Section

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

J I Case co Printed in England

A Tenneco Company Don 8-59030 November. 1987
 SPECIFICATIONS

Static Timing (Degrees BTDC) *

D-155 VA/VE/PS O - 239 0 246 VAJV E/ PS * 0-358 *

423, E-423 10 DT - 239 VAlVE/PS 824 18 DT-358 VANE

383 10 724, 734 14 834 18 1055, 955 19

500C/E 12 824.744. S.U. 16 844 18 1056. 956 14/ 8/2.2

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 433 Series II 8/ 8/2.5 TB 8 C. P.S. 12 2681T 16 531. 541. (8--ill) 18

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

5033 12 H-3OBNice, 16 1730B-1930B 18

433 8/ 8/2.5 321.431 12 0-268 VA/VE/PS Galion 102 Grader 16

533/385 10/ 8/2.5 Ingersoll-Rand 16 844 S 8/ 8/2.5 DU-2D 16

5000/5500 W.R. 16/ 8/2.8 845 - 8/ 8/2.5 H-60 16
1130/1 230 TOE 12 620 B 8 Series 200 ATk. M.T. 18
D-179 VAlVE/PS 743, 745 S/833 16/ 8/2.8 510 18 1046 16

553 14 574H.S. 16 TD-8CA 8 1521 S 18

633/633 V + E SlI 14/ 8/2.2 574 G.D. 12 884/885 16/ 8/2.5 725 SP 14

4500 B T.C. 14 3654, 3654 S.U. 14 270 A 16 H65B 17

454 G.D./454 ItS. 14 3500 A G.D./H.S. 14 866 -- HS (Austr.) 16

464 GD/U.S. 14 674 G.D. 14 3964/3965 18

3654 S . U. 14 2500AG.D. 12 D-310 VA 3980 16
484. 248 IT 485 14/ 8/2.2 1258 u. TD-8B 946 (2100 RPM) 16 515 16
12
SU-644-LD 14 Ser. II 946 (2200 RPM) 10 976, 986. 886 (U.S.) 18

2454 GD/U.S. 14 S.U. 644 H.D. - 686 14 S-8A.SlO 16

14/ 8/2.8
240A SM/U.S/CC. 14 4WD- 766 10 Ii-60B,520A 16

3400 A G.D./H.S. 14 3400 B S.M. 955 12 It-65C 16

18
2400 A GD/I -IS. 14 H.S./f.C. 431, 531 16 530A 16

Irrigation Unit 14 684/685 16/ 8/2.8 H SO B 12 943 18

506 14 2574G.D. 12 DU-2D 16 953 - 16

250 A. SM. 12 0 1500 C 18 923 16
260 ATC SM./H.S. 18 - 616/622 H.S. 16 933 18
D - 206 VAlVE/PS Irrigation Unit 18 711 S.P Header Harv. 10 1420/782 --/10
554. 654. 644 12 2500 AH.S. 14 165C 8 3990 16
221 14 2574 H.S. 14 696 14 650 16
TD-7CG.D. 12 250A H.S./T.C. 14 1 3820 A 14 3980 8/3984 B 20
100 G.D. 12 856 XL /8 9000 F. L. 14 630 18
733/733 V + F SIt 12/ 8/2.8 833 V + [ / 8 715 Comb. 12 280 PH 20
474 G.D/H.S. 14 782 Couon Picker 16 1246 16 -
100 B Series II 10 786 10 1255 /8
584/585 121 8/2.8 86 Ilydr. 8 786 18
TD-68 10 1400 /12
100 B. 624 10 Irrigation Unit 16
25811 12 640(D-358) 16
624 (Mexico) 12 640 )DT 358) 20

VA = Machines with VA Injection Pump 5208 /10

VIE = Machines with VIE Injection Pump 8581
PS = Plunger Stroke total stroke of injection plunger in mm with a
tolerance of 0.02 mm (pumps without timing window only). DT-402 VIE
3994, 650 HO 16
953 ItS. 953 GB 16
1455 14
53OASH 16

-13-
 INJECTION PUMP EP/VA
General:
This section consists of the following subsections:
Checking Static Timing
Removal
Installing and Timing the Pump to the Engine
Checking Timing with Dial Indicator
For all other service instructions refer to service Manual
"Fuel System. Injection Pump and Turbocharger".
Checking Static Timing:
It is good practice to check static timing of the injection
pump before removing it from the engine.
Note: The dial indicator method A) may be used with all
injection pumps, whereas Method B) is restricted to
pumps with timing window: Illust. 193b.
A. Dial Inidicator Method
1. Shut off fuel supply.
2. Position the engine on the compression stroke num-
ber one cylinder (intake and exhaust valves are
closed).
1. Remove central plug from distributor head and mount
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.
lIlust. 193 a.
1 - Dial indicator
2 Extension (special tool 1329 159C1)
3 - Packing ring
4. Slightly turn the crankshaft to and fro to find the bot-
tom dead centre of the distributor plunger.
5. With the distributor plunger in BDC, zero the dial
indicator,
-91-
VE
6. Slowly turn the crankshaft in direction of the rotation
until the dial indicator shows 1.0 mm travel of the
distributor plunger.
7. Read actual degrees of static timing on crankshaft
pulley, see lIlust, 194 and 195, and compare with
"Technical Data",
8. (Pumps without timing window only). Turn the engine
to check the total plunger stroke and compare with
timing specifications. If out by more than 0.02 mm
repeat steps 4 - 8.
B. Timing Window Method
1. Shut oft fuel supply,
2. Remove lower cover plate of the pump. Illust.
193 b.
3. Position the engine on the compression stroke num-
ber one cylinder (intake and exhaust valves are
closed).
4. Turn the crankshaft in direction of rotation until the
timing pointer (1) Illust. 194 is in line with the
specified timing mark (2) on the graduation.
For static degrees of the engine, see "Technical
Data".
5. Read the graduation on the front pulley as outlined in
lIlust. 195.
Illust. 1 93b
1 - Pointer on roller ring
2 - Scribe line on face cam
6. With static timing correct, both pointers (Illust. 1 93b
and 1 94) must be in line with their respective
timing marks.
Note: On EP/VA pumps the face cam has a second
scribe line marked with letter "L". Do not use this scribe line
for adjustment.
 INJECTION PUMP EP/VA VE

Removal

Thoroughly clean the left side of the engine to prevent

dirt from entering the pump. Cap or plug all lines and
ports as they are opened.

Remove the injection pipes. Disconnect all lines from

the pump.

. I

Illust. 194

1 - Pointer 2 - Graduation on the front pulley

DC 10 2W

Must. 196

1
\2 3 1 Drive shaft nut
2 - Hub
Illust. 195 3 - Hub cap screws (three)

One graduation mark = 2 0

1 - TDC mark 2 100 BTDC 3 20 BTDC

-91a-
 INJECTION PUMP EP/VA - VE
Remove rectangular cover plate from the crankcase front
cover.
Remove nut (1) lllust. 196 and hub capscrews (3).
Note: Turn engine if necessary to place keyway in "up
Position" (eleven oclock) to prevent the Woodruff-key
from dropping into the oil pan, when the hub is removed.
/-
lllust. 197
Pulling hub from drive shaft
Remove gear with hub from the shaft, lIlust. 197.
Remove injection pump retainer nuts, using a special
wrench extension for loosening the inner nut, see Illust.
198,
Note: When removing the injection pump be sure mating
gears (pump drive gear - idler gear) are not disengaged
to maintain the original timing.
,.
. $.
..
0 0
lllust. 198
1 - Stud nuts (two)
2 - Washers (two)
3 - Wrench, with extension (special tool 3055 700RT)
Installing and Timing the Pump to the Engine
The engine must be in static timing position (first cylinder
on compression stroke and timing pointer lined up).
Proceed as follows:
1. Remove cover plates of the injection pump (Illust.
1 93b) or mount dial indicator (lIlust. 1 93a). Remove
cover plate of the front cover (lllust. 196).
Must. 199
CIW
Engine front plate 2 - Gasket
2. Apply liquid sealer to both sides of new gasket (2)
Illust. 199.
3. Place woodruff-key into keyway of injection pump
drive shaft.
4. Turn keyway in 11 oclock position and install the
pump.
Note. The following step 5 A. does not apply for DT-
402 engines equipped with water channel version (1)
Must. 200. On these engines position the pump as
shown in Must. 201, step 5 B.
Illust. 200
OT-402 engines
1 - Water channel, pump position according to
step 5 B
2 - Water pump carrier, injection pump postition
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".

