Continental TMD Series TMD13 TMD20 TMD27 Diesel Engine Service Repair Manual

CONTINENTAL DIESEL ENGINES OPERATORS GUIDE & REPAIR MANUAL "-'=' MOTORS, LLC

Good operation and a planned maintenance program as outlined in this manual are vital in ob- taining maximum engine performance and long engine life. The instructions on the following pages have been written with this in mind, to give the operator a better understanding of the various problems which may a rise, and the manner in which these problems can best be solved or avoided. The operator is cautioned against the use of any parts, other than genuine Wisconsin Motors, LLC parts, for replacement or repair. These parts have been engineered and tested for their particular job, and the use of any other parts may result in unsatisfactory performance and short enginel ife. Wisconsin Motors, LLC distributors and dealers, because of their close factory relations, can render the best and most efficient service. THE LIFE OF YOUR ENGINE DEPENDS ON THE CARE IT RECEIVES The MODEL, SPECIFICATION and SERIAL NUMBER of your engine must be given when ordering parts. The MODEL and SPECIFICATION number are on the nameplate. The SERIAL NUMBER is stamped either on the crankcase or the engine’s identification tag. Copy the MODEL, SPECIFICATION and SERIAL NUMBER in the spaces provided below so that it will be available when ordering parts. MODEL SPECIFICATION SERIAL NUMBER To insure prompt and accurate service, the following information must also be given: 1. State EXACTLY the quantity of each part and part number. 2. State definitely whether parts are to be shipped by express, freight or parcel post. 3. State the exact mailing address.

IMPORTANT READ THESE INSTRUCTIONS CAREFULL V All points of operation and maintenance have been covered as carefully as possible, but if further information is required, send inquiries to the factory for prompt attention. When writing to the factory, ALWAYS GIVE THE MODEL, SPECIFICATION AND SERIAL NUMBER of the engine referred to. Starting and Operating New Engines Careful breaking-in of a new engine will greatly increase its life and result in trouble-free operation. A factory test is not sufficient to establish the polished bearing surfaces, which are so necessary to the proper performance and long life of an engine. These can only be obtained by running a new engine carefully and under reduced loads for a short time. -Be sure the engine is filled to the proper level with a good quality engine oil. -For proper procedures to follow when breaking-in a new engine, see 'Testing Rebuilt Engine'. The various bearing surfaces in a new engine have not been glazed, as they will be with continued operation, and it is in this period of "running in" that special care must be exercised, otherwise the highly desired glaze will never be obtained. A new bearing surface that has once been damaged by carelessness will be ruined forever. ,..,' , t

Proper repair is important to the safe and reliable operation of an engine. This Service Manual outlines basic recommended procedures, some of which require special tools, devices or work methods. Improper repair procedures can be dangerous and could result in injury or death. READ AND UNDERSTAND ALL SAFETY PRECAUTIONS AND WARNINGS BEFORE PERFORMING REPAIRS ON THIS ENGINE Warning labels have also been put on the engines to provide instructions and identify specific hazards which if not heeded could cause bodily injury or death to you or other persons. These labels identify hazards which may not be apparent to a trained mechanic. There are many potential hazards for an untrained mechanic and there is no way to label the engine against all such hazards. These warnings in the Service Manual and on the engine are identified by this symbol: Operations that may result only in engine damage are identified in the Service Manual by the word CAUTION. Wisconsin Motors, LLC cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this manual are therefore not all inclusive. If a procedure, tool, device or work method not specifically recommended by Wisconsin Motors, LLC is used, you must satisfy yourself that it is safe for you and others. You should also ensure that the engine will not be damaged or made unsafe by the procedures you choose. IMPORTANT SAFETY NOTICE IMPORTATNT the information, specifications and illustrations in this book are on the basis of information available at the time it was written. The specifications, torques, pressures of operation, measurements adjustments, illustrations and other items can change at any time. These changes can effect the service given to the product. Get the complete and most current information before you start any job. Continental Distributors/Dealers have the most current information which is available. For a list of current Distributors/Dealers, refer to directory LIT1017 or www.wiscosninmotors.com. WARNING ! 1

WARNING ! Most sub-systems used in conjunction with Wisconsin Motors, LLC industrial engines including, but not lim- ited to, radiators, hoses, fans fuel tanks, fuel lines or other fuel systems components, hydraulic pumps and generators, are not supplied by Wisconsin Motors, LLC, but are provided by the manufacturer of the end item in which the eingine is used. Some of the dangers assoicatied with servicing such items are generally mentioned in this manual; however, the appropriate handbooks and safety instructions procided by the manufactureer of the end item should always be consulted prior to undertaking any work on sub-systems attached to the engine, to avoid any hazards inherent to these sub-systems. Read and observe all individual safety warnings as you use this manual to operate, service or repair your engine. Always exercise caution whenever working with an engine or any associated system. Injuries may be caused by lack of care when working with, or near, moving parts, hot parts, pressurized systems, electrical equipment, or fuel systems. Always wear eye and hearing protection when working on or near engines. Improper attire such as loose clothing, ties, rings, soft shoes or bare feet could be hazardous and should be avoided when servicing engines. Use or service of the engine (including the use of modified parts or materials) not in accordance with manufacturer’s specifications could damage your engine or cause personal injury. Starting fluids or aids such as ether or gasoline must not be used in a diesel engine air intake system. The use of these fluids will cause severe internal engine damage and/or bodily injury. Some equipment and materials used in the overhaul or maintenance of an engine such as machine tools, electrical equipment, compressed air, solvents, diesel, gasoline or other fuels may be dangerous and can cause injury. Always observe safety precautions associated with these items. WARNING ! WARNING ! WARNING ! 2

CONTENTS CONTINENTAL INDUSTRIAL ENGINES SECTION 1 General Information ................................................................... Page 5 SECTION 2 Operating Instructions ................................................................ Page 7 SECTION 3 Lubrication ............................................................................... Page 13 SECTION 4 Cooling System ........................................................................ Page 15 SECTION 5 Fuel System .............................................................................. Page 21 SECTION 6 Charging System ...................................................................... Page 32 SECTION 7 Preventive Maintenance ........................................................... Page 34 SECTION 8 Engine Repair & Overhaul ....................................................... Page 39 SECTION 9 Trouble Shooting ...................................................................... Page 61 SECTION 10 Torque Specifications ............................................................... Page 67 SECTION 11 Limits & Clearance Data .......................................................... Page 69 INDEX ........................................................................................... Page 71 3

MADE IN USA WISCONSIN MOTORS, LLC MEMPHIS TENNESSEE TME27 08500 1001

Section 1 - General Information CONTINENTAL DIESEL ENGINE Continental Diesel Engines are Comet V combustion chamber indirect injection diesel engines. The combustion chamber design has been tailored for the required turbulence, charge flow and burning characteristics to provide depend· able and economical heavy duty service. Some of the principal design features are: 1. Individual Porting - of the intake manifold whereby each cylinder is fed with the air charge individually and is not influenced by other cylinders of the engine. This is accomplished by casting the cylinder head with individual intake valve passages for each cylinder and connecting these passages to an intake manifold which also has individualized passages for each cylinder. f. Water Jackets - completely surround all J;ylinder bores to a depth sufficient to cover the hot piston ring travel, resulting in minimum bore distortion for good oil control yet maintaining low heat rejection to the coolant. CHOICE OF FUELS - Continental Industrial Diesel Engines have been tailored for heavy duty operation for use with #1 or #2 diesel fuel that meet a minimum cetane number of 45 (see fuel recommendations, page 29). OHV Design Individual Porting 5

Wal'" Hellde, - ___ _ CylindQ, HeI.d------_ In_IIII"", ------ ..... -----41 W8tsr Jacket ---------- Connecting Rod Heel T,eoled Alloy ConnQCllng ROd, M&Jn s..."no Cep & Cyhnde, He.d Bolls at! PlIn'----~ all Pump Plck-cln" Cross section of typical Contlnantallndustrial Diesel JC'I,linde, Head eo.e, :..._---- p,QCOmbustion Ch.moo, 1 ... ",,1 .,,)n)<>C1:lon Pump Oro.en G. -'C;a",,"'al1 Gea, 'Irll''':IIO,nPump Orlye Gea, 'C,.nksh"ftGea,

Section 2 - Operating Instructions The person operating the engine naturally as- sumes responsibility for its care while it is being operated. This is a very important responsibility since the care and attention given the engine goes a long way in determining how long a period it will operate satisfactorily before having to be shut down for repairs. The operating and preventive maintenance instructions for the Diesel Engines are simple and should be followed without deviation. The entire aim in setting forth these instructions is to give you a benefit of the knowledge and expe- rience gained over a long period of collaboration between Engineering Research and Field Service. PREPARATION OF A NEW ENGINE FOR OPERATION Before placing a new engine in operation, it must be thoroughly inspected for external damage and particular attention paid to the following items: 1. Close water drain cock - on the side of the block. (In some cases, this may be a pipe plug.) Water Drain Cock Fill radiator and water jacket with coolant. (See Cooling System Section 4). Radiator Coolant Inlet 2. Fill Crankcase with oil - Use the oil recommended for the ambient temperature (see chart on page 14). 3. Fill Fuel Tank - See fuel recommendations on page 29. ~WARNING Stop engine before checking battery terminals or electrical connections. Sparks or flames near a battery could cause an explosion or fire. Battery acid can cause corrosive burns. Always wear eye protection. Use of jumper cables or battery charging should be done only as directed by manufacturers' safety instructions. Read and observe safety warnings on pages 1 and 2. 4. Electrical Connections - Check storage battery terminals and all electrical connections. STARTING THE ENGINE ~WARNING Bodily injury or death may result to individuals during operation of an engine within any enclosure not adequately or properly ventilated. En- gine operation in any enclosure requires ad- equate and proper ventilation to avoid asphyxia- tion or other interruption of normal breathing. To supply sufficient air to cool the engine, provide air to mix with fuel and to carry away heated air from the building. Read and observe safety warnings on pages 1 and 2. If the engine is new or rebuilt or if fuel filters have been serviced or any low pressure lines discon- nected, fuel system must be bled to remove any air that may have become trapped in the system. Bleed the entire fuel system. Detailed instructions for bleeding the injection systems are given in section 5. 7

Continental TMD Series TMD13 TMD20 TMD27 Diesel Engine Service Repair Manual

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