speed, Pa (PSI) Oil pressure at low idle speed and 9tTC (194· F)

oil temperature, Pa (PSI) lubricant Oil consumption, less than

INJECTION SYSTEM

Injection pump Nozzle opening pressure: Flange mounted nozzle holder, MPa (PSI) Nozzle opening pressure: Crab mounted nozzle holder, see "Nozzle Holder Combinations" Page 177

ELECTRICAL SYSTEM

Altemator

Starting Motor

CGE5-310-1

3

4-Cycle-Diesel-Engines

L.H. 16:1 (except 0-268 and DT -402)

15:1 (0-268 and OT -402) 2.2-2.4 (313-341)

1-3- 2 1-3-4-2

1-5-3-6-2-4 0.30 mm (.012 in.l

9O"-95"C (194--203"F)

635 mm (25 inch) of water

303-414 (44-601

min. 90 (12.8) see "Operator's Manual"

1 g!HP hr

Robert Bosch Rotary

20-21 (2845-3000)

"Bosdl " 14 V-2B A 14 V-35 A 14 V-55 A 2B V-27 A 28 V-45 A

"8osd1" 12 V 3kW (4 HP) 24 V 4kW (5.3 HPJ

24 V 4.8kW (6.4 HP)

PRINTED IN UNITED STATES OF AMERICA



4

Crankcase Pressure and Blow-by Chart

Max. Crankcase Preswre Max. Permissible Blow-By

Engine (Hiah Idle, No Load) - - at Engine Idling at ff~~ L.oad mmH?J in HzO ReM cu; m.Jhr (cu. ft./hr) cu. m./hr (cu. fr.thr)

0·155 38 1.5 1500 1.0 ( 35,3) 2.0 ( 70.6) 2500 1.5 ( 53.0) 2.5 ( 88.0)

0·179 38 1.5 2'00 1.5 ( 53.0) 2.0 ( 70.6) 2500 1.5 I 53.0) 2.5 ( 88.0 )

0-206 51 2.0 2100 1.5 I 53.01 2.5 I 88.01 2500 1.5 ( 53.oi 3.0 (l06.0)

·D·239 5' 2.0 2100 1.5 ( 53.0) 2.5 ( 88.0)

He·239 114 4.5 2200 1.5 ( 53.0) 2.5 f 88.0)

DT·239 152 6.0 2500 2.0 ( 70.6) 3.5 (123.0)

0·246 51 2.0 2500 2.0 ( 70.6) 3.0 (lO6.0) 200 2.0 ( 70.6) 3.5 (123.0)

2500 2.0 ( 70.6) 3.0 (106.0) 0-268 51 2.0 2200 1.5 I 53.0) 3.5 (123.0)

2300 2.0 ( 70.6) 3.5 (123.0)

0·310 64 2.5 2400 2.0 I 70.61 3.S 1123.01 3000 2.0 ( 70.6) 4.0 (141.0)

0-358 127 5.0 2200 1.5 ( 53.0) 3.0 (106.0) 3000 2.0 ( 70.6) 4.0 (141.0)

DT·358 165 6.S 2200 4 .0 1141.0) 6.0 (212.0) 2500 4.0 (141.0) 6.0 1212.0)

DT-402 165 6.S 2200 2.0 ( 70.6) 3.0 (106.0) 2500 2.0 ( 70.6) 3.0 (1 06.0)

-With rectangular top ring • -vlith full keystone top ring

NOTE: Refer to "Checks" for testing procedure and proper tools.

IMPORTANT

Pressure readings obtained must not be used as the main source of en~ne condition. Oil consumption trend data must also be used if the pressure readings are beyond the specified limits. Neither changes in oil consumption trends nor crankcase pressure trends can establish a specific component problem but are only indicators that some problem exists.

CG ES-31 ().1 PRINTED IN UNITED STATES OF AMERICA



D 155 • 423.E-423 10 383 10 500 C/E 12 453 10 V/E-433,V/E-533 10 VIE 433 Series II 8 VIE 533 Series II 10 S.U. 533 10 5033 12 433 8 533 10

D 179 553 14 633 14 4500 B T.C. 14 454 G.0 ./454 H.S. 14 464 G.D./H.S. 14 3654 S,U. 14 484 248 IT 14 SU-644-LD 14 2454 G.D./H.S. 14 240AS.M/H.S./T.C. 14 3400 A G.D./H.S. 14 2400 A G.D.lH,S, 14 Irri ation Unit 14

Static Timing (Degrees BTDC) •

"

u. TO-B8 I '2

'4 '8

D 246 • !'_ - 3.sa. 824 18 DT - 358 834 18 1055.955 844 18 1730 A , 784 16 1830 A

1"8",4",H",Ydd",~. __ _f-,1",6_1 1531. 541.18-11 268 IT 16 Acco 1820 w ith 2781: 16

•

14

18

18

18

o 268 H-ilO 16 844 S 8 845 8 620 8 8 510 18 TO-8 CA 8 884 16 270A 16

Seri., 200 ATk. M.T. 1046 1521 S '25SP H 65 B

18

16 18 14 17 16

r-'D..----3""10.-------r----, i= :: 946 (2100 RPM) 16 16 94612200 RPM) 10 -ilA.S-lO 16 686 14 IA 16 766 10 IH-65 , 16 955 12 530 A 16 431 , 531 16 1943 18 H 508 12 1953 16 DU 20 16 n3 16

~D~-~'~500~C~-_f~1~8_1 1~933=_---~1.><-i8 616/622 H.S. 16 11420 10 711 S,P. Header Harv. ~

l6se 696 I 3820 A 9000 F.L. 715 Comb. 782 Cotton Plcker 786 86 Hydr.

10 13990 16 1650 16

8 13980 18 20 14 1630 18 14 1280 PH

~~ (4,,---6 ___ +~ 16

'0 B ,- Un;,

1640 ) - 358) 1640 r - 358)

DT 402 3994,650 HO 953 HS, 953 GO 1455 530 AS II

16 16 14 16

CGES-310-1 PRINTED IN UNITED STATES OF AMERLCA


5


11 VALVE LEVER ASSEMBLY

\I1ust.4 General

The valve lever assembly receiyes its lubrication through the hollow vatve lever shaft. Oil holes are provided in the valve lever shaft (5) lIIurt. 5 to lubricate individual valve levers.

An oil port is provided in the shaft which must tine up with the respective oil-way in the bracket. The mark (3) lIIust. 9 must be in line with the clamping slot of the front bracket. Replaceable oil plugs (24) lIIust. 4 are used to close up both ends of the shaft.

Valve lellers for intake and exhaust valves differ in length but are provided with the same replaceable bushings which must be reamed to size after installation.

Replacement levers are supplied with bushings in place.

Specifications

Removal and Disassembly

Thoroughly clean the engine externally.

Remove valve housing cover.

Remove nuufram studs (1) Illust. 5 and lift the complete valve lever assembly clear of the cylinder head. Loosen clamping bolu (2) and press in brackets slight ly towards the center, taking care they do not slide off the shaft, resulting in levers and springs, etc. being scattered all over the floor. Slide all parts off the shaft and place them on a table in removal order to faci litate correct reassembly.

IIlust. 5

1 - Stud nuu 2 - Clamping bolts 3 - Bracket, front 4 - Bracket, rear 5 - Spring

In bracl<eu ( ) max. permissible wear before reconditioning.

Valve lever shaft, dia

Valve lever bushing, dia

Clearance on shaft

21.593-21.568 mm '"' .850-.849" (0.03 mm - .0012" out of round)

21.615-21.640 mm" .851 - .852" (0.03 mm - .0012" out of round)

0.022-0.062 mm - .0009-.0025"

Radius on contact end (3) lIIust. 6 (+ 0.5 mm - .020") 12.70 mm '"' .050"

Hardness on radius Depth of hardness

Spring (12) lIIust. 4, Free length Test length Test load

CG ES·31 0-1

RC55 0.8 mm ... 031"

37.7 mm= 1.48" 25.0 mm" 1.00"

29N c 3 kg:: 6.6 Ibs.

PR INTED IN U NITED STAT ES OF AMERICA



24

Removal and Disassembly

The cylinder head can be rmeoved without removing injection nozzles, intake- exhaust -and water manifolds. However, disassembly is necessary when cleaning intake and exhaust bores.

It is also possible to remove the cylinder head without removing the valve lever assembly. If the cylinder head is removed without removing the nozzle holders, it must be supported on wood blocks to prevent damage to the nozzle tips.

When the engine is overhauled however, it is recommended that above mentioned components be removed prior to taking the cylinder head off, so that the cylinder head can be properly cleaned and inspected.

Clean the engine externally. Mark disassembled parts, such as valves, valve stem guides and springs and place them on a table in removal order to facilitate reassembly.

lIIust. 30

1 - Alternator 2 - Injection pipes 3 - Nozzle holders 4 - Fuel return line 5 - Intake manifold

On the left hand engine side remove .components (1) to (5 ) Illust. 30.

Plug all openings of injection pump, injection pipes, fuel line and nozzle holder to prevent entry of dirt into the fuel system.

• • : ,

lIIust. 31

1 - Exhaust manifold 2 - Water manifold 3 - Valve housing cover

On the right hand engine side remove components (1) to (3) IIlust. 31.

Proceed as follows:

Illust.32

1 - Valve lever shaft brackets 2 - Studs 3 - Clamping bolts

Remove valve lever assembly, Illust. 32.

lIIust. 33

Take out valve push rods, lIIust. 33.

CGES-310-1 PRI NTED IN UNITED STATES OF AMERICA



lIIust.34

l oosen cylindef head bolts evenly and alternately after checking torque value.

NOTE: To avoid warpage do not remove cylinder head unless the engine has cooled down.

lII ust.35 Removing valves

To remove valves compress valve springs with compresor tool and take out spring retainer locks, Illust. 35.

Cleaning, Inspection and Repair

Clean cylinder head thoroughly.

Remove carbon deposi ts from the bottom of the cylinder head and out of exhaust valve ports.

Flush out water jacket to remove scale and dirt.

NOTE: Make sure water passages are free of obstructions, rust or scale.

Inspect cylinder head (including nozzle bore/valve seat area) for hair cracks, using modern spraying methods, lIIust. 36.

lI1ust. 36 Crack check

I1lust.37

25

Inspect the cylinder head (and the crankcase) for war' page, if engine has been run with a blown head gasket .

. iIIust. 37.

Observe checking pattern, lIIust. 38, see "Specification".

• , , , 2

---------

,

---- ---------- ----, lIIust.38

'0".9

----------

Checking pattern, cylinder head and crankcase

, ,

s

6

If more than a 0.12 mm (.0047 inch) feeler gauge can be entered under the straightedge, the head (not the crankcase) may be reworked to true up on possible warpage or d istortion.

NOTE: Check the cylinder head height before reworking.

Do not reface the head, if its minimum allow' able reconditioned height is below specified limits.

Replace distorted or cracked head. CGES·31o-1

PR INTED IN UNITED STAT ES OF AMERICA



D155, D179, D206, D239, D268, D310, D358, DT239, DT358 ......Diesel Engines Covered D155, D179, D206...

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Transcript of D155, D179, D206, D239, D268, D310, D358, DT239, DT358 ......Diesel Engines Covered D155, D179, D206...