5 B. On DT-402 engines with water channel (1) I Ilust.

200 take care to tilt the injection pump toward the However, if the complete timing gear train has been re-
engine all the way within the play of the flange slots moved, the timing of the gear train must be reset as
(2) lIlust. 201 before tightening. shown in lIlust. 212.

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

6. Tighten stud nuts (1) Illust. 198 to specified torque.

-
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: )

M - 12 = (19 mm spanner) 6 - 7 daNm

M 14 = (22 mm spanner) 8.5-10 daNm

9. Loosen bolts (3).

Illust. 208

1 - Graduation marks, pulley

Illust. 206
Adjusting the injection pump
10. Turn the injection pump drive shaft until the pointer on
the roller ring is in line with the scribe mark on the face
cam lIlust. 207 or the dial indicator shows 1.0 mm
plunger stroke, lIlust. 1 93a.
2 - Pointer shows degrees of timing as specified
3 - Pointer on roller ring
4 - Scribe line on face cam
5 - Extension (special tool)
6 - Dial indicator, shows 1.0 mm plunger stroke
If the position of timing pointer (1) lIlust. 207 is in doubt or
if scribe mark on face cam cannot be clearly seen check
pump timing with dial indicator, following method A. See
also Illust. 1 93a

At this point tighten the retainer bolts to specified tor-

que. See "Special Bolt and Nut Torque Data".

Finally turn the engine through a complete cycle and

check to make sure that the timing of the front pulley
at compression stroke coincides with that of the face
cam lIlust. 207 or with the 1.0 mm plunger stroke
shown on the indicator lIlust. 1 93a.

lIlust. 207

1 - Pointer on roller ring 2 - Scribe line on face cam

94 -
 INJECTION PUMP EP/VA - VE

Note: (VE-pumps only). When connecting the fuel lines,
make sure to use the fuel return valve (5) lllust. 211 on
the pump return port.
Fuel Feed Pump
The feed pumps is a diaphragm-type pump driven by the
engine camshaft. It can also be operated manually on
hand lever (6) lIlust. 209 to fill the fuel system or for
venting purposes.

A filter screen is installed in the feed pump to primarily

filter the fuel from the fuel tank. When servicing the
engine it is good practice to remove the filter screen. Use
a soft brush and carefully clean in Diesel fuel, On reas-
sembly make sure all parts seat properly to avoid leaka-
ge. Install a new feed pump if the diaphragm is damaged
or the operating mechanism is defective.

Install plug (11) using liquid sealer.

10

5 Note: The fuel feed pump is attached to the crankcase

side cover by means of an additional flange with two
studs. To prevent dropping the flange into the crankcase
13 on removal or installation, stud nuts should be cauti-
ously removed and installed respectively.

14
lIlust. 209

_95-
 INJECTION NOZZLE HOLDER

Installation <"
4j
A. Flange Mounted Holder

Place the sealing 0-ring approx. 6 mm (24 in.) above the 5\ ) /2

nozzle holder nut, them install the nozzle holder.

Make sure the 0-ring is not twisted

Tighten stud nuts or necked-down bolts in two steps to

specified torque.

lllust. 211

.1 1 - Nozzle holder 4 - Fuel return line

2 - Crab 5 - Return valve
3 Bolt 6 Return line

Make sure hollow screws, show to the valve cover,

Must. 211.

Illust. 210
1 - Nozzle holder seat capped up
B. Crab Mounted Holder
Clean sleeves in cylinder head and install nozzle holders
using new 0-rings.
Place the nozzle crabs into position and install the dish-
ed washers and crab bolts.
Tighten the bolts (3) to specified torque.
2 - Nozzle holder
Connect the fuel supply pipes and the fuel return line
to the nozzle holders.
Tighten pipe union nuts and fuel return hollow screws to
specified torque, refer to "Special Nut and Bolt Torque
Data".

1111"I
 TIMING GEAR TRAIN

Adjustment
78

A - B
AA BB
lllust 212

1 - Crankshaft pinion 6 End play of camshaft =

2 Idler gear 0.09-0.44mm(.0035.fl173in.)
3 Injection pump drive gear 7 - Scribe mark on pump flange (displaced)
4 Camshaft drive gear 8 Front plate
5 End play of idler gear = 9 Injection pump hub
0.20 0.33 mm (.0078 -.0130 in.) 10 Idler gear carrier

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.

If the engine is on number one compression at the

On all engines the timing marks of gears (1) and (4) must
specified static timing and the injection pump is installed
be in line with the timing marks of the idler gear (2).
with the injection plunger at 1.0 mm stroke. the pump will
be timed.

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

Timing Instructions for Injection Pump Gear (3) IlIust. 212

(Part Numbers 3055 066 R3, 3056 885 R3, 3218 450 Ri)

Illust. 212 a.

3 - Cylinder Engines
Engines with water channel A, use timing, mark 1.

Engines with water pump carrier B, use timing mark 3.

Cylinder Engines
Engines with water channel A. use timing mark 2.

Engines with water pump carrier B, use timing mark 4.

6 - Cylinder Engines
Engines with water channel A, use timing mark 5.

Engines with water pump carrier B, use timing mark 6.

 Fuel Rator Test Specifications

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)

Injection Pump "Bosch" EP/VA31100H 1100 CR-62 (3 144 402 R91)

Pump speed ....................................................1/2 engine speed

Low idle speed - engine ............................................750
High idle speed - engine ............................................ max. 2455
Rated load speed - engine ..........................................2200
Minimum overload speed - engine .....................................1600
Max. torque daNm (ft.lbs) at 1600 engine rpm .............................18.3
Rated kW (HP) at engine rated load speed ................................38

Timing Advance

Static timing - engine, degrees BTDC ...................................14

Total advance - engine, degrees BTDC ..................................25.9
Start to advance - engine rpm ........................................380
Pump advance at minimum overload engine speed
(travel of advance piston) mm (inch) ....................................4.7 (.19)

Full pump advance (travel of advance piston) mm (inch).......................5.4 (.21)

Charging Pump Pressure, at:

Low idle, MPa (PSI) ...............................................0.29 (43)

Minimum overload speed, MPa (PSI) ....................................0.50 (73)
Rated load speed, MPa (PSI) .........................................0.57 (85)
Max. permissible vacuum at inlet side of pump kPa (PSI) ......................20 (-2.9)

Fuel Ra tar Specifications

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

Engine: D 179 Rated Speed: 2200 RPM

Application: 2400 A G.D., 2454 G.D., 4500 A, 454 G.D., 3400 A G.D. (Britain), 240 A S.M./G.D.
(Britain), 484 (xxx), 248 (xxx)
Injection Pump I H CNo. BoschNo.
3 144 402 R91 EP/VA3/100H 1100 CR-62

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

1.4 Idler-Governor Run-Out 375 16 - 22 " 3

1.5 Start 100 mm. 95 " Opening P. 20 MPa
1.6 End-Governor Run-Out 1170 31 - 39
2. Check Data and in Brackets (Re-check Data)
2.1 Injection Advance RPM 160-300 (120-330) 600 820.970 (790-1000)
mm Begin (2,7-4.3) End (5.2-5.9)
2.2 Charging Pump Pressure RPM 200 600 1100
MPa 0.16-0.21 (0.14-0.23) (0.38-0.47) 0.61-0.66 (0.59-0.68)

