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Service ManualD361, DT361,D407, DT407

Diesel Engines

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.

Serv

ice

Man

ual

G55-1346-G

Supplement

361 and 407 SERIES DIESEL ENGINES and

FUEL SYSTEM (Roosa Master)

CONTENTS

Page

SPECIFICATIONS

Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Injection Pump Timing . • . • • . . • . . . . • . . . . . . . . . . • . . . . . . . . . . . . • . . 14 Turbochar ger . • . . . . . . . . . . . . • . . . • . . . . . • . . . • • . . . . . . . . . . • . . . . 14 Fuel Rater Specifications .........•..........................• 15 Special Torques. • . • . . . . . • . . . . . . . • . • . . . • . . . . . . . • . . . . . . . • . • . • 20

Injection Pump

Pump Number

.. .. . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 610 689 C91 610440 C91 702476 C91 702 476 C92 672 711 C91 702 477 C91 702477 C92 672 374 C91 627 083 C91 672 709 C91 625 150 C91 672 737 C91 627 082C9l 702 520 C92

· . . . . • . . . . . . . . . . . • . • . . . . . . . . . . • . . . . . . . . • . . .• 22, 23

· ........................................... J

· .......................................... . · .......................................... .

· • . . • . . . . . . . • . • • . . . . • . • . • • • . . • • . . . . • . . • . • . .. 24, 25 · ........................................... } · .......................................... . · . . • . . . . . . • . • . . . . . . . • • . • • • • • • . . . • . . . • . . . • . .. 26, 27 · ........................................... } · . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . · . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . · ........................................... f 28, 29 · ............................................................................... .. •

Springs (pump number)

610689 C91 .....................•....................•. } 702476 C91 ...•........•.. , ...•.......................• 610440 C91 .••.......•.•..•..•.•...•..........•.....•.• 702 476 C 91 and C 9 2. . . . . . . . . . . • • • . . . . . • . . . . . . . . . . • . . • • . • . • l 702477 C91 and C92 ..•.•........•...... " .............•.... f 672 711 C91 ............•...........•..•................ } 627 083 C91 .......................•................•... 672 374 C91 •..............••................•.......•.. t 672 709 C91 .........................•........••.••.•..• 625 150 C91 .•..•.•..................•...•.............. 672 737 C91 .•.....•.•..................•.•.........•... 672 713 C91 ..•••..•................•....•............•• l 672 373 C91 ...•..................•.•...••..•........... f 627 082 C91 .......................•...•.....•..••...... t 702 520 C92 ............................................ \

Flow Bench Adjustments (pump number)

610689 C91 .•.......................................... J 610440 C91 ........................................... . 702 476 C91 ...............................•............ 702 476 C92 ........................................... . 672711 C91 ....................•.......................

3

30

31

32

33

34

35

36

38

Page Flow Bench Adjustments (pump number) - Continued

702477 C91 ••..••..... . .••. 702 477 C92 .••...•••.. . ...•••. 672 374 C91 •..•.... . ..... . ::::::::::::} 627 083 C91 .......•..• . ..... . 672 709 C91 . . . . . . . ..... . 625150C91 ....•........... 672 737 C91 ................ .

. . . . . . . . } : : : : :: :: : :

672 713 C91 . . . . .. . ........•. 672 373 C91 ........ . ........•.....•. 627 082 C91 .••..... . •.........•..... 702 520 C92 ••..•... . ..•......•.....

Fuel Rater Specifications ..................... .

} }

Injection Nozzles . ........................................ .

Models

Engine

General

Number of cylinders.

Type of cylinder sleeves

Bore and stroke - inches

Displacement - cubic inches

Engine Speed - rpm

High idle

Low idle

Rated load

Compression ratio.

Compression pressure - psi

Cranking speed @ 125 rpm.

