This shop manual contains the specification, con struction, operation, adjustment and service proce dures of the Model 6D22, diesel engine for service mechanics engaged in servicing of t
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0 0
ENGOME
...............................................
1 1
I Í E1
LUBRBCATI0IM .............................. FUEL AMP ENGUWE COMTRO L ..... .
0
0
he Mitsub ishi
diesel engines. Please make the m ost of this shop m
GENERAL
anual to p erform
correct servicing and wasteless operations. Note that some of the contents of this shop manual are subject to change owing to improvements, etc. that may be introduced after publication of this shop
COCLIMG
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DMYABÍE AMB EX HA US T ENGBME ELECTRBCAL
1 4
..... ....... ...
1 5
........ ...... ....
1 6
manual.
CLUTCH .......................................
? 1
SPECOAL EQ UIPM ENT
6 1
MAR. 1989
Ap pl ic ab le En gi ne M od el s 6D22 1 6D22-T 6D22-TC
[
J
For
indus trial
use
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ORGANIZATION-
1. GROUP
CL A SSIFICAT
GRO UP CLASSIFI CATION
ION
This manual is organized into several groups classified according to the engine basic elements. Group name
No. General
External view, major specifications, engine outputs classified by application, engine numbers, caution plate, general precautions for servicing, general bolts and nuts tightening torque table
11
Engine
Engine proper (cylinder head, valve mechanism, camshaft, piston, crankshaft, timing gear, flywheel), specifications, service standards, special tool, troubleshooting
12
Lubrication
Lubrication system (oil pump, oil filter, oil cooler), specifications, service standards, special tool, troubleshooting
13
Fuel and engine control
Fuel system (injection pump, injection nozzle, fuel filter, pump drive case, water separator), specifications, service standards, special tool, troubleshooting
14
Cooling
Cooling system (water pump, thermostat, radiator, cooling system cleaning procedures, fan), specifications, service standards, special tool, troubleshooting
15
Intake and exhaust
A ir cle ane r, tur bo ch ar ge r, aft er co ole r, sp ec ific at ion s, se rv ice st an da rds , sp eci al to ol , tro ub le sh oo tin g
16
Engine electrical
Starter, alternator, preheating system, relays, automatic stop device, specifications, service standards, special tool, troubleshooting
21
Clutch
Clutch proper, bearing case, specifications, service standards, special tool, troubleshooting
61
Special equipment
A ir co m pr es so r, ai r pr es su re go ve rn or , sp ec ifi ca tio n, se rvi ce sta nd ard s, spe cia l to ol
No mi n al v alue Shows the nominal dimensions, dimension of an individual part, standard clearance between parts in an assembly, or the standard performance of an assembly.
L im it Shows the value of a part at which the part is no longer serviceable from the performance as well as strength viewpoints, requiring replacement or repair.
(4) Tightening Torque Over- or undertightening of bolts and nuts has critical effects on performance and functions. Tightening torque is therefore specified for some tightening points. Al l tig h te n in g t o rq u e s pec if ic at io ns m ay be c o ns id ere d as " d r y " un le ss " w e t " is s pe ci fi ed . Where no tightening torque is specified, use a torque value specified in the General Bolts and Nuts Tightening Torque Table. (5) Units For length, weight, area, and volume, the SI unit (International System of Units) is used with the metric notation jo in tl y s h o w n in pa re nt he se s. Temperature is shown in centigrade (°C).
l Indicates that the disassembly procedure is explained in the text.
C2337C
4
ORGANIZATION
REA DI NG
THE
I
LL USTRA
TI ON
(Ex. 2: Reassembly)
(1) Illustrations ings)
sho w
(exploded a typic al
views and assem bly draw-
service
proc edur es
i f it
is
identical
amo ng various
types of
available
systems
and units. 5
00
CONTENTS
1. EXTERNA L VIEW 2.
........................ ............ CA TIONS ..........
MAJO R SPEC IFI CA TIONS
2.1
MAJ OR SPE CIFI
2.2
ENGINE
OUTP UTS
BY APPLICATION
2
3.
3
4.
3
5.
......................
4
GENERAL PRECAUTIONS FO R SERV ICI NG
CLA SSIFI ED
...........................
ENGINE NUMBERS AND CAUTION PLATE
3
..... .
GENERAL BOLTS AND NUTS TIGHTENING TORQUE TABLE
5 6
00-1
00 i.
G E N E R AL
E X T E R N A L V IE W
EXTERNAL VBEW
Natural-a spirate d engine>
A0 243 A
A0 244 A
00-2
G EN ER AL
2» MA JOR 2.1
- M AJ O R
00
SP EC IFI CATI O NS
SPEC IFICAT ION S
MA JO R SPEC0F1CAT1O MS Engine model
Item Type
C o m b u s tio n m e th o d
C ylin d e rbo rexs tro ke T o tadl is p la ce m e n t
6D22-T (Turbocharged)
D iesel, 4 -cycle , w a te r-c o o le d
Diesel, 4-cycle, w a te r-co o le d
Diesel, 4-cycle, water-cooled
D ire ctin je c tio n
Direct injection
D irectin je c tio n
No. and arrangement of cylinder
6 in -lin e mm cc
6D22-TC (Turbocharged, with after cooler)
6D22
in -lin e 6
6 in-line
130 x 140
130 x 140 11149
11 149
130 x 140 11
149
Engine dimension (without fan) Overall length
mm
1 390
1 390
Overall width
mm
898
872
882
Overall height
mm
1 023
1 162
1 209
Empty weight
kg*
980
1 010
1 015
1 401
* Empty weight as measured according to Mitsubishi Motors Corporation standard.
2.2
ENGINE
OUTPUTS
CL A SSIFI ED BY AP PLICA TION Engine model 6D22
6D22-T (Turbocharged)
Ap pl ic at io n Intermittent rated output
Continuous rated output
6D22-TC (Turbocharged, with after cooler)
kW(HP)/rpm
kW(HP)/rpm
109 (1461/1 500
161 (2161/1 500
179 (2401/1 500
129 (1731/1 800
186 (2491/1 800
207 (2771/1 800
141 (1891/2 000
195 (2611/2 000
219 (2341/2 000
149 (200I/2 200
201 (269I/2 200
227 (3041/2 200
99 (1321/1 500
146 (1961/1 500
163 (2181/1 500
117 (1571/1 800
169 (2261/1 800
188 (2521/1 800
128 (1711/2 000
178 (2381/2 000
199 (2671/2 000
135 (1811/2 200
183 (2451/2 200
206 (2761/2 200
MOTE: 1. Tine ou tpu t {S AE, gros s) I s co rrec ted to standard ambient conditions based on SAE J1349. 2. The continuous rated o utpu t allows 10% tone hour) overload operation.
00-3
00 3. ENG INE PLATE (1) Engine
GENERAL
-
ENG INE
NUM B ERS
AND
NUMB ERS
AND
CAUTION PLAT E
CAU YOON
Num ber VAL VE CLEA RAN CE ( CO LD) ______ 1 INLE T 0 .4 mm ( 0. 0 l6 in U EXHAU ST0. 6m m(0.0 24 in) ------ 2 FIRING OR DE R 1 -5-3-624FUELINJECTION TIMINGEZTBTDC-
3
1 Valve cle arance 2 Firing orde r 3 Fuel injec tion tim ing B9012A
The engine number is stamped on the position as illustrated. Ex: 6 D 2 2 - 0 1 2 3 4 5
-------------------------Engine number ----------------Engine model The engine number is important in knowing the history of the engine.
(2 )
Caution Plate
E0175
The caution plate is located as illustrated. The caution plate bears the valve clearance, fuel injection sequ ence and timing.
00-4
GENE RAL -
4.
GRO UP PRECA
G EM EFAL PRECAUTI ON S
UTI ONS
FOR
SERVI
CI NG
FO RS E R »
WOCONG
Before starting the service procedures, check the vehicle for total time driven, use conditions, and user's complaints and requests to know exactly the engine conditions. Record information where neces sary. To ensure you are doing correct and efficient service
MITSUBISHI MOTORS
GEwuiiE .
V__ __
m m s
jo bs , ob se rv e th e f o ll o w i n g pre c au ti on s :
A0 006 A
(7) The oil seals, packings, O-rin
gs, and other rub
ber
parts, gaskets, and split pins must be replaced with a new one whenever they are removed. For replace ment, use Mitsubishi Genuine parts.
(1) Before performing the service procedures given in this manual, know the trouble spots and isolate the possible cause to determine whether the removal or disassembly procedure is required. (2) Select a flat surface for the service job. (3) When servicing the electrical system, be sure to disconnect the negative cable from the battery. (4) Careful ly check parts for oil lea ks before cleaning. A f te r cl ea ni ng , it m ay bec o m e d if f ic u l t to s po t de fe c
(8) Apply the specified grease to U-packings, oil seals, dust seals, and bearings before installation.
tive areas. (5) Ready and make the most of the special tools
(9) When work requires an assistant or two, always
required for servicing. Use the right tools (specified
make sure of the safet
special tools) in the right place to prevent damages to
switches and levers. (10) Make sure that your shoes are free from grease
parts and personal injury. (6) Make alignment marks and keep disassembled parts neatly arranged to ensure that they are reas Sp ec ia l ca re must b e tak en for assemb lie s involv ing a number of parts, similar parts, or parts identical at right- and left-hand sides to ensure For alignment a
nd punch ing marki ngs, s ele ct a
position that would not mar the appearance and Cle arl y di stingui sh part s t o be
ff
(12) Special care must be taken in handling sensors and relays which are suspectible to shocks and heat. (13) Use ca re so that hands and fin
gers are not injured
(14) Wear saf ety goggles whenever
handling a
grinder
or welding machine. Wear gloves as required to ensure utmost safety.
(11 ) When chec king or chan ging lubricants, wipe o
by sharp edges or corners of the parts.
correct reassembly. ®
and oil especially when working on a heavy item. grease and oil from parts immediately with a waste.
sembled into the right positions. ®
y each other. Never play with
rep lac ed fro m
those reused. 00-5
GENE RAL GENE RAL B OLT S AND NU TI GHTEN ING TORQ UE TABLE
00
5. GEMEI3AL BOLTS AM® MUYS TIGHTEMDMG TORQUE TABLE Unless otherwise specified, the parts and equipment of vehicle must be tightened by the following stan dard bolts and nuts. Tightening torques for these bolts and nuts are shown below.
........ 1. GENERAL 2 ........ 2. SPECIFICATIONS 8 3. SERVICE STANDA RDS .............. 9 ..... 3.1 SERVICE STAN DAR D TAB LE 9 3.2 TIGHTEN ING TORQUE TABL E ... 12 ..................................... 13 4. SPECIAL TOOL
5.3
5. SERVICE PROCEDURES 5.1 MEA SUREMENT OF COMPRES SION PRESSURE ...... ............ ...... 5.2 CYLON DER HEAD AND VAL VE ......... MECHANISM 5.2.1 Di s as s em b ly ................... ....... 5.2.2 Inspection ....... 5.2.3 Reassembly
PARTS ...... 5.4.1 Disassembly .......... 5.4.2 Inspection 5.4.3 Reas se m b ly .... ..... .... .... .... .... ... 5.5 INSPECTI ON AND ADJ USTMENT ............. OF VAL VE CLEARANCE ................... 6. TROUBLESHOOTING
...................
17 17 18 18 21 27
FLYWHEEL , TIMING GE AR AND ................................... CAMSHAFT ................................ 5.3.1 Disassembly ................................... 5.3.2 Inspection .............................. 5.3.3 Disassembly 5.4 CRANKCA SE AND MAIN MOVIN G
..............................
30 30 34 38
42 42 46 56 62 64
11-1
11
ENGI NE -
1. Q EI^Efm
GENE RAL
iL
(1 ) Com bus ti on
Chamber
For more
effec tive cooling of th
e com bustion
cham
ber, water directors which direct coolant flow are pressed into the bottom of the cylinder head.
(2) Valve
The combustion
chamber
is made up of t
Mech anism
he cylinder
head and piston top. The injection nozzle as well as the nozzle tube is mounted to the cylinder head. The nozzle tube holds the nozzle in position and protects the nozzle sheathed by it from coolant. Since the outside of the nozzle tube is exposed to the water ja ck et , th e to p en d o f th e tub e is se al ed o f f w it h an O-ring and the bottom end staked to prevent entrance of water. Combustion
is accompli shed by compressing the fue
l
directly injected into the combustion chamber.
The valve mec
hanism
is of overhead valve type and is
constructed as shown above.
11-2
ENGI NE (a) Both
11
GEN ER AL
in let and ex haus t valves are ma de of
surface-treated heat-resistant steel. The valve seat angle is 45 . A v al v e s te m seal is p ro v id e d on th e st em of v al v e to control the quantity of lubricant of the valve and valve guide sliding portions. (b) The valve springs are unevenly-pitched springs. Two inner and outer springs different in coiled direction are installed. (c) The rocker and rocker
shaft are sup por ted on the
rocker shaft bracket and are independently installed for each cylinder. Som
e rockers are used for both inlet
B0378A
and exhaust valves, and the end sliding portion is quenched.
(b) The coolant fed in
The rocker shaft is a hollow round rod sealed off by
front end of the crankcase cools the oil cooler, then
from the water pu mp at the left
thrust plates at both ends. The inside of the shaft
flows through the water jacket holes and around all
constitutes an engine oil passage.
the cylinders to cool them before reaching the
(d) A steel ball and concave piece are respectively welde d to the botto
m and top ends of
the push rod
cylinder head. (c) The cylinder liner is
of remo vable we t type and it s
and both ends are case-hardened.
top and bottom are press-fitted at the top of the
(e) The tappet is of
crankcase and the water jacket in crankcase, respec
cylindrica l shape and its mating
surfaces with the camshaft are spherical. The tappet is removable through the side of the crankcase. (f)
The cam prof ile of the
cam sh aft has a special
tively. Rubber rings and O-rings are installed at the top and bottom of cylinder liner to prevent entry of coolant.
curve. The surface is induction-hardened to improve
The water jacket has a coolant throttling shelf for
the performance of the valve mechanism at high
higher cooling performance.
speed operation and improve wear resistance.
(4) Pastora asid Pastora Rarag
(3) Crankcase and Cylinder Liner
(a) Pastora
(a) Seven camshaft bushings are installed to the
The piston, made of alu
cams haft bearing p
toroidal type combustion chamber at its top.
ortion
of the crankca se. To facili
min um alloy casting, ha
s a
tate insertion and removal of the camshaft from the rear end of the case, the bearing I.D. is narrower toward the front.
11-3
11
ENG INE
A N ir es is t pi sto n ri ng in ser t is ca st in to th e 1st pis to n ring groove to increase durability.
-
GENERAL
(5 ) Con nec ting Bearing
Rod
and Conn
ecting
Ro d
Stamped on the top surface of the piston are a size mark (or oversize dimension on oversize pistons) for selection fit with the cylinder liner, a piston weight mark, part number, identification mark, and the "F" with an arrow for the front mark showing the piston installing direction. Piston pin for connecting piston to connecting rod is of full-floating type and is prevented from moving out by means of a snap ring installed on each end of the pin ends. On the piston for the 6D22-TC, a cooling cavity is provided.
(b) Piston ring
The conn ecti ng rod is a die fo rg ing of I cross section providing high rigidity. A lead bronze bushing is press-fitted onto the small end. The connecting rod There are three piston rings installed: two compres sion rings and one oil ring. The sliding surface of each ring is hard chrome plated to improve durability. The piston rings are shaped as shown in the figure.
bearing of the big end is a split type plain bearing. Thro ugh the stem of co
nnecting
rod, an o il passag e is
provided obliquely to lubricate the small end bushing. On the top of connecting rod for the 6D22-TC, an oil hole is provided for cooling the piston. The connecting rod and connecting rod cap are coupled with four bolts.
11-4
ENGI NE -
GENE RAL
m
(6) Crankshaft and Main Bearing
(a) The crankshaft is
a high -rigid ity die forgin g in teg
ral with the balance weight. An oi l ho le in eac h jo u rn al is th ro u g h to th at in pi n, feeding som e of the main bearing
lubricating oil to
the pin for lubrication of the connecting rod bearing. Flywheel
hous ing
O-ring
The front portion of the crankshaft is a flange type to which the crankshaft pulley is mounted with bolts. A torsional damper mounted to the pulley absorbs the torsional vibration of the crankshaft.
(b) The crankshaft
gear driving tim
ing gear i s fitted
onto the rear end of the crankshaft. Note that the crankshaft has an axial lip type oil seal fitted to each of its front and rear ends.
11-5
11
ENGI NE -
la} Maim bearing
GEN ER AL The main bearing is a split type plain bearing made of special alloy plated kelmet metal with backing metal. The upper main bearing has an internal oil groove and oil hole which coincides with the oil hole in the crankshaft. Seven pairs of main bearings are provided. Split type thrust plates are mounted to the rear-most bearing to bear the thrust of the crankshaft.
Upper main bearing
Lower main bearing
Thrust
plat e
B0382A
{7} Tim ing Gears
The timing gear s ar e accomm odated in the flywheel housing at the rear of the engine. The gear train is a s
11-6
shown abov e,
ENG INE
Each gear is a carbon steel helical gear having a
11
- GENERAL
(8) Flywheel
high-prescision tooth surface machined by the shav ing machine and given surface treatment to improve durability. A tim in g
m ar k is sta m ped
on
ea ch
tim in g
gea r.
Correct meshing can be achieved by aligning the timing marks at reassembly. The crankshaft gear, press-fitted onto the crankshaft and held in position by a dowel pin, drives all gears.
The flywhee l is made of cas t iron. The pilot bearing of the clutch shaft is installed at the center of the flywheel. The ring gear which meshes with the starter pinion is shrinkage-fitted on the outside periphery of the flywheel. The ring gear teeth crests are induction-hardened to assure high durability. One side of the teeth is chamfered to make sure that the starter pinion fits The idler gear is, at one end, mounted to the
easily.
crankcase with the idler shaft bolt, and supported, at
The cylinde r num bers and angle scale
the other end, on the flywheel housing.
the outside periphery of the flywheel as shown in the
A bu sh in g is pr es se d in to th e id le r ge ar w h ic h tu rn s
figure.
are stamped on
on the idler shaft. The bushing is lubricated by the engine oil flowing through the inside of the idler shaft from the crank case oil hole.
11-7
11 2.
ENGINE -
SPECIFICATION S
SPECIFICATIONS Item
Sp e cifica tio ns 6D22
Engine model
Water cooled, 4-cycle diesel
Type
6D22-T
6D22-TC
Water cooled, 4-cycle diesel
Water cooled, 4-cycle diesel
N u m b e ro fc ylin d e rs -a rra n g e m e n t
6 -in -lin e
6 -in -lin e
Valve mechanism
Overhead valve
Overhead valve
Direct
Combustion chamber Cylinder bore x stroke Total displacement
mm cc
Compression ratio Firing order
Direct
6 -in -lin e Overhead valve Direct
injection type
injection type
injection type
130 x 140
130 x 140
130 x 140
11 149
11 149
11 149
17
16
15.5
1-5-3-6-2-4
1-5-3-6-2-4
1-5-3-6-2-4
Cylinder liner
Type
Wet type
Wet type
Piston
Type
Trunk, slipper skirt type
Trunk, slipper skirt type
Trunk, slipper skirt type (Cooling cavity provided)
Q'ty
Compression ring: 2 Oil ring: 1
Compression ring: 2 Oil ring: 1
Compression ring: 2 Oil ring: 1
Piston ring
11-8
Wet type
ENG INE
3. 3.1
- SER VICE
11
STAND ARDS
3EFÍVD CE STA NDA RDS SERVICE
STANDA
RD TABL E Unit: mm
Description
Compression pressure (at 200 rpm)
Nominal value (Basic diameterl
Limit
2.75 MPa (28 kgf/cm2)
1.96 MPa 20 kgf/cm2
|28|
0.2
Replace bushing.
85
Replace.
Rocker to rocker shaft clearance
Correction and remarks
Difference between cylinder within 0.39 MPa (4 kgf/cm2)
0.03 to 0.08 O u te r va lve sp rin g
Free le n g th
89.38
Load (Installed length: 58.35) In n e r va lve sp rin g
450N(46.1 kgf)
Free le n g th
65.04
Load (Installed length: 50.35)
115N(12kgf)
Squareness Crankcase tappet hole to
tappet clearance
Cylinder head bottom surface distortion
2.5 0.2
Replace tappet.
-
0.5
Replace.
0.07o rless
Exhaust Valve stem to valve guide clearance
Depth of valve from cylinder head bottom surface
11.85
Replace.
11.91 to 11.93
112[ 0.09 to 0.12 0.25 to0.75
-0.05 to 0.45 45°
Va lvem a rgin
In let Exhaust
Sea t width of valve se
Replace.
11.95 to 11.96
Exhaust
Exhaust
at inser t
Eccentricity of flywheel housing
Correct or replace.
129.8
[12| 0.05 to 0.09
Va lve seat an gle
0.08
130
Inlet
Inlet
Replace.
-
Height from top to bottom surface of cylinder head In let
62.0 100N (10.2 kgf)
(35| 0.06 to 0.10
Push rod runout
Va lveste mO.D.
380N (39 kgf)
0.2
Replace valve guide.
0.7
Replace valve seat insert. Service limit: va lue when a new valve is installed. (- indicates projection amount.)
1.0
2.2
1.7
Replace.
2.5
2.0
2.69 to 2.96
3.5
Corre ct o r replace.
-
0.2
Correct installed condition.
11-9
n
ENG INE
- SERVICE
STANDARD S
Unit: mm D e scrip tion
Flywh e e l
N om in a lva lu e [Basic diameter]
Ec ce nt ricity (Flywheel housing)
Depth from clutch cover mounting surface to friction surface Backlash of timing gears
Between crankshaft gear idler gear "B"
an d
Correct installed condition.
0.1 or less
0.2
Corre ct.
48
49.5
Replace.
0.12 to 0.26
0.4
Replace.
Between idler gear "A" camshaft gear
and
0.13to0.26
0.4
Between idler gear "A" idler gear "C"
an d
0.13 to 0.26
0.4
Between injection pump idler gear "C"
g e a r and
Correction and remarks
0.2
-
Friction surface distortion
Limit
0.12to 0.26
0.4
0.1 to 0.28
0.4
Replace thrust plate.
I40] 0.03 to 0.06
0.2
Replace b u sh in g.
Id le r sh a ft " C " to id le r g e a r "C " b u sh in g cle ara nce
(46] 0.03 to 0.06
0.2
Replace b u sh in g.
End play of camshaft gear
0.05 to 0.22
0.4
Replace th ru s t p la te.
No. 1 jo u rn a l
I65] 0.03 to 0.08
0.25
Replace b u sh in g .
No. 2 journal
[65.25] 0.03 to 0.08
End play of idler gear Idler shaft "A " to idler gear "A"
Camshaft jo u rn al to camshaft bushing clearance
bushing clearance
No. jo 3 u rn a l
(65.50] 0.03 to 0.08
No. 4 journal
(65.50] 0.03 to 0.08
No. 5 journal
(65.75] 0.03 to 0.08
No. 6 journal
(65.75] 0.03 to 0.08
No. 7 journal
(66] 0.03 to 0.08
Cam profile (Difference between lobe height and base circle diameter)
Inlet
(8.83|
8.3
Inlet: lobe height, 56.167; base circle diameter, 47.334
Exh a ust
(8.821
8.3
Exhaust: lobe height, 56.036; base circle diameter, 47.216
Camshaft bend
0.05 or less
0.08
Crankcase top surface distortion
0.07 or less
0.2
11-10
Replace. Correct.
ENGINE
-
SERVI
CE STANDA
m
RDS
Unit: mm Description
Cylinder liner
Nominal value IBasic diameter]
I.D.
130.014 to130.054
Cylindricity (diameter base)
-
0 to 0.08
-
[1301 0.178 to 0.204
-
6D22-T
(130) 0.173 to 0.199
-
6D22-TC
[130] 0.188 to 0.214
-
Piston ring groove to ring clearance
6D22
1st ring 2nd ring
0.06 to 0.11 6D22
0.05to0.08
6D22-T, 6D22-TC
0.07 to 0.10
Oil ring
Replace or correct to oversize.
Repair or replace cylinder liner, or replace piston.
0.25
Replace piston ring or piston.
0.15
0.03to0.06
Piston ring open end clearance
Correction and remarks
130.25
0.02 or less
Projection from crankcase top surface Piston to cylinder liner clear ance (selec tion fit)
Limit
0.15
0.4 to 0.6
1.5
Projection of piston from top surface of crankcase
0.87 to 1.33
-
Piston pin hole to piston pin clearance
[50] 0.01 to 0.02
0.1
-
More than 0.1
[50] 0.02 to 0.05
0.1
Flatness of cylinder liner flange supporting surface on crankcase Connecting rod
Bushing to piston pin clearance
Bend and torsion
Connecting rod bearing
0.2 0.5 to
Oil clearance
Cr an ksha ft
End play
0.4 0.1
Replace bearing.
Replace.
A dj us t w ith ove rsi ze th ru st pla te. Correct or replace.
0.01 o r less
Cylindricity of journal and pin
0.006 or less
-
Oil clearance
[100| 0.08 to 0.15
0.25
-
Less than 106.5
Valve clearance
Correct or replace.
Replace.
Out-of-roundness of journal and pin
Tension when free
Replace crankcase.
Replace bushing.
Less than 90.5
0.09 to 0.23 less 0.04 or
Replace piston or pistón pin.
0.25
-
Bend
Main bearing
1.0
|84| 0.07 to 0.13
Tension when free
Check each part.
0.05 or less
-
End play
Replace.
0.08
G rind and correct to undersize.
Replace bearing.
Replace.
Inlet
0.4
-
Ad jus t.
Exhaust
0.6
-
Adjust.
11-11
11 3.2
ENG INE
TBG IHITEMiMG TO RQ UE
STAND ARDS
TA B LE
Description
Engine proper
- SER VICE
Thread size O-D. x Pitch mm
Cylinder head bolt
Tightening torque Nm (kgfm)
Remarks
We t For tightening procedure refer to 5.2.3 (6).
M14 x 2
Rockers h a f tbracke tb o lt
M10x 1.5
34 (3.5) 9.8 (1)
Rockerc o ve rb o lt
M10x1.25
Rocker a d ju s tin g s c re w lo ck nut Oilje tcheckvalve
M12x1.75
C o n ne c tingro dnut
M13x1.25
Main bearing cap bolt
M18 x 2.5
Crankshaft pulley bolt
M14x 1.5
Camshaft gear nut
M27x1.5
Idler shaft bolt "A" Idler shaft bolt
"C "
59 (6) 34 (3.5) 115(12)
W et
370 (38)
W et
175(18) 265(27)
M16 x 2
155 (16)
M16 x 2
155 (16)
Idler shaft nut (for mounting collar)
M16x1.5
98(10)
Flywheel bolt
M16x1.5
315(32)
Flywheel housing bolt
11-12
M10 x 1.25
M12 x 1.75
69 (7)
W et
Wet
ENGI NE -
SPE CI AL
TOOL
II
SPECIAL T@OIL
11-13
11
ENGINE -
Tool name Rocker bushing puller
SPECIAL TOOL
Use
Shape
Part No.
Removal and installation of rocker Dushing
MH061236
B5311A Valve guide puller
30091-08100
Removal and installation of valve guide
35111 a
Valve seat insert caulking tool
Installation and caulking of valve seat insert
Caulking tool body MH061360 Caulking tool body
1 Caulking ring inlet MH061650
{Ip—-— [ i
Caulking ring exhaust MH061651
O.D. Inlet 59 Exhaust 54
— Valve lapper
Caul king ring
Di am et er 12
B520 2A Lapping of valve
30091-07500
B5261A Idler gear bushing puller
Removal and installation of idler gear bushing (Idler gear "A ")
MH061228
'
B5121A Removal and installation of idler gear bushing (Idler gear "C")
MH062046
^ J -' Crankcase table
B4384A Measurement of flatness of cylinder liner flange supporting surface on crankcase
MH061889
B1480A
11-14
ENGI NE -
Tool name Cylinder liner extractor
SPECI
II
AL TOOL
Part No.
Shape
Use
MH061490
Removal of cylinder liner
129.5^^C B5131A Cylinder liner installer
MH061759
Press-fitting of cylinder liner
\ O.D. 129 .5 \\
w j B5141A Connecting rod bushing puller
MH061238
Rear oil seal slinger installer
MH061652
Removal and installation of connecting rod bushing
B5321A Press-fitting of rear oil seal slinger
Diameter'. 123
\ B5161B
Front oil seal slinger installer
Press-fitting of
MH061817
fron t oil seal slinger
y Diameter \ 95 V " B0585A Piston guide
Piston guide clamp Pisto n g u id e le ve r
MH061666
Piston
guid e
1.IX 130
Insertion of piston
MH 061658
Piston guide leve
B5171B
11-15
11
11-16
ENGINE -
SPECIAL
TO OL
ENGINE
-
SERVI CE PRO
5. SERV ICE PROCEB U RES 5.1
ME A SU RE M EN T
m
CEDURES
NOTE: Cover the mounting holes and injection pipes to prevent entry of dust and dirt.
Compression pressure must be measured prior to disassembly of the engine. Measure the compression pressure at regular inter
NV ... L ...
Nom inal Value Lim it
vals and keep track of its changes. During the break-in period or after parts have been replaced with new ones, there is a slight increase in the pressure as the piston rings and valve seats fit snugly in position. As rough edges and friction between parts are gradually reduced, the pressure comes down.
Measurement Procedure
B5561A
(3) Insta ll Compres sion Gauge Ada ptor (specia l tool) (1) Retighten the cylinder head bolts to specified
on the injection nozzle mounting hole together with a
torque and let the engine warm up until the coolant
gask et and connect t
temperature reaches 75°C to 85°C.
ing instrument).
NOTE: In retigliitening the cylinder head bolts, observe the tightening sequence in {6} in 5.2.3.
(4) To make sure that the fuel is not fed under
he compression
gauge (me asur
pressure from the injection pump, pull the stop lever of the Injection pump all the way In the stop direction beforehand. (5) In this con ditio n, let the starter run the engin e and measure the compression pressure at a rotating speed of 200 rpm.
NOTE: 1. Make sure th at the engine spee d is also measured as compression pressure varies with the engine speed. 2. Make meas urem ent for all cylind ers, as wear and other conditions vary from one cylinder to another.
(2) Remove all injection nozzles from the cylinder head.
11-17
11 5.2
ENG INE
- SER VICE
PROCE DURE S
CYLINDER H EAD AND VALVE MECHANISM
5.2.1
Disassembly
1 Rocker cover 2 3 4 5 '6 7
Rocker bracket mou nti ng bolt Cylinde r head bolt Thrus t plate Rocker Set screw Rocker shaft (DRocker shaft bracket 9 Push rod 10 Valve cap 0 Valve cotter 12 Up per retainer
Inner valve spri ng Valve stem seal Lower retainer Inlet valve Exhaust valve Nozzle tube Water director Sealing cap Cylinder head Crankcase side cover Tappet
For disassembly of parts with an encircled number, see following items.
C1542A
11-18
ENGI NE -
SERVI CE PROC
Disassembly Procedure
m
EDURES
(2} Rem ov al o ff Cylind er H ead As sem bly
{11} [Removal off She Ro c k er Sh aft B ra c k et A s s em b l y
Cylinder head
Cylinder head gasket Knock pin
B9014B
The cylinder head is held in position by the dowel pins on the top surface of the crankcase. To remove (a) Whe re the push rod is rocker adjusting screws s
1. When letting the valve hit against the valve seat in sert, do not turn the valve. 2. Con tact p attern should be ch ecked when the valve guide is inspected or replaced.
11-24
M@TE; 1. K eep grinding margin to a minim um . 2. if the valve margin is below the limit after the grinding correction, replace the valve. 3. A fter the grinding co rrec tion , fee sure to lap the valve and valve seat insert. [Fieff er to Item (14) th at fo llo w s.]
ENGI NE -
SERVI CE PRO
(12) Correction of Value Seat Insert
CEDUR
II
ES
(13) Replacement oí Value Seat Insert Since the valve seat insert is installed by expansion fit, replace it by the following procedures.
C3127A
(a) Grind inside surface of the valve seat insert to reduce the thickness and then remove it at room temperature.
(a) Using a valve seat cutter, cut the insert to obtain the specified valve seat angle and seat width. Use 15° or 75° cutter first, then 45° one.
MOTE; 1. Keep t he amou nt of cut to a min imum . 2. If the value sinkage after cutting ex, seeds th e limit, rep lace th e ualue seat insert. (b) After correction, lightly grind by holding about #400 sandpaper between the cutter and valve seat insert.
MOTE; A f t e r t h e c o r r e c t i o n p r o c ed u r e , h e s u r e t o lap the ualue and ualue seat insert. [Refer to Item (14) that follows.]
(b) Make sure that the cylinde
r head and valve seat
insert are provided with sufficient interference. (c) Immerse the valve seat insert In liquid nitrogen for cooling it, and fully heat the cylinder head.
11-25
11
ENG INE
-
SER VICE
(d) Install the valve seat insert using the Caulking Tool Body, Caulking Ring and Caulking Tool (special tools) and caulk the periphe
ry o f the valve sert insert
.
M0TE:
When the valve seat insert is installed, direct the chamfered side of the caulking ring toward the valve seat insert. (e) Refa ce the valve seat inse rt so that the seat and valve sinkage are up to specifications.
w idth
PROC EDUR ES
MOTE: 1. Make sure that no compound sticks to the valve stem. 2. (LPse in te rm ed ia te -m es h compou nd (12 0 to 150 meshes) first, then fine-mesh or more) for compound (200 meshes finishing. 3. Add ition of a small amou nt of engine oil t o the compound helps make t o apply it evenly.
it easier
(14) Lapping the Valve and Valve Seat Insert The valve and valve seat insert contact must be even throughout their contacting surfaces. They must be lapped whenever either the valve or valve seat insert has been corrected or replaced.
C3130A
(b) Using V alve Lappe r (special t ool), seat t he valve and valve seat insert. While turning the valve slightly at a time, strike it against the valve seat insert. (c) Wash away the compound in gas oil, etc. (d) Ap ply engine o il t o the contacting surface to seat (a) Apply a thin, even coat of lapping compound to -the seating surface of the valve.
11-26
them with oil. (e) Check to ensure that they are properly seated.
ENGI NE 5.2.3
SERV ICE PRO
CEDURES
11
Reassembly
11-27
11
ENG INE
- SER VICE
Reassembly Procedure (1) Installation
PROC EDUR ES
(3) Ins tallati on of Valve Stem
Sea l
of W ater Director
The valve stem seal should be installed by applying Install the water director with its notch directed as
engine oil to the lip and striking down Valve Stem
shown.
Seal Installer (special tool) until it touches the cylinder head.
(2 ) Ins tallati on of No zzle Tube
NOTEs 1. Before the valve is installed, apply a sm all a mo unt of engine oi l to the stem. 2. Af ter ins tallation, check to e nsure that the valv e stem seal spring has not bee n deformed or damaged.
Nozzle Tube Installer B o lt. MH061231 Nozzle Tube Flange MH061416
. 15 to 20 Nm (1.5 to 2.0 kgfm)
Nozzle Tube Stamp MH061229
• M8 x 1.25
(4) Installation
of Valve
Cotter
O-ring A p p ly en gi ne oi l. Nozzle tube A p p ly se ala nt (THREEBOND 1211 or equivalent). C6620B
(a) Ap ply sea lant to the end of
the nozzle tube and
insert into the cylinder head. (b) Using Nozzle Tube F lange (special nozzle tube against the cylinder.
too l), press the
(c) Apply engine oil to Nozzle Tube Stamp (special tool) and insert into the nozzle tube. (d) Thread Nozzle Tube Installer Bolt (special tool) to push the stamp until it can be removed from the
Install the valve cotter, while compressing the valve
bottom of the cylinder head.
spring, using Valve Lifter (special tool).
(e) After
installation, p
water-tightness.
11-28
erform
lea k test to verify
MQTEs
Install the valve spring with the closely coiled portion toward the cylinder Snead.
ENGI NE {5} Installation of Ro cket and Cylinder Head
11
SERV ICE PR OCEDURES
Shaft B rack et
(8) Tightenin
g of the
Cylinder Head
Bolts
Tighten the cylinder head bolts in the sequence shown above to 175 Nm (18 kgfm). A ft e r ti g h te n in g , v e ri fy th e co rr ect to rq u e , th en re tighten 90°
!_q° .
Seat the cylinder head on the crankcase, while lining it up with the locating pin.
For disassembly of parts with an encircled number, see following items.
C1926F
11-30
ENG INE
- SER VICE
PROCE DURE S
NV ...
11
Nom inal Value
-x-Camshaft gear end play NV 0.05 to 0.22 L 0.4
fii) Camshaft *(Í2) Camshaft gear 13 Thr ust plate 14 Idler shaft bolt 15 Thrust plate 16 Idler gear "C" 17 Idler gear "A" 18 Idler gear "B" 19 Idler shaft "A" 19A Idler shaft "C" 20 Rear plate For disassembly of parts with an encircled number, see following items. The part marked -x- must be inspected before disassembly. Part marked with * should not be removed unless defects are evident. C1927C
To re move th e oi l se al r et ai ner , tur n down the
attaching bolts into the removing threaded holes evenly, while making sure that the oil seal retainer does not have eccentricity, remove the retainer with the oil seal attached.
If the end play exceeds the limit, replace the thrust
Remov e t he coll ar by screwi ng M4 x 0.7 bol ts i nto
the removing threaded holes.
11-32
ENGI NE (5 ) Remo val of
SERV ICE PRO
CEDURES
II
MOTE; Do not strike the gears with a hammer. Make sure that the gears are removed by use of a gear puller.
Cam sh aft S eat* Thrust plate
(7) Removal off Ring Gear
C1932B
A cc ess in g th ro u g h th e h ol es in ca m sh a ft ge ar , lo os en the thrust plate attaching bolts. Then, remove the gear together with the camshaft.
fS j Remo val off Cam sh aft Gear Using an acetylene torch, heat evenly the ring gear and apply a rod to t
he ring gear to tap it thro ug ho ut its
periphery.
Remove the lock nut and lock washer from the camshaft gear and, using Gear Puller (special tool), remove the camshaft gear.
11-33
ENG INE
5.3.2
-
SER VICE
PROC EDUR ES
Dtispection
Depth from clutch cover mounting surface to friction surface NV 48 L 49.5
NV ... L ...
Nom inal Val ue Limit
Distortion of friction surface NV 0.1 or less L 0.2
C2758C
11-34
ENGINE -
BD
Ba sic D ia me te r
NV ...
No mina l Value
SER VICE
PROCE DURES
11
C2759C
11-35
11
ENG INE
- SER VICE
Inspection Procedure
PROCE DURE S
(2 ) Correctio
(1 ) Oi stor tii ow of Fric tion
n of Flyw heel Friction Surface
Surf ace
Correct the friction surface with a surface grinder. Place the flywh ee l on a surface plate and indicator in the diametral d
mo ve a dial
ir ection o f t he flywhe el to
Make sure that the friction surface is parallel to surface A within 0.1 mm.
measure distortion.
If the d imen sion
Use of a po rtable jack w ill m ake it possib le to t ake a
lim it, repl ace.
more accurate reading.
(3 ) Idler Gear
If the disto rtion
is i n excess of
of p ortion
B exceeds
the servic e
to Idler Shaft Clearance
the rep air li m it, grind
the friction surface.
M®TEs Off Sit e ring ge ar sh ow s and abn or m al co n di tion, replace the ring gear before m easure m en t. [Ref er to 5. 3.1 (7)1
If the lim it is exceeded, the bushing be replaced.
11-36
in the gear shou
ld
ENG INE
(4 ) Replac em ent
of Idler Gear
- SER VICE
Bushing
11
PROC EDUR ES
(6) Cams haft Journal to Crank shaft Bushing Clearance
case
Cam
Replace the bushing by the procedures shown in illustration, using Idler Gear Bushing Puller (special tool).
MOTE: H. (Inst al l the hushing w ith ch am fered side of gear LO. inward. 2. After installati on , ch eck to e nsu re that the hushing to idler shaft clearance is w ithin the no m inal dim ension . Iff it i s below th e nom inal dimension, ream the bushing. (5) Gam Profile
If the limits are exceeded, the bushing In the cranio case should be replaced.
(7 ) Bend
of Cam sh aft
C4118A
Measure the lobe height and base circle diameter and replace the camshaft if the difference between the two is below the limit.
Measure the
bend of the cam
shaft. If
the lim it is
exceeded, replace.
NOTE: The cam must he measured at locations shown as it is tapered.
NOTE: Turn the camshaft a turn and read the deflection of the pointer, using a dial in dicator. One half off the reading is the bend. 11-37
11 5.3.3
ENG INE
- SER VICE
Disassembly
For assembly of parts with an encircled number, see following items. For assembly of part marked *, refer to Group 61 Special Equipment.
11-38
PRO CEDU RES
___________ B1902F
ENGI NE -
SERVI CE PRO
Reassembly Procedure
(3)
11
CEDURES
Installation
of Cams haft Ge ar
(1) Installation of Rear Plate
C6230C
Install the camshaft gear so that the side having The bottom of gasket installed between the rear plate
stamped numbers "4" faces front.
and cra nkca se will p rotr ude. A fter t he fl ywh eel hous
(4)
Installation of
Cams haft
ing has been installed, cut away the protruding portion.
(2) Installation of Idler Gears
Ins tal l the cam shaft so that the alignme
nt mark "4" on
the camshaft gear is aligned with the alignment mark
"4" on idler gear A. Then, install the idler gear B so that its alignment mark "1" is aligned with the alignment mark "1" on the crankshaft gear. Next, install idler gears A and C so that their alignment marks "2" are aligned. Tighten the idler shaft bolt to specification.
NOTE; When the camshaft is inserted, false care not to damage the camshaft bushing. (5) Check cam sh aft gear a nd idler correct end play.
gear for
[Refer to Section 5.3.1 (4)]
|6J Ch eck b ac klas h on gears . [Refer to S ect ion 5.3. 1 (3)]
11-39
11
ENG INE
- SER VICE
(7) Ins tal la tio n of Reas1@51 Seal Sliwger
PROC EDUR ES
(9) Ins tal lat io n of Fly w he el Hous ing
(8) Ins tall atio n of Ring Geai?
Install the flywheel housing and gasket so that they are aligned with the locating pins in the crankcase. Cut the bottom
portions
of t he gasket aft er installation
as they are excess. Cut at the same time the excess portions of the gasket between the rear plate and crankcase.
(1 0) Flyw heel Housing Ecc entr icity
(a) Heat the ri ng ge arfo r 3 m inutes with p
Check
iston heater
(approx. 100°C). ' (b) Fit the
ring gear
onto
the flyw hee l w ith
the
nonchamfered side of the teeth end toward the flywheel.
Install the flywheel housing to the crankcase by tightening to the specified torque. Measure the mounting condition (eccentricity) at the flywhe el h ousing joint.
If the pointer o
f a dial indicator
deflects beyond the limit, loosen the bolts and lightly strike the housing to correct the mounting condition.
For disassembly of parts with an encircled number, see following items. Part marked with * should not be removed unless defects are evident. Servi ce items marked with -X- should be inspected before disassem bly. C2337D
11-42
ENGI NE -
SERV I CE PROCEDURES
13 Front oil seal
19 Crankshaft
14 Front cover
20 Upper main bearing
15 Front oil seal slinger
•1
@
Crankshaft
24 Oil jet gear
25 Oil spray plug 26 Crankcase
16 Main bearing cap For disassembly of parts with an encircled number, see following items. The part marked x- must be inspected before disassembly. Parts marked with ‘ 1 should not be removed unle ss def ects a re evident. For inspection of the part marked with *2, refer to Group 12 Lubrication.
B0599G
11-43
11
ENG INE
-
SERVICE
PROCED URES
(3 ) Remo val of Piston
[Disassembly Procedure (1) Piston Projection The piston
projection
mu st be up to specification, as
it
affects engine performance and is also necessary for preventing interference with the valve.
When the w ithdrawing
the pist on from
the c ran kcas e
by pushing up together with the connecting rod.
(a) Hold the dial indic
ato r to the top surface o
f the
MCTis When re mo ving th e pistons, use prevent damage to the cylinder liner (4 ) Separating Pi
crankcase and make zero adjustment.
care to
ston from Connecting Rod
(b) Find the top dead center of piston with a dial indicator. (c) Measure t hree po ints on the
top surface of piston
to find the average value. (d) If the pro jection
is ou t of spe cification , check the
connecting rod, bushing, piston pin, connecting rod bearing, etc. and replace defective parts.
(2) Connecting Rod End Play
Remove the snap ring and, using a rod, tap piston pin off. If, however, the piston pin is hard to remove, heat the piston with a piston heater or in hot water.
Measure the end play of each connecting rod. If the lim it is
exceeded, repl ace the conne
crankshaft.
11-44
cting
rod or
ENGI NE (5)
SERV ICE PRO
(7 ) Remo val of
Rem ov al oí Piston Ring
(6) Crankshaft End Play
11
CEDURES Main Bearing Cap
The rearmost main bearing cap is held in position by dowel pins. Remove it by use of a slide hammer.
(S) Remo val o ff Cran ks haft
d ear
Before removing the main bearing caps, measure the end play in the crankshaft. If the end play exceeds the lim
it, replace
the thrust
plate with an oversize one. [Refer to Section 5.4.3 (3)]
(a) Remove the
rear oil se al sli nge r from
the crank
shaft by cutting it with a punch. (b) Remove the cranksha
ft gear from
the crankshaft ,
using Gear Puller (special tool).
MOTE; Bo not attempt removing the crankshaft gear by striking with a hammer or prying with a lever.
11-45
11 5.4.2
ENG INE
- SER VICE
PROCE DURE S
Inspection
Open end clearance NV 0.4 to 0.6 L 1.5
Clearance BD 50 NV 0.01 to 0.02 L 0.1
Clearance BD 50 NV 0.02 to 0.05 L 0.1
Bend or torsion L 0.05 or less
Piston ring groove to piston ring clearance 1st ring NV 0.06 to 0.11 L 0.25 2nd ring NV 0.05 to 0.08 <6D22> 0.07 to 0.10 <6D22-T, 6D22-TC:; L 0.15 Oil ring NV 0.03 to 0.06 L 0.15
Clearance BD 130 NV 0.178 to 0.204 <6D22> 0.173 to 0.199 <6D22-T> 0.188 to 0.214 <6D22-TC:
Distortion of top surface NV 0.07 or less
L
0.2
Flatness of cylinder liner flange supporting surface L Mor e than 0.1
BD NV L
Projection of cylinder liner from top surface of crankcase NV 0 to 0.08
Basic Diameter Nominal Value Limit
Inside diameter NV 130.014 to 130.054 L 130.25 Out of roundness of cylindricity NV 0.02 or less
Oil clearance BD 84 NV 0.07 to 0.1 3 L 0.25 Ten sion whe n free L Less than 90.5
C2760C
11-46
ENGINE
-
SERVI CE PROC
[Inspection Procedure
RH
EDURES
{2) Crank case Top Surf ace Dis tort ion
(1) Flatness off Ci/DimcOer Liner Flange Sup porting Surface on Crankcase
Measure the crankcase top surface distortion. If it exceeds Repla ce the crankcas e w ith new one if the lim
it i s
the limits,
correct the distortion
with
a
surface grinder.
exceeded. 11-47
11
ENG INE
- SER VICE
PROCE DURES
(4 ) Cylind
MOJE:
er Liner F lange
Pro jection
When S he cr ank cas e is groun d, m ake sure that the piston projection do es not exceed the nominal value. [Refer to Item (1) , Sec tion
5.4.1. ]
(3) Cylinder Liner I.D.
If the projection is out of specification, replace the cylinder liner or crankcase. [For replacement of the cylinder liner, refer to Item (5).]
(5)
Rep lacem ent of
(a) Removal Measure the cylinder liner I.D. at six positions as shown in the right figure. If the I.D. is more than the limits, replace the cylinde
r liner or
bore it to oversi
[For replacement of the cylinder liner, refer to Item (5).]
11-48
ze.
Cylinder Line
r
ENGI NE -
SERV ICE PRO
CEDUR
ES
U
(b) Installation
Size
mark
Piston
3) 1)
When replacing the cylinder liner, u
se a cylinder
Securely seat
the cylinde r liner on the crankc ase
by lightly striking the flange portion, using Cylinder Liner Installer (special tool).
liner with the same size mark as that of the piston to
MOTE; Bo not use the bearing by artificially ex panding it.
Main bearing
I D.
(15) Connecting Rod Bearing to Crank shaft Pin Clearance
C5524A
If the lim it i s exceeded, replac
e the upp er and low er
bearings as a set.
If the lim it is exceeded, repl ace the upp er and low er bearings as a set.
11-53
11
ENG INE
(1 7) C rank sh aft Roundness and
- SER VICE
Cyli ndri-
city
PROCE DURES
(1 9) Correc size
tion of Crank
sh aft
to Un der
If the journal or pin is damaged or seized, grind the Roundness Measuring
crankshaft by the following procedures. Replace the
Cylindricity
direction
Measuring
bearing with an undersized one.
position
Determine the out-of-roundness on the basis of the crankshaft j ourna l and pin O. D. meas urements. If the lim it is exceeded, g rind to un dersize. [Refer to (19)]
(a) When the crankshaft is ground, take care not to change the center distance o
(1 8) C rank sh aft
Bend
f journ al and
pin.
(b) Grind the crankshaft in such a way as not to change the width of journal and pin. (c) Finish the fillet smooth to the specified R. (d) Chec k for groun d cracks by
the m agne tic particl e
inspection method. The surface hardness (Hs 75 or more) should also be checked to confirm that it has not decreased.
Measure the bend
of the crankshaft. If the lim
it is
exceeded, correct with a press or grind to undersize. NOTE:
Ule ad the cran w ith a dial i
ing is the bend.
11-54
ks haft c ent er journ al runout
nd icator. One half
of t he r ead
ENGI NE -
'
ft
A / v . ' * ' -J
\
\
m
PROCEDURES
Finishing
Grinding
V
SERV I CE
\
r
Whestone or sand paper
Gri nder
Crankshaft C5509A
(e) To grind the crankshaft with grinder, the grinder and crankshaft should be turned clockwise as viewed from the crankshaft front end. (f) To finish the crankshaft with a grindstone or sandpaper, turn the crankshaft counterclockwise. Unit: mm Undersize
-0.25
-0.50
-0.75
-1.00
Journal O.D. finish dimension
Pin O.D. finish dimension
O ut-o froundness
C ylin dricity
99 75 " 0 08 a - 0.10
83 75 “ 0 06 0 0 / 0 - 0.09
0.01 or less
0.006 or less
99 50 _ ~~08'^1Q 8 aa.ou
- 0.0 6 83,5 0 - 0.09
99 25 “ 0 08 80,25-0.10 99 00 _~ Q8'^1Q 8 sa.uu
83,251o 'o 9
83,0 0 '
0*09
11-55
ENG INE -
5 .4.3
11-56
Reass em bly
SER VICE
PROCE DURES
ENGI NE -
SERV ICE
(Reassembly Procedure (15 Ins tall atio n of Oil Spray Plug
Install the oil spray plug with the arrow stamped on the plug toward the top of the engine.
(2) Installation off Oil Jet and Check Valve
PROCEDURES
11
(3) Ins tal lat io n of Upper Main (B earing and Thrust Plate
(a) Install the oil jet, while making sure that Its locating pin fits In the crankcase. (b) Mount the lock washer in such a way that its bending portion w ill fit the end of the oil jet. (c) After the check valve has been ti
ghte ned to the
specified torque, bend the lock washer to fit the hexagonal portion of the check valve.
(a) Heat the gear to about 100°C, using a piston heater, etc.
11-57
11
ENG INE
-
SER VICE
(b) Locate the gear so that the dowel pin of the crankshaft w
ill fit in the notch
of t he gear and fit the
gear by lightly striking the gear end with a soft
PROCE DUR ES
(7) Installation of Lo w er Main Bea Main Bearing Caps
rings a nd
Follow the procedure given below.
hammer. (c) Install the rear oil seal slinger. [Refer to Item (7), Section 5.3.3.]
(5) In s tal lat io n o f Fron t @51 Seal Slin
ge r
(a) Drive the locating dowel pins into the rearmost main bearing cap in the direction shown.
Install the front oil seal slinger, using Oil Seal Slinger Installer (special tool).
(6 ) Ins tall ation of Cranks
haft
Lift the crankshaft with chain blocks, etc. While keeping it in horizontal position, slowly lower it into the crankcase.
(b) Mate the lower main bearing with each main bearing cap, m aking su re tha t the lug in bearing fitted into the lug groove in cap.
11-58
is
ENGI NE (c) Only to both sides
SERV ICE PRO
of t he rearm ost main be aring
cap , install the thrust plates facing th
eir oi l groov eless
(f)
Hi
CEDURES
Check to see if the end play of
the cran ksh aft is
within nominal value.
side toward the cap.
[Refer to Item (6), Section 5.4.1.]
MOTE?
(0) flrsstalfiaffioM) off Co n n ec tin g Rod Bol t
Iff an oversize ffinrast piaffe is used, use the bearing cap rear ffhrusff piaffe off the same size as that off the thrust plate in the crankcase rear end [liefer to Item (3)]. Mote, however, that the bearing cap ffront and rear thrust plates may be off difffferent sizes.
A ft e r ch eck in g th e co n n ecti n g ro d fo r da m ag e an d burr in the bolt hole, apply engine oil to the connect ing rod bolt and press-fit it into the connecting rod.
(d) Install the main bearing caps, making sure that the side with the lug groove placed on the right-hand side of the engine and they are installed in the order of embossed numbers from the front of engine. (e) Tighten
main
bearing
cap bolts to
specified
torque. Then, tighten main bearing cap side bolts to specified torque. A ft e r th e b o lts are ti g h te n e d , m ak e su re th a t th e crankshaft is free to rotate by hand.
11-59
11
ENG INE
{9} Reassembly
- SER VICE
o? Piston and Connecting
PROCE DURE S
(10) Installation
of Poston Ring
Ro d
Using Piston Ring Tool (special tool), install the piston Connect the piston to the connecting rod with the
rings in the following sequence.
piston pin so that the Front mark on piston and lug
1.
Oil rin g
groove mark in connecting rod are placed on the
2.
2nd com press ion ring
same side.
3.
1st com pression ring
If the piston and piston pin are hard to insert, heat the , piston w ith a piston he ater or in h ot water.
-------------------------------------------------------------> Light B
C
D
E
F
G
H
J
K
ENGI NE -
SERV ICE PRO
(11) Dnsfallafio u of Up per amd Lowes' Con necting Rod Bearings
11
CEDURES
MOTE: 11. M ak e sure th at t he s ize sym bol o f the piston is the same as that off the cylin der liner. 2. Make sure that th e pisto n ring open end directions do not change. 3. Put a vinyl hose or something else on the bolt of connecting rod for protec tion of the crankshaft pin against dam age by the bolt. Usi ng the Piston G uide d am p and P iston Guide Lever (special tools).
Install the upper connecting rod bearing, making sure that the bearing lug is aligned with the lug groove in the connecting rod. Install the lower connecting rod bearing, making sure that the bearing lug is
aligned w ith the lug groov
e in
the connecting rod cap.
MOTE: Mole that the only the upper connecting rod bearing has an oil hole. (12) Inst allati on of Piston a nd Connecti ng Bod
Line up the Piston Guide with the piston skirt and set the lever into position. Then, turn the adjusting bolt so that the clam
p I.D. equals piston
O.D. After the
adjustment, apply engine oil to piston outer surfaces, Piston Guide inner surfaces, and cylinder liner inner surfaces. A ft e r th es e
pro c edu re s
Piston Guide onto the p
ha ve
been
iston so that it i
c o m p le te d ,
fi t
s flush w ith the
pistonhead. Using a mallet or wood block, tap piston Into position with care not to damage it.
Using Piston Guide Clamp and Piston Guide Lever (special tools), install the piston and connecting rod so that the front mark on piston head faces the front of engine.
The valve clearance should be checked and adjusted as described below while the engine is cold.
Make sur e that the ali gnm ent m arks and l ug groove marks on the connecting rod cap and connecting rod
B5713A
are aligned.
(1 4) Cheek the co
nn ecting
rod end pla
the p rojection
(1) Crank the engine to align the pointer of the inspecti on w indow
(Refer to Item (2), Section 5.4.1.]
(15) Check
y.
of the piston.
of the fl ywh eel housing w
ith the
inscribed mark 1.6 of the flywheel. Check the push rods, and the piston whose push rod is not pushing
[Refer to Item (1), Section 5.4.1.)
up the rocker is at the top
(16) Installation of Front Oil Seal
compression stroke.
dead center o
(2) When the No. 1 cylind er piston is at
f the
the top dea d
center on the compression stroke, check and adjust the clearance of valves marked "o" in the following table. When the No. 6 cylinder piston is at the top dead center on the compression stroke, check and adjust the clearances of valve marked "x". Turn the crank shaft through a rotation, and make sure that valve clearance inspection and adjustment are performed for all of the six cylinders.
C ylin d e rNo. Valve arrangement
Evenly press the oil seal throughout its entire periphery to prevent it from tilting. Press-fit the oil
No. 1 at TDC on the compres sion stroke
2
1
3
4
5
6
In. Ex. In. Ex. In. Ex. In. Ex. In. Ex. In.
o
o
o
o
Ex.
o
o
seal into the front cover until the oil seal flange is held tight up against the front cover.
11-62
No. 6 at TDC on the compres sion stroke
X
X
X
X
X
X
ENG INE
- SER VICE
11
PROCE DURES
(3) Mea sure the rocker arm to valve cap cl
earance
with a thickness gauge to determine whether the clearance is up to specification. If the thickness gauge of the specified thickness is somewhat hard to move, the clearance is good. If the clearance is out of specification, loosen the lock nut and adjust with the adjusting screw. After adjust ment, turn down the lock nut to lock the adjusting screws.
MOTE: A f t e r t h e lo c k n u t h as b e en f u m e d d o w n , recheck
1. GENERAL .......... .......... ............ ...... 2. SPECIFIC AT IONS ... ............ ........... 3. SERVICE STANDA RDS .................. 3.1 SERVICE STANDA RD TAB LE ..... 3.2 TIGHTE NING TORQUE TABL E ... 4. SERVICE PROCEDU RES ................ 4.1
REMOVAL AMD INSTA LL A TION ...........................................
2 HO 10 10 11 12 12
4.2
DISASSEMBLY, INSPECTI ON AND REASSEMBLY ............................ 13 4.2.1 Oil Pump ........................ ......... 13 18 4.2.2 Oil Fi ll er ....... ....... ............ ........ 4.2 .3 050 Coo ler ................... ............. 4.2.4 Regu lat or Valv e ............ ...... .... 4.2.5 Ch eck Val v e ...... ...... ....... ....... . 5. TROUBLESHOOTING ....................
19
12-1
12
LUBRICATION
-GENERAL
1. GENERAL
Engine lubrication is accomplished by forced lubrica tion system
using gear pum
p. The engine oil in t
he oil
pan is drawn up through the oil strainer by the oil pump and force-fed to the oil filter and oil cooler to lubricate all parts.
Oil pressure gauge
B1539F
12-2
LUB RI CATI ON -
12
GENE RAL
fH J050 Pu m p Oil pump gear
A t th e ti m e, th e en g in e o il is d ra w n in fr o m th e su ctio n side by the negative pressure produced as the gear turns along the
inside of t he pum p case , and is car ried
along the gear and case inside wall to the delivery side. The oil strainer at the suction port prevents entry of foreign matter in the oil pan and air. The engine oil Is « /
^
routed to the crankcase by the oil pipe connected to the delivery port. B1540A
The oil pump, of a gear pump type, is mounted in the rear bottom portion of the crankcase, driven by the crankshaft gear. An o il s tr a in er is m o u n te d at th e su cti o n p o rt o f t h e oi l pump; an oil pipe at the delivery port. The crankshaft gear drives the oil pum
p idler gear and
oil pump gear to transmit rotation to the oil pump drive gear. In the oil pump, the oil pump drive gear is in mesh with the oil pump driven gear. When the oil pump drive gear is driven, the oil pump driven gear is turned in the opposite direction. Since the oil pump is driven at speeds proportional to the engine's, the delivery pressure of the oil pump increases during starting in cold weather. A relief valve is provided
in t he oil pum p to make sure that no
excessive pressure acts on the lubrication system.
12-3
12
LUBRICATION
-GENERAL
(2) Oil Filt er
B1543A
When the oil filter element is clogged and the difference in pressure between the filtered and unfil
The oil filter is a double oil filter consisting of a
tered oil exceeds the lim
full-flow filter made integral with bypass filter. Ele ment is a filter paper element.
allowin g the un fil tered
Engine oil fed under pressure from the oil pump pass es through from
the oil hole
in t he crankcase and fl
the oil fi lter head into the full-flow
, bypass fil ter.
The engine
oil filt ered
ow s
filter and throug h the
the crankcase oil hole to the oil cooler. The engine oil filt ered throug h the bypass filter returns to the oil pa
oil t o flow
the
to the fi ltered oil
path. The oil bypass alarm has electric contacts that are closed to turn on the pilot lamp, warning the driver of clogged element when the valve is opened.
full-flow filter is routed from the oil filter head through
mounted in the coolant path on the left side of the crankcase. Engine oil forced through the oil filter flows inside the oil cooler element; whereas the coolant forced from the water pump flows around the element. The engine oil in the element is then cooled or heated before it flows to the main oil gallery.
When the oil viscosity is high at low temperatures or when the elem of clogging,
ent has high resist
the bypass valve
ance to flow
beca use
install ed at the oil cooler
opens to allow engine oil to flow to the main gallery bypassing the oil cooler.
12-5
12
LUBRICATION -
GENERAL
(b) Cam sh aft
(5 ) Reg ulato r Valve
B1529A
The regulator valve is mounted in the main oil gallery
Lubrication of the camshaft bushings is accomplished
in the crankcase to make sure that no excessive
by the oil flowing through the oil holes from the
pressure acts on the lubrication system.
outside periphery of the crankshaft main bearing to the individual camshaft bushing.
(6) Lu b ric atio n o f AID Far ts The engine oil routed to the m
ain oil gallery lubricat
es
(c) Valve mechanism
all parts as described in the following.
(a) Main bearing, connecting rod bearing, and connecting rod bushing
The oil hole extends from the main oil gallery to the crankshaft main bearing to lubricate the main bear ing. Part of the engine oil that has lubricated the main bearing passes through the oil hole in the crankshaft to lubricate the connecting rod bearing, and then through the oil hole in the connecting rod to lubricate connecting rod bushing. On 6D22-TC, there is a hole provided in top of connecting rod, from which oil spurts out to the piston.
12-6
The engine oil that has lubricated the No.
1
camshaft
bushing flows through the oil hole provided at the top of the crankcase to each cylinder head.
LUBRICATION
12
GENERAL (e) Cooiira g t h e p is to n (oiO je t)
Engine oil fed to the cylinder head flows through the oil holes in the rocker shaft bracket and rocker shaft to lubricate each rocker bushing. The engine oil is also sprayed out of the rocker arm oil holes for lubrication of the sliding surfaces of valve cap and valve stem as well as the sliding surfaces of push rod and adjusting screw. The oil then flows through the push rod holes in the cylinder head and crankcase to lubricate the tappet and cam of the camshaft and returns to the oil pan.
(d) Tómórag g ea r s
B1535B
The oil j et prov ided unde r the m ain oil gallery for eac
h
cylinder sprays engine oil against the reverse surface of the piston to cool the piston. The oil jet i s equipped w
ith a check val ve w hich opens
and closes at specified oil pressure, preventing the decreased amount of oil at low oil pressure and loss in oil pressure. On the piston for the 6D22-TC, a cooling cavity is provided . The oil injected from
the oil jet enter
s the
cooling cavity to cool the piston. The timin g gear idler shaft ar
e lubricated, as shown
in
the figure, by engine oil flowing through the oil holes routed from the main oil gallery and the crankshaft main bearing in the rear end. Each gear is lubricated by the engine oil sprayed from the oil spray plug.
12-7
12 (7) Lub ricati on of Turb
LUBRICATION -
oc harger
GENERAL
The injection pump and air compressor are lubricated as follows:
Part of the engine oil is directed through the oil pipe from the crankcase into the turbocharger. The engine oil passes through the oil hole in the turbocharger bearing housing to lubricate the bearings. It is then returned through the oil outlet at the bottom of the bearing housing back to the crankcase and to the oil pan. A piston ring is installed on the outside of each bearing, serving as an oil seal.
(8) Injection Pump and Air Compressor
12-8
LUBRICATI ON
(9 ) Lu bric ation
of Water
-
12
GENERAL
Pump
The engine oil drawn by the oil pump is routed
The engine oil is
through the crankcase oil passage to the water pump.
to the crankcase and returns to the oil pan.
then forced
back from the drain p ort
The engine oil delivered to the water pump flows through the oil hole of the water pump and lubricates the bearings.
12-9
12
LUBRICATION -
SPECIFICA TIONS,
SERV ICE
S TANDARDS
SPECIFICATIONS
2n
Item
Specifications Q ua lity
Engine oil
(W ith o u ttu rb o c h a rg e rl API cl as si fic at ion Cla ss CC or be tte r (With turbocharger) API cl as si fic at io n Cla ss CD or be tte r [F or gene ral po w er)
(For co n stru c tio n m a chin ery)
Ap pr ox . 27 lit.
Oil pan capacity Oil filter capacity Lubrication method
Ap pr ox . 25 lit.
4 to 4.5 lit. 4 to 4.5 lit. Forced lubrication by oil pump
Oil pump Relief valve
Type
Forced lubrication by gear pump (with built-in relief valve)
T ype
Ball valve
Oil filter F u ll-f lo w f ilteerle m en t
Filter paper type
Type
Filter paper type
Type
Bypass filter element Oil bypass alarm
Piston valve type with built-in electric contacts
Type Type
Oil cooler Oil bypass valve Regulator valve
Shell and plate type (multi-plate type)
Type
Piston valve type
Type
Piston valve type
Type
Piston valve type
Oil jet Check valve
3. SERVICE 3.1
SERVICE
STANDA RDS SYAM OAR0
TAB LE Unit: mm
Description
Oil pressure (Oil temperature at 70 t o 90' C
At idle
Oil pump
12-10
At m ax im um spe ed
Nominal value (Basic diameter)
L im it
145 kPa (1.5 kgf/'cm2) or more
49 kPa (0.5 kgf/cm2)
C o rre ctio n and rem arks
Inspection.
295 to 490 kPa (3 to 5 kg f/cm 2)
195 kPa (2 kgf/cm2)
Ad jus t.
Backlash between crankshaft gear and oil pump idler gear
0.13 to 0.25
0.4
Replace.
Backlash between idler gear and oil pump gear
0.11to0.24
Difference between pump case depth and gear height
0.05 to 0.11
0.15
Replace.
Gear tooth tip to pump case clearance
0.11 to 0.18
0.2
Replace.
Drive gear shaft to cover clearance
(20) 0.04 to 0.07
0.15
Replace.
Driven gear shaft to driven gear clearance
(20) 0.04 to 0.07
0.15
Replace.
Idler gear shaft to idler gear clearance
(22) 0.03 to 0.05
0.15
R eplace b ushin g.
0.4
R eplace.
LUBRI
Oil pump
CATI ON -
SERVI
Description
Nominal value IBasic diameter)
Relief valve valve opening pressure
1180 kPa (12 kgf/cm')
Relief valve spring load (Installed length: 46.3)
150 to 165 N (15.3 to 16.9 kgf)
Oil bypass alarm valve opening pressure (ON start pressure)
CE STA
12
NDARDS
Limit
Correction and remarks
Replace spring.
345 to 390 kPa (3.5 to 4 kgf/cm'')
Replace.
Oil cooler bypass valve opening pressure
175 to 215 kPa (1.8 to 2. 2 kg f/cm 2)
Replace.
Regulator valve
360 to 420 kPa (3.7 to 4. 3 kg f/cm 2)
Replace.
Valve opening pressure
Spring load (Installed length: 48.3) Check valve
3.2
76 to 80 N (7.8 to 8.2 kgf)
opening pressure
TIGHTEN
ING
265 to 325 kPa (2.7 to 3.3 kgf/cm2)
TORQUE
Replace.
TABLE
Description
Thread size O.D. x Pitch mm
Tightening torque Nm (kgfm)
M12 x 1.25
59to 78 (6 to 8)
Oil pump idler gear shaft nut
Oil bypass ala rm
Remarks
A p pl y LOC TITE No. 262. ’
M20 1.5 x 44 to (4.5 to 54 5.5)
Oil filter center bolt
M16 x 1.5
Oil cooler bypass valve
M27x1.5
R e gu la va to rlve
M27 1.5 x
Oil pan d rapinlu g
M18 1.5 x
Oil je check t valve
M12 1.75 x
59 to 69 (6 to 7) 15to 20 (1.5 to 2.0) 98 to 115 (10 to 12) 69 (7) 34 (3.5)
12-11
12
LUBRICATION
-SER VICE
4. SERWOCE PROCEDURES At idle NV 145 kPa (1.5 kgf/ cm 2) or more 49 kPa (0.5 kgf/cm2) L At m ax im um spe ed NV 295 to 490 kPa (3 to 5 kgf/cm2) 195 kPa (2 kgf/ cm 2) L NV . L .
PROC EDUR ES
MOTE: 1. To remove the oil cooler, remove the injection pump beforehand. 2. After the element has been installed, start the e ngine a nd check co nnection for oil leaks. (2) Oil Pump, Oil Strainer
Nominal Value Limit
B9016A
With the.oil pressure switch removed and pressure gauge installed, worm up the engine until the oil temperature reaches 70°C to 90°C. Measure the oil pressure at idle and maximum speeds. If the measurement is below the limit, overhaul the lubricating system.
4.1
REMOVAL
AM O INSTA LL A TION
(1) Oil Filter, Oil Cooler
M O T E:
1. Measure the backlash in advance of removal of oil pump. 2. The oil str ainer and oil pipe should be removed together with the oil pump unless anything wrong is evident. 3. After the oil pump has been installed, verify that the backlash is within the specified range.
12-12
s
LUBR IICATI ON 4.2 4.2. 1
SERVI CE
12
PRO CED URES
DISASSEM BL Y, IMSPECYI OM AMD ¡REASS EMBLY Oil Pump
(1) Disassemb
ly and Ins pectio n
6 Idler gear 7 Seat 8 Spring
1 Oil strainer Oil pump cover Driven gear
(2) 3 4 5
Driven gear shaft Idler gear shaft
9 Ball 10 Case and gear assembly
For disassembly of parts with an encircled number, see following items. The part marked * must be inspected before disassembly.
NOTE: 1.
Do not remov
e the driven
gear shaft unless
Removal of the shaft may resu
it is faulty
.
lt in l oss of all
ow ance
a non-disa
ssemb led
for tightening the oil pump case. 2.
The case a
nd gear
assembly is
type. Replace the assembly if it is defective.
C9518D
12-13
12
LUBRICATION
-SER VICE
PROC EDUR ES
Disassembly and Inspection Procedure (a) Before disasse m bly, m easu re and record the backlash between the oil pump gear and the idler gear.
2)
Measure the cl earance between the drive and
driven gear tooth end and the oil pump case with a thickness gauge.
(b) Remove the oil strainera
nd drive out the oil pum p
cover with a plastic hammer etc.
INIOTE; The oi l pump cov er is loc ated by the dow pins installed to the oil pump case.
el
(c) Before the driven gears are removed, measure and record the following items.
(d) Measure and record the outside diam
eter of e ach
of the drive gear shaft, driven gear shaft and idler gear shaft. Then, measure and record the inside diameter of each of the oil pump case, cover and driven gear bushings. Calculate the clearance be tween eac h sha ft and bushing. exceeded, replace the assembly.
1)
Measure the di fference b etween the drive and
driven gear height and the oil pu thickness gauge.
12-14
m p case depth w ith a
If the service lim
it is
LUB RI CATI ON (2 ) Reassemb
NOTE: 1. Before
SERV ICE PRO
CEDUR
ES
12
ly
reassem
bly, apply
engine oil
to a ll parts unless
otherwise specified. 2.
Temporarily
tighten the oi
l strainer,
taking int
o consid
eration its installation to the crankcase.
C9525C
12-15
12 4.2.2
LUBRICATI ON -
SER VICE
PROC EDUR ES
Oil Filte r
1 2 3 4 5 6 7 8
Drain plug Center bolt Washer Oil fi lter case Oil filt er element Element retain er Oil fi lter head Oil bypass alarm
C9705C
Inspection of Oil Bypass Alarm
With no air pressure applied, check for continuity across the terminals as shown and replace the oil bypass alarm if there is continuity. Next, with the air pressure applied and gradually increasing, measure the air pressure when there is continuity. If the m easurem ent is out of spec oil bypass alarm.
Oil pressure switch not functioning properly Loaded oil filter element
Replace Replace element
Lo aded o il s tra in e r, lo o s e o il p u m p jo in t, cracked pipe
C o rre c t o r replace
Relief valve, bypass valve not functioning properly Worn or damaged oil pump proper Excessive oil consumption
Oilleaksf ro meng in e
Replace C o rre c o t rrepla ce
Oil leaks fro m c ra n ks h a f t f ro n t o r re a r o il seal
G ro u p11
C o rre c t o r repla ce
Leaks to cooling system ® Defecti ve oil cooler
water jacket
A bn or m al co m pr es si on pre ss ure
Correct or replace Check
G ro u p 11
12-19
í
F O D tliL AND
NG E INE
C O N T R O L. eOPJTEMTS
1. GENERAL ......... . 2. SPECIFICA TIONS ..... .............. ....... 3. SERVICE STANDARDS .................. 3.1 SERVICE STANDARD TAB LE ..... 3.2 TIGHTENING TORQU E TABLE ... 4. SPECIAL TOOL ................ ............ .. 5. SERVICE PROCEDURES ..... ...... .....
2 22 23 23 25
27 30
5.3
FEED PUM P
5. 3. 1
..............
......... .......
Disass em bly , Insp ectio n and l Rea ss em b ly .... .... .... .... .... .... ..
5.3.2 Tes t and A dju stm ent .. .. .. .. .. .. 5.4 A UTO MA TIC TIMER .. .. .. .. ... .. ... . 5. 4. 1
SA Type A uto m atic Tim er
....
5.4.2
SP Type Au tom ati c Timer
....
5.1 INJ ECT ION PUMP .................. .... 31 5.1.1 Removal ................................. 31 5.1.2 AD Type Injec ti on Pump ......... 32 5.1.3 P Type Injec ti on Pump .......... . 40 5.1.4 Adjus tment after Reassembly ............................ 49 ........ . 5.1.5 Installation 57 5.1.6 Bleeding the Fuel Syst em ...... 60
5.4.3 Tes t and A dju stm ent .. .. .. .. .. .. 5.5 PUM P DRIVE CASE ... .... .... .... ...
5. 6. 1
Rem ov al and Ins tallatio
5. 1. 7
5.6.2 5.6.3
Dis as s em b ly ... .... .... .... .... ... ... Cleaning and Insp ectio n .. .. ..
5. 6. 4
Reassembly
5. 6. 5
(1-sp rin g n o zzle) Reassembly and
5. 1. ®
Insp ecti on a nd Ad justm ent Fuel Inject ion Sta rt Tim ing
GOVERNOR . RSV Ty pe Go ................................... ver no r ... .... .... .... . RFD Typ e Go ver no r ... .... .... .... . Ad justment Inspec tion
after Reassembly and A djus tm ent
61
62 64 64 67 70
5. 5. 1
Rem ov al and Ins tallatio
5. 5. 2
Disa ssemb ly and Ins pec tion .......................................
n
5 .7
5.8 6.
and
Ad justm
81 82 83 83 88
.. .. .
5.5.3 Rea ss em b ly .... .... .... .... .... .... .. 5.6 INJE CTIO N NOZZL E .. ... ... ... ... .. n
81
.. ...
93 94 95 95 95 96
ent
... .... .... .... .... Ad justm ent
97
(2-spr ing n o zzle) ... .... .... ... .... . FUE L FIL TER ............. ......... ......
98 104
WA TER SEPA RA TOR
105 106
TR OU B L ESH OO TING
... ... ... ... ... ... ... .... .... ... .
off
No-load Minimum and Maximum Speeds
............................................
80
13-1
13 1.
FUEL
AND
ENGINE
CONTROL GE - NERAL
GENERAL
NOTE: The figure shows the AD improved version injection pump. B2115A
The fuel system consists of the injection pump general assembly (injection pump proper, governor, timer, feed pump and coupling), fuel filter, water separator, injection pipe, injection nozzle, fuel leak-off pipe, etc. The injection pump is driven at one-half the engine speed.
13-2
FU EL AN D ENGINE (1)
CON TROL -
13
GENERAL
Inj ec tio n Pu m p Ps-opes1
(a) Injec tion pump
The cam shaft driven
at half
the eng ine speed is
3)
To prevent the
fuel in the oi l sump from
leaki ng
supported by taper roller bearings at both ends. The
into the cam chamber, an O-ring is provided on the
camshaft has a cam for operating the plunger and a
outer circumference of the plunger barrel, thereby
cam for operating the feed pump.
maintaining its tightness.
A ta p p e t o pe ra ti n g w it h th e p u m p h o u s in g as th e
4)
guide is in contact with the camshaft. The tappet
of t he p lunger barrel to prevent erosion o
changes the rotary mo
housing
tion o f the ca m to up -and-down
motion which is transmitted to the plunger.
A deflec tor is prov ided on the oute r circum ference that m ay be caused by coun
f the pump ter flow o f fuel at
the end of an injection.
The P type injection pump offers the following features. 1)
The pump
2)
The plunge r barr el has an obliqu e hole made to
housing
is a tota lly enclosed
type.
return the fuel that has leaked to the oil sump to m inimize the leakage of
the fuel into the cam
chamber.
13-3
13
FUEL
AND
ENGINE
{lb! Plunger
CONTROL GE - NERAL
The plunger has an oblique groove and a vertical groove, while the plunger barrel has 2 inlet-outlet holes. Pressurized feeding of fuel oil begins when the plunger, pushed up by the cam of camshaft, closes the inlet-outlet holes of plunger barrel. When the plunger is further pushed up, fuel oil is discharged through the vertical groove of plunger from the inlet-outlet holes.
Fuel drawn
in
Beginn ing of pressure feed
Pressur e feed
End of pressure feed
B2204A
AD ty p e in jec tio n pum p
P ty p e in jec tio n pum p
Control rod Plunger
barrel
Plunger
B2206A
B2224A
A d e fl e c to r is in s ta ll ed on th e p e ri p h e ry o f t h e p lu n g e r
which engages with the control rod (or the control
barrel so that high pressure fuel oil discharged from
rack and pinion). Since the driving face of plunger
inlet and outlet ports will not erode the pump
meshes with the control sleeve at the lower part
housing. Fuel injection volume is controlled by the
thereof, t he plunger turns w
governo r which
sleeve and injection volume is controlled through the
moves the control
rod (or the control
rack) left and right and rotates the control sleeve
13-4
ith the rotation
changing of the effective stroke.
of control
FU EL AN D ENG INE CONTROL -
13
GENE RAL
A d e li v e ry v alv e s to pp er, p ro v id e d on th e to p o f th e delivery valve spring, limits the lift of the delivery Effective stroke
valve to prevent the surging of the valve during high speed operation. It also reduces the dead volume between the delivery valve and nozzle and stabilizes the injection rate.
(d) Overflow valve
B2205A
The effective stroke means the length of the plunger stroke from the time when the upper end of plunger closes the inlet-outlet holes of plunger barrel until the oblique groove of plunger opens to the inlet-outlet holes. When the effective stroke stands at zero, it indicates that no fuel injection takes place.
(c) Delivery valve When the fuel pressure in the injection pump exceeds a predetermined pressure, the steel ball in the overflow valve is pushed up to let the fuel flow out from
the injection p
thereby stabili
um p and return to
the f uel tank,
zing the fuel temperature and temp
era
ture distribution in the injection pump and maintain ing the injection rate into each cylinder constant.
The fuel highly pressurized by the plunger pushes the delivery valve up and gushes out. When delivery of the fuel under pressure by the plunger is completed, the delivery valve is pushed back by the de
livery valve
spring and closes the fuel passage to prevent counter flow
of the f uel.
The delivery valve is further brought down until it is held against the seat surface tightly. The amount of fuel corresponding to the stroke during the period is drawn bac k from above to instantly low
er the resi dual
pressure in the line between the delivery valve and nozzle. The draw back effect improves the cutting of fuel from the nozzle and prevents after-injection dripping.
13-5
13
FUEL
AND
ENGINE
CONTRO L -
GENERAL
(2) Governor (aj KSW ftyp e g ov ern or Supporting lever
B2657B
The RSV type governor is a centrifugal type all-speed
The governor, as shown, consists of flyweights
governor coupled to the camshaft of the injection
mounted to the injection pump camshaft. When the
pump. The governor not only controls the maximum
flyweights turning on the flyweight supporting shaft
and minimum speeds but also automatically controls
open outward, the roller mounted to the end of
the engine speed at any intermediate speed position.
flyweight arm pushes the end of the sleeve in the axial direction. The governor sleeve, being made integral with the control block through a bearing, moves only in the axial direction. The control block, mounted to the guide lever hung on the supporting lever shaft of the governor cover, prevents rotation.
13-6
F UE L AND
ENGI NE CONTROL -
13
GEN ERAL
When the governor spring receives tension, the bottom end of the tension lever touches the adjust able full-load stopper bolt. When the angle of the adjusting lever is changed, the angle of the swivel lever is also changed and the tension of the governor spring changed. This is because t he turn ing center of the swivel lever an m ounting
position of the gove
d the
rnor spri ng inst all ed to
the tension lever are eccentric to each other as mentioned above. A n a dju s ti n g sc re w is al so m o u n te d to th e s w iv el lever. Adjustment of the screw changes the tension of the governor spring, thereby making it possible to adjust the speed regulation. An U n g le ic h s pri n g is p ro v id e d in th e b o tt o m p o rt io n of the tension
lever . Ad just the tension of the spri
ng
by adding or removing shims. An
id li n g
provided
su b
s p ri n g
adju s ta ble
fr o m
o u ts id e
in t he m iddle of the governor cover. Duri
is
ng
idling, the spring always keeps in contact with the tension lever to maintain a constant idling speed. The st op lever, mounted through the supporting lever to t he b ottom end of the control lever , returns t he The control lever
is m ounted
to the m iddle of th e
guide lever by the shaft with the bottom end as the
control rack to the stop position with a slight pressure irrespective of the adjusting lever position.
fulcrum, whereas the top of the lever is coupled
H| Start of engine
through the shackle to the control rack. The start spring, attached to the top end
of the control
lever, always pulls the control rack in the direction that fuel is increased.
When the adjusting lever is moved to the start position (until it touches the maximum speed stop per ), the sw ivel lever
wh ich moves w ith the adjusti
The turning shaft of the swivel lever is fitted into the
lever pulls the governor spring and moves the tension
bushing of the governor cover and its center is
lever until it touches the full-load stopper bolt.
eccentr ic with
ng
respec t to the m oun ting position of the
governor spring installed to the tension lever. The gov erno r spring is install lever.
ed to the end of the swivel
13-7
13
FU EL AN D ENGINE CONTROL -
A t th a t ti m e , th e fl y w e ig h ts are s ta ti o n ary , an d the
GENE RAL
3) Ma ximum
spee d control
start spring with weak tension pulls the control lever in the direction that fuel is increased. A t th e sa m e ti m e, th e c o n tr o l blo c k an d g o v e rn o r sleeve push the flyweight roller to the left. As th e re s ul t, th e te n s io n le v er an d c o n tr o l bl oc k are spaced that much apart, and the corresponding amount of fuel is supercharged to facilitate starting.
2) Ddling control
When the adjusting lever is moved to the full-load position, the tension of the governor spring is in creased and pulls the tension
lever until it
touches the
full-load stopper bolt. When the engine exceeds the specified speed, the centrifugal force of flyweights becomes larger than the force of the governor spring pulling the tension lever. So the tension lever is moved to the right and moves the control rack in the direction that fuel is Once the engine is started and the adjusting lever
redu ced, t hereby
returned to the idling position, the tension of the
ing the specified speed.
preventing the engine from
excee d
governor spring is drastically reduced.
If the speed fu rther incr eases, the centrifugal force o
Now the flyweights can move outward even at a low
flyweight increases and pushes the tension lever to
speed, so the tension lever is pushed back until it
the righ t and also com presses the idling sub spring to
touches the idling sub spring and places the control
pull the control rack back to the no-load maximum
rac k at the idling
position.
speed position, thereby preventing over-speed opera
In t his state, the centrifugal
force of the flyweights and the weak-state governor
tion of the engine.
spring and idling sub spring achieve balance and
The RSV type governor controls the entire speed range from idling to maximum speed. If load in
maintain smooth idling. When the speed fall s, the ce ntrifugal
force decre ases,
the f lywe ights m ove inward, and t he idling sub spri pushes the tension lever to the left and moves the control rack in the direction that fuel is increased. If the speed falls radically, the start spring with weak tension acts and moves the control rack in the direction that fuel is increased to maintain the idling speed.
13-8
f
ng
creases of decreases at a certain speed determined by the pos iti on o f the adjusting lever, the gov erno r automatically functions and maintains the engine speed constant at all times.
FU EL AND
ENGI NE CONTROL -
4) UsugleSch operation
13
GENE RAL
The air intake rate of the engine falls as the engine speed increases. The injection pump, on the other hand, increases the per-stroke injection as the speed
When max. injection is set at low-speed operation \
Injection/stroke
A
increases, even with the control rack at the same position.
Injecti on matched \ with air intake rate
Therefore, if full load is set at point A to derive
1
enough output at low speeds, the injection will reach
-
4
-
-
-
1 B
A'
°
B as the speed increases, and
1 When max. injection is set at high-speed o peration |
the en gine w ill produ ce
black smoke. If full load is set at point B' to prevent black smoke, the low speed injection will come down to A', allowing
Engine speed
combustion of more fuel. B2663A
So the Ungleich device accomplishes the function of setting full load at point A to derive the largest
The Ungleich device controls fuel injection in such a
possible torque in the low speed range, and changing
way as to match the engine performance (the re
it to adjust the injection to point B' in the high speed
quired injection varies with engine speed).
range.
n , / \ Pum p sp ee d Ir pm)
^
Enqine speed (rpm ) a r
B2664A
When the engine speed is low and the centrifugal force of flyweight smaller than the pressure of the Ungleich spring, the control block is moved as much as the Ungleich stroke to the left, so the control rack moves in the direction that fuel is increased to increase the torque of the engine at low speeds.
13-9
13
FUEL AND ENGINE
CONTRO L -
GENERAL
5) Stopp ing of
eng ine
As th e e n g in e sp ee d in cr ea se s, th e c e n tr if u g a l fo rc e o f flyweight increases. If it becomes larger than the
When the stop
pressure of the Ungleich spring, the Ungleich spring
control rack is moved to the stop position to stop the
is slowly compressed before the start of high speed
engine regardless of the position of the adjusting
control, and the control rack moves in the direction
lever.
that fuel i s reduced. The Ungleich
lever i s move d to the stop pos
iti on, the
stroke is com pleted
at the position where the control block directly touches the tension lever.
6)
Operation of
torqu e spri ng [Option]
B2667A
Con struction m achinery engines ar to a large load during ope ration,
13-10
e oft en subjected
and reduced speeds
often lea d to stal ls. To prevent this, a torque spring is provided.
FU EL AMD ENGI
NE CONTRO
When the adjusting lever is fixed in the lever set
L -
13
GENE RAL
A t th e ti m e , th e te n s io n le v er pin pu sh es th e b o tt o m
position, a sudden increase of load, if no torque
of the torque control lever, and the lever moves with
spring is provided, will move the control rack along
the pin "A " as the fulcrum , whereas the portion
the B-D curve as the speed falls. The rotational
pushed to right. As the result, the torque spring
displacement at the time may be expressed as P,.
performs the function of reducing movement of the
If a torque spring is provided, the control rack moves
tension lever.
"B " is
along B-C, and the rotational displacement at the time may be expressed as P2. Therefore, large changes
(b) RFD (type governor [Option]
occ ur in P 2 and eng ine spee d, and because of increased fuel injection, the engine torque increases, and lar ge com bustion
nois e warns the operator of the
increased load, enabling him to take proper action to prevent stopping the engine.
The RFD type governor is a minimum-maximum governor which controls only the minimum and maximum speeds. The RF D type go vern or m ake it possible to increa reduce fuel by the load control lever which operates In an abrupt increase of load occurs when the engine
the control rod. Any desired speed can be set as a
is running at continuous rating, the engine speed
displacement of the speed control lever changes the
falls. So the flyweights are moved inward and the
tension of the governor spring.
tension lever pulled to left by the control spring,
Becau se of the con struction
causing the control rack to move in the direction that
gov erno r can be operated as a
fuel is increased.
described above, the
se or
RFD
n all -speed go verno r by
holding the load control lever in the FULL position and operating the speed control lever. On the top of the governor, an engine stop lever is provided which creates a no-fuel injection state for stopping the engine. A cancel spring is provided to make sure that when the lever is operated, no undue force is applied to the link.
13-11
13 1)
Start of
FUEL
AND
eng ine a nd co ntrol of
ENGINE
CONTROL GE - NERAL
idli ng
Increase
Injectio n rate —*- Decrease
B2605A
If the load control lever is placed to the idling position When the engine is stationary, the flyweight is in
after the engine has started, the floating lever will
closed position, pushed by the governor spring, idling
move the control rod back to a position where a fuel
spring and start spring. If, in this condition, the load control lever is moved all the way to the FULL position (in the direction of greater fuel delivery), the start spring and idling spring will cause the control rod to move to the fuel increasing position.
injection rate suitable for the idling speed is available, with the point B as the fulcrum. As th e eng in e sp ee d inc re as es , th e fl y w e ig h ts w ill move outward by the centrifugal force and will shift the shifter by the point A until the shifter compresses the idling spring. A t th is ti m e, th e fu lc ru m B w il l al so s li g h tl y m ov e toward the tension lever and will move the control rod back in the direction for reducing the fuel injection rate. As th e en gi n e sp ee d de cr ea se s, th e c en tr if u g al fo rc e of the flyweights will decrease and the flyweights will move inward, so the point A will return toward the pump housing. This will set the shifter in the free state, pushing it back toward the pump housing by idling spring force.
13-12
FU EL
A t th e sa m e ti m e, th e fu lc ru m
AND
ENGI NE CONTRO
B w il l al so s li g h tl y
L -
13
GEN ERAL
As th e eng in e sp ee d inc reas es , th e c e n tr if u g a l fo rc e o f
move toward the pump housing to push the control
the flyweight will increase, and the flyweight will
rod back in the direction for decreasing the fuel
push the shifter. In the normal speed range, however,
injection rate.
the shifter will have only a thrust enough for com
In this manner, the idling speed is maintained stable
pressing the idling spring and will not be able to push
by slight adjustment of the injection rate.
the tension lever out by
ove rcom ing the tension of t
he
governor spring.
2} Norma
l speed ope
rati on
In this manner, the fuel injection rate is increased or reduced simply by operation of the load control lever which moves the control ro d.
3) Gorji
ral of
m aximu m speed
Increase
Injec tion rate -*»- Decrease
If the control lever is moved toward FULL (in the direction of greater fuel delivery), the eccentric shaft coupled
to the load control
lever will cause
the sliding
lever to turn with the point D of the tension lever as the fulcrum . In addition, the f loating lever will push
If the engine speed exceeds a predetermined max
the control rod back in the direction of greater fuel
imum speed because of changes in engine load,the
injection rate, with the point B as the fulcrum.
centrif ugal force of the fl tension of the gove
yw eight w ill overcome the
rnor spring and w
ill push the
tension lever together with the shifter.
13-13
13
FUEL
Mo vem ent of the shifter will m
AND
ENGINE
ove the point B, a
CONTROL GE - NERAL
nd
movement of the tension lever will move the point D, and will
also mo ve the p oint C with the p
With smoke set assembly
oint E as the
fulcrum. Movement of the point B and movement of the point C w ill com bine to
pull the control
direction o f le ss fuel injection
rod back
in t he
rat e, t hereb y preventing
the engine speed from increasing. If an engine control mechanism which operates the speed control lever adjusting the tension of the governor spring is employed, the governor can be operated as an all-speed governor which maintains a desired engine speed constant.
45 Start booster (smoke set assembly)
Pump speed (rpm) B2674B
As in dic ate d by th e g o v e rn o r c h ar ac te ri s ti c s s h o w n above, when without the smoke set assembly, the shifter and floating lever are pushed back by the idling spring for
ce, m oving the control rack
tow ard
fuel increasing direction when pump speed reaches N.. N am ely, N. i s the smoke lim
it in this cas e.
When with the smoke set assembly, the spring force of the smoke set assembly overcomes that of the idling spring so that the floating lever motion is inhib ited un til the speed reaches N2 lim it decreases
from
. Thus, the sm oke
N. to N2.
It is also possible to secure rack position Rs needed at time of start.
The smoke set assembly installed to the rear of the gov erno r has a spring w ith setting force and a
stopper
as functional parts. It also has sleeve, stroke adjusting nut, spring adjusting nut and cap.
13-14
FU EL AN D ENG INE CONTRO 5} Engine stop
L -
13
GENE RAL
The floating lever A pushed by the floating lever link turns in such a way as to make the cancel spring bend over the shaft B. So no load is placed on the floating lever C blocked by the idle stopper bolt outside the governor. Operation of the ungleich device is the same as the RSV type governor.
{3 } Feed
Pum p
To stop the engine, fuel is cut off by operating the stop lever on the top of the governor. If the stop lever is operated, the internal lever pushes the pawl of the floating lever link to force the control rod out to the no-injection position. Since the amount the control rod is moved by operation of the stop lever exceeds the operating range of the floating lever mechanism, damage to the link and allied parts is prevented by the cancel
Supply of fuel to the injection pump proper is
mechanism shown.
accomplished by the feed pump mounted to the side of t he injecti on pum p p roper and dri
ven by t he cam of
the injection pump camshaft provided for the pur pose. The priming pump mounted to the feed pump makes it possible to lift fuel manually when the engine is stationary.
B1631A
13-15
13
FUEL
AND
ENGINE
CONTRO L -
GENER AL
When the pressure of the pressure chamber or the delivery pressure exceeds specification, the piston cannot be brought back by the pressure of the piston spring, so the pump action stops and the fuel pressure in the fuel filter does not rise more than necessary.
(4) Autom
ati c Tim er
The interval between fuel injection into the cylinder and its ignition is called the ignition delay interval. The ignition delay interval is constant regardless of the engine speed. If
the ignition
tim ing
is always
constant, changes in the engine speed will vary the The feed pump feeds fuel under pressure as follows.
relation between the piston position and ignition
When the piston is pushed up by the cam of the
timing , m aking it impossible to obtain the best engi
camshaft, the fuel in the suction chamber opens the
performance. To maintain the relation between the
outlet check valve, so most of the fuel is forced out
piston po sition and ignition tim
and drawn into the pressure chamber. When the cam
times, the injection timing
is mo ved aw ay by rotation of the camshaft, the piston
the engine speed.
is pushed back by t
The automatic timer is a device which automatically
he p ressure of the piston
spring. At
the time, the outlet check valve closes and the inlet
changes the i njection tim
check valve opens. So fuel is drawn into the suction cham ber, whereas the fuel in t he pressure cham ber is
speed.
ing
ne
constan t at all
mu st be changed to match
ing according to the
engine
forced out.
(a) SA type automatic timer [6P22]
Flyweight
B3210A
13-16
FU EL
AND
ENGI NE CONTROL -
13
GEN ERAL
The two flyweights have a hole at one end. The pins of the flyweight holder fit in the holes. The flange legs touch the curved surfaces of the flyweights. Timer
e Spnng extension
At max imum , . advance anqle J
springs are mounted to the flyweight pins and flange legs. Rotation of the engine is
trans m itted to the fl ange and
from there t o the f lange legs , fl yw eights and fl yw eight holder and to the injection pump camshaft.
B3212A
When the engine runs at a high speed, a centrifugal force acts on the flyweights and causes them to open outward with the pins of the flyweight holder as the fulcrums. The flange legs are pushed by the curved surf aces of the flyweigh
ts in t he d irecti on of the ti m er
spring compression, but they cannot be moved because they are coupled to the drive side. As a re s u lt, th e p in s o f th e f ly w e ig h t h o ld e r are dra w n During low speed ope rati on of the engine , no cen tri fugal force acts o n the flyw eights, so t he tim er springs
in the turning direction, while compressing the timer spri ngs, and move the c amshaft of t he pum p in t he
have the longest installed length.
turning direction to advance the injection timing. If the engine speed chan
ges from
the centrifugal force of the flyw
a hi gh to low speed, eights
w ill de cre ase
and the flyweights will return to their srcinal posi tions. At the same time, the pins of the flyweight holder w ill be pushed back b
y the tim er springs.
13-17
13
F UE L AND
{IsSSP typ e auto m atic
ENGI NE CONTROL -
tim er [6022
GEN ERAL
-Y, TC]
Oil seal
B3201A
Two flyweights are fitted on the pins of the timer
Timer springs are held between the spring seats fitted
housing
on the time r housing pins which extend through
and ar e held in
other hand, the inject
the tim er hou sing. On the
ion p um p conn ection side f
lange
has a curved surface, and the roller fitted on the pin
tim er hou sing and are
installed in
O-ring and oil seal.
13-18
the fl yw eig ht touches the curved
surf ace.
th e
flange and flyweight. These parts are housed in the tota lly enclosed with
a cover,
FUEL
AND
ENGINE
CONTROLGEN - ERAL
13
(5) Cou pling [For AD type] Time r spring
Flange
B3405A
[For P type]
B3202A
When the en gine is running
at a low speed, the time r
spring pressure is stronger than the centrifugal force of fl yw eight, so th e roller of fl yw eigh t is hel d dow n by the flange, creating no advance state. When the engine reaches a high speed, the centrifug al force of flyweight becomes stronger, the roller of flywe ight pushe s the curved surfa time r housing pin as opens outwa
the f ulcrum,
ce of flange with the and t he flywe ight
rd, while compressing the time
r spri ngs.
In this manner, the roller installed on the flyweight moves the flange in the turning direction and adv
The coupling which transmits drive power from the air compressor crankshaft or injection pump drive cranksh aft t o the autom atic time r is a laminated coupling consisting of thin plates placed one upon another.
ances the injection timing. The laminated coupling, thanks to the reversibility of the plates, absorbs excess forces other than the torque, thereby providing protection against applica tion of forces other than necessary to the injection pump. A d ju s tm e n t o f th e fu el in je c ti o n s ta rt ti m in g is m ad e by changing the installed condition of the driving coupling.
The high pressure fuel which has forced the needle valve up is injected from
the orifice at the en
d of the
nozzle into the engine combustion chamber. Some of the high pressure fuel lubricates the needle valve, etc. and is returned through the fuel leak-off pipe to the fuel tank. The injec tion p ressure of t he injec tion adjusted by cha
nging the tension
nozzl e is
of the nozz le spring
with the adjusting screw.
(b) Hole type (2-spring nozzle) [Option]
The pump drive case is mounted on the flywheel housing the timing
on the left side of
the engine and
is driven by
gear of the engine at half the engine speed.
To leak-off pipe
Cap nut
The pump drive shaft, with its end connected to the
Ad ju st in g sc rew
coupling of the injection pump, drives the injection
From injection pump
pump.
2 spring
(7) O irajectiori IMozzl e
Prelift adjusting shim Spacer
(a) Hole type (1-spring nozzle)
No. 2 pushrod Nozzle holder Valve opening pressure adjusting shim No. 1 spr ing No. 1 push rod Needle valve
Nozzle Retaining nut
B3406A
The fuel delivered from the injection pump enters the nozz le holde r and overcome s the No . 1 and No . 2 springs, depending on its pressure, and pushes the needle valve up. The high pressure fuel which has forced the needle valve up is properly injected from the orifice at the end of the nozzle into the engine combustion cham ber. Some of the high pressure fuel lubricates the needle valve, etc. and is returned through the fuel leak-off B3407A
The fuel delivered from the injection pump enters the nozzle holder and has a pressure higher than the specified pressure. So the fuel overcomes the nozzle spring and pushes the needle valve up. 13-20
pipe to the fuel tank. The injection pressure of the injection nozzle is adjusted by changing the tension of the nozzle spring with the shim and adjusting screw.
FU EL AND (3) Fuel
ENGINE CONTROL -
Filt er
(9} W ater
13
GENE RAL Separato
r [Option]
B3551A
The fuel filter is a spin-on type. So the element Is
The sedimenter type water separator separates gas
easily replaceable.
oil and water centrifugally by taking advantage of
The fuel filter separates the water contained in the
their difference in specific gravity.
fuel fed under pressure from the feed pump of the
The fuel that has flowed in from the inlet connector is
injection pump and removes dust and dirt by the
squeezed by the fuel path of the head to increase the
element.
flow velocity and spins. The separated water is sedimented in the case, whereas the water-separated fuel is drawn th
roug h the fuel
path in t he center of th e
head into the feed pump. The water separator sediments not only water but also mud components. A red fl o a t go es up an d d o w n w it h th e w a te r leve l in the semi-transparent case, making it possible to visually check the water quantity.
13-21
13 2.
FUEL
AND ENG INE
CON TRO L
-
SPEC IFICATI ONS
SPECIF0CAT0ONS
Specification
Item (Diese
Kik i Co., Ltd. product) (6D22-TJ
16D22I Injection pump proper Type Model Turning direction (as viewed from drive side) P lu n ge r
D ia m e te r
G o v e rn o r
Type
Fee d pump
mm
(Standard)
(O p tio n)
Bo sch in -lin e type
Bosch in-line type
AD
AD
C lo ckw ise
Clo ckw ise
10.5
P
RFD
RSV
RFD
KE
KE
K
K
Mechanical automatic timer
SA
Mechanical automatic timer
SA
Piole type (1-spring nozzle)
Type
Orifice diameter
4 0.37
mm
Orifice angle
°
Injection pressure MPa (kgf/cm2)
13-22
RSV K Mechanical automatic timer
Hole type (1-spring nozzle)
DLLA 4
DLLA 4
0.37
0.37
SP (Sta ndard)
Hole type (2-spring nozzle)
DLLA 4
Al l spe ed governor
SP (O p tio n )
Piole type (1-spring nozzle)
DLLA
Model o rif oNo. fice s
Mechanical automatic timer
SP (S tan d ard )
12
Minimum maximum mechanical governor
RSV
Mechanical automatic timer
Clockwise
12
A ll spe ed governor
Model
Model
Type
Clockwise
12
Minimum maximum mechanical governor
Bosch in-line type
P
Clockwise
In je ctio nnozzle
F uel f ilte r
Bosch in-line type
Model
A ut om at ic tim er Ty pe
Water separator
(O p tio n )
Bosch in-line type
10.5
A ll speed governor
16D22-TC)
(Stan d ard )
0.37
(Option)
Hole type (1-spring nozzle)
Hole type (2-spring nozzle)
D LLA
DLLA
5
5
0.36
0.36
154
154
154
154
150
150
21.6 (220)
21.6 (220)
17.7 (180)
21.6 (220)
21.6 (220)
17.7 (180)
S p in-otype n Sediment trap type
FU EL AND ENGI NE CO NTROL SERVICE STANDARDS
13
3c SEPVDGE STAE\3DA13I0)S 3„H
SERVICE
(1 ) Injec
tion
STAN DA RD TAB LE Pump Unit: mm Description
Fuelin je c tio ns ta rttim in g (BTDC)
D ep e n de n ton specification
Eccentricity with respect to air compressor crankshaft (or pump drive shaft) Injection pump proper
0.2 or less
Injection spacing Prestroke
60 AD ty pe P typ e
4.8i 0.05
6D22 (for general power application)
155 kPa (1.6 kgf/cm 2)
6D22 (for construction machinery) 6D22-T, 6D22-TC
255 kPa (2.6 kgf/cm2)
0.02to0.06
Correction and remarks
-
Ad jus t.
-
Ad jus t.
-
Ad jus t.
-
Ad jus t.
0.2
-
Endp la yo cf a m s ha f t
Replace. Replace.
0.1
A d ju s st h im s.
Sliding resistance of control rack (when stationary)
AD ty pe
1.5 gf N or or less) less (150
-
Check.
Sliding resistance of control rod (when stationary)
P type
1.3 N or less (130 gf or less)
-
Check.
T a p pe tcleara nce
ADtype
Full stroke of control rack (or control rod)
Governor
± 30'
4.5 ± 0.05
Overall tappet clearance Ov e rf lo w va lv e o p e n in g p ress ure
Limit
Nominal value (Basic diameter)
Backlash between control rack and pinion
AD ty pe
Dimension from governor housing to shifter
RSV type RFDtyp e
0.3o m r o re
A d ju s t.
21 or more
-
0.15
0.3
19 to 19.2
-
33to 33.4
Check. Replace.
A dj us t sh im s.
-
13-23
FUEL
AND ENGI NE CONTROL SERV ICE STANDARDS
-
Unit: mm D es c rip tio n
Lim it
0 cc/min.
-
Tightness (when 195 kPa (2 kgf/cmz) of air pressure is applied)
Feed pump
Lifting capacity
No. of strokes required before lifting when operated at 60 to 100 strokes per minute
C o rrec tio n and remarks A dj us t or rep lac e nozzle.
0.10 ± 0.02
Ad ju st .
2-spring regulated pressure (open pressure)
24.8 to 25.4 MPa (253 to 259 kgf/cm2)
Ad ju st .
2-spring regulated pressure (cover pressure) with a 0.05 needle valve lift
23 to 23.5 MPa (235 to 240 kgf/cm2)
Ad ju st .
Prelift
13-24
FU EL
3.2
TIGHTEN
ING
TORQUE
TABLE
Description
Thread size O.D. x pitch (mm)
Injection pump bracket Injection pump
13
AND ENGI NE CO NTROL SERVI CE STAN DAR DS
M10 x 1.5
Tightening torque Nm (kgfm)
35 to 53 (3.6 to 5.4)
Delivery valve holder
AD ty pe in je ct io n pump
64 to 69 (6.5 to 7)
Lock plate P type injection pump
Remarks
4.4 to 5.9 (0.45 to 0.6)
Flange sleeve nut
39 to 44 (4 to 4.5)
Delivery valve holder
110 to 1 15 (11 t o 12)
Governor flyweight nut
Tig ht en t hr ee ti mes t o the specified torque.
49 to 59 (5 to 6)
SA typ e a u tom a tic t ime r
Ro und n ut
83 to 98 (8.5 to 10)
SP typ e au tom a tic t ime r
Ro und n ut
125 to 145 (13 to 15)
Cap screw
29 to 39 (3 to 4) 22 to 24 (2.2 to 2.4)
Cover mounting bolt
(For AD type injection pump) B
wf
\
A bo lt
49 to 54 (5 to 5.5)
B bolt
29 to 34 (3 to 3.5)
C bolt
29 to 34 (3 to 3.5)
Q C
-
Eg "* A *
/
\
B B3408A
(For P type injection pump)
A bo lt
74 to 83 (7.5 to 8.5)
B b o lt
59 to64 (6 to6.5)
C bolt
B
59 to 64 (6 to 6.5)
Xji
c[ / r A
B B3401A
Injection nozzle
On e-sp ring nozzle
Re taining nut
M22 x 1.5
Inlet connector
M14 x 1.5
Cap n ut Two-spring nozzle
Retaining nut
M14 1 x M19 x 1
Set s cre w
In le tc o n n e c to r
69 to 78 (7 to 8) 39 to 49 (4 to 5) 59 to 78 (6to 8) 49 59 to 6) (5
Lock nut Cap nut
59 to 78 (6 to 8)
20 to 25 to (2 2.5) M22 1.5 x M14x 1.5
39 to 49 (4 to 5) 69 to 78 (7 to 8)
13-25
FU EL
13
AMD ENGINE CONTRO SERVI CE STA NDARDS
Description
Thread size O.D. x pitch (mm)
In je c tio n nozzle b o lt (f o r a tta c h in g t o c y lin d e r head) Injection pipe union nu t
On pump side
M8 x 1.25
type P
M14 1.5 x
AD ty pe M12 1.5 x
Leak opf fipeye eb o lt Fuelf ilte r Water separator
Injection pump piping tightening eyebolt
29 (3)
9.8 to 15 (1 to 1.5) M14x1.5
25 (2.5)
Ring nut
-
5.9 to 7.8 (0.6 to 0.8)
Drain plug
-
2.9 to 3.9 (0.3 to 0.4)
A ir plu g
M8 x 1.25
7.8 to 9.8 (0.8 to 1.0)
Connector bolt
M14 x 1.5
25 (2.5)
Fuel inlet
-
20 to 25 (2 to 2.5)
Fuel feed (feed pump)
-
20 to 25 (2 to 2.5)
Fuel feed (pump proper)
-
20 to 29 (2 to 3)
Fuel overflow L ub ric a n t(inle t)
L ub ric a n t (o utle t)
Injection pump gear mounting nut of pump drive case
13-26
15 (1.5)
29 (3)
M8 1x C o n n e c to b r o lt
Tightening torque Nm (kgfm)
29 (3)
M1 2 x 1.5
On nozzle side
L -
-
20 to 29 (2 to 3)
A Dtyp e
-
9.8 to 13 (1 to 1.3)
P type
-
12 to 15 (1.2 to 1.5)
AD typ e
-
15 to 18 (1.5 to 1.8)
P type
-
20 to 29 (2 to 3)
M24 x 1.5
22 (2.2)
Remarks
FU EL AN D EN GI NE CONTROL -
13
SPECI AL TOOL
SPECDAL TOOL Unit: mm Tool name Injection pump centering tool
Part No.
Shape
Use
MH061270
Centering of bracket of AD type injection pump
B5032A MH061340
Centering of bracket of P type injection pump
B5031A F iltew r re n c h
MH 061572
Removal of fuel filter element
94 2
1
B5222A
BieseO Kiki [Producís fUjAB Type Injection Pump Proper The part n um bers are the DIESE L KIKI part num bers. Special Tool Name
No. Part
Use
AD ty pe in je ct io n pu m p sp ec ial tool set
105790-1060
Disassembly and reassembly
Universal vice
105794-0090
Mounting base
Tappet pin
157931-7320
Supporting of tappet
Measuring device
105782-4130
Me as ur em en t of ca ms ha ft end p lay
Wrench
157910-1120
Re mo val a nd i ns tal lat ion o f s cr ew
Guide
157920-5400
Pro tec tio n of oi l seal
Roller pincers
157921-3020
Removal and installation of tappet
Tappet pincers
157931-6120
Plunger pincers
157921-6120
Re mo val an d i ns tal lat ion o f p lun ge r
Wrench
157914-0500
Removal and installation of delivery valve holder
Extractor
157925-6520
R em o val of in n e r race
157925-0520
Re mo val o f o ut er race ( timer side)
157925-0120
Removal of outer race (governor side)
157930-4620
Correction of pump housing
Reamer
13-27
13
FU EL AMD
ENGI NE C ONTROL -
SPECI AL TOOL
The part nu mbers are t he DIESE L KIK I part numbers. Special Tool Name
Part No. 105781-0430
Stand
Use Test and adjustment of injection pump
105782-6010
Measuring device
105782-4020 Holder
157931-4400
Nozzle holder wrench
157916-8220
(2)
P Typ e Obje ction
Pum p Prop er The part numb ers are the DIESE L KIKI part numbers.
Sp ecialT o o l N am e P type injection tool
pum p special
Use
Part No. 105790-7050
Disassembly and reassembly
Universal vice
105794-0010
Mo u n tin g b ase
Fitting plate
157944-3620
In sta lla tio n
Plate
157944-3820
Tappet holder
157931-4700
Supporting of tappet
Bracket
157920-9900
Removal of bearing cover
Extractor bearing cover
157920-7720
Tappet mounting device
157921-8020
Removal and installation o
Plunger insert
157921-4820
Removal and installation of plunger
Plunger clamp device
157921-5620
Removal and installation of control sleeve
Extractor
105792-0030
Removal of plunger block assembly
Fitting plate
157944-3520
Disassembly and reassembly of plunger block assembly
Socket wrench
157914-0500
Removal and installation of delivery holder
Special wrench
157915-6500
Re mo va l a nd i ns ta llat ion o f sc rew b us hi ng
Inner race extractor
157925-7120
Removal of inner race
Outer race extractor
157925-2020
Removal of outer race
O-ring insert
105792-0000
Ins tal lat ion o f O- rin g
Plate measuring
157828-7200
Positioning of governor side taper roller bearing
Camshaft measuring device
105782-4140
Measurement of camshaft end play
Fixing stand
105781-0170
Test and adjustment of injection pump
Measuring device
105782-4210 105782-4270
13-28
f tappet
FU EL AN D ENGI NE CO NTROL -
SPECI AL TOOL
13
{3) R8W Ty pe Go vern or The part num bers are the DIESEL Special Tool Name
Part No. 157910-1 120
Handle So cketw ren ch
Use Re mo va l a nd i ns ta llat ion o f l ock nu t
157914-0500
W ren ch
157915-0100
R em o valand in s ta lla tio n o f ro un d n ut
Extractor
157926-5320
Re mo va l an d in st al lat ion of fl ywe igh t
Special w ren c h
(41
KIKI part numbers.
157916-2620
A d ju s tm e n t o f A n gle ich
Typ e Go vern or The part nu mb ers are the DIESE L KIKI part numbers. Special Tool Name
No. Part
Use Removal and installation of lock nut
Handle
157910-1120
Socket wrench
157914-0500
Special wrench
157915-0100
Extractor
157926-5320
R em o val o f f ly we ig h t
Special wrench
157916-2620
Ad jus tme nt of idle speed
Guide screw
157976-3100
Ad jus tme nt of rack limi t
Removal and installation of round nut
(S}SA Type Automatic Timer The part num bers are the DI ESEL KIK I part numbers. Special Tool Name
Use
Part No. Disassembly and reassembly
SA type automatic timer special tool set
105790-5010
Special spanner
157916-5320
Removal and installation of round nut
Extractor
157926-6210
R em o val
Guide bolt
157924-0200
Disassembly and reassembly
Base
157924-0110
Hand spanner
157916-6120
Removal and installation of timer case
Thrust bushing
157924-1500
Ins tal la tio n o f oi l s eal
Guide bushing
157924-1200
Block
157924-0800
Guide bushing
157924-1300
Guide
157924-0900
Support
157932-0100
Guide
157924-0400
Thrust bushing
157924-0500
Installation of flange
Oil seal guide
157914-0600
In se rtion of time r case
Ins tal la tion of f lyw ei gh t
13-29
FU EL AND
13
ENGI NE CONTROL - SPE CI AL TOOL, SERVICE PROCEDURES
(6) SP Type Au tom atic Tim er The part num bers are the DIESEL K Special Tool Name
Part No.
SP type autom atic time r special tool set
105790-5050
Disassembly and reassembly
Box spanner
157915-2320
Removal and installation of round nut
Box wrench
157916-2800
Special spanner
157916-5320
Extra cto r
157926-7220
Base
157924-2520
Specials p an n e r
IKI part numbers.
Use
Removal and installation
Disassembly and reassembly
157916-8320
{7 }¡i njecti on M obile The part nu mbe rs are the DIESE L KIKI part numb ers. SpecialT o o l N am e Nozzle cleaning tool Nozzletes ter A d ju st in g de vic e set
A dj us tin g de vic e Dialgau ge
Part No. 105789-0010 105785-1010 105789-0500 (*: Components)
Ad ju st m en t an d te st in g A dj us tm en t an d te st in g of 2- sp rin g noz zle
*15 789 2-0 220 *157954-3800
Pin
( = 50
*157892-1200
Pin
( = 60.5
*157892-1100
Connector
Use Cleaning of nozzle
*157892-1320
Base
*157892-1800
Gasket
*157892-1500
Retaining nut
*157892-1420
Gasket
*026508-1140
5» SERVICE PR O Gi Dy RE S
Scrupulous car
Wherever possible, test the fuel system parts before
ling and reassembling critical parts.
disassembly to precisely know their conditions.
Use the specified special tools for disassembly and
e m ust be exer cised when
disassemb
Select a clean site for disassembly and reassembly
reassembly; never apply excessive force or handle
work, as even small dust particles on the fuel system
parts carelessly.
parts can adversely affect engine performance. When
Before disassembly, test the system to know exactly
disassembling the injection pump, keep work bench
the trouble spots.
clean and disassembled parts neatly arranged for each cylinder. Use special care to ensure correct combination of plunger and plunger barrel and of delivery valve and delivery valve seat.
remove the Roller Pincers (special tool), and then take out the tappet and shim.
threaded portion. 2. To remo ve the cam sh aft, direc t the first cam lobe on t he remo val side of cam shaft tow ard the top of the pump to prevent
the
touching th
cam
sh aft
lobe
e tappets, and then
fr om li ghtl y
strike.
(l ) Remove
the plunger t ogether w ith th e lower
spring seat, using Plunger Pincers (special tool). (m) Mea sure the backlash be twee n the co ntrol rack and pinion . If the bac klash is i n excess of t he lim it,
13-34
replace.
F UE L AN D ENGI NE CO NTROL SERVICE PROCEDURES (n) Use Wre nch (special
13 tool) to remov e the delivery
valve holder.
MOTE: Immerse the delivery valve combined wish delivery valve seat and the plunger com bined with plunger barrel in gas oil without changing their combinations.
(2) Inspect ion a nd Correct ion
(a) Plunger and plung er barrel
A ft e r c le a ni n g in ga s o il, ch ec k to see th a t th e p lu n g e r falls smoothly in the plunger barrel under its own weight. Check by the following procedure. 1)
T ilt the plun ge r barrel appro x. 60°.
2)
Pul l the plunge r abo ut 2 0 mm out.
3)
Turn the plung er and check
several points.
13-35
FUEL AND ENGINE CONTROL SERVICE PROCEDURES
13 (b) Delivery
(cl) Rep lacem ent
valve
-
of tap er roller
bearing
Inner race
Cle an the valve and valve seat portions
of the delivery
valve in gas oil and check worn condition.
To remove, use Extractor (special tool).
Seal off the bottom of the valve seat portion with a
To install, put the ring and shims and then install the
finger tip and press down the valve portion with a
taper roller bearing.
finger. If the valve portion bounces back when released, the valve portion is good. If it does not
Outer race
bounce back, the valve portion is badly worn. Replace the delivery valve.
(c) Tapped
The beari ng co ver side outer rac
e should
be removed
by use of Outer Race Extractor (special tool). To install, put a new oil seal in position, and then install the outer race. Hold a dial gauge to the roller portion of tappet and check the overall clearance by moving the roller up and down. If the ove rall clearance is in excess of the lim the tappet assembly.
13-36
it, replace
FU EL AND ENGI NE CO NTROL SERVICE PROCEDURES
13
(3} Reassemb ly OC£f$i o
(a) M ou nt the pum p hou sing in Universal
-i - i 4.5 to 5.8 Nm (0.45 to 0.6 kgfm)
18
64 to 68 Nm
Vic e (spe
(b)
Insert the plunge r barr el into t he hou sing.
cial tool). After the control rack has been inserted,
M@TEs
thread the screw into the back of the pump housing.
H. Align She notch of the plunger barrel with the dowel pon of the housing. 2. Do not ligh tly str ik e the plun ger barre l but securely push in by finger.
Check to see if the control rack lightly operates.
13-37
FU EL AND ENGI NE CONTROL SERV ICE PROCEDURES
13
-
Manufacturer mark
B9111A
B9109A
(c) Pla ce the pu m p ho using
on its si de and set the
control rack so that the punched marks of the control rack will be positioned the same dimension away
NOTE: Ins tal l the plunger with the stam ped m odel num ber t ow ard you (the housing cover }.
from the ends of the housing. After the pinion and control sleeve have been combined, put the pinion in mesh with the teeth of the control rod. MOTE;
H. Install the pinion and con tha t the joint of the pini the con trol sleeve will be you. 2. After each p
ini on
trol sleev
e so
on and notch faced tow
has been ins
move the control rack to con can be moved the same amo
of ard
tall ed,
fi rm th at it unt to ri ght
and left. (e) Hold the tappet and shim In Tappet Pincers (special tool) and insert into the housing.
(d) Instal l the low er spring seat a
nd plung er together,
using Plunger Pincers (special tool). (f)
Pus h the tappet insert
ed into the housing up with
Roller Pincers (special tool) and insert Tappet Pin (special tool) into the hole in the tappet.
13-38
FUE L A ND ENG INE CO NTRO L - -SERVI CE PRO CEDU RES
13
MOTE:
(h) Install the screws, using Wrench (special tool).
She camshaft is inserted, face the inscribed line on the end of She camshaft toward the timer.
Governor (Refer to 5.2.1. or 5.2.2.)
(g)
A u to m a ti c ti m e r (R ef er to 5.4 .1.)
when
Confirm t he follow ing items.
1)
End play of
2)
Sliding
cam sha ft [Refer
resistance of con
to 5. 1.2 (l)(g) .]
trol rack [ Refer to 5. 1.2
(i)
Instal l the follow ing
part s.
Feed pump Coupling (j)
After t he reassem bly has been com pleted, adjust
the injection pump.
(1 He).] Check after removal of Tappet Pin (special tool).
13-39
FUEL AND ENGINE CONTROL SERV ICE PROCEDURES
13 5.1.3
-
P Typ e Onjecti on Pom p
(1) Disassembly
^W ea r, da mag e, 12 ' disco loration
6 Worn or damaged
Rotating condition Wear, damage
Overflow valve opening pressure NV 255 kPa (2.6 kg f/c m 2'
17 N ut For disassembly of parts with an encircled number, see following items.
13-40
D1568A
FU EL AND ENGI NE CONTROL SERVICE PROCEDURES
13
(a) Remove the feed pump.
(e) Remove the screw plug, turn the camshaft to (b)
Install Fitting Plat
e (special tool) i n Unive rsal Vi ce
place the tappet at the top dead center position, and insert Tappet
(spe cial t o o l)1.
Plo lde r (speci al tool) into
the screw
plug
hole to space the tappet away from the camshaft. (f)
Remove the
cou pling.
(g) Remove the automatic timer. (Refer to 5.4.2) (h) Remove the governor. (Refer to 5.2.1 or 5.2.2)
(c)
Utilizing the threade
d hole, install Pla te (special
tool).
(i)
Rem ove the
bearing co ver, using Bracket and
Bearing Cover Extractor (special tools).
MOTE; 1. When the bearin g cove s’ is remo ved , use car e no t So lose th e end play adju stin g shims. 2. Check th e oil seal a nd do not remov e it unless defective. (d) Install the injection pu
m p in Un iversa l Vice (spe
cial tool).
13-41
FU EL AMD ENGI NE C ONTRO SERVICE PROCEDURES
13
(I)
L -
Rem ove the plun ge r, using Plung er Insert (special
tool).
SVIOTEs Put the remo ved p lungers ord containing clean gas oil.
(j)
Install
erly i n a tray
Tap pet Mo un ting Device (speci al tool) to
the pump housing. Then operate the lever to push the tappet up, remove Tappet Holder (special tool), and take out the tappet assembly. (m)
Remove the upper spring seat
and control slee
ve.
The control sleeve can be easily removed by use of Plunger Clamp Device (special tool).
NOTE: cannot he removed The control sleeve un less th e ball mo un ted o ra th e flang e of the control sleeve and the tappet guide groove in the pump housing are in align ment.
Extractor
(k) Remove Tappet M
oun ting
Device (sp ecial tool),
install a wire in the hole of the lower spring seat, pull it together with the plunger until the lower spring seat can be removed, and remove only the lower spring seat.
(n) Mount Extractor (special tool) to the delivery holder and remove the plunger block assembly.
13-42
FU EL AND ENGI NE CONTROL SERV ICE PROCEDURES
-
13
1 Fitting Plate 157944-3520
(o)
Disassemble
the plunger block assembly by
the
following procedure. a)
M ou nt Fitting Plat e (special
(q) Remove the governor side screw bushing with special Wrench (special tool) and remove the pin and
tool) in
the vice .
bushing. Then remove the control rod and bushing from the time r sid e. NOTE:
1. Arrange all removed parts orderly by cylinders. 2. Be sure not to change the combination of the paired plunger barrel and plunger and that of delivery valve and delivery valve seat.
(p) Secur e the plunge r block assem
bly to the Fitti ng
Plate (special tool) and loosen the delivery valve holder with Socket Wrench (special tool).
13-43
13
FUEL AND ENGI NE CONTROL SERVICE PROCEDURES
-
(2) Inspection and Correction The inspection procedure is the same as that for the AD ty pe ex ce pt th e fo ll o w in g .
Replacement oí taper roller bearing
Outer race
Inner race
Remove the bearing cover side outer race by use of Remove inner race by use of Inner Race Extractor (special tool). To install, use press.
13-44
Outer Race Extractor (special tool). To install, install a new oil seal and then install the outer race.
FU EL AND ENGINE CONTROL SERVICE PROCEDURES (3} Reassemb
-
ly
Control rod sliding resistance (when stationary) MV 1.3 N (0.13 kgf) or less
110 to 115 Nm (11 to 12 kgfm) (Tighten three times)
The end with smaller distance between end face and hole facing downward
NV...
L
Nominal Value
... Limit (27— 25—>24—>23—>22— >21
26— 19) 18 17-15-14 33—32—30—31- 29—28 ------------------>t?>— 11—fto }- > 7- 9— >2— 1—16 For disassembly of parts with an encircled number see following items.
—1 3
D1569B
13-45
13
(a) M oun t the pum p housing
FUEL AND ENG INE CONTROL SERVICE PROCEDURES
in Universal Vi ce ( spe
(c) Using Socket Wrench (special tool), tighten the
cial tool).
delivery valve holder to the specified torque (tighten
Then install bushings and control rod, pin and screw
in three stages).
bushing with Special Wrench (special tool). Check to
NOTE: Df th e tigh tenin g tor qu e is sm aller than the spec ifie d to rque, oil lea kag e or damage to the related parts could result. If the tigh tening to rque is excessive, un
barrel, and insert the lower side O-ring into the pump housing with O-ring Insert (special tool).
NOTE: Make sure that the lo w er side O- ring is not set on the plunger barrel and slided along the wall surface of pump housing.
13-46
(d) M oun t the p lung er t o P lunger Insert and insert it into the plunger barrel.
(speci al tool)
FU EL
AN D E NGINE CONTRO L SERVI CE PROCED URES
13
(e) Mount Tappet Mounting Device (special tool) to
(g) Install the gov erno r housing. At
the pump housing.
the following operation. Mount Measuring Plate (spe
Then install the tappet by operating the Tappet
cial t ool) to the tim
Mounting Device.
camshaft, and install and position the governor side
A t th is ti m e, c o m pre ss th e p lu n g e r sp ri n g an d in sert
taper roller bearing outer race in the ring so that the
the mitt portion of the plunger into the guide groove
dime nsion from
in the control sleeve, and insert Tappet Holder
end of the M eas uring Plate will be 13
this time, perform
er side taper portion
of the
the en d of t he pum p housing to the .85 ± 0. 5 mm .
(special tool) into the screw plug hole. The operation of inserting the mitt po
rtion of t he plun ger into the
guide groove of the control sleeve can be easily performed by inserti
ng the m itt porti on, wh ile moving
the control rod to right and left.
Installation of the taper roller bearing outer race will produce a clearance between the governor housing and taper roller bearing outer race. Change shims to eliminate the clearance. Shim thickness: 0.6, 1.2, 1.5, 1.8, 2.0 mm (f)
Insert the camsh aft from
the ti m er sid e.
When the cam shaft is i nstalled, face of the end of the camshaft towa
the inscribed
line
rd the tim er side .
13-47
FU EL
13
AMD ENGINE CONTROL SERVI CE PROCEDU RES
-
(h) Measure the camshaft end play. Install Camshaft Measuring Device (special tool) to
check to see that the con trol rod slides sm
the timer side of the camshaft to measure the end
the entire stroke without exceeding the standard
play.
sliding resistance value. Rem ove the Tappet Pin (speci (j)
Instal l the follow ing
oo thly over
al tool) b efore checking.
part s.
Governor (Refer to 5.2.1 or 5.2.2.) Feed pump A u to m a ti c tim e r (R ef er to 5.4 .2.) Coupling (k) Afte r reassem bly has been com pleted, ad just the injection pump.
,lf the camshaft end play is out of the nominal value, adjust by changing shims between the bearing cover and pump housing. Shim thickness: 0.10, 0.12, 0.14, 0.16, 0.18, 0.30, 0.50 mm
13-48
FU EL AND ENGINE CONTROL SERVICE PROCEDURES 5. 1.4
Ad justm ent after
Reassemb
13
ly
For fuel injection rate adjusting standard, see Service Information published separately.
(11} AD Ty p e Inj ec tio n Pum p
(a) Install the pump on the injection pump tester Fixing Stand (special tool) and secure it.
MOTE: Mak e su re tha t S he cen ter of cou pling 5s ali gned with th at of injecti on pump so that She coupling and injection pump turn smoothly.
MOTE: 1. Supp ly o ol So She in jec tio n pu m p c am chamber. 2 . 'Adjust S he injectio n amo un t after ad j u s t i n g She g o v er n o r . Injection sequence 1 — 5 —3 —6 —2 —4
13-49
FUEL AND ENGINE CONTROL SERVICE PROCEDURES
13
-
(c) Checking strok e of con trol rack Move the control rack to confirm that the total stroke is over the specified value. In addition, check to see that the start spring and idling spring smoothly move the control rack in the maximum injection direction.
(b) Setting position 0 of control rack M oun t Mea suring Device (speci
al tool) to the injection
pump. 1)
Keep the pum p runn ing at 750 rpm.
2)
Loosen
the stopper bolt and pull
the adjusting
lever toward the non-injecting direction.
(d) Adjusting prestroke
3) Press the end of the mea suring device al l the wa y toward the governor and adjust the position of point
1) Pull the con trol rack ou t to the total inje ction position and secure it there.
"0" on the scale of the measuring device.
2)
bottom dead center position and mount Measuring
1)
Fix the l oad con trol leve r at the idling
2)
Let the pum p run at 500 to 6 00 rpm and tem po r
pos ition.
Place the plunge r of the No.
Device (speci al tool). Set the con 3)
Couple
the injection p
4)
Send a high pressure
1 cylinde r in the
tactor on the tappe
t.
um p and t ester noz zle .
arily fix the speed control lever so that the governor w ill begin to provide c 3)
ontrol at the spe
ed.
Pres s the end of the me asu ring device all
the way
.toward the governor and adjust the position of point "0" on the scale of the measuring device.
speed mentioned above, position 6 won’t be obtained even iff the control racEt is presse d w ith a strong p ressure, and there will be danger off damage to the link mechanism off the pump.
to let the fu el flow nozzle holder.
13-50
fuel i nto t he inj ection pum p
out from
the overflow
pipe of the
FUEL AND ENGINE CON TROL SERV ICE PROCEDURES
-
13
MOTE: The pressure of the fuel forced into the injection pump must be higher than the delivery valve opening pressure.
7)
After adjus tme nt of the prestroke,
check t o se e
that, at the static injection beginning, the inscribed lines of the pointer and time
r ar e in alignm ent.
If they are out of alignment, restamp a line on the 5)
Slow ly t urn the camsha
ft until the f uel ce ase s to
automatic timer.
flow from the overflow pipe of the nozzle holder (until static injection begins).
MOTE: Make measurement by turning the camshaft clockwise.
(e) Adjustment of injection start interval 1)
Cou ple tester nozzles
to all the cylind ers o f the
injection pump as in the case of adjustment of the prestroke. 2) For ce fuel into the injection 6)
Read the pr estroke f rom the bo ttom dead center
to the po int where the fuel ceases
to flow
(stati c
flow 3)
out from
pum p to let the f uel
the tester noz zle .
On the basi s of the stati c inj ection b eginning
injection begins), using a dial gauge.
the No. 1 cylinder, m easure the
If the prestroke is out of specification, adjust by
ceases to flow out according to the injection sequ
shims. [Refer to (e).j
ence, using an angle scale.
of
interval when the fue
l
MOTE:
Injection sequence 1 — 5 — 3 — 6 — 2 — 4
13-51
FUEL AND ENGINE CONTROL SERVICEPROCEDUR ES
13
3)
-
Measure the st roke of
the t app et from
the top
dead center to the point where the plunger barrel is touched. 4)
If the tappe t clearance is
less than the n om inal
value, adjust within the extent permitted by the injection start interval. If correcti on w ithin the p set
ermitted ex
tent is i mp ossible,
the prest roke of t he No . 1
cylinder to
the
maximum of the set value and readjust.
4)
If the prestroke
and injectio n start interv al ar e out
of specification, insert a Holder (special tool) between the tappet and lower seat and then adjust by chang ing the shim thickness. Shim thickness: 0.2 to 1.60 mm, 29 types in 0.05 mm increment
(g) A djustm ent of f uel injecti on am ount To check whether the injection amount is up to spec ifi cation at the spe cifi ed rack pos iti on and speed, measure with a measuring cylinder. If the injection amount is out of specification, adjust by the following procedures.
D3522A
1)
Loosen t he screw of
2)
W hile bl ocking m ove m ent of the con trol rac k, turn
the control sleeve with an adjusting rod. 3)
(f)
Ad justm en t of tappe t clearance
1)
Place the tappet in the top dead center position.
2)
Rais e the t app et w ith a scr ew drive r, etc. un til the
driving face of
the plunger touches the bottom
the plunger barrel.
13-52
the pinion.
Tighten the screw of
the pinion.
MOTE:
end of
1. A maladjus ted injection amo unt w ill produce marked effects on engine per» form anc e. Make sure t lhe injection amount is carefully adjusted.
FUEL AND ENGINE CONTROL SERV ICE PROCEDURES
2. The i njec ti on
am oun t vari es on diffe
tion amo each Un ev en ra t io (+ )
unt in
Average
injec
—tion amou
nt of
cylinder
each
t
A ft e r th e g o v e rn o r ha s be en adj u st ed, m ea su re th e fuel injection rate adaptable to the engine.
each cylinder
Minimum
injec-
Average
injec
tion amo
unt in
—tion amo
unt of
Unev en ra tio (—)
each
Insp ection of f uel and oil l eaks
a
Fue l leaks from de livery valve attaching position
(a) Mount two Fixing Stands (special tools) to an injection pump tester. Secure the injection
pum p firm ly to the speci al tools.
MOTEs
To m ake sure tha
2. When t he p ositi on “ 0” i s set , r em ove the dam per spri ng be for ehand.
t S he cou pli ng and i n jec
ti on pump rotate sm oothl y, al ign the c en ters o ff the cou pli ng and injec ti on pump accurately.
(c) Checking stroke of control rod Move the co ntrol rod to co D3409A
nfirm that the total str
more than the specified value. Check to see that the control rod is moved smoothly
(b) Setti ng po sition "0 " of control rod M oun t Mea suring Device (speci
in the maximum injection amount direction by the
al tool) to the inj
ection
pump. 1)
Keep the pum p runn ing at 750 rpm.
2)
Loosen the
stop per bolt and
pull the
adjus ting
lever toward the non-injecting direction. 3)
Press the end of the mea suring de vice al l the wa y
toward the governor and adjust the position of point "0" on the scale of the measuring device.
13-54
start spring and idling spring.
oke is
F UE L AND ENGINE CONTRO SERVICE PROCEDURES 5)
L -
13
Slow ly t urn the
flywh eel of
the pum p tester
clockwise until the fuel ceases to flow out from the overflow pipe (until static injection begins).
Prestroke
(d) Adjustment of prestroke 1)
Remove the gove rnor side No. 1 cylinder
delivery
D3414A
valve holder; spring, delivery valve and gasket. 2)
M oun t Meas uring Device (sp
ecial
tool) to
the
flange sleeve. 3)
dead center of
prestroke of
the plung er f rom
the
to flow out (static injection beginning).
the plun ger w ith a di al gauge.
7) 4)
Measure the
bottom dead center to the point where the fuel ceases
Turn the flywh eel of t he pum p tester to detect the
bottom
6)
W ith the con trol rod set
in the full position, force a
high pressure fuel into the injection pump to let the fuel flow out from the overflow pipe.
If the prestroke is
out o f spe cification, adjust by
changing the shim thickness between the flange sleeve and pump housing. Shim thickness: 0.50 to 1.975 mm, 59 types in 0.025 increment If the prestroke is smaller, increase the thickness. If the prestroke is larger, reduce the thickness.
clockwise until the fuel ceases to flow out from the tester nozzle.
If they are out of alignment, inscribe another line on
Read the rotation angles (injection start intervals)
the ti mer.
where the fuel ceases to flow, according to the
When the
autom atic ti m er was
rep laced
with a new one, proceed in the same way.
injection sequence. 4)
If the injection start interval is
angle, adjust by the same proced
out of the standard ures as for pr estroke
adjustment.
KIOTEs Injection sequence; H
—5 —3 —6 —2 —4
(e) Adjustment of injection start interval 1)
Set the st atic injection be
ginning
pos iti on of the
No. 1 cylinder on the pump tester scal e plat e. 2) For ce a high pressure fuel i nto the injection pum
p
to let the fuel flow out from the overflow pipe of the tester nozzle.
(f)
MOTE;
A t th e s peci fi ed rac k p o s it io n an d sp ee d, m ea su re th e
The pressure of the fuel forced into the injection pump mu st be higher tha delivery valve opening pressure.
Adjustm ent of
injection am
n the
fuel i njecti on am ount
oun t and uneven ratio
cylinde r to check w he ther they
If the injection amount is out of specification, adjust by the following procedures.
13-56
with a mea suring
are up to specification.
FU EL AND ENGI NE CO NTROL SERVICE PROCEDURES 1)
Loosen t he two nuts tighten
2)
Turn the
3)
Tigh ten the nut s to the specified torque to
13
ing the f lange sl eeve.
flange sleev e by li gh tly striki ng. secure
Minimum
inje c-
tion amou
nt in —tion amo
each Un ev en r at io ( -)
the flange sleeve. (39 to 44 Nm (4 to 4.5 kgfm)]
each cylinder
on
am ount w
il l
produce co nsiderable effects on engi ne perf orm ance . Mal te sur e tha t t he injec tion amount is carefully adjusted. 2. Since t he injec ti on am oun t varies o n different nozzles and pipes, make sure tha t
t he
m easuri
ng
co nd iti on s
are
observed. 3. I njec ti on am oun t uneven ratio Maximu
(b) Slide the dial indicator of the centering tool
on the injection pump bracket, hold a dial indicator to
toward the air compressor (or injection pump drive)
the mandrel of the centering tool, and perform
and measure the positions of the compressor crank
O-point adjustment.
shaft (or injection pump drive shaft) shown in the illustration with the dial indicator.
13-58
FU EL AND ENGI NE C ONTR OL SERVICE PROCEDURES
13 Keyway
(c) If the eccentricity between the mandrel and air
(b) At this point, check
compressor crankshaft is in excess of the nominal
the crankshaft of the air compressor (or injection
dimension, adjust by adding or removing injection
pump drive) is in the uppermost position.
to ensure that t he ke yway o f
pump bracket shims.
If the keyway is not in the uppermost position, turn
Shim Inserting Condition
the engine crankshaft.
•
The num ber of shims inser ted i nto a singl e point
®
The
e
number. The difference i n num ber between t he top an d
must not exceed three. front an d rea r shi ms m ust b e e qua l i n
bottom shims must not exceed one. (d) After adjustment, tighten
the tightening
bolts to
the specified torque before confirmation.
(2 ) DnisiaSlaiSoiiti of
InJecSóorii P u m p
(c) Align the poin
ter of the injection pum
inscribed m ark of the auto time
p and t he
r. (On engines with
no
auto timer, align the inscribed mark on the pump bearing cover with that on the pump side coupling.)
(a) Crank the engine to adjust the fuel inj ection tim ing.
the No. 1 cylinde r to
For this purpos e, align the
angle scale inscribed on the outer periphery of the flywheel with the pointer of the inspection window of the flywheel housing.
13-59
FUE L AND ENGIN E CONTROL SERVICE PROCEDURES
13
(d) Instal l the driving co
upling
on the cranksha ft of
the air compressor, and put it a little toward the air compressor.
5.1.6
Install the injection pump on the injection pump
Bleed the fuel system as described below.
Bleed ing the
FueB Sys tem
bracket. Move the driving coupling toward the cou pling plate a nd ti ghte n it w ith the ti m ing a djusting bolt. Then tighten the cotter bolt to the specified torque to reduce the clearance between the driving coupling and coupling plate to less than 0.5 mm.
IM0TE:
A f t e r t h e i n j e c t i o n p u m p h as b e e n i n s t a l led, be sure to check and adjust the fuel injection start timing. (Refer to 5.11.7.)
(1) Loosen the air plug of the fuel filter. (2) Turn the prim
ing
pum p knob o f the injection
pump counterclockwise to let the knob float up.
13-60
FUE L AND ENGI NE CO NTRO L SERVICE PROCEDURES 5.1. 7
33
Insp ectio n and Ad jus tm ent off Fue l Injection Start Timing
B5908A
(3) Move the priming pump knob up and down by
C0599A
hand to force the fuel out until no air bubbles come out from the air plug.
(1) Crank the crankshaft more than 180° in normal
(4) A fter air bubbles have ceased to come ou fuel, fi rm ly ti ghten
t in the
the air pl ug.
scale inscribed on the periphery of the flywheel with
(5) Move the priming pump knob several times up and down and turn down the knob, while pressing it down.
Off th e en gin e is rev ers ed (by cr ank ing or when it is stopped), the automatic timer will stay operated in advancing direction and w ill not readily return to norm al e ven iff it is made to resume normal operation by turning the eng ine in normal d irection ffor a while. Make sure that the crankshaft is cranked more than 180° in normal direc tion by hand.
(2) If, unde r the co nd ition o f Item (1) , the p ointe r of the Injecti on
pum p and the inscribed
line of t he
automatic timer are in alignment, the injection start timin g is correct .
13-61
FUEL AND ENGI NE CONTROL SERVICE PROCEDURES
13
5.1. 8
[AD type injection pump]
-
insp ection a nd Ad justm ent of Moload Minimum and Maximum Speeds
(1) RSV Type Governor
[P type injection pump]
(a) Inspection and adjustment of idling Run the engine at idle and check to ensure that the con trol lever
touches the stopper bolt "A
", and
measure the engine speed at the time. If the idling speed is not within the specified limits, adjust with the stopper bolt "A". (b) Inspection and
adjus tme nt of no-l oad m axim um
speed Pus h the control (3) If the f uel
injection
loos en the two tim
start tim ing
is not corr ect,
ing adjusting bolts and adjust
the
timing by turning the automatic timer. Tighten the adjusting bolts to the specified torque. Reche ck the fuel injection s
(e) In the above con dition (d) , measure the ma xim um speed to determine whether it is within the specified limits. (f)
If it is not w ithin the spec ified limits, a djust t he
fixed position of the speed control lever with the stopper bolt. MOTE;
(a) Check to ensure that the load control lever is touching the idle stopper bolt.
1. Df th e fixe d po siti on of th e full lo ad stopper bolt is changed, the amou nt of fuel injection will change. Be careful not to change the fixed position. 2. Check to ensure that even if the load control lever is quickly returned from the full load position to the idling posi tion, the engine does not stop and is free from hunting.
(b) In the above condition (a), measure the idling speed to determine whether it is within the specified limits. (c) If it is not w ithin the specified lim
its, adjust with
the idle stopper bolt. (d) Operate the load control lever to the full load position (until it touches the full load stopper bolt).
Using Special Wrench (special tool), remove the round nut tightening the flyweight. At this time, hold the drive side to prevent it from turning.
Before removing the housing, use Tap pet Insert (special tool} to separate the camshaft from the tappet.
Thread Extractor (special tool) into the flyweight. A ft e r th e b o lt en d ha s to uc h ed th e ca m sh af t, li g h tl y strike the bolt head and turn down the bolt to remove the flyweight.
MOTE;
(a) Removal of ungleich spring assembly Using Socket Wrench (special tool), loosen the nut tightening the ungleich spring assembly to the ten sion lever, and remove the ungleich spring capsule.
When the shifter and sleeve are assembled, be sure
of shifter
snap ring in the sleeve, and the shifter and sleeve can
not to change the adjusting shim, as the assembly
be separated.
dimension of the shifter has been adjusted by the shim. If readjustment is necessary, assemble all related parts correctly and select the right shim thickness to make sure that the dimension from the housing end to the shifter complies with the specified value. Shim thickness (6 types): 0.2, 0.3, 0.4, 0.5, 1.0, 1.5 mm
IM0TE: Measure t he assem flyweight lifted.
bly dimension w
ith al l
D2024A
Use a press to remove the shifter and bushing.
MOTE: When the sh use care not t su rface of
ifter and bushing are installed, o dam age the chrom e plate d the sh ifte r.
13-69
FUEL AND ENGI NE CONTROL SERVICE PROCEDURES
13
-
5.2.3 Adjustment after Reassemb ly ÍHJRSV Type Governor For governor performance curve, see Service In formation published separately.
A dj us tm en t of spe ed regulation
A dj us tm e nt of to rq ue spring
A dj us tm en t o f hi gh spe ed control
A dj us tm en t o f id lin g su b spring
Ad ju st m en t of id lin g spring or ungleich spring A dj us tm en t of st op pe r bolt NOTE:
A dj us tm en t of in te rm ed ia te speed control
1.
Suppl y e ngine oi
2.
Loosen
l to the
injection pump cam chamber.
3.
Remov e the i dling
4.
Do not allow the Ungleich spring or
the adj usting lever
and torque spri
stopp er bolt.
sub spring. idling
sub spri ng
ng to w ork.
(a) "0 " p osition setting of control [Refer to Item (1) (b) or (2) (b), Sectio
B9163A
rack n 5.1.4.1
(b) Install the angle scale plate for fixin g the adjus ting lever.
A d ju s t th e re la ti o n s h ip bet w een p u m p sp ee d an d th e rack position to specified governor performance curve by the following procedure.
13-70
FUEL AND ENGI NE CONTROL SERVICE PROCEDURES
-
13
Full position
(c) Temporary adjustment of high speed control
(e) Adjustment of Ungleich spring (governor with Ungleich spring only)
With the adjusting lever in full position, adjust the maximum speed stopper bolt so that high speed
1)
Keep the pum p run ning
control starts to work when the pump speed is "Nd".
littler lower than "Na" (speed at which Ungleich
at a speed wh ich is a
spring starts to work). 2)
Fix the adjus ting lev er at the full pos ition.
3)
Using the
special
too l, Speci al W rench , tighte n
the Ungleich spring so that the rack will move from "Rc" to "Ra". Fix the spring with lock nut. 4) Chec k that the pum p spee d is "Na " and "N b" when the rac k position is "Ra" and "R
b", resp ectively.
(d). Ad justm ent o f intermed iate speed control W ith the pum p speed at "Nc
" ( c point) wh ich is a littl e
lower than "Nd", adjust the full load stopper bolt so that the rack is positioned at "Rc".
(f) Adjustm ent of idli ng spring (governor with idli
ng
spring only) A d ju s t th e id lin g s p ri n g so th at th e rac k st ar ts to m ov e from "Rc" to direction to increase fuel rate at point k.
13-71
FUEL AND ENGIN E CONTROL SERVICEPROCEDURES
13
-
(g) Adjustment of low speed control
B9170A
(i)
Ad justm ent of
speed
regulation
Check that the rack is pulled back to position "Re" 1)
Adjustm ent of
when the pump speed is increased from "Nd" to
stopper bol t
A d ju s t th e s to pp er b o lt so th a t th e rac k is p o s itio n ed
"Ne".
at "Rg" when the adjusting lever is set at idling position with the pump stationary.
Governor spring
D3482A
If the pump fails to do so, adjust tightening amount of the swivel lever adjusting screw. Tightening gives better speed regulation. Loosening gives poorer speed regulation. 2)
Adjus tme nt of i dling sub
A d ju s t th e
id lin g
spring
su b s p ri n g
so
th a t th e rack
is
positioned at "Ri" when the pum p spee d is "N i". Check that the rack is positioned at "Rh" when the pump speed is further increased. (h) Adjustment of high speed control A d ju s t as in (c) an d fi x th e m a x im u m sp ee d s to pp er bolt in position.
13-72
Speed regulation
NOTE:
Ne - Nd
------------- — ------------- x 100 (%)
1. Ilf the speed regulation is poor, the engine will exceed the specified max imum speed at no load and will enter a hazardous condition. 2. The maximum exten t to whic h th ® ad ju s tin g s c r ew can he loosen ed is 20 notches (5 turns) from the fully tight ened position. Loosening it any further can be dangerous. 3. Iff the adjusti ng s crew is a djus ted, the tension of the governor spring will change and the high speed control s tart point will change. Be sure to readjust the high speed control in accordance with (h).
F UE L AND ENGI NE CO NTROL SERVICE PROCEDURES 1)
13
Fix the adjustin g leve r at the fu ll positio n and set
the pump speed at "Nk". 2)
Screw in until the torqu e spring contacts t
he lever
and fix temporarily. 3)
Ad just the torque s
pring
so that the rack i s
positioned at "R7" when the pump speed is lowered to "N /". 4)
Chec k that
the pum p speed i s "N j" whe n the
pump speed is lowered to position the rack at "Rc". 5) Afte r the adjustme nt, check that t he rac k position is as specified at each pump speed.
Normal position
B9171A
If the rack position
is out o f specification,
readjust the
torque spring and full load stopper bolt. (j)
Stop l ever ope ration check
(m) Adjus tme nt o f a daptati on to engine
With the adjusting lever fixed at the full position, pull the stop lever all the way to the stop side and check that the rack is positioned at 0 mm.
A ft e r
th e
g o v e rn o r
ha s
be en
ad ju s te d ,
m ea su re
overall injection amount at the same lever angle as in the high speed control and In accordance with the
(k) Adjustment of full load
adjustment standard and readjust as necessary. (n) Locking with wire
1)
Install
2)
With the adjusting lever
the lever
the full load stopper
to the gov ern or cover. at the full position, adjust
bolt so that the rack i
at "Rc". (I)
Ad justm en t of torqu e spring
A ft e r a dju s tm e n ts , lo ck th e g o v e rn o r w it h w ir e s.
(2) RFD Typ e Gov erno r For governor performance, curve, see Service In formation published separately.
Setting position 0 of control rod
B9174A
MOTE: 1. Remove the damper spring. 2. Remove the idling spring. 3. Keep the stopper holt of the speed control lever loosened. ' 4. Keep the stop per bolt of th e load con trol lever loosened. 5. Supply engin e oil to th e inj ecti on pump cam chamber.
13-74
A d ju s t th e re la ti o n bet w een pu m p sp ee d an d th e rac k position to specified governor performance curve by the following procedure. (a) "0" position setting of control rack [Refer to Item (1 >(b) or (2) (b), Se ction 5.1.4.] (b) Install the angle sc lever.
ale plate for fixing
the control
FU EL
Pump speed (rpm)
AN D EN GI NE CO NTROL SERVI CE PRCED URES
13
----------- B4061A
(c) Ad justm ent of flyw eig ht lift and f ull load position
3)
Divide the flyweight full lift into the lift necessary for
high speed lift "L" with the stroke adjusting screw.
Low er the pum p speed
to "N u" and adjust
high speed 'control and the lift necessary for idling
(d) Adjustment of high speed control
the
control. 1)
W ith the l oad contro l lever fixed at the full load
position, temporarily set the speed control lever so that high speed control works when the pump speed is 700 to 800 rpm.
Set the control lever at the full load position and set the spe ed control
lever a t the m axim um
speed
position. Increase the pump speed slowly and adjust the speed 2)
Incr ease the pump speed slow
ly and adjust t he
control lever stopper bolt so that the rack starts to
full load stopper bolt so that the rack is positioned at
move from "Ra" toward fuel decreasing direction
"Rt" when the pump speed reaches "Nt".
when the pump speed reaches "Na".
13-75
FUEL
13
2)
AND ENGINE CONTRO L SERVICE PRCEDURES
Check of speed regu lation
2)
Low er the pum p spe ed to "N e" and adjust
Increase the pump speed slowly until the control rack
Idling spring using the special tool, Wrench so that
is pulled back to "Rb" position.
the rack is positioned at "Re". 3)
Upon reaching "Rb" position, check that the pump speed is "Nb".
positioned at "Rc" when the pump speed is increased
Further increase the pump speed and check that the rac k pull back
to "Nd".
am oun t "L " is as specified.
IMOTE:
1. Df fthe sp eed reg u lat io n c h ec k po int (point b) is where the damper spring acts, check the speed regulation after idling and damper spring adjustment. 2. Of the value is ou t of s pec ifi cat io n, replace the governor spring. (e)
Adjustm ent of idli ng spring (governor
with idling
spring only)
D4506A
1)
Set the pump speed at
adjust the stopper "Rc".
13-76
Whe n the pum p is stopped the rac k should be
"Rf" or higher position. Also check that the rack Is
"N c" (Nd + 100 rpm) and
bolt so that the rack I
s positioned
at
the
at
FU EL AND ENGI NE CO NTROL SERVICE PRCEDURES (f)
13
Ad justm ent of Ungleich spring
(Vehicles with Ungleich spring only)
B4317A
3)
Slow ly i ncre ase t he pump spee d from
"N f" to
"Ng" and adjust the screw position so that the 1)
Set the pum p spee d at "N f" and plac e the load
control lever in the full load position. 2)
Using the special too l. Special W rench , adjus t the C
in the state of Step 1 w ill have the specifi
val ue. After t he adjustment, firm lock nut.
ly tighten
Unglei ch spring stops 5)
Ungleich spring capsule position so that the Ungleich stroke
Ungleich spring will start working. 4) Increase the pump speed to check that the
ed
it with the
wo rking at "Nh
Chang e the pum p speed between "N
". f" and "N a"
to check that the Ungleich stroke has the specified values.
M@TEs 1. Df th e U ng leich
st ro k e 5s owt of sp ec i
ficati on , readiest th capsulle position. 2. If the speed at w
e Ungleich spring hich
the y ng iei ch
spri ng stops w orking is out of sp ecifica ti on, replace the Unglei ch spri ng c ap sule.
13-77
FUEL
AND ENGINE CONTROL SERVICE PRCEDURES
-
(g) Measurement of load control lever angle Check that when the load control lever is held at the idling position-and the full load position, the lever angle a t the respective po
sitions is up t o sp ecificati on.
If the lever angle is out of specification, replace the shim installed between the shifter and sleeve.
SMOTE: If S he shim w as rep laced, rep eat adju st ment of the go vernor f rom the beginni ng. (h) Adjustment of damper spring
2)
Adjust the
damp er spr ing tightening am
that the r ack i s positioned
1)
Holding the l oad control lever at
ount so
at "Rg - 0.1 m m ".
the i dle position
(point e) and slowly increase the pump speed from "N e" until the r ack is pos itioned at "Rg Hold
- 0.2 m m ".
the pum p speed "N h " w hen the rack
positioned.
is so 3)
After adjustm
adjust the stop "Ri".
13-78
ent, stop the pump and l oosen a nd
per b olt so t ha t the rack i s positione d at
FU EL
AMD ENG I NE CONTROL SERVI CE PRCED URES
(i)
Ad justm ent of rac k lim it
Afte r adjustm ent,
1)
Cap typ e
2)
a)
Remove the guide screw from
the back
of the
-
13
install
the cap nut securely.
Sc rew typ e
a) Place
the load co ntro l lever in
pump housing and install the special tool, Guide
position and kee
Screw.
b)
the full load
p the pum p spee d at "N v".
Ad just the screw of
the rack lim iter so that the ro d
pos ition and fuel injection
(point E ) w ill be u p to
specification, and secure it with the lock nut. (j)
Ad justm en t of start boos ter (smoke set assembly)
B3768A
b)
Using a depth gauge, mea
sure the rack cap depth.
c)
Adjus t the adjusti ng nu t mou nted to the tip of the
rack for the same depth as the rack cap depth measured above. Fix the nut in position with the lock nut.
13-79
13
FUEL
AND ENGINE CONTROL SERVICE PRCEDURES
1) W ith the load control lever set at the full load position, set the smoke set assembly adjusting nut at 0 to 4 mm from the stopper tip. 2) Ad just t o make sur e that when the pum p speed is changed to "Nd", the rack position will change from "Ra" to "Ra"'.
-
(I) Locking with wire
To be locked with wire
f evP N^ lt\rS
SP'
P
r
S ""
\ Í «v /
-x- To be locked with cap
To be cap locked
B4320C
After adjustments, lock the governor. MOTE; Lock parts marked w ith * af ter adj of no H oad max im um speed.
3) Set and fi x the nut so that the rac k is positioned at "Ru" when the pump speed is "Nu". (k) Adjustment of adaptation to engine After the governor has been adjusted, measure overall injection amount at the same lever angle as in the high speed control and in accordance with the adjustment standard and readjust as necessary.
13-80
5.2. 4
Ins pec tion and load Minimum Speeds
[Refer to 5.1.8.)
ustm ent
A djus tm ent o ff Moand Maximum
FU EL AND ENGINE CONTROL SERVICE PRCEDURES 5.3 5. 3. 1
FEED
13
PUMP
Disassemb
ly, Inspecto
ra and
Reassem
bly
1 Eye bolt
(suct ion sid e: w ith gau ze fil ter)
7 Plug
2 Eye bo lt (delivery side)
8
3 Priming pump
9 P iston
Piston spring
10 Sn ap ring
4 C heck valve p lug 5 Check valve sp ring
11 Tappet
6 Check valve
12 Feed pump housing
For reassembly, reverse the order of disassembly. NOTE: Before disassembly, know th
e trouble spots throughly by
making tests. B9175A
13-81
FUEL
5. 3. 2
Test
and
Ad justm
AND ENGINE CONTROL SERVICE PRCEDURES
-
ent
The feed pump tests are as follows.
Lifting capacity Condition No. of strokes required before lifting when operated at 60 to 100 Delivery Condition
Fuel passed through 1.54-dia. nozzle for 15 seconds when pump is operated a t 1 000 rpm NV Refer to 3 .1 Service S tand ard Table.
Spanner (special tool) to prevent it from turning, remove the au
tomatic time
r w ith E xtract or (spe ci al
tool).
(d)
(f)
Using H and Spann er (special
timer case by turning clockwise.
M ou nt Bas e and Guide Bo lt (special too ls) in the
vice.
13-84
too l), r em ove t he
FU EL AND ENGI NE CO NTROL SERVICE PRCEDURES
13
(2) Rea ss emb ly
9
3
D3153A
(a) M ou nt Base and Gu ide Bo lt ( special tools) in a vice.
(b) Install the oil seal in the flange. 1)
M oun t Block
2)
Put the flange so that its pins
(speci al tool) to
the bas e.
w ill fit i n the holes in
the block. 3)
A pp ly NEJI LOCK to the oil se al ins talling
hole in
the flange. 4)
Put the oil sea l in the hole in the flang e. Install the
oil seal by turning down Thrust Bushing (special tool) with Guide Bushing (special tool) in between.
13-85
13
FU EL AND ENGI NE CO NTROL SERVI CE PRCEDU RES (e) Aft er
p lacing
S upp ort
(special
tool)
on
the
flyweight, install the shim and spring. Thread Guide (special tool) onto the guide bolt. MOTE:
Select the proper shim thic knes s so it ahie for the advance angle of the automatic timer.
(c) Insta ll the oil seal i n the tim er case. 1)
M oun t Bl ock and Guide ( special tools) to the ba se.
2)
Put the tim er case on the guide.
3)
Ap ply NEJI LO CK to the oil seal installing
hole i n
the timer case. 4)
Put the oil s eal in the ho le in the tim er cas e. Install
the oil seal by turning down Thrust Bushing (special tool) with Guide Bushing (special tool) in between.
(f)
Put the fl ang e so tha t the pin of the
flang e will
touch one end of the spring. Mount Special Spanner (Special tool) to the coupling mounting hole of the flange. Furthermore, mount Thrust Bushing (special tool) with a bolt.
(d) Place the holder on Base (special tool).
(g)
Aft er placing Oil Sea l Guide (special
flange, insert the tim
13-86
er case
too l) o n the
FU EL AN D EN GI NE CO NTROL SERVICE PRCEDURES (i)
Inject
from Hand Spanner
150 g of autom atic time r gr ease
the ti m er plug hole.
A ft e r gr ea se has be en In je ct ed , ti g h te n th e ti m e r plu g.
(h) After the oil se al guide has been removed
, turn
down
Hand
the t im er ca se onto the holder with
approx.
33
Spanner (special tool), and punch It.
MOTE: Tur n do wn She tim er c as e «rato! She imjee» Sion start timing lines inscribed on the timer case and Mange are in alignment.
(j)
After the autom
atic ti m er ha s bee n Install ed on
the camshaft, fit Special Spanner (special tool) Into the coupling mounting hole. While holding it to prevent turning, tighten the round nut to the specified torque.
13-87
FUEL
13 5. 4.2
SP Type
A uto m atic
AND ENGINE CON TROL SERVICE PRCEDURES
Timer
(1) D isas sem bly a mid Ins pec tio n For disassembly and reassembly of the automatic timer, use the special tool, SP Type Automatic Timer Special Tool (105790-5050).
Connector Retaining nut Needle valve Nozzle Nozzle ho lder
D7027A
(2-spring nozzle)
Disassembly sequence
Cracks, deterioration
4
1 2 3 4 5 6 7 8 9 10 11 12 13 14
Cap nu t Adjusting screw Lock nut No. 2 spring Set screw No. 2 push rod Spacer No . 1 spr in g No . 1 pus h rod Retaining nut Nozzle Needle valve Nozzle holder Connector D7015A
13-95
13
FU EL AND ENGI NE CONTROL SERVICE PROCEDURES
-
5.6.3 Cleaning and (Inspection (1) Cleaning
(b)
Inser t, w hile turnin g, a cleaning needle into the
injection orifice of the nozzle to remove carbon. Use A ft e r w as h in g th e no zz le in ga s o il, re m o v e depo s ite d
the needle of proper size for injection orifice.
carbon using the Nozzle Cleaning Tool (special tool) by the following procedures.
MOTE; Mev er change the co zle and needle valve.
m bination of the noz
(c) Clean the nozzle sea t using the c leaning (d) To remove b urn t and hardene d carbon, use
needle. FUSO
Carbon Remover or equivalent. (2)
(a) Remove the needle valve from
Inspection
the nozzl e and
clean the needle valve with the needle valve cleaning wood piece.
Clean and immerse the nozzle in gas oil, slide the needle valve and check that it moves smoothly.
13-96
FU EL AN D ENGINE CONTROL SERVICE PROCEDURES (1) Injection
Next, pull up the needle valve vertically about 1/3 of
13 Pressure
its entire stroke and check that it falls under its own weight. If it does not fall, replace the nozzle.
5. 6. 4
Rea ssemb ly a nd spiring nozzle)
Ad justment
in
(a) Remove the cap nut and install to the nozzle tester. (b) Loosen the a djusting
screw and
operate the
nozzle tester two or three times for bleeding. (c) Operate the nozzle tester at specified speed, adjusting the adjusting screw for specified injection pressure. MOTE;
Met/er Bet yourself exposed directly to the atomized fuel injected from the nozzle.
D7008A
(d) After adjustment, tighten the cap nut to specified torque. Fix the adjusting screw with a screwdriver inserted through the cap nut hole to prevent turning of the adjusting screw. (e) After tightening the cap nut, check again the injection pressure.
13-97
FUEL AND ENGINE CONTROL SERV ICE PROCEDURES
13 (2) Spray Condition
-
5.6.5 Reassembly and Adjustment (2spring nozzle) A d ju s t w h il e a s s em blin g th e par ts by th e fo ll o w in g procedures. As th e p re li ft is adj us te d in 1/10 0 m m in c re m e n ts , use clean detergent to thoroughly remove dust and dirt before adjustment. For adjustment, the following special tools are required. Specialto o l
DieselKikip a rtNo.
Nozzle tes ter (500 kg /c m 2) A dj us tin g dev ice
105785-1010 1057 89-0 500
When adjusting the pressure with a nozzle tester, check also for clogged injection orifices, spray condi tion, and fuel
leak s from
the orifices.
Replace
the
nozzle if defective.
(3) Fuel Tightness Test
1
Ad ju st in g de vic e as se m bly
15789 2-022 0
2
Dial gauge
157954-3800
3
Pin,
( -
4
Pin,
/ = 60.5 mm
5
Connector assembly
157892-1320
6
Base
157892-1800
this condition, check for fuel leaks from the bottom of
7
Gasket (for retaining nut)
157892-1500
the nozz le. The nozz le is func tionin g norm ally if ther e
8
Retaining nut for adjustment
157892-1420
is no leak.
9
Gasket (for bolt of retaining nut)
026508-1140
50 mm
157892-1200 157892-1100
Install a nozzle that has been adjusted to specified injection start pressure to the nozzle tester. Slowly increase the pressure to the test pressure and keeping
tool) install the nozzle and needle valve to the nozzle
* 0 Check of need
holder.
(5)
Insta llation of
*(6 ) Checking
le valve full lift pre lift shim s
of pre lift
* 0 Checking of 2-spring adjusting pressure 0
' In spec tion
Inspection make operations marked with * as neces sary for inspection or confirmation.
MOTE: H. Make sure that the kn oc k pin ha s sea ted completely in the nozzle before tightening the retaining nut for adjustorient. Tighten the retaining nut finger tight and then tighten to specified tor que using a torque wrench. 2. IRemove the bolt from the tip of the retaining nut.
13-99
13
FUEL AND ENGINE CONT ROL SERVICE PROCEDURES
NOTE: 1= When u sing a shi m , be sure S o c h eek its thickness by a m icrom ete r. 2. Use same shim for prelift adjustment. 3. Use of a 0.02 mm th ick s him ch anges the valve opening pressure by about 235 kPa (2.4 kg f/em 2} (2 ) Selec tio n of Prell if S Ad justin g Shim (a) 0 point adjustment of adjusting device
one) and spacer to the nozzle holder. Then tighten the setscrew to specified torque.
Install the Dial Gauge (special tool) to the Adjusting Device (special tool). Install the 2nd push rod to the Base (special tool) and install the assembly to a vice. Set the pin and adjusting device as indicated in the above illustration
and adjust 0 point of the dial
gauge.
Use a 60.5 mm long pin. (c) Install the nozzle holder to the Nozzle Tester
(b) Install the 2nd push rod to the nozzle holder.
nominal injection pressure. Shim types: 0.50 to 1.54 mm (by 0.02 mm)
13-100
FU EL AND ENGINE CONTROL SERVICE PROCEDURES (e) Remove the a djusting
13 device from
the nozzl e
holder.
{3 ) Ad jus tm ent o ff 2- sprin g A dju sting Pre ssu re
Install the 2nd spring, adjusting screw and lock nut to the nozzle holder.
Bo mot install the prelift adjusting shim. (c) Install the adju sting de vice to the set screw using its intermediate screw. A ft e r in s ta ll a ti o n , h o ld in g th e dia l ga u ge at its h o ld er, mo ve it up and down
to check t hat the gauge operates
smoothly. Push down the gauge, holding its holder and read its lift h.
MOTE? Read t® 1/100 mm. (d) Selection of prelift adjusting shim t = ( + h Wh ere t:
Shim thickness
(measured)
C\ Prelift (0.10 + 0.0 2 mm ) h:
Dim ens ion selected
in (c)
Thickness of
ure) to the nominal value, using the adjusting screw and nozzle tester. A ft e r a d ju s tm e n t, ti g h te n th e lo ck n u t to s pec if ie d
T = t ± 0.015 mm T:
A d ju s t th e 2 -s pri n g a d ju s ti n g pre ss ur e (o pe n pr es s
shim to b e used
torque.
Type of shims 0.75 to 1.50 mm (by 0.01 mm)
13-101
FU EL AMD ENG INE CO NTROL SERVICE PROCEDURES
13
-
MOTEs
(4) Checking Full Lott off Meeále Valve
Mever loosen tine lock nut as loosening it changes the 2-spring adjusting pressure. (b) Install the prelift shim
selected in ( 2) betw een the
spacer and 2nd push rod. (c) Install the 2nd push rod and 2nd spring and tighten the setscrew, lock nut and adjusting screw as an assembly to specified torque. (d) Check again that the needle valve full li
ft dim en
sion "S" with the dial gauge by the procedures described in (4).
scribed in (5) and repeat steps (4) and (5) so that
A ( will fall within
C
± 0.02 mm.
Select thickness t' of shim to be used as follows. t'
s= t + [C - AC)
T = t' ± 0.015 mm where t: Thickness of existing shim t': Shim thickness T: Thickness of shim to actually replace existing shim
C: Prelift (0.1 mm)
(a) Remove the setscrew, lock nut and adjusting screw as a n assem bly from
13-102
the nozzle holder.
FUE L AMD EMGI ME CO NTRO L SERVICE PROCEDURES 1?) Chec king
Ad justing
A llow anc e
oí 2-
13
(b) Spray condition
spring
(a) Afte r checking the p relift in Item (6) , increase t he pressure again to about 34.5 to 44 MPa (350 to 450 kgf/c m 2) so that the
needle valve
of the nozzle is
fu lly
lifted.
NOTE: The Ret aini ng Nut for Ad justm
ent {special
tool} must have a holt fitted at its tip. (b) Whe n the nozzl e tester lever opera tion is stopped with the nozzle needle valve fully lifted, the pressure will start to drop and the needle valve will go down. (c) At the mo m en t the nozzl e lift has drop ped to 0. 05 mm, read the pressure gauge indication. (d) If the 2-spring adjus
When adjusting the pressure with a nozzle tester, check also for clogged Injection orifices, spray condi tion, and fuel leaks
fro m th e orifices. R eplace
the
nozzle If defective.
ting press ure (cover pressure)
is out of specification, adjust the 2-spring adjusting
(c) Fuel tightness test
pressure as described in (3).
MOTE: A d ju s t w ith o u t in s tallin g p r e lif t s h im . (e) Remove special tools.
{8 } I ns pec tion (a) Tighte n the retaining n
ut and cap nut to specified
torque.
MOTE: 1. Make sure that the kn oc k pin ha s sea te d co m pletel y b efore tightening the retaining nut. 2. Tighten th e retai nin g n ut fi ng er fi gh t and then tighten to specified torque using a torque wrench.
Install a nozzle that has been adjusted to specified Injection start pressure to the nozzle tester. Slowly incr ease the pressure this cond ition, check
to the test pressure
and keeping
for fuel lea ks from the botto m o f
the nozzle. The nozzle is functioning normally if there is no leak.