2.3 Feed Quantity

Speed Lever Feed Lever Overflow Quantity
RPM cu.cm ./1000 Strokes
End-Position Full cu.cm./10 sec.
1190-1240
10
0

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

Shim thickness under advance piston spring 2 mm

Pre-load length of governor spring 24.6 mm

(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

Injection Pump: EP/VA31100H 1200 CR 61 (3 144 403 R91)

Pump speed .......................................................... 1/2 engine speed

Engine speed:
low idle ..................................................... 1 /min 700-800
high idle ..................................................... 1 /min 2710
rated load .................................................... 1 /min 2400
minimum overload .............................................. 1 /min 1600
Rated power at rated load speed ......................................... kW 39
Max. torque at minimum overload speed .................................. daNm 18.5
Torquerise ........................................................ %
Static timing - engine ......................................... degrees BTDC 14
Start to advance - engine speed ....................................... 1/min 650
Total advance - engine ........................................ degrees BTDC 27.9
Pump advance at minimum overload speed .................................. mm 3.1
Full pump advance at rated load speed ..................................... mm 6.3

Charging pump pressure at:

low idle .......................................................kPa 248
minimum overload speed ............................................kPa 448
rated load speed ..................................................kPa 675
Max. permissible vacuum at inlet side of pump ................................kPa - 20

Fuel rator specifications:

Fuel consumption at:

rated load speed ................................................. kg/h 9.7
time......................................................... s/I 314
1 00/min below rated speed .......................................... kg/h 9.3
time......................................................... s/I 328
minimum overload speed ........................................... kg/h 6.9
time......................................................... s/I 440
Turbocharger, boost pressure at rated speed .................................. kPa

Engine power, fuel consumption and charging pump pressure + 3 %

(NEZG 2835)

5-21
 Flow Bench Test Specifications

Engine: D-179 Rated Speed: 24001rn/n

Application: 454 H.S., 464 H.S./G.D., 240A H.S./T.C., 2400A H.S., 2454 H.S.,
3400A H.S./G.D. (U.S.), 4500B, T.C., 506
Injection Pump IHCNo. BoschNo.
3 144 403 R91 EP/VA3/100H1200CR61

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)

1 . Control Specifications 1/mm.

I Delivery Difference
cm-_/_1000_Strokes
1.1 Injection Advance 800 3.9 - 4.9 mm
1.2 Charging Pump Pressure 800 480 - 530 kPa
cm3
1.3 Full Load Delivery 800 68 -69 2.5
1000 Strokes
1.4 Idler-Governor Run-Out 400 12 - 18 " 3
1.5 Start 100 mm. 95 " Opening P. 20 MPa
1.6 End-Governor Run-Out 1250 34 -42
2. Check Data and in Brackets (R e-chec k Data )
2.1 Injection Advance 11mm. 200-350 (170-380) 800 980-1130(950-1160)
mm Begin (3.6-5.2) End (6.0-6.7)
2.2 Charging Pump Pressure 1/mm. 200 800 1200
kPa 160-210 (140-230) (460-550) 630-680 (610-700)
2.3 Feed Quantity
Speed Lever Feed Lever . Delivery Overflow Quantity
mm.
End-Position Full cm 3 / 1000 Strokes cm3 / 10 sec.
1290-1340
10.0
0.
(1275-1355)
1250 (33.0-43.0)
1150 69.0-72.0 (68.5-72.5)
800 (67.5-69.5) 55-100 (40-110)
500 67.0-71.0 (66.0-72.0)

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

1: Shim thickness under advance piston spring 1.6 mm

2: Pre-load length of governor spring 24.6 mm

(NEZG 2776)

5-22