Injection pump timing - static

SPECIFICATIONS

ENGINE

806 & 1206 Series

0-361 & OT-361

6

856,1256& 1026 Series

0·407 & OT ·407

6

1456 Tractor

OT-407

6

Replaceable, dry

4-1/8 x 4-1/2

361

2630 ± 10

700 i' 25

2400 i' 10

17: 1

365 - 410

4-5/16 x 4-5/8 4-5/16 x 4-5/8

407 407

2640 ~ 10 (See Note 1)

650 i' 25

2400i' 10

17: 1

350 - 425

Refer to page 14

2640 ~ 10

650 ~ 25

2400 ± 10

17: 1

350 - 425

NOTE 1: High Idle for 1026 is 261 0 ~ 10 rpm.

4

39

40

41

42

43

44

Engine

Models 806 Series 1206 Series 856 Series 1256 Series

Engine 0·361 OT·361 0·407 OT·407

Fuel Rater Specifications

Rated load speed -maximum fuel (lbs./hr.). . . · 45 53 47.5 53

Minimum time {sec. /qt. )'l: • · 140-1/2 119 145-1/2 119

Overload speed -(1800 rpm) max-imum fuel (lbs. /hr. ) . . . · 37 46 38 45

Minimum time (sec. /qt. )'l: • 171 137-1/2 166-1/2 140-1/2

IMPOR TANT: Horsepower, automatic advance and transfer pump pressure are affected by the soft rubber hose used in filling the fuel rator. Shut off valve {FES 97-34} should be installed at the transfer pump test port, when checking or adjusting transfer pump pressure, automatic advance or horsepower. The valve should be opened only enough to obtain a transfer pump pressure reading in making the above checks. When filling the fuel rator the valve should be fully opened.

~~Seconds per quart is based on No. 2 Diesel Fuel weighing 7. 03 pounds per gallon, having approximately 138,200 BTU per gallon and an API gravity of 36".

15

General Contents Page

Special Service Tools Required ....................................... IV

Standard Torque Chart ............................................ VI

Section

III

Section 1

ENGINE

CONTENTS

Specifications

Engine Checks

Valve Lash Adjustment. Valve Timing ...... . Compression Pressure .... .

Special Overhaul Instructions· ..................... .

Engine Removal .............................. .

Mounting the Engine to the Stand (361 and 407 Engines) .. .

Cylinder Head and Valves ..

Crankcase . ............ .

Connecting Rod, Pistons and Piston Rings

Piston Fit In Sleeve . . . . . • . . . . . . . . .

Cylinder Sleeves ................. .

Sleeve and Piston Fitting Procedures ...... . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rebuilt Diesel Engine Run-In Schedule ................... .

Crankshaft and Main Bearings ........................ .

Replacing Main Bearing Caps. • Rear Oil Seal ... . • . . . . . . . Wear Sleeve •.•••....•... Installation . . . . . . . . . . . . . . . . . . . . .

Timing Gear Train and Front Cover ............................... .

Crankshaft Front Oil Seal and Wear Sleeve. . . . . • . . . . . . . . .......•

Camshaft .................................... . ....... .

Lubrication System

Oil Pump ....... . Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Oil Jet Tubes ............................... . Oil Cooler •••.••.•.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cooling System

Water Pump ........•..•.•.......... . . . . . . . . . . . . . . . . . . . . . . .

1-1

Page

1-2

1-10 1-10 1-11

1-11

1-12

1-13

1-15

1-27

1-27

1-29

1-30

1-31 1-32 1-34

1-35

1-36 1-38 1-39 1-39

1-41

1-42

1-44

1-45 1-50 1-51 1-55

1-57

3. Place a .004 inch feeler gauge be­tween the valve lever and valve "stem of the No.1 intake valve and slowly_,,rotate the en­gine forward until the feeler gauge becomes tight. This is the point at which the No.1 intake valve starts to open which should be 25 degrees .± 3 degrees before top dead center.

NOTE: One tooth "out of time" equals approximately 12 flywheel degrees.

4. Readjust the No.1 intake valve to its proper lash of .013 inch.

Compression Pressure

1. Warm up the engine, then remove the injection nozzles from the cylinder head. Install the compres sion test adapter FES 68-6 with a nozzle gasket. Install FES 13-1 gauge with FES 59-1, 2 and 3 adapters. See Illust. 1-3.

2. With the throttle in the shut- off posi­tion, crank the engine with the cranking motor until the pressure gauge reading re­mains constant. Compression pressure should be 365 to 410 psi for the D and DT-361; 350-425 for the D and DT-407 engines.

NOTE: Each 1000 feet altitude will cause compression pressure to be 3 to 3-1;2 percent lower than specified.

Illust. 1-3. Tooling for checking compression pressure.

SPECIAL OVERHAUL INSTRUCTIONS

During reassembly of the overhauled parts of the engine, note and perform the following steps:

1. Cylinder Head Reassembly:

(a) Thoroughly lubricate the valve guides with engine oil.

(b) Dip the valve stems in engine oil.

2. Piston installation:

1-11

(a) Dip the piston and ring assembly in engine oil.

3. General engine reassembly:

(a) Coat all O-rings with l30A Lubri-plate.

(b) Coat all pipe plugs with IH gasket maker.

4. Retorque the cylinder head bolts after approximately 100 hours of operation.

Removal

Illust. 1-21. Removing the valve seat.

If necessary, remove valve seats with valve seat puller or use the large end of a punch to pry out old valve seat (Illust. 1-21). Put the punch under valve seat and tap with hammer. Do not use the sharp end of a chisel as there is the danger of damaging the underside of the seat area, causing a poor contact around the insert or pre­mature cylinder head failure.

Repair

1. Clean the counterbore in the cylin­der head, to insure good heat transfer.

2. If oversize valve seat inserts are to be installed, enlarge the insert counter-

Intake

~_015" t%1'.030" R

Exhaust

015" :030" R

FESM·2464

IIlust. 1-22. Valve seat insert counterbore.

1-21

bore in the cylinder head to the dimension shown in the chart below to obtain the cor­rect fit.

OVERSIZE VALVE SEAT INSERT CHART

Oversize Counterbore Diameter*

Insert Intake Valve Exhaust Valve

Inch Insert Insert

.005 1.995 - 1. 996 1.727 - 1.728

.015 2.005 - 2.006 1.737 - 1. 738

~,<It is not necessary to enlarge the insert counterbore before installing the standard size insert.

Installation

1. Chill the new valve seats with Liquid Freon or in dry ice before installa­tion. This prevents metal scraping from the side of the counterbore, insuring full contact of the insert on the bottom and sides of the counterbore.

Illust. 1·23. Driving the valce seat insert into place.

2. Install new insert using an insert driver as shown in Illust. 1-23. Only two or three light blows with a hammer will be required to set the ring in place.

Section 2

FUEL SYSTEM (Roosa Master Model DB)

For Servicing of the Model RD Injection Pump, Refe:!;, to GSS-1345-B

CONTENTS

Specifications

Special Torques (Nozzle) .

Special Torques (Pump)

Inj ection Pump ..... .

Spring Specifications - D-36l and DT-36l Engines.

Spring Specifications - D-407 and DT-407 Engines.

Flow Bench Adjustments .....••...•......•

Inj ection Nozzles ..... .

Fuel Rator Specifications

General Description and Operation

Filter System •••••••••••..

Factors Affecting Pump and Nozzle Life

The Injection Pump (Roosa Master Model DB)

Trouble Shooting ..... .

Checks and Adjustments

General .......... .

Fuel Shut-Off Adjustment

Governor Linkage Hook Adjustment ..

Transfer Pump Pressure ....... .

High and Low Idle Speed Adjustment.

Throttle Linkage Adjustment ..

Transfer Pump Checks ..... .

Restriction in Suction Side of Fuel System •

Air Leaks in Suction Side of Fuel System ••

Inefficient Transfer Pump or Malfunctioning Pressure Regulator Valve ••••..•••••

2-1

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

Page

2-3

2-3

2-4

2-6

2-7

2-8

2-10

2-10

2-12

2-12

2-12

2-20

2-28

2-28

2-28

2-30

2-30

2-31

2-31

2-31

2-31

2-31

Speed Advance Adjustment.

Fuel Rator Adjustments .............. .

Leaf Spring and Torque Screw Adjustments

Fuel Return Line Check ..... .

Pump Timing and Rotor Rotation

Iniection Pump Service

Pump Removal

Drive Shaft Removal.

Pump Disassembly ..

End Plate AsseIl1bly ....................................... .

Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

End Plate ••••

Transfer Pum.p ......................................•....

Hydraulic Head and Rotor ••.....•••••.•••••••.•.......•••..••

Governor •••••

Cam, Drive Shaft and Pump Housing

Pilot Tubes- ............................................ .

Throttle Shaft Bushing Replacement

Advance Mechanism·

Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . End Plate · . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Head and Rotor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Advance Mechanism. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Governor ••••••

Pump Drive Shaft and Inj ection Pump Installation

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Iniection Nozzles

General Description

Nozzle Service · . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nozzle Testing · . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair. . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . Reconditioning.

Reassembly •.

· . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . · . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking Reconditioned Nozzle.

2-2

Page

2-32

2-33

2-33

2-36

2-36

2-37

2-38

2-38

2-46

2-48

2-48

2-48

2-48

2-49

2-51

2-52

2-52

2-54

2-54

2-54

2-54

2-60

2-62

2-65

2-66

2-69

2-69

2-70

2-71

2-72

2-72

Section 3

CONTENTS

SOLAR MODEL TC-3B TURBOCHARGER Page

Specifications ............................................... 3-2

Description ................................................. 3-3

General Maintenance and Cleaning Procedures ....................... 3-3

Turbine'and Compressor Cleaning p'rocedure . . . . . . . . . . . . . . . . . . . . . . . .. 3-4

Inspection Before Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-4

Preliminary Inspection 3-4

Turbocharger Testing 3-5

Removal . ............... . 3-6

Inspection After Removal 3-7

Disassembly

Compressor Wheel. '. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-8 Compressor Housing ......................................... 3-9 Turbine Wheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-10 Nozzle Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-11 Radial Movement and End Play. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-11 Check End Play. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-12 Check Compressor Wheel, Radial Movement ............. .- . . . . . . . . . . .. 3-13 Removing Compressor Wheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-14 Removing Turbine Wheel Shaft Assembly, Turbine Bearing and

Turbine Back Plate ......................................... 3 -14 Removing Compressor Seal Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-15 Removing Thrust Bearing and Thrust Washer. . . . . . . . . . . . . . . . . . . . . . . .. 3-16 Removing Compressor Bearing and Bearing Spacer. . . . . • . . . . . . . . . . . . . .. 3-16

Inspection of Internal Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-17

Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3 -21

Servicing of Air Induction System in Case

of Turbocharger Compressor Failure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-24

Installation ................................................. 3-25

3-1

Section 4

SCHWITZER MODEL 3LD TURBOCHARGER CONTENTS

Specifications . ....................... .

Description ......................... .

General Maintenance and Cleaning Procedures.

Turbine and Compressor Cleaning Procedure Inspection Before Removal

Preliminary Inspection . Turbocharger Testing.

Removal . ..

Disassembly

Inspection of Internal Parts. Reassembly . . . . . . . . . . . .

Servicing of Air Induction System in Case

of Turbocharger Compressor Failure

Installation ............. .

SPECIFICATIONS

Intake manifold pressure at 2400 rpm, 110 PTO horsepower (with new air cleaner elements) ...•..........

Intake manifold pressure at 1800 rpm (min. overload).

Exhaust manifold pressure at 2400 rpm.

Exhaust manifold pres sure at 1800 rpm.

.. . . . .

Page

4-1 4-2 4-3 4-3 4-4 4-4 4-5 4-6 4-7 4-9 4-11

4-13

4-14

9-tol2psi

7 to 10 psi

10 to 13 psi

5 to 8 psi

Inlet vacuum at rated load (ahead of Turbocharger) ... 20 to 25 inches H 20 (water manometer)

*Exhaust temperature - maximum - degrees F.

Compressor cover cap screw torque - ft. lbs.

Compressor wheel lock nut torque - ft. lbs.

Turbine housing clamp band nut torque - ft. lbs.

*Install pyrometer at the same location as gauge for checking exhaust pressure. Temperatures will rise with an increase in altitude, air cleaner restriction, bad nozzles, or inefficient turbocharger. It should not be allowed to exceed the maximum permitted temperature.

4-1

1100

. 5

13

10