Componente Motor
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SEBEKTURB001
TURBOCHARGER TURBOCHARGER MODEL KTR100 KTR110 KTR130 KTR150
©2001 All Rights Reserved Printed in Japan 02-01(02)
00-001 1
CONTENTS
00
INTRODUCTION
01
GENERAL ........................................................................................................ 01-001
11
STRUCTURE AND FUNCTION
13
DISASSEMBLY AND ASSEMBLY ................................................. 13-001
14
MAINTENANCE STANDARD AND INSPECTION OF PARTS ................................................................... 14-001
00-002 1
........................................................................................ 00-011
....................................................... 11-001
TURBOCHARGER
The affected pages are indicated by the use of the Revision Revision Mark Page Page that necessary Mark acPage following marks. It is Mark requested number number tions be taken to these pages according to the table below.
Revision Mark number
(
Mark
Revision Indication Page number
Revision Action required Page
Mark
number
c
Page to be newly added
Add
b
Page to be replaced
Replace
Page to be deleted
Discard
)
Pages having no marks are those previously revised or made aditions.
LIST OF REVISED PAGES Mark
b b c
Page
00-001 00-002 00-003 00-011
Revision number
Mark
Page
Revision number
Mark
Page
Revision number
Mark
Page
Revision number
Mark
Page
Revision number
1 1 1
01-001 01-002 11-001 11-002 11-003 11-004 11-005 11-006
b b b b b b b b b
13-001 13-002 13-004 13-005 13-006 13-007 13-008 13-009 13-010 13-011 13-012 (13-013)
1 1 1 1 1 1 1 1 1
14-001 14-002 14-003 14-004 14-005 14-006 14-007 14-008 14-009
TURBOCHARGER
00-003 1
5 d
0
0
c3
KTURBO
2 ?
Q
0
3
2 0
It) Z
n Z
a
... .. .. .. ..
... . .. .. ....
GENERAL
STRUCTURE
KTRI 00
1. Flinger 2. Bearing cover 3. Journal bearing 4. Center housing 5. Ring seal 6. Shield 7. Turbine housing 8. Turbine impeller (Rotor shaft) 9. Thrust bearing 10. Insert 1 1. Ring seal 12. 13. 14. a. b. c. d. e. f.
Blower impeller Blower housing Rock nut Oil inlet (from oil filter) Oil outlet (to oil pan) Air inlet Air outlet Exhaust inlet Exhaust outlet
11 FOO9A
KTRl IO
1. Blower housing 2. Blower impeller 3. Clamp 4. Center housing 5. Journal bearing 6. shield 7. Turbine impeller 8. Flinger 9. Thrust bearing 10. Turbine shaft 11. 12. a. b.
61 62F609A
1 l-002
Ring seal Turbine housing Oil inlet (from oil filter)
Oil outlet (to oil pan) Air inlet :: Air outlet e. Exhaust inlet f. Exhaust outlet
KTRI 30 1
3
2
4
5
3
6
7
6 1. Blower housing
2. 3. 4. 5. 6. 7. 8. 9. IO.
Blower impeller Clamp Center housing Journal bearing Shield Turbine impeller Turbine housing Flinger Insert
11. Thrust bearing 12. Turbine shaft a. Oil inlet (from oil filter) b. Oil outlet (to oil pan) Air Jn!e? Z: Air outlet Exhaust inlet Y. Exhaust outlet
e 6 162F610
KTRI 50
1. Blower housing 2. Blower impeller 3. 4. 5. 6. 7. 8. 9. 10. a. b. c. d.
Clamp Center Journal Turbine Turbine
housing bearing impeller housing
Flinger Thrust bearing Turbine shaft Oil inlet (from oil filter) Oil outlet (to oil pan) Air inlet Air outlet
e. Exhaust inlet f. Exhaust outlet
8
!i F6166009
1 l-003
3L
CD = CD
-0
3
-*
2
5
2 c) +
2
D
m
113
Structure * The turbocharger
has a turbine
impeller
which
rotates
under high-temperature,
high-pressure
ex-
haust gases. Then, the blower impeller installed on the same shaft with the turbine impeller is rotated, thereby compressing
and supercharging
the intake air with the engine. A shaft connecting
the turbine
impeller to the blower impeller is normally intergrated with the turbine impeller. A blower impeller is fixed with nuts to the tip of a shaft on the opposite side of the turbine impeller. * ,The impeller shaft rotates at a very high speed while subject to the thrust force of the intake air compression supported
pressure
imposed
on the inpeller
and the exhaust
pressure.
Consequently,
the shafting
is
on a floating type cylindrical journal and thrust bearings.
The center housing holds bearings, forming the circuit of oil for lubricating
bearings.
The turbine
circuit. The exhaust
housing
from the exhaust
contains
manifold
the turbine
impeller,
are led to the turbine
gases which by their expanding
forming
the exhaust
gases
impeller at high speed and pressure. Thereby,
the
action rotate the impeller at high speed are expelled from the engine
in this exhaust circuit. On the other hand, the blower housing contains a blower impeller, forming intake air is led to the biower impeiier and compressed by the rotating pressed air is superchanrged
the air intake circuit. The I !tCslli this comImpeller. Than
into the engine.
Lubrication of turbocharger Oil is supplied fron the engine through the top of the center housing. After lubricating the bearings and sliding parts, the oil drains through the hole at the bottom of the center housing and returns to the engine oil pan. Notes l
l
Rotating speed (revolutions) of turbochargers 50,000 to 125,000 rpm (continuous allowable rotating speed) Allowable revolutions vary deprending on the size of the impeller. Engine exhaust temperature: 500 to 700°C (turbine impeller inlet temperature
in full-load
operation)
1 l-005
Function In a diesel engine, the energy of fuels burnt in cylinders
is in the ratios indicated at right.
The effective approx.
l/3
energy as shaft horsepower
of the fuel energy. The remainder
is is
expelled from the engine. A turbocharger
takes the speed and pressure
energy of high speed gases from the exhaust to be expelled from the engine with the turbine impeller
as the rotating
the blower impeller
power
source.
Thereby,
on the same shaft with the
turbine impeller is rotated so that the air is compressed and supercharged
into the engine.
In order to obtain the effective
horsepower
in a diesel engine, a quantity of air approx. 17 to 22 times greater than the amount of fuel to be injected is generally required. This corresponds to 1.2 to 1.5 the excess air ratio.
Intake
Note Excess air ratio: The ratio of the quantity
of air necessary
to actually obtain optimum combustion efficiency, assuming that the theoretical quantity of air required for complete fuel combustion is 1. For combustion in a diesel engine, an excess air ratio of 1.2 to 1.5 is required because of the fuel mist-air mixture, combustion time limit, etc. If the quantity of air is less than 1.2 to 1.5 the excess air ratio, incomplete combustion will take place, resulting in black exhaust smoke and an increased heat load.
Exhaust gases
E k is
300
ln a turbocharged engine, a quantity of air corresponding to the fuel injection quantity is
i* 5 _.c
compressed and supercharged. In an engine of the same cylinder capacity, the horsepower can be increased as indicated in the graph at right. If an after-cooler is used with the turbocharger, the horsepower can be further improved.
ii ‘i5, 200 15
100
1’200
1400
1600
1800
2000
2200
Engine speed (rpm) Comparison of horsepower between turbocharged and naturally aspirated engine (NTA 855 engine).
1 l-006
gz ??
FP
.. .
..
..
.. .
..
c9c9
*.
P
00 c;
KTU R BO
n
DISASSEMBLY AND ASSEMBLY
GENERAL DISASSEMBLY
GENERAL DISASSEMBLY •
Before disassembling the turbocharger, clean its outside surface and apply match marks to ensure that the blower housing and turbine housing are reassembled in their original positions.
KTR100, KTR130
KTR110, KTR150
13-004 1
TURBOCHARGER
DISASSEMBLY AND ASSEMBLY
GENERAL DISASSEMBLY
fl Replace the entire rotor assembly, if the dynamic balance check on the rotor assembly is impracticable. fl Before disassembling the turbocharger assembly, measure the radial clearance in the following manner and keep the measurement on record. 1) Depress the front end of the rotor in the radial direction with a finger. 2) Measure the clearance between the blower impeller and the housing by using filler gauge 1.
1. Housing fl When removing the blower housing and turbine housing, take care not to damage the blower impeller and turbine impeller. •
For KTR100, KTR130 1) Remove the nut and clamp (1), (2). 2) Remove turbine housing (3) and blower housing (4).
•
For KTR110, KTR150 1) Remove the nut and V-band clamp (1). 2) Remove blower housing (2).
3) Staighten the lock washer, remove mounting bolts (3), and then remove lock plate. 4) Remove turbine housing (4).
TURBOCHARGER
13-005 1
DISASSEMBLY AND ASSEMBLY
GENERAL DISASSEMBLY
fl Before removing the blower impellers, measure the end play and the radial play of the rotor assembly in the following manner and keep the measurement on record. 1) Measurement of the end play (A play in the axial direction) i) Set dial gauge 2 in position. ii) Read the dial gauge indicator when the rotor assembly is moved in the axial direction.
2) Measurement of the radial play (A play in the radial direction) i) Set dial gauge 2 in position. ii) Read the dial gauge indicator when the rotor assembly is moved in the radial direction.
2. Blower impellers 1) Clamp the end of the turbine rotor in a vice. fl Securely clamp the turbine rotor in the vice so as to prevent it form overturning or from falling. 2) Loosen and remove nut (5).
3) Extract the bolwer impellers from the turbine rotor in the following manner. i) Immerse the rotor assembly in an oven or oil that is heated at 140 to 160˚C for 5 to 20 minutes. ii) Extract blower impellers (6) from the turbine rotor. fl When extracting the blower impeller, take care not to apply an excessive force to the impeller. fl When heating the rotor assembly in oil, make sure that the oil does not contain dirt, chips, etc.
13-006 1
TURBOCHARGER
DISASSEMBLY AND ASSEMBLY
GENERAL DISASSEMBLY
3. Insert (Back plate) • For KTR100, KTR130. 1) Straighten the lock washer and remove bolt. 2) Alternately drive two bolts into the tap holes of the insert (7) to remove it.
•
For KTR110, KTR150. 1) Straighten the lock washer and remove bolt. 2) Remove turbine rotor from the back plate (7).
4. Flinger 1) Pull out flinger (8) from the insert (back plate). 2) Remove seal ring (9) from the flinger.
5. Thrust bearing Remove thrust bearing (10). 6. Thrust collar Remove thrust collar (11).
TURBOCHARGER
13-007 1
DISASSEMBLY AND ASSEMBLY
GENERAL DISASSEMBLY
7. Center housing Pull out center housing (12) from the turbine rotor. fl Take care not to damage the journal bearing.
8. Journal bearing Remove journal bearing (13). 9. Shield Remove shield (14) from the turbine rotor.
10. Turbine rotor Remove two seal rings (16) from tturbine rotor (15).
13-008 1
TURBOCHARGER
DISASSEMBLY AND ASSEMBLY
GENERAL ASSEMBLY
GENERAL ASSEMBLY •
Before assembly parts, wash and clean the parts, allow them to dry by air blow, and apply egine oil to the sliding parts. • Remove burrs completely from the parts. (Pay attention to seal ring grooves, in particular.) fl When reassembling the rotor assembly after the dynamic balance check has been made, be sure to align all the match marks stamped on the component parts.
1. Turbine rotor Fit seal rings (16) into turbine rotor (15). fl Apply a coat of engine oil to the side of seal rings and install the seal rings in such a way that the gap of each ring is positioned at 180˚ apart from that of the neighboring ring.
2. Shield Install shield (14) into the turbine rotor.
3. Center housing Install center housing (12) on the turbine rotor. fl When installing the center housing, take care to prevent the seal ring from slipping out.
4. Journal bearing Install journal bearing (13). fl Apply sufficient amount of engine oil to the inside, outside, and both sides of the journal bearing prior to the installation.
TURBOCHARGER
13-009 1
DISASSEMBLY AND ASSEMBLY
GENERAL ASSEMBLY
5. Thrust collar 1) Install thrust collar (11). fl Make sure that the thrust collar is free from foreign matter on both sides, apply engine oil to both sides of the collar, and install the collar with the match mark aligning with the mating mark. 2) Drive a dowel pin in the center housing. 6. Thrust bearing Install thrust bearing (10) with the dowel pin fitted in position. fl Before installing the thrust bearing, apply engine oil to both sides of the oil hole. 7. Finger 1) Fit sial ring (9) into finger (8). fl Apply engine oil to the sides of the seal ring. 2) Install flinger into the insert. (back plate) fl Let the gap of the seal ring on the flinger direct to the oil filler port on the center housing.
8. Insert (Back plate) • For KTR100, KTR130. 1) Fit an O-ring and install insert (7). 2) Tighten the insert mounting bolts and then bend the lock washer.
•
For KTR110, KTR150. 1) Install the turbine rotor onto the back plate (7). 2) Tighten the back plate mounting bolts and bend the lock washer.
13-010 1
TURBOCHARGER
DISASSEMBLY AND ASSEMBLY
GENERAL ASSEMBLY
9. Blower impellers 1) Install blower impellers onto the turbine rotor in the following manner. i) Immerse blower impellers (6) in an oven or oil that is heated at 140 to 160˚C for 5 to 20 minutes. fl When heating the rotor assembly in oil, make sure that the oil does not contain dirt, chips, etc. ii) Install the blower impellers onto the turbine rotor, aligning the match mark. fl Apply engine oil to the inner face of the blower impeller and install the impeller without using an excessive force. 2) After the blower impellers are cooled, tighten nut (5). fl Tighten the nut to the specified torque, then return it by a half turn and match the match marks in the tightening direction. When tightening, take care that the “match mark” of each part will not be shifted.
fl Measure the end play and the radial play of the rotor assembly in the following manner. 1) Measurement of the end play (A play in the axial direction) i) Set dial gauge 2 in position. ii) Read the dial gauge indicator when the rotor assembly is moved in the axial direction.
2) Measurement of the radial play (A play in the radial direction) i) Set dial gauge 2 in position. ii) Read the dial gauge indicator when the rotor assembly is moved in the radial direction.
TURBOCHARGER
13-011 1
DISASSEMBLY AND ASSEMBLY
GENERAL ASSEMBLY
10. Housing fl Take care not to damage the blower impeller and turbine impeller when installing the blower housing and turbine housing. •
For KTR100, KTR130. 1) Install the blower housing (4) and turbine housing (3) into the center housing and the rotor assembly. 2) Tighten clamp (2), (1).
•
For KTR100, KTR150. 1) Install the turbine housing (4) into the center housing and the rotor assembly. 2) Install lock plate, tighten mounting bolt (3), and bend the lock washer. 3) Install blower bousing (2) aligning it with the center housing and the rotor assembly. fl Apply a thin coat of grease (G2-LI) to the flange section. 4) Tighten V-band clamp (1).
fl Measure the clearance in the radial direction in the following manner. 1) Depress the end of rotor in the radial direction with a finger. 2) Measure the clearance between the blower impeller and the housing by using filler gauge 1. fl After completing the assembly, rotate the rotor assembly while depressing it lightly and make sure that the rotor can be rotated smoothly without binding.
13-012 1
TURBOCHARGER
cl
z
a
8
II
4
TURBOCHARGER KTRI 00
14FOOlA Unit:mm Check item
No.
2
Standard
End play (play in axial
1
direction) Radial play (play in radial
I
3
I
direction) Outside
diameter
to 0.11
0.18
0.20
to 0.04
0.60 Tolerance
of journal
Standard
Hole +0.020
24
-0.040 -0.060
16
-0.030 -0.050
+0.020 0
Standard 5
0
Repair limit: 0.010 size
r
-0.17
Turbine side
2
-0.08 -0.10
6
Blower
2
-0.08 -0.10
I
Thickness
of seal ring
parts
related to thrust Replacing
I lated
Shaft
Hole
23.91
24.04
15.94
16.05
indicated
parts re-
to bearing
runout) Repair
limit Replace
Groove
Width
Groove
0
-0.08 5.5
I
(Total
Tolerance Width
of thrust bearing
Raplacing
Repair limit
Shaft
Bend of wheel shaft
Thickness
limit
size
of center housing
Inner diameter of Journal bearing Outside diameter of wheel shaft
4
Repair
0.06
bearing Inner diameter
Remedy
Criteria
1
1
-0.02 -0.03 -0.04
5.34 1.85
,
5.52
I
A
2.05
1.85
side -0.12 -0.13
4 Clearance 7 8 9 10
between
blower
housing and impeller Tightening impeller
torque
Tightening
of V band
14-002
Replace parts Tolerance:
4.25 of insert
torque
4.05
(min.) 0.15
related to bearing
of blower
locknut
Tightening torque mounting bolt
locknut
,
kO.25
1.25 & 0.25
0.9 kO.1
kgm kgm
kgm
Tighten
-
E
2
-._ .k
x ii -
s ?’
co--
I I
Or dC
KTRI 30 6
9
8
5
2
10
4
3
6162F402
6162F401
Unit:
Check item
NO.
I I
Criteria
Standard
End play (play in axial
Repair
Remedy Rapiace parts
limit
related-to
direction)
0.08
to 0.13
0.18
thrust
0.25
to 0.43
0.60
Raplace parts related to bearing
Radial play (play in radial direction)
I
I Tolerance
Standard Outside diameter of journal bearing. Inner diameter of center housing.
mm
,
.Shaft
30
Inner diameter of journal bearing. Outside diameter of wheel shaft.
1
Bend of wheel shaft
I
Repair
limit
size 1
Xo!e
-0.060 -0.080
2.
1
--;:;;;
Shaft
+0.020 0
/
Xo!e
29.89
+;*‘15
/
1
30.04
19.95
/
20.05
1
4 Repair limit: 0.010
(Total
indicated
runout)
Tolerance Standard Thickness
Thickness
7
Clearance between blower housing and impeller Tightening torque impeller locknut
of blower
8
Tightening
of insert
10
mounting Tightening locknut
14-004
Repair limit Groove
Width
Groove
of thrust bearing
6
9
Replace
size Width
5
I
of seal ring
torque
-0.08 -0.11
+0.02 0
5.86
6.04
3
-0.08 -0.10
-0.03 -0.04
2.85
3.05
Tolerance:
(min.) 0.20
8.5 kO.5
1.35 kO.15
bolt torque
6
kgm
kgm
of V band I
0.9 fO.l
Replace parts related to bearing
kgm
Tighten
KTRI 50
7-
F6166056 Unit: No
Check item
Remedy
Criteria Standard
1
Repair
End play (play in axial direction)
Raplace parts
limit
0.08 to 0.13
0.18
0.25 to 0.43
0.60
I
Tolerance Outside diameter
of journal
Standard
of center 30
housing.
Inner diameter
of journal
Outside diameter
Shaft
Hole
-0.060
+0.020
-0.080
20
Shaft
0
bearing.
of wheel shaft.
limit
size
bearing. Inner diameter
Repair
related to thrust Raplace parts related to bearing
Radial play (Play in axial direction)
mm
29.89
30.04
19.95
20.05
+0.015
-0.030 -0.045
Hole
0
4 Bend of wheel shaft
Repair
limit: 0.010
(Total
indicated
runout)
Tolerance Standard 5
6
Thickness
Thickness
of seal ring
Clearance
between
9 IO
Tightening impeller
torque
Groove
6
-0.08 -0.11
+0.02 0
3
-0.08 -0.10
Width
Groove
5.86
6.04
2.85
3.05
Tightening
of turbine
housing bolt torque
-0.04
Tolerance:
(min.)
9.5 f0.5 of insert
torque
-0.03
0.20
Replace parts related to
I
of blower
Tightening torque mounting bolt
locknut
Width
blower
locknut
Tightening
limit
size
of thrust bearing
housing and impeller 8
Repair
Replace
kgm
6.75
kO.75
kgm
5.75
kO.25
kgm
Tighten
of V band 0.9 kO.1
kgm
14-005
Inspection l
of parts and judgement
In order to make correct diagnoses special attention to the following
Check
Part Blower
housing
l
Contact
standards
of faulty parts, first clean the parts, then inspect them, paying
check points.
points
with
Check points
Part
Blower
blower
impeller
0
l
Damage the
l
or deformation
surface
center
Damage
or bending
of the
with
housing
blade
impeller fitted
l
of
with
the
or failure
at
Contact
blower
housing
Deformation
Journal
joints
bearing
l Scuffing
and seizure
l Wear Center
housing
0
Failure
or wear
at
seal
bore 0
Scratches
0
Deformation
at
bearing or
bore
failure
Thrust
bearing
at
@ Wear and cracks
joints
Turbine
housing
l
Contact
l
Corrosion
with
turbine
rotor
Shield
of the inner surfact l Wear and cracks
Turbine
shaft
l
Damage ring
or wear of the seal
portion
of
the
l Wear, discoloration seizure of the journal
shaft and portion
Flinger and thrust
B For criteria
14-006
with the back plate
Bend of the shaft
about wear and bending,
@ Discoloration @ Wear of the surface in contac
of the shaft l
collar
refer to the Maintenance
standard
Standards for Reuse of Parts l
Use the photographs
in the shop manual (SEBG4080)
as reference when making judgement.
Failure Location
Part name
or type
Use after Use again
of failure Inner surface of
Light contact
1 blower housing
extending entire
.-F : r
Surface 2
fitted
to the
center housing.
flaw not
over the
inner surface.
No damage
Connections 3
parts.
No deformation
Flaws other than use
Flaw extending
again and do not use
the entire surface.
again, The contacting
or
deformation.
at air
inlet and outlet
Do not use again
reconditioning
G 2 m
degree
or
cracks.
There
is clearance
with
has a flaw but does not
the center
allow air to leak.
caused by deformation.
housing
Minor
deformation
More faulty
which
does not allow
than in use after re-
air to leak. No scratches.
surface
over
inner
Very
thin wear.
condition
conditioning. Large scratches. Wear.
Corrosion
or oxidation
of the inner surface.
oxidized
surface. removable
inlet flange
oxide film.
is less
than 0.3 mm.
14-007
Failure degree Location
Part name
or type
of failure
Use again
Use after reconditioning
1
Bending, deformation of the blade.
There is a slight bend but no cracks at the tip.
Cracks, lack of metal at the tip, easily observable bend.
Trace of slight contact is on the whole surface of the blade. However, there are no burrs.
Burrs or deformation.
2
Flaw due to contact between blade and housing.
Seal ring groove.
No wear or damage.
Deformation to the point that the seal ring is stuck.
No discoloration.
4
Journal iscolored) (d
Discolored surface can be easily removed with No. 400 to No. 600 sandpaper.
Discoloration other than use after reconditioning.
5
Journal (flaws)
Scratches not detectable by fingernail.
One or two flaws which catch on nails (Such flaws need not be repaired.)
Flaws other than use after reconditioning.
6
Journa!
No seizure.
No seizure.
Seized bearing metal.
3
c -!! : ._ + 5
(seizure)
O.Olmm or less T.I.R. (Total indicated runout)
Exceeding T.I.R.
Surface of fitted portion of a blower impeller.
No scuffing or flaw.
The surface has a flaw or scuffed area due to the turned impeller,
o Shaft back surface. ;’ ’
No trace of contact.
B
There is evidence of
’ contact. Slight bending of the tip.
Marked bending of the tip.
2
Cracks or damage of the blade.
No cracks or damage.
Cracks or damage.
3
Contact between and housing.
There is a trace of slight contact.
blade
I 41 Con +rrc.+ *;+L. LabLIv-vt u, +Lhe back
14-008
mm
Bend of the blade tip.
1
g ._ & 3 _o m
0.01
Bend of the shaft. 7
& =
Do not use again
’ No contact.
There is contact that can be easily removed with sandpaper.
’ Ns contact.
Contact other than use again and use after reconditioning. Contact.
plate. Damage of the contact surface with nut.
No damage.
No damage.
Damage.
5
6
Damage of inner surface of shaft hole.
No damage.
No damage.
Damage.
Flaw on the contact surface with thrust collar.
No flaw.
No flaw.
Flaw.
7
??
.-c
5
I
I
Gupaq pulnor
I
I
©2001 All Rights Reserved Printed in Japan 02-01(02)
00-001 2
CONTENTS
01
GENERAL ........................................................................................................ 01-001
11
STRUCTURE AND FUNCTION
12
TESTING AND ADJUSTING ............................................................ 12-001
13
DISASSEMBLY AND ASSEMBLY ................................................. 13-001
14
MAINTENANCE STANDARD AND INSPECTION OF PARTS ................................................................... 14-001
00-002 2
....................................................... 11-001
AIR COMPRESSOR
The affected pages are indicated by the use of the Revision Revision Mark Page Page that necessary Mark acPage following marks. It is Mark requested number number tions be taken to these pages according to the table below.
Revision Mark number
(
Mark
Revision Indication Page number
Revision Action required Page
Mark
number
c
Page to be newly added
Add
b
Page to be replaced
Replace
Page to be deleted
Discard
)
Pages having no marks are those previously revised or made aditions.
LIST OF REVISED PAGES Mark
b b b
Page
Revision number
00-001 00-002 00-003
2 2 2
01-001 01-002 01-003 01-004 01-005 01-006 01-007
1 1 1 1 1 1
Mark
b b b
11-001 11-002 11-003 11-004 11-005 11-006 11-007 11-008 11-009 11-010 11-011 11-012
1
b
Page
Revision number
13-014 13-015 13-016 13-017 13-018 13-019 13-020 13-021
1 1 1 1 1 1 1 1
14-001 14-002 14-003 14-004 14-005 14-006 14-007 14-008 14-009
2 2 2 2 1 1 1 1 1
Mark
Page
Revision number
Mark
Page
Revision number
Mark
Page
Revision number
1 1 1 1 1
12-001 12-002
1
13-001 13-002 13-003 13-004 13-005 13-006 13-007 13-008 13-009 13-010 13-011 13-012 13-013
1 1 1 1 1 1 1 1 1 1 1 1 1
AIR COMPRESSOR
00-003 2
. .
.
003kllV
SPECIFICATIONS
Assembly
Manufacturer’s
Engine
6206-91-I 100
part number
part number
DK408717-0300
model
(S)6D95L-
1
Water cooled - single cylinder - double acting
DK408717-0251
DK408717-0271 S(A)GDl 1 O-l
S6D105-1
Water cooled - single cylrnder - double acting
70 x 40
70 x 40
70 x 40
8.5
8.5
8.5
1,200
1,250
1,100
250 (rpm)
38.5
38.5
38.5
500 (rpm)
77
77
77
600 (rpm)
92.4
92.4
92.4
800 (rpm)
123.2
123.2
123.2
bore X stroke
Normal
max. pressure
Normal
max. speed
Discharge (Urnin)
6138-81-3111
Water cooled - single cylinder - double acting
Type Cylinder
6136-81-3112
(mm) (kg/cm2)
(rpm)
8
I
/
1,000 (rpm)
154
154
154
1,500 0-p-d
231
231
231
-
-
2,000
(rpm)
6D95L- 1 l PWI 50-I
S6D105-1 l LWI 60-I
S6Dll l
:: 3
O-l
WA350-1
#50001S6D95L-
1
SAGDI IO-I
. PWIOO-3 Application
(Note)
Normal
w-002 0
l
WA380-1
l
WA400-
l
WA420-1
models
max. speed and discharge
speed are shown
in air compressor
speed.
1
m ti
In
ai
8 ;;_
0 ;;;
0 Lo
‘c .
8 -
Y
-_
;T;;
0
Al RCOO
CD
B
.!
Assembly
part number
Manufacturer’s
Engine
part number
model
I
Type Cylinder
bore X stroke
Normal
max. pressure
Normal
max. speed
!mm)
I I
(kg/cm2)
(rpm)
6162-83-6700
6162-83-6800
DK408738-5102
DK408738-5280
S6DI 70 Water cooled - single cylinder - double acting
Water cooled - single cylinder - double acting
85 X 60
85 X 60
8.5
8.5
I ,700 I
250 (rpm)
500 (f-pm)
r---Gz-
170
170
204
204
276
340
1,500 (rpm)
510
2,000
680
(rpm)
PC I 000
Application
models
WD600
Assembly
part number
Manufacturer’s
Engine
6165-91-l
part number
DK408728-5085 SA8V170-1 SA12V170-1
model
6165-91-1004
6165-91-I
DK408728-5092 DK408728-5093 DK408728-5094
005
DK408728-5100
SA8V170-1 SAI 2V170-1
SA8V170- 1 SAI 2V170-1
Water cooled - two cylinder - double actins
Water cooled - two cylinder - double acting
Water cooled - two cylinder - double acting
2 - 85 X 60
2 - 85 X 60
2 - 85 X 60
8.5
8.5
8.5
2,100
2,100
2,100
250 (rpm)
-
-
-
500 (rpm)
340
340
340
600 (rpm)
408
408
408
800 (rpm)
544
544
544
1,000 (rpm)
680
680
680
1,500 (rpm)
1,020
1,020
1,020
2,000
1,360
1,360
1,360
Type Cylinder
001
bore X stroke
Normal
max. pressure
Normal
max. speed
Discharge (Urnin)
(mm) (kg/cm*)
(rpm)
r
1
(rpm)
SA8V170l
1
10246-I l
Application
!?lC!Ck?iS
SA8V170-1 l WA800-1
WA800-1 (Application Serial No. 0292)
l
0230)
SA12V170-1 l HD1200-1 (Application Serial No. 10004-10009)
01-006
0
0 HD785
(Application Serial No.
HD785-2 (Application Seriai No. 10182-I
SA8V170-1
10294HD785-2
. WA800-1
)
(Application Serial No. 10231-J SA12V170-1 l HDI 200-I (Application Serial No. lOOlO-)
SAI 2V170-1 l
HD1200-1
I
I
(Jew) (-Jew)
008VM * OOLAH o
(JeW) E-58LClH
l
l-OPLAZ tvs
Wo4) (Juo-Jj)
008VM OOLAH
slapocu uo!~eyddV
l l
buo-4) E38LCIH l l-OPLAZ tvs
POZ
POZ
ZLZ
ZLZ
OH
OtrE
01s
01s
089
089
WdJ)000’2 WdJ)00s’
1
------I WJ) 000’
1
W!WJ)
(MdJ) 008
s 3 0
a6_dey3s!a
WJdJ) 009
WJ) osz WdJ)
09 X 28
6u!43e
alqnop
al6u!s -
I
-
Japu!lA3
pal003
JaieN\
5uye
ium)
09 X G8
(,W3/6y)
5’8
alqnop
~316~9-
-
paads
anssald
‘XBUI
(k?UlJON
adAl
JaleN\
Jaqurnu Iced s,mn~sejnueyy
ZZ lF8EL80PXl
Jaqwnu Iced AlqwassV
LOLE-18-91Z9
LOZE- 18-S 1Z9
‘XE?LU [EXlJlON
ayos~s x aioq ~apugA3
~apu!lA3
pa(OO3
1apou.1au!6u3
1-O-h LAZ LVS
l-OP LAZ LVS _ ZE 1%8EL80PlCl
I
I
. . . . . . . . .
COCOO00-r. ????
.
z . . . . . . . :g
.
. . . . . . . . .
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. ’
. . . . . . . . . :
g
: : .,o
:X
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1% : : . . :‘iij
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:p.. .-l
.s.. m
2%
. . . . . . . .
003kl IV
Al RCOO
C
m
3
-I C
c)
I--
&
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0 -
.
.
r\a3cno-cv
.
77F
.
.
.
l
6210-81-3121
1. 2. 3. 4. 5. 6.
Cylinder head Piston Piston ring Piston pin Connecting rod Cylinder
1 l-004
7. 8. 9. 10. 11. 12.
Crankcase Roller bearing Crankshaft Flange Ball bearing Cover
a. b. c. d.
Air intake Cooling water inlet Cooling water outlet Lube oil inlet
003u IV
_I 7
Al RCOO
-
\
m
N
003kl IV
I
n 8
AIRCOO
STRUCTURAL FEATURES OF AIR COMPRESSORS
connection part number
Separ- Integrat- Split Injection Feed ate type ed type bearing pump pump
1d”
\
I
6215-81-3201
I
e
I
I
0
I
0
I
Crankshaft bearing support Ball Roller bearing bearing
E%Y:’
1
*: One sliding bearing
2. Cylinder l
The
bottom
crackcase bolts.
of cylinder
(7)
mates
(12), and is installed
with
with
5. Piston * Two piston
four
3. Crankcase l
Crankcase (12) has holes in the side surface for installing the compressor, and has mounting holes for the oil supply joint. It has an overflow to allow any excess oil to flow to the engine crankcase. The face with the holes is put against the appropriate face of the timing gear case when installing the compressor.
6. Connecting l
4. Crankshaft l
Crankshaft (2) forms one piece with the balance weight. It is supported by two bearings (I), and at one end it is connected by taper shaft to the gear. Depending on the model, it is connected to the injection pump or feed pump. * 6165-91-1005 This is supported by one ball bearing and one sliding bearing: one end is connected by a taper shaft to the gear, and the other end is connected to the feed Pump.
rings (6) are installed
to the
top of piston (4), and one oil ring (5) is installed to he bottom. To allow for heat expansion when the piston is operating, the outside diameter at the top is smaller than at the bottom, or it forms an oval shape. rod
There are two types of big end for connecting rod (3): a separate type and an integrated type. Adjustment of tightening cannot be carried out using shims, so if there is wear, the connecting rod must be replaced. When assembling the separate type, the match mark is given as a line on the side face. * A steel bushing is used for the small end of 6165-91-I 005.
7. Lubrication Engine oil is used as the lubricant. The oil force-fed from the engine to the oil suplly joint in the side face of the crankcase is splashed up by the balance weight of the crankshaft and the big end of the connecting rod, and flows out through the overflow hole at the engine end. l
1 l-009 co
FUNCTION This
equipment
and is directly
is driven connected
by the
engine
to the engine,
air compressor is always engine is rotating.
rotating
gear, so the
when
the
l
When below
the air pressure the specified
governor,
the rod of unloader
to its original its normal
The
inlet
matically
valve
and delivery
opened
and closed
valve
are auto-
by the pressure
to discharge
and delivery
the compressed
On the down-stroke, and the inlet
valve
*
compressed. * 621 O-81 -3121, 6162-83-6700, 6165-91-I 001 When the air pressure inside the air tank reaches the specified pressure, the compressed air inside the tank passes through the air governor, and pushes down the rod of unloader valve (9) to block the intake hole. As a result, while the unloader valve is being actuated, no air is taken in, and no compressed air is discharged. 6165-91-I 004, 6215-81-3101, 6165-91-I 005, 6215-81-3201 When the air pressure inside the air tank reaches the specified pressure, the compressed air inside the tank passes through the air governor, pushes down the rod of the unloader valve, and opens the inlet valve. At the same time, it pushes down the valve of the exhaust valve, and opens the discharge side.
11-010 0
the air pressure
returns
valve closes,
hole
to suck in air from
There is an air governor to control the amount of air inside the air tank. When the air pressure inside the air tank reaches the specifierd pressure, the compressed air inside the tank passes through the air governor, pushes down the rod of unloader valve (9), and opens inlet valve (10). As a result, while the unloader valve is being actuated, the intake air is not
again,
valve (9) returns valve
(10) starts
and air is force-
6165-91-I 001, 6162-83-6700, 621 O-81 -3121 When
air.
the air cleaner.
operation
inlet
inside
the air tank
goes below the specified pressure of the air governor, the rod of unloader valve (9)
valve (11) opens
the delivery opens
position,
fed again.
inside the cylinder. On the piston up-stroke, the air inside the cylinder is compressed, inlet valve (10) closes,
inside the air tank goes pressure of the air
*
to its original
is opened,
position,
the
and air is force-fed
intake again.
6165-91-1004,6215-81-3101, 6165-91-1005,6215-81-3201 When the air pressure inside
the air tank
goes below the specified pressure of the air governor, unloader valve (9) and the exhaust valve return to their original position, and air is force-fed again.
Operation 0
of unloader
valve
6151-81-3110
Air pressure from aIt- governor
Intake Port
Intake port
0
When intake
8 E 3
l
valve
is actuated
When
intake
valve
is open
6210-81-3111
Air pressure air governor
intake port
from
Intake I port
L
When intake
valve
is actuated
When
intake
valve is open
11-011 co
AIRCOO
3
el ?
0
l
.
003&l IV
After disassembly, as follows.
Division Test
inspection,
1) Testing
I
and assembly,
carry
I
airtightness
Apply air pressure of 7 k /Cm* at the same time to the c?IS-
method
out the airtightness
2) Charging Time taken of 35 liters
test and performance
test
performance
to charge tank pressure from 0 to 7 kg/cm*
of tank
with
capacity
charge port and unloader valve, and measure the amount of leakage from the air intake port. Standard
speed
(rpm)
Charging
time
1,100
cc/min
max.
1,100
158 max.
cc/min
max.
1,100
158
cc/min
6136-81-3112
450
6138-81-3111
450
100
Rotating
max.
450
6206-91-l
(set)
158 max.
100 cc/min
max.
250/I
,500
6151-81-3110~
450
cc/min
max.
250/l
,500
100 cc/min
max.
500/l
,500
100 cc/min
max.
500/l
,500
100 cc/min
max.
500/l
,500
145
max./60
max.
100 cc/min
max.
500/l
,500
145
max./60
max.
621 O-81 -3111
j,
6210-81-3121
*
“I
6162-83-6700
260
max.
6136-81-3120*
6151-81-3140*
220
maxY45.5
max.
max./40
max.
145
max./60
max.
145
max./60
max.
6162-83-6600
+r
1500
cc/min
max.
500/l
,500
133
max./50
max.
6162-83-6800
*
1500
cc/min
max.
500/I
,500
133
max./50
max.
6165-91-l
001
*
“2
1500
cc/min
max.
500/l
,500
98 max.138
max.
6165-91-l
004
*
“2
1500
cc/min
max.
500/I
,500
98 max./38
max.
6165-91-l
005
*
“2
1500
cc/min
max.
500/l
,500
1500 1500
cc/min cc/min
max. max.
500/l 500/l
,500 ,500
98 max.138 198 max./83
max. max.
198
max.
6215-81-3101 6215-81-3201
*:
for leakage
* *
Time taken to charge *? Air tightness test
tank pressure
of tank with
capacity
of 30 liters
max./83
from 0 to 8 kg/cm*
When air pressure of 7 kg/cm2 is applied to the intake port and unloader port, the amount of leakage from the discharge port must be a maximum of 2300 - 4000 cc/min. “2 Air tightness test When air pressure of 2 kg/cm2 is applied from the discharge port piping of the exhaust valve, the amount of leakage from the exhaust port must be a maximum of 100 cc/min. When air pressure of 7 kg/cm* is applied to the unloader line of the exhaust valve and unloader valve, there must be no leakage of air. l
3) 0il leaking up Remove the pipe from the discharge port in the cylinder head, and check the operation. Check that there is no abnormal spray of oil from the discharge port.
12-002 0
8 z 3
13 DISASSEMBLY AND ASSEMBLY
Tightening Disassembly
torque
and assembly
6206-91-l 6136-8i
. . . . . . . _. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-002
100 -3112
......
(S)6D95L-1
......
S6D105-1
6138-81-3111 6151-&i
...... -31 i 0 ......
6136-81-3120
......
6151-81-3140 6210-81-3111 6210-81-3121
...... ...... ......
6162-83-6700
S(A)GDl (SA)GDI
5 Series IO-1 25-l
. . . . . . . . . . . . . . . . . 13-006
1 ,J
S6D105-1, S6D125-1 S6D140-1
S6Dll
O-l
SAGD140-1
......
S6D140-1, S6D170-1
6162-83-6600 6162-83-6800 6215-81-3101 6215-81-3201
...... ...... ...... ......
S6Dl70-1 S6D170-1 SAl2V140-1 SA12V140-1
6165-91-1001 6165-91-1004.. 6165-91-1005
...... SA8V170-1, .... SA8V170-1, ...... SA8V170-1,
Series
. .
1 ’ Series
SA12V170-1 SAI 2V170-1 SAI 2V170-1
Series
. . . . . . . 13-018
1
13-001 @
TIGHTENING
TORQUE
(Standard
Values) Unit: kgm
Part No’
6206-91-l
100
6136-81-3112
6138-81-3111
6136-81-3120
6151-81-3110
12+
lo+1
lo+1
-
-
Inlet valve guide
@
12 + 1.2
12+
Delivery
valve body
@
105
10.1
Delivery
valve seat
@
-
Unloader
04
valve
1
1.2
lOAIl -
-
5 + 0.5
1.2
5 XII 0.5
lo+1
5 + 0.5
15 X!I 1.5
5 + 0.5
5 + 0.5
Bearing cover mounting bolt
05
Connectin mounting
rod 1 olt
8
mounting
0
3 f
0.3
3 * 0.3
3 + 0.3
5 * 0.5
3 + 0.3
Cylinder head mounting bolt
08
3 * 0.3
3 + 0.3
3 I!I 0.3
3 I!I 0.3
5 * 0.5
Flange bolt
@
1.5 +0.15
-
-
0.6 AI 0.06
0.6 + 0.06
-
-
-
-
-
-
-
-
0&nder
mounting
Exhaust valve bracket mounting bolt
0,o
Exhaust
0
valve cap
2.75
f
0.25
0.6 + 0.06
0.6 + 0.06
2.5 I+I 0.25
2.5 + 0.25
2.5 f
-
0.25
2.75
+ 0.25
2.75
2.5 AI 0.25
+ 0.25
2.5 + 0.25
mounting
bolt @
-
-
-
-
-
Delivery valve mounting bolt
013
-
-
-
-
-
Inlet valve seat mounting bolt
0,4
_
-
-
-
-
Plate
8
2
,8 i l-
5,
650ACF040
650ACF039
General 6206-91-l
13-002 0
drawing 100
650ACF041
General 6206-91-l
100
drawing
6151-81-3110
m
s; M
mo d -3
$1
In0
d -3
+I
-.
-,
I
I
I
I
I
003wv
D
90’0 + 9’0
sa
E
90’0 f SP’O SL’OT
9’1
SO’0 + SP’O 91’0 f 9’1
90.0 f !a’0 91’0 f 9’1
90’0 f 9l7’0 91’0 f 9’1
I71 0
-
I
-
c-0 f &
E’O f E
E’O f E
E’O f E
s-0 f 9
9’0 f 9
s-0 + 9
9’0 + 9
P’O f P
P’O T P
I
0 POO-EL
Iloq Gu!wnow leas EmleA Ii3lUl lloq Guyunocu a/ye/I AJaAyaa
SO’0 + 37’0 91’0 + 9’1
0
0
I
SZ’O f S’Z
SZ’O + S’Z
SZ’O f S’Z
0O1
1pq
6ugunoLu
de:,
CIAI~A
100 l- 16-99 19
0089-E8-Z9
1108 Gu!lunow POJ
1fXS
@
U!lXHJUO~
aAlE!/\
nJE3A!laa
63AleA
ap!nS
t%J!Jeaa
Japeolun
aAle/\
ApOq
@
01
POOL-16-9919
aIeld
lloq Gu!lunow Peav JaPu! lb
08 0L
09
iloq Gullunour JEIA03
I I
SOOL-16-9919
vsneyxg
lloq Guwnow lay3eJq arilfa vineyxj
06
-
04 0P
LOLE- 18-S 1Z9
AJaA!laa
ElAlt?A
lalul
19
w6y gun
003kl IV
I
AIRCOO
\
\
o-h,0 . . . . . . . . . . . .
AAdO
&AA_
bcli,bL
. . . . . .
. . . . . .
1. Cylinder
head
1) Remove
cylinder
(31). 2) Tap cylinder
head
head (11)
mounting with
bolts
6. Delivery valve assembly 1) Remove delivery valve body (12) from top of cylinder head.
a plastic
hammer from below to remove it. 3) Remove gasket installed between cylinder
Air pressuje from air governor
(20) and cylinder head (11).
/
1 Air discharge port
2. Cylinder, connecting rod, piston Remove cylinder mounting bolts (33), then 1)
2)
remove cylinder (20) from crankcase (21). Remove 2 nuts (34) installing big end of connecting
Air intake 0 port
rod (27).
3) Remove piston (30) and connecting (27) from crankcase (21).
rod
4) Using a tool, remove 2 piston rings (I 8) and oil ring (19) from piston (30).
650ACF048
5) Remove 2 snap rings (29) from piston pin holes, then pull out piston pin (28) and remove piston from connecting rod (27). If thread portion where delivery valve seat (7) is screwed in and installed to bottom of cylinder head is caulked, remove caulking before removing parts. valve seat (7), then 3) Remove delivery remove delivery valve spring (3), delivery 2)
3. Bearing cover I) Remove 4 mounting bolts (22) mounting bearing cover to crankcase (21), then remove together with oil seal (23) from crankcase (21). 2) Remove
oil seal (23) from bearing
cover
(26). 4. Crankshaft 1) Pull out crankshaft (24) in direction of bearing cover (26), with 2 ball bearings (25) still fitted. 2) Using a hand press, remove ball bearings (25) from crankshaft (24). 5. Unloader valve assembly 1) Remove unloader valve body (10) from top of cylinder head. 2) Remove snap ring (5) from inside unloader
valve (6), gaskets (5) and (4), and delivery valve guide (8) from inside delivery valve seat. 7. Inlet valve assembly 1) If thread portion where inlet valve guide (1) is screwed in and installed to bottom of cylinder head (11) is caulked, remove caulking before removing parts. 2) Remove inlet valve guide (I), then remove inlet valve spring (2), inlet valve (3), and inlet valve seat (4) at the same time.
valve body (IO), then pull out washer (6), unloader valve spring (7), and rod (9).
13-007 a
ASSEMBLY 6206-91-I
100
1
6136-81-3112 6138-81-3111 6151-81-3110
l
6151-81-3110
Series
Air pressure from air governor
J
0
2
1 Air discharge
/
port A
/
Clean all parts, check for dirt or damage, and
l
blow with air to dry. Coat the sliding surfaces and press-fitting portions of all parts with clean engine oil before installing. I.
Inlet valve assembly 1) Insert inlet valve seat (4) in cylinder
Air intake 0 port
head
(1 I), then fit inlet valve (3) and inlet valve spring
(2), and temporarily
tighten
valve guide (1). * *
*
650ACF048
inlet
1 Assemble
1
delivery valve spring (3) to head (l), then put delivery valve
Check that inlet valve (3), and inlet valve
cylinder
spring (2) move smoothly. If inlet valve guide (1) is protruding from the bottom surface of cylinder head (1 I), there is danger that it will interfere with the top surface of the piston, so check that it is not protruding. Do not carry out punch caulking on 615181-3110.
(6) on top of it. Put gasket (4), delivery valve guide (8), and gasket (5) in position, then temporarily tighten delivery valve seat (7). Check that delivery valve (6) moves smoothly, then tighten delivery valve seat (7) to the specified tightening torque.
&
~--LFI
Inlet valve guide thread: Thread tightener (Three Bond 1360) Inlet valve guide: See Tightening Torques and Standard Values Table
2. Delivery valve assembly 6206-91-I 000 6136-81-3112 6138-81-3111 Insert gasket into cylinder l
l
m
head (11).
Standard
m
Bond
1360) K&
*
Delivery valve seat: See Tightening Torques and Standard Values Table Check that the seat does not protrude from the bottom of the cylinder head.
Sliding surface: Molybdenum disulphide grease (Dow Corning Coorporation [MOLYCOTE 44M]) 2) Insert unloader valve spring (7) and
Torques
Values Table
and
washer (6), then secure with snap ring ,_* (51. 3) Tighten unloader valve body (10) to cylinder head (11). m
*
13-008 0
Delivery valve seat thread: Thread tightener (Three
&
Delivery valve thread: Thread tightener (Three Bond 1360) Inlet valve guide: See Tightening
*
3. Unloader valve assembly 1) Assemble O-ring (8) to rod (9), then intall inside unloader valve body (10).
l
&
2)
Unloader valve assembly: See Tightening Torques and Standard Values Table Push rod (9) with a bar, and check the movement of inlet valve (3).
8 g 3
4. Crankshaft 1) Using a press, press fit ball bearing to crankshaft a
&
Crankshaft pin: Coat with engine oil
&
Cap mounting bolt: Coat with engine oil
(25)
(24).
Oil seal sliding poriton:
2) Insert
Coat with engine oil crankshft (24) from bearing
cover
D
Cap mounting
(26) end of crankcase (21). 5. Bearing cover 1) Press fit oil seal (23) to bearing cover (26). e,
Press-fitting
(Loctite
bolts.
hydraulic
seaiant) Applicable compressors
*
6136-81-3112,
mA
6138-81-3111
/c(l_7L, Mating It *
with mounting
bolts (22).
surface of cover and case:
Gasket sealant (LG-4) Applicable compressors 6136-8l-3112,6138-81-3111 For 6826-91 _11CC and 6J5j_8j_31’jC, insert an O-ring in the bearing cover, then install.
w
Bearing cover mounting bolt: See Tightening Torques Standard Values Table
and
6. Cylinder, connecting rod, piston i) Align piston pin hole and hole at small end of connecting rod (27), then push in piston pin (28), and secure both-ends with snap rings (29). fln3
2) jt
Whole
inside
cylinder:
Piston pin: Coat with engine
Install oil ring (19) and piston Assemble piston rings (18) stamped ring surface facing up, sure that the end gaps of the in different places.
Mating
surface
at bottom
of
Coat with engine oil surface of cylinder and crank-
case: Gasket sealant (LG-4)
2) Press fit bearing cover (26) to ball bearing, then tighten
and
5) Compress piston rings (18) and oil ring (19), then assemble cylinder (20) to crankcase (21), and tighten with mounting
portion of oil seal:
Adhesive
bolt:
See Tightening Torques Standard Values Table
*
Applicable
*
6136-81-3112, 6138-81-3111 For 6206-91-1100 and 6151-81-3110, insert and O-ring in the cylinder skirt. m
compressor
Cylinder mounting bolt: See Tightening Torques Standard
and
Values Table
7. Cylinder head 1) Fit gasket to top surface of cylinder (20). 2) Assemble cylinder head (11) to cylinder, then tighten with mounting bolts. * Tighten the bolts slowly and uniformly to the specified torque. m Cylinder head mounting bolt: See Tightening Torques and Standard Values Table
oil ring (18). with the and make rings are
*
There is no top or bottom to oil ring (19). 3) Insert connecting rod assembly (27) from top of crankcase (cylinder end). 4) Assemble cap at connecting rod big end, then tighten with mounting bolts. * Check that connecting rod match marks are aligned.
13-009 (iJ
DISASSEMBLY 6136-81-3120
.......
S6D105-1,
6151-81-3140
.......
S6D125-1
6210-81-3111
.......
S6D140-1
6210-81-3121
.......
S6D140-1,
6162-83-6700
.......
S6D170-1
.
l
S6Dll
Series SAGD140-1
Before disassembly the air compressor, of oil from the mating surfaces. When disassembling then disassemble.
the
cylinder
O-l
clean
head,
it and check from the otitside
connecting
rod, and piston,
for damage
remove
from
or leakage the engine,
650ACF050
13-010 0
1. Cylinder
head
1) Remove
5. Unloader
cylinder
(20). 2) Tap cylinder
head
head
(11)
mounting with
bolts
valve body (8) from top
of cylinder head (11). 2) Remove rod (7) and O-ring
a plastic
hammer from below to remove it. 3) Remove gasket installed between cylinder (23) and cylinder
valve assembly
1) Remove unloader
unloader *
head (11).
from
inside
valve body (8).
The unloader
valve of 6210-81-3121
and 6162-83-6700
cannot
be disas-
sembled. 2. Cylinder,
piston,
piston
ring
11 Remove
cylinder mounting remove cylinder (23).
2)
Remove
bolts (18), then
valve assembly
1) Remove
snap rings (33) from piston
hoies, then pull out piston remove piston (34).
6. Delivery
pin
pin (32j and
3) Using a tool, remove 2 piston rings (21) and oil ring (22) from piston (34).
delivery
remove delivery
(17),
then
valve (16), delivery
valve
seat
valve
spring (15), O-ring (4 3), spring guide (I Oj, and O-ring (12). 7.
Inlet valve assembly 1) Remove inlet valve guide (I),then remove
3. Bearing cover, crankshaft 1) Remove mounting bolts (25) from bearing cover. Tap tip of crankshaft (26) with a wooden 2) hammer, and remove bearing cover (27).
inlet valve spring (2), inlet valve (3), inlet valve seat (4), gasket (9), and unloader valve spring (5).
partiaiiy
3) From the place where cylinder (23) mates with crankcase (31), hold crankshaft (26) and connecting rod (24) by hand, then tap with a plastic hammer from crankcase end to remove bearing cover (27). Using a gear puller, remove ball bearing (28) from crankshaft (26). 5) Remove connecting rod (24) from crankshaft (26), then pull out from mating portion of cylinder (23) in crankcase (31). 6) Using a hand press, pull out outer race of roller bearing (30) from crankcasee (31), and inner race from crankshaft (26). * For disassembly of 6136-81-3120, see 6151-81-3110. 4.
Flange 1) Remove hexagon socket head screws tightened from flange (29) side, then remove flange. * 6136-81-3120 has bolts.
13-011 c.0
ASSEMBLY 3. Unloader
6136-81-3120
1) Assemble O-ring (6) to rod (7), then install inside unloader valve body (8).
6151-81-3140 6210-81-3111
Series
621 O-81 -3121
a
6162-83-6700
valve assembly
sliding surface: Molybdenum
I
disulphide
(Dow Corning l
Clean all parts, check for dirt or damage, and blow with air to dry. Coat the sliding surfaces and press-fitting clean engine
portions
[MOLYCOTE
oil before installing.
unloader
valve
body (8). * For 621 O-81 -3121 spring
(5),
gasket (9), inlet valve seat (4), inlet valve (3), and inlet valve spring (2) to cylinder head (1 I), then tighten
/cm=-;
Inlet valve guide thread: Thread tightener (Three Bond 1360)
m
Inlet valve guide: See Tightening Torques Standard Values Table
spring (15). 3) Put delivery valve (16) on top of delivery valve spring (15), then tighten delivery valve seat (17). * Check that delivery valve (16) moves smoothly. * Check that delivery valve seat (17) is below the surface of cylinder head (II). Thread of delivery valve seat (15): Thread tightener (Three Bond
13-012 0
head.
Delivery valve seat: See Tightening Torques Standard Values Table
4.
and
and 6162-83-6700,
unloader
to
the
Unloader valve body: See Tightening Torques
and
Standard
valve
Values Table
Flange Fit O-ring to crankcase (31), then assemble flange (29), and tighten with mounting bolts. ra
Bolt thread:
5~
Mounting bolt: See Tightening Torques Standard Values Table.
Thread tightener Bond 1360)
(Three
and
5. Bearing cover, crankshaft 1) Press fit outer race of roller bearing (30) to crankcase (31), and inner race to crankshaft (26) so that both clearances are 0. 2) Insert crankshaft (26) into crankcase (31), insert big end of connecting rod (24) from cylinder mating portion, then push in crankshaft. -Crankshaft
pin: Coat with engine
oil
3) Press fit ball bearing (28) to crankshaft (26) with a press. 4) Fit O-ring, then press fit bearing cover (27) to ball bearing, and tighten with mounting bolts (25). w
1360) m
the
w
and
2. Delivery va!ve assembly 1) Fit O-ring (12) to spring guide (IO), then install to cylinder head (II). Install O-ring (13) and delivery valve 2)
a
install cylinder
inlet valve guide
(1). * Check that inlet valve (3) moves smoothly. * Check that inlet valve guide (1) is below the surface of cylinder head (1 I).
44M])
2) Insert so that rod (7) enters unloader valve spring (5), then tighten unloader valve
of all parts with
I. Inlet valve assembly 1) Assemble
grease
Corporation
Bearing cover mounting bolt (25): See Tightening Torques and Standard Values Table 5) Push tip of crankshaft with a hand press, and make a clearance at roller bearing. * For asembly of 6136-81-3120, see 6151-81-3110
8 : 3
003kllV
DISASSEMBLY 6162-83-6600
. . . . . . . S6D 170- 1
6162-83-6800
. . . . . . . S6D170-1
6215-81-3101
. . . . . . . SA12V140-1
6215-81-3201
. . . . . . . SAI 2V140-1
1 Series 1
Before disassembly the air compressor, of oil from the mating surfaces. When disassembling then disassemble.
the cylinder
clean it and check from the outside for damage or leakage
head, connecting
Air pressure from air
rod, and piston,
remove
Air discharge
4,
6
Air intak Port
/ 1
/ 9
A-i
B-i \
\
6
7 Section
B-B
i2
36
Section
16
j5
‘14
A-A
i3 650ACF051
I
”
\
LI
-
26
28
650ACF05i
13-014 0
F
from the engine,
1. Cylinder
head
5. Plate
I ) Remove cylinder head mounting and (41).
bolts (40)
1) Remove hexagon socket head screws (18) installed from top of cylinder head. *
2) Tap cylinder head (6) with a plastic hammer from below to remove it. 3) Remove gasket (34) installed between cylinder (32) and cylinder head (6). 2. Cylinder, piston, piston ring 1) Remove cylinder mounting bolts(33), then remove cylinder (32) from crankcase (30).
2)
Remove snap rings (21) from piston pin holes, then pull out piston pin (22) and
remove piston (23). 3) Using a tool, remove 2 piston rings (19) and oil ring (20) from piston (23).
Do not remove
blind plug (37) of the
water passage plate (8).
in the top surface
2) Remove mounting bolts (39) of plate (38) of water passage in side surface of plate (8), then remove plate. 6.
Inlet valve assembly 11 When cylinder head (6) and plate are . V., removed, inlet valve (l6), inlet valve spring (14), removed.
2)
Remove cylinder
3. Bearing cover, crankshaft Remove oil feed pipe
8 E 3
of
and
bolt (40)
washer installed
(15)
can
from
be
top of
head (6) then remove inlet valve
seat (17). (26)
secured
to
bearing cover (25) and flange (31). * Applicable compressor 6162-83-6600, 6162-83-6800 Remove mounting bolts (24) from bearing 21 cover (25). 3j Tap tip of crankshaft (28) with a plastic hammer, and partially remove crankshaft and bearing cover (25). 4) From the place where cylinder (32) mates with crankcase (30) hold crankshaft (28) and connecting rod (42) by hand, then tap with a plastic hammer from crankcase end to remove bearing cover (25). 5) Using a gear puller, remove ball bearing (27) from crankshaft (28). 6) Remove connecting rod (42) from crankshaft (28), then pull out from mating portin of cylinder (32) in crankcase (30). 7) Using a hand press, pull out outer race of roller bearing (29) from crankcase (30), and inner race from crankshaft (28). 8) Remove hexagon socket head screws tightening flange (31), then remove flange.
7. Delivery valve assembly 1) Remove hexagon socket head screws (36) installed in intermediate plate, then remove stopper (1 I), delivery valve (12), and delivery valve guide (10). * The bushing assembled to the discharge port in the cylinder head is coated with adhesive and press fitted. This bushing forms the cooling water passage and cannot be removed.
4. Unloader valve assembly 11 Remove unloader valve body (5) from top of cylinder head (6). 2) Remove snap ring (1) from inside unloader valve body (5), then pull out washer (9), unloader valve spring (2), and rod (4), and remove O-ring (3).
13-015 3
ASSEMBLY Air pressure from air
6162-83-6600 6162-83-6800 8215-81-3101
4,
5, wvepr
Series
Air discharge Port
6215-81-3201 l
Clean all parts, check for dirt or damage,
and
blow with air to dry. Coat the sliding surfaces and press-fitting portions of all parts with clean engine oil before installing.
/
1
1. Delivery
/A--/
\
9
8
B-l \
7
valve assembly
1) Install
delivery
valve (12), delivery
valve
Section
R-B
Section
A-A
guide (10) and stopper (1 I), then tighten with hexagon socket head screws (36). * Be careful not to let the delivery valve
10
il
j2
and delivery valve guide (10) overlap. Thread: Thread tightener (Three Bond
a
1360) Be careful not to get the thread tightener on the delivery valve.
* m
2.
36
1:
16
i5
‘14
i3 650ACF05
Hexagon socket head screw (36): See tightening Torques and Standard Values Table
Inlet valve assembly 1) Assemble inlet valve seat (17) to cylinder head (6), then tighten mounting bolt (40). &
Thread and washer: Thread tightener
(Three
Bond
1360) sm
Mounting bolt (40): See Tightening Torques Standard Values Table
and
3. Plate 1) Insert washer (15), inlet valve spring (14), and inlet valve plate (16) to plate (8), then assemble gasket (13) and O-ring (7), and tighten with hexagon socket head screws (4 8). * Push inlet valve unloader valve movement. j,
Check that the tip of the hexagon socket head screw does not protrude from the surface of the plate.
13-m 6
0
650ACF052
plate (I 6) from the end to check the
1
&
Thread and seat: Thread
c=
tightener
(Three
Bond
Bearing cover mounting bolt (24): See Tightening Torques and
1360) w
Standard Values
Hexagon socket head screw (18): See Tightening Standard Values
Torques Table
and
insert
unloader valve spring (2) and washer then install snap ring (1).
2) Install
(9),
disulphide
a
cm
Unloader valve: See Tightening Standard
Values
(Three
2) Install oil ring (20) and piston rings (19) to piston (23). * Assemble piston rings (19) with the
Bond *
Torques
and
Table
Mounting bolt thread: Thread tightener 1360) Flange mounting
facing
up, and
make sure that the end gaps of the rings are in different places. There is no top or bottom to oil ring
mounting fid
Bond
bolts (33).
Whole inside surface at bottom cylinder: Coat with engine oil Cylinder
mounting
of
bolt:
See Tightening Standard Values
Torques Table
and
bolt (31):
See Tightening Torques and Standard Values Table 2) Press fit outer race of roller bearing (29) to crankcase (30), and inner race of crankshaft (28) so that both clearance are 0. 3) Insert crankshaft (28) into crankcase (30), insert big end of connecting rod (42) from cylinder mating portion, then push in crankshaft. e-crankshaft
ring surface
(20). 3) Fit O-ring to cylinder (32), then with piston ring (19) press fitted, assemble cylinder to crankcase (30), and tighten with
QKI (Three
rod (42), then push in
Piston pin: Coat with engine oil
stamped
5. ‘Bearing cover, crankshaft 1) Fit O-ring to crankcase (30), then assemble flange (3l), and tighten with mounting bolts. &?&I
a
Thread of unloader valve body: tightener
bearing.
piston pin (22), and secure both ends with snap rings (21 j.
grease
(Dow Corning Corporation [MOLYCOTE 44M]) unloader valve body (5) to cylinder
Thread 1360)
at roller
6. Cylinder, piston, piston pin 1) Align piston pin hole and hole at small end of connecting
head (6)
m
and make a clearance
Sliding surface: Molybdenum
Table
with a hand press,
7) Install oil feed pipe (26) secured to bearing cover (25) and flange (31).
4. Unloader valve assembly 1) Assemble O-ring (3) to rod (4),
a
6) Push tip of crankshaft
pin: Coat with engine
oil
4) Press fit ball bearing (27) to crankshaft (28) with a press. 5) Fit O-ring, then press fit bearing cover (25) to ball bearing, and tighten with mounting bolts (24).
7. Cylinder head 1) Fit gasket to top surface of cylinder (32). 2) Assemble cylinder head (6) to cylinder (32), then tighten with mounting bolts (41). * Tighten the bolts slowly and uniformly to the specified torque. m
Cylinder
head mounting
See Tightening Standard Values
bolt:
Torques Table
and
AIRCOO
1. Cylinder
5. Plate
head
1) Remove
cylinder
head
mounting
(30). 2) Tap cylinder head (1) with hammer from below to remove
bolts
1) Remove installed
a plastic it.
3) Remove gasket (32) installed between cylinder (31) and cylinder head (1).
hexagon from
disassemble
socket
head screws
top of cylinder cylinder
(IO). * Do not remove water passage
head,
(2) and
head (1) and plate
blind plug (49) of the in the top surface of
plate (10). *
2. Cylinder, piston, connceting rod Remove cylinder mounting bolts(48), 1) remove cylinder (31) from crankcase
2)
Remove
mounting
connecting
bolts
rod (42), then
(43) and connecting
at
big
remove
rod from
then (37).
end
of
piston
piston
(43). (46)
3. Bearing cover, crankshaft bolts (36) of bearing 1) Remove mounting cover (35). 2) Pull out bearing cover (35) and crankshaft
3
water then
passage
for
passage remove
in side surface
of plate (lo),
piate.
6. Inlet valve assembly 1) When
(39). 6165-91-100-l 6165-91-1004 Tap the tip of the crankshaft at the flange end with a plastic hammer to remove the crankshaft. bolts (33) of coupling 3) Remove mounting (34) at bearing cover end, then remove coupling. 4) Using a hand press, remove bearing cover (35) from crankshaft (39). Using a hand press, remove ball bearing 5) (38) from crankshaft (39).
cylinder
removed, spring
4) Using a tool, remove 2 piston rings and oil ring (47) from piston (43).
8 :
the water
the cylinder head, so do not remove it. 2) Remove mounting bolts of plate (22) of
crankcase
(37). 3) Remove snap rings (44) from piston pin holes, then pull out piston pin (45) and remove
Link (20) forms
head (1) and plate (10) are
inlet (15),
and
valve
(14),
washer
inlet (16)
valve can
be
removed. 2) Remove bolt (3) installed from top of cylinder head (I), then remove inlet valve seat (I?). 7. Delivery valve assembly 1) Remove hexagon socket head screws (19) installed in plate (IO), then remove stopper (12), delivery valve (1 I), and delivery valve guide (18). 8. Exhaust valve 1) Remove cap (53) tightened from below exhaust valve (50), then pull out rod (51), spring (54), and O-rings (52) and (55). * Applicable compressors 6151-91-1004, 6165-91-1005
4. Unloader valve assembly 1) Remove unloader valve body (4) from top of cylinder head (1). Remove snap ring (9) inside body, then
a
pull out O-ring (6), rod (5), washer unloader valve spring (7). 6165-91-1001 *
Do not disassemble assembly.
the unloader
(8) and
valve
13-019 cc
ASSEMBLY 6165-91-1001
*
6165-91-1004
Push inlet valve (14) from the unloader
Series
valve end to check the movement. *
6165-91-1005
Check that the tip of the hexagon socket head screw does not protrude from the
Clean all parts, check for dirt or damage, and blow with air to dry. Coat the sliding surfaces and press-fitting portions of all parts with
surface of the plate. &
Thread and seat: Thread tightener
clean engine oil before installing. . * Exhaust
m
valve
1) Assemble
O-rings
(52)
(55),
and
spring (54) to rod (51), then tighten
cap
and
(53). &
Slinding
*
*
tightener
Bond ? 360) Be careful not to get tightener on the delivery
CZZZl
3.
valve guide (18) overlap. Thread
(Three
the thread valve plate.
Hexagon socket head screw (19): See Tightening Torques and Standard Values Table
Inlet valve assembly 1) Assemble inlet valve seat (17) to cylinder head (I), then tighten mounting bolts (3). &-L
Thread: Thread tightener 1360)
m
Mounting bolt (3): See Tightening Standard Values
(Three Bond
Torques Table
and
4. Plate 1) Insert washer (16), inlet valve spring (15), and inlet valve (14) to plate (IO), then
13-020 0
(6) to rod (5),
insert (8),
#&
Sliding surface: Grease (NOK Klueber [BARRIERTA JFE5221) 2) Install unloader valve assembly (4) to cylinder head (I ). cm Unloader valve assembly: See Tightening Torques and Standard Values Table
6. Bearing cover, crankshaft 1) Press fit ball bearing (38) to crankshaft (39) with a press. * Only at bearing cover end on 616591-1005. Press fit ball bearing (38) in bearing cover (35) with a press, the assemble O-ring to bearing cover pilot. 3) Assemble coupling (34) at bearing cover (35) end, and tighten mounting bolts (33). 4) Assemble flange (40) to crankcase (37), and tighten with mounting bolts (41). 5) Insert crankshaft (39) from bearing cover (35) end of crankcase, adjust bearing cover so that it is properly centered, then tighten with mounting bolts (36).
a
a
Crankshaft *
assemble gasket (13), and tighten hexagon socket head screws (2).
O-ring
valve spring (7) and washer
then install snap ring (9).
with hexagon socket head screws (19). * Be careful not to let the delivery valve Thread:
Values Table
valve assembly
unloader
2. Delivery valve assembly 1) Install delivery valve guide (18), delivery valve (1 1) and stopper (12) then tighten
ax1
Standard
1) Assemble
Cap (53): See Tightening Torques and Standard Values Table. Applicable compressors 6165-91-1004, 6165-91-1005
and delivery
Hexagon socket head screw (2): See Tightening Torques and
5. Unloader
surface of rod:
Grease (NOK Kluever [BARRIERTA JFE5221) m
(Three Bond
1360)
with
*
pin: Coat with engine
oil
(Front journal on 6165-81-I 005) When installing the bearing cover, check that the O-ring is fitted properly. With 6151-91-1005, fix the washer to the flange with grease.
8 $ 3
&
Bearing cover flange mounting See Tightening Torques Standard Values Table
7. Cylinder, 1) Install
*
bolt: and
%B
piston, connecting rod oil ring (47) and piston rings (46)
stamped
piston
rings (46) with
ring surface
facing
2)
There (47).
Align
piston
pin hole and hole at small rod (42), then push in
piston pin (45), and secure both ends with snap rings (44).
and
Table
005
exhaust
valve
mounting
bracket
(58) at the same time. 9. Exhaust
valve assembly
1) Tighten
mounting
valve assembly
end of connecting
&
Install
up, and
is no top or bottom to oil ring
Values
6165-91-1004
the
make sure that the end gaps of the rings are in different places. *
Cylinder head mounting bolt: See Tightening Torques
6165-91-I
Assemble
the bolts slowly and uniformly
Standard
to piston (43). *
Tighten
to the specified torque.
m
Mounting See
bolts (56) of exhaust
(50). bolt: Tightening
Standard
Values
Torques
and
Table.
Piston pin: Coat with engine oil
3) Insert connecting rod (42) from top of crankcase (37); then tighten mountmg bolts of cap at big end. + Check that, the . . .V match marks on the connecting &Crankshaft &
rod are aligned. pin: Coat with engine
oil
Cap mounting bolt: Coat with engine oil
s-
Connecting rod mounting bolt: See Tightening Torques and Standard Values Table 4) Fit O-ring to cylinder (31), then with piston ring (46) press fitted, assemble cylinder to crankcase (37), and tighten with mounting bolts (48). fi m
Whole inside surface at bottom cylinder: Coat with engine oil Cylinder mounting bolt: See Tightening Torques Standard Values Table 6165-91-I 004 6165-91-1005 Install exhaust
valve
mounting
of
‘53 650ACF055
and
bracket
(57) at the same time. 8. Cylinder head 1) Fit gasket (32) to top surface (31). 2) Assemble cylinder (31), then tighten
of cylinder
head (1) to cylinder with mounting bolts
(30).
13-021 @
14-001 2
14-002 2
14-003 2
14-004 2
l
6165-91-I
001
l
6165-91-1004
l
6165-91-1005
650ACF060
+r Apply for only 6165-91-I items
1
Clearance between cylinder and piston (Measure the outside diameter of the piston at the skirt)
between
piston ring and ring groove
Clearance piston
qemedy
Criteria
No
Clearance
Unit: mm
005
between
Standard
size
Standard
clearance
Clearance
85
0.070
-
0.120
0.25
Piston ring
2
0.020
-
0.050
0.15
Oil ring
4
0.030
-
0.070
0.20
Piston ring
-
0.1 -
0.30
0.6
Oil ring
-
0.15 -
0.35
0.7
ring open-
limit
Replace piston or cylinder Replace piston or pisfnn ripn‘3 .“.I .I
Replace
nings
16
0.006
-
0.026
0.5
Replace piston or piston pin
Clearance between piston pin and connecting rod small end
16
0.006
-
0.026
0.5
Replace connecting rod
Clearance between crankpin and connecting rod big end
35
0.034
-
0.075
0.15
Replace connecting rod
Clearance between front journal and flange inner diameter
45
0.009
-
0.095
0.2
Replace crankshaft or flange
End play of crankshaft
-
Clearance between pin and piston
piston
0.1 -
0.74
0.9
Replace crankshaft or flange
I Drive spline
30 -
connector:
Air inlet port connector: Air discharge connector: 8
8 I!I 0.8 kgm port
I
Unloader port connector: Cooling water connector:
8 f 0.8 kgm 3 I!I 0.3 kgm
port
Retighten
3 f 0.3 kgm
Exhaust valve connector: Air compressor ing bolt:
35 kgm
3 f 0.3 kgm mount-
5 I!I 0.5 kgm
I
14-005 m w
PARTS INSPECTION
l
Be careful
AND JUDGEMENT
not to damage
dry. Check visually
disassembled
particularly
parts.
for the following
Wash
them
Cylinder
in diesel
Part
0 Scuffing, wear, seizure sliding surface l Scratches on head mounting surface l Scratches, dents on O-ring contact surface
of
Bearing cover and flange, oil seal
6i3 0
0
0
0
cl
0
oil, then
blow
with
air to
points.
Check point
Part
STANDARD
Check point 0 Scratches, roughness surface l Scratches, ring contact
degree of of sliding dents on Osurface
0
Piston
and piston
rings
Scuffing, wear, sliding surface Scratches, groove Degree width
dents
seizure
of
in ring
of ring contact
Inlet valve, va Ive
delivery
Scratches, plate
wear
of valve
B Scratches,
wear
of valve
l
l
Connecting
rod
l l
seat Settling
Scratches, cracks, dents Scuffing, wear, seizure of sliding surface
8
2 Unloader
valve
Scratches, dents, wear on sliding surface of rod Settling
Crankshaft
* Scuffing, scratches, wear, discoloration, in rotating parts l
Scratches tact surface
14-006 0
of valve spring
dents
on oil seal con-
of valve spring
a
JUDGEMENT
STANDARDS
FOR REUSE
Judgement Part Name
Position
l
for reuse
of damage A: Can be used as it is
1
category
Sliding
No scuffing, seizure
surface
wear,
B. Can be repaired ’ used again
and
C: Cannot be used again
Scuffing, seizure
-
wear,
2
l
Head mounting surface
No scratches
or dents
-
Scratches
or dents
I
1
l
Sliding piston
surface
of
No scuffing, seizure
wear,
-
Scuffing, seizure
wear,
2
l
Piston
ring groove
No scratches
or dents
-
Scratches
or dents
No scratches
or dents
-
Scratches
or dents
-
Contact than A
-
Scratches, dents
No scratches
-
Scratches
No discoloration
-
Discoloration
-
3
ring SllLdlll~
1;,4;n,
* Piston surface
Normal
contact
width
other
1
l
Overall external appearance
No scratches, dents
cracks,
cracks,
-
1
l
Journal
portion
1
l
O-ring contact surface
No scratches
or dents
Scratches, dents that can be easily removed with an oil stone
Oil seal sliding surface
No scratches, ness
rough-
-
Scratches,
roughness
2
l
Scratches or dents other than A or B
1
l
Valve
seat
Slight
scratches,
wear
-
Scratches,
wear
2
l
Valve
plate
Slight
scratches,
wear
-
Scratches,
wear
spring
No scratches, settling
-
Scratches, wear settling If valve spring is broken, replace cylinder head assembly
-
-
3
* Valve
wear,
-
14-007 co
AIRCOO
Head gasket w h,
Unloader
valve
.
ca
I!.
?
A
PERIODIC
INSPECTION
Carry out the following hours. 1.
Discharge
maintena
nce every 4000
air piping (between
air compres-
sor and wet tank) Remove the discharge the follows.
air piping
and do as collected than 1.5
mm (see diagram below), blow compressed air into the pipe to clean it. If the cannot
be removed,
pipe. If cleaning
agent
41 l-3310
oil
circuit)
(for
is available,
out the carbon. the instructions.)
replace
the
KO: Part No. 600-
cooler
element
oil
it can be used to clean (For details
of use,
see
Carbon tends to stick to restricting portions such as joints and check valves, so check these parts particularly carefully.
inside piping
mm, the pipe rep1 aced. 6206F913
2) If
there
is carbon
Air compressor Remove the head, and carry out the following maintenance. 1) If there
1) If the thickness of the carbon on the inside surface is more
carbon
2.
stuck to the connecting
joints, remove it with a screwdriver, and blow with compressed air to clean it. 3) If there is carbon stuck to the inside of the check valve installed between the air compressor and wet tank, remove it with a screwdriver, and blow with compressed air to clean it. (If the rubber valve seat is broken, replace it.)
are no deep vertical
the cylinder,
and carbon
scratches
is stuck
top surface of the piston, carbon from the top surface
in
to the
remove the of the piston.
Do not use a sharp tool to do this. When doing this, be careful not to let the carbon go through the gap between piston and the cylinder. *
If there
are deep vertical
the cylinder
which
replace the cylinder, ring kit.
the
scratches
in
catch the fingernail, piston,
and piston
2) If there is carbon stuck to the bottom surface of the head, or the air intake and discharge holes, remove it with a screwdriver, and blow with compressed air to clean it. 3) If there is carbon stuck to the delivery valve, intake valve, seat, guide, and spring, remove it with a screwdriver, and blow with compressed air to clean it. 4) If there is carbon stuck to the unloader valve and spring, remove it with a screwdriver, and blow with compressed air to clean it. (If the O-ring is worn, replace the unloader valve assembly.) * When removing the valve with a screwdriver, be careful not to damage the machined surface.
1d-009 3
0
0
El OOddM
II
2 II)
a
/
F
0
W
0
t -I W
3 LL
I
co
P
4
ii e
P
a a ii
k
CONTENTS
No. of page
01
GENERAL ...............................................................~.......~........................ 0%001
11
STRUCTURE
12
TESTING
13
DISASSEMBLY
14
MAINTENANCE
15
OTHERS ................................................................................................... 15-001
00-002
AND FUNCTION
AND ADJUSTING
................................................... 11-001
........................................................ 12-001
AND ASSEMBLY
STANDARD
............................................. 13-001
....................................................... 14-001
: . : *
’ * : * * : : .
: . :
OOddH
FUEL INJECTION SYSTEM OUTLINE
Fig. 1 Fuel injection pump system
Fig. 1 shows a diesel fuel injection pump system. Engine rotation is transmitted to the injection pump camshaft by a coupling or drive gear. The supply pump, driven by the camshaft, sucks fuel oil from the fuel oil tank and supplies it to the fuel oil filter at a pressure of approximately 1.8-2.5 kg/cm*. Filtered fuel oil is then sent to the fuel oil chamber in the injection pump housing. The plunger, raised by camshaft rotation, further increases fuel oil pressure. This fuel oil is then delivered by the injection
01-002
pump through the injection pipe to the nozzle holder, to be injected into the engine combustion chamber. Because the quantity of fuel oil delivered by the supply pump is at least twice the maximum injection quantity of the injection pump, an overflow valve is installed to return excess fuel oil to the fuel oil tank when the fuel oil pressure exceeds a set value. Excess fuel oil from the nozzle (which also lubricates the inside of the nozzle holder) flows through the nozzle holder’s overflow valve and is returned to the fuel oil tank.
cn 2
0 Ia c) E W
c)
n
tn mmJ
a n c)
2
.
OOddM
2 0
It)
z
1
LL
n 2
a
W
: :
OOddM
FIPPOO
2
0 w m a b -_I 0
2 B 2 u
0
To nozzle
t Delivery valve holder
Delivery valve
lilllillA‘il,
type InjectIon
Fig. 3 E(S)-A
I-
When the fuel oil pressure exceeds the nozzle spring set force, fuel oil is sprayed into the engine combustion chamber by the nozzle.
Plunger barrel
Plunger 4
Delivery starts
Pump housing
pump: cut-away view
Helix
4
I --A-
4 Delivery ends
Fig. 4 Plunger: effective stroke
The plunger further ascends, and at the position where the plunger helix meets the suction and discharge port of the plunger barrel, delivery of fuel oil ends. (At the same time, the nozzle spraying ends.) The delivery valve is closed by the force of the delivery valve spring, so that fuel oil is no longer delivered, even though the plunger further ascends. If the plunger is rotated, the effective stroke shown in Fig. 4 is altered, and consequently fuel injection quantity is altered.
1 l-003L
0
%
z?G
Injection
E
8
quantity 2 0
& It: 00000
(mm3/st)E;:
% %
PLUNGER ROTATING MECHANISM
Partial delivery
Non delivery
Fig. 7 Plunger
rotating
Maximum
delivery
mechanisms
Fig. 7 shows the plunger rotating mechanisms. ‘VVith the PE(S)aA pump, the flange at the io’wer portion of the plunger is inserted into the groove of the control sleeve, and teeth on the control sleeve’s upper portion are engaged with the teeth of the control rack. Accordingly, the plunger rotates when the control rack is moved and the injection quantity is therefore altered.
TWO-STEP HELIX PLUNGER I No. 1 helix
o. 2 helix
Combared to the standard helix (No. 2 helix), when using a plunger with a larger helix angle (No. 1 helix) during operation in the low-speed/ low-load range, an increased fuel injection quantity alteration rate can be obtained with only a small movement of the control rack. (Fig. 8) The purpose of this is to improve fuel injection quantity characteristics in the low-speed range.
Fig. 8 Two-step
helix plunger
1 l-005
DELIVERY VALVE ASSEMBLY The delivery valve delivers high pressure fuel oil to the nozzle through the injection pipe. After the plunger finishes delivery of fuel oil, the delivery valve prevents reverse flow of the fuel oil from the injection pipe to the plunger barrel. When the delivery valve descends, fuel oil pressure inside the injection pipe is reduced by the absorbing action of the piston, in order to prevent any leakage of fuel oil after the nozzle is closed. (Fig. 9)
Delivery valve spring -0 Delivery valve
4
O 0
0
0
Fig. 9 Delivery valve
DELIVERY VALVE (for variable retraction piston) Due to the modification of the delivery valve piston the fuel oil retraction effect has been lessened (the retraction quantity has been decreased) in the low-speed range, and as the residual fuel oil pressure inside the injection pipe is increased, stable fuel injection can be obtained. (Fig. IO) However, in the high-speed range the variable retraction piston has scarcely any effect.
t: Retraction piston diameter
“shaved” amount
Fig. 10 Delivery valve (for variable piston)
1 l-006
retraction
8 E E
DAMPING VALVE EQUIPPED DELIVERY VALVE HOLDER A delivery valve holder provided with a damping valve is available. (Fig. 11) Purpose If there is a sudden decrease in fuel oil pressure due to delivery valve retraction during operation in the high-speed/high-load range, negative pressure and air bubbles (cavitation) may be generated in the injection pipe. In extreme cases the injection pipe may be broken. The damping valve is used to prevent the generation of negative pressure and air bubbles. Construction
Open
Closed
The damping valve (ball valve) is installed inside the delivery valve holder. A spring seat and spring are installed in the upper portion of the delivery valve holder. In the lower portion a delivery valve stopper with an orifice is pressfitted. Below this stopper the delivery valve spring and delivery valve a,re ti located. , Operation
8 Fig. 11 Damping delivery valve EL h
At the time of fuel injection from the plunger, the damping valve (ball valve) is opened, and fuel oil is delivered through the delivery valve stopper’s central portion to the nozzle. However, after fuel injection the damping valve (ball valve) closes quicker than the delivery valve, and due to this fuel oil flows through the upper part of the delivery valve stopper orifice. The inside pressure of the injection pipe then decreases only the retraction volume. Because of this, delivery valve movement becomes comparatively slower, and a sudden fuel oil are cavitation and decrease pressure prevented.
1 l-007
CAMSHAFT The camshaft is driven by the engine through a coupling or timing device. Depending on specifications, tangential, convex, or tangential/eccentric combination cams may be used to operate the plungers. (See Fig. 12)
Tangential cam
Convex cam
Eccentric cam
Tangential/ Eccentric cam
In addition to the plunger cams, an eccentric cam is fitted to the camshaft to drive the supply pump.
Fig. 12 Cam profiles
TAPPET ASSEMBLY Standard type
For high-speed
engine
/
Adjusting shim Tappet
The tappet assembly is designed to change rotary camshaft motion into reciprocating motion, therefore raising and lowering the plunger, as well as regulating injection pump timing. Two types of tappets may be used, with their upper construction differing. For ordinary injection pumps the boltadjustable tappet is generally used, while for high-speed injection pumps the shimadjustable type is generally used. (Fig. 13)
Fig. 13 Tappets
SUPPLY PUMP A KS or KE type supply pump is used with the A type injection pump. As their basic construction and function are the same, only the construction and function of the KE type are explained below. Construction Fig. 14 shows the construction supply pump.
Fig. 14 KE type supply pump construction
1 l-008
of the KE type
Camshaft movement is transmitted through a tappet and pushrod to the supply pump piston. The piston spring acts to return the piston. The reciprocating motion of the piston results in alternating suction and discharge of the fuel oil.
8 /$
Operation
Camshaft
Camshaft
Position B
Position A
(A)
w
03
(Cl
Discharge
Regulating
Check valves
Suction
Fig. 15 Supply pump operation
0
za
Fig. T5 shows supply pump operation.
Priming pump
As shown in Fig. 15 (A), when the cam is moving toward position A, fuel is sucked in through the suction port check valve.
A priming pump may be installed on the supply pump to manually supply fuel oil to the fuel injection system from the fuel oil tank during the priming and bleeding operation (See Page 62).
ii
As the cam moves away from position A to position B, the fuel oil is compressed, the suction port check valve is closed, and fuei oil is discharged through the discharge port check valve, as shown in Fig. 15 B. If discharge side fuel oil pressure increases abnormally, the piston spring acts to compress the fuel oil in the pump chamber, therefore closing the suction port check valve and preventing further suction of fuel oil, as shown in Fig. 15 C.
Note:
After using the priming pump ensure the priming pump screw is secured tightly to prevent water and dirt etc., from entering the supply pump. A gauze filter is installed at the suction port to prevent dirt etc., from entering the supply pump.
1 l-009
12 TESTING AND ADJUSTING
SPECIAL TOOLS .............................................. Service tools for adjustment.. ...................... ADJUSTiVlENT .................................................. .................................................... Preparation Setting control rack “0” position ................ Injection timing adjustment ........................ Injection quantity adjustment ...................... Supply pump test ......................................... Injection timing aligning mark .................... PRECAUTIONS .................................................. Fuel oil ........................................................... Fuel filter ........................................................ Bleeding the fuel system .............................. Lubrication ..................................................... procedure ................................. Lubrication
12-002 12-002 12-007 12-007 12-008 12-009 12-014 .12-015 12-017 12-021 .12-021 12-021 12-021 .12-022 .12-023
12-001
SPECIAL TOOLS To service prepared.
the
PE(S)mA(D)
type
injection
pumps,
the
following
special
tools
and general
tools
should
SERVICE TOOLS FOR ADJUSTMENT Key No.
Part Number P/No.
( ): ZEXEL
Tool Name
1
Common tool (105780-2080)
Nozzle
2
Common tool (105780-0000)
Nozzle
Common tool (157805-0520)
Injection
Common tool (157805-3320)
Injection
Common tool (157916-8220) 6
7
10
holder
Q’ty
Application
8
8
pipe
pipe
8
2mmx6mmX600mm, Ml4 x 1.5; Ml2
8
2 mm x 6 mm x 600 mm, Ml4 x 1.5; Ml2 x 1.5
Wrench
1
For purging
Common tool (15781 O-0500)
Stand
2
For mounting PEmA(D) pump (for test stand models 5NP and IONP, shaft center height: 110 mm)
Common tool (105781-0480)
Stand
2
For mounting PEaA pump (for test stand models 7NP and 15NP, shaft center height: 125 mm)
Common tool (105781-0010)
Clamping
1
For fixing PE=A(D) pump models 5NP and IONP)
Common tool (105781-0150)
Stand
1
For mounting PESA(D) pump (for test stand models 5NP and shaft center height: 110 mm)
Common
Stand
1
For mounting PESmA(D) pump (for test stand models 7NP and 15NP, shaft center height: 125 mm)
1
Used together with the mounting stands (key nos. 9 and 10) D: 68 mm and 78 mm
tool
device
(105781-0180)
air from
11
Common tool (15781 I-0620)
Adapter
12
Common tool (105782-6280)
Measuring
device
1
For measuring
13
Common
Measuring
device
1
For measuring installed with compensator
(105782-6130)
12-002
x 1.5
tool
nozzle
holder
(for test
stand
IONP,
control rack travel
control rack travel: driveside mounted boost
be
-
OOddld
C
O
0
b
FIPPOO
OOddlj
d ?
r-
(u
FIPPOO
ADJUSTMENT After reassembling the injection pump, adjust it in the following manner using the injection pump test stand.
Prepare the special service tools described “Service tools for Adjustment”.
in
PREPARATION 1. Mount the injection pump on the test stand as shown in Fig. 86. 2. Connect the fuel pipes and injection pipes.
Fig. 86
Injection stand
pump
installed
on the test
3. Fill the camshaft chamber and governor chamber with injection pump oil. (Fig. 87) Camshaft chamber: Governor chamber:
Fig. 87 Adding
lubricant
20 cc for each cylinder Depends on governor type
to the cam chamber
12-007
z Fir ..
0
0
:
FIPPOO
9. If the pre-stroke is not within the specified range, adjust in the following manner. (1) Rotate the camshaft until the No. 1 cam reaches the T.D.C. position. (2) Insert the plunger spring holder between the lower spring seat and the tappet. (Fig. 96)’
(3) Remove the adjusting shim and adjust the shim thickness so that the desired preshim stroke can be obtained. Adjusting 97) (Fig. steps. mm 0.05 in thickness varies
Fig. 97 Adjusting
shim replacement
Note:
tappet adjustment adFor bolt-type just the position of the adjusting bolt (15791 I-01 00) spanners 2 using (Fig. 98)
If the pre-stroke exceeds the specified value, rotate the adjusting bolt counter clockwise. If less than the specified value, rotate the adjusting bolt clockwise. Remeasure the No. 1 cylinder’s
Fig. 98 Adjusting
pre-stroke.
bolt adjustment
12-011
FIPPOO
0
“0
.I
c-’
.-
OOddM
INJECTION QUANTITY
ADJUSTMENT 1. Check
the (Fig. 104)
Fig. 104
Checking
the control
rack “0”
control
rack
“0”
position.
position
2. Remove the control rack guide screw (68). 3. Attach the lock screw (to secure the control rack) to the pump housing. (Fig. 105)
Fig. 105
Fixing
the control
rack
Set the pump speed, control rack position and plunger strokes as specified in the service data. 5. Measure the fuel injection quantity for each cylinger. If the fuel injection guantity is not as specified, adjust as follows. pinion clamp screw. (1) Loosen the control (Fig. 106)
4.
Fig. 106
12-014
Loosening screw
the control
pinion
clamp
Rotate the control sleeve clockwise or counterclockwise using an appropriate tool. In Fig. 107 the control sleeve is rotated toward the governor side to increase fuel injection. quantity.
Fig. 107
Fuel injection
quantity
adjustment
SUPPLY PUMP TEST 1. Suction test
(1) Attach a pipe (2 m x 8@ mm) to the supply pump suction port and insert the other end into a fuel oil container. (Fig. 108) Note:
Ensure metre.
suction
head
of
approx.
I
(2) Operate the injection pump at 100 rpm. (3) Fuel oil must be discharged seconds.
Fig. 108
Supply
pump
in less than 40
test piping
2. Priming pump test (I) Fully loosen the priming pump’s screw cap. (2) Operate the priming pump using the screw per minute. cap, at 60-I 00 strokes (Fig. 109) (3) Fuel oil must be d ischarged in less than 25 strokes.
Fig. 109
Priming
pump
test
12-015
FIPPOO
INJECTION TIMING ALIGNING
MARK
SA-type timing device 1. Attach
the timing
device
to the injection
pump 2. Attach the coupling (157840-4020) to the timing device. 3. Connect the coupling to the pump test stand. 4. Connect the injection pipes to the delivery valve holder. (Fig. 113)
Fig. 113 Mounting
the injection pump
5. Operate the pump test stand flywheel manually. 6. Place the No. 1 cylinder plunger in the beginning-of-injection position. (Fig. 1 14j
Fig. 114 Confirming the No.1 cylinder’s beginning-of-injection position
Confirm that the injection pump pointer (360A) aligning mark and the flyweight holder aligning mark are aligned. 8. If not aligned, remove the incorrect flyweight holder aligning mark, and remark the position where the pointer aligns with the flyweight holder. (Fig. 115) 7.
Fig. 115 Remarking the aligning mark
12-017
Retard/Advance
timing device (Eccentric-cam
Pump speed (rpm)
Fig. 116
1. The
EC type timing device has retard/ advance angle characteristics as shown in Fig. 116. (Discrimination can be made by referring to the Bosch-type Number). The retard/advance timing device’s injection timing aligning mark aligning procedure differs from the above, and is explained below.
RI : retard angle value
I
EC type timing device angle characteristics
-
[EC] type timing device)
I
retard-advance
2. Install the coupling between the injection pump and the timing device. 3. Measure the retard angle (RI in Fig. 116) using the timing checker. (Fig. 117) the EC-type timing device service manual for the measuring procedure and special tools.
Mote: Refer to
8 k ii
Fig. 117
Measuring
Measured value
Fig. 118
12-018
Restamping
the retard
angle
Retard angle value
the retard
angle
value
4. Compare the retard angle value measured in Step 3 with the specified retard angle value stamped on the timing device housing. If they are not the same, remove the retard angle vaiue marked on the timing device housing, and restamp the value measured in Step 3. (Fig. 118)
5. Remove the coupling installed between the injection pump and timing device, and attach the timing device to the camshaft. 6. Attach the injection pipes. (Fig. 119)
Fig, 119
Attaching the injection pipes
Operate the pump test stand flywheel manually. 8. Place the No. 1 cylinder plunger in the beginning-of-injection position. (Fig. 120) 7.
Fig. 120 Confirming the No.1 cylinder’s beginning-of-injection position 9. At
this time, the injection pump pointer aligning mark and the timing device housing aligning mark do not match, as shown in Fig. 121, (Injection timing is retarded) The reason for this is that the timing device housing aligning mark has been stamped so that the timing advance angle is “0”, as shown in Fig. 116.
Fig. 121
12-019
FIPPOO
PRECAUTIONS FUEL OIL As inferior quality fuel oil will damage the injection pump and impede performance, use only diesel fuel oils recommended by a reputable authority. Ensure fuel oil is of the correct viscosity, and is clean. As the fuel oil lubricates the plungers, delivery valves, and nozzles, the correct viscosity fuel oil is necessary to ensure adequate lubricaton. Too low a viscosity may result in seizing of these parts. Too high a viscosity results in poor combustion. Particles of dirt, rust etc. are extremely abrasive to the injection equipment, as the moving parts operate with extremely small clearances. Ensure that the fuei oii is ciean, fuei filters are serviced regularly and that storage and
handling facilities are properly maintained and serviced regularly. Too high a sulphur content in the fuel oil adversely affects the injection pump; combustion results in the formation of sulphur oxide which, reacting with any moisture in the fuel oil results in the formation of internal the corroding sulphuric acid, components of the injection pump and the engine. Use only low sulphur-content fuel oil. Moisture in the fuel oil causes the formation of rust inside the injection pump, eventually resulting in seizing of the injection pump’s moving parts. Ensure fuel oil is free of moisture. Excessive carbon residue results in carbon deposits in the engine and on the injection nozzle tips, adversely affecting injection. Use only low carbon-residue fuel oil.
E FUEL FILTER As liquid and solid contaminants in fuel oil adversely affect the injection pump and performance, ensure the fuel oil is properly filtered.
Observe regarding filters.
instructions the manufacturers servicing and replacement of fuel
BLEEDING THE FUEL SYSTEM After installation or reassembly of the injection pump, the fuel system (from the fuel oil tank to the nozzles) must be properly bled and primed to expel all air from the system. Air in the system may result in reduced engine output, improper idling and difficulty in starting the engine. The priming pump attached to the supply pump is used to bleed and prime the system. 1. Fully loosen the priming pump’s screw cap. 2. While operating the priming pump open the overflow valve or air bleeder screw on the fuel oil filter.
3. Continue operating the priming pump until there are no air bubbles in the fuel oil flowing from the valve or screw. 4. Close the valve or screw. 5. Open the injection pump’s overflow valve and continue operating the priming pump until there are no air bubbles in the fuel oil flowing from the injection pump’s overflow valve. 6. Turn the engine over until it starts. The fuel injection system is now properly bled and primed.
12-021
LUBRICATION Use only specified lubricants and observe the specified lubrication quantities and intervals as
described
LUBRICATION LOCATION
below and in the following
TABLE
LUBRICANT (ZEXEL PART NO.)
Injection pump plungers Delivery valves Injection nozzles etc.
Diesel fuel oil (as specified by manufacturer)
Injection pump camshaft Mechanical governor etc. (independently lubricated injection pumps)
Injection Pump oil: 131453-0120 x 1,000
Pneumatic governor diaphragm
Diaphragm oil: 155413-1320 x 60 cc 155413-0220 x 950 cc
Injection pump (engine integrated lubrication system) Camshaft, mechanical governor etc.
Engine oil (as specified by manufacturer)
SCD, SCDM and SBZ type timing devices
Engine Oil (as above)
SAG and SAZ type timing devices
Mobil Oil #20, #3O
SA type timing device
Auto timer grease 156118-0120 x 150 a
REMARKS
Check: cc
Every 4,000 km or 100 hrs. Replace: Every 12,000 km or 300 hrs.
(Auto Timer Grease)
Fig. 124 Injection pump oil, syringe, diaphragm
12-022
table.
oil and auto timer grease
LUBRKATION
PROCEDURE With the independently lubricated injection pump, check oil level and condition using gauge in camshaft chamber; ensure level lies between upper and lower marks. Change oil if dirty or too “thin”. Filling and removal is facilitated by the use of an oil syringe. (Part No. 131499-0320).
Fig. 125 Adding
injection
pump oil
With the engine integrated lubrication system, oil level is checked on the engine side. Ensure engine oil quantity is sufficient by checking engine oil pan. When installing or remounting the injection pump be sure to fill camshaft chamber and governor housing with engine oil.
Diaphragm -’ Drain used pour 4-5 diaphragm intervals of
:ig. 126 Adding
diaphragm
oil oil. through the drain plug and cc of diaphragm oil onto the blades through the filler plug at 4,000 Km, or 100 hours.
oil
4. Auto timer grease After removing the two plugs, screw in the auto timer grease tube and squeeze grease into the timing device.
Fig. 127 Inserting auto timer grease
12-023
OOddM
SPECIAL TOOLS I
To service prepared.
SERVICE Key No.
the
PE(S)-A(D) type
TOOLS _
injection
FOR DISASSEMBLY
Part Number ( ): ZEXEL
pumps,
Tool
P/No.
the
following
special
tools
and general
tools
should
(157944-7820
and
AND REASSEMBLY
Name
Q’ty
vise
1
Used with 157944-8720)
Application
1
Common tool (157944-8520)
Universal
2
Common tool (157944-7820)
Bracket
1
For fixing
PESA(D)
3
Common tool (157944-8720)
Bracket
1
For fixing
PEaA
4
Common tool (15791 O-0300)
Ratchet
1
Used
together
with
socket
wrench
5
Common tool (15791 O-l 120)
Handle
1
Used
together
with
socket
wrench
Common tool (15791 o-51 00)
Pin
2
For fixing each extractor (6 mm diameter)
Common tool (157911-2100)
Spanner
2
For removing and installing pneumatic governor link fixing bolt and nut (SW 9 mm)
8
Common tooi (157913-0100)
Box
wrench
1
For removing and instaiiing supply pump fixing nut (SW 10 mm)
9
Common tool (157913-3120)
Box
wrench
1
For adjusting RSV governor stopper bolt (SW 10 mm)
full-load
10
Common tool (157914-0100)
Socket
wrench
1
For removing and installing of SA and SCD type timing (SW 14 mm)
round nuts devices
11
Common tool (157914-0200)
Socket
wrench
1
For removing and installing standard nuts and bolts (SW 17 mm)
12
Common tool (157914-0300)
Socket
wrench
1
For tightening (SW 19 mm)
13
Common tool (157914-0500)
Socket
wrench
1
For removing and installing valve holder (SW 22 mm)
14
790-l 579150100 (157915-0100)
Wrench
1
For removing and installing RLD, RSV, RAD, RFD governor flyweight fixing nut (2.9 mm wide tooth)
13-002
handle
bracket
Pump
Pump
extractor
bolts
delivery
be
s
.-0
5 .a 2
OOddM
I-Key No.
Part Number P/No.
Tool Name
( ): ZEXEL
Application
Q’ty
.
790-l 579208700 (157920-8700)
Seal
guide
1
For protecting camshaft oil seal (for 17 mm dia. camshaft)
lip
790-l 579205400 (157920-5400)
Seal
guide
1
For protecting camshaft oil seal (for 20 mm dia. camshaft)
lip
Common tool (157921-5620)
Inserter
1
For removing and installing PE(S)lA pump plunger (shim-type tappet adjustment)
Common tool (157931-2500)
Tappet
holder
6
For holding PE(S)mA pump tappet
79D-1579213020 (157921-3020)
Tappet
inserter
1
For Inserting
79D-1579317320 (157931-7320)
Tappet
holder
10
For holding
35
79D-1579250520 (157925-0520)
Extractor
1
For removing PE(S)=A(D) pump bearing outer race (for 20 mm dia. camshaft)
36
79D-1579256520 (157925-6520)
Extractor
1
For removing PE(S) -A(D) pump bearing inner race (for 20 mm dia. camshaft)
37
Common tool (105782-4200)
Measuring
device
1
For measuring PE(S)=A pump camshaft end play (for 17 mm dia. camshaft)
38
Common tool (105782-4130)
Measuring
device
1
For measuring PE(S)lA(D) pump camshaft end piay (for 20 mm dia. camshaft) /
Common tool (157914-2400)
Socket
1
For removing and type timing device (SW 12 mm)
Common tool (157926-5820)
Extractor
1
For removing device (M24
41
I--
Common tool (157926-6920)
Extractor
1
For removing (M22 x 1.5)
42
Common tool (157926-7220)
Extractor
1
For removing SAZ type timing (M26 x 1.5 and M32 x 1.5)
43
Common tool (157916-5320)
Spanner
1
For holding SA, SG type (installed with laminated
44
Common tool (157914-0900)
Wrench
1
For removing and installing pump plug (SW 32 mm)
29
L
I= I
13-004
wrench
high speed
PE(S) =AD
PE(S)*AD
pump
pump
tappet
tappet
installing SCDM fixing nut
SCD, SAG x 1.5) SCDM
type
type
type
timing
timing
device
device
timing device coupling) supply
Key No.
Part Number P/No.
Tool Name
( ): ZEXEL
Application
Q’ty.
45
Common tool (157925-8120)
Guide
1
For installing outer race
46
Common tool (157925-9120)
Guide
1
For installing .PE(S)=A pump bearing inner race (for 17 mm dia. camshaft)
47
Common tool (157925-9300)
Rod
1
For installing PE(S) -AD-S pump governor side bearing inner race (used together with holder: part no. 1579259700)
48
Common tool (157925-9400)
Rod
1
49
Common tool (157925-9500)
Push
50
Common tool (157925-9600)
51
52
NOTE:
For installing side with
bearing holder:
PE(S) #A pump
PEW AD-S
bearing
pump
drive
inner race (used together part no. 157925-9700)
1
For installing PE(S) -AD-S pump ourter race (used together with part no. 157925-9600)
Bush
1
For installing PE(S) -AD-S outer race (used together rod: part no. 157925-9500)
pump bearing with push
Common tool (I 57925-9700)
Holder
1
For installing PE(S) =AD-S inner race (used together key nos. 47 and 48)
pump bearing with rods:
Common tool (157921-6120)
Inserter
1
For removing and pump plunger
The special 4 to 39.
tool
KIT (105790-I
rod
060)
for the
PE(S) =A, AD
pump
includes
inserting
tools
with
bearing bush:
PEW AD
key numbers
13-005
4
;3
,c -__q’
/’
,/-; __\ L.9 l-.1,
FIPPOO
OOddM
co
0
b
8
Y
FIPPOO
V
OOddld
n
a
FIPPOO
r-l
R
CL >
3
.a a
PI
LiJ W
F
x lA 0
W
3 > n W n
I
0 CL X W
261
v901 _ .^A. 8 ?I6
OOddM
EXPLODED VIEW OF THE SUPPLY PUMPS KS type
KE type
0
77 _-
I
13-012
t-25
DISASSEMBLY PREPARATION Keep the work bench clean and tidy. Before beginning disassembly, record performance data for later reference. This data will facilitate detection and diagnosis of malfunctions and defects, if any, in the disassembled pump.
In the course of disassembly, lay out the disassembled parts neatly and sequentially on the work bench, labelling if necessary. This will make the reassembly much easier.
INJECTION PUMP DISASSEMBLY Clean the outer surface of the pump before disassembly. Remove grease and dirt, and drain the pump camshaft chamber and governor chamber. Collect the drained pump oil so that it can be examined. ) are those key The number in brackets ( numbers described in Fig. 18. Special service
toois are also indicated -with their part numbers in brackets. This section describes the disassembly of the RLD governor mounted on the PE6A type fuel injection pump.
1. Mount bracket (157944-8720) (Fig. 20) vise (1&7Q/I4-8520). \ I"I V-r
Fig. 20 Mounting
on universal
the bracket
2. Securely attach the injection pump to the bracket using the four bolts. (Fig. 21)
Fig. 21 Attaching
the injection pump
13-013
FIPPOO
j-
OOddki
4
c7
FIPPOO
A
17. Lay the pump on its side as shown in Fig. 31., and remove the screw plugs (16) using the L-shaped handle. (Fig. 31)
Fig. 31 Removi
!?g
the screw plug
18.With a screwdriver (96). (Fig. 32)
remove the two screws
0
2 n ii
Fig. 32
Removing screw
the center
bearing
fixing
19. Secure
the pump upright in the universal vise and remove the coupling from the camshaft using the socket wrench. (Fig. 33)
Fig. 33
Removing
the coupling
13-017
\
-\\
FIPPOO
23. Remove the camshaft together with the center bearing from the drive side. (Fig. 37)
Fig. 37 Remov,t,,inn the camshaft
24.Again lay the pump on its side. Insert the (A: 157921-0120, tappet inserter AD: 157921-3020) into the bottom plug hole. 25. Push the tappet using the tappet inserter and remove the tappet holder. (Fig. 38)
Fig. 38 Removing
the tappet holder
26. Insert the clamp (157931-6120) through the bearing cover hole, clamp the tappet and remove it from the pump housing. (Fig. 39)
Fig. 39 Removing the tappet
13-019
27. Remove the plunger (30) together with the lower spring seat (63), using inserter (A: 157921-5620, AD: 157921-6120). (Fig. 40) Caution:
Fig. 40 Removing seat
the plunger
and lower
Be careful not to let the plungers contact other parts during removal. Place them in clean fuel oil in their order of removal.
spring
28. In the case of the standard type pump, use inserter (157921-4120). Pinch the plunger as shown in Fig. 41 and remove the plunger from the plunger barrel. (Fig.41)
Fig, 41 Removing the plunger and lower seat (for standard type pump)
spring
29.Through the bottom plug hole, remove the plunger spring (61). (Fig. 42)
Fig. 42 Removing
13-020
the plunger
spring
OOddM
34.
Fig. 46
Removing
the delivery
valve
Remove the delivery valve assy. (36) and gasket (40) using a pair of tweezers. Place the delivery valves in clean fuel oil in their order of removal, as was done with the plungers. (Fig. 46)
and gasket
35. If the delivery valve gasket is 66 nylon, screw the extractor (I 57920-0320) into the delivery valve (36), push the pin down and remove the delivery valve and gasket. (Fig. 47)
Fig. 47
the delivery Removing _ y,,LI ylull yasket
valve
and 66
36. Push the plunger barrel by finger to remove. Attach them to their corresponding plungers, and place in fuel oil. (Fig. 48) Caution:
Fig. 48
13-022
Removing
the plunger
barrel
Be sure to keep each plunger with plunger barrel. its corresponding barrels are not and If the plungers between matched, the clearances them may not meet the standard values.
OOddM
\\ ‘\\\ _i
40. Remove the bearing’s outer race from the bearing cover using extractor (17 mm dia.: 157925-0120, 20 mm dia. : 157925-0520). (Fig. 52) Disassembly of the injection pump is now complete. The disassembled parts should be washed thoroughly with clean fuel oil.
Fig. 52
Removing
the bearing
outer
race
SUPPLY PUMP DISASSEMBLY The numbers in parenthesis following the part names indicate the key numbers in Fig. 19. 1. Clamp the supply pump in a vise. (Fig. 53) Caution:
Fig. 53 Clamping
the
Use vise jaw cover to avoid damaging the pump housing.
supply pump
2. Remove the eye bolts (30, 32), eye and gaskets (35, 36). 3. Using a spanner (SW 24 mm), remove the priming pump (25) and O-ring (18). (Fig. 54)
Fig. 54 Removing
13-024
the priming
pump
.-cn LL
OOddM
0) ii
10. Clamp the supply pump in the vise so that the tappet assembly (10 ) faces upward. 11. Remove the snap-ring (20) holding the tappet. (Fig. 58)
Fig. 58
Removing
the snap-ring
12. Remove the tappet assembly. 13.Draw out the pushrod (1).
(Fig. 59)
Disassembly of the supply pump is now complete. The disassembled parts should be washed thoroughly in clean fuel oil.
Fig. 59
13-026
Removing
the tappet
INSPECTION GASKETS AND O-RINGS Replace all gaskets and O-rings when they are removed. Do not reuse.
PLUNGER 1. Clean the plungers and plunger barrels in fuel oil. Check that the plunger helix is not damaged, that the color of the plungers and plunger barreis has not changed and that the plungers move smoothly in the plunger barrels. If there are problems, replace plunger assemblies. (Fig. 60)
Fig. 60 Plunger
helix
r 2. After cleaning the plunger with clean fuel oil, make sure that the plunger slides smoothly into the barrel under its own weight when the plunger iassembly is inclined 60” as shown in Fig 61. Change the plunger position by rotating it and check plunger movement several times in the above manner. If the plunger slides into the barrel too quickly or does not slide smoothly, replace the plunger assembly.
Fig. 61 Plunger
slide test
13-027
o-l
P
FIPPOO
1. Check the tappet rollers, bushes and pins for excessive wear, flaws or peeling. If found, replace the tappet. (Fig. 65)
Fig. 65 Tappet
Check the top surface of the tappet adjusting bolt or lower spring seat, which contacts th’e lower end of the plunger, for damage. If damaged replace the tappet adjusting bolt or lower spring seat. (Fig. 66) 3. Before replacing the tappet adjusting bolt, measure the distance between the tappet roller and the top surface of the adjusting bolt so that the same distance may be retained after replacement with a new adjusting bolt. This will facilitate later adjustment. 2.
I
Fig. 66 Lower spring
seat and adjusting
bolt
CAMSHAFT AND BEARINGS 1. Check the camshaft for a damaged or worn cam surface. Also check for damage to the thread on both ends of the camshaft, and check that the key groove is not damaged. (Fig. 67)
Fig. 67 Camshaft
13-029
FIPPOO
In generai, reassembly procedure is the reverse of disassembly, so only points requiring special attention are explained below. Plunger barrel installation Install the plunger barrel so that the locating pins in the pump housing correctly contact the grooves in the plunger barrels. (Fig. 71)
Fig. 71
Installing
the plunger
barrel
Ensure that the barrel cannot manually. (Fig. 72)
Fig. 72 Assembled
plunger
be rotated
barrel
Delivery valve installation Place the delivery valve, together with a new gasket, on the plunger barrel. When using the 66 nylon gasket lightly tap the extractor (157926-0120) to secure the gasket against the delivery valve seat. (Fig. 73) Note:
Fig. 73 Attaching
the 66 Nylon
When the gasket is securely in contact with the delivery valve seat the sound generated by tapping the extractor changes. Do not tap the extractor after the gasket is correctly contacting the valve seat.
gasket
13-031
Fig. 74 Tightening
the delivery
valve
holder
3. Delivery valve holder installation (1) After installing the delivery valve spring, fix the delivery valve holder. (Fig. 74) Tightening torque: 1) Tighten to 3.0 Kg-m Nylon gasket: 2) Loosen to 0 Kgam 3) Retighten to 3.0 Kg-m 4) Loosen to 0 Kgsm 5) Finally tighten to 3.5 Kg-m I) Tighten to 4.0 Kgam Metal gasket: 2) Loosen to 0 Kg-m (Delivery valve holder: M20x 1.5) 3) Retighten to 4.0 Kgem 4) Loosen to 0 Kg-m 5) Finally retighten to 4.5 Kg-m 1) Tighten to 5.0 Kg-m Metal gasket: 2) Loosen to 0 Kg-m (Delivery valve holder: M24~1.5) 3) Retighten to 5.0 Kgem 4) Loosen to 0 Kg-m 5) Finally retighten to 5.5 Kg-m 4. Control rack installation (I) Insert the control rack into the pump housing. (2) Screw the guide screw into the back of the pump housing, and ensure the control rack moves smoothly.
0 0 k ii
5. Control sleeve installation (1) Lay the pump housing on its side. (2) Position the control rack referring to the marking lines on both ends of the control rack. Ensure that the distances from the marking lines to the sides of the pump housing are the same. (Fig. 75)
Fig. 75
13-032
Positioning Dosition
the control
rack in the centre
OOddlj
0_
.-c
iD” ..
FIPPOO
Ql
-.
.-0, Ll-
OOddM
.-UI LL
cl,
.-
I I
12. Control rack stroke Ensure control rack stroke is 21 mm, from the position where the control rack is fully pushed toward the governor to the position where it is fully pulled toward the drive side. Use a vernier caliper or depth gauge to perform measurement. (Fig. 84) Note:
Fig. 84
Measuring
the control
If the control rack 21 mm reengage with the control control rack stroke
stroke is not within the control pinion rack to obtain the of 21 mm.
rack stroke
73. Lock plate tightening Secure the lock plate with the specified tightening torque shown below. (Fig. 85) Tightening Torque Rectangular lock plate: 0.45 to 0.6 Kgmm Triangular lock plate: 0.35 to 0.5 Kg-m
Fig. 85 Tightening
13-036
the lock plate
I
a P 2
a
Iv) W
t) 2
a
z W
I-
z
-
. :
OOddkl
By Specified
M6; 0.5-0.7
Torque
(Nylon
Gasket) Gasket)
For Governor
I i
M4; 0.3 (Minimum
Torque)
The torques
M12; M6m
FIPPOO
not specified
z-2.5\
M24; 6.5 - 0 - 6.5 - 0 - 6.5+“.5 (Metal Gasket)
M20; 4 - 0 - 4 - 0 - 4+“.5 (Metal
M20; 3-3.5
5_,,
7-7
5 _._
should
conform
.5 (Copper
MIO; 1.2-I
I
to Standard
Gasket)
Gasket)
(Nylon
(Stud Bolt)
,
MlO; 0.5-0.7
in this drawing
o
, .
MIA. I., .
Tightening
/M12;
Torques.
Unit: Kg-m
6-7
M14; 8.5-10
m
C
13
m
0
-I
2 c)
m
*sanblol
6u!ua~y6!1
p~epuels
laddo
01 LUJO~OD plnoys
(iayseg
6u!~e~p s!y~ u! pa!ywds
/
IOU sanblol
iptm
1 IPL Vu
@uJo:)) 9-Z-Z
uolAN) %I,-&
pue 6uyed
(WsW
OOddM
ayl
M26; 8-9
\ \ \
~18;
FIPPOO
The torques
4-4.5
not specified
\
in this drawing
M16; 4-4.5 -7
M24; 2-2.5
M16; 4-4.5
M8; 0.5-0.8\
M5; 0.5-0.8
should
/
conform
to Standard
Tightening
Torques.
Unit: Kg-m
and Copper Gasket)
: .
m .
.
. . :
.
. .
.
;
:
: .
OOddld
FIPPOO
Malfunctions Engine “knocks”
“Black smoke” and engine “knocks”
Uneven engine output
Causes 1. Injection timing is too early 2. Nozzle opening pressure is excessively high 3. Injection holes are slightly clogged (in case of hole-type nozzle) 4. Nozzle injection function has deteriorated 1. Injection timing adjustment was incorrect 2. Nozzle opening pressure is excessively low 3. Nozzle spring is broken 4. Nozzle injection function has deteriorated 5. Plunger is worn excessively 6. Faulty delivery valve seat 7. Fuel injection quantity is too large, and injection timing is adjusted incorrectly 1. Clogged filter element results in insufficient fuel oil supply 2. Insufficient supply pump delivery 3. Air remains in injection pump 4. Fuel oil contains water 5. Plunger tends to stick and does not reach its full stroke 6. Plunger spring is broken 7. Control rack does not move smoothly 8. Tappet does not move correctly, or one part is worn excessively 9. Delivery valve spring is broken 10. Faulty sealing by delivery valve gasket due to insufficiently secured delivery valve holder 11. Delivery valve does not function correctly 12. Faulty nozzle injection function 13. Nozzle needle valve does not move smoothly 14. Nozzle spring is broken 15.The nozzle opening pressures for each cylinder differ excessively 16. Injection timing is not adjusted correctly 17. Control lever does not contact fullload stopper
Remedies Readjust Readjust Clean or replace Replace Readjust Readjust Replace Clean or replace Replace Replace Readjust
Clean or replace Replace check valve Purge of air Change to high grade fuel Replace Replace Repair or replace Replace Replace Replace gasket and secure delivery valve holder to the specified torque Replace Clean or replace Replace Replace Readjust Readjust Adjust the rod length between accelerator pedal and governor control lever
15003
Engine output is insufficient 1. Insufficient fuel injection quantity
Remedies
Causes
Malfunctions
The governor full-load stopper is not correctly positioned 2. Control lever does not reach fullload position 1.
3. Governor spring is stretched such that the governor starts functioning while the engine operates at a relatively low speed 4. Plunger is worn excessively 5. Delivery valve gasket is damaged, causing leakage (Delivery valve holder is not secured correctly) 6. Delivery valve seat is damaged 7. Delivery valve is damaged 8. Excessive amount of fuel oil leaks from nozzle
15004
Replace Replace
Replace Replace Replace
Readjust
Clean or replace 1. Governor spring force is too weak
Readjust
2. Control lever does not contact fullspeed stopper
Adjust the rod length between accelerator pEXhi and governor control lever Clean or replace
3. Nozzle injection function teriorated Engine maximum speed is excessively high
Adjust the rod length between accelerator pedal and governor control lever Readjust or replace
Replace Readjust
2. Nozzle spring is broken 3. Engine “knocks” due to early injection timing 4. Engine has overheated and “black smoke” is emitted due to late injection timing 5. Nozzle injection function has deteriorated Engine speed does not reach its maximum
Readjust
has de-
1. Control rack does not move
smoothly 2. Governor spring force is too strong 3. Governor flyweight does not operate adequately 4. idling-sub spring or damper spring is not adjusted correctly
Repair or replace Readjust Replace Readjust
OOddM
2
I-.
3 -. Gf & -. 5 -.
0
b .
FIPPOO
c.n ul
0 . . . . . . . . . . coo3\lol
bin
46,
-8-G -8 -8
UludN-~ .. .. .. .. ..
7 2
3
-2 --.
u-l
b.2
cd
cL)cDcn . . . . . .
P
P
I
w
m X
E
x
.-5
72 -.-s
E 2
.-5
5t ..3
-is .-al
2
.-5 .-+-J
OOddH
5 7
x
FIPPOO
g
i?
I3
-.
a
5
u
L.
cn %-
ET
z
3 -.
co w -.
JJ -. cc1
U
3
-.
OOddld
m .
0,
cn pl,
v) ti
m
e
e
lil
k
.
.
. .
. .
.
.
n cn
m
II I:
0
FIPPOO
. .
. .
.
.
.
u
3111
D
7 u
E!
cn
2 D 2 c) m
m
z --I
D
3
.
. .
.
.
.
.
2 0
n C
2 0
D
R
c
-I
c)
C
-I 3
cn
.
F r-
2 m
c) m
2 -I cn
m
2 -I
0
c)
2 W
w, 0
OOddld
FUEL INJECTION
SYSTEM OUTLINE Injection pipe
Nozzle holder
Overflow
valv
Fig. 1 Diesel engine’s
fuel injection
system
Fig. 1 shows the diesel engine’s fuel injection system. Engine rotation is transmitted to the injection pump camshaft by a coupling or drive gear through the timing device. The supply pump, driven by camshaft rotation, sucks fuel oil from the fuel oil tank and supplies it to the fuel oil filter at a pressure of 1.82.5 kg /cm*. Filtered fuel oil is then sent through the fuei oil chamber in the injection pump housing to the plunger. The plunger, raised by camshaft rotation, further increases the fuel oil pressure, with the fuel oil then being delivered through the injection pipe and the nozzle holder to the nozzle. When the high pressure fuel oil delivered to the nozzle exceeds the specified nozzle opening pressure it is injected into the engine’s combustion chamber.
01-002
/
Because the quantity of fuel oil supplied by the supply pump is at least twice the injection pump’s maximum injection quantity, overflow valves are installed at the top of the filter or on the injection pump to return excess fuel oil to the fuel tank when the fuel oil pressure exceeds a set value. Fuel oil which has lubricated the inside of the nozzie and nozzie holder is returned to the fuei tank or the filter through the nozzle holder’s overflow nipple. The priming pump installed on the supply pump is used to manually bleed air from the fuel pipes and to feed fuel oil from the fuel oil tank to the injection pump. Note: Take care not to bend the injection pipes at too acute an angle (radius: less than 30 mm).
PRINCIPAL SPECIFICATIONS injection pump type
PI
-P3
P-S
Plunger stroke (mm)
10
11
12
21
Control rod travel (mm)
1 to12
I
Number of cylinders
21
Plunger diameter (#mm) & Maximum allowable injection quantity
1 to12
I
I
Plunger diameter
Injection quantity
Plunger diameter
Injection quantity
10.0
235
(I 0.0)
(235)
11.0
285
11.0
285
11.5
310
11.5
310
(mm3/stroke)
12.0
1
Plunger lead (Standard tvoe)
340
I
12.0
1
340
22 mm
INJECTION QUANTITY
CHARACTERISTICS Injection quantity characteristics for the various plunger diameters are shown in Fig. 2.
I
I
I
Plunger dia.: 10 to 12 @mm Plunger lead: 22 mm Cam lift: 10 mm
/
400
5 10 15 Control rod position (mm)
Fig. 2 Injection quantity
I,
20 -+
characteristics
01-003
I I
a 2
a
OOddM
8
I
N
0 0
FIPPOO
0 2
0 2 P 2 u 0 v m
As shown in Figure 4, the plunger and delivery valve etc are fixed in the sleeve flange to form the plunger block assembly. The plunger block assembly is then attached to the pump housing. The plunger barrel is positioned by a knock pin press-fitted to the sleeve flange.
Deliverv valve hol
Sleeve flange
A deflector is attached to the outside of the plunger barrel by a snapring to prevent corrosion of the pump housing caused by the reverse flow of fuel generated at the end of injection. FSucfion-delivery
port
/ Plunger
+
Fig. 4 Plunger
block assembly
O-rings are installed to prevent leakage of the fuel oil from the fuel oil chamber. To increase the oil-tightness of the delivery valve a metal gasket is installed on its highpressure side, while an O-ring is installed on the delivery valve holder (low-pressure side). (Fig. 5)
-ring
Fig. 5 O-ring
and gasket positions
11-003
FI PPOO
A cover is installed at the bottom of the pump housing and is secured by screws. The PE-P type injection pump generally employs an integrated lubrication system to circulate the engine’s lubricating oil. The engine’s lubricating oil is forced, through an inlet adjacent to the tappet’s sliding portion, to the injection pump’s cam chamber to lubricate the cam chamber and the governor chamber before returning to the engine. (Fig. 8)
Fig. 8 Injection pump lubrication
system
OPERATION
Control sleeve
Figure 9 shows the operation of the PE(S)-P type injection pump. Engine rotation is transmitted through a coupling (or drive gear) and timing device to the injection pump camshaft. This rotational movement is changed to reciprocating movement by the tappets to operate each cylinder’s pump element (plunger assembly). The plungers are lifted by the camshaft and returned by the plunger springs in a reciprocating motion. A fuel oil chamber is located in the pump housing, and this chamber is always filled with low pressure fuel oil filtered by, and delivered from, the fuel filter. The plunger barrel’s suctiondelivery ports open onto this fuel oil chamber.
Fig. 9 PE(S)-P type injection pump operation
11-005
C
A Fig. IO Fuel-suction
process
During the camshaft’s downward stroke the plunger is forced down by the plunger spring, and when the plunger’s upper end-face meets the plunger barrel’s suction-delivery port fuel oil is first sucked into the plunger barrel. (Fig. 1 O-A)
Suction is completed when the plunger reaches its lowest position. (Fig. 1 O-B) With further camshaft rotation the camshaft begins its upward stroke and the plunger spring is compressed as the plunger is raised. (Fig. 1O-C)
When the plunger’s upper end-face closes the plunger barrel’s suction-delivery port, compression of fuel oil begins. This closed position is referred to as the beginning of static injection. (Fig. 1 I-A) As the piunger ascends, the fuel oii pressure exceeds the set force of the delivery valve spring and the residual pressure of the fuel oil in the injection pipes, the delivery valve is raised, and delivery of fuel oil to the nozzle holder begins. With further ascent of the plunger, injection continues. (Fig. 1 I-B)
Fig. 11 Fuel-delivery
11-006
process
(I)
As the plunger continues to ascend, the plunger helix meets the plunger barrel’s suctiondelivery port. (Fig. 1Z-A) Because the compressed fuel oil simultaneously escapes to the fuel oil chamber, the pressure inside the plunger barrel suddenly decreases. Then, because the delivery valve is forced down by the delivery valve spring, delivery of fuel oil is completed. (Fig. 12-B)
J
Fig. 12 Fuel-delivery
process (II)
Control rod
i0 in-delivery -
Plunger flange
Control sleeve
I Fig. 13 Mechanism for varying plunger’s effective stroke Effective stroke
Although the plunger may continue to ascend, further delivery of fuel oil can not be performed. Variations in the quantity of fuel delivered by the plunger are performed by varying the plunger’s effective stroke. Figure 13 shows the mechanism for varying the plunger’s effective stroke. The plunger barrel is fixed to the sleeve flange by a knockpin and cannot move. However, the plunger construction is such that it can move both up and down and rotate. Each plunger’s flange is inserted into a control sleeve groove. Balls are welded to the control sleeve and these balls are inserted into grooves in the control rod. Because of this, movement will result in simultaneous cylinders’ plungers, thereby tive stroke and increasing or jection quantity.
of the control rod turning of all the varying the effecdecreasing the in-
The effective stroke indicates the stroke during which fuel is delivered, from the beginning of static injection to the end of injection, and is proportional to the fuel injection quantity. (Fig. 14)
&Plunger
Fig. 14 Plunger’s effective stroke
11-007
INJECTION PUMP: MAIN COMPONENTS Plunger Assembly
I
Fig. 15 Double helix plunger
The plunger can be manufactured with identically shaped helixes in diameterically opposed positions which act to rapidly return the fuel oil at the top of the plunger to the fuel oil chamber following the end-of-injection. (Fig. 15)
Helix
Beginningof-injection
The plunger, which both pressurizes the fuel oil and varies the fuel injection quantity, is the most important component of the injection pump. As the sliding portions of the plunger and the plunger barrel are finished to extremely precise specifications, the components of the plunger/ plunger barrel pair can not be interchanged or used separately. The plunger is manufactured with a helix, and at the edge of the helix is a vertical groove which opens onto the plunger’s upper endface. Two suction-delivery ports are located in the plunger barrel, in diametrically opposed positions.
Delivery
-4
Endof-injection
Fig. 16 Plunger’s effective stroke
When the plunger’s upper end face closes the plunger barrel’s suction-delivery port fuel oil delivery (injection) begins, and when the plunger’s helix meets the plunger barrel’s suctiondelivery port, delivery (injection) simultaneously finishes. This period is referred to as the effective stroke. (Fig. 16) Cutting of the fuel oil delivery (non-injection) is also utilized as one method of stopping the engine, where by operating the control rod, endof-injection may be obtained at the same time as the beginning-of-injection. (Fig. 17)
Non-delivery
Fig. 17 Engine-stopping
11-008
mechanism
8 & h
As shown in Figure 18, plungers or left helix types.
may be right
When right helix type plungers are rotated clockwise (viewed from the bottom of the plunger) the effective stroke is increased, and when left helix plungers are rotated counterclockwise, their effective stroke is increased. The use of either right or left helix plungers is dependant on the installation position of the governor.
Left helix
Right helix
Fig. 18 Plunger helixes
Delivery Valve Assembly
Delivery valve spring
a: retraction stroke
The delivery valve assembly consists of the delivery valve and the delivery valve seat. When high pressure fuel oil delivered from the plunger exceeds the pressure of the delivery valve spring force and the residuai pressure of the fuel oil in the injection pipe, the delivery valve spring is compressed, the delivery valve opens and fuel oil is delivered via the injection pipe to the nozzle holder. Then, when the plunger helix meets the plunger barrel’s suction-delivery port, delivery of fuel oil finishes, and the delivery valve is rapidly closed by the delivery valve spring.
Fig. 19 Delivery valve assembly
Thus, the injection pipe’s residual pressure is retained, enabling rapid completion of the subsequent injection operation, with the delivery valve also acting to prevent reverse flow of fuel oil. However, adverse effects may result from the cutting of fuel oil delivery after the end-ofinjection if the residual pressure is too high. To overcome this, the fuel oil in the injection pipe is only retracted an amount equal to the piston’s retraction stroke “a“ (Fig. 19) and the residual pressure is adjusted, thereby preventing leakage of fuel oil from the nozzle following the end-of-injection. (Fig. 19)
11-009
Tangential
Fig. 20 Camshaft
Convex
cam
cam
Eccentric
cam
Tangential/eccentric
cam
cam shapes
Camshaft The camshaft is rotated by the engine’s drive shaft (through the coupling or gear) and the timing device, while the plungers and the supply pump are operated by the camshaft via the tappets. Cam shapes may be tangential, convex or eccentric, or a combination of these (e.g.
tangential/eccentric cams). Cams are chosen depending on the engine’s specifications. Tangential cams or combination cams (generally tangential/eccentric cams) are generally used to operate the plungers. An eccentric cam is also installed specifically to drive the supply pump. (Fig. 20)
Tappet Assembly
Lower spring
The tappet assembly construction is shown in Fig. 21. Rotational movement of the injection pump camshaft moves the plunger up and down, and is therefore changed to reciprocating movement.
seat
guide
Roller bush/
Fig. 21 Tappet assembly
11-010
W
-42
16 I8 15
1. Housing
14
2?
5. 6. 10. 14.
Piston Piston spring Tappet Check valve
15. Check valve spring 25. Priming pump 30. Eyebolt (filter inlet) 32. Eyebolt
;
f-g. ee KU rype supply
pump: exploded
35. Gaskets 36. Gaskets 42. Cover
view
KD Type Supply Pump g k E
Fig. 22 shows an exploded view of the KD type supply pump, a large number of which are used with the PE(S)-P type injection pump. The KD type supply pump differs from the single-action KE type supply pump used with
/
the PE-A(D) type injection pump in that the KD type is a double-action type supply pump with 4 check valves. Fig. 23 shows the standard operation of the KD type supply pump.
Camshaft
Piston spring chamber /
A Suction Delivery
B Suction Delivery
Fig. 23 KD type supply pump operation
11-011
As shown in Fig. 23-A, when the camshaft cam pushes the tappet the piston is also pushed via the pushrod, and the fuel oil pressure in the piston spring chamber increases. Because of this the suction side check valve closes, the delivery side check valve opens, and the fuel oil in the piston spring chamber is fed via the fuel filter to the injection pump. Meanwhile, because the pushrod chamber’s fuel oil pressure decreases, the delivery side check valve closes, the suction side check valve opens, and fuel oil is sucked from the
11-012
fuel oil tank to the pushrod chamber. Furthermore, as the camshaft rotates to the position shown in Fig. 23-B the piston is pushed by the piston spring, the fuel oil in the pushrod chamber is fed via the fuel filter to the injection pump, and new fuel oil is sucked from the fuel oil tank to the piston spring chamber. In this way one reciprocating movement of the piston results in two suction and delivery actions, and suction and delivery are continuous during injection pump operation.
a
a
. .. : ..
. .. : ..
. .. : ..
. .. : :
. .. : :
. .. : : .: : :
.: : :
: : .:
: : .:
: : .:
: : .:
: : :-
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: : .:
KEY NO.
PART NO.
1 2
105780-2080 105780-0000
Nozzle holder Nozzle
3
157805-4720
injection
4 5
105780-2090 105780-0050
Nozzle holder Nozzle
12 1 12
6
157805-5420
Injection pipe
1
7
105781-0420
Fixing stand
2
8
15781 I-0920
Flange
1
9
105781-0450
Fixing stand
1
10
105781-0180
Fixing stand
1
11
105781-0480
Fixing stand
2
12
157840-3620
Flange
1
13
105781-0160
Fixing stand
1
14 15 16 17 18 19 20
157827-6520 ? 57827-6820 105782-4270 157954-3700 157912-2000 157840-0900 157916-8220
Adapter Connecter Measuring device Dial gauge Spanner Lever Wrench
1
21
157970-0500
Measuring
1
22
157842-6220
Coupling
1
23
157842-4620
Coupling
1
24
157840-4020
Coupling
1
25
157916-0200
Box spanner
1
,
12 12 I 1 (set)
pipe
cylinder
Note: 1. The I5 NP type test stand is provided 20, 22 and 23) as standard.
12-002
Q’TY
TOOL NAME
1
1
1 1 1 1
APPLICATION For adjusting injection timing and injection quantity. Injection quantity: up to 200 cc/l000 st (Assembly No: 105780-8140) For adjusting injection timing and injection quantity (set of 12) For adjusting injection timing and injection quantity. Injection quantity: exceeds 200 cc/ 1000 st (Assembly No: 105780-8130) For adjusting injection timing and injection quantity (set of 6) For mounting PE-P type injection pump (for 15 NP type test stand) For mounting PE(S)-P type injection pump (for 15 NP type test stand) For mounting P.E(S)-P type injection pump (for 15 NP type test stand) For mounting PE(S)-P type injection pump (used together with 15781 I-0920) For mounting PE-P type injection pump (for 10 NP type test stand) For mounting PE(S)+P type injection pump (for 10 NP type test stand) For PES-P type injection pump (used together with 157840-3620) For measuring control rod position , For mea.siJring
control
rod positien
For measuring plunger pre-stroke For measuring control rod position For removing delivery valve holder For manual flywheel operation For operating the nozzle holder over-flow valve. For measuring quantity of test oil discharged from supply pump. For driving injection pump (for 25 mm dia. camshaft) For driving injection pump (for 20 mm dia. camshaft) For driving injection pump (installation pitch: $66; $72) For removing and installing injection pipes (SW1 9)
with tools (Key Nos. 1 to 3, 7 to 10, 14, 15, 17, 19,
2. The adjustment kit (Part No.: 105765-1250) for the PE(S)-P type inject ion pump includes tools with key numbers 16 and 25. 4. The centre height* of the IO NP type test stand is 100 mm. 3. The centre height* of the 15NP type test stand is 125 mm *The centre height is the distance from the pump test stand bent I-I to the centre of flywheel rotation. (SW refers to the width across flats of bolts etc in mm) 2
A15
3 M14Xl.5 \”
5
6
14x1.5
.8
8
MIOXl.S/
Fig. 25-l
12-003
/
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FIPPOO
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ADJUSTMENT After reassembling the injection pump, adjust it in the following manner using the injection pump test stand. Prepare the special service tools described in “Service Tools for Adjustment”.
PREPARATION 1. Using the fixing stand, mount the injection pump on the pump test stand. Test stand type 15NP
IONP Fig. 126 Injection pump installed on the test stand _!I
II
” I 3
M IT II I I I I I I I I I
Fig. 127 Adding lukxicating
12-006
oil
I
Fixing Stand Part Number 105781-0420 15781 I-0920 10578 I-0450 105781-0180 105781-0480 157840-3620 105781-0160
2. Connect the fuel pipes and the injection pipes. (Fig. 126) 3. Fill the injection pump cam chamber and the governor chamber with lubricating oil (131453-0121). (Fig. 127) Amount: 50-60 cc for each cylinder.
8 k iz
4. Attach the measuring rod tip. (Fig. 128)
Fig. 128 Attaching
the measuring
device to the control
device
5. Adjust the speed control lever so that the pump’s governed speed is 500-600 r.p.m. (Fig. 129)
Fig. 129 Adjusting
the speed control lever
12-007
6. With the pump above, operate the contacts the idling control rod towards set the measuring tion. (Fig. 130) Note:
Fig. 130 Setting the control rack’s “0” position
as described adjusted load control lever until it stopper bolt, move the the governor side and device to the “0” posi-
1. The method of setting the measuring device’s “0” position differs according to the type of governor. service relevant Refer to the manual. 2. If the pump is not operating when device is set to the measuring “0”, excessive force will be applied to the linkage. Be sure to operate the pump when setting the measuring device to “0”.
INJECTION TIMING ADJUSTMENT 1. Exchange the pump overflow
valve for the
plug (02911 I-4050). 2. Using a socket wrench (SW22) remove the No. 1 cylinder’s (viewed from the drive side or the governor side) delivery valve holder. (Fig. 131) 3. Remove the delivery valve assembly.
Fig. 131 Removing the No. 1 cylinder’s delivery valve holder
4. Screw the measuring device (I05782-4270) onto the sleeve flange. (Fig. 132) 5. Maintain the control lever in the full-load position.
Fig. 132 Attaching
12-008
the measuring
device
6.
Rotate the test stand’s flywheel in the specified direction to set the No. 1 cylinder’s tappet in the bottom dead centre (B.D.C.) position. (Fig. 133)
Fig. 133 Setting the tappet’s bottom-deadcenter position 7. Set
the measuring device’s dial WJge indicator to “0”. (Fig. 134) Then, supply test oil to the injection pump at as low a pressure as possible; eg. 0.2 kg/cm2.
Fig. 134 Setting the measuring position
device’s “0”
8. Rotate the test stand’s flywheel in the specified direction and measure the No. 1 cylinders’ pre-stroke (from the dial gauge reading) at the point where fuel oil ceases flowing from the measuring device’s overflow pipe. (Fig. ‘135) Note:
Fig. 135 Measuring
the pre-stroke
1. Reverse helix plungers are used with some pumps, depending on the pump specifications. In this case the tappet is placed in the top dead centre position, the dial gauge is set to “0” and the flywheel is rotated in the reverserotation direction. The pre-stroke is then measured when fuel oil ceases flowing from the measuring device’s overflow pipe.
12-009
2. Pre-stroke indicates the amount of plunger movement from the bottom dead centre position until the plunger’s end-face closes the plunger barrel’s suction-delivery port (beginning-of-static-injection position). (Fig. 136)
Fig. 136 Beginning-of-static-injection
position
9. If the pre-stroke value measured in 8. above is outside the specified value, the thickness of the shim (23/l) must be altered to adjust the pre-stroke. (Fig. 137) When injection timing is retarded: replace the shim with a thinner shim. When injection timing is advanced: replace the shim with a thicker shim. Table 1 shows the types of adjusting shim.
Fig. 137 Adjusting
the pre-stroke
Thickness (mm) 0.5 139400-0900 -1000 0.525 -1100 0.55 0.575 -1200 -1300 0.6 -1400 0.625 -1500 0.65 -1600 0.675 -1700 0.7 -1800 0.725 0.75 -1900 -2000 0.775 -2100 0.8 -2200 0.825 139400-2300 0.85 Part Number
Part Number
Thickness (mm) 139400-2400 0.875 -2500 0.9 -2600 0.925 -2700 0.95 -2800 0.975 -2900 1.o -3000 1.025 -3100 1.05 -3200 1.075 -3300 1.I -3400 1.I25 -3500 1.15 -3600 1.I75 -3700 1.2 139400-3800 1.225 Table
12-010
Part Number
Thickness (mm) 139400-3900 1.25 -4000 1.275 -4100 1.3 -4200 1.325 -4300 ? .35 -4400 1.375 -4500 1.4 -4600 1.425 -4700 1.45 -4800 1.475 -4900 1.5 -5000 1.525 -5100 1.55 -5200 1.575 139400-5300 1.6 1
Part Number
Thickness (mm) 139400-5400 1.625 -5500 1.65 -5600 1.675 -5700 1.7 -5800 I .72= -5900 1 .75d -6000 1.775 -6100 1.8 -6200 1.825 -6300 1.85 -6400 1.87 -6500 1.9 -6600 1.925 -6700 1.95 139400-6800 1.975
1O.After determining the No. 1 cylinder’s beginning-of-injection position, set the pump test stand flywheel pointer at an arbitary position. (Fig. 138)
Fig. 138 Positioning the pointer
11. Remove the measuring device from the No. 1 cylinder. 12. Install the delivery valve assembly in the sleeve flange and tighten the delivery valve holder to the specified torque. (Fig. 139) Specified tightening torque: 11 kg-m.
Fig. 139 Tightening holder
the No. 1 delivery valve
13. Following the order of injection, position the next cylinder’s tappet in the bottom dead centre position. 14. Using a special wrench (157916-8220), open the nozzle holder overflow valve so that fuel oil flows. (Fig. 140)
Fig. 140 Opening the nozzle holder overflow valve
12-011
15. Rotate the test stand flywheel in the specified direction of rotation to raise the plunglG&ad the pointer indication on the flywheel when fuel oil stops flowing from the nozzle holder overflow valve. (Fig. 141) 17. If the injection interval is not as specified, adjust the pre-stroke using the adjusting shim. 18. Confirm the pre-stroke of all cylinders in the correct order of injection.
Fig. 141 Measuring the beginning-of-injection position
INJECTION QUANTITY ADJUSTMENT Before performing injection quantity adjustment install the specified overflow valve in order to maintain a constant transfer pump pressure, and perform adjustment as follows: Nozzle (105780-OOOO)-injection quantity: up to 200 cc/l000 st. Nozzle (105780-0050)-injection quantity: exceeds 200 cc/l 000 st. Nozzle holder (105780-2080)-injection quantity: up to 200 cc/l 000 st. Nozzle holder (105780-2090)-injection quantity: exceeds 200 cc/l 000 st. Nozzle opening pressure: 175 kg/cm* Transfer pump pressure: 1.6 kg/cm* Test oil: IS0 4113 or SAE standard test oil (SAE J967d) Injection pipes For 15NP test stand: 157805-4720 (set of 12)-injection quantity: up to 200 cc/l000 st. 157805-5420 (set of 6)-injection quantity: exceeds 200 cc/l000 st. For IONP test stand: 157805-2520-injection quantity: up to 200 cc/l 000 st. 157805-2620-injection quantity: exceeds 200 cc/l 000 st. Note:
12-012
These test conditions apply to adjustment of the PE(S)-P type injection pump. As they differ according to the type of pump be sure to confirm the test conditions by referring to the Service Date before performing adjustment.
1. Confirm the control rod’s “0” position. 2. Operate the injection pump at the specified speed and fix the control rod in the specified position. (Fig. 142) 3. Under the above conditions measure the fuel injection quantity. If not as specified, loosen the injection pipe and two nuts fixing the sleeve flange and make adjustment by altering the sleeve flange position. (Fig. 143) Note:
Fig. 142 Fixing the control rod
When the sleeve flange is turned counterclockwise as shown in Fig. 143:Right helix plunger (governor instaiied on right hand The injection quantity inside): creases. Left helix plunger installed on left hand (governor side): The injection quantity decreases.
4. After fixing the injection pipe and sleeve flange repeat the measurement and the adjustment until the specified fuel injection quantities are obtained at the specified pump speed and in the specified control rod position. 5. Next, adjust the injection quantities until the variation between each cylinder’s injection quantity satisfies the specified value.
Fig. 143 Adjusting
the sleeve flange
average of injection quantity of all cylinders . . . . Injection quantity variation (-) = average of injection quantity of all cylinders - m’n’mum ‘nJection quantity Injection quantity variation (+) = maximum
injection quantity
-
maximum injection average injection quantity Injection quantity variation rate +) = quantity average injection quantity average injection - minimum injection quantity quantity Injection quantity variation rate -) = average injection quantity
xl00
(%)
xl00
(%)
12-013
ALIGNING
MARK
1. Attach the timing device to the injection pump. 2. Attach the coupling to the timing device and then connect it to the test stand. 3. Attach the injection pipes and install the fuel oil piping. (Fig. 144) 4. Exchange the pump overflow valve for the plug (02911 I-4050). .
Fig. 144 Attaching the injection pipes and fuel oil piping 5.
Operate the test stand flywheel to position plunger in the the No. 1 cylinder’s beginning-of-injection position. (Fig. 145)
Fig. 145 Adjusting the No. 1 cylinder’s beginning-of-injection position
6, In the above cond i,tion confirm that the pointer and the align ing mark stamped on the timing device’s flyweight holder are aligned. (Fig. 146)
Fig. 146 Confirming the No. 1 cylinder’s beginning-of-injection position
12-014
7. If not aligned, realign the mark with the pointer and stamp the correct position. Erase the old mark so that the new mark can be distinguished. (Fig. 147) Note:
When the flyweight holder has been exchanged, there will not be an aligning mark on the new flyweight holder. Therefore, stamp a new aligning mark on the flyweight holder, aligning it with the pointer’s aligning mark.
Fig. 147 Remarking the aligning mark
KD TYPE SUPPLY PUMP ADJUSTMENT Adjustment of the KD type supply pump installed on the PE(S)-P type injection pump is explained below. Preparation
Fig. 148 Suction test
1. Mount the injection pump on the test stand. 2. Install the fuel piping as specified below. Suction .pipe: $8 (inside dia.)x$lO (outside dia.)x2 m. Suction head: 1 m Test oil: IS0 4113 or SAE standard test oil (SAE J967d) Suction Test 1. Loosen the suction side pipe and confirm that test oil does not flow from the discharge side. Retighten the suction side pipe. 2. Drive the pump at 100 r.p.m. and confirm that test oil flows from the discharge side of the pipe within 40 seconds. (Fig. 148) Priming Pump Suction Test After all the test oil has been discharged from the supply pump, operate the priming pump at 60-100 strokes/minute and confirm that test oil is discharged within 25 strokes. (Fig. 149)
Fig. 149 Priming pump.test
12-015
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CD Q
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a
PRECAUTIONS FUEL OIL As inferior quality fuel oil will damage the injection pump and impede performance, use only diesel fuel oils recommended by a reputable authority. Ensure fuel oil is of the correct viscosity, and is clean. 1. As the fuel oil lubricates the plungers, delivery valves and nozzles, the correct viscosity fuel oil is necessary to ensure adequate lubrication. 2. Too low a viscosity may result in seizing of these parts. 3. Too high a viscosity results in poor combustion. 4. Particles of dirt, rust etc. are extremely abrasive to the injection equipment, as the moving parts operate with extremely small clearances. Ensure that the fuel oil is clean, fuel filters are serviced reguiarly and that storage and
g 3 E
handling facilities are properly maintained and serviced regularly. 5. Too high a sulphur content in the fuel oil adversely affects the injection pump; combustion results in the formation of sulphur oxide which, reacting with any moisture in the fuel oil results in the formation of sulphuric acid, corroding the internal components of the injection pump and the engine. Use only low sulphur-content fuel oil. Moisture in the fuel oil causes the formation of rust inside the injection pump, eventually resulting in seizing of the injection pump’s moving parts. Ensure fuel oil is free of moisture. Excessive carbon residue results in carbon deposits in the engine and on the injection nozzle tips, adversely affecting injection. Use only low carbon-residue fuel oil.
FUEL FILTER As liquid and solid contaminants in fuel oil adversely affect the injection pump and performance, ensure the fuel oil is properly filtered.
Observe the manufacturer’s instructions garding servicing and replacement of filters.
refuel
BLEEDING THE FUEL SYSTEM After installation or reassembly of the injection pump, the fuel system (from the fuel oil tank to the nozzles) must be properly bled and primed to expel all air from the system. Air in the system may result in reduced engine output, improper idling and difficulty in starting the engine. The priming pump attached to the supply pump is used to bleed and prime the system. 1. Fully loosen the priming pump’s screw cap. 2. While operating the priming pump open the overflow valve or air bleeder screw on the fuel oil filter.
3. Continue operating the priming pump until there are no air bubbles in the fuel oil flowing from the valve or screw. 4. Close the valve or screw. 5. Open the injection pump’s overflow valve and continue operating the priming pump until there are no air bubbles in the fuel oil flowing from the injection pump’s overflow valve. 6. Turn the engine over until it starts. The fuel injection system is now properly bled and primed.
12-017
LUBRICATION The injection pump cam chamber, the governor chamber and the timing device chamber
must always be filled with the correct quantity of the specified lubricants.
Lubrication Table Part No. (quantity)
Lubricant Diesel fuel oil
As specified
Auto timer grease
156118-0120
by engine manufacturer
Injection pump plungers Delivery valves Injection nozzles etc. SA type timing device
(150 g)
SP type timing device
Mobil Oil #20, #30 Engine oil
Location
As specified by engine manufacturer Note: When reinstalling the injection pump on the engine fill the injection pump cam chamber with injection pump oil (Part No: 130453-0121; 1000 cc) until oil overflows from the overflow nir>de
Injection pump cam chamber Mechanical governor SPM type timing device
LUBRICATION PROCEDURE
‘: Injection pump oil 131453-0121
Syringe 13 1499-0320
Auto-timer grease 156118-0120 Fig. 152 Injection pump oil, syringe and autotimer grease
12-018
With the PE-P type injection pump the engine’s lubricating oil is generally circulated inside the injection pump to lubricate the injection pump cam chamber and the governor chamber. Because of this an oil level gauge is not used. inspection of the oil inside the injection pump is not particularly necessary, and instead the specified instructions engine manufacturer’s should be followed in relation to the inspection and replacement of the engine oil. However, prior to operation on the pump test stand or engine, the governor chamber and injection pump cam chamber must be filled with engine oil or injection pump oil (131453-0121; 1,000 cc) until oil overflows from the overflow nipple.
(3 2 I
0 0
I:
co W
ml
m 3 0
PC OOddkl
Malfunctions 4. The nozzle does not operate
Engine starts, but operates only for a limited time
The engine “knocks”
“Black smoke” and engine “knock”
Unstable output
engine
Causes 5. Injection pipe contains air 6. Clearance between the nozzle body and the needle is too great 7:Nozzle nut is improperly tightened 1. Injection pipes leading to the pump are blocked or the filter is dirty 2. Air or water is mixed with the fuel oil 3. Injection pipe contains air 4. Fuel pipe between fuel tank and supply pump is damaged or the connections are not airtight, allowing air to enter 5. Supply pump is not functioning properly, resulting in insufficient fuel oil supply 6. The fuel oil tank ventilating device is blocked 1. The injection timing is too early 2. Nozzle opening pressure is too high 3. Some injection holes are blocked (in hole-type nozzle) 4. Nozzle injection function has deteriorated 1. Injection timing is maladjusted 2. Nozzle opening pressure is too low 3. Nozzle spring is broken. 4. Nozzle injection function has deteriorated 5. Plunger is worn 6. Faulty delivery valve seat 7. Fuel injection quantity is too large, and injection timing is incorrectly adjusted
Clogged filter element results in insufficient fuel oil supply 2. Insufficient supply pump delivery I.
3. Injection pump contains air 4. Fuel oil contains water 5. Plunger tends to stick and does not reach its full stroke 6. Plunger spring is broken
12-020
Remedies Bleed of air Replace Retighten at the specified torque Clean or replace
Bleed of air or change to high grade fuel and bleed of air Bleed of air Replace the fuel pipe, tighten the connections, or replace the gasket Inspect the check valve seat and the body/piston clearance and replace defective parts Replace
Readjust Readjust Clean or replace Replace Readjust Readjust Repiace Clean or replace Replace Replace Readjust
Ciean or replace Inspect the check valve seat and the body/piston clearance and replace defective parts Bleed of air Change to high grade fuel Replace Replace
Engine cannot reach its maximum speed
Engine’s maximum speed is too high
Idling speed is unstable 1. The injection pump’s control rod does not move smoothly
2. Fuel injection quantities of each cylinder differ excessively 3. Plunger is worn excessively 4. Plunger spring is broken 5. Fuel oil contains air or water 6. Governor idling spring force is too weak or improperly adjusted 7. Governor links are twisted resulting in excessive friction between each connection or excessive blav
12-022
1. Governor spring force is too weak 2. Control lever does not reach the full-load position 3. ,Nozzle injection function has deteriorated 4. Control lever does not contact the full-load stopper bolt
Readjust Readjust Clean or replace Readjust the accelerator rod
1. Control rack does not move smoothly
Repair or replace
2. Governor spring force is too strong 3. Governor flyweight does not operate adequately
Readjust Replace
1. Plunger does not move smoothly or is stuck 2. Control rod is improperly connected to the control sleeve 3. Plunger spring does not seat correctly 4. Clearance between plunger and lower spring seat is too small 5. Delivery valve holder is overtightened
Replace Repair Replace Replace Repair (secure delivery valve holder at specified torque) Readjust
Replace Replace Bleed of air or change to high grade fuel Readjust
Repair or replace
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SPEClAl
tools and attachments may result in damage to the injection pump, subsequent fuel oil leaks and an inability to properly perform injection pump adjustment.
The following special tools and general tools (spanners, hammer etc) are necessary for PE(S)-P type injection pump disassembly, reassembly and adjustment. Non-use of the special
SERVICE TOOLS FOR DISASSEMBLY KEY NO.
PART NO.
1
157944-8520
2 3 4 5 6
TOOLS
AND REASSEMBLY Q’TY
APPLICATION
Universal Vise
1
157944-9420 157944-8620 105792-0030 105792-0000 105782-4130
Bracket Bracket Extractor O-ring inserter Measuring device
1 1 1 1 1
7
105782-4140
Measuring
1
8
79D-1579156500
Wrench
1
9
157916-4820
Spanner
1
10
15792 I-8020
Tappet inserter
1
11
79D-1579205300
Oil seal guide
1
12
79D-1579205400
Oil seal guide
1
13
79D-1579205500
Oil seal guide
1
For fixing brackets (157944-9420 and 157944-8620) For fixing PE(S)-P type pump For fixing PE-P type pump For removing plunger block assembly For inserting O-ring in pump housing For measuring camshaft end play (for 20 mm dia. camshaft) For measuring camshaft end play (for 25 mm dia. camshaft) For removing and installing control rod screw bush For fixing and rotating timing device and coupling For removing and installing tappets (for 6-cylinder engine) For protecting bearing cover oil seal (17 mm dia.) For protecting bearing cover oil seal (20 mm dia.) For protecting bearing cover oil seal I (25 mm dia.) For removing bearing cover For removing bearing cover For removing outer race For removing inner race For removing flyweight For removing timing device (M24x 1.5) For removing timing device (M45x 1.5; M5Ox 1.5, M30x 1.5) For holding tappets (for 10 mm and 1 1 mm cam lift) For installing camshaft (for 17 mm and 20 mm dia. camshaft) For installing camshaft (for 25 mm and 35 mm dia. camshaft) For removing plunger block assembly For removing and installing tappets (for 8-12 cylinder engines; used with 157921-8020)
TOOL NAME
device
I
I
I
157920-7720 157920-9900
Extractor Bracket Extractor Extractor Extractor
1
14 15 16 17 18 19
79D-1579252020 79D-1579257120 79D-1579265320 79D-1579266220
20
79D-1579266120
21
15793 I-4700
Tappet holder
22
157828-7100
Plate
1
23
157828-7200
Plate
I
24 25
157944-3520 15792 I-8900
Plate Shaft
1 1
13-002
1
Extractor
1 1 1 1
Extractor
1 10
KEY NO.
PART NO.
26
157914-0500
Socket wrench
1
27
157931-4800
Tappet holder
12
28 29
157921-4820 157921-5620
Inserter Inserter
1
30
157914-0200
Socket wrench
1
31
157914-0300
Socket wrench
1
32
’
157916-9520
TOOL NAME
Q’TY
1
’ Spanner
1
33
1579 16-5320
Spanner
1
34
79D-1579267220
Extractor
1
35
79D-1579267420
Extractor
1
36
79D-1579267620
Extractor
1
37 38 39
157916-2800 1579 16-2900 79D-1579150100
Box wrench Box wrench Wrench
1 1 1
40
79D-1579150200
Wrench
1
41
79D-1579150300
Wrench
1
42 43 44
15791 O-l 120 157914-0090 157991-0100
Handle Socket wrench Inserter
1 1 1
45
157991-0200
Inserter
1
46 47
157954-l 000 157992-l 500
Dial gauge Inserter
1
48
157992-l 600
Cap
1
Note: The special tool kit (105790-7050) tools with key nos. 4-26.
1
APPLICATION For removing delivery valve holder (SW22) For holding tappets (for 10 mm, 11 mm and 12 mm cam lift) For removing and installing plunger For removing and installing control sleeve and upper spring seat For removing and installing roundnut (SW1 7) For removing and installing roundnut (SW1 9) For preventing V/T type timing device rotation (installation pitch: $76) For preventing timing device rotation (installation pitch: 466; $72; @85) For removing SP type timing device (M32x 1.5; M26x 1.5) For removing SPM type timing device (M30x 1.5) For removing SPGH type timing device (M36x 1.5) For removing roundnut (SW1 9) For removing roundnut (SW1 7) For removing RSV, RAD and RFD-type governor roundnuts For removing RQ type governor roundnut For removing roundnut fixing timing device For socket wrench SW32 For press-fitting camshaft sleeve (20 mm dia. camshaft) For press-fitting camshaft sleeve (25 mm dia. camshaft) For measuring camshaft axial play For installing snap-ring to plunger barrel (used together with cap: 157992-l 600) For protecting O-ring groove of plunger barrel (used when installing snap-ring)
for PE-P type injection pump disassembly
includes
13-003
a-
FIPPOO
ILn
A
\
OOddH
“\
x N
r
-0
o-l
FIPPOO
0”
\
OOddl4
R
FlPPoo
R
OOddld
EXPLODED VIEW OF THE PEmPPUMP AND SUPPLY PUMP Figure 26 shows an exploded view of the PE-P type fuel injection pump, and Figure 27 shows an exploded view of the KD type supply pump. II3 II2 Ill
23/I
Fig. 26 PE-P type fuel injection pump: exploded
view
1
25
Fig. 27 KD type supply pump: exploded view
13-010
DISASSEMBLY PREPARATION
Fig. 28 Mounting the bracket
Keep the work bench clean and tidy. Before beginning disassembly record performance data for later reference to facilitate the diagnosis of malfunctions and defects, if any, in the disassembled pump. In the course of disassembly lay out the disassembled parts neatly and sequentially on the work bench, labelling if necessary, to faciliate later reassembly. Clean the outer surface of the pump before disassembly, removing all grease and dirt. Drain the pump camshaft chamber and the governor chamber and collect the drained pump oil so that it can be examined. The numbers in brackets ( ) following part names and tool names are the key numbers of the parts and the part numbers of the special too!s.
INJECTION
PUMP DISASSEMBLY
1. Mount the bracket (PES-P: 157944-9420; PE-P: 157944-8620) on the universal vise (157944-8520). (Fig. 28) 2. Remove the lubricating oil inlet’s eye bolt (147) and drain the lubricating oil from the pump* Fig. 29 Attaching
the injection pump
3. Securely attach the injection pump to the bracket using the 4 bolts (Fig. 29) 4. Using a hexagon wrench (SW5), remove the plug (96). (Fig. 30)
13-011
---
---A--
r
FIPPOO
0
2
-.
9. Attach the coupling to the camshaft’s driveside and use the spanner (see 8. above) to prevent camshaft rotation. Then, remove the roundnut fixing the flyweight using the special wrench. (Fig. 34) Part Name Special wrench
1 Part
Number
157915-0100 1579 15-0200 157915-0300
Fig. 34 Removing
the flyweight
1
Remarks Tooth width: 2.2 mm Tooth width: 3.9 mm Tooth width: 5.9 mm
roundnut
10. Remove the flyweight using the extractor (157926-5320). (Fig. 35) Note:
As various types of mechanical governors may be installed on the PE(S)P type injection pump, refer to the relevant governor service manual before proceeding with governor disassembly.
Fig. 35 Removing the flyweight
11. Using a spanner (SWIO), loosen the supply pump’s fixing nuts (93) and then remove the supply pump. (Fig. 36)
Fig. 36 Remsving the supply pump
13-013
P
FIPPOO
..
oz G-
15.Attach the oil seal guide to the camshaft drive side’s tapered portion. (Fig. 40) Part Name
Part Number
Oil seal guide
157920-5300
157920-5400
157920-5500
Remarks Shaft diameter: $17 Shaft diameter: 020 Shaft diameter: Q25
Fig. 40 Attaching the oil seal guide
16. Using the extractor (157920-7720) and bracket (157920-9900), remove the bearing cover (80) from the pump housing (1). (Fig. 41) Note:
Fig. 41 Removing
the bearing
When removing the bearing cover take care not to lose the shim adjusting the axial end-play of the camshaft inserted between the pump housing and the cover.
cover
17 Lay the pump on its side and move the camshaft (71) toward the driveside to remove the centre bearing. (Fig. 42)
13-015
l-l -.
(a3
5 -.
0’
1
0
3
s
0
cn
CD
s
2
z -.
3
?
%
co .
FIPPOO
21 .Operate the tappet inserter lever to raise the tappet, and then remove the tappet holder. (Fig. 46) Note:
Return the lever slowly after removing the tappet holder, as the plunger spring force may cause the tappet assembly to spring out.
Fig. 46 Removing the tappet holder
22. Remove the tappet inserter from the pump housing. 23. Extract the tappet assembly (47) from the pump housing. (Fig. 47)
Fig. 47 Removing the tappet assembly
24. Hook the lower spring seat’s (45) lubricating hole with a . piece. of wire and pull out the plunger and the lower spnng seat to a position where the lower spring seat can be removed. Then, remove the lower spring seat. (Fig. 48)
Fig. 48 Removing the !ower spring seat
13-017
25. Extract the plunger using the plunger inserter (157921-4820). (Fig. 49) Be sure to place the plungers in a container of clean light oil.
Fig. 49 Removing
the plunger
26. Remove the plunger spring (44). (Fig. 50)
Fig. 50 Removing
the plunger spring
27. Using the plunger inserter (157921-5620) remove the control sleeve (41) and the upper spring seat (43) together. (Fig. 51) Note:
Fig. 51 Removing the control sleeve and the upper spring seat
13-018
If the ball attached to the sleeve and the pump housing’s tappet guide groove are not aligned during control sleeve removai, the control sleeve and upper spring seat cannot be removed.
-
-
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31.Using two spanners (SW14 and 27), operate the extractor to extract the plunger block assembly (7). (Fig. 55) Ndte:
Place the plunger block assembly together with its previously removed plunger in their correct matching order in a container of light oil.
*Refer to paragraph 38 for important points relating to “Plunger Block Assembly Disassembly. ”
Fig. 55 Removing the plunger block assembly
32. Using the special wrenc h (157915-6500), remove the governor side screw bush (34). (Fig. 56)
Fig. 56 Removing
the screw bush
33. Remove the pin (33) installed pump’s governor-side (Fig. 57)
Fig. 57 Removing
13-020
the pin
on
the
~
\ \ \
E -.-
.-6, LL
OOddld
u s
FIPPOO
-3. Remove the ring (7/l 2) and place the plunger block assembly on top of the plate. (Fig. 64) Note:
As the ring is press-fitted to the plunger block’s flange using the separate-type shim, place the plunger block on the plate without removing the ring.
Fig. 64 Positioning the plunger block assembly
-4. Loosen the delivery valve holder (7/4) using a socket wrench (SW22, 1579140500) and remove. (Fig. 65) -5. Remove the delivery valve spring (7/7).
Fig. 65 Removing the delivery valve holder -6. Use tweezers to remove valve (7/3). (Fig. 66)
the delivery
=;Removing the delivery valve I ly. 66
13-023
s
CD
FIPPOO
39.When it is necessary to remove the camshaft sleeve (if equipped), split the sleeve with a chisel and remove it. (Fig. 70) Disassembly of the injection pump is now complete. The disassembled Darts should be Gashed thoroughly in clean’fuel oil.
Fig. 70 Removing the camshaft sleeve
SUPPLY PUMP DISASSEMBLY The numbers in brackets following the part names are the key numbers of -the parts shown in Figure 27. I.
Using a spanner, remove the fuel oil inlet and outlet eyebolts (30,32). Also remove the cover (42) if installed.
2. Fix the supply (Fig. 71)
pump assembly
in a vise.
Fig. 71 Fixing the supply pump
3. Using a wrench (SW19), remove the three plugs (16). (Fig. 72)
Fig. 72 Removing the plugs
13-025
FIPPOO
-
,i
OOddM
FIPPOO
.
-’
0
03
“3.
cn’
CD
s
3
2
clean all disassembled parts in clean gasoline or light oil and inspect them closely for wear, scratches and damage. Exchange all parts that cannot be reused for new parts.
Thoroughly
PE-P TYPE PUMP INSPECTION Plungers I. If the plunger
discoloured, (Fig. 80) Fig. 80 Plunger
helix is scratched, worn or replace the plunger assembly.
helix
2. After cleaning the plunger thoroughly, ensure that the plunger slides smoothly into the barrel under its own weight when inclined 60”. Repeat the above operation several times while rotating the plunger. If the plunger slides into the barrel too quickly or does not slide smoothly, replace the plunger assembly. (Fig. 81)
Fig. 81 Plunger
slide test
Delivery Valves 1.
If the delivery valve’s piston or seat is scratched or worn, replace the delivery valve. (Fig. 82)
Fig. 82 Delivery valve piston/seat
13-029
FIPPOO
1
0
3
0
2
cn
-.
1
5-
5 -
r-t
0
$ ..
7 0
N
Camshaft 1. If the new key is loose in the key groove, replace the camshaft. 2. Inspect the camshaft’s tapered portions, the cam surface and the camshaft’s threaded portions thoroughly. Replace any defective parts. (Fig. 86) 3. If the sleeve press-fitted to the camshaft is worn, replace the sleeve.
Fig. 86 Camshaft
Bearings 1. Inspect the surface of the center bearing, where it contacts the camshaft, for wear. If It is worn, replace the center bearing. 2. If the inner race’s rollers are scratched, or the contact surfaces of the outer race are worn, replace the bearing. (Fig. 87)
Fig. 87 Bearings
r
Oil Seals Check the lip of the oil seal installed in the bearing cover for scratches, wear and damage. Replace the oil seals if defective. (Fig. 88)
I Fig. 88 Oi! sea!
13-03 1
ki
6
LJ
P
: cn -. (a3
3 u
2
g
11 -. CQ .
FIPPOO
KD-TYPE SUPPLY PUMP INSPECTION Check Valves The check valves are generally nylon and must not be reused. They must be replaced. If of bakelite construction they must also be replaced. (Fig. 92) Springs If the check valve spring or the piston spring are worn unevenly, bent or rusted, they must be replaced. I
Fig. 92 Check valves
Tappets And Pushrods 1. Inspect the roller, guides and shaft for wear, and replace any defective parts. (Fig. 93) 2. Pushrod Inspection Inspect the pushrod for wear. If worn, replace the supply pump housing assembly. Note:
If pushrod wear is extreme, fuel oil may pass to the pump cam chamber past the pushrod’s outer surface and dilute the lubricating oil, or air may be sucked into the fuel line.
Fig. 93 Tappet assembly
Piston Inspect the portion of the piston contacting the pushrod. Replace the piston if worn. (Fig. 94) Other Parts Check each part carefully. If they are damaged or worn excessively they must be replaced.
Fig. 94 Piston
13-033
ra3
Ql -.
!I
5
%
l-l -. cc2 .
FI PPOO
iD” ..
7 0
I-----
4.
Install holder, screw sleeve
a new O-ring on the delivery valve apply grease to the O-ring and then the delivery valve holder into the flange. (Fig. 98)
I
Fig. 98 Installing
the O-ring
Using a torque wrench, tighten the delivery valve holder to the specified torque. (Fig. 99) Specified tightening torque: 11 kgem. 6. Remove the flange and delivery valve holder from the plate.
5.
Fig. 99 Tightening
the delivery
valve holder
7.
Install the washer and deflector.
Note:
Fi g. 100 installing
(Fig. 100)
The deflector has a top and a bottom. Furthermore, the deflector is to be installed so that the deflector ports do not align with the plunger barrel’s suction-delivery ports. If the ports do align, the reverse fuel oil flow following injection will act to erode the pump housing.
and def!ector th, * \Alasher .._
13-035
FIPPOO
3
d
OOddkJ
0
..
5.
Using a torque wrench, tighten the two plunger block assembly fixing nuts (26) equally to the specified torque. (Fig. 107) Specified tightening torque: 4-4.5 kgem.
Fig. 107 Tightening the plunger block assembly fixing nuts
6. Secure the injection pump on its side in the universal vise. 7. Install the control sleeve (41) so that the control sleeve ball enters the control rod groove. Then, confirm that each cylinder’s control sleeve is moved when the control rod is operated. (Fig. 108)
Fig. 108 Installing the control sleeve
9. Place the upper spring seat (43) on top of the plunger spring (44) and install them in the pump housing using the plunger inserter (157921-5620). (Fig. 109) Note:
Fig. 109 Installing the upper spring seat and plunger spring
13-038
If the upper spring seat and spring are not inserted horizontally, the spring wiii catch during insertion and cannot be withdrawn. Take care not to scratch the housing during the above procedure.
10. Position the plunger helix (or stamping) so that it faces in the same direction as the sleeve flange aligning knockpin and then install the plunger in the plunger barrel using the plunger inserter (157921-4820). (Fig. 1 IO) During this procedure install the lower spring seat to the plunger.
Fig. 110 installing the plunger
11 .Align the tappet guide and the housing guide groove and then install the tappet (47) in the pump housing. (Fig. 111)
Fig. 111 Installing the tappet
12. Using the tappet inserter (157921-8020), push the tappet in and move the control rod a little to insert the plunger flange into the control sleeve. Then, insert the tappet holder into the plug hole. (Fig. 112)
Fig. 112 Inserting the tappet holder
13-039
P 0
6
3
-.
FI PPOO
0
.-
CD c-
.-6, U
OOddM
k
3 CD
FIPPOO
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0000000
..
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C In cn
0 3xI D
2 2 c) -4
ni
n
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s
g
.. : ... : : . : .: : : : .: : :
: .: : : : :. : ;
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SEBM012702
FUEL INJECTION PUMP (With KOMATSU ELECTRONIC GOVERNOR)
FUEL INJECTION PUMP MODEL KFE
©2001 All Rights Reserved Printed in Japan 02-01(02)
00-001 2
CONTENTS
01
GENERAL ........................................................................................................ 01-001
11
STRUCTURE AND FUNCTION
12
TESTING AND ADJUSTING
13
DISASSEMBLY AND ASSEMBLY ................................................. 13-001
14
ADJUSTING .................................................................................................. 14-001
15
OTHERS
00-002 2
....................................................... 11-001
............................................................ 12-001
........................................................................................................... 15-001
FUEL INJECTION PUMP
The affected pages are indicated by the use of the Revision Revision Mark Page Page that necessary Mark acPage following marks. It is Mark requested number number tions be taken to these pages according to the table below.
Revision Mark number
(
Mark
Revision Indication Page number
Revision Action required Page
Mark
number
c
Page to be newly added
Add
b
Page to be replaced
Replace
Page to be deleted
Discard
)
Pages having no marks are those previously revised or made aditions.
LIST OF REVISED PAGES Mark
b b c
Page
Revision number
00-001 00-002 00-003
2 2 2
01-001 01-002 01-003 01-004 01-005 01-006 01-007 11-001 11-002 11-003 11-004 11-005 11-006 11-007 11-008 11-009 11-010 11-011 11-012 11-013 11-014 11-015 11-016 11-017 11-018 11-019 11-020 11-021 11-022 11-023 11-024 11-025 11-026 11-027
Mark
1
13-001 13-002 13-002-1 13-003 13-004 13-005 13-006 13-007 13-008 13-009 13-010 13-011 13-012 13-013 13-014 13-015 13-016 13-017 13-018 13-019 13-020 13-021 13-022
1
1 1
1
FUEL INJECTION PUMP
Revision number
12-002 12-004 12-005 12-007 12-008 12-008-1 12-009 12-010 12-010-1 12-010-2 12-010-3 12-011 12-012 12-013
c
12-001
Page
c
14-001 14-002
Mark
c
1 1 1 1 1 1 1 1 1 1
c c c c c c c
Page
Revision number
14-003 14-004 14-005 14-006 14-008 14-009 14-010 14-011
2 2 2 2 2 2 2 2
15-001 15-002 15-003 15-003-1 15-004 15-005 15-006
Mark
Page
Revision number
Mark
Page
Revision number
1 1 1 1 1
1 1 1 1 1 1 1 1 1 1 1 1 1
2 2
00-003 2
OOddkl
SPECIFICATIONS
Machine
model
H D785-3, H D985-3
Engine model
SA12V140-1
Fuel injection pump type
(Mounts 2 fuel injection pumps)
KFE6S135R-1
Dimensions (length x width x height)
I
Weight
I
mm
kg
I I
526x139x320 30.0 (Not including flyweight)
*I
Clockwise
Direction of rotation
l-5-3-6-2-4
Firing order
60” + 20’
Injection interval mm
Plunger diameter
13.5
Cam lift (plunger stroke) Prestro ke
*2
I
mm
I
1.70 (I 7.3)
Delivery valve cracking pressure Equal pressure valve cracking pressure (built into delivery valve) Delivery valve retraction volume
*3
MPa {kg/cm21 m m3/st.
*I : The flyweight mentioned he:e is the small flyweight connecting the fuel injection pump and the engine. *Z : With this pump, the prestroke automatically varies within the range shown in the chart. (This is called the prestroke control and is a special function of the fuel injection pump with electronic governor.) *3 : The deliverv
valve on this pump is an equal pressure type, so it differs from the normal equal volume type, so it does not have a retraction function. However, the abilityto stop the flow of fuel after the completion of injection is good in the same way as the equal volume type.
01-002
4-6
9.80 {IO01 -
g k L
OOddM
.-0
FIPPOO
OOddkl
FIPPOO
0
To cylinder
block
OOddld
u .-c
m
tr g
h
0
.-c .-
.+P p:
m-
2
3
co
l
: . . . . . .
: . . . . . . . . . .
: * . . . . .
. . . . . . . . . * . . . . . . . . . . .
EG
F?
7’c
45 . . . . . . . . . . . . . . . . . . . . . : . . . . . . . . . . * . . . . . . . . . . . . . .
E s
E
26
OOddlJ
0 N
6
--I
d
FIPPOO
---
OOddM
I .----.
I
I
I
’
I
8I
SWE00989
1. Priming pump (installed to part other than fuel injection pump) 2. Feed pump 3. Bypass valve 4. Relief valve (0.3 MPa (3 kg/cm*}) 5. Filter 6. Fuel gallery 7. Plunger and plunger barrel 8. Overflow valve 9. Komatsu fuel injection pump with electronic governor IO. Fuel tank
1 l-004
IO
Y
I
I
-__
OOddlzl
_ -.
--I
U)
8I
FIPPOO
OOddki
FIPPOO
OOddM
FIPPOO
-0 -
P
Y f t
L
0
YL
L
0
CL
.-
EZ “C
c-
OOddM
__-_-----
FIPPOO
-7
OOddM
FIPPOO
OOddld
II
i-l
8 -. -
0
l_LJ
\:
n -.
D
7
D
D
m
FIPPOO
[ Hydraulic pump (for KFE6S135R-1)
]
‘pass /
E-E
(Fuel)
D-D
(Oil)
+A
Rel val
B-
B
va I ve
(Fuel)
D A-A
lter
Cd C-C
(Oil)
SWE01089
::a
7
FIPPOO
Y
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[ Delivery
valve and equal pressure valve 1
Delivery
valve
holder
A4
Equal
Delivery
A-A
11-020
Pressure
valve
valve
OOddkJ
I--
F’
FIPPOO
\ \
\
\
\\ \
/I
I’ : i\
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.--___A
/’
/I
/
I I
\\ \\
\
,/I’
\\
Function
of governor
Basic function
of governor
Function to know when has started
Function celerator
to know pedal
angle
Function
to know engine
I
governor
Electronic
I
governor
Basic functions are governed by all component parts inside mechanical governor (flyweight, lever, spring, etc.) Note :For details of the mechanical governor, see “COMPONENTOF ENGINE” (No. SEBECOMP003).
The basic functions are governed by the rack position control system (rack position control cylinder, rack position control valve, rack position control solenoid built into electronic governor, and rack position sensor, and controller outside electronic governor).
It is known that the engine has started, from the spring inside the mechanical governor.
The electric signal from the starting switch passes through the wiring harness and informs the controller that the engine has started.
of ac-
This is known from the angle of the speed control lever installed to the mechanical governor.
This is known from the angle sensor installed to the accelerator pedal.
speed
This is known from the flyweight inside the mechanical governor.
This is known from the engine speed sensor installed to the engine flywheel housing.
The timer
This function is governed by the prestroke control system (prestroke control cylinder, prestroke control valve and prestroke control solenoid inside electronic governor, and controller and engine speed sensor outside electronic governor).
engine
Function to advance fuel injection timing according to rise in engine speed
Function
Mechanical
governs
this function
This is known
to know rack position
from the rack position
sensor.
-
! ! -023
RACK POSITION CONTROL SYSTEM
Rack position control cylinder
Rack position sensor Rack
i-I-1
Rack
I
Fuel in_iection (exclusive for governor)
Pump electronic
Lubricat
Electric --____--
1
,Electric
,
I ’ Electronic governor
%;;;;;d
1
1 Elztric
signal,
‘\
Angle sensor (installed to housing)
Note .- “0” and “R” are both connected circumference.
11-024 0
I
,/
/._II__p___@ sizl
I
Engine speed sensor (installed to flywheel
oi
I I
Pump
signal
--I , ~
ina
Hydraulic
---------k---
Controller
,
t
position
,
accelarator
Pedal) SWE01205
on the
The controller knows the speed desired by the operator from the electric signal (output voltage) from the angle sensor installed to the accelerator pedal. To obtain the desired speed, it selects the necessary rack position from the data already stored in the controller memory. It then selects the value for the solenoid current that matches the rack position from the data and sends the current to thn nncitinn rnntrnl .* .Y rarlr sWY..yvvm..v.. “V..L. V. cnlnnnid Y”.“..“.U. (The above explanation shows the concept of the system. In fact, it determines the solenoid current directly from the voltage output from the angle sensor on the pedal.) When the solenoid pushes the rack position control valve spool, it pushes the spring inside the valve and compresses it to move the spool. The solenoid stops at the point where the pushing force is balanced with the reaction force of the spring. The solenoid pushing force and the change in the position of the spool are proportional. The change in the position of the spool and the hydraulic pressure at portion P are also proportional.
c .-
6%
Solenoid
0
current
0.418 Solenoid
The oil pressure at portion P passes through the oil passage and is transmitted to the rack position control cylinder. It pushes the spring inside the cylinder and compresses it to move the piston. It stops at the point where the hydraulic pressure at portion P is balanced with the reaction force of the spring. The hydraulic force at portion P and the change in the position of the piston are pronnrtinnzal nncitinn nf y-u .I”. .%.a*. Thn . ..V rhanrtn “*nu*my” in II. thn Lll” y”“.‘.“.. VI the piston means the change in the position of the rack. By controlling the solenoid current, the rack position is controlled indirectly.
4)
The controller knows if the rack position is being correctly controlled from the rack position sensor. If the rack position is not correct, it corrects it.
5)
The amount of fuel injected corresponds to the position of the rack. If any load is applied to the engine, the controller knows that the engine speed has dropped from the engine speed sensor, so it controls the position of the rack to increase the injection volume and prevents the engine speed from going down.
Q) >
aaam cz a¶
/
3)
Solenoid
/
pushing
force
Change valve
0.682 current
in position
of
spool
20 25 (A)
Rack
position
(mm)
SWEOlO70
1 l-025
\
-___------
FIPPOO
L______----__
I
I
I
t
/
_._l
/
Operation
of prestroke
control system The solenoid pushing force and the change in the position of the spool are proportional. The change in the position of the spool and the hydraulic pressure at portion Y are also proportional.
1) The controller knows the engine speed from the electric signal from the engine speed sensor. It selects the matching value for the angle of advance suitable to the engine speed from the data already stored in the controller memory, then selects the value for the prestroke that matches the angle of advance from the data, and then selects the value for the solenoid current that matches the value of the prestroke from the data, and sends the current to the prestroke control solenoid. (The above explanation shows the concept of the system. In fact, it determines the solenoid current directly from the engine speed.)
3)
2) By controlling
the solenoid current, the prestroke is controlled indirectly, and as a resuit it controis the angie of advance. The current flowing to the solenoid and the solenoid pushing force are proportional. When the solenoid pushes the prestroke control valve spool, it pushes the spring inside the valve and compresses it to move the spool. The solenoid stops at the point where the pushing force is balanced with the reaction force of the spring.
The hydraulic force at portion Y passes through the oil passage circuit and is transmitted to the prestroke control cylinder inside the plunger. It pushes and compresses the spring inside the plunger, pushes up the top part of the plunger, and extends to increase the length of the plunger until the hydraulic force and spring force are balanced. The prestroke becomes shorter by the amount that the plunger becomes longer. The fuel injection timing is advanced by the amount that the prestroke becomes shorter. That is, the injection angle is advanced. As a result of the flow of controls described above, if the engine speed is changed, the angle of advance is changed as shown in the charts below.
/
Solenoid
current
Solenoid
/ current
Oi I pressure portion Y
at
Chanee
in prestroke J
La rae t ln.iec t ion
amount
Sma I I
Engine Solenoid
current
speed SWEO1072
12 TESTING AND ADJUSTING
SPECIAL TOOLS OF ADJUSTING . . . . . . . . 12-002 PREPARATION. . . . . . . . . . . . . . . . . . . . . . 12-004 PRESTROKE ADJUSTMENT.. . . . . . . . . . . . . . . . . . . 12-007 ADJUSTMENT OF FUEL INJECTION VOLUME. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-009 GOVERNOR PERFORMANCE CHECK.... 12-010-2 PRESTROKE OIL PRESSURE CHECK..... 12-010-3 FIGURE O F SPECIAL TOOLS. . . . . . . . . .12-011
12-001 - 0
FIPPOO
-.
0
-.
3
0
G;
0
0
FIPPOO
3
5 -. 0
3
-.
u*
5
u
L.
CD -
r”
Carry out the wiring as shown in the diagram below.
Prestroke adjustment To
Digital
Power
current knob
Governor adjustment
current knob
source
meter Power
switch
XEP checker
Komatsu fuel with electronic
Prestroke Rack
vol tag
Detail
of
ee
display
injection governor
Pump
current
1 Governor
selector
switch
current
TWE00752
PRESTROKE AD.9USTMENT 1.
2.
Remove the delivery valve (15) of the No. 1 cylinder from the driven end. Remove spring, spring seat (17) and delivery valve
17
(16). 3.
Install measuring device T to the plunger then tighten with the nut. zm
barrel,
18
Nut: 49 + IO Mm (5 IL 1 kgm}
4.
Set the fuel supply pressure of the locally available pump stand to 0.05 MPa (0.5 kg/cm2}.
5.
Change rack stopper bolt to rack adjusting
6.
Fix the control rack at the FULL position, rotate the pump drive coupling by hand, and when the plunger is at the bottom dead center, set the scale of the dial gauge fitted to the measuring device to “0”.
7.
Rotate the pump by hand slowly in the direction of rotation, and read the dial gauge to measure the plunger stroke to the point where fuel stops flowing from the overflow pipe of measuring device T. This is the prestroke. * Prestroke: See calibration data (the calibration data is given in each engine shop manual) * If the fuel flow does not stop properly, use the point where the interval is 1 drop per second as the point where the flow of fuel stops.
bolt V.
Note : The moment where the fuel flow stops is the moment where the injection starts.
TWE00602
j2-nn7 __I 0
8.
9.
If the prestroke is not within the standard value, adjust the prestroke as follows. Loosen the nut and pull out the shim between the plunger barrel and housing (C). Change the thickness of shim, then tighten the nut and measure the prestroke again. Continue this process until the prestroke is within the standard value (see calibration data). Note : The calibration data is given in each engine shop manual. After adjusting, match the angle scale of the test stand to the standard position. (Set the angle standard for injection interval adjustment to O”.) Check that the mark lines of the pointer and flyweight are matched to each other. If these mark lines are not matched to each other, make a new mark line on the flyweight, matching to the mark line of the pointer. Remove measuring device T, then install the delivery valve assembly, gasket, seat and delivery valve holder temporarily. * Adjust the shim thickness as follows: DECREASE shim thickness if prestroke is too LARGE INCREASE shim thickness if prestroke is too SMALL * Fit the shim so that the side where the thickness is stamped is facing up, and insert the same thickness of shims on both sides of the plunger barrel flange to adjust. * Be careful not to get any dirt caught. After determining the start of fuel injection for the No. 1 cylinder, use this as a base to adjust the other cylinders in the firing order, and measure the injection start interval of each cylinder using the angle scale on the test stand. * Injection start interval: +r if the Injection start interval No.2
is not within the
cylinder 1 239"40' !I240"20' 3 4 5 6
1
119"40' + 120"20' 299"40' k 300"20' 59"40' f
60"20'
179"40' Ifr180"20
standard value, repeat the adjustment procedure for the prestroke and adjust the shim thickness to bring within the standard value.
1 Z-008 0
Nut
Plunger barrel Shim
. . 0 .
.
.
Remove delivery valve holder (15) of the fifth cylinder from the drive side. Remove the spring, spring seat (17) and delivery valve assembly (18). Install measuring device T to the flange sleeve, then tighten the nut. Slowly turn the pump manually in the turning direction and read the turning angle (the angle from the above standard position) when the fuel stops flowing from the overflow pipe of measuring device T (when injection starts). _fi_r\l ,V-:till.-J,..:~- 1;I ,c.+in/1 ,GaIIuvc ItlGa~ulllly UGVILG I, +L-“. LllGll Aft,,Or-ad,LKW ‘3, rAW-t-bn\,fi install the delivery assembly, gasket, seat and delivery valve holder. Adjust the other cylinders according to this procedure.
12-008-l 0
ADJUSTMENT OF FUEL INJECTION VOLUME .
.
After adjusting the fuel injection timing for all the cylinders, remove the measuring device, assemble the delivery valve, and connect the fuel injection pipe. Adjust the fuel injection volume as follows.
1.
Preparatory
work
1) Loosen the rack adjustment 2)
3)
4)
bolt V, and set the rack position to “0” (the point where there is no reaction force from the spring). Put a dial gauge in contact with the head of rack adjustment bolt V and set the scale on the dial gauge to “0”. Assemble so that the stud bolt is more or less at the center of the oblong hole for installing the barrel. Remove bolt (20) at the front face of the fuel injection pump, fit joint bolt W (8mm, P=1.25mm), then connect oil pressure gauge
0. 2.
Adjusting
injection volume
at rated point
1) Set the pump speed to low idling.
a
3) 4)
5)
6)
Using the prestroke current adjustment knob on the XEP checker, set the prestroke hydraulic pressure to the specified pressure at the rated point (see calibration data *I). Set the pump speed to the specified speed at the rated point (see calibration data *I). Gradually push in rack adjustment bolt V and set so that the average injection volume for each cylinder is the specified value at the rated point (see calibration data *I). If the amount is not equal, adjust with the oblong hole of the plunger barrel so that it is equal to the specified value at the rated point (see calibration data *I). . If the injection volume for any cylinder is far outside the average value, loosen injection pipe (8) and 2 plunger barrel mounting nuts (9). . Using a screwdriver, turn plunger barrel (IO) a little to adjust. . After completing adjustment, tighten nuts (9) in turn. * When tightening the nuts, be careful not to let the plunger barrel position move. (See tightening torqu table.) . Tighten injection pipe (8). The average injection volume may go outside the specified value when the unequal amount is adjusted, but in this case, adjust rack adjustment bolt V again to bring the average injection volume within the specified value.
TWE00603
I
7)
3.
Stop the rotation of the injection pump and oil pump. After adjusting the injection volume at the rated point, measure the output voltage of the rack position sensor with the XEP checker. Adjust the rack position sensor mount with shims so that the output voltage of the rack position sensor is the specified voltage at the rated point (see calibration data *I). Measure the rack position (amount rack adjustment bolt V is pushed in) with the dial gauge and compare it with the specified position at the rated point (see calibration data *I). (Do not make any judgement.) * Adjust the output voltage of the rack sensor as follows: INCREASE shim thickness if voltage is too HIGH DECREASE shim thickness if voltage is too LOW
*I :The calibration shop manual.
data is given in each engine
Adjusting
volume at low idling
1) 2) 3)
4)
injection
Return rack adjustment bolt V and set the rack position to “0”. Set the pump speed to the specified value for low idling (see calibration data *I). Use the prestroke current adjustment knob on the XEP checker to set the prestroke hydraulic pressure to the specified value for low idling (see calibration data *I). Gradually push in rack adjustment bolt V and set so that the average injection volume for each cylinder is the specified value for low idling (see calibration data *I).
12-010 0
Shim
,I?\
i’l
cl
L
+
-;
9 Rack
position
sensor TWE00753
5)
If the amount is not equal, adjust with the oblong hole at the plunger barrel position so that it is the specified value at low idling (see calibration data *I). :The calibration data is given in each engine shop manual.
6)
7)
4.
After adjusting the average ratio, if the average injection volume is out of the specified range, adjust the push-in distance of the rack adjustment bolt V again, then check the result. Read the rack voltage and rack position at this time with the XEP checker and dial gauge respectively.
Recheck of injection
volume at rated point
1) Using the prestroke current
8 k ii
adjustment knob on the XEP checker, set the variable prestroke hydraulic pressure to the specified pressure. 2) Set the pump speed to the specified speed. 3) Push in the rack adjustment bolt V gradually and measure the injection volume in each cylinder, then check the average injection volume and average rate. 4) Repeat following procedures (5), (6) and (7) until the result is in the specified range. 5) If the recheck result is out of the specified range, push in the rack adjustment bolt V again and barrel fitting position. 6) Adjust and check the injection volume at the low idling again. 7) Adjust and check the injection volume at the rated point again. a
Take care that your clothing, etc. is not caught in the driving sections of the pump. *
*
Use the specified measuring cylinder (having a test stand). Before measuring, remove all light oil from the measuring cylinder. If the injection volume of a cylinder at the low idling is extremely lower than the other cylinders, the delivery valve of that cylinder may be broken. Replace the delivery valve in this case.
I+
l-t
C
I-l
c
l-t
c c :: 8
-
C f’= k C a
-1
b
h
-
-
iA
!2
b
cc
?
-
-
0
n
3-l
2
3 t
u +
FIPPOO
OOddM
v)
-
al
PcnuY
.-
.-
3
(v . .
OOddM
”
FIPPQO
Z ? -
0
m
OOddM
CL
-
al
a 5: .-
4 In
13 DISASSEMBLY AND ASSEMBLY
SPECIAL TOOLS FOR DISASSEMBLY AND ASSEMBLY . . .. . ... . .... . . .. .. . . . . .. .. .. .. . . .. . . . . 13-002 DISASSEMBLY . . .. . .. . .. . ... . ... .. . ... .. . . .. . .. ... . . . . . . . . 13-003 ASSEMBLY . . .. . .. . .. . . ..*..*.............*.................. 13-009 FIGURE OF SPECIAL TOOLS . .. . .. .. . . . .. . .. .. . .. . 13-016
SPECIAL TOOLS FOR DISASSEMBLY
AND ASSEMBLY
When carrying out disassembly and assembly of the Komatsu fuel injection ernor, use the special tools listed below in addition to the normal tools.
Symbol
Part No.
Part Name
pump with electronic
gov-
Remarks
Q’tY
A
79A-474-1410
Plate
1
Remova I of flyweight
B
79A-4474-1111
Eyebolt
1
Measuring
sliding resistance of rack
e
79A-264-0020
Push-pull scale
‘I
D
79A-474-I
Slide hammer
1
Removing
plunger barrel
E
79A-474- 1162
Pusher
1
Holding down plunger spring
F-l
79A-474-1270
Lifting tool (1)
1
Removal and installation of spring
F-2
79A-474- 1260
Lifting tool (2)
1
Removal and installation of tappet
G
79A-474-1130
Puller
1
Removing
gear
M
79A-474-1420
Handle
1
Measuring
camshaft end play
202
79A-474-1290
13-002
Nm: {kgm}
Model Item
NO.
KFE6S135R-1 1
I
Delivery valve holder
I
2
Flange holding nut
3
Governor housing mounting
4
Gear pump cover mounting bolt
5
I
bolt
*
8
bolt
Deflector
bolt
151.9I!I 4.9 {I 5.5 rf:0.5) 53.9 I!I 4.9 (5.5 f 0.5)
30.9 I!I 3.4 (3.15 + 0.35)
30.9 It 3.4 (3.15 I!I 0.35)
11.27 f 1.47 (1.15 I!I 0.15)
6 1 Control solenoid valve mounting
I
53.9 f 4.9 (5.5 * 0.5)
30.9 ?I 3.4 (3.15 I!Y0.35)
Joint bolt
7 I Rack sensor circuit mounting
151.9 + 4.9 {I 5.5 I!I 0.5)
KFEGS135L-1
1,
30.9 * 3.4 (3 15 f n.35)
I
11.27 f 1.47 (I.15 + 0.15)
I
13.23 ?I 1.47 (I.35 f 0.15)
I
13.23 I!Z1.47 (1.35 I!I 0.15)
I
17.2 f 1.47 (1.75 I!I 0.15)
17.2 f 1.47 (1.75 + 0.15)
I
17.2 + 2.47 (1.75 z!z0.25)
17.2 f 2.47 (1.75 I!I 0.25)
13.23 + 1.47 (1.35 I!I 0.15)
13.23 f 1.47 (I.35 Z?I0.15)
-__ *
9
*
10
*
11
Bearing stopper mounting bolt
12
Joint bolt
29.4 f 4.9 (3.0 + 0.5)
29.4 * 4.9 (3.0 z!I0.5)
*
13
Joint lock nut
39.2 * 4.9 (4.0 t- 0.5)
44.1 f 4.9 (4.5 I!I 6.5)
*
14
Joint lock nut
39.2 I!I 4.9 (4.0 + 0.5)
39.2 t- 4.9 (4.0 & 0.5)
Joint bolt
29.4 f 4.9 (3.0 + 0.5)
Lock nut
29.4 + 19.6 (3.0 If:
8 E ii
15 16 17
Upper seat lock mounting bolt
I
I
Tappet lock mounting bolt
I Air bleed bolt (Fuel)
I I
I
13.23 I!I 1.47 (1.35 !I 0.15) 11.27 _+1.47 (1.15 -t 0.15)
8.82 I!Z0.98 (0.9 + 0.1)
I I
I
13.23 + 1.47 Il.35 +_0.15) 11.27 + 1.47 (1.15 Z!I0.15)
29.4 * 4.9 (3.0 I?I0.5) 29.4 I!I 19.6 (3.0 f 2)
I
8.82 I!I 0.98 (0.9 I!I 0.1)
20.6 N {Max. 2.1 kg}
20.6 N {Max. 2.1 kg}
0 - 0.02 mm
0 - 0.02 mm
8.82 I!I 0.98 (0.9 +_0.1)
8.82 f 0.98 (0.9 + 0.1)
Rack stopper bolt
17.15 3: 2.45 (1.75 f 0.25)
17.15 + 2.45 (1.75 f 0.25)
Rack guide bolt
13.23 f 1.47 (1.35 + 0.15)
13.23 I!I 1.47 (1.35 I!I 0.15)
18
Control rack sliding resistor
19
Cam shaft end play
20
Air bleed bolt (Variable prestroke control oil)
21 22
DISASSEMBLY -k
Before disassembling the fuel injection pump, clean it thoroughly and check that there is no leakage of oil from the mating surface of the plug or gasket.
1.
Rack position sensor 1) Remove connector (I), then remove 4 mounting bolts and remove rack position sensor circuit (2). 2)
2.
Loosen nut, then remove rack position sensor (3). * Confirm the quantity and thickness of shims, and keep them till reassembly.
Solenoid and valve 1) Remove mounting bolt, then remove prestroke control solenoid (4) and rack position control solenoid (5).
Rack bush
-b
Shi
\
DWE00242
DWE00121
13-003 0
2)
Using pincette, remove spool (6) and spring (7) from governor body. * Note down if the spring spool is for the prestroke control or for the rack position control, and assemble in the same place when reassembling.
DWE00122
3.
+
Gear pump
1)
Remove the oil relief valve, fuel relief valve and bypass valve.
2)
Remove the oil inlet strainer and screen filter.
3)
Remove 6 mounting (8).
4)
Remove gears (9) and (IO).
5)
Remove gear pump body (11). * The gear pump body, drive gear, and driven gear are supplied as an assembly, so when replacing, replace the whole assem bly.
HQusiwg (A) 1) Remove 6 mounting ing (A) (12). 2)
Fuel relief
Screen
bolts, then remove plate
valve
Oil inlet strainer
valve DWE00243
bolts, then remove hous-
Remove piston (13) of the rack position control hydraulic cylinder from housing (A).
DWE00123
DWE00125
13-004 0
II
\ I
OWE00124
DWEOOl 26
OOddM
-
0 0
0-l -
0
w B
9. Control sleeve Using pincette, remove control sleeve (23). 10. Plunger Using pincette, remove plunger (24). * When removing the plunger from the lower spring seat, rotate the plunger approx. 35” clockwise.
r
23
24
DWE00134
DWE00133
11. Rack Remove stopper frontward.
bolts
and pull
out rack (28)
DWE00136
12. Plunger spring, upper spring seat 1) Using tool E, compress plunger spring, then remove stopper bolt (29). Ir If tool E is not used to remove the stopper bolt, the thread of the stopper bolt may be damaged by the tension of the spring, so always use tool E. 2)
Fixing nut
Loosen the mounting nuts in turn to release the tension of the plunger spring, then remove tool E. u
3) Remove upper spring spring (31).
\
DWE00230
seat (30) and plunger
13. Lower spring seat, tappet assembly Remove lower spring seat (32) and tappet assembly (33). Remove tappet guide bolt (33-l).
33-l
13-006 0
DWE00235
OOddld
.-c,
+ .-
.-CIY .-+
.-cn Y-
H L.
00
s
FIPPQO
A
ASSEMBLY *
*
Wash all parts in clean diesel oil, take care not to get dirt or dust on the parts, replace O-rings and gaskets with new parts, remove all Loctite stuck to the housing deflector holes or other places. Studbolt of housing (C) When replacing studbolt (47) of housing (C), tighten new one so that its tip will be in contact with the bottom of the mounting hole. ~xz-‘]
1.
Stud bolt : 32 2;: Nm {3.2+$~ kgm}
Housing (B) 1) Install oil seal (37) to housing (B). 2) When replacing bearing outer race (36), install new one to housing (C) so that it will protrudes approx. Imm from the ring. 3) Fit the O-rings to housing (B) and housing (C), then install housing (B). &
1
DWE00150
Oil seal lip : Grease (G2-LI)
DWE00143
DWE00144
Pump housing
2.
3.
Bearing If bearings were removed, press fit bearings (46), (45) to camshaft. * When press fitting the bearing, put special tool J in contact with the bearing inner race, and press fit the bearing with a press fully as far as the stepped portion of the camshaft.
Camshaft 1) Put 2 center bearings (44) on camshaft (43 L then fit in pump housing (C). * Coat the inside of the center bearing thinly with grease (G2-LI), and be careful not to let the center bearing slip out of position. * When inserting the camshaft, fit special tool K to the tip of the shaft to prevent damage to the oil seal.
/
Rine
\
outer race
0 ring
DWE00244
46
45
44 \
DWE00149
2)
4.
Replace 4 seal washers with new parts, then temporarily tighten 4 center bearing mounting bolts (42). * Tighten the mounting bolts fully after adjusting the end play.
42
Bearing cover Using special tool L, install oil seal (41) to bearing cover (38), if bearing outer race (40) is removed, install bearing outer race (40).
38
5.
Gear pump drive gear Press fit gear pump drive gear (34) in the hole chamfered more.
6.
Adjustment of camshaft end play 1) Measure end play of camshaft as follows, and adjust with shims so that end play is within specified value. i) Assemble same thickness of shim (39) that was noted during disassembly, then install bearing cover (38). ii) Put probe of dial gauge @ in contact with end face of camshaft, measure end p!ay of camshaft by moving the camshaft frontward and backward, then adjust shim thickness so that end play is within specified value. * Move the camshaft forward and backward from the gear pump drive gear side. * End play of camshaft : 0 - 0.2 (mm) 2)
Install the shims of correct thickness and attach the O-ring, bearing cover (38) and pointer.
3)
Tighten 4 center bearing
DUE00241
3
DUE001 42
DUE00151
mounting
bolts.
7. Tappet assembly, lower spring seat Mount tappet guide bolts (33-l) 2)
Ir *
to housing
0. Mount the tappet guide bolts. Set tappet assembly (33) on lower spring seat (32), then use tool F-2 to install into housing (0. Align the lower spring seat with the dowel pin on the top face of the tappet when installing. Install the tappet assembly by adjusting the side surface groove to tappet guide bolt (331j of the pump housing. &I=,
Tappet guide bolt: Thread tightener
33-l
DWE00235
(LT-2) Fixing nut
8. Plunger spring, upper spring seat 1) Using special tool F-2, install plunger spring (31) and upper split spring seat (30) to housing (C). 2) Fit tool E, tighten mounting nuts in turn, and compress plunger spring. 3) Align with drill hole in upper spring seat, then tighten stopper bolt (29). & 4)
Stopper bolt : Thread tightener
(LT-2)
Loosen the fitting nuts by turns to reduce the tension of the plunger spring, then remove the special tool E.
9. Plunger Align plunger (24) with lower spring seat, and install. * Insert the bottom of the plunger into the hole of the lower spring seat, then turn 35” clockwise. * Hold the head of the plunger and check that it does not come out when it is pulled.
IO. Rack Assemble rack (28) from the front side in pump housing (C), then tighten stopper bolts. fi
Stopper bolt: Thread tightener
(LT-2)
DWE00136
11 Control sleeve Align hollowed part on control sleeve (23) with stamped line on rack, then install. * If the stamped lines on the rack and hollowed part on control sleeve are not aligned, the injection volume for each cylinder will change, so be careful to align accurately.
Hollowed part
Stamped
line Plunger barrel
Control sleeve
DWE00245
DWE00229
12. Plunger barrel assembly 1) Using special tool M, fit O-ring to plunger barrel (21), then insert in cylinder. &
O-ring : Grease (G2-LI)
2) Assemble
same thickness of shim (22) that was checked during disassembly to bottom of flange, then tighten nuts (20) in turn. 5~ *
*
* *
Nut : 54 + 5 Nm (5.5 + 0.5 kgm} Assemble the shim so that the side with the thickness stamped on it, is facing up, of shim at the and use the sam, n +h+ness ,I 1uB left side and right side. Check that the control rack slides smoothly after assembling the plunger barrel assembly to each cylinder. Check the injection timing with the test stand and adjust the shim thickness again. Install the plunger barrel assembly so that the pump housing studbolt will be at the center of the mounting oblong hole.
Plunger barrel
Oblong hole DWE00246
13-012 0
13. Rack spring 1) Use tools B and 6 to measure sliding resistance of rack. Sliding resistance : Max. 21 N (2.1 kg} 2) Assemble stopper and spring (25) to rack, compress spr *ing, and fix with stopper (26).
b\Y/
' DWE00135
14. Delivery valve Fit gasket, then assemble seat (19), delivery valve (18), and spring (17). Using special tool N, give oil to the O-ring and threaded part of delivery vaive holder (15) and fit O-ring, then install delivery valve holder (15). QKI
*
Holder : 152 + 5 Nm (15.5 + 0.5 kgm) lighten in three stages When adjusting after assembling, tighten delivery valve holder (I 5) temporarily. Tighten it normally after adjusting the injection timing.
15. Deflector Install deflector &
Deflector
DWEOOt30
DWE00129
15
(14). : Thread tightener
(LT-2)
14
DWE00156
P
FIPPOO
2)
Fit O-ring, assemble rack position control solenoid (4) and prestroke control solenoid (5) to housing (A), then tighten 4 mounting bolts. * Apply gasket sealant to the surface of each solenoid to contact with the rear housing.
DWE00121
DWEOOl19
8
k
u.
19. Rack sensor 1) Aassemble the disassembled and kept at disassembly shims, then fit rack position sensor (3) and tighten nut.
Rack senso core
2) Fit rack sensor circuit (2) to pump body, then tighten 4 mounting bolts and install connector (1). -k Fit an adiabatic plate at the back of the rack sensor circuit, then tighten bolts. DWE00242
20. Flyweight 1) Fit key in camshaft key groove. 2)
Fit flyweight QKI
and tighten with nut.
Nut:29_+2Nm{30+2kgmI
DWEOOtt8
FIGURE OF SPECIAL TOOLS SPECIAL TOOL
A
Part No. : 79A-474-1410 Part Name : Plate (including : Iron Material
1 bolt)
100
DWE00161
SPECIAL TOOL
B
: 79A-474-1111 Part No. Part Name : Eyebolt : Iron Material
DWE00162
13-016
OOddM
t
( P.1)
SPECIAL TOOL
F-l
: 79A-474-1270 Part No. Part Name : Lifting tool (I) Material : SWP-A (spring steel)
DWE00166
SPECIAL TOOL Part No. Part * _.. .vame Material
F-2
: 79A-474-1260 I ifiinn tog! (2) .- “““.~ : SWP-A (spring steel)
DWE00167
13-018
aI
.. .. ..
OOddkl
SPECIAL TOOL
J
: 79A-474-1430 Part No. Part Name : Push tool : s43c Material Heat treatment : Quenching and tempering of completed part (KES122501400)
a7
102 DWE00169
Jl: 50 (knurled portion)
SPECIAL TOOL Part No. D-V+ I a#~
y~-~ I atlm
Material
K
: 79A-4474-l . : s43c . f..:rln Gutuc
DWE00170
13-020
n
t= 084’
OOddkl
e
a
$_
i
FIPPOO
924.
5:“’ _,
14 ADJUSTING
Adjusting fuel injection pump .................. 14-002 Preparation work ...................................... 14-002 Testing fuel injection timing ................... 14-003 Measuring fuel injection rate .................. 14-005 Calibration data ........................................ 14-006 Adjusting electronic governor .................. 14-008 Adjusting rack sensor .............................. 14-009 Check of governor performance ............ 14-010 Check of pre-stroke oil pressure ............. 14-011
FUEL INJECTION PUMP
14-001 2
ADJUSTING
ADJUSTING FUEL INJECTION PUMP
ADJUSTING FUEL INJECTION PUMP PREPARATION WORK After disassembling and assembling the fuel injection pump and electronic governor, set the fuel injection pump assembly on the test stand and perform various performance tests. •
Connect the fuel outlet and inlet tubes, pre-stroke oil pressure control tube, etc. as shown below.
•
Install stand A to the test stand and set the fuel injection pump assembly, then install pump drive coupling B.
¤
Install the coupling mounting bolts securely.
14-002 2
FUEL INJECTION PUMP
ADJUSTING
ADJUSTING FUEL INJECTION PUMP
TESTING FUEL INJECTION TIMING (PRESTROKE) •
Remove delivery valve holder (3) of the 1st cylinder from the drive side.
•
Remove stopper (4), spring (5), delivery valve assembly (6), and seat (7).
•
Install measuring device C to the flange sleeve and tighten the nut. 3 Nut: 49 ± 9.8 Nm {5 ± 1.0 kgm}
• •
•
Set the fuel supply pressure of the pump stand to 49 KPa {0.5 kg/cm2}. Fix the control rack to the “Full” position and turn the pump drive coupling by hand and set dial gauge 1 to “0” at the bottom dead center of the plunger. Turn the pump slowly by hand in the forward direction and measure the plunger stroke until fuel stops flowing out of the overflow pipe of measuring device C (until fuel injection starts) with dial gauge 1. fl Plunger stroke: 6 ± 0.05 mm fl If fuel does not stop sharply, assume the point at which fuel drops at the rate of 1 drip/second to be the starting point of fuel injection.
FUEL INJECTION PUMP
14-003 2
ADJUSTING
ADJUSTING FUEL INJECTION PUMP
1. Adjusting fuel injection timing (pre-stroke) If the pre-stroke is out of the standard range, adjust it according to the following procedure. •
Loosen the nut and pull out shim (7) between the flange and pump housing.
•
Change the thickness of the shim between the flange and pump housing, then tighten the nut and check to see if the plunger stroke is in the specified range. fl If the pre-stroke is too long, reduce the shim thickness. If the former is too short, increase the latter. fl Set each shim with the side of the stamped thickness up. Insert shims of the same thickness on both sides, one by one. fl Take care that both sides of the shim, top of the housing, and underside of the barrel flange will be free from foreign matter.
2. Adjusting fuel injection interval Measure the injection start interval of the 2nd cylinder and after ones with the angle scale in the injection order on the basis of the injection start time of the 1st cylinder. fl Injection start interval: 2nd cylinder 3rd cylinder 4th cylinder 5th cylinder 6th cylinder
240˚ ± 120˚ ± 360˚ ± 60˚ ± 180˚ ±
20' 20' 20' 20' 20'
fl If any injection start interval is out of the standard range, adjust it by changing the thickness of shim (7) according to the procedure for “Adjusting pre-stroke”.
14-004 2
FUEL INJECTION PUMP
ADJUSTING
ADJUSTING FUEL INJECTION PUMP
MEASURING FUEL INJECTION RATE •
•
Remove measuring device C and install the delivery valve assembly, delivery valve holder (3), etc. correctly, then connect fuel injection pipe (8). Drive the pump at the standard speed and measure the fuel injection rate of each cylinder for the specified stroke.
¤
Take care that your clothes, etc. will not be wound into the pump drive section.
fl Use the specified measuring cylinder (attached to the test stand) and discharge the all diesel fuel from it before starting measurement. 1. Adjusting fuel injection rate If the fuel injection rate is out of the standard range, adjust it according to the following procedure. •
Loosen 2 mounting nuts (9) of the cylinder, the fuel injection rate of which is out of the standard range.
•
Adjust the fuel injection rate by turning flange (10) with screwdriver 2 little by little, then tighten the nuts alternately. fl When tightening the nuts, take care that the cylinder will not shift.
•
Adjust the fuel injection rate of each cylinder into the standard range.
FUEL INJECTION PUMP
14-005 2
ADJUSTING
ADJUSTING FUEL INJECTION PUMP
CALIBRATION DATA Injection Pump Assembly Number
Applicable Machine
6553-00-1112 (106682-4751) (Left bank) 6553-00-1212 (106684-4013) (Right bank) ( ): Injection pump manufacture's part No. Injection Pump Type
Injection Pump Manufactuer
PFE6S135
KOMATSU
Model
Injection order
Serial No.
Model
Engine Specification Clockwise
Flywheel horsepower (kw{HP}/rpm)
1–5–3–6–2–4
Maximum torque (Nm{kgm}/rpm)
59˚30' – 60˚30'
High idling speed
(rpm)
Plunger pre-stroke (mm)
5.95 – 6.05
Low idling speed
(rpm)
Delivery valve 3 retraction volume (mm /st)
—
Injection interval
Calibration Standard Conditions • Service standard indicates data using calibration test parts. • Manufacture standard is data for factory test.
Nozzle & nozzle holder part No. Nozzle part No. Nozzle holder part No. Injection pipe (mm) (Outside dia. ✕ inside dia. ✕ length)
Test oil Oil temperature (ºC) Nozzle opening pressure (MPa{kg/cm2}) Transfer pump pressure (kPa[kg/cm2})
Injection volume Prestroke
Serial No.
SA12V140-1
HD785-3 HD985-3 (With electronic governor)
Injection pump specification Rotating direction
Applicable Engine
Rack Pump • Rack positions pressure Rack voltage position speed B to E are the ref(kPa (V) (mm) (rpm) erence volume {kg/cm2}) when adjusting the injection volume. Rated 882 2.55 – 12.4 – 1,050 point {9.02} 2.57 13.2 • Marks ★ are average Low volumes. 490 Approx. Approx. 300 idling {5.0} 1.26 5.5 point
783{1,050}/2,100 (HIGH POWER mode, Net) 4,170{425}/1,500 (HIGH POWER mode, Net) 2,400 – 2,500 (HIGH POWER mode) 650 – 700 (HIGH POWER mode)
Pump tester capacity for Service standard
Motor: 7.5 KW
( ): Injection pump manufactuere's part number Service standard Manufacturer standard (105780-8130) (105780-0050) (105780-2090) 8 ✕ 4 ✕ 1,000 ASTM D975 No.2 diesel fuel or equivalent 40 – 45 17.7 – 18.2 {180 – 185} — Service standard (cc/1,000 st.) Injection volume
Maximum variance between cylinder
403 – 409
Max. 24
29 – 35
Max. 10
Manufacturer standard (cc/1,000 st.) Injection volume
Maximum variance between cylinder
Governor performance curve (Not specified)
14-006 2
FUEL INJECTION PUMP
ADJUSTING
ADJUSTING ELECTRONIC GOVERNOR
ADJUSTING ELECTRONIC GOVERNOR •
Execute control of the rack device and pre-stroke oil pressure using an XEP checker at the time of testing of a fuel injection pump with elecrtonical governor. Furthermore, make monitoring of the rack position.
Functions of XEP checker • To control the rack position and pre-stroke oil pressure by changing tha current in the range of 0 – 1.0A by means of the control dial on the panel front face. • To take measurement of current and voltage through terminals for measurement of governor, pre-stroke current and rack voltage.
Preparations • Connect the harness of XEP checker (2) to the electronical governor unit (1) of the fuel injection pump before making adjustment of the electronical governor.
14-008 2
FUEL INJECTION PUMP
ADJUSTING
ADJUSTING ELECTRONIC GOVERNOR
ADJUSTMENT OF RACK SENSOR 1. Remove rack stopper bolt (1) and set the rack in position “0” (range in whick motion by the slit on the rear side of the control rack occurs). Make adjustment by shim (3) so that dimension A enters the range indicated below. fl Dimension A: 8.5 ± 0.05 mm 2. Turn in rack adjust bolt (2) and make adjustment by the shim so that the rack voltage enters the range indicated below. fl Rack voltage (when rack position is 14 mm): 2.80 ± 0.01 V fl Shim thickness: 0.1, 0.3, 0.5 mm 3. Remove rack adjust bolt (2), fit rack stopper bolt (1) and check the rack voltage. fl Rack voltage: 0.30 – 0.41 V 4. If the rack voltage is outside of the specified range, replace rack sensor (4) and measure the rack voltage once again.
FUEL INJECTION PUMP
14-009 2
ADJUSTING
ADJUSTING ELECTRONIC GOVERNOR
CHECK OF GOVERNOR PERFORMANCE 1. Rotate the fuel injection pump at the specified speed. 2. Make adjustment by the pre-stroke control dial so thet the pre-stroke oil pressure enters the specified range. 3. Make adjustment by the governor control dial so that the rack voltage enters the specified range.
4. Measure the fuel injection rate and governor current after the pre-stroke oil pressure and rack voltage were adjusted to the spesified ranges. fl Governor performance measurement standard. Fuel injection pump speed (rpm)
Rack voltage (V)
Governor current (A)
1
325 ± 5
1.0 ± 0.01
0.51 ± 0.1
2
325 ± 5
2.2 ± 0.01
0.56 ± 0.1
fl Replace the solenoid, if the measured value fails to enter the specified range. fl The controller is controlled by current and voltage. But conversion is made to “1A/1V” with the EXP checker so as to permit measurement using a voltmeter.
14-010 2
FUEL INJECTION PUMP
ADJUSTING
ADJUSTING ELECTRONIC GOVERNOR
CHECK OF PRE-STROKE OIL PRESSURE 1. Remove bolts from the fuel injection pump front face, connect joint 1 (8 mm, p=1.25) and then connect oil pressure gauge 2. 2. Rotate the fuel injection pump at the specified speed. 3. Make adjustment by the pre-stroke control dial so that the pre-stroke current enters the specified range. 4. Check the pre-stroke oil pressure at this time. Set point Fuel injection pump speed (rpm)
ª Pre-stroke current (A)
1
325 ± 5
0.7 ± 0.05
2
325 ± 5
0.8 ± 0.05
Measuring item (specified range) ª Governor Pre-stroke current oil pressure (A) (MPa{kg/cm2}) 0.71 ± 0.03 0 {7.2 ± 0.3} 0
0.89 ± 0.03 {9.1 ± 0.3}
fl Replace the pre-stroke solenoid if the maximum value of an item wi0th ª mark is outside of the specified range.
FUEL INJECTION PUMP
14-011 2
I-
2
z W
c)
a
B
CL
OOddld
PARTS INSPECTION .
Be careful not to damage the disassembled parts. After washing in diesel oil, blow with compressed air to dry, and make a visual check particularly of the following points.
Part
Check point
Delivery valve
There must be no scratches or damage to seat surface or outside circumference of spool Valve must slide smoothly
Holder
inside holder
There must be no scratches or damage to contact surface of spool and seat SPOOI
Seat HWE00327
Tube
for
Install the delivery valve assembly to the holder for check of valve opening pressure. Apply pressure with the nozzle opening pressure tester as shown in the figure at left, and check the valve opening pressure and sealing performance of the two-way delivery valve.
test
Valve-
Couper gasket Holder nozzle Pressure
open ine test
HWE00334
Plunger barrel and plunger assembly
t
Pull
There must be no scratches, wear, or discoloration to outside circumference of plunger assembly
UP
assembly
barrel
HWE00328
15002 0
Wash plunger assembly with cIean diesei oif, assemble plunger barrel as shown on left, then pull up plunger assembly and check that plunger barrel is not pulled up, and that only plunger comes out. * Change the relative positions of the plunger barrel and plunger assembly (move plunger assembly) and check 2 or 3 times.
Part
Check point
Tappet
.
There must be no peeling, wear of important points, or scratches to roller surface
.
There must be no play between roller pin
.
Check depth of wear at plunger tion
Plunger contact portion Tappet
Roller
roller
and
contact por-
HWE00329
Camshaft
There must be no peeling, wear of important points, or scratches to cam surface
Key groove
There must be no play between groove
key and key
There must be no wear of oil seal contact surface
Oil seal contact surface HWE00330
*
There must be no peeling from surface or abnormal noise
.
There must be no scratches or wear of lip surface
Bearing (taper roller)
Oil seal
Center bearing
d
There must be no peeling, to bearing surface
wear, or scratches
HWE00314
Spool of rack position control hydraulic cylinder
HWE00315
.
There must be no scratches or wear of surface
.
Must slide smoothly
inside bushing
FIPPOO
F 8 P
Delivery
valve
Tappet
FIPPOO
Camshaft
Plunger
barrel
7
0 -.
Part name
Position of damage
r
Judgment
A: Can be used as it is
-
Opening 3
sealing
pressure
and
performance
two-way
delivery
of
valve
categories
for reuse
B : Can be repaired used again
and
C : Not permitted again
.
Injection volume of any cylinder is not extremely little at injection volume adjustment (particularly when rpm is low). Opening pressure of tvwoeway delivery
.
to use
lniection volume of a cylinder is extremely little at injection volume adjustment (particularly when rpm is low). Fuel injection pump Operiing piWSiiii3 zrf tvwv,“ay delivery
.
Less’than
More than 8Qkg/cm2
80kg/cm2
-
1
Peeling from surface, luster,
No peeling
abnormal
noise
noise
or abnormal
Heavy rotation, mal noise
-
abnor-
-
I 2
No rust on ball or race
Rust on bearing
Slight that
rust on outside can be easily
moved
re-
There is rust
with sandpaper
-
1
Threaded ing
portion
of hous-
No damage
or crushing
of thread
Slight dents or damage
Damage,
to thread
other than B
crushing
-
-
2
Damage,
cracks in housing
No cracks
Damage or dents that can be easily removed
Damage
other than B
Damage
other than B
Damage
other than B
with oilstone Damage 1
Damage,
cracks in housing
No cracks
or dents
can be easily
that
removed
with oilstone -
1
Scratches
on surface
No scratches
Damage that easily removed
can be with oil-
stone -
1
Peeling,
wear, or scratches
to surface of gear tooth
Slight wear or scratches
Damage
which
easily removed
are not enough
to catch your fingernail
that
can
be
with oil-
stone
Scratches or wear other than in A and B
-
2
Wear or scratches to surface of plate
Slight wear or scratches
Damage
which
easily removed
are not enough
to catch your fingernail
stone
that
can
be
with oil-
Scratches or wear other than in A and B
-
15-005 0
Judgment Part name
Position
categories
for reuse
of damage C : Not permitted to use again
used again
-
More than 0.075mm
3
End play of drive shaft
Less than 0.075mm
4
Wearorscratchestosurface of oil and fuel relief valve
Slightwearorscratches which are not enough
Damage that can be with easily removed
seats
to catch your fingernail
oilstone.
Clogging of oil inlet strainer
Strainer can be cleaned perfectly by washing light oil and blowing air.
6
Clogging of screen filter
Filter can be cleaned perfectly by washing in light oil and blowing air before 4000H.
7
Wear of contact surface of drive shaft oil seal
5
15-006 0
Less than o 2mm
-
in
Scratches or wear other than in A and B
Strainer cannot cleaned perfectly.
Filter cannot be used any more after 4000H. Filter cannot cleaned perfectly before 4000H.
More than O.x2mm
p1
2
2 0 0
w 1
CONTENTS
No. of page
01 GENERAL
...... .............. ...,.........................,.
11 STRUCTURE
12 TESTING
AND
FUNCTION
01-001
. . . . . . . . . . . . . . . . . . . . . . . . . II-OOI
AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-001
13 DISASSEMBLY
14 MAINTENANCE
AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . .
STANDARD
...........................
13-001
14-001 ,
8 5? u.
15 OTHERS
00-002
... ... ..... .................. ....................... .
15-001
.
cn
FIPGOO
CD
2 --
cn
m
C 325
_
II
STRUCTURE AND FUNCTION
CONSTRACTION .............................................. OPERATION ..................................................... Governor spring operation .......................... Performance line drawings of the governor ............................................ Control of engine startings .......................... Idling control .................................................. Maximum speed control .............................. Torque control device .................................. No-load maximum speed operation .......... .................................. Condition at stopping Torque spring operation .............................. Boost compensator operation ....................
1 I-002 .I I-004 1I-004 1 I-005 II 1-006 1 I-007 11-008 1 I-009 1 I-012 I I-013 1 I-015 II -018
11-001
FIPGOO
2
0
The swivel lever shaft is fitted to the governor cover by bushes. One end of the governor spring is connected to the swivel lever, with the other end connected to the tension lever. When the governor spring is extended, the lower end of the tension lever will contact the adjustable full-load stopper bolt. The swivel lever is so constructed that at the time of stopping the engine it will contact and move the guide lever. The floating lever attached to the guide lever will then also move, therefore placing the control rack in a non-injection position.
An adjustment screw is attached to the opposite end of the swivel lever through which governor spring tension and therefore the speed droop can be adjusted. The torque control spring regulates fuel injection quantity (within. a specific range) to assure optimum fuel injection quantity between idling speed and maximum speed. Constant idling speed is maintained through the installation of an idling sub-spring, incorporated into the governor cover, which at idling rnntwtc VW. I.UV.V
the _*I_ tpncinn _V,.V._. . Ip\/er I_. _. .
Movement of the control lever position will position and swivel lever the alter subsequently governor spring tension, as the centre of revolution of the swivel lever and the tension lever attachment point for the governor spring are mutually eccentric.
\ Start spring Floating lever
\ Control rack
\ Supporting
The governor may be equipped with a stopping device to return the control rack to the stop position when desired, regardless of control lever position. As shown in Fig. 2, the pin at the bottom of the floating lever is inserted into the supporting lever slot. The supporting lever spring is installed to prevent excessive pressure and resultant damage to the lever mechanisms under no-load high-speed conditions.
\ Pin
lever /
Fig. 2 Stop lever mechanism
1 I-003
FIPGOO
0
0 w
Performance Line Drawings of the Governor The solid line in Fig. 4 shows control rack position until contact with the maximum-speed stopper. A-B shows control rack position for engine starting; B-C represents control rack position while the start spring is extended due to the flyweights’ centrifugal force; C-D shows control rack position during injection of excessive fuel sufficient for the torque control stroke.
Pump speed (rpm)-
Fig. 4
D-E shows control rack position at low and medium speed when the centrifugal force of the flyweights exceeds the torque control spring force, with the torque control spring being compressed. E-F represent’s control rack position when the shifter contacts the tension lever at normal-full load operation. At point F the governor spring is actuated; point G is the control lever set point. At point G the rated output of the engine can be obtained. (For construction equipment, which experience extreme load changes, operation at this point is normal) Point H represents no-load maximum speed; the maximum speed of the engine. H-l represents the range where the governor spring and the idling sub-spring actuate together. The bold broken line shows control rack position during idling; the control lever is in the idling position and speed is increased from zero. Point L is the specified idling position; if idling speed decreases below this point the idling sub-spring will move the control rack in the fuel-increase direction.
1 l-005
Control of Engine Starting
stop
(rpm)
Flyweights
/
Shifter Fig.
i and sleeve/
5
As shown in Fig. 5, prior to starting, when the to contact the control lever is moved maximum-speed stopper, the swivel lever --(c~~ected to the control lever) extends the governor spring to move the tension lever, until it contacts the full-load stopper bolt. (See Fig. 5) As the flyweights are not moving at this time, the floating lever is held in the fuel-increase position by the start spring, and the flyweight
1 l-006
roller is held by the shifter and sleeve. As a result, the distance between the tension lever and shifter is greater than at full-load operation, lln ; a,,,w,ng an increased fuel injection quantity and facilitating starting. Immediately after starting the centrifugal force of the flyweights exceeds the start spring force, resulting in movement of the shifter, which then contacts the tension lever; consequently the fuel injection quantity is reduced.
Idling Control
[art
.springw
~
.-: .E
Idling
ti
n
Control lever
-7
y0 f?
‘ump speed (rpm)
-w
Flyweights/
I
Fig. 6
After starting, the control lever is moved to the idling position and governor control will begin. As seen in Fig. 6, with the control lever in the idling position the governor spring will be in a completely contracted state, allowing the flyweights to open even though engine speed is low. Shifter and sleeve movement will then be transmitted to the tension lever, which moves to the right to contact the idling subspring. The floating lever will move to its idling position, moving the control rack in the fueldecrease direction and resulting in a decreased fuel injection quantity suitable for idling.
If engine speed decreases, the flyweights’ centrifugal force will decrease, allowing the idling sub-spring force to move the tension lever and shifter, and consequently the guide and floating levers to the left. The control rack is therefore moved in the fuel-increase direction to return the engine to the required If the engine speed drops idling condition. further, the start spring acts to quickly move the floating lever and control rack in the fuelincrease direction, preventing the engine from stopping and thus maintaining constant idling.
1 l-007
00
Q
FIPGOO
Torque Control Device suction Fuel requirement
Increased setting
,
ye_;___$L-q _--- _#--
A?--?----
I I
&educed setting
I
I
I
Na Engine speed (rpm)
Nb ____F
Fig. 8
1 l-009
If full-load fuel injection quantity is set at point B’ in order to reduce emission of black smoke, engine output will be reduced at low and intermediate speeds. The torque control device operates in such a way that, during full-load satisfies the fuel operation the engine requirement curve as shown in Fig. 8. This torque control device is mounted with the tension lever. However, its use and specificadepend on the various . engine tions applications and range of engine speeds.
This movement, referred to as the torque control stroke, is transferred to the guide/floating levers, resulting in control rack movement in the fuel-increase direction. However, as engine speed increases, the flyweights’ centrifugal force will also increase until it exceeds the force of the torque control spring, which will then be compressed. The shifter will then contact and move the tension lever to decrease fuel injection quantity.
Figs. 9 and 10 show torque control device operation. At low speed the torque control spring force is greater than the flyweights’ centrifugal force and will therefore move the shifter and sleeve in the direction of the arrow ti in Fig. 9.
Pump speed (rpm)-
Fig. 10
11-010
-
I I I I
__-____-___-------
--------_-
(UNU) uo!ysod ycm low03
0
rr-
a-----(LU~J)
_-_.----_____f
paads au!Bu~
009dM
0
l-
z
a g
2
I F
It
2
3
67 -.
. l-l/
z
CE .
FIPGOO
Condition at Stopping
Guide lever
stop
Control
&j
Swivel lever
9
2
Fig. 14
When the control lever is moved to the stop position, the swivel lever will contact and move the guide lever, which in turn moves the floating lever and link, resulting in movement of the control rack to the non-injection position; the engine will then stop.
11-013
Flyweights /
Fig. 15
Where the governor is equipped with a stopping device, operation of the stopping device results in stopping of the engine regardless of control lever position.
11-014
Torque Spring Operation
Tension lever
n
Engines used with construction equipment are subject to abrupt increases in load, causing speed to decrease, which may result in the engine stopping. To prevent this a separate torque spring is utilized, as shown in Fig. 16.
Torque spring
Adjusting
nut
As engine speed decreases, this torque spring operates to slow control rack movement, therefore resulting in increased fuel injection quantity.
stopper bolt
Fig. 16
If the control lever is in the maximum speed position and’ load increases suddenly, without a torque spring the controi rack wiii trace the B-D curve as engine speed decreases, as shown in Fig. 17. Speed decrease wiii be PI. if the torque spring is installed, the control rack moves along B-C and speed decrease will be Pp.
Pump speed (rpm)-!--
; i
1t---
In both cases there is no difference in control rack movement. That is, when the engine experiences an abrupt increase in load from control lever set point B, for control rack movements to the fullload position, there is a greater decrease in speed when the torque spring is utilized.
Fig. 17 Relation between governor performance and engine output
u-015
Control lever
Pump speed (rpm) -
-tt-
Torque spring stroke
Fig. 18
Figs. 18 and 19 show torque spring operation. Point B in Fig. 17 represents the control lever position suitable for rated output. If the increased load exceeds the rated output, the tension lever will act to move the control rack in the fuel-increase direction as engine speed decreases, as shown in Fig. 19. However the torque spring will act to retard the tension lever, and therefore, control rack movement from point B to C. (See Fig. 17)
11-016
Speed decrease will be P2, with the torque spring acting to extend the time taken for this decrease. As fuel injection quantity is increasing during this period, engine torque will increase, the decrease in speed can be felt and time is available for preventative action (gear change etc) to be taken, and stopping of the engine is prevented.
.
/f
\ \
OOSdki
I
00
4
-I-l -.
ON
cn .
FIPGOO
-(UJW)
uo!q!sod ycm lo.quo~
ri E’
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s :E -0
u
c-’
s
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0
t?” _a .-
00!3dlj
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n 2
a Iv) W
I-
009dM
FIPGOO
--
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G’ .
FIPGOO
\ Y
/’
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FIPGOO
I-
2 w
3 7 n
0
.-
Et ..
7 0 I N-, . .
1:
u-l
FIPGOO
\
\
-.
--h
-.
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--5
6. Mount the measuring device (105782-6030) to. measure the control lever angle. (Fig. 73)
ig. 73 Mounting
the measuring
cievice
7. Move the control lever fully in the stop and set the minimum-speed directon, stopper bolt (53) so that the control rack position is 0.5-I .O mm, to prevent undue force on the link mechanism when the control lever is moved in the stop direction. (Fig.
Fig. 74 Setting the minimum-speed
h
74)
stopper bolt
8. The performance of the governor depends on the engine specifications. The performance chart in Fig. 75 is typical of this type of governor. (Fig. 75)
Rh
Na
Nb
NC NdNeNfNg
Pump speed (rpml-
Fig. 75 Governor
performance
chart
12-009
-a
-r-l
:
en .
r
--h
1z
HO;
FIPGOO
P J
rack position
__-___________
Control
(mm)-
ll-
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co
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rack position
(mm)-
8
11 -. ccl .
FIPGOO
Control
rack position
(mm) -
-(w.u)
uo!ysod
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Control
FIPGOO
rack position
(mm) -
-
(Sd) P’dJ”O
I 0
(ww)
009dM
I I
n CT
uo!ysod
yx~
lowo~
2 -
Adjusting screw
If the pump speed is not within the standard value, adjust the height of the adjusting screw provided on the swivel lever. (Fig. 90) Tightening the adjusting screw decreases the speed droop. Loosening the adjusting screw increases the speed droop. Note 1: The adjusting screw can be loosened a maximum of 20 notches (5 turns) from the position where it is completely tightened. Loosening further may disengage the adjusting screw from the swivel lever, resulting in damage to the governor. Note 2: Always be sure to tighten the adjusting screw to the point where a click is heard.
i
Fig. 90
3. Remove the plug (4) with the socket wrench (I 57914-1400 SW30). (Fig. 91)
4. Place the adjusting screw below the plug hole of the governor housing. 5. If Ng rpm exceeds the specified value, tighten the adjusting screw; if Ng rpm is iess than the specified vaiue, ioosen the adjusting screw. (Fig. 92)
Fig. 92 Setting
12-016
adjusting
screw
m ii
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a)
a: (UJUJ)uo!ysod yx.~ lo.wo~
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Control
rack position ?
(mm)-
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l
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--
009dM
0
I
___------
I I I I
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I I
I
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I I I I I
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E
rack position
rf
----
Control
(mm) -
FIPGOO
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--as .u
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QE .!=-
-(UJLU)
onm
0
uo!g!sod yBel ~OJJUO=)
CTCTM
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-A
3. Boost compensator stroke adjustment -.I. Connect the compressed-air pipe the cover (268).
to
boost compensator stroke Note: During adjustment it is not necessary to supply compressed air.
Fig. 1 IO Adjusting
boost compensator
-2.
Fix the control lever in the maximumspeed position. (Fig. 109)
-3.
Maintaining pump speed of Na rpm, shift the control rack position from Rb mm to Ra mm using adjusting screw (270) and then lock it with the locknut (271). (Figs. 110 and 111)
stroke
I
Na Pump speed (rpm) -
Fia. 111
12-023
FIPGOO
xl
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0
7
Control
rack position
I Iu
(mm)-
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.
SPECIAL TOOLS For service of the RSV type mechanical governor cial tools and general tools should be prepared.
SERVICE Key No.
TQOLS
FOR DISASSEMBLY
Part Number ( ): ZEXEL P/No.
Tool Name
Common tool (157944-8520)
Universal
Common tool (157944-7820) Common
tool
vise
mounted
on the
PE(S) -A(D)
pump,
the following
spe-
AND REASSEMBLY Application
Q’ty 1
Used with 157944-8720)
Bracket
1
For fixing
PESA(D)
Bracket
1
For fixing
PEmA(D)
1
Used
together
with
socket
wrench
1
Used
together
with
socket
wrench
brackets
(157944-7820
and
pump
pump
(157944-8720)
Common tool (15791 O-0300)
Ratchet
Common tool (15791 O-l 120)
Handle
Common tool (15791 o-51 00)
Pin
For fixing each extractor (6 mm diameter)
Common tool (157916-5320)
Spanner
For holding pump side coupling (installed with laminated coupling)
Common tool (157842-4420)
Coupling
1
For camshaft camshaftj
rotation
(for 17 mm
dia.
Common tool (157842-4620)
Coupling
1
For camshaft camshaft)
rotation
(for 26 mm
dia.
10
Common tool (157914-0100)
Socket
wrench
1
For removing and installing fixing nut (SW 14 mm) 1
11
Common tool (I 579?4-0300)
Socket
wrench
1
For tightening mm)
12
Common tool (I 57913-0100)
Box
1
For removing and installing supply pump fixing nuts (SW 10 mm)
13
79D-15793121 (157931-2100)
14
15
13-002
handle
wrench
extractor
coupling
bolt (SW
19
Tappet
holder
8
For holding PE(S) -A pump tappets (bolt-type tappet adjustment)
Common tool (157931-2500)
Tappet
holder
6
For holding PE(S)mA pump tappets
Common tool (157931-7320)
Tappet
holder
10
For holding
Or
PE(S) =AD
high speed
pump
type
tappets
kiz
3
-0
0 .-t
00!3dlj
FIPGOO
P
r
ln
8
I
FIPGOO
a
0
z
a
w > 0 (3 >
to a W
r )I LL 0
s
W >
al W
n
0
n
x
W
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161 I
0 --.
v)
2 -. c?
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b
d
FIPGOO
\\ \
\b4
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b
FIPGOO
19. Lightly tap the governor cover with wooden or plastic hammer to separate from the governor housing. (Fig. 37)
a it
Fig. 37 Separating the goveriior cover
20 Push the link’s (174) leaf spring from above and move the governor cover to the left or right to separate the link from the control rack. (Fig. 38) Idtie Note: T-I
Fig. 38 Separating
care
not to bend
the link.
the link
21 Using long-nose pliers, remove the starting spring (132) from the spring eye. The governor cover can now be removed. (Fig. 39)
Fig. 39 Starting spring removal
13-013
22. Attach the spanner (157916-5420) to the drive side coupling and then remove the roundnut (103) and spring washer (102) using the wrench (I 57915-0100) and handle (15791 O-l 120). (Fig. 40)
Fig. 40 Roundnut
removal
23 Attach the extractor (157926-5110) to the flyweight holder and using the socket wrench (157914-0300) and handle (15791 O11 ZO), remove the flyweight (100) and woodruff key (101). (Fig. 41)
Fig. 41 Removal of the flyweight
24. Remove the seven boits (7 and IO) fixing the governor housing in place. (Fig. 42)
Fig. 42 Removal of the bolts
13-014
b
d
FIPGOO
009dld
6. Remove the two snaprings screwdriver. (Fig. 50)
(153) with
a
Fig. 50 Removal of the snaprings
7. Lightly tap the swivel lever (150) with a wooden or plastic hammer to remove the two bushes (151). (Fig. 51)
Fig. 51 Removal of the bushes
8. After removing the two bushes (15i), the swivel lever (150) can then be removed. (Fig. 52) Note: The swivel lever should not be removed unless it is necessary to repair or replace any parts. If removed, O-rings (152) and oil seals (154) shouid be replaced with negw ones.
Fig. 52 Swivel lever removal
13-018
009dkl
FIPGOO
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2 0 t-
CJ W
n v)
2
LL
.-6
LL
.-0)
00!3dkl
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FIPGOO
E! 0 Cc--
I-
(ll
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009dlj
FIPGOO
CD
H <
cn
tz
3
73 0-.
3
2 -.
3
m
P
cn cn
m
n
L-J--- 0
I
009dkl
FIPGOO
a z
x
I-
:
Separate
Type Lever
B !_-
I -
M6; 0.7 - 0.9
The torques
M8; 1 - 1.4
not specified
FIPGOO
in this drawing
~____
should
\Yll%-
M14.: 6 - 7 -
\
(Full Side)
Groove)
@ Bolt after @ Bolt-tightening.
M6. o 5 _ o 7
Tighten
/
M8; 1.5 - 1.8 (Minus
conform
to Standard
Tightening
Torques.
Unit: Kg-m
cn W
Q1 I I-
O
FIPGOO
DD
E
3 CT z
2 E
CD
9 u
3 op m n c/B
2 C
0 n v D n -I
2
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--
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FIPGOO
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iz
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8 a
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if I.
2 m
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4
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009dlj
The RSUV mechanical governor is a variable speed governor which has been developed for use with generators, marine engines, construction and industrial machines, which are generally large sized, medium speed diesel engines. The RSUV type governor is the result of modification of the RSV type governor, to which an acceleration gear has been added. By selecting the appropriate gear, the acceleration gear’s gear ratio can be altered and the desired controlled speed range can be obtained. Flyweight speed, and therefore centrifugal force, has been increased, making this governor suitable for use with medium speed diesel engines.
01-002
The RSUV type governor is identical to the RSV type mechanical governor in regard to the following functions. 1. Speed droop adjustment can be easily performed without governor spring replacement, by adjustment of the swivel lever’s adjusting screw. 2. Engine speed can be maintained automatically at an intermediate level between maximum speed and minimum speed by selecting the appropriate control lever position. 3. The delivery of excess starting is automatic.
fuel for engine
c3 2 Iv) 1 3
n
a
n 2
a
.: .: .: . ** .: .. . .: : : :
. : : .. : .: .: .: : .. .: .. . .: : : :
. : : .. :
u; i 65 P$ g k!o’ CnQ
.. : . . : :. .: .: : .. . : : : *: .. .:
.. . : . : .: : .: .: . .. . : : : .: .. .:
SPECIAL TOOLS
In addition to ordinary tools such as spanners,
hammers, etc., the following special tools and adjustment of the RSUV type governor pump.
are required for disassembly, reassembly mounted on the PES8ZW type fuel injection
Tool No.
No.
Tool Name
Remarks
Q’ty
1
157944-8520
Universal vise
1
Used with bracket (157944-8620)
2
157944-8620
Bracket
1
For fixing PE-Z pump (during disassembly and reassembly)
3
157945-0120
Bracket
1
For fixing PESZW pump
4
157931-7800
Tappet holder
8
For holding tappets
5
157916-4820
Handle
1
For fixing coupling
6 7gD-1579150300 Wrench
1
For removing & installing flyweight roundnut
7 79D-1579266220 Extractor
1
For removing flyweight
1
For removing & installing gear’s fixing nut
157914-1700
8
Socket wrench
(SW27 mm) 9
79D-1579266120 Extractor
1
For removing gear
10
157923-5520
Extractor
1
For removing gear shaft
11
157914-l 200
Socket wrench
1
For removing & installing torque control spring’s locknut (SW24 mm)
12
157915-8300
Wrench
1
13
105782-6350
Measuring device
1
14
105781-0460
Fixing stand
2
For attaching PE.ZW pump (during adjustment)
15
105781-0520
Fixing stand
1
For attaching PESZW pump (during adjustment)
16
157913-3220
Box wrench
1
For adjusting full-load stopper bolt (SW14 mm)
17
157917-0820
Wrench
1
For adjusting torque control spring
18
105780-8130
Nozzle & nozzle
8
Nozzle : 105780-0050 (NP-DNGTDllSNPlT),
holder assembly
For removing & installing rack cap I
For measuring control rack position
Nozzle holder : 105780-2090 (NP-EFFP215)
19
157805-2020
Injection pipe
8
pr4mm~~8mmX1,500mm
20
157843-2720
Coupling
1
For driving PE=ZW pump (during adjustment)
21
157843-3200
Coupling
1
For driving PESZW pump (during adjustment)
Note:
12-002
(M18X1.5-M18~1.5)
The special tool kit (105790-3010) for the PE=Z type pump includes tools with key numbers: 6, 7, 9, 10 and 16.
I.
15794498520 Universal vise
2. 15794418620 Bracket
3. 157945-0120 Bracket 4- Ml OX1 5,
4. 157931-7800 Tappet holder
7. 79D-1579266220 Extractor
5. 157916-4820 Handle
6. 79D-I 579150300 Wrench
8. 157914-1700 Socket wrench
9. 79D-1579266120 Extractor
Ml 2X1.5
SW27
60
:
-lg.
i-1
special tools
12-003
0
L-+---A
FIPGOO
19. 157805-2020
Injection pipe
20. 15784392720 Coupling
I
L’
21. 157843-3200 Coupling
AR3 --._
Fig. 1-3 Special tools
12-005
ADJUSTMENT
Fig. 82
The following adjustments are necessary after reassembly of the RSUV type governor. l Adjustment of the injection pump’s injection timing and injection quantity l Full load adjustment l Maximum speed control adjustment 0 Idling adjustment @ Torque control spring adjustment l Boost compensator adjustment Use the pump test stand for these adjustments, and carefully check the pump speed and control rack position at the same time.
Injection pump installed on the test stand
Preparation 1. Fill
the governor chamber and the injection pump’s cam chamber with lubricating oil (131453-0120). Cam chamber: 30cc/cylinder Governor chamber: 1,200~~ (RSUV for PE-Z
84
Fig. 83
Removing the rack cap
pump) 2. Remove the idling sub-spring (135) and the torque control spring (140). 3. Remove the control rack cap using a spanner (W/21), and then mount the measuring device (105782-6350) on the control rack. (Fig. 83) 4. If a boost compensator is installed, fully screw in the boost compensator stroke adjusting screw and lock it using the locknut. (Fig. 84)
Fig. 84
12-006
Temporarily setting the boost compensator adjusting screw
5. Setting the control rack’s ‘0’ position -1, Maintain the pump speed at 300 rpm. -2, Fully loosen the STOP side stopper screw (407), and set the stop lever in the STOP position. -3, Loosen the minimum speed stopper screw (53) to decrease the governor spring’s set force. (Fig. 85)
Fig. 85
Loosening the minimum speed stopper screw -4. Push the control pinion fully to the drive side using a screwdriver. The position where the control rack does not move any further is the ‘0’ position. -5. In this position, set the measuring device’s scale at ‘0’. (Fig. 86)
Fig. 86
Setting the control rack’s ‘0’ position -6 Confirm that the full control rack stroke exceeds 26 mm by operating the stop lever (404). (Fig. 87) If the control rack does not move through its full stroke, or does not move smoothly, recheck the injection pump and governor.
Fig. 87
Confirming control rack movement
12-007
2” e
E
d, ii
i t
$lI?J
lOJ)UO=)
/’_______
Uo!ysod
I(MU)
009dlzl
Control rack postlion (mm) +
FIPGOO
0
Control rack position (mm) _t
IDLING SUB-SPRING ADJUSTMENT Before adjusting the idling sub-spring, fully loosen the boost compensator stroke adjusting screw. 1. While maintaining a pump speed of 100 rpm, temporarily set the speed control lever so that the control rack is positioned at Rd mm. (Figs. 97 and 98)
Pump speed (rpm) -
i
Fig. 97
Fig. 98
Temporarily setting the speed control lever 2. Increase the pump speed to Ne rpm, and maintain this speed. (Fig. 99) 3. Assemble the idling sub-spring capsule (135) and the nut (136) in the governor cover (35).
0
Ne Pump speed (rpm)
F RSV7006
Fig. 99
12-011
4. Adjust the idling sub-spring
capsule so that the control rack is positioned at Rb mm, and then fix the idling sub-spring capsule . (Fig. 100) 5. Check that the control rack is positioned at Rd mm when the pump speed is decreased to approximately 100 rpm.
Fig. 100 Adjusting the idling sub-spring PUMP SPEED ADJUSTMENT AT THE START OF MAXIMUM SPEED CONTROL 1. Gradually Na rpm.
increase
2. Set the minimum
the pump
speed
speed stopper (53) so that the control rack moving from the Ra mm position fuel decrease direction. (Figs. 101 and 102)
Na
to
screw starts in the
Nb
Pump speed (rpm) i?sv7001
Fig. 101 If Ra is not as specified, adjust it using the boost compensator stroke adjusting screw.
Fig. 102 -Pump speed adJustment at the start of maximum speed controi
SPEED DROOP ADJUSTMENT Engine output performance curve
Speed droop formula:
can be calculated
NC - NbMOO Nb
Governor performance curve RSV7002
Fig. 103 Relation between engine output and governor performance
NC
Pump speed (rpm) RSV7003
Fig. 104
the
(%)
Excessive speed droop increases the engine’s no load maximum speed (NC rpm) over the specified speed, resulting in engine damage. Conversely, too small a speed droop can result in high speed hunting. The speed droop of the RSUV type mechanical governor can be freely adjusted corresponding to engine use. 1. Slowly increase the pump speed. Check that the pump speed is NC rpm when the control rack position is Rb mm. (Fig. 104) 2. If the pump speed is not as specified, adjust the adjusting scre-w provided on the swivel lever. (Fig. 105) e Tightening the adjusting screw decreases the speed droop. e Loosening the adjusting screw increases the speed droop.
Rb
Nb
using
Note 1: The adjusting screw can be loosened a maximum of 24 notches (6 turns) from the position where it is completely tightened. Loosening it further may disengage the adjusting screw from the swivel lever, resulting in governor damage. 2: Always be sure to tighten the adjusting screw to the poin where a ‘click’ is heard.
Fig. 105 Adjusting screw
12-o-l 3
3. Remove the plug (5) using a socket wrench (SW32). (Fig. 106)
~~_
~~
RSV3195
Fig. 106 Removing the plug 4. Loosen the minimum speed stopper screw (53) and position the speed droop adjusting screw below the governor housing’s plug hole. (Fig. 107)
Fig. 107 Loosening the minimum speed stopper bolt 5. Adjusting screw adjustment If NC rpm exceeds the specified value, tighten the adjusting screw; if NC rpm is less than the specified value, loosen the adjusting screw. (Fig. 108)
RSV3197
Fig. 108 Adjusting screw adjustment
12-014
6. Reset the minimum speed stopper screw (53) so that the speed at the start of maximum speed control is Nb rpm. (Fig. 109) 7. Check that the no-load maximum speed is NC rpm (described in item 1. above). Continue the adjustment until the specified value is obtained.
Fig. 109 Pump speed readjustment at the start of maximum speed control SETTING THE MAXIMUM STOPPER SCREW
SPEED
Tighten the maximum speed stopper screw (12) until it contacts the speed control lever (190), and then lock it using the nut (13). (Fig. 110)
Fig. 110 Setting the maximum speed stopper screw
12-015
BOOST COMPENSATOR (when installed)
1. Temporary adjustment of the boost compensator adjusting screw (270) -1. Remove the capnut (276) and loosen the locknut (271).
t
-z
ADJUSTMENT
Perform at Nh rpm
Boost compensalor stroke
Pl Boost
5
.= 2
L----7
p2
pressure (mmHg) +
Rf
Pump speed (rpm) _I)
1
RSV70 10
J
Fig. 111 Boost compensator equipped governor performance chart
0 0
2 ii
-2. Fully screw in the adjusting screw and lock it using the locknut. (Fig. 112) 2. Perform all the previously explained adjustments. NOiC
‘ihe
id
lOad stopper
bdt shdd
be adjusted at a control rack position of Rg mm.
Fig. 112 Temporarily setting the boost compensator screw
12-016
3. Boost compensator stroke adjustment -1. Connect the compressed air pipe to the cover (268).
Note: During boost compensator stroke adjustment, it is not necessary to supply compressed air. -2. Fix the speed control lever in the maximum speed position. -3. Set the stop lever in the NORMAL position. -4. Maintain a pump speed of Nh rpm.
Fig. 113 Adjusting the boost compensator stroke -5‘. Alter the control
rack position from Rg mm to Rf mm using the adjusting screw (270) and then lock it using the locknut (271). (Figs. 113 and 114)
Nh Pump speed (rpm) e RSV70 11
Fig. 114
Pump speed
4. Boost compensator spring adjustment -1. Operate the pump at Nh rpm. -2. Position the speed control lever in the maximum speed position. -3. Position the stop lever in the NORMAL POSITION. -4. Supply compressed air to the boost compensator.
: Nh rpm
Bcost pressure (mmHg) RSV7012
12-017
FIPGOO
-(UJW)
UO!l!SOd
y%?J lOJ)UO=)
00!3dM
t--
(UJUJ)
UO!j!SOd
yCN?J lOJWO3
b
FIPGOO
s
m
2.0 to 3.0 mm
Stopper screw &
RSV3209
3. Fully loosen the NORMAL position side stopper screw (407). 4. fvlove the stop lever (404) toward the NORMAL position until the governor’s internal stopper contacts the governor cover. 5. Maintain the stop lever in this position. 6. Adjust the stopper screw so that the clearance between the stopper screw and the stop lever is 2.0 to 3.0 mm. (Fig‘. 125) 7. Fix the stopper screw using the locknut (408) rn
Fig. 125 NORMAL position side stopper screw adjustment CHECKING
THE SPEED CONTROL LEVER AND STOP LEVER ANGLES
Idling
Full-speed
Check that the speed control lever __ aPecified_ _I stop [ever angles are a5
and
(Fig. 126)
SPEED CONTROL LEVER ANGEL
STOP LEVER ANGLE RSV7015
Fig. 1126 Checking the lever angles
CONTROL
RACK LIMITER
ADJUSTMENT
I_ Remove the rack guide screw pump housing. (Fig. 127)
from the
uide screw
12-02 1
~
_
FIPGOO
Control rack positlon (mm) +
.I
F L
m
M
Control rack posltion (mm) --+
FIPGOO
Y
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&I -
n
F
Q
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0
n
Control rack poshon (mm)-
O:
Control rack position (mm) -
Screw in the idling spring capsule until the control rack is positioned at Rd mm, and then lock it at this point using a locknut (332) and a wrench (1579170820; SW27 end). (Fig. 141)
Fig. 141 Adjusting the idling spring capsule
0
Nd
NC
Pump speed (rpml RSV702 1
6. Slowly increase the pump speed and ensure that when the control rack the reaches the Rc mm position, corresponding speed is NC rpm. (Fig. 142) e When the pump speed is less than NC rpm, reset the load control lever toward the control rack’s ‘0’ position, but with the control rack position still within the specified range. 7. Make sure the control rack position remains above Rh mm, even when pump speed is decreased to 0 rpm.
Fig. 142
Torque control spring adjustment RQ
t
* --
Ra
F g
7
1. Fully screw in the boost compensator stroke adjusting screw again 2. Set the load control lever at the NORMAL position. 3. While maintaining a pump speed of Na rpm, confirm that the control rack is positioned at Ra mm. 4. Operate the injection pump at a speed slightly less than Nf rpm.
\ \ \
\
5 ._ .5
\ \
8 z
3 e E 8 0
Nf
Na
Pump speed Vpm) A RSV7022
Fig. 143
12-027
Control rack posltion (mm)---+
FIPGOO
Control rack posihon (mm) -
-.
cn
5 -.
3
T-
.
-
.-F 3
2
ci
(WI)
UO!$SOd
y3eJ
lOJ)UO3
P’
.-4”%; !? .cI
X
G=
E 3
E
FIPGOO
L.
Y
3
0
rc -.
0
(D
3
-.
(D
--.
3
%
:
L-.
3
I -.
3
Control rack position (mm)+
5 ._ .= 8 0. 0
x T =
l?
Boost compensator adjustment 1.
I
t
Perform at Nh rpm
2.
0
Pl
p2
Boost pressure (mmHg)----_, Boost compensator stroke
P E S
0
\
I
Nh Pump speed (rpm) -
RSV7030
Fig. 155 Boost compensator equipped governor performance chart
1. Maintain a pump speed of 0 rpm. Ri
2. Confirm that the speed control lever is positioned in the maximum speed position. 3. Hold the load control lever in the full load position. 4. Position the stop lever in the NQRMAL position. Pump speed (rpm) ---+ RSV703 1
Fig. 156
12-032
E
2
0 ii
0
.-c.0
2
-(ww)
uo!qsod ~CELIloquo=)
STOPPERS All adjustment stoppers that directly affect engine performance are lock-sealed after adjustment. Do not readjust any stopper without using the pump test stand or the engine test bench, as this will adversely affect the engine and engine performance. (Fig. 160)
RSV3220
Fig. 160 Stoppers
LUBRICATION Integrated lubrication system In this system, oil is pumped to the injection pump housing (or governor cover) to lubricate the injection pump cam chamber and the governor chamber. After passing through the overflow nipple located on the injection pump or governor, the oil returns to the engine.
12-034
Replenishment or replacement of governor and injection pump oil is not necessary. However, prior to operation on the pump test stand or engine test bench, the governor chamber and the injection pump cam chamber must be filled with engine oil or injection pump oil (Part No 131453-0120) until oil overflows from the overflow nipple.
S t? iT:
ALAR
.
.
.
.
: . :
:
-
.
.
.
.
.
. . : .* : . . :
:
-
.
.
.
.
.
: : : . . : . . .
.
.
.
rrr-r
P5ch5&
0000
.
: . -.
: .
:
.
s
: : : . . : .
.
SPECIAL TOOLS
In addition to ordinary tools such as spanners, hammers, etc., the following special tools are required for disassembly, reassembly and adjustment of the RSUV type governor mounted on the PES8ZW type fuel injection pump.
Tool
NO.
No.
Tool Name
Remarks
Q’ty
1
157944-8520
Universal vise
1
Used with bracket (157944-8620)
2
157944-8620
Bracket
1
For fixing PE.Z pump (during disassembly and reassembly)
3
1579450120
Bracket
1
For fixing PESZW pump
4
157931-7800
Tappet holder
8
For holding tappets
5
157916-4820
Handle
1
For fixing coupling
6 79D-1579150300 Wrench
1
For removing & installing flyweight roundnut
7 79D-1579266220 Extractor
1
For removing flyweight
1
For removing & installing gear’s fixing nut
157914-l 700
8
Socket wrench
(SW27 mm) 9
79D-1579266120 Extractor
1
For removing gear
10
157923-5520
Extractor
1
For removing gear shaft
11
157914-l 200
Socket wrench
1
For removing & installing torque control spring’s locknut (SW24 mm)
12
157915-8300
1
Wrench I
For measuring controi rack position
13
105782-6350
Measuring device
14
105781-0460
Fixing stand
2
For attaching PEmZWpump (during adjustment)
15
105781-0520
Fixing stand
1
For attaching PESZW pump (during adjustment)
16
157913-3220
Box wrench
1
For adjusting full-load stopper bolt (SW14 mm)
17
157917-0820
Wrench
1
For adjusting torque control spring
18 , 105780-8130
, Nozz!e & nozz!e
,
i
For removing & installing rack cap I
8
holder assembly
I
Nozzle : 105780-0050 (NP-DNSTD119NPl T), Nozzle holder : 105780-2090 (NP-EFFP215)
19
157805-2020
Injection pipe
8
~4mmX~8mmx1,500mm
20
157843-2720
Coupling
1
For driving PEmZWpump (during adjustment)
21
157843-3200
Coupling
1
For driving PESZW pump (during adjustment)
Note:
13002
(M18x1.5-M18x1.5)
The special tool kit (105790-3010) for the PEmZtype pump Includes too& with key numbers: 6, 7, 9, 10 and 16.
CL
0
z W > 0
u
W
n
009dM
FIPGOO
111
0
z
3
m
c
0
G)
C 0
c
cn
10
m
-I I
11
0
s
c iii
0
m
0
0
r
m x v
DISASSEMBLY Preparatlon
ism125
Fig. 4
Attaching the brackets
1. Keep the bench and workshop clean. Clean the outside of the governor and injection pump thoroughly before disassembly. 2. Before disassembly record the positions of all adjustable parts to facilitate reassembly, and record governor performance so that a comparison may be made after adjustment. Q LJ. The numbers in parentheses following part names refer to the key numbers in figures 2 and 3, and those following tool names refer to tool part numbers. Disassembly The following is an explanation of the disassembly procedure for the RSUV type mechanical governor mounted on the NPPES8ZW type fuel injection pump. 1. Attach the brackets
RSV3127
Fig. 5
(157944-8620 and 157945-0120) to the universal vise (157944-8520). (Fig. 4) 2. Remove the fuel supply pump and the cover plate. 3. Securely fix the injection pump to the brackets using the six bolts. (Fig. 5)
Attaching the injection pump 4. Rotate the camshaft to position the cams in the top dead center position. 5. Insert a screwdriver between the tappet adjusting bolt and the locknut. 6. Lever the tappet up and insert the tappet holder (157931-7800) into the tappet’s groove, into which the tappet guide is installed. (Fig. 6) When inserting the tappet holder, place a cloth between the screwdriver and the pump housing to prevent damage to the pump housing.
Fig. 6
Inserting the tappet holders
13-005
FIPGOO
14. Remove the flyweight from the gear shaft (107) using an extractor (1579266220). (Fig. IO)
RSV3131
Fig. 10
Removing the flyweight 15. Remove the washer (104).
(Fig. 11)
RSV3132
Fig. 11
Removing the washer
16. Remove the four bolts (IO) fixing the cover (112) using a socket wrench (SW13). (Fig. 12)
RSV3 133
Fig. 12
Removing the bolts
13-007
FIPGOO
4
6, ii 009dM
23.Screw plate.
the extractor (Fig. 19)
bolt
0
into
the
Note: The extractor bolt has a left hand thread.
Fig. 19
Attaching the extractor bolt 24Aount shaft.
Fig. ad
the fixing (Fig. 20)
bolt
@ on the
gear
Attaching the fixing b
25Turn the extractor bolt slowly clockwise using a spanner (SW32) to extract the gear shaft and bearing together from the governor housing. (Fig. 21)
RSV314
Fig. 21
13-010
Extracting the bearing
26.Remove the extractor, gear bearing. (Fig. 22) 27. Remove the washer (11 I).
shaft
and
RSV3142
Fig. 22
Removing the gear shaft and bearing 28.Remove (175).
the link (Fig. 23)
from
the
connector
RSV3143
Fig. 23
Removing the link 29. Disengage the start spring (132) from the governor housing pin. 30.Straighten the two lock washers (178). 31. Remove the bolt (176) and nut (177). (Fig. 24)
Fig. 24
Removing the bolt and nut
13-011
-
FIPGOO
,
35.Lightly tap the governor
housing with a plastic hammer to separate it from the pump housing. (Fig. 28)
148
i
Fig. 28
Removing the governor housing If it is necessary to disassemble the governor cover assembly, the procedure is as follows.
36. Remove the capnut (138; SW32). (Fig. 29)
I
8
2 G
Fig. 29
Removing the capnut
37. Loosen the locknut (136) the idling sub-spring (135).
Fig. 30
and remove (Fig. 30)
Removing the idling sub-spring
13-013
FIPGOO
FIPGOO
49.Pull the tension lever towards the top of the governor cover. (Fig. 40)
Fig. 40
Positioning the tension iever 50.Remove the governor spring and the tension lever together from the swivel lever. (Fig. 41)
Fig. 41
Removing the governor spring and tension lever 51 .Loosen the bolt (SW17) and remove the speed control lever (190) from the swivel lever shaft. (Fig. 42)
Fig. 42
Removing the speed control lever
13-017
FIPGOO
3 P
.
Fl PGOO
d, ii
FIPGOO
FIPGOO
Z
0
Tension lever 1. Replace the tension lever and the shaft when the clearance between the shaft and the tension lever is excessive due to wear. (Fig. 63) 2. Replace the tension lever and the full load adjusting screw when the contact surfaces between the full load adjusting screw, the shifter and the tension lever are worn excessively. (Fig. 63) I
RSV3090
Fig. 63
Tension lever and shaft Inspection Swivel lever Replace the swivel lever and the bushings when the clearances between the swivel lever and the bushings are excessive due to wear. (Fig. 64)
RSV3175
Fig. 64
Swivel lever and bushing inspection Boost compensator 1. Replace the pushrod when the surface of the pushrod is worn excessively. (Fig. 65) 2. Replace the diaphragm if the rubber is damaged (ie, broken or flawed). (Fig. 65)
RSV3092
Fig. 65
Diaphragm and pushrod inspection
13-025
Guide lever 1. Replace the guide lever assembly when the surface of the shifter (where it contacts the tension lever) is worn (ie, the chrome plating is peeling off). (Fig. 66)
RSV3093
Fig. 66
Shifter inspection 2. Worn ball bearings are primarily responsible for excessive axial play between the shifter and the sleeve. If worn, replace the sleeve assembly. Replace the guide lever assembly when the play in the connection between the shifter and the guide lever is excessive. (Fig. 67) 8 2 LL RSV3114
Acceleration gear 1. Replace the gear and the gear shaft when the gear play is excessive due to wear. 2. Replace the four rubber dampers if the gear can be rotated manually while the gear holder is fixed. (Fig. 68)
Fig. 68
13-026
Acceleration gear inspection
1
REASSEMBLY For clockwise rotation (with distinguishing
groove)
For counter clockwise rotation
Because the reassembly procedure is the reverse of the disassembly procedure, only are attention special points requiring explained.
groove
1. Impeller (when installed) Two types of impeller can be used, depending on the direction of pump rotation. (Fig. 71) Counterclockwise rotation: 155412-5600 Clockwise rotation: 155412-5500 RSV31.20
Fig. 71
Impellers 2. When attaching the gear to the camshaft, tighten the nut to the following torque. (Fig. 72)
1 $30 (M20 thread)
1
15.0-17.0
1
RSV3 176
Fig. 72
Tightening the gear nut the cover on the 3. When installing governor housing, tighten the four bolts to the following torque. (Fig. 73) Bolt thread size
Fig. 73
13-028
Tightening the cover bolts
Torque
d CD
LL
x
d, ii
FIPGOO
3
-.
Guide lever
-2. After placing the snapring on the bushing, pressfit the shifter to the bushing. (Fig. 80) Do not alter the thickness of the shim inserted between the bushing and the shifter. Note: Take care not to damage the chrome-plated portion of the shifter.
Shifter
RSV3182
i
Fig. 80
Pressfitting the shifter
e -
RSV3 183
Fig, 81
1
Reassembling the sleeve
-3, Reassemble the inner race, the ball and cage assembly, and the shifter in the sleeve, and fix them using the snapring. (Fig. 8i j -4. After completing reassembly, fix the shifter and confirm that it rotates smoothly when the sleeve is rotated.
I-
: . :
110; 1.2-1.5
/
7
The torques torques
FIPGOO
should
- \
M6; 0.7-0.9 M8; 1.5-1.8
in this drawing
MlO; 1.3- 1.5
conform
M20; 11-12
M14; 6-7
M6; 0.5-0.7
F
M10; 1.2-1.5
_/
M6; 0.7-0.9
1.8-2.2
i
tightening
M3; 0.2-0.3
M5; 0.3-0.45
M6; 0.3-0.5
M6; 0.7-0.97
MlO; 1.2-1.5
M6: 0.5-0.7
MlO; 1.2-1.5
M6; 0.5-0.7
- M20; 2.2-2.5
-M16;
to standard
M8; 1.8-2
M12; 5-6
M8; 1.8-2
M24; 8-- 10
not specified
M8; 1 - 1.4
MlO; 1.5-2 M12; 1.5-2
Mlo; 0.7-
1
RSVlOll
Unit: kg-m
L- M6; 0.7-0.9
L
M30; 2.5-3
M12; 1.2-1.6
M30; 3-3.5
M12: 1.6-2
SEBM024001
FUEL SUPPLY PUMP (COMMON RAIL TYPE)
FUEL SUPPLY PUMP MODEL DENSO CRI TYPE
©2001 All Rights Reserved Printed in Japan 07-01(02)
00-001 1
CONTENTS
01
GENERAL ............................................................................. To be issued next time
11
STRUCTURE AND FUNCTION
12
TESTING AND ADJUSTING
13
DISASSEMBLY AND ASSEMBLY ................................................. 13-001
14
PERFORMANCE TEST
15
OTHERS
00-002
............................ To be issued next time
................................. To be issued next time
.......................................................................... 14-001
................................................................................ To be issued next time
FUEL SUPPLY PUMP
The affected pages are indicated by the use of the Revision Revision Mark Page Page that necessary Mark acPage following marks. It is Mark requested number number tions be taken to these pages according to the table below.
Revision Mark number
(
Mark
Revision Indication Page number
Revision Action required Page
Mark
number
c
Page to be newly added
Add
b
Page to be replaced
Replace
Page to be deleted
Discard
)
Pages having no marks are those previously revised or made aditions.
LIST OF REVISED PAGES Mark
b c
b b b b b b
b b b b b b b b b b b b b
b b b b b b b b
Page
00-001 00-002 00-003 13-001 13-002 13-003 13-004 13-005 13-006 13-007 13-008 13-009 13-010 13-011 13-012 13-013 13-014 13-015 13-016 13-017 13-018 13-019 13-020 13-021 13-022 13-023 13-024 13-025 14-001 14-002 14-003 14-004 14-005 14-006 14-007 14-008 14-009 14-010 14-011
Revision number
1
Mark
Page
Revision number
Mark
Page
Revision number
Mark
Page
Revision number
Mark
Page
Revision number
14-012
1
1 1 1 1 1 1
1 1 1 1 1 1 1 1 1 1 1 1 1
1 1 1 1 1 1 1 1
FUEL SUPPLY PUMP
00-003 1
13 DISASSEMBLY AND ASSEMBLY
Special tools list ......................................... 13-002 Consumable parts list ................................ 13-003 Sketches of special tools ........................... 13-004 Disassembly of fuel supply pump ............ 13-005 Assembly of fuel supply pump ................. 13-014 Tightening torque table ........................... 13-025
FUEL SUPPLY PUMP
13-001
SPECIAL TOOLS LIST
DISASSEMBLY AND ASSEMBLY
A
B
1
799-609-1010
Puller, PCV
1
2
799-609-1020
Mounting, PCV
1
3
Purchased
Socket, B = 42 mm
1
4
Purchased
Deep socket, B = 22 mm
1
1
799-609-1030
Extractor
1
799-609-1040
Holding spanner
1
799-609-1050
Holding spanner
1
799-609-1310
Pliers
1
1
799-609-1320
Puller
1
2
799-609-1330
Hook set
1
3
799-609-1060
Base (ø100)
1
799-609-1070
Support (ø31)
1
799-609-1080
Support (ø37)
1
2 C
D 4
799-609-1090
Support (ø39)
1
5
799-609-1110
Wear ring stopper
1
1
799-609-1120
Handle
1
2
799-609-1130
Adapter
1
799-609-1140
Replacer (ø34)
1
799-609-1150
Replacer (ø43)
1
799-609-1160
Replacer (ø52)
1
799-609-1170
Replacer (ø60)
1
799-609-1180
Replacer (ø61)
1
799-609-1190
Replacer (ø71)
1
799-609-1210
Replacer (ø81)
1
799-609-1220
Base housing (ø62)
1
3 4 E
5 6 7
F
799-609-1230
Base housing (ø72)
1
8
799-609-1260
Pipe (ø30)
1
9
799-609-1270
Guide pin
1
1
799-609-1240
Oil seal presser
1
2
799-609-1250
Oil seal guide
1
799-609-1340
Guide rail, nut (ø25)
1
799-609-1440
Guide rail, nut (ø30)
1
799-609-1450
Cam clearance measure (ø25)
1
1 G 2 H
I
6UHD
Part name
6HD
Part No.
Symbol
Q’ty
SPECIAL TOOLS LIST Nature of work, remarks
Removal, installation of PCV assembly
Removal, installation of upper spring seat Removal, installation of feed pump Removal of bearing outer race
Removal of bearing inner race Installation of wear ring
Removal, installation of bearing
Installation of oil seal
Installation of camshaft
799-609-1460
Cam clearance measure (ø30)
1
1
799-609-1280
Depth measure
1
2
799-609-1290
Sensor measure
1
1
Purchased
Slide calipers
1
2
Purchased
Hexagon wrench
1
B = 3 mm, 5 mm
3
Purchased
Tweezers
1
L = 100 mm, 150 mm
4
Purchased
Torque wrench
1
Preset type
5
Purchased
Dial gauge
1
Accuracy: 0.01 mm
6
Purchased
Gasket sealant
1
LG-6
7
Purchased
Liquid adhesive
1
LT-2
13-002 1
Installation of G sensor
FUEL SUPPLY PUMP
DISASSEMBLY AND ASSEMBLY
CONSUMABLE PARTS LIST
Part No.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46
094086-0210 094086-0090 094137-0010 094086-0100 949150-3030 949150-3200 094086-0120 094086-0150 094095-0100 094095-0130 094095-0140 094095-0150 094095-0160 094095-0330 094095-0340 094095-0350 094095-0360 094095-0370 094086-0110 094086-0160 094086-0130 094086-0170 949140-6310 094096-0050 094096-0060 094096-0070 094096-0080 090222-0070 090222-0120 095331-0020 090207-0100 094086-0200 094087-0050 092125-0010 090222-0070 094092-0010 094093-0050 094093-0060 094093-0070 094093-0080 094093-0090 094093-0100 094093-0110 094093-0120 949018-0350 949010-3020
FUEL SUPPLY PUMP
Part name O-ring O-ring Gasket O-ring Seal Seal O-ring O-ring Shim Shim Shim Shim Shim Shim Shim Shim Shim Shim O-ring O-ring O-ring O-ring O-ring Shim Shim Shim Shim Washer Washer Stopper Ring O-ring Seal Gasket Washer Washer Washer Washer Washer Washer Washer Washer Washer Washer Washer Washer
Q’ty 1 2 2 6 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 5 2 2 1 1 1 1 6 4 1 1 1 1 1 1 1 1 1 1
6UHD
No.
6HD
CONSUMABLE PARTS LIST Remarks
T = 0.05 T = 0.1 T = 0.2 T = 0.3 T = 0.5 T = 0.05 T = 0.1 T = 0.2 T = 0.3 T = 0.5
T = 0.15 T = 0.20 T = 0.25 T = 0.40
13-003 1
DISASSEMBLY AND ASSEMBLY
SKETCHES OF SPECIAL TOOLS
SKETCHES OF SPECIAL TOOLS Note) Manufacture the bracket according to the following mounting dimensions drawing and the dimensions of the test stand in hand. When manufacturing it, consider that it will be used for the performance test of the pump, too. fl The bracket parts are shown below the drawing for reference. 1 Bracket (Dimensions drawing for mounting fuel supply pump)
6HD 6UHD
A 214.4 239
B 57 59
C 60 60
For reference Bracket 1 on drive shaft side
13-004
D 129±0.15 139.5±0.15
E 11.0 12.5
F 75 75
G 55±0.05 57±0.05
H 54±0.2 70±0.2
I 27 35
J 14.5 14.5
K M12x1.75 M12x1.75
For reference Bracket on feed pump side
FUEL SUPPLY PUMP
DISASSEMBLY AND ASSEMBLY
DISASSEMBLY OF FUEL SUPPLY PUMP
DISASSEMBLY OF FUEL SUPPLY PUMP 1. Securing fuel supply pump 1) Hold bracket 1 with a vise. (Manufacture bracket 1 in the field.)
2) Fix pump assembly (1) to bracket 1 with 4 bolts (M8 or M10).
2. Removal of element assembly 1) Remove the mounting nut of element assembly (2) and install tool A1. Tool: A1 (PCV puller) 799-609-1010
2) Tighten the bolts of tool A1 evenly to remove element assembly (2). • Lift up the element assembly vertically so that its housing will not be damaged.
FUEL SUPPLY PUMP
13-005 1
DISASSEMBLY AND ASSEMBLY
DISASSEMBLY OF FUEL SUPPLY PUMP
3) Pull plunger (3) out of the housing, taking care not to damage it.
3. Removal of PCV 1) Secure tool A2 with the vise and fix removed element assembly (2) to tool A2. Tool: A2 (PCV mounting) 799-609-1020
2) Remove PCV (4) with tool A3. • Use an extension bar about 50 cm long.
3) Remove stopper (5) with tweezers. • Do not reuse stopper (5).
13-006 1
FUEL SUPPLY PUMP
DISASSEMBLY AND ASSEMBLY
DISASSEMBLY OF FUEL SUPPLY PUMP
4) Loosen the vise and change the fixing angle of tool A2, then remove valve holder (6) with tool A4.
5) Remove the stopper, washer, spring, gasket, and valve with magnet 1. • Do not mix the parts of element assembly PCV1 and element assembly PCV2.
4. Removal of upper spring seat 1) Fix tool B1 to housing (35). Tool: B1 (Extractor) 799-609-1030
2) Install tool B2 to the drive shaft end. Tool: B2 (Holding spanner) 799-609-1040 (6UHD) 799-609-1050 (6HD) 3) Turn the shaft with tool B2 to bring the cam of upper spring seat (34) of the cylinder to be removed to the bottom dead center.
FUEL SUPPLY PUMP
13-007 1
DISASSEMBLY AND ASSEMBLY
DISASSEMBLY OF FUEL SUPPLY PUMP
4) Put the pin of tool B1 in the semicircular groove of upper spring seat (34). Pushing it in, turn the handle by 90 degrees and remove upper spring seat (34). fl Do not push in the pin more than necessity since it can cut the housing surface under the seat.
5) Remove the spring, lower spring seat, and tappet (9) with magnet 1.
6) Drain the oil from the pump.
5. Removal of feed pump 1) Remove pump cover (10) with a hexagon wrench (5 mm), then remove the O-ring. • Drain the fuel remaining in the pump with the priming pump.
13-008
FUEL SUPPLY PUMP
DISASSEMBLY AND ASSEMBLY
DISASSEMBLY OF FUEL SUPPLY PUMP
2) Remove four mounting bolts (12) of side plate (11) (outer) with a hexagon wrench (3 mm).
3) Using tool C, remove side plate (11). Tool: C (Pliers) 799-609-1310
4) Remove casing (13). 5) Remove outer rotor (14). 6) Remove inner rotor (15) and key (39).
7) Remove side plate (16) (inner).
FUEL SUPPLY PUMP
13-009 1
DISASSEMBLY AND ASSEMBLY
DISASSEMBLY OF FUEL SUPPLY PUMP
6. Removal of feed pump and crank position sensor 1) Remove the mounting bolts and feed pump housing (17) from housing (35).
2) Remove G sensor (18). • When removing the G sensor, take care not to damage the shim and housing.
7. Removal of camshaft 1) Remove mounting bolts (21) of bearing cover assembly (19) with a hexagon wrench (5 mm).
2) Remove key (20).
13-010
FUEL SUPPLY PUMP
DISASSEMBLY AND ASSEMBLY
DISASSEMBLY OF FUEL SUPPLY PUMP
3) Hit the end of camshaft (22) on the feed pump side with a plastic hammer to remove bearing cover assembly (19) from the housing.
4) Pull out camshaft (22).
FUEL SUPPLY PUMP
13-011
DISASSEMBLY AND ASSEMBLY
DISASSEMBLY OF FUEL SUPPLY PUMP
8. Removal of bearing outer race 1) Set tools D1, D2, and D3 and place bearing cover assembly (19) on tool D3. Tools: D1 (Bearing puller) 799-609-1320 D2 (Hook set) 799-609-1330 D3 (Base) 799-609-1060
2) Pull out bearing outer race (24) with a hand press.
9. Removal of oil seal Remove oil seal (30) with tools E3 and E1 and a hand press. Tools: E1 (Handle) 799-609-1120 E3 (Replacer) 799-609-1140 (6HD) 799-609-1150 (6UHD)
10. Removal of wear ring 1) Set shaft (22) to a vise. 2) Break wear ring (25) with a hammer. 3) Pull wear ring (25) out of shaft (22).
13-012 1
FUEL SUPPLY PUMP
DISASSEMBLY AND ASSEMBLY
DISASSEMBLY OF FUEL SUPPLY PUMP
11. Removal of bearing roller Secure the camshaft with tool D4 and pull out bearing rollers (26) (2 pieces, 1 each on both sides). •
Install thread protection nut 1 to the shaft end on the drive side.
Tool: D4 (Support) 799-609-1070 (6HD) 799-609-1080 (6HD) 799-609-1090 (6UHD)
12. Removal of oil seal of feed pump case Using tools D1 and D2, pull out the oil seal with a hand press. Tools: D1 (Bearing puller) 799-609-1320 D2 (Hook set) 799-609-1330
13. Removal of bearing outer race of pump housing Place the housing on tool E7 and assemble the replacers of 2 types, handle, and adapter to make a jig. Remove the bearing outer race with that jig and a hand press. Tools: E1 (Handle) 799-609-1120 E2 (Adapter) 799-609-1130 E4 (Replacer) 799-609-1160 (ø52) (6HD) 799-609-1170 (ø60) (6UHD) E5 (Replacer) 799-609-1180 (ø61) (6HD) 799-609-1190 (ø71) (6UHD) E7 (Base) 799-609-1220 (ø62) (6HD) 799-609-1230 (ø72) (6UHD)
FUEL SUPPLY PUMP
13-013 1
DISASSEMBLY AND ASSEMBLY
ASSEMBLY OF FUEL SUPPLY PUMP
ASSEMBLY OF FUEL SUPPLY PUMP fl When installing each part, clean it in clear diesel fuel and take care that foreign matter will not enter it. Replace O-rings with new ones. fl Prepare the consumable parts indicated in the list. 1. Assembly of bearing outer race 1) Place bearing outer race (27) by using tool E7, then remove tool E7. 2 Outside surface of outer race: Gear oil (SAE #90 or equivalent) Tool: E7 (Base) 799-609-1220 (ø62) (6HD) 799-609-1230 (ø72) (6UHD) 2) After removing tool E7, place tool E6 on bearing outer race (27) and press fit to the end of retainer (28) with a hand press. Tool: E6 (Replacer) 799-609-1210 (ø81)
2. Assembly of feed pump housing 1) Set tool F2 to feed pump housing (17) and insert the oil seal, then press fit with tool F1 with a hand press. 2 Outside surface of oil seal: Adhesive (LT-2) • •
After press fitting, wipe off all projected adhesive. Apply gear oil to the oil seal lip surface. Tool: F1 (Oil seal presser) 799-609-1240 F2 (Oil seal guide) 799-609-1250
2) Install camshaft clearance adjustment shim (29).
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FUEL SUPPLY PUMP
DISASSEMBLY AND ASSEMBLY
ASSEMBLY OF FUEL SUPPLY PUMP
3) Fit the O-ring to camshaft housing (35) and install feed pump housing (17). 3 Mounting bolt: 6.8 – 11.8 Nm {0.7 – 1.2 kgm}
3. Press fitting of bearing outer race Assemble the replacers of 2 types, handle, and adapter to make a press fitting jig. Press fit bearing outer race (27) on the feed pump side to the feed pump housing end with the press fitting jig and a hand press. Tools: E1 (Handle) 799-609-1120 E2 (Adapter) 799-609-1130 E4 (Replacer) 799-609-1160 (ø52) (6HD) 799-609-1170 (ø60) (6UHD) E5 (Replacer) 799-609-1180 (ø61) (6HD) 799-609-1190 (ø71) (6UHD)
4. Installation of bearing roller 1) Press fit bearing (26) on the drive side. Tool: E8 Pipe (ø30): 799-609-1260 • Do not receive the press fitting force with the cam at part a but receive it with the shaft end. 2 Inside surface of bearing: Gear oil (SAE #90 or equivalent)
2) Press fit bearing (26) on the feed pump side. Tool: E8 Pipe (ø30): 799-609-1260 2 Inside surface of bearing: Gear oil (SAE #90 or equivalent)
FUEL SUPPLY PUMP
13-015 1
DISASSEMBLY AND ASSEMBLY
ASSEMBLY OF FUEL SUPPLY PUMP
3) Using tool D5, set wear ring (25) in the inserting position and press fit it with a press. Tool: D5 (wear ring stopper) 799-609-1110
5. Installation of bearing outer race 1) Press fit bearing outer race (24) to bearing cover (19). Tool: E1 (Handle) 790-609-1120 E2 (Adapter) 790-609-1130 E4 (Replacer) 790-609-1160 (ø52) (6HD) 790-609-1170 (ø60) (6UHD) E5 (Replacer) 790-609-1180 (ø61) (6HD) 790-609-1190 (ø71) (6UHD) 2 Outside surface of outer race: Gear oil (SAE #90 or equivalent)
2) Press fit oil seal (30) to the bearing cover end. 2 Outside surface of oil seal: Adhesive (LT-2) • •
After press fitting, wipe off all projected adhesive. Apply gear oil to the oil seal lip surface.
6. Installation of PCV 1) Install new stopper (5) with tweezers.
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FUEL SUPPLY PUMP
DISASSEMBLY AND ASSEMBLY
ASSEMBLY OF FUEL SUPPLY PUMP
2) Fit the new O-ring to element (4) and apply grease to them.
3) Fix element (2) to tool A2 and install PCV (4) to element (2). 3 PCV: 157 – 177 Nm {16 – 18 kgm} •
Using a limit-type torque wrench, tighten the element to the specified torque without stopping halfway.
7. Installation of delivery valve holder 1) Change the fixing direction of tool A2 and replace gasket (36) with new one, then install check valve (31) and washer (37A). 2) Install spring (32), washer (37B), and stopper (38). 3) Replace the O-ring with new one and apply grease to it and the threads of delivery valve holder (6), then assemble them temporarily.
FUEL SUPPLY PUMP
13-017
DISASSEMBLY AND ASSEMBLY
ASSEMBLY OF FUEL SUPPLY PUMP
4) Using tool A4, install delivery valve holder (6). 3 Delivery valve holder: 137 – 167 Nm {14 – 17 kgm} •
Use a limit-type torque wrench.
5) Fit O-ring (40).
8. Installation of camshaft and bearing cover 1) Install camshaft (22) to pump housing (1), then install guide pin E9 and bearing cover (19) and camshaft clearance adjustment shim without fitting the O-ring. Tool: E9 (Guide pin) 799-609-1270 • When installing the camshaft and bearing cover, take care not to damage the oil seal on the feed pump side and bearing cover side.
2) Using a hand press, press fit bearing cover (19) and secure it with the bolt. Tool: E8 (Pipe) 799-609-1260 Tightening torque for bolt of bearing cover (19) 3 : 9.8 – 11.8 Nm {1.0 – 1.2 kgm} •
13-018 1
Replace the washer with a new part when installing the bolt.
FUEL SUPPLY PUMP
DISASSEMBLY AND ASSEMBLY
ASSEMBLY OF FUEL SUPPLY PUMP
9. Measuring camshaft clearance • Hit both ends of camshaft (22) lightly with a plastic hammer to fit the camshaft.
1) Install guide rail G1 to the camshaft end and measure the projection of the camshaft in the axial direction. If the projection is out of the standard range, change the thickness of adjustment shim (29) [See 2.2)]. Tools: G1 (Guide rail) 799-609-1340 (ø25) (6HD) 799-609-1440 (ø30) (6UHD) Standard projection: 16.5 ± 0.3 mm (6HD) 13.5 ± 0.3 mm (6UHD) 2) Install camshaft clearance measure G2 to the camshaft and measure the clearance. Standard clearance: 0.03 ± 0.03 mm Tool: G2 (Camshaft clearance measure) 799-609-1450 (ø25) (6HD) 799-609-1460 (ø30) (6UHD) • If the clearance is out of the standard range, change the thickness of adjustment shim [See 8.1)]. If the clearance is in the standard range, fit the O-ring to bearing cover (19) and apply grease to them and install them. Then, measure the clearance again. fl If the clearance is “0”, reduce the turning torque of the camshaft to 0.6 Nm {0.06 kgm} or below.
FUEL SUPPLY PUMP
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DISASSEMBLY AND ASSEMBLY
ASSEMBLY OF FUEL SUPPLY PUMP
10. Installation of G sensor 1) Install a dial gauge to tool H2 and insert the attached master pin. Tool: H2 (Measure sensor) 799-609-1290 • Push master pin 1 into measure sensor 2 firmly and set dial gauge 3 to “0”.
2) Push in G sensor (18) firmly and read the value of the dial gauge (L1). fl If the sensor is longer than the master pin, the dial gauge indicates a positive value (L1) (the pointer moves clockwise). Accordingly, select a thicker shim in this case.
3) Install the dial gauge to tool H1 and press it against attached master pin 4 firmly and set the dial gauge to “0”. Tool: H1 (Depth measure) 799-609-1280
4) Insert tool H1 in the mounting hole of the G sensor and read the value of the dial gauge (L2). • Calculate the thickness (t) of the air gap adjustment shim by the following expression. t = L1 + L2 (6HD) t = L1 + L2 + 0.4 (6UHD) fl If value L2 is positive, the distance between the sensor fitting face and barrel is less than the depth of the master pin hole. Accordingly, select a thicker shim in this case.
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FUEL SUPPLY PUMP
DISASSEMBLY AND ASSEMBLY
ASSEMBLY OF FUEL SUPPLY PUMP
fl There is a difference of 0.4 mm in length between the master pins used for measurement. Accordingly, if a shim having thickness nearest to the calculated shim thickness is selected, the air gap is set in the standard range. fl Standard air gap: • 0.4 +– 0.20 0.05 mm (6HD) • 0.8 +– 0.15 0.05 mm (6UHD) •
Shim size Part No. 094096-0050 094096-0060 094096-0070 094096-0080
Thickness (mm) 0.15 0.20 0.25 0.40
5) Apply grease to the O-ring and install crank position sensor (18) and selected shim together. 3 : 4.4 – 8.34 Nm {0.45 – 0.85 kgm}
11. Installation of tappet 1) Insert tappet (9) in pump housing (35). 2) Insert lower spring seat (8). 3) Install plunger spring (7).
12. Installation of upper spring seat 1) Set upper spring seat (34) in the inserting position and push it in with tool B1, then turn the handle by 90 degrees.
FUEL SUPPLY PUMP
13-021 1
DISASSEMBLY AND ASSEMBLY
ASSEMBLY OF FUEL SUPPLY PUMP
fl When installing the upper spring seat, set the cam at the bottom dead center. • Install tool B2 to the drive shaft end and turn the shaft to bring the cam to the bottom dead center. fl Do not push in the upper spring seat with the extractor too much, since it can cut the housing end. Tool: B1 (Extractor) 799-609-1030 B2 (Holding spanner) 799-609-1040 (6HD) 799-609-1050 (6UHD)
13. nstallation of element 1) Install plunger (3). • Install plunger (3) so that its bottom will be at the cut of lower spring seat (8).
2) Install element assembly (2), taking care not to damage the plunger, then tighten the nuts alternately. 2 O-ring: Grease (G2-LI) 3 Nut: 15.7 – 23.5 Nm {1.6 – 2.4 kgm}
14. Installation of feed pump 1) Install side plate (16) (inner). • Install the plate with the wider groove facing down. (UHD) • Install the plate with the wider groove facing up. (HD)
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FUEL SUPPLY PUMP
DISASSEMBLY AND ASSEMBLY
ASSEMBLY OF FUEL SUPPLY PUMP
2) Install the inner rotor. Fit key (39) to camshaft (22) and install inner rotor (15). • Make sure that the inner rotor is inserted smoothly.
3) Install casing (13). • The position of the hole is off center to the bottom, so when installing, set the eccentric side at the bottom (UHD) or top (HD).
•
Install inner rotor (15) and outer rotor (14) with their ends having punch marks a on this side.
4) Install outer rotor (14).
FUEL SUPPLY PUMP
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DISASSEMBLY AND ASSEMBLY
ASSEMBLY OF FUEL SUPPLY PUMP
5) Install side plate (11) (outer). • Assemble the plate so that the face with wider groove b is at the bottom (UHD) or top (HD). • Install the plate with hole a on the left side. 3 Screw: 1.96 – 2.94 Nm {0.2 – 0.3 kgm}
6) Fit the O-ring to housing (17) and install cover (10). 3 Bolt: 5.88 – 9.8 Nm {0.6 – 1.0 kgm}
15. Refilling with oil Pour lubricating oil in the fuel supply pump to oil filler (41).
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FUEL SUPPLY PUMP
DISASSEMBLY AND ASSEMBLY
ASSEMBLY OF FUEL SUPPLY PUMP
TIGHTENING TORQUE TABLE
No.
Item
Tightening torque Nm {kgm}
1 2 3 4 5 6 7 8
Piston Priming pump (M16) Screw Bolt Nut (With washer) PCV Holder Bolt
1.96 – 2.94 {0.2 – 0.3} 39.0 – 58.8 {4.0 – 6.0} 14.7 – 19.6 {1.5 – 2.0} 6.8 – 11.8 {0.7 – 1.2} 17.6 – 24.5 {1.8 – 2.5} 157.0 – 177.0 {16.0 – 18.0} 137.0 – 167.0 {14.0 – 17.0} 15.7 – 23.5 {1.6 – 2.4}
9
Overflow valve (Temporarily tightened)
14.8 – 19.6 {1.5 – 2.0}
10 11 12
Screw (Temporarily tightened) 7.9 – 12.7 {0.8 – 1.3} Bolt 9.8 – 11.8 {1.0 – 1.2} Bolt 6.8 – 11.8 {0.7 – 1.2}
FUEL SUPPLY PUMP
No. 13 14 15 16 17 18 19 20 21
Item Bolt Bolt Screw (M10) Screw Plug (M16) Filter Plug (M10) Plug Air breeder
Tightening torque Nm {kgm} 5.88 – 9.8 {0.6 – 1.0} 4.4 – 8.3 {0.45 – 0.85} 7.8 – 11.8 {0.8 – 1.2} 1.96 – 2.9 {0.2 – 0.3} 39.0 – 58.8 {4.0 – 6.0} 1.98 – 3.92 {0.2 – 0.4} 7.8 – 11.8 {0.8 – 1.2} 29.5 – 39.2 {3.0 – 4.0} 4.9 – 6.9 {0.5 – 0.7}
13-025 1
14 PERFORMANCE TEST
Special tools list ......................................... 14-002 Sketches of special tools ........................... 14-003 Performance test on fuel supply pump .... 14-004 1. Preparation ........................................... 14-004 2. Bench setting ........................................ 14-005 3. Electrical wiring .................................... 14-009 4. Performance test .................................. 14-011
FUEL SUPPLY PUMP
14-001
SPECIAL TOOLS LIST
PERFORMANCE TEST
SPECIAL TOOLS LIST
K
M
799-609-5020
Cap nut assembly
1
2
799-609-5030
Joint, nipple assembly
1
799-609-5130
Timer joint (ø25)
1
799-609-5140
Timer joint (ø35)
1
2
799-609-5150
Coupling (ø25)
1
3
799-609-5160
Coupling (ø35)
1
1
799-609-5070
Tube (4 x 8 x L 500 outside screw)
2
2
799-609-5080
Tube (4 x 8 x L 500 inside screw)
2
3
799-609-5090
Tube (4 x 8 x L 900 inside screw)
2
4
6UHD
Part name
1
1 L
Part No.
6HD
Symbol
Q’ty
Nos. marked ª are Komatsu part Nos. Nature of work, remarks Installation of common rail
Installation of coupling
Piping for test
799-609-5110
Nozzle, Nozzle holder
2
N
799-609-5050
Pressure gauge (with adapter)
1
Pressure gauge
P
799-609-5040
Pressure regulator assembly
1
Pressure regulator
799-609-5170
Cover
1
Coupling cover
Q
799-609-5010
Hose
1
Fuel suction hose
1
799-607-4040
Wiring harness
1
Controller wiring harness
2
7872-10-910A
Controller
1
3
Purchased
Electric power supply
1
R S T
799-609-5180
U
Purchased
V
6217-71-1210
14-002 1
Filter
1
Pipe bender
1
Common rail assembly
1
DC28V/5A For ø8
FUEL SUPPLY PUMP
PERFORMANCE TEST
SKETCHES OF SPECIAL TOOLS
SKETCHES OF SPECIAL TOOLS Note) The shapes of the tools shown in the following drawings depend on the shapes of the fuel filter and bench. Accordingly, when manufacturing these tools in the field, confirm the actual parts in advance. 6 Common rail mounting channel (Reference drawing)
FUEL SUPPLY PUMP
14-003 1
PERFORMANCE TEST
PERFORMANCE TEST ON FUEL SUPPLY PUMP
PERFORMANCE TEST ON FUEL SUPPLY PUMP 1. Preparation 1) Remove 2 flow damper assemblies (2) from common rail assembly (1). 2) Install blind plug 8. • Blind plug 8 is a component part of tool K1. Tool: K1 (Cap nut assembly) 799-609-5020
3) Taking care not to damage the sealing surface of flow damper assembly (2), insert pin puller rod 1 (ø3 – L = 100) to drive out the internal parts.
4) Install 2 empty flow damper assemblies (2) to common rail (1) again. 3 Flow damper: 98.1 ± 5.0 Nm {10.0 ± 0.5 kgm}
5) Fit the steel ball of tool K1 and secure it from above with the cap nut (4 places). 3 Cap nut: 44.1 ± 5.0 Nm {5.0 ± 0.5 kgm} Tool: K1 (Cap nut assembly) 799-609-5020
14-004 1
FUEL SUPPLY PUMP
PERFORMANCE TEST
PERFORMANCE TEST ON FUEL SUPPLY PUMP
2. Bench setting 1) Install bracket 1 to the bench temporarily.
2) Install tool L to the bench. Tool: L (Timer joint) 799-609-5130 (6HD) 799-609-5140 (6UHD)
3) Install supply pump (3) to bracket 1.
4) Install coupling 2 to supply pump (3). Tool: B2 (Holding spanner) 799-609-1040 (6HD) 799-609-1050 (6UHD) 3 Coupling: 176 – 196 Nm {18 – 20 kgm} (6UHD) 127 – 147 Nm {13 – 15 kgm} (6HD)
FUEL SUPPLY PUMP
14-005 1
PERFORMANCE TEST
PERFORMANCE TEST ON FUEL SUPPLY PUMP
5) Connect the couplings on the bench side and pump side. • Connect by joint 3. (Tighten temporarily.)
6) Tighten bracket 1 to the bench permanently. 7) Install rear bracket 4. (Prepare rear bracket 4 in the field.)
8) Turning the drive shaft, align the camshaft and coupling. • Limit the turning speed of the drive shaft to 20 rpm. After aligning, tighten the nut for coupling joint 3.
9) Installation of filter i) Install fuel filter fixing bracket 5. ii) Install the fuel filter. (Prepare filter fixing bracket 5 in the field.)
14-006
FUEL SUPPLY PUMP
PERFORMANCE TEST
PERFORMANCE TEST ON FUEL SUPPLY PUMP
10) Install hose T between the pump and filter. T (Filter): 799-609-5180 • Insert the copper tubes for blinding the port in the pipe fitting parts (2 places) on the pump side.
11) Install channel 6 to common rail (1). (Prepare channel 6 in the field.) 12) Install tube M1 between delivery valve holder (5) (High-pressure discharge check) and common rail (1). • When installing the tube, bend it to match it the other parts. M1 (Tube): 799-609-5070 3 Tube: 39.2 – 49.0 Nm {4.0 – 5.0 kgm} 13) Install tube M1 between delivery valve holder (6) (discharge pressure check side) and nozzle M4 and M5. • When installing the tube, bend it to match it the other parts. M1 (Tube) : 799-609-5070 M4 (Nozzle) : 799-609-5110 3 Tube: 39.2 – 49.0 Nm {4.0 – 5.0 kgm}
FUEL SUPPLY PUMP
14-007 1
PERFORMANCE TEST
PERFORMANCE TEST ON FUEL SUPPLY PUMP
14) Install pressure gauge, adapter N, and tube M2 to flow damper (2). • When installing the tube, bend it to match it the other parts. N (Pressure gauge) : 799-609-5050 M2 (Tube) : 799-609-5080 3 Tube: 39.2 – 49.0 Nm {4.0 – 5.0 kgm}
15) Install tube M2 between pressure regulator P (IN side) and flow damper (2a). P (Pressure regulator) : 799-609-5040 M2 (Tube) : 799-609-5080 3 Tube: 39.2 – 49.0 Nm {4.0 – 5.0 kgm}
16) Install tube M3 between pressure regulator P (OUT side) and nozzle M4 and M5. • When installing the tube, bend it to match it the other parts. M3 (Tube) : 799-609-5090 M4 (Nozzle) : 799-609-5110 3 Tube: 39.2 – 49.0 Nm {4.0 – 5.0 kgm}
17) Install hose 6 between overflow valve (7) and bench “TO TANK”. • Use the hose attached to the bench as hose 6.
14-008 1
FUEL SUPPLY PUMP
PERFORMANCE TEST
PERFORMANCE TEST ON FUEL SUPPLY PUMP
18) Install hose 7 between common rail pressure limit (8) and bench “LEAKAGE”. • Use the hose attached to the bench as hose 7. • Install tool K2 on the pressure limit side. K2 (Joint nipple): 799-609-5030 19) Install cover Q. Q (Cover): 799-609-5170
20) Install hose R between feed pump inlet (9) and fuel tank. R (Hose): 799-609-5010
3. Electrical wiring • Prepare controller (13) and a battery (DC 24 V) or a DC 24 V power supply (purchased). Controller: 7872-10-910A 1) Turn off the power switch of wiring harness (14). Wiring harness: 799-607-4040 2) Connect the PVC and G sensor to the controller. fl Connect the drive shaft side by the connector of PCV1 and connect the feed pump side by the connector of PCV2. fl Connect CN2, CN4, and CN7 to the controller. 3) Connect the wiring harness to the battery or power supply. • Take care not to mistake the positive and negative terminals for each other.
FUEL SUPPLY PUMP
14-009 1
PERFORMANCE TEST
PERFORMANCE TEST ON FUEL SUPPLY PUMP
Drawing of bench set
14-010
FUEL SUPPLY PUMP
PERFORMANCE TEST
PERFORMANCE TEST ON FUEL SUPPLY PUMP
4. Performance test 1) Testing condition • Test oil: ISO 4113 test oil • Oil temperature: 40 +50 ˚C (104 – 113˚F) • Lubricating oil: 10W30 • Set source voltage: 28 ± 0.2 V • Make sure that the fuel supply pump is filled with lubricating oil up to the specified level.
2) Checking priming pump i) Drain the oil between the tank and feed pump (11). ii) Disconnect discharge pipe T on the filter side and prepare a measuring cylinder to receive the fuel.
iii) Operate priming pump (12) at the rate of 1 stroke/sec and make sure that the fuel is sucked up by 55 strokes or less. (Revolution of pump: 0 rpm)
3) Checking discharge of feed pump i) Drain off the fuel between than tank and feed pump (11) again. ii) Disconnect discharge pipe T on the filter side and prepare a measuring cylinder to receive the fuel. iii) Operate the pump at the speed of 400 rpm and make sure that the discharge is 120 cc in 20 revolutions or more.
FUEL SUPPLY PUMP
14-011 1
PERFORMANCE TEST
4) Checking high-pressure discharge i) Make sure that the pipes and wires are connected normally. ii) Turn on the power switch and make sure that the source voltage is 28 ± 0.2 V. iii) Turn the all knobs of the 4 valves of the pressure regulator to the left end. iv) Operate the pump at the speed of 200 rpm and check for fuel leakage. v) Raise the pump speed to 1,100 rpm. vi) Turn the valve knobs of the pressure regulator to the right end in the order of pressure (No. 1 – No. 4) and set the common rail pressure to 120 MPa {1,224 kg/cm2}. • No. 1, No. 2, No. 3, and No. 4 are stamped on the knob fitting parts. vii) Measure the discharge of PCV2 (high pressure side). viii)Turn off the power switch of the wiring harness and lower the pump speed slowly to 0. ix) Turn the all knobs of the pressure regulator valves to the left end. x) Replace the fuel tube connected to PCV1 and PCV2, then connect PCV1 to the pressure regulator valve. xi) Repeat steps ii), iii), iv), and v) shown above. xii) Measure the discharge of PCV1 (high pressure side)
PERFORMANCE TEST ON FUEL SUPPLY PUMP
5) Check of display on controller i) Just after the power switch is turned ON The controller displays 88ECAA101100 by 2 letters, then displays 00. ii) While the pump drive shaft is turning The controller displays 13. If 13 is displayed, the signals from the G sensor are normal. iii) When the controller displays 74 or 75 • If 74 is displayed, the PCV1 circuit is disconnected or shorted. Check the wiring harness and connector. • If 75 is displayed, the PCV2 circuit is disconnected or shorted. Check the wiring harness and connector.
Standard value: • HD pump (6217-71-1120): 172.5 ± 15 cc/100 revolutions Difference between PCV1 and PCV2: 9 cc/100 revolutions • UHD pump (6217-71-1110): 240 ± 15 cc/100 revolutions Difference between PCV1 and PCV2: 9 cc/100 revolutions
14-012
FUEL SUPPLY PUMP
SEBM026200
WATER PUMP
©2001 All Rights Reserved Printed in Japan 10-01(02)
00-001
CONTENTS
01
GENERAL ........................................................................................................ 01-001
11
STRUCTURE AND FUNCTION
13
DISASSEMBLY AND ASSEMBLY ................................................. 13-001
14
MAINTENANCE STANDARD AND INSPECTION OF PARTS
00-002
....................................................... 11-001
...................................................................................................... 14-001
WATER PUMP
01 GENERAL
Introduction ................................................ 01-002 Cooling system ........................................... 01-003 Specifications ............................................. 01-004
WATER PUMP
01-001
GENERAL
INTRODUCTION
INTRODUCTION
The cooling system employs a highly reliable centrifugal volute pump to keep the engine at proper operating temperature, reduce the cooling loss, and give full play to the engine performance. To keep the function of the water pump, “proper maintenance and inspection” and “repair work” must be carried out. This Shop Manual describes “Outline”, “Structure and function”, “Disassembly and assembly”, “Maintenance standard”, and “Parts inspection” of the water pump which are necessary to the inspection and repair works that are performed mainly in repair shops among the above works. Since this Shop Manual is so made that it will help you learn the correct knowledge and repair method of the water pump and make proper judgment to improve the quality of the repair, understand its contents sufficiently and use it positively.
01-002
WATER PUMP
GENERAL
COOLING SYSTEM
COOLING SYSTEM
1. 2. 3. 4. 5. 6.
Water pump Oil cooler Thermostat Radiator Fan Fan belt
WATER PUMP
7. 8. 9. 10. 11. 12.
Cylinder liner Piston Cylinder block Intake and exhaust valves Injection nozzle or injector Cylinder head
01-003
GENERAL
SPECIFICATIONS
SPECIFICATIONS Item Type Engine
Speed increasing ratio ª
Water flow amount (¬/min)
Total head (m)
Remarks
100
5.0
Impeller diameter ø 85
150
6.5
Impeller diameter ø 90
95
3.5
Impeller diameter ø 100
0.717
190
6.0
Impeller diameter ø 130
Centrifugal, belt-driven
1.19
250
8.0
PC300
110
Centrifugal, belt-driven
0.668
290
7.0
125
Centrifugal, belt-driven
1.5
6D140
Centrifugal, belt-driven
1.56
12V140
Centrifugal, gear-driven
1.8
155
Centrifugal, gear-driven
1.565
6D170
Centrifugal, gear-driven
1.8
8V170
Centrifugal, gear-driven
1.618
12V170
Centrifugal, gear-driven
1.618
95
Centrifugal, belt-driven
105
Centrifugal, belt-driven
108
ª
1.0 0.9
210
5.2
375
10.0
400 800
14.0
6D125 S(A)6D125 Other than following WS23-2, HD325
1,500
17.0
480
18.5
S6D155
820
36.0
SA6D155
800
28.0
1,400
23.0
D475, WA800
2,000
27.5
HD785-2
2,000
27.5
Water pump speed = Engine speed x Speed increasing ratio
01-004
WATER PUMP
11 STRUCTURE AND FUNCTION
General structure ........................................ 11-002 Structure and function ............................... 11-005
WATER PUMP
11-001
STRUCTURE AND FUNCTION
GENERAL STRUCTURE
GENERAL STRUCTURE PUMP 95 SERIES
1. 2. 3. 4. 5. 6.
105•110 SERIES
1. 2. 3. 4. 5. 6.
Pump cover Impeller Water seal Pump body Boss Drive shaft
125 SERIES
1. Water pump drive gear (No. of teeth: 22) 2. Pump shaft 3. Ball bearing 4. Pump body
11-002
Nut Fan pulley Pump shaft Spacer Water seal Pump body
7. Impeller 8. Snap ring 9. Pump cover A. To each part of engine (Cooling water)
140 SERIES
5. Water seal 6. Impeller 7. Pump cover
1. 2. 3. 4. 5.
Alternator drive pulley Oil seal Ball bearing Pump shaft Water pump drive gear (No. of teeth: 23)
6. 7. 8. 9.
Pump body Water seal Impeller Pump cover
WATER PUMP
STRUCTURE AND FUNCTION
GENERAL STRUCTURE
12V140 SERIES
155-4 SERIES
1. 2. 3. 4. 5. 6. 1. 2. 3. 4.
Pump shaft Water seal Pump body Water pump drive gear (No. of teeth: 25)
5. 6. 7. 8.
170 SERIES
1. 2. 3. 4. 5.
Pump body Impeller Floating seal Water seal Pump shaft (Rear)
WATER PUMP
7. 8. 9. A. B. C.
Ball bearing Oil seal Impeller Pump cover
Cover Impeller Floating seal Water seal Pump body Drive gear (No. of teeth: 23) Bearing housing Pump shaft V-ring From radiator From thermostat To oil cooler
8V170 SERIES
6. Pump shaft (Front) 7. Inlet housing a. From radiator b. To oil cooler
1. 2. 3. 4. 5.
Pump body Impeller Water seal Oil seal Ball bearing
6. Pump shaft a. Water inlet (From radiator) b. Water outlet (To oil cooler)
11-003
STRUCTURE AND FUNCTION
GENERAL STRUCTURE
12V170
1. 2. 3. 4. 5. 6.
Pump body Impeller Floating seal Water seal Pump shaft (Rear) Pump shaft (Front)
Water pump • Revolving speed: Engine speed x 1.618 • Flow amount: 2,000 ¬/min (3,235 rpm)
A. Water inlet (From radiator) B. Water outlet (To oil cooler)
11-004
WATER PUMP
STRUCTURE AND FUNCTION
STRUCTURE AND FUNCTION
STRUCTURE AND FUNCTION
1. 2. 3. 4. 5. 6. 7. 8.
Fan Fan pulley Ball bearing Pump shaft Pump housing Water seal Impeller Cover
A. From thermostat B. To engine C. From radiator
Structure and function of water pump • The drive shaft of the water pump is connected to the pulley by means of press fitting or a key, which is driven through V-belts. The impeller is press fitted to this drive shaft and rotated to suck and supply the engine cooling water forcibly. • The drive shaft is usually supported on the front and rear ball bearings and lubricated with grease. • The water is sealed in and out of the water pump (lubricated parts) by the water seal.
WATER PUMP
Type of water pump • Almost all the water pumps are centrifugal volute pumps since they have simple structures and high reliability and can be manufactured in various sizes. • In a centrifugal volute pump, an impeller having volute guide vanes is rotated to supply cooling water forcibly by utilizing the centrifugal force.
11-005
13 DISASSEMBLY AND ASSEMBLY
Standard values and tightening torque table ............................ 13-002 95, 105, 108, and 110 Series General disassembly ................................ 13-004 General assembly ..................................... 13-008 125, 12V140 Series General disassembly ................................ 13-012 General assembly ..................................... 13-015 6D140 General disassembly ................................ 13-018 General assembly ..................................... 13-021 155 Series General disassembly ................................ 13-025 General assembly ..................................... 13-028 170 Series General disassembly ................................ 13-032 General assembly ..................................... 13-035
WATER PUMP
13-001
DISASSEMBLY AND ASSEMBLY
STANDARD VALUES AND TIGHTENING TORQUE TABLE
STANDARD VALUES AND TIGHTENING TORQUE TABLE Unit: Nm {kgm} Item
Body mounting bolt or nut
Cover mounting bolt
Impeller mounting bolt
Housing mounting bolt or nut
95
fl
24.5 ± 4.9 {2.5 ± 0.5}
—
—
105
fl
—
—
—
108
See drawing below
See drawing below
—
—
110
fl
—
—
—
125
fl
30.9 ± 3.4 {31.5 ± 0.35}
—
—
6D140
fl
fl
—
—
12V140
fl
—
—
—
M10: 65.7±6.9{6.7±0.7} M12: 112.8±9.8{11.5±1.0}
—
6D170
fl
—
—
fl
8V170
fl
—
—
fl
12V170
66.2 ± 7.4 {6.75 ± 0.75}
—
—
fl
Engine
155
76.0 ± 2.5 {7.75 ± 0.25} M10: 65.7±6.9 {6.7±0.7}
fl As per KES Tightening Torque Standard.
108 Series
Marked
13-002
18.6±9.8 Nm {1.9±1.0 kgm} Cover mounting 18.6±9.8 Nm {1.9±1.0 kgm} bolt 18.6±9.8 Nm {1.9±1.0 kgm} fl 66.2±7.4 Nm {6.75±0.75 kgm} Body mounting bolt
WATER PUMP
DISASSEMBLY AND ASSEMBLY
STANDARD VALUES AND TIGHTENING TORQUE TABLE
Unit: Nm {kgm} Item
Pulley mounting bolt
Shaft mounting nut
Alternator drive pulley mounting nut
95
—
—
—
105
103.0 ± 14.7 {10.5 ± 1.5}
—
—
108
—
—
—
110
ø25:103.0±14.7{10.5±1.5} ø30:171.6±24.5{17.5±2.5}
—
—
125
—
—
—
6D140
—
—
—
12V140
—
—
—
155
—
198.1 ± 29.4 {20.2 ± 3.0}
—
6D170
—
—
—
8V170
—
—
588.4 ± 29.4 {60 ± 3.0}
12V170
—
—
588.4 ± 29.4 {60 ± 3.0}
Engine
WATER PUMP
13-003
DISASSEMBLY AND ASSEMBLY
GENERAL DISASSEMBLY (95, 105, 108, AND 110 SERIES)
GENERAL DISASSEMBLY 95, 105, 108, AND 110 SERIES fl Before disassembling, clean the pump thoroughly and check it for outside damage and water leakage.
95 and 108 Series 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
Mounting bolt and nut Fan pulley Mounting bolt and snap ring Cover Impeller Body Shaft assembly Snap ring Water seal Shaft Boss and ball bearing Ball bearing Floating seal
105 and 110 Series
13-004
WATER PUMP
DISASSEMBLY AND ASSEMBLY
GENERAL DISASSEMBLY (95, 105, 108, AND 110 SERIES)
1. Pulley Remove bolt or nut (1), then remove fan pulley (2) with puller 1.
2. Cover Remove mounting bolt or snap ring (3) to remove cover (4). fl Remove mounting bolt (3) for 95 and 108 series.
fl Remove snap ring (3) for 105 and 110 series.
WATER PUMP
13-005
DISASSEMBLY AND ASSEMBLY
GENERAL DISASSEMBLY (95, 105, 108, AND 110 SERIES)
3. Impeller Remove impeller (5) with gear puller 2. fl For 108 series, use forcing screws (8 mm, P = 1.25) to remove the impeller.
4. Shaft assembly Remove shaft assembly (7) from body (6) using with push tool 3.
fl For 105 and 110 series, remove snap ring (8) before pulling out shaft assembly (7).
13-006
WATER PUMP
DISASSEMBLY AND ASSEMBLY
GENERAL DISASSEMBLY (95, 105, 108, AND 110 SERIES)
5. Water seal Remove water seal (9).
6. Disassembly of shaft assembly • For 95 and 108 series Remove boss (11) from shaft (10) using with the push tool.
•
For 105 and 110 series Remove bearings (11) and (12) from shaft (10) using with push tool 4 and stand 5.
WATER PUMP
13-007
DISASSEMBLY AND ASSEMBLY
GENERAL ASSEMBLY (95, 105, 108, AND 110 SERIES)
GENERAL ASSEMBLY 95, 105, 108, AND 110 SERIES fl Before assembling, clean the all parts and blow compressed air against them. fl When press fitting each bearing, apply clean engine oil to it.
95 and 108 Series 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
Mounting bolt and nut Fan pulley Mounting bolt and snap ring Cover Impeller Body Shaft assembly Snap ring Water seal Shaft Boss and ball bearing Ball bearing Floating seal
105 and 110 Series
13-008
WATER PUMP
DISASSEMBLY AND ASSEMBLY
GENERAL ASSEMBLY (95, 105, 108, AND 110 SERIES)
1. Shaft assembly 1) Assembly of shaft assembly • For 105 and 110 series Press fit bearings (12) and (11) to shaft (10) using with push tool 6 and stand 7. fl Press fit each bearing with the side on which the balls are seen in. • For 95 and 108 series Press fit shaft (10) to boss (11) using with the push tool. fl Press fit the shaft until its end is flush with the boss end. fl Receive the shaft end from the impeller side.
2) Install shaft assembly (7) to body (6). fl Press fit the shaft until its end is flush with the body end.
fl For 105 and 110 series, install snap ring (8) after press fitting the shaft assembly.
WATER PUMP
13-009
DISASSEMBLY AND ASSEMBLY
GENERAL ASSEMBLY (95, 105, 108, AND 110 SERIES)
2. Fan pulley 1) Press fit fan pulley (2). fl Perform this procedure for only 105 and 110 series.
2) Secure the fan pulley with nut or mounting bolt (1). 3 Nut: See standard values and tightening torque table.
3. Water seal Press fit water seal (9) using with push tool 8. 8 Periphery of outer cylinder of water seal: ThreeBond No. 110 (Nondrying gasket sealant) fl Receive the shaft end and body end simultaneously to press fit the water seal. fl Press fit with the rubber on the impeller side. fl When replacing the water seal, replace floating seal (13), too. fl Apply water-soluble lubricant (toilet soap, etc.) thinly to the periphery of the rubber part of the seat assembly.
13-010
WATER PUMP
DISASSEMBLY AND ASSEMBLY
GENERAL ASSEMBLY (95, 105, 108, AND 110 SERIES)
4. Impeller Press fit impeller (5) to the shaft assembly using with push tool 9. fl Press fit the impeller until its end is flush with the shaft end.
5. Cover Fit the gasket or O-ring and secure cover (4) with mounting bolt or snap ring (3). 3 Mounting bolt: See standard values and tightening torque table.
fl For 105 and 110 series, secure the cover with the snap ring. fl After assembling, turn the fan pulley with the hand to check that it rotates smoothly.
WATER PUMP
13-011
DISASSEMBLY AND ASSEMBLY
GENERAL DISASSEMBLY (125 AND 12V140 SERIES)
GENERAL DISASSEMBLY 125 AND 12V140 SERIES Special tools
•
Symbol
Part No.
Part name
Q’ty
Remarks
A
790-475-1100
Impeller
1
Impeller puller tap (6D125, 6 mm, P = 1.0)
Before disassembling, clean the pump thoroughly and check it for outside damage and water leakage.
125 Series 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.
Mounting bolt Cover and housing Impeller Gear Spacer Snap ring Shaft assembly Oil seal Water seal Shaft Ball bearing Spacer Bearing Body Floating seal
12V140
13-012
WATER PUMP
DISASSEMBLY AND ASSEMBLY
GENERAL DISASSEMBLY (125 AND 12V140 SERIES)
1. Cover Remove mounting bolts (1) to remove cover or housing (2). fl For 12V140, remove housing (2) using with forcing screws 1 (12 mm, P = 1.75).
2. Impeller Remove impeller (3) using with tool A or gear puller 2. fl Impeller puller tap For 125 series: 6 mm, P = 1.0 For 12V140 : 10 mm, P = 1.5
3. Gear 1) Remove gear (4) using with gear puller 3. fl Gear puller tap for 12V140: 10 mm, P = 1.5. 2) Remove spacer (5). fl The spacer is not used for 12V140. 3) Remove snap ring (6).
WATER PUMP
13-013
DISASSEMBLY AND ASSEMBLY
GENERAL DISASSEMBLY (125 AND 12V140 SERIES)
4. Shaft assembly Remove shaft assembly (7). fl Lightly hit the shaft end on the impeller side using with a hammer to push out the shaft.
5. Oil seal Remove oil seal (8).
6. Remove water seal (9).
7. Disassembly of shaft assembly Remove bearing (11), spacer (12), and bearing (13) in order from shaft (10) using with push tool 4 and stand 5. fl The spacer is not used for 12V140.
13-014
WATER PUMP
DISASSEMBLY AND ASSEMBLY
GENERAL ASSEMBLY (125 AND 12V140 SERIES)
GENERAL ASSEMBLY 125 AND 12V140 SERIES fl Before assembling, clean the all parts and blow compressed air against them. fl When press fitting each bearing or gear, apply clean engine oil to it.
125 Series 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.
Bolt Cover and housing Impeller Gear Spacer Snap ring Shaft assembly Oil seal Water seal Shaft Bearing Spacer Bearing Body Floating seal
12V140
WATER PUMP
13-015
DISASSEMBLY AND ASSEMBLY
GENERAL ASSEMBLY (125 AND 12V140 SERIES)
1. Assembly of shaft assembly Press fit bearing (13), spacer (12), and bearing (11) in order to shaft (10) using with push tool 6 and stand 7. fl The spacer is not used for 12V140. fl Press fit the above parts until the shaft flange face is flush with the bearing face.
2. Oil seal Press fit oil seal (8) to body (14) using with push tool 6. 8 Periphery of fitting part of oil seal: ThreeBond No. 1102 (Nondrying gasket sealant) 8 Oil seal lip: Grease (G2-LI) fl Set the lip of the oil seal toward the gear and press fit it until it is flush with the fitting part. fl Take care that dirt and chips will not stick around the lip. fl Take care not to damage the lip in handling. 3. Shaft assembly Install shaft assembly (7).
4. Water seal Press fit water seal (9) to the body using with push tool 7. 8 Periphery of metallic ring fitting part of water seal: ThreeBond No. 1102 (Nondrying gasket sealant) fl Press fit with the rubber on the impeller side. fl When replacing the water seal, replace floating seal (15), too.
13-016
WATER PUMP
DISASSEMBLY AND ASSEMBLY
GENERAL ASSEMBLY (125 AND 12V140 SERIES)
fl When installing the floating seal to the impeller, apply water-soluble lubricant (toilet soap, etc.) thinly to the inside wall of the impeller seat fitting part. 5. Gear 1) Install snap ring (6). fl For 12V140, install the snap ring with the tapered side out. fl Check that the snap ring is fitted to the groove.
2) Install spacer (5). fl The spacer is not used for 12V140. 3) Press fit gear (4) using with push tool 8.
6. Impeller Press fit impeller (3) using with push tool 9. fl Position of impeller vanes 125 series: Inside of body 12V140 : Outside of body
7. Cover Fit the gasket and install cover or housing (2) and secure it with mounting bolts (1). 3 Mounting bolt: See standard values and tightening torque table. fl After assembling, turn the gear with the hand to check that it rotates smoothly.
WATER PUMP
13-017
DISASSEMBLY AND ASSEMBLY
GENERAL DISASSEMBLY (6D140 SERIES)
GENERAL DISASSEMBLY 6D140 SERIES Disassembly of water pump assembly •
Before disassembling, clean the pump thoroughly and check it for outside damage and water leakage.
6D140 Series
Water pump assembly 1. Bolt 2. Cover 3. Impeller 4. Floating seal 5. Shaft 6. Sleeve 7. Water separator 8. Oil seal 9. Ball bearing 10. Spacer 11. Gear 12. Spacer 13. Snap ring 14. Ball bearing 15. Oil seal 16. Body
13-018
WATER PUMP
DISASSEMBLY AND ASSEMBLY
GENERAL DISASSEMBLY (6D140 SERIES)
1. Cover Remove mounting bolts (1) to remove cover (2). fl The covers of some models (WS23-2) are secured with snap rings.
2. Impeller Remove impeller (3) using with gear puller 1.
3. Shaft Remove shaft (5) using with push tool 2. fl Remove sleeve (6), water seal (7), oil seal (8), bearing (9), spacer (10), gear (11), and spacer (12) in order.
4. Snap ring and bearing 1) Remove snap ring (13). 2) Remove bearing (14).
WATER PUMP
13-019
DISASSEMBLY AND ASSEMBLY
GENERAL DISASSEMBLY (6D140 SERIES)
5. Oil seal Remove oil seal (15).
13-020
WATER PUMP
DISASSEMBLY AND ASSEMBLY
GENERAL ASSEMBLY (6D140 SERIES)
GENERAL ASSEMBLY 6D140 SERIES fl Before assembling, clean the all parts and blow compressed air against them. fl When press fitting each bearing or gear, apply clean engine oil to it.
6D140 Series
Water pump assembly 1. Bolt 2. Cover 3. Impeller 4. Floating seal 5. Shaft 6. Sleeve 7. Water separator 8. Oil seal 9. Ball bearing 10. Spacer 11. Gear 12. Spacer 13. Snap ring 14. Ball bearing 15. Oil seal 16. Body
WATER PUMP
13-021
DISASSEMBLY AND ASSEMBLY
GENERAL ASSEMBLY (6D140 SERIES)
1. Oil seal Press fit oil seal (15) to body (16) using with push tool 3. 8 Periphery of fitting part of oil seal: ThreeBond No. 2 (Nondrying gasket sealant) 8 Oil seal lip: Grease (G2-LI) fl Set the lip of the oil seal toward the gear and press fit it until it is flush with the fitting part. fl Take care that dirt and chips will not stick around the lip. fl Take care not to damage the lip in handling. 2. Bearing and snap ring 1) Press fit bearing (14) to body (16) using with push tool 4.
2) Snap ring Secure the bearing with snap ring (13). fl Check that the snap ring is fitted to the groove.
3. Shaft Install spacer (10) and gear (11) in order to the body, then press fit shaft (5) using with push tool 5. fl Set the thinner side of the shaft up and press fit it until it is projected a little from the bearing face. (If the shaft is inserted too deeply, gear (11) cannot be installed. Take care.) fl Place a stand (100 mm in length, 45 mm in outside diameter, and 30 mm in inside diameter) under the gear and press fit the shaft until the flange face touches the bearing face.
13-022
WATER PUMP
DISASSEMBLY AND ASSEMBLY
GENERAL ASSEMBLY (6D140 SERIES)
fl If the thinner part of the shaft is pressed, it may be bent. Accordingly, be sure to press the flange face. 1) Bearing Install spacer (12), then press fit bearing (9) using with push tool 6.
2) Oil seal Press fit oil seal (8) using with the push tool. 8 Lip: Grease (G2-LI) fl Take care that dirt and chips will not stick around the lip. fl Take care not to damage the lip in handling.
3) Sleeve Press fit sleeve (6) using with push tool 7.
4) Water seal Press fit water seal (7) to the body using with push tool 8. 8 Periphery of outer cylinder of water seal: ThreeBond No. 1102 (Nondrying gasket sealant) fl Press fit water seal with the rubber part on the impeller side. fl When replacing the water seal, replace floating seal (4), too. fl Apply water-soluble lubricant (toilet soap, etc.) thinly to the periphery of the rubber part of the seat assembly.
WATER PUMP
13-023
DISASSEMBLY AND ASSEMBLY
GENERAL ASSEMBLY (6D140 SERIES)
4. Impeller Press fit impeller (3) using with push tool 9.
5. Cover Fit the gasket and install cover (2) and secure it with mounting bolts (1). 3 Mounting bolt: See standard values and tightening torque table. fl After assembling, turn the gear with the hand to check that it rotates smoothly.
13-024
WATER PUMP
DISASSEMBLY AND ASSEMBLY
GENERAL DISASSEMBLY (155 SERIES)
GENERAL DISASSEMBLY 155 SERIES Special tools
•
Symbol
Part No.
Part name
Q’ty
Remarks
A
790-475-1100
Remover
1
Impeller puller tap (8 mm, P = 1.25)
Before disassembling, clean the pump thoroughly and check it for outside damage and water leakage.
155 Series
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21.
WATER PUMP
Mounting bolt Cover Impeller Mounting bolt Bearing housing shaft assembly V-ring Oil seal Water seal Nut Lock washer Plate Snap ring Bearing housing assembly Shaft assembly Bearing housing Bearing Shaft Gear Bearing Body Floating seal
13-025
DISASSEMBLY AND ASSEMBLY
GENERAL DISASSEMBLY (155 SERIES)
1. Cover Remove mounting bolts (1), then remove cover (2) using with forcing screws 1 (8 mm, P = 1.25).
2. Impeller Remove impeller (3) using with tool A. fl Impeller puller tap (8 mm, P = 1.25)
3. Bearing housing and shaft assembly 1) Remove mounting bolt (4), then remove bearing housing and shaft assembly (5). fl Lightly hit the shaft end on the water seal side with a hammer to push out the shaft. 2) Remove V-ring (6).
4. Oil seal Remove oil seal (7).
13-026
WATER PUMP
DISASSEMBLY AND ASSEMBLY
GENERAL DISASSEMBLY (155 SERIES)
5. Water seal Remove water seal (8).
6. Disassembly of bearing housing and shaft assembly Remove nut (9), lock washer (10), plate (11), and snap ring (12), then remove bearing housing assembly (13) and shaft assembly (14) using with push tool 2 and stand 3.
7. Disassembly of bearing housing assembly Remove bearing (16) from bearing housing (15) using with the push tool.
8. Disassembly of shaft assembly 1) Remove gear (18) from shaft (17) using with the push tool. 2) Remove bearing (19) using with push tool 4 and stand 5.
WATER PUMP
13-027
DISASSEMBLY AND ASSEMBLY
GENERAL ASSEMBLY (155 SERIES)
GENERAL ASSEMBLY 155 SERIES fl Before assembling, clean the all parts and blow compressed air against them. fl When press fitting each bearing or gear, apply clean engine oil to it.
155 Series
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21.
13-028
Mounting bolt Cover Impeller Mounting bolt Bearing housing shaft assembly V-ring Oil seal Water seal Nut Lock washer Plate Snap ring Bearing housing assembly Shaft assembly Bearing housing Bearing Shaft Gear Bearing Body Floating seal
WATER PUMP
DISASSEMBLY AND ASSEMBLY
GENERAL ASSEMBLY (155 SERIES)
1. Assembly of shaft assembly 1) Press fit bearing (19) to shaft (17) using with the push tool. fl Press fit the bearing until its face is flush with the flange face. 2) Press fit gear (18) using with push tool 6 and stand 7, matching it to the shaft key.
2. Assembly of bearing housing assembly 1) Press fit bearing (16) to bearing housing (15) using with push tool 8 and stand 9. fl Press fit the bearing until its face is flush with the bearing housing face.
3. Assembly of bearing housing and shaft assembly 1) Press fit shaft assembly (14) to bearing housing assembly (13) using with the push tool and stand 0, then install plate (11) and lock washer (10) and secure them with nut (9) and snap ring (12). 3 Nut: See standard values and tightening torque table. fl Check that the snap ring is fitted to the groove. fl Bend the lock washer securely.
4. Oil seal Press fit oil seal (7) to body (20) using with the push tool. 8 Periphery of fitting part of oil seal: ThreeBond No. 1102 (Nondrying gasket sealant) 8 Oil seal lip: Grease (G2-LI) fl Set the lip of the oil seal toward the impeller and press fit it until it is flush with the fitting part.
WATER PUMP
13-029
DISASSEMBLY AND ASSEMBLY
GENERAL ASSEMBLY (155 SERIES)
fl Take care that dirt and chips will not stick around the lip. fl Take care not to damage the lip in handling.
5. Bearing housing and shaft assembly Install bearing housing and shaft assembly (5) and secure it with mounting bolt (4). 3 Mounting bolt: See standard values and tightening torque table.
6. Water seal Press fit water seal (10) using with the push tool. 8 Periphery of outer cylinder of water seal: ThreeBond No. 1102 (Nondrying gasket sealant) fl Press fit the water seal with the rubber part on the impeller side. fl When replacing the water seal, replace floating seal (21), too. fl Apply water-soluble lubricant (toilet soap, etc.) thinly to the periphery of the rubber part of the seat assembly. 7. Impeller Press fit impeller (3) using with push tool B. fl Press fit the impeller until its face is flush with the shaft end.
13-030
WATER PUMP
DISASSEMBLY AND ASSEMBLY
GENERAL ASSEMBLY (155 SERIES)
8. Cover Fit the O-ring and install cover (2) and secure them with mounting bolts (1). 3 Mounting bolt: See standard values and tightening torque table.
fl After assembling, turn the gear with the hand to check that it rotates smoothly.
WATER PUMP
13-031
DISASSEMBLY AND ASSEMBLY
GENERAL DISASSEMBLY (170 SERIES)
GENERAL DISASSEMBLY 170 SERIES •
Before disassembling, clean the pump thoroughly and check it for outside damage and water leakage.
170 Series (6D170, 8V170, 12V170)
Water pump assembly 1. Bolt assembly 2. Housing cover 3. Impeller 4. Floating seal 5. Snap ring 6. Shaft 7. Shaft assembly 8. Water seal 9. Oil seal 10. Retainer ring 11. Ball bearing 12. Ball bearing 13. Body
13-032
WATER PUMP
DISASSEMBLY AND ASSEMBLY
GENERAL DISASSEMBLY (170 SERIES)
1. Housing Remove mounting bolts (1), then remove housing (2) using with forcing screws 1 (12 mm, P = 1.75). fl If the forcing screws do not go in, repair the screw holes with a tap.
2. Impeller 1) Remove impeller (3) using with gear puller 2. fl If the forcing screw holes of the impeller are corroded, repair them with a tap. 2) Remove floating seal (4).
3. Snap ring Remove snap ring (5). 4. Shaft assembly Remove shaft assembly (7). fl Hit the shaft from the impeller side with a plastic hammer so lightly that it will not be damaged.
5. Water seal Remove water seal (8). fl Remove the water seal from the bearing side so that the body will not be damaged. 6. Oil seal Remove oil seal (9).
WATER PUMP
13-033
DISASSEMBLY AND ASSEMBLY
GENERAL DISASSEMBLY (170 SERIES)
8. Retainer ring Remove retainer ring (10) using with snap ring puller 3.
9. Bearings Remove bearings (11) and (12) from shaft (6).
13-034
WATER PUMP
DISASSEMBLY AND ASSEMBLY
GENERAL ASSEMBLY (170 SERIES)
GENERAL ASSEMBLY 170 SERIES •
Before assembling, clean the all parts and blow compressed air against them. fl When press fitting each bearing or gear, apply clean engine oil to it.
170 Series (6D170, 8V170, 12V170)
Water pump assembly 1. Bolt assembly 2. Housing 3. Impeller 4. Floating seal 5. Snap ring 6. Shaft 7. Shaft assembly 8. Water seal 9. Oil seal 10. Retainer ring 11. Ball bearing 12. Ball bearing 13. Body
WATER PUMP
13-035
DISASSEMBLY AND ASSEMBLY
GENERAL ASSEMBLY (170 SERIES)
1. Bearings Press fit bearings (12) and (11) to shaft (6) using with push tools 4 and 5.
2. Retainer ring Secure the bearings with retainer ring (10). fl Check that the retainer ring is fitted to the groove.
3. Oil seal Press fit oil seal (9) to the body using with push tool 6. 8 Periphery of fitting part of oil seal: ThreeBond No. 2 (Nondrying gasket sealant) 8 Oil seal lip: Grease (G2-LI) fl Take care that dirt and chips will not stick around the lip. fl Take care not to damage the lip in handling. fl Set the lip of the oil seal toward the bearing and press fit it until it is flush with the fitting part. 4. Water seal Press fit water seal (8) to the body using with push tool 7. 8 Periphery of outer cylinder of water seal: ThreeBond No. 2 (Nondrying gasket sealant) fl Press fit the water seal with the rubber part on the impeller side. fl When replacing the water seal, replace floating seal (4), too. fl Apply water-soluble lubricant (toilet soap, etc.) thinly to the periphery of the rubber part of the seat assembly.
13-036
WATER PUMP
DISASSEMBLY AND ASSEMBLY
GENERAL ASSEMBLY (170 SERIES)
5. Shaft assembly Press fit shaft assembly (7). fl Press fit the shaft by hitting it lightly with a plastic hammer. 6. Snap ring Secure the shaft with snap ring (5). fl Check that the snap ring is fitted to the groove.
7. Impeller Press fit impeller (3) using with push tool 8. fl Press fit the impeller to the standard position. fl Replace floating seal (4).
8. Housing Fit the O-ring and secure housing (2) with mounting bolts (1). 3 Mounting bolt: See standard values and tightening torque table. fl After assembling, turn the gear with the hand to check that it rotates smoothly.
WATER PUMP
13-037
MAINTENANCE STANDARD AND 14 INSPECTION OF PARTS
Maintenance standard 95 Series .................................................. 14-002 105 Series .................................................. 14-003 110 Series .................................................. 14-005 125 Series .................................................. 14-007 140 Series .................................................. 14-008 155 Series .................................................. 14-010 170 Series .................................................. 14-011 Parts inspection and evaluation criteria ... 14-013 Reuse criteria .............................................. 14-014
WATER PUMP
14-001
MAINTENANCE STANDARD AND INSPECTION OF PARTS
95 SERIES
95 SERIES 3 (4) D95S, (SA) 4D95L, (SA) 6D95L
Unit: mm
No.
Check item
Criteria
1
Clearance between impeller and body
Standard clearance: 0.30 – 1.00
2
Interference between shaft and fan pulley boss
Basic dimension
Remedy
Allowance
Standard interference
Shaft
Hole
15.9
+0.020 +0.005
– 0.045 – 0.065
0.050 – 0.080
3
Interference between shaft and body
35
0 – 0.015
– 0.025 – 0.050
0.010 – 0.050
4
Interference between shaft and impeller
12
0 – 0.015
– 0.045 – 0.070
0.030 – 0.070
5
Bend of shaft
6
Wear of seal ring of water seal
Allowable limit: Facial runout of face A: 0.1
Allowable limit: Dimension A: 0
Thermostat
• Valve opening temperature (Opening fully: Valve must open : 76 ± 1.5˚C fully when heated to 95˚C and then submerged in water at 71˚C for 4 – 5 minutes.) • Fully opening temperature : 90˚C • Fully opening lift: Min. 8 (When submerged in water at 90˚C)
Thermostat (For generators) (For ships)
• Valve opening temperature (Opening fully: Valve must open : 82 ± 2˚C fully when heated to 95˚C and then submerged in water at 77˚C for 4 – 5 minutes.) • Fully opening temperature : 95˚C • Fully opening lift: Min. 8 (When submerged in water at 95˚C)
Replace
7
14-002
WATER PUMP
105-5 SERIES
MAINTENANCE STANDARD AND INSPECTION OF PARTS
105-5 SERIES (S) 4D105-5 (FOR CONSTRUCTION MACHINERY AND GENERATORS)
Unit: mm
No.
1
Check item
Inside diameter of impeller and outside diameter of shaft
2
Clearance between impeller and body
3
Wear of seal ring of water seal
4
Bend of shaft
Full opening lift of thermostat 5 Function of thermostat
WATER PUMP
Criteria Standard dimension 15.9
Remedy
Outside diam- Inside diameter eter of shaft of impeller +0.020 +0.005
– 0.020 – 0.050
Standard interference 0.025 – 0.070
Standard clearance: 0.1 – 0.63 (Including end play)
Allowable limit of dimension A: 0
(Total runout of indicator: Prescribed Allowable limit: 0.1 mm by facial runout of fan pulley at radius of 40 mm) For construction machinery
Min. 10: Check by submerging in water at 90˚C for 4 – 5 minutes.
For generators
Min. 10: Check by submerging in water at 95˚C for 4 – 5 minutes.
For construction machinery For generators
Replace Replace impeller usually (Outside diameter of shaft changes little)
Replace
Valve must close fully when heated to fully opening temperature of 90˚C and then submerged in water at fully closing temperature of 71˚C for 4 – 5 minutes. Valve must close fully when heated to fully opening temperature of 95˚C and then submerged in water at fully closing temperature of 77˚C for 4 – 5 minutes.
14-003
105-5 SERIES
MAINTENANCE STANDARD AND INSPECTION OF PARTS
(S) 4D105-5 (FOR SHIPS)
Unit: mm
No.
1
Check item
Inside diameter of impeller and outside diameter of shaft
2
Clearance between impeller and body
3
Wear of seal ring of water seal
Criteria Standard dimension 15.9
Remedy
Outside diam- Inside diameter eter of shaft of impeller +0.020 +0.005
– 0.020 – 0.050
Standard interference 0.025 – 0.070
Replace Replace impeller usually (Outside diameter of shaft changes little)
Standard clearance: 0.1 – 0.63 (Including end play)
Allowable limit of dimension A: 0 Replace
4
Bend of shaft
(Total runout of indicator: Prescribed by faAllowable limit: 0.1 cial runout of fan pulley at radius of 40 mm)
Full opening lift of thermostat
Min. 10: Check by submerging in water at 95˚C for 4 – 5 minutes.
Function of thermostat
Valve must close fully when heated to fully opening temperature of 95˚C and then submerged in water at fully closing temperature of 77˚C for 4 – 5 minutes.
5
14-004
WATER PUMP
110 SERIES
MAINTENANCE STANDARD AND INSPECTION OF PARTS
110 SERIES S(SA) 6D110-1 (FOR CONSTRUCTION MACHINERY AND GENERATORS)
Unit: mm
No.
1
Check item
Inside diameter of impeller and outside diameter of shaft
2
Clearance between impeller and body
3
Wear of seal ring of water seal
4
Bend of shaft
Full opening lift of thermostat 5 Operation of thermostat
WATER PUMP
Criteria Standard dimension 15.9
Remedy
Outside diam- Inside diameter eter of shaft of impeller +0.020 +0.005
– 0.020 – 0.050
Standard interference 0.025 – 0.070
Replace Replace impeller usually (Outside diameter of shaft changes little)
Standard clearance: 0.2 – 0.6
Allowable limit of dimension A: 0
Allowable limit: 0.1 (Total runout of indicator: Prescribed by facial runout of fan pulley at radius of 40 mm) Replace
For construction machinery
Min. 10: Check by submerging in water at 90˚C for 4 – 5 minutes.
For generators
Min. 10: Check by submerging in water at 95˚C for 4 – 5 minutes.
For construction machinery For generators
Valve must close fully when heated to fully opening temperature of 90˚C and then submerged in water at fully closing temperature of 71˚C for 4 – 5 minutes. Valve must close fully when heated to fully opening temperature of 95˚C and then submerged in water at fully closing temperature of 76˚C for 4 – 5 minutes.
14-005
MAINTENANCE STANDARD AND INSPECTION OF PARTS
110 SERIES
S(SA) 6D110-1 SERIES (FOR SHIPS)
Unit: mm
No.
1
Check item
Inside diameter of impeller and outside diameter of shaft
2
Clearance between impeller and body
3
Wear of seal ring of water seal
Criteria Standard dimension 15.9
Remedy
Outside diam- Inside diameter eter of shaft of impeller +0.020 +0.005
– 0.020 – 0.050
Standard interference 0.025 – 0.070
Replace impeller Usually (Outside diameter of shaft changes little)
Standard clearance: 0.3 – 0.6
Allowable limit of dimension A: 0 Replace
4
Bend of shaft
(Total runout of indicator: Prescribed by faAllowable limit: 0.1 cial runout of fan pulley at radius of 40 mm)
Full opening lift of thermostat
Allowable range: Min. 10 (Check by submerging in water at 95˚C for 4 – 5 minutes.)
Operation of thermostat
Valve must close fully when heated to fully opening temperature of 95˚C and then submerged in water at fully closing temperature of 76˚C for 4 – 5 minutes.
14-006
WATER PUMP
125 SERIES
MAINTENANCE STANDARD AND INSPECTION OF PARTS
125 SERIES (S) 6D125-1 SERIES
Unit: mm
No.
1
Check item
Interference between impeller and shaft
2
Interference between drive gear and shaft
3
Clearance between impeller and body
4
Wear of seal ring of water seal
Criteria
Remedy
Allowance
Basic dimension
Shaft
Hole
Standard interference
15.9
+0.020 +0.005
– 0.020 – 0.050
0.025 – 0.070
20.0
+0.015 0
– 0.025 – 0.055
0.025 – 0.070
Replace Replace impeller usually (Outside diameter of shaft changes little) Replace (Replace gear usually)
Standard clearance: 0.31 – 1.10 (Including end play)
Replace
WATER PUMP
Allowable limit: Dimension A: 1.5
14-007
140 SERIES
MAINTENANCE STANDARD AND INSPECTION OF PARTS
140 SERIES SA6D140-1 (HD325-5)
Unit: mm
No.
1
Check item
Interference between impeller and shaft
Criteria
Remedy
Allowance
Basic dimension
Shaft
Hole
Standard interference
16
– 0.082 – 0.095
– 0.120 – 0.150
0.025 – 0.068
2
Interference between drive gear and shaft
28
+0.015 +0.002
– 0.023 – 0.053
0.025 – 0.068
3
Interference between flange and shaft
25
+0.015 +0.002
– 0.021 – 0.041
0.023 – 0.056
4
Clearance between impeller and body
Replace Replace impeller usually (Outside diameter of shaft changes little) Replace (Replace gear usually)
Standard clearance: 0.6 – 0.9 (Including end play) Replace
5
Wear of seal ring of water seal
14-008
Allowable limit of dimension A: 1.5
WATER PUMP
140 SERIES
MAINTENANCE STANDARD AND INSPECTION OF PARTS
SA12V140-1 SERIES
Unit: mm
No.
1
Check item
Interference between impeller and shaft
2
Interference between drive gear and shaft
3
Clearance between impeller and body
4
Wear of seal ring of water seal
Criteria
Remedy
Allowance
Basic dimension
Shaft
Hole
Standard interference
19.0
+0.018 +0.006
– 0.025 – 0.050
0.031 – 0.068
30.0
+0.015 +0.002
– 0.018 – 0.045
0.020 – 0.060
Replace Replace impeller usually (Outside diameter of shaft changes little) Replace (Replace gear usually)
Standard clearance: 0.25 – 1.02 (Including end play)
Replace
WATER PUMP
Allowable limit of dimension A: 1.5
14-009
155-4 SERIES
MAINTENANCE STANDARD AND INSPECTION OF PARTS
155-4 SERIES S4D155-4, S(A) 6D155-4 SERIES
Unit: mm
No.
Check item
1
Interference between impeller and shaft (Excluding tapered shaft)
2
Clearance between impeller and connection
3
Tightening torque of impeller locknut
4
Tightening torque of bearing locknut
14-010
Criteria Allowance
Basic dimension 15.85
Remedy
Shaft
Hole
Standard interference
+0.070 +0.055
+0.030 0
0.025 – 0.075
Standard clearance
Allowable clearance
0.62 – 1.70
—
Target (Nm {kgm})
Range (Nm {kgm})
76.0 {7.75}
73.6 – 78.5 {7.5 – 8}
196.0 {20}
166.7 – 225.6 {17 – 23}
Replace
Retighten
WATER PUMP
170 SERIES
MAINTENANCE STANDARD AND INSPECTION OF PARTS
170 SERIES S(A) 6D170 SERIES
Unit: mm
No.
1
Check item
Interference between front shaft and bearing
Criteria
Remedy
Allowance
Basic dimension
Shaft
Hole
Standard interference
30
+0.015 0
0 – 0.010
0 – 0.025
2
Interference between rear shaft and bearing
25
+0.010 0
0 – 0.010
0 – 0.020
3
Interference between rear shaft and impeller
19.9
+0.020 +0.005
– 0.025 – 0.05
0.030 – 0.070
4
Clearance between impeller and connection
WATER PUMP
Standard clearance
Allowable clearance
0.23 – 0.66
—
Replace
14-011
MAINTENANCE STANDARD AND INSPECTION OF PARTS
170 SERIES
SA 8V170-1, 12V170-1 SERIES
Unit: mm
No.
1
Check item
Interference between front shaft and bearing
Criteria
Remedy
Allowance
Basic dimension
Shaft
Hole
Standard interference
45
+0.018 +0.002
0 – 0.012
0.002 – 0.030
2
Interference between rear shaft and bearing
35
+0.018 +0.002
0 – 0.012
0.002 – 0.030
3
Interference between rear shaft and impeller
25
+0.054 +0.041
+0.009 – 0.016
0.032 – 0.070
4
Clearance between impeller and connection
14-012
Standard clearance
Allowable clearance
0.43 – 1.41
—
Replace
WATER PUMP
PARTS INSPECTION AND EVALUATION CRITERIA
MAINTENANCE STANDARD AND INSPECTION OF PARTS
PARTS INSPECTION AND EVALUATION CRITERIA •
Handle the removed parts carefully not to damage them. Clean them in diesel fuel oil, then dry them by blowing compressed air against them. In particular, check the following points visually. Part
Checkpoints
Shaft
• •
Damage and wear of shaft Bend of shaft
Ball bearing
• •
Damage and wear of inside and outside surfaces Rusting
Impeller
• •
Damage and wear of inside surfaces Wear of surfaces
Drive gear
• •
Damage and wear of gear Damage and wear of inside surface of gear
Bearing housing
• •
Damage and wear of inside surfaces Wear of surfaces
Snap ring
• •
Lowering of tension Bend and deformation
Cover
•
Corrosion and bend
Body
• • •
Damage and wear of inside surfaces Damage and distortion of threads Cracking of corrosion of whole body
fl Replace the oil seal and water seal with new ones.
WATER PUMP
14-013
MAINTENANCE STANDARD AND INSPECTION OF PARTS
REUSE CRITERIA
Part name
REUSE CRITERIA Division of reuse criteria Damaged portion A: Reusable
C: Not reusable
1
Seal contact surface
Damage which can be reFlaw which is not caught moved easily with sand- Damage other than A and B, stepped-type wear on nail, slight wear paper
2
Impeller fitting part
No scuff mark and flaw
1
Flaking of inside and No flaking outside surface, gloss
2
Rust on outside which Inside and outside of Balls and races are not can be removed easily Rusted, rotation is not smooth rusted bearing with sandpaper
3
Abnormal sound
No abnormal sound
—
Abnormal sound is generated
1
Blade tip
Slight bend of tip
—
Clear bend
2
Cracking, damage of No cracking and damage blade
—
Cracked, damaged
3
Contact mark which can Damage other than A and Contact portion of Slight contact mark at tip be removed easily with B blade and body sandpaper
1
Flaw which can be reDamage, wear other than Flaking, flaw, wear of Flaw which is caught on moved easily with oilA and B nail, slight wear tooth surface stone
2
Wear, flaw, seizure of Very slight scratch bearing part
—
Flaw which is caught on nail
1
Flaking of inside and No flaking and abnormal outside surface, gloss, sound abnormal sound
—
Turning resistance is heavy, abnormal sound is generated
2
Rust on outside which Rusted, rotation is not Inside and outside of Balls and races are not can be removed easily smooth rusted bearing with sandpaper
3
Threads of housing
No damaged or crushed Slight bruise or flaw of Damage or crush other threads than B threads
1
Tension
There is tension
—
Broken or cracked
2
Deformation bend
No deformation and bend
—
Deformed or cracked
Shaft Bearing Impeller Drive gear Bearing housing Snap ring
B: Reusable after repair
14-014
and
—
Impeller turns and has flaw or scuff mark on its surface
—
Heavy turning resistance
WATER PUMP
REUSE CRITERIA
Division of reuse criteria Damaged portion A: Reusable
B: Reusable after repair
C: Not reusable
1
Crush and wear of threads
No damaged or crushed Slight bruise or flaw of Damage or crush other than B threads threads
2
Damage and cracking of cover
No cracking
3
Corrosion and oxidation of inside surface
Combination of cracking No corrosion and oxida- Corrosion which can be and corrosion, oxide film tion removed which cannot be removed
1
Inside of body
Light contact mark which does not cover all inside Other than A and C surface
2
Crush and wear of threads
No damaged or crushed Slight bruise or flaw of Damage or crush other threads threads than B
3
Corrosion and oxidation of inside surface
Combination of cracking No corrosion and oxida- Corrosion which can be and corrosion, oxide film tion removed which cannot be removed
4
Damage and cracking of body
No cracking
Body
Cover
Part name
MAINTENANCE STANDARD AND INSPECTION OF PARTS
WATER PUMP
Flaw which can be removed easily with oil- Damage other than B stone
Flaw which covers all inside surface
Flaw which can be removed easily with oil- Damage other than B stone
14-015
TURBOCHARGER TURBOCHARGER MODEL KTR100 KTR110 KTR130 KTR150
©2001 All Rights Reserved Printed in Japan 02-01(02)
00-001 1
CONTENTS
00
INTRODUCTION
01
GENERAL ........................................................................................................ 01-001
11
STRUCTURE AND FUNCTION
13
DISASSEMBLY AND ASSEMBLY ................................................. 13-001
14
MAINTENANCE STANDARD AND INSPECTION OF PARTS ................................................................... 14-001
00-002 1
........................................................................................ 00-011
....................................................... 11-001
TURBOCHARGER
The affected pages are indicated by the use of the Revision Revision Mark Page Page that necessary Mark acPage following marks. It is Mark requested number number tions be taken to these pages according to the table below.
Revision Mark number
(
Mark
Revision Indication Page number
Revision Action required Page
Mark
number
c
Page to be newly added
Add
b
Page to be replaced
Replace
Page to be deleted
Discard
)
Pages having no marks are those previously revised or made aditions.
LIST OF REVISED PAGES Mark
b b c
Page
00-001 00-002 00-003 00-011
Revision number
Mark
Page
Revision number
Mark
Page
Revision number
Mark
Page
Revision number
Mark
Page
Revision number
1 1 1
01-001 01-002 11-001 11-002 11-003 11-004 11-005 11-006
b b b b b b b b b
13-001 13-002 13-004 13-005 13-006 13-007 13-008 13-009 13-010 13-011 13-012 (13-013)
1 1 1 1 1 1 1 1 1
14-001 14-002 14-003 14-004 14-005 14-006 14-007 14-008 14-009
TURBOCHARGER
00-003 1
5 d
0
0
c3
KTURBO
2 ?
Q
0
3
2 0
It) Z
n Z
a
... .. .. .. ..
... . .. .. ....
GENERAL
STRUCTURE
KTRI 00
1. Flinger 2. Bearing cover 3. Journal bearing 4. Center housing 5. Ring seal 6. Shield 7. Turbine housing 8. Turbine impeller (Rotor shaft) 9. Thrust bearing 10. Insert 1 1. Ring seal 12. 13. 14. a. b. c. d. e. f.
Blower impeller Blower housing Rock nut Oil inlet (from oil filter) Oil outlet (to oil pan) Air inlet Air outlet Exhaust inlet Exhaust outlet
11 FOO9A
KTRl IO
1. Blower housing 2. Blower impeller 3. Clamp 4. Center housing 5. Journal bearing 6. shield 7. Turbine impeller 8. Flinger 9. Thrust bearing 10. Turbine shaft 11. 12. a. b.
61 62F609A
1 l-002
Ring seal Turbine housing Oil inlet (from oil filter)
Oil outlet (to oil pan) Air inlet :: Air outlet e. Exhaust inlet f. Exhaust outlet
KTRI 30 1
3
2
4
5
3
6
7
6 1. Blower housing
2. 3. 4. 5. 6. 7. 8. 9. IO.
Blower impeller Clamp Center housing Journal bearing Shield Turbine impeller Turbine housing Flinger Insert
11. Thrust bearing 12. Turbine shaft a. Oil inlet (from oil filter) b. Oil outlet (to oil pan) Air Jn!e? Z: Air outlet Exhaust inlet Y. Exhaust outlet
e 6 162F610
KTRI 50
1. Blower housing 2. Blower impeller 3. 4. 5. 6. 7. 8. 9. 10. a. b. c. d.
Clamp Center Journal Turbine Turbine
housing bearing impeller housing
Flinger Thrust bearing Turbine shaft Oil inlet (from oil filter) Oil outlet (to oil pan) Air inlet Air outlet
e. Exhaust inlet f. Exhaust outlet
8
!i F6166009
1 l-003
3L
CD = CD
-0
3
-*
2
5
2 c) +
2
D
m
113
Structure * The turbocharger
has a turbine
impeller
which
rotates
under high-temperature,
high-pressure
ex-
haust gases. Then, the blower impeller installed on the same shaft with the turbine impeller is rotated, thereby compressing
and supercharging
the intake air with the engine. A shaft connecting
the turbine
impeller to the blower impeller is normally intergrated with the turbine impeller. A blower impeller is fixed with nuts to the tip of a shaft on the opposite side of the turbine impeller. * ,The impeller shaft rotates at a very high speed while subject to the thrust force of the intake air compression supported
pressure
imposed
on the inpeller
and the exhaust
pressure.
Consequently,
the shafting
is
on a floating type cylindrical journal and thrust bearings.
The center housing holds bearings, forming the circuit of oil for lubricating
bearings.
The turbine
circuit. The exhaust
housing
from the exhaust
contains
manifold
the turbine
impeller,
are led to the turbine
gases which by their expanding
forming
the exhaust
gases
impeller at high speed and pressure. Thereby,
the
action rotate the impeller at high speed are expelled from the engine
in this exhaust circuit. On the other hand, the blower housing contains a blower impeller, forming intake air is led to the biower impeiier and compressed by the rotating pressed air is superchanrged
the air intake circuit. The I !tCslli this comImpeller. Than
into the engine.
Lubrication of turbocharger Oil is supplied fron the engine through the top of the center housing. After lubricating the bearings and sliding parts, the oil drains through the hole at the bottom of the center housing and returns to the engine oil pan. Notes l
l
Rotating speed (revolutions) of turbochargers 50,000 to 125,000 rpm (continuous allowable rotating speed) Allowable revolutions vary deprending on the size of the impeller. Engine exhaust temperature: 500 to 700°C (turbine impeller inlet temperature
in full-load
operation)
1 l-005
Function In a diesel engine, the energy of fuels burnt in cylinders
is in the ratios indicated at right.
The effective approx.
l/3
energy as shaft horsepower
of the fuel energy. The remainder
is is
expelled from the engine. A turbocharger
takes the speed and pressure
energy of high speed gases from the exhaust to be expelled from the engine with the turbine impeller
as the rotating
the blower impeller
power
source.
Thereby,
on the same shaft with the
turbine impeller is rotated so that the air is compressed and supercharged
into the engine.
In order to obtain the effective
horsepower
in a diesel engine, a quantity of air approx. 17 to 22 times greater than the amount of fuel to be injected is generally required. This corresponds to 1.2 to 1.5 the excess air ratio.
Intake
Note Excess air ratio: The ratio of the quantity
of air necessary
to actually obtain optimum combustion efficiency, assuming that the theoretical quantity of air required for complete fuel combustion is 1. For combustion in a diesel engine, an excess air ratio of 1.2 to 1.5 is required because of the fuel mist-air mixture, combustion time limit, etc. If the quantity of air is less than 1.2 to 1.5 the excess air ratio, incomplete combustion will take place, resulting in black exhaust smoke and an increased heat load.
Exhaust gases
E k is
300
ln a turbocharged engine, a quantity of air corresponding to the fuel injection quantity is
i* 5 _.c
compressed and supercharged. In an engine of the same cylinder capacity, the horsepower can be increased as indicated in the graph at right. If an after-cooler is used with the turbocharger, the horsepower can be further improved.
ii ‘i5, 200 15
100
1’200
1400
1600
1800
2000
2200
Engine speed (rpm) Comparison of horsepower between turbocharged and naturally aspirated engine (NTA 855 engine).
1 l-006
gz ??
FP
.. .
..
..
.. .
..
c9c9
*.
P
00 c;
KTU R BO
n
DISASSEMBLY AND ASSEMBLY
GENERAL DISASSEMBLY
GENERAL DISASSEMBLY •
Before disassembling the turbocharger, clean its outside surface and apply match marks to ensure that the blower housing and turbine housing are reassembled in their original positions.
KTR100, KTR130
KTR110, KTR150
13-004 1
TURBOCHARGER
DISASSEMBLY AND ASSEMBLY
GENERAL DISASSEMBLY
fl Replace the entire rotor assembly, if the dynamic balance check on the rotor assembly is impracticable. fl Before disassembling the turbocharger assembly, measure the radial clearance in the following manner and keep the measurement on record. 1) Depress the front end of the rotor in the radial direction with a finger. 2) Measure the clearance between the blower impeller and the housing by using filler gauge 1.
1. Housing fl When removing the blower housing and turbine housing, take care not to damage the blower impeller and turbine impeller. •
For KTR100, KTR130 1) Remove the nut and clamp (1), (2). 2) Remove turbine housing (3) and blower housing (4).
•
For KTR110, KTR150 1) Remove the nut and V-band clamp (1). 2) Remove blower housing (2).
3) Staighten the lock washer, remove mounting bolts (3), and then remove lock plate. 4) Remove turbine housing (4).
TURBOCHARGER
13-005 1
DISASSEMBLY AND ASSEMBLY
GENERAL DISASSEMBLY
fl Before removing the blower impellers, measure the end play and the radial play of the rotor assembly in the following manner and keep the measurement on record. 1) Measurement of the end play (A play in the axial direction) i) Set dial gauge 2 in position. ii) Read the dial gauge indicator when the rotor assembly is moved in the axial direction.
2) Measurement of the radial play (A play in the radial direction) i) Set dial gauge 2 in position. ii) Read the dial gauge indicator when the rotor assembly is moved in the radial direction.
2. Blower impellers 1) Clamp the end of the turbine rotor in a vice. fl Securely clamp the turbine rotor in the vice so as to prevent it form overturning or from falling. 2) Loosen and remove nut (5).
3) Extract the bolwer impellers from the turbine rotor in the following manner. i) Immerse the rotor assembly in an oven or oil that is heated at 140 to 160˚C for 5 to 20 minutes. ii) Extract blower impellers (6) from the turbine rotor. fl When extracting the blower impeller, take care not to apply an excessive force to the impeller. fl When heating the rotor assembly in oil, make sure that the oil does not contain dirt, chips, etc.
13-006 1
TURBOCHARGER
DISASSEMBLY AND ASSEMBLY
GENERAL DISASSEMBLY
3. Insert (Back plate) • For KTR100, KTR130. 1) Straighten the lock washer and remove bolt. 2) Alternately drive two bolts into the tap holes of the insert (7) to remove it.
•
For KTR110, KTR150. 1) Straighten the lock washer and remove bolt. 2) Remove turbine rotor from the back plate (7).
4. Flinger 1) Pull out flinger (8) from the insert (back plate). 2) Remove seal ring (9) from the flinger.
5. Thrust bearing Remove thrust bearing (10). 6. Thrust collar Remove thrust collar (11).
TURBOCHARGER
13-007 1
DISASSEMBLY AND ASSEMBLY
GENERAL DISASSEMBLY
7. Center housing Pull out center housing (12) from the turbine rotor. fl Take care not to damage the journal bearing.
8. Journal bearing Remove journal bearing (13). 9. Shield Remove shield (14) from the turbine rotor.
10. Turbine rotor Remove two seal rings (16) from tturbine rotor (15).
13-008 1
TURBOCHARGER
DISASSEMBLY AND ASSEMBLY
GENERAL ASSEMBLY
GENERAL ASSEMBLY •
Before assembly parts, wash and clean the parts, allow them to dry by air blow, and apply egine oil to the sliding parts. • Remove burrs completely from the parts. (Pay attention to seal ring grooves, in particular.) fl When reassembling the rotor assembly after the dynamic balance check has been made, be sure to align all the match marks stamped on the component parts.
1. Turbine rotor Fit seal rings (16) into turbine rotor (15). fl Apply a coat of engine oil to the side of seal rings and install the seal rings in such a way that the gap of each ring is positioned at 180˚ apart from that of the neighboring ring.
2. Shield Install shield (14) into the turbine rotor.
3. Center housing Install center housing (12) on the turbine rotor. fl When installing the center housing, take care to prevent the seal ring from slipping out.
4. Journal bearing Install journal bearing (13). fl Apply sufficient amount of engine oil to the inside, outside, and both sides of the journal bearing prior to the installation.
TURBOCHARGER
13-009 1
DISASSEMBLY AND ASSEMBLY
GENERAL ASSEMBLY
5. Thrust collar 1) Install thrust collar (11). fl Make sure that the thrust collar is free from foreign matter on both sides, apply engine oil to both sides of the collar, and install the collar with the match mark aligning with the mating mark. 2) Drive a dowel pin in the center housing. 6. Thrust bearing Install thrust bearing (10) with the dowel pin fitted in position. fl Before installing the thrust bearing, apply engine oil to both sides of the oil hole. 7. Finger 1) Fit sial ring (9) into finger (8). fl Apply engine oil to the sides of the seal ring. 2) Install flinger into the insert. (back plate) fl Let the gap of the seal ring on the flinger direct to the oil filler port on the center housing.
8. Insert (Back plate) • For KTR100, KTR130. 1) Fit an O-ring and install insert (7). 2) Tighten the insert mounting bolts and then bend the lock washer.
•
For KTR110, KTR150. 1) Install the turbine rotor onto the back plate (7). 2) Tighten the back plate mounting bolts and bend the lock washer.
13-010 1
TURBOCHARGER
DISASSEMBLY AND ASSEMBLY
GENERAL ASSEMBLY
9. Blower impellers 1) Install blower impellers onto the turbine rotor in the following manner. i) Immerse blower impellers (6) in an oven or oil that is heated at 140 to 160˚C for 5 to 20 minutes. fl When heating the rotor assembly in oil, make sure that the oil does not contain dirt, chips, etc. ii) Install the blower impellers onto the turbine rotor, aligning the match mark. fl Apply engine oil to the inner face of the blower impeller and install the impeller without using an excessive force. 2) After the blower impellers are cooled, tighten nut (5). fl Tighten the nut to the specified torque, then return it by a half turn and match the match marks in the tightening direction. When tightening, take care that the “match mark” of each part will not be shifted.
fl Measure the end play and the radial play of the rotor assembly in the following manner. 1) Measurement of the end play (A play in the axial direction) i) Set dial gauge 2 in position. ii) Read the dial gauge indicator when the rotor assembly is moved in the axial direction.
2) Measurement of the radial play (A play in the radial direction) i) Set dial gauge 2 in position. ii) Read the dial gauge indicator when the rotor assembly is moved in the radial direction.
TURBOCHARGER
13-011 1
DISASSEMBLY AND ASSEMBLY
GENERAL ASSEMBLY
10. Housing fl Take care not to damage the blower impeller and turbine impeller when installing the blower housing and turbine housing. •
For KTR100, KTR130. 1) Install the blower housing (4) and turbine housing (3) into the center housing and the rotor assembly. 2) Tighten clamp (2), (1).
•
For KTR100, KTR150. 1) Install the turbine housing (4) into the center housing and the rotor assembly. 2) Install lock plate, tighten mounting bolt (3), and bend the lock washer. 3) Install blower bousing (2) aligning it with the center housing and the rotor assembly. fl Apply a thin coat of grease (G2-LI) to the flange section. 4) Tighten V-band clamp (1).
fl Measure the clearance in the radial direction in the following manner. 1) Depress the end of rotor in the radial direction with a finger. 2) Measure the clearance between the blower impeller and the housing by using filler gauge 1. fl After completing the assembly, rotate the rotor assembly while depressing it lightly and make sure that the rotor can be rotated smoothly without binding.
13-012 1
TURBOCHARGER
cl
z
a
8
II
4
TURBOCHARGER KTRI 00
14FOOlA Unit:mm Check item
No.
2
Standard
End play (play in axial
1
direction) Radial play (play in radial
I
3
I
direction) Outside
diameter
to 0.11
0.18
0.20
to 0.04
0.60 Tolerance
of journal
Standard
Hole +0.020
24
-0.040 -0.060
16
-0.030 -0.050
+0.020 0
Standard 5
0
Repair limit: 0.010 size
r
-0.17
Turbine side
2
-0.08 -0.10
6
Blower
2
-0.08 -0.10
I
Thickness
of seal ring
parts
related to thrust Replacing
I lated
Shaft
Hole
23.91
24.04
15.94
16.05
indicated
parts re-
to bearing
runout) Repair
limit Replace
Groove
Width
Groove
0
-0.08 5.5
I
(Total
Tolerance Width
of thrust bearing
Raplacing
Repair limit
Shaft
Bend of wheel shaft
Thickness
limit
size
of center housing
Inner diameter of Journal bearing Outside diameter of wheel shaft
4
Repair
0.06
bearing Inner diameter
Remedy
Criteria
1
1
-0.02 -0.03 -0.04
5.34 1.85
,
5.52
I
A
2.05
1.85
side -0.12 -0.13
4 Clearance 7 8 9 10
between
blower
housing and impeller Tightening impeller
torque
Tightening
of V band
14-002
Replace parts Tolerance:
4.25 of insert
torque
4.05
(min.) 0.15
related to bearing
of blower
locknut
Tightening torque mounting bolt
locknut
,
kO.25
1.25 & 0.25
0.9 kO.1
kgm kgm
kgm
Tighten
-
E
2
-._ .k
x ii -
s ?’
co--
I I
Or dC
KTRI 30 6
9
8
5
2
10
4
3
6162F402
6162F401
Unit:
Check item
NO.
I I
Criteria
Standard
End play (play in axial
Repair
Remedy Rapiace parts
limit
related-to
direction)
0.08
to 0.13
0.18
thrust
0.25
to 0.43
0.60
Raplace parts related to bearing
Radial play (play in radial direction)
I
I Tolerance
Standard Outside diameter of journal bearing. Inner diameter of center housing.
mm
,
.Shaft
30
Inner diameter of journal bearing. Outside diameter of wheel shaft.
1
Bend of wheel shaft
I
Repair
limit
size 1
Xo!e
-0.060 -0.080
2.
1
--;:;;;
Shaft
+0.020 0
/
Xo!e
29.89
+;*‘15
/
1
30.04
19.95
/
20.05
1
4 Repair limit: 0.010
(Total
indicated
runout)
Tolerance Standard Thickness
Thickness
7
Clearance between blower housing and impeller Tightening torque impeller locknut
of blower
8
Tightening
of insert
10
mounting Tightening locknut
14-004
Repair limit Groove
Width
Groove
of thrust bearing
6
9
Replace
size Width
5
I
of seal ring
torque
-0.08 -0.11
+0.02 0
5.86
6.04
3
-0.08 -0.10
-0.03 -0.04
2.85
3.05
Tolerance:
(min.) 0.20
8.5 kO.5
1.35 kO.15
bolt torque
6
kgm
kgm
of V band I
0.9 fO.l
Replace parts related to bearing
kgm
Tighten
KTRI 50
7-
F6166056 Unit: No
Check item
Remedy
Criteria Standard
1
Repair
End play (play in axial direction)
Raplace parts
limit
0.08 to 0.13
0.18
0.25 to 0.43
0.60
I
Tolerance Outside diameter
of journal
Standard
of center 30
housing.
Inner diameter
of journal
Outside diameter
Shaft
Hole
-0.060
+0.020
-0.080
20
Shaft
0
bearing.
of wheel shaft.
limit
size
bearing. Inner diameter
Repair
related to thrust Raplace parts related to bearing
Radial play (Play in axial direction)
mm
29.89
30.04
19.95
20.05
+0.015
-0.030 -0.045
Hole
0
4 Bend of wheel shaft
Repair
limit: 0.010
(Total
indicated
runout)
Tolerance Standard 5
6
Thickness
Thickness
of seal ring
Clearance
between
9 IO
Tightening impeller
torque
Groove
6
-0.08 -0.11
+0.02 0
3
-0.08 -0.10
Width
Groove
5.86
6.04
2.85
3.05
Tightening
of turbine
housing bolt torque
-0.04
Tolerance:
(min.)
9.5 f0.5 of insert
torque
-0.03
0.20
Replace parts related to
I
of blower
Tightening torque mounting bolt
locknut
Width
blower
locknut
Tightening
limit
size
of thrust bearing
housing and impeller 8
Repair
Replace
kgm
6.75
kO.75
kgm
5.75
kO.25
kgm
Tighten
of V band 0.9 kO.1
kgm
14-005
Inspection l
of parts and judgement
In order to make correct diagnoses special attention to the following
Check
Part Blower
housing
l
Contact
standards
of faulty parts, first clean the parts, then inspect them, paying
check points.
points
with
Check points
Part
Blower
blower
impeller
0
l
Damage the
l
or deformation
surface
center
Damage
or bending
of the
with
housing
blade
impeller fitted
l
of
with
the
or failure
at
Contact
blower
housing
Deformation
Journal
joints
bearing
l Scuffing
and seizure
l Wear Center
housing
0
Failure
or wear
at
seal
bore 0
Scratches
0
Deformation
at
bearing or
bore
failure
Thrust
bearing
at
@ Wear and cracks
joints
Turbine
housing
l
Contact
l
Corrosion
with
turbine
rotor
Shield
of the inner surfact l Wear and cracks
Turbine
shaft
l
Damage ring
or wear of the seal
portion
of
the
l Wear, discoloration seizure of the journal
shaft and portion
Flinger and thrust
B For criteria
14-006
with the back plate
Bend of the shaft
about wear and bending,
@ Discoloration @ Wear of the surface in contac
of the shaft l
collar
refer to the Maintenance
standard
Standards for Reuse of Parts l
Use the photographs
in the shop manual (SEBG4080)
as reference when making judgement.
Failure Location
Part name
or type
Use after Use again
of failure Inner surface of
Light contact
1 blower housing
extending entire
.-F : r
Surface 2
fitted
to the
center housing.
flaw not
over the
inner surface.
No damage
Connections 3
parts.
No deformation
Flaws other than use
Flaw extending
again and do not use
the entire surface.
again, The contacting
or
deformation.
at air
inlet and outlet
Do not use again
reconditioning
G 2 m
degree
or
cracks.
There
is clearance
with
has a flaw but does not
the center
allow air to leak.
caused by deformation.
housing
Minor
deformation
More faulty
which
does not allow
than in use after re-
air to leak. No scratches.
surface
over
inner
Very
thin wear.
condition
conditioning. Large scratches. Wear.
Corrosion
or oxidation
of the inner surface.
oxidized
surface. removable
inlet flange
oxide film.
is less
than 0.3 mm.
14-007
Failure degree Location
Part name
or type
of failure
Use again
Use after reconditioning
1
Bending, deformation of the blade.
There is a slight bend but no cracks at the tip.
Cracks, lack of metal at the tip, easily observable bend.
Trace of slight contact is on the whole surface of the blade. However, there are no burrs.
Burrs or deformation.
2
Flaw due to contact between blade and housing.
Seal ring groove.
No wear or damage.
Deformation to the point that the seal ring is stuck.
No discoloration.
4
Journal iscolored) (d
Discolored surface can be easily removed with No. 400 to No. 600 sandpaper.
Discoloration other than use after reconditioning.
5
Journal (flaws)
Scratches not detectable by fingernail.
One or two flaws which catch on nails (Such flaws need not be repaired.)
Flaws other than use after reconditioning.
6
Journa!
No seizure.
No seizure.
Seized bearing metal.
3
c -!! : ._ + 5
(seizure)
O.Olmm or less T.I.R. (Total indicated runout)
Exceeding T.I.R.
Surface of fitted portion of a blower impeller.
No scuffing or flaw.
The surface has a flaw or scuffed area due to the turned impeller,
o Shaft back surface. ;’ ’
No trace of contact.
B
There is evidence of
’ contact. Slight bending of the tip.
Marked bending of the tip.
2
Cracks or damage of the blade.
No cracks or damage.
Cracks or damage.
3
Contact between and housing.
There is a trace of slight contact.
blade
I 41 Con +rrc.+ *;+L. LabLIv-vt u, +Lhe back
14-008
mm
Bend of the blade tip.
1
g ._ & 3 _o m
0.01
Bend of the shaft. 7
& =
Do not use again
’ No contact.
There is contact that can be easily removed with sandpaper.
’ Ns contact.
Contact other than use again and use after reconditioning. Contact.
plate. Damage of the contact surface with nut.
No damage.
No damage.
Damage.
5
6
Damage of inner surface of shaft hole.
No damage.
No damage.
Damage.
Flaw on the contact surface with thrust collar.
No flaw.
No flaw.
Flaw.
7
??
.-c
5
I
I
Gupaq pulnor
I
I
©2001 All Rights Reserved Printed in Japan 02-01(02)
00-001 2
CONTENTS
01
GENERAL ........................................................................................................ 01-001
11
STRUCTURE AND FUNCTION
12
TESTING AND ADJUSTING ............................................................ 12-001
13
DISASSEMBLY AND ASSEMBLY ................................................. 13-001
14
MAINTENANCE STANDARD AND INSPECTION OF PARTS ................................................................... 14-001
00-002 2
....................................................... 11-001
AIR COMPRESSOR
The affected pages are indicated by the use of the Revision Revision Mark Page Page that necessary Mark acPage following marks. It is Mark requested number number tions be taken to these pages according to the table below.
Revision Mark number
(
Mark
Revision Indication Page number
Revision Action required Page
Mark
number
c
Page to be newly added
Add
b
Page to be replaced
Replace
Page to be deleted
Discard
)
Pages having no marks are those previously revised or made aditions.
LIST OF REVISED PAGES Mark
b b b
Page
Revision number
00-001 00-002 00-003
2 2 2
01-001 01-002 01-003 01-004 01-005 01-006 01-007
1 1 1 1 1 1
Mark
b b b
11-001 11-002 11-003 11-004 11-005 11-006 11-007 11-008 11-009 11-010 11-011 11-012
1
b
Page
Revision number
13-014 13-015 13-016 13-017 13-018 13-019 13-020 13-021
1 1 1 1 1 1 1 1
14-001 14-002 14-003 14-004 14-005 14-006 14-007 14-008 14-009
2 2 2 2 1 1 1 1 1
Mark
Page
Revision number
Mark
Page
Revision number
Mark
Page
Revision number
1 1 1 1 1
12-001 12-002
1
13-001 13-002 13-003 13-004 13-005 13-006 13-007 13-008 13-009 13-010 13-011 13-012 13-013
1 1 1 1 1 1 1 1 1 1 1 1 1
AIR COMPRESSOR
00-003 2
. .
.
003kllV
SPECIFICATIONS
Assembly
Manufacturer’s
Engine
6206-91-I 100
part number
part number
DK408717-0300
model
(S)6D95L-
1
Water cooled - single cylinder - double acting
DK408717-0251
DK408717-0271 S(A)GDl 1 O-l
S6D105-1
Water cooled - single cylrnder - double acting
70 x 40
70 x 40
70 x 40
8.5
8.5
8.5
1,200
1,250
1,100
250 (rpm)
38.5
38.5
38.5
500 (rpm)
77
77
77
600 (rpm)
92.4
92.4
92.4
800 (rpm)
123.2
123.2
123.2
bore X stroke
Normal
max. pressure
Normal
max. speed
Discharge (Urnin)
6138-81-3111
Water cooled - single cylinder - double acting
Type Cylinder
6136-81-3112
(mm) (kg/cm2)
(rpm)
8
I
/
1,000 (rpm)
154
154
154
1,500 0-p-d
231
231
231
-
-
2,000
(rpm)
6D95L- 1 l PWI 50-I
S6D105-1 l LWI 60-I
S6Dll l
:: 3
O-l
WA350-1
#50001S6D95L-
1
SAGDI IO-I
. PWIOO-3 Application
(Note)
Normal
w-002 0
l
WA380-1
l
WA400-
l
WA420-1
models
max. speed and discharge
speed are shown
in air compressor
speed.
1
m ti
In
ai
8 ;;_
0 ;;;
0 Lo
‘c .
8 -
Y
-_
;T;;
0
Al RCOO
CD
B
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Assembly
part number
Manufacturer’s
Engine
part number
model
I
Type Cylinder
bore X stroke
Normal
max. pressure
Normal
max. speed
!mm)
I I
(kg/cm2)
(rpm)
6162-83-6700
6162-83-6800
DK408738-5102
DK408738-5280
S6DI 70 Water cooled - single cylinder - double acting
Water cooled - single cylinder - double acting
85 X 60
85 X 60
8.5
8.5
I ,700 I
250 (rpm)
500 (f-pm)
r---Gz-
170
170
204
204
276
340
1,500 (rpm)
510
2,000
680
(rpm)
PC I 000
Application
models
WD600
Assembly
part number
Manufacturer’s
Engine
6165-91-l
part number
DK408728-5085 SA8V170-1 SA12V170-1
model
6165-91-1004
6165-91-I
DK408728-5092 DK408728-5093 DK408728-5094
005
DK408728-5100
SA8V170-1 SAI 2V170-1
SA8V170- 1 SAI 2V170-1
Water cooled - two cylinder - double actins
Water cooled - two cylinder - double acting
Water cooled - two cylinder - double acting
2 - 85 X 60
2 - 85 X 60
2 - 85 X 60
8.5
8.5
8.5
2,100
2,100
2,100
250 (rpm)
-
-
-
500 (rpm)
340
340
340
600 (rpm)
408
408
408
800 (rpm)
544
544
544
1,000 (rpm)
680
680
680
1,500 (rpm)
1,020
1,020
1,020
2,000
1,360
1,360
1,360
Type Cylinder
001
bore X stroke
Normal
max. pressure
Normal
max. speed
Discharge (Urnin)
(mm) (kg/cm*)
(rpm)
r
1
(rpm)
SA8V170l
1
10246-I l
Application
!?lC!Ck?iS
SA8V170-1 l WA800-1
WA800-1 (Application Serial No. 0292)
l
0230)
SA12V170-1 l HD1200-1 (Application Serial No. 10004-10009)
01-006
0
0 HD785
(Application Serial No.
HD785-2 (Application Seriai No. 10182-I
SA8V170-1
10294HD785-2
. WA800-1
)
(Application Serial No. 10231-J SA12V170-1 l HDI 200-I (Application Serial No. lOOlO-)
SAI 2V170-1 l
HD1200-1
I
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6210-81-3121
1. 2. 3. 4. 5. 6.
Cylinder head Piston Piston ring Piston pin Connecting rod Cylinder
1 l-004
7. 8. 9. 10. 11. 12.
Crankcase Roller bearing Crankshaft Flange Ball bearing Cover
a. b. c. d.
Air intake Cooling water inlet Cooling water outlet Lube oil inlet
003u IV
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Al RCOO
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AIRCOO
STRUCTURAL FEATURES OF AIR COMPRESSORS
connection part number
Separ- Integrat- Split Injection Feed ate type ed type bearing pump pump
1d”
\
I
6215-81-3201
I
e
I
I
0
I
0
I
Crankshaft bearing support Ball Roller bearing bearing
E%Y:’
1
*: One sliding bearing
2. Cylinder l
The
bottom
crackcase bolts.
of cylinder
(7)
mates
(12), and is installed
with
with
5. Piston * Two piston
four
3. Crankcase l
Crankcase (12) has holes in the side surface for installing the compressor, and has mounting holes for the oil supply joint. It has an overflow to allow any excess oil to flow to the engine crankcase. The face with the holes is put against the appropriate face of the timing gear case when installing the compressor.
6. Connecting l
4. Crankshaft l
Crankshaft (2) forms one piece with the balance weight. It is supported by two bearings (I), and at one end it is connected by taper shaft to the gear. Depending on the model, it is connected to the injection pump or feed pump. * 6165-91-1005 This is supported by one ball bearing and one sliding bearing: one end is connected by a taper shaft to the gear, and the other end is connected to the feed Pump.
rings (6) are installed
to the
top of piston (4), and one oil ring (5) is installed to he bottom. To allow for heat expansion when the piston is operating, the outside diameter at the top is smaller than at the bottom, or it forms an oval shape. rod
There are two types of big end for connecting rod (3): a separate type and an integrated type. Adjustment of tightening cannot be carried out using shims, so if there is wear, the connecting rod must be replaced. When assembling the separate type, the match mark is given as a line on the side face. * A steel bushing is used for the small end of 6165-91-I 005.
7. Lubrication Engine oil is used as the lubricant. The oil force-fed from the engine to the oil suplly joint in the side face of the crankcase is splashed up by the balance weight of the crankshaft and the big end of the connecting rod, and flows out through the overflow hole at the engine end. l
1 l-009 co
FUNCTION This
equipment
and is directly
is driven connected
by the
engine
to the engine,
air compressor is always engine is rotating.
rotating
gear, so the
when
the
l
When below
the air pressure the specified
governor,
the rod of unloader
to its original its normal
The
inlet
matically
valve
and delivery
opened
and closed
valve
are auto-
by the pressure
to discharge
and delivery
the compressed
On the down-stroke, and the inlet
valve
*
compressed. * 621 O-81 -3121, 6162-83-6700, 6165-91-I 001 When the air pressure inside the air tank reaches the specified pressure, the compressed air inside the tank passes through the air governor, and pushes down the rod of unloader valve (9) to block the intake hole. As a result, while the unloader valve is being actuated, no air is taken in, and no compressed air is discharged. 6165-91-I 004, 6215-81-3101, 6165-91-I 005, 6215-81-3201 When the air pressure inside the air tank reaches the specified pressure, the compressed air inside the tank passes through the air governor, pushes down the rod of the unloader valve, and opens the inlet valve. At the same time, it pushes down the valve of the exhaust valve, and opens the discharge side.
11-010 0
the air pressure
returns
valve closes,
hole
to suck in air from
There is an air governor to control the amount of air inside the air tank. When the air pressure inside the air tank reaches the specifierd pressure, the compressed air inside the tank passes through the air governor, pushes down the rod of unloader valve (9), and opens inlet valve (10). As a result, while the unloader valve is being actuated, the intake air is not
again,
valve (9) returns valve
(10) starts
and air is force-
6165-91-I 001, 6162-83-6700, 621 O-81 -3121 When
air.
the air cleaner.
operation
inlet
inside
the air tank
goes below the specified pressure of the air governor, the rod of unloader valve (9)
valve (11) opens
the delivery opens
position,
fed again.
inside the cylinder. On the piston up-stroke, the air inside the cylinder is compressed, inlet valve (10) closes,
inside the air tank goes pressure of the air
*
to its original
is opened,
position,
the
and air is force-fed
intake again.
6165-91-1004,6215-81-3101, 6165-91-1005,6215-81-3201 When the air pressure inside
the air tank
goes below the specified pressure of the air governor, unloader valve (9) and the exhaust valve return to their original position, and air is force-fed again.
Operation 0
of unloader
valve
6151-81-3110
Air pressure from aIt- governor
Intake Port
Intake port
0
When intake
8 E 3
l
valve
is actuated
When
intake
valve
is open
6210-81-3111
Air pressure air governor
intake port
from
Intake I port
L
When intake
valve
is actuated
When
intake
valve is open
11-011 co
AIRCOO
3
el ?
0
l
.
003&l IV
After disassembly, as follows.
Division Test
inspection,
1) Testing
I
and assembly,
carry
I
airtightness
Apply air pressure of 7 k /Cm* at the same time to the c?IS-
method
out the airtightness
2) Charging Time taken of 35 liters
test and performance
test
performance
to charge tank pressure from 0 to 7 kg/cm*
of tank
with
capacity
charge port and unloader valve, and measure the amount of leakage from the air intake port. Standard
speed
(rpm)
Charging
time
1,100
cc/min
max.
1,100
158 max.
cc/min
max.
1,100
158
cc/min
6136-81-3112
450
6138-81-3111
450
100
Rotating
max.
450
6206-91-l
(set)
158 max.
100 cc/min
max.
250/I
,500
6151-81-3110~
450
cc/min
max.
250/l
,500
100 cc/min
max.
500/l
,500
100 cc/min
max.
500/l
,500
100 cc/min
max.
500/l
,500
145
max./60
max.
100 cc/min
max.
500/l
,500
145
max./60
max.
621 O-81 -3111
j,
6210-81-3121
*
“I
6162-83-6700
260
max.
6136-81-3120*
6151-81-3140*
220
maxY45.5
max.
max./40
max.
145
max./60
max.
145
max./60
max.
6162-83-6600
+r
1500
cc/min
max.
500/l
,500
133
max./50
max.
6162-83-6800
*
1500
cc/min
max.
500/I
,500
133
max./50
max.
6165-91-l
001
*
“2
1500
cc/min
max.
500/l
,500
98 max.138
max.
6165-91-l
004
*
“2
1500
cc/min
max.
500/I
,500
98 max./38
max.
6165-91-l
005
*
“2
1500
cc/min
max.
500/l
,500
1500 1500
cc/min cc/min
max. max.
500/l 500/l
,500 ,500
98 max.138 198 max./83
max. max.
198
max.
6215-81-3101 6215-81-3201
*:
for leakage
* *
Time taken to charge *? Air tightness test
tank pressure
of tank with
capacity
of 30 liters
max./83
from 0 to 8 kg/cm*
When air pressure of 7 kg/cm2 is applied to the intake port and unloader port, the amount of leakage from the discharge port must be a maximum of 2300 - 4000 cc/min. “2 Air tightness test When air pressure of 2 kg/cm2 is applied from the discharge port piping of the exhaust valve, the amount of leakage from the exhaust port must be a maximum of 100 cc/min. When air pressure of 7 kg/cm* is applied to the unloader line of the exhaust valve and unloader valve, there must be no leakage of air. l
3) 0il leaking up Remove the pipe from the discharge port in the cylinder head, and check the operation. Check that there is no abnormal spray of oil from the discharge port.
12-002 0
8 z 3
13 DISASSEMBLY AND ASSEMBLY
Tightening Disassembly
torque
and assembly
6206-91-l 6136-8i
. . . . . . . _. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-002
100 -3112
......
(S)6D95L-1
......
S6D105-1
6138-81-3111 6151-&i
...... -31 i 0 ......
6136-81-3120
......
6151-81-3140 6210-81-3111 6210-81-3121
...... ...... ......
6162-83-6700
S(A)GDl (SA)GDI
5 Series IO-1 25-l
. . . . . . . . . . . . . . . . . 13-006
1 ,J
S6D105-1, S6D125-1 S6D140-1
S6Dll
O-l
SAGD140-1
......
S6D140-1, S6D170-1
6162-83-6600 6162-83-6800 6215-81-3101 6215-81-3201
...... ...... ...... ......
S6Dl70-1 S6D170-1 SAl2V140-1 SA12V140-1
6165-91-1001 6165-91-1004.. 6165-91-1005
...... SA8V170-1, .... SA8V170-1, ...... SA8V170-1,
Series
. .
1 ’ Series
SA12V170-1 SAI 2V170-1 SAI 2V170-1
Series
. . . . . . . 13-018
1
13-001 @
TIGHTENING
TORQUE
(Standard
Values) Unit: kgm
Part No’
6206-91-l
100
6136-81-3112
6138-81-3111
6136-81-3120
6151-81-3110
12+
lo+1
lo+1
-
-
Inlet valve guide
@
12 + 1.2
12+
Delivery
valve body
@
105
10.1
Delivery
valve seat
@
-
Unloader
04
valve
1
1.2
lOAIl -
-
5 + 0.5
1.2
5 XII 0.5
lo+1
5 + 0.5
15 X!I 1.5
5 + 0.5
5 + 0.5
Bearing cover mounting bolt
05
Connectin mounting
rod 1 olt
8
mounting
0
3 f
0.3
3 * 0.3
3 + 0.3
5 * 0.5
3 + 0.3
Cylinder head mounting bolt
08
3 * 0.3
3 + 0.3
3 I!I 0.3
3 I!I 0.3
5 * 0.5
Flange bolt
@
1.5 +0.15
-
-
0.6 AI 0.06
0.6 + 0.06
-
-
-
-
-
-
-
-
0&nder
mounting
Exhaust valve bracket mounting bolt
0,o
Exhaust
0
valve cap
2.75
f
0.25
0.6 + 0.06
0.6 + 0.06
2.5 I+I 0.25
2.5 + 0.25
2.5 f
-
0.25
2.75
+ 0.25
2.75
2.5 AI 0.25
+ 0.25
2.5 + 0.25
mounting
bolt @
-
-
-
-
-
Delivery valve mounting bolt
013
-
-
-
-
-
Inlet valve seat mounting bolt
0,4
_
-
-
-
-
Plate
8
2
,8 i l-
5,
650ACF040
650ACF039
General 6206-91-l
13-002 0
drawing 100
650ACF041
General 6206-91-l
100
drawing
6151-81-3110
m
s; M
mo d -3
$1
In0
d -3
+I
-.
-,
I
I
I
I
I
003wv
D
90’0 + 9’0
sa
E
90’0 f SP’O SL’OT
9’1
SO’0 + SP’O 91’0 f 9’1
90.0 f !a’0 91’0 f 9’1
90’0 f 9l7’0 91’0 f 9’1
I71 0
-
I
-
c-0 f &
E’O f E
E’O f E
E’O f E
s-0 f 9
9’0 f 9
s-0 + 9
9’0 + 9
P’O f P
P’O T P
I
0 POO-EL
Iloq Gu!wnow leas EmleA Ii3lUl lloq Guyunocu a/ye/I AJaAyaa
SO’0 + 37’0 91’0 + 9’1
0
0
I
SZ’O f S’Z
SZ’O + S’Z
SZ’O f S’Z
0O1
1pq
6ugunoLu
de:,
CIAI~A
100 l- 16-99 19
0089-E8-Z9
1108 Gu!lunow POJ
1fXS
@
U!lXHJUO~
aAlE!/\
nJE3A!laa
63AleA
ap!nS
t%J!Jeaa
Japeolun
aAle/\
ApOq
@
01
POOL-16-9919
aIeld
lloq Gu!lunow Peav JaPu! lb
08 0L
09
iloq Gullunour JEIA03
I I
SOOL-16-9919
vsneyxg
lloq Guwnow lay3eJq arilfa vineyxj
06
-
04 0P
LOLE- 18-S 1Z9
AJaA!laa
ElAlt?A
lalul
19
w6y gun
003kl IV
I
AIRCOO
\
\
o-h,0 . . . . . . . . . . . .
AAdO
&AA_
bcli,bL
. . . . . .
. . . . . .
1. Cylinder
head
1) Remove
cylinder
(31). 2) Tap cylinder
head
head (11)
mounting with
bolts
6. Delivery valve assembly 1) Remove delivery valve body (12) from top of cylinder head.
a plastic
hammer from below to remove it. 3) Remove gasket installed between cylinder
Air pressuje from air governor
(20) and cylinder head (11).
/
1 Air discharge port
2. Cylinder, connecting rod, piston Remove cylinder mounting bolts (33), then 1)
2)
remove cylinder (20) from crankcase (21). Remove 2 nuts (34) installing big end of connecting
Air intake 0 port
rod (27).
3) Remove piston (30) and connecting (27) from crankcase (21).
rod
4) Using a tool, remove 2 piston rings (I 8) and oil ring (19) from piston (30).
650ACF048
5) Remove 2 snap rings (29) from piston pin holes, then pull out piston pin (28) and remove piston from connecting rod (27). If thread portion where delivery valve seat (7) is screwed in and installed to bottom of cylinder head is caulked, remove caulking before removing parts. valve seat (7), then 3) Remove delivery remove delivery valve spring (3), delivery 2)
3. Bearing cover I) Remove 4 mounting bolts (22) mounting bearing cover to crankcase (21), then remove together with oil seal (23) from crankcase (21). 2) Remove
oil seal (23) from bearing
cover
(26). 4. Crankshaft 1) Pull out crankshaft (24) in direction of bearing cover (26), with 2 ball bearings (25) still fitted. 2) Using a hand press, remove ball bearings (25) from crankshaft (24). 5. Unloader valve assembly 1) Remove unloader valve body (10) from top of cylinder head. 2) Remove snap ring (5) from inside unloader
valve (6), gaskets (5) and (4), and delivery valve guide (8) from inside delivery valve seat. 7. Inlet valve assembly 1) If thread portion where inlet valve guide (1) is screwed in and installed to bottom of cylinder head (11) is caulked, remove caulking before removing parts. 2) Remove inlet valve guide (I), then remove inlet valve spring (2), inlet valve (3), and inlet valve seat (4) at the same time.
valve body (IO), then pull out washer (6), unloader valve spring (7), and rod (9).
13-007 a
ASSEMBLY 6206-91-I
100
1
6136-81-3112 6138-81-3111 6151-81-3110
l
6151-81-3110
Series
Air pressure from air governor
J
0
2
1 Air discharge
/
port A
/
Clean all parts, check for dirt or damage, and
l
blow with air to dry. Coat the sliding surfaces and press-fitting portions of all parts with clean engine oil before installing. I.
Inlet valve assembly 1) Insert inlet valve seat (4) in cylinder
Air intake 0 port
head
(1 I), then fit inlet valve (3) and inlet valve spring
(2), and temporarily
tighten
valve guide (1). * *
*
650ACF048
inlet
1 Assemble
1
delivery valve spring (3) to head (l), then put delivery valve
Check that inlet valve (3), and inlet valve
cylinder
spring (2) move smoothly. If inlet valve guide (1) is protruding from the bottom surface of cylinder head (1 I), there is danger that it will interfere with the top surface of the piston, so check that it is not protruding. Do not carry out punch caulking on 615181-3110.
(6) on top of it. Put gasket (4), delivery valve guide (8), and gasket (5) in position, then temporarily tighten delivery valve seat (7). Check that delivery valve (6) moves smoothly, then tighten delivery valve seat (7) to the specified tightening torque.
&
~--LFI
Inlet valve guide thread: Thread tightener (Three Bond 1360) Inlet valve guide: See Tightening Torques and Standard Values Table
2. Delivery valve assembly 6206-91-I 000 6136-81-3112 6138-81-3111 Insert gasket into cylinder l
l
m
head (11).
Standard
m
Bond
1360) K&
*
Delivery valve seat: See Tightening Torques and Standard Values Table Check that the seat does not protrude from the bottom of the cylinder head.
Sliding surface: Molybdenum disulphide grease (Dow Corning Coorporation [MOLYCOTE 44M]) 2) Insert unloader valve spring (7) and
Torques
Values Table
and
washer (6), then secure with snap ring ,_* (51. 3) Tighten unloader valve body (10) to cylinder head (11). m
*
13-008 0
Delivery valve seat thread: Thread tightener (Three
&
Delivery valve thread: Thread tightener (Three Bond 1360) Inlet valve guide: See Tightening
*
3. Unloader valve assembly 1) Assemble O-ring (8) to rod (9), then intall inside unloader valve body (10).
l
&
2)
Unloader valve assembly: See Tightening Torques and Standard Values Table Push rod (9) with a bar, and check the movement of inlet valve (3).
8 g 3
4. Crankshaft 1) Using a press, press fit ball bearing to crankshaft a
&
Crankshaft pin: Coat with engine oil
&
Cap mounting bolt: Coat with engine oil
(25)
(24).
Oil seal sliding poriton:
2) Insert
Coat with engine oil crankshft (24) from bearing
cover
D
Cap mounting
(26) end of crankcase (21). 5. Bearing cover 1) Press fit oil seal (23) to bearing cover (26). e,
Press-fitting
(Loctite
bolts.
hydraulic
seaiant) Applicable compressors
*
6136-81-3112,
mA
6138-81-3111
/c(l_7L, Mating It *
with mounting
bolts (22).
surface of cover and case:
Gasket sealant (LG-4) Applicable compressors 6136-8l-3112,6138-81-3111 For 6826-91 _11CC and 6J5j_8j_31’jC, insert an O-ring in the bearing cover, then install.
w
Bearing cover mounting bolt: See Tightening Torques Standard Values Table
and
6. Cylinder, connecting rod, piston i) Align piston pin hole and hole at small end of connecting rod (27), then push in piston pin (28), and secure both-ends with snap rings (29). fln3
2) jt
Whole
inside
cylinder:
Piston pin: Coat with engine
Install oil ring (19) and piston Assemble piston rings (18) stamped ring surface facing up, sure that the end gaps of the in different places.
Mating
surface
at bottom
of
Coat with engine oil surface of cylinder and crank-
case: Gasket sealant (LG-4)
2) Press fit bearing cover (26) to ball bearing, then tighten
and
5) Compress piston rings (18) and oil ring (19), then assemble cylinder (20) to crankcase (21), and tighten with mounting
portion of oil seal:
Adhesive
bolt:
See Tightening Torques Standard Values Table
*
Applicable
*
6136-81-3112, 6138-81-3111 For 6206-91-1100 and 6151-81-3110, insert and O-ring in the cylinder skirt. m
compressor
Cylinder mounting bolt: See Tightening Torques Standard
and
Values Table
7. Cylinder head 1) Fit gasket to top surface of cylinder (20). 2) Assemble cylinder head (11) to cylinder, then tighten with mounting bolts. * Tighten the bolts slowly and uniformly to the specified torque. m Cylinder head mounting bolt: See Tightening Torques and Standard Values Table
oil ring (18). with the and make rings are
*
There is no top or bottom to oil ring (19). 3) Insert connecting rod assembly (27) from top of crankcase (cylinder end). 4) Assemble cap at connecting rod big end, then tighten with mounting bolts. * Check that connecting rod match marks are aligned.
13-009 (iJ
DISASSEMBLY 6136-81-3120
.......
S6D105-1,
6151-81-3140
.......
S6D125-1
6210-81-3111
.......
S6D140-1
6210-81-3121
.......
S6D140-1,
6162-83-6700
.......
S6D170-1
.
l
S6Dll
Series SAGD140-1
Before disassembly the air compressor, of oil from the mating surfaces. When disassembling then disassemble.
the
cylinder
O-l
clean
head,
it and check from the otitside
connecting
rod, and piston,
for damage
remove
from
or leakage the engine,
650ACF050
13-010 0
1. Cylinder
head
1) Remove
5. Unloader
cylinder
(20). 2) Tap cylinder
head
head
(11)
mounting with
bolts
valve body (8) from top
of cylinder head (11). 2) Remove rod (7) and O-ring
a plastic
hammer from below to remove it. 3) Remove gasket installed between cylinder (23) and cylinder
valve assembly
1) Remove unloader
unloader *
head (11).
from
inside
valve body (8).
The unloader
valve of 6210-81-3121
and 6162-83-6700
cannot
be disas-
sembled. 2. Cylinder,
piston,
piston
ring
11 Remove
cylinder mounting remove cylinder (23).
2)
Remove
bolts (18), then
valve assembly
1) Remove
snap rings (33) from piston
hoies, then pull out piston remove piston (34).
6. Delivery
pin
pin (32j and
3) Using a tool, remove 2 piston rings (21) and oil ring (22) from piston (34).
delivery
remove delivery
(17),
then
valve (16), delivery
valve
seat
valve
spring (15), O-ring (4 3), spring guide (I Oj, and O-ring (12). 7.
Inlet valve assembly 1) Remove inlet valve guide (I),then remove
3. Bearing cover, crankshaft 1) Remove mounting bolts (25) from bearing cover. Tap tip of crankshaft (26) with a wooden 2) hammer, and remove bearing cover (27).
inlet valve spring (2), inlet valve (3), inlet valve seat (4), gasket (9), and unloader valve spring (5).
partiaiiy
3) From the place where cylinder (23) mates with crankcase (31), hold crankshaft (26) and connecting rod (24) by hand, then tap with a plastic hammer from crankcase end to remove bearing cover (27). Using a gear puller, remove ball bearing (28) from crankshaft (26). 5) Remove connecting rod (24) from crankshaft (26), then pull out from mating portion of cylinder (23) in crankcase (31). 6) Using a hand press, pull out outer race of roller bearing (30) from crankcasee (31), and inner race from crankshaft (26). * For disassembly of 6136-81-3120, see 6151-81-3110. 4.
Flange 1) Remove hexagon socket head screws tightened from flange (29) side, then remove flange. * 6136-81-3120 has bolts.
13-011 c.0
ASSEMBLY 3. Unloader
6136-81-3120
1) Assemble O-ring (6) to rod (7), then install inside unloader valve body (8).
6151-81-3140 6210-81-3111
Series
621 O-81 -3121
a
6162-83-6700
valve assembly
sliding surface: Molybdenum
I
disulphide
(Dow Corning l
Clean all parts, check for dirt or damage, and blow with air to dry. Coat the sliding surfaces and press-fitting clean engine
portions
[MOLYCOTE
oil before installing.
unloader
valve
body (8). * For 621 O-81 -3121 spring
(5),
gasket (9), inlet valve seat (4), inlet valve (3), and inlet valve spring (2) to cylinder head (1 I), then tighten
/cm=-;
Inlet valve guide thread: Thread tightener (Three Bond 1360)
m
Inlet valve guide: See Tightening Torques Standard Values Table
spring (15). 3) Put delivery valve (16) on top of delivery valve spring (15), then tighten delivery valve seat (17). * Check that delivery valve (16) moves smoothly. * Check that delivery valve seat (17) is below the surface of cylinder head (II). Thread of delivery valve seat (15): Thread tightener (Three Bond
13-012 0
head.
Delivery valve seat: See Tightening Torques Standard Values Table
4.
and
and 6162-83-6700,
unloader
to
the
Unloader valve body: See Tightening Torques
and
Standard
valve
Values Table
Flange Fit O-ring to crankcase (31), then assemble flange (29), and tighten with mounting bolts. ra
Bolt thread:
5~
Mounting bolt: See Tightening Torques Standard Values Table.
Thread tightener Bond 1360)
(Three
and
5. Bearing cover, crankshaft 1) Press fit outer race of roller bearing (30) to crankcase (31), and inner race to crankshaft (26) so that both clearances are 0. 2) Insert crankshaft (26) into crankcase (31), insert big end of connecting rod (24) from cylinder mating portion, then push in crankshaft. -Crankshaft
pin: Coat with engine
oil
3) Press fit ball bearing (28) to crankshaft (26) with a press. 4) Fit O-ring, then press fit bearing cover (27) to ball bearing, and tighten with mounting bolts (25). w
1360) m
the
w
and
2. Delivery va!ve assembly 1) Fit O-ring (12) to spring guide (IO), then install to cylinder head (II). Install O-ring (13) and delivery valve 2)
a
install cylinder
inlet valve guide
(1). * Check that inlet valve (3) moves smoothly. * Check that inlet valve guide (1) is below the surface of cylinder head (1 I).
44M])
2) Insert so that rod (7) enters unloader valve spring (5), then tighten unloader valve
of all parts with
I. Inlet valve assembly 1) Assemble
grease
Corporation
Bearing cover mounting bolt (25): See Tightening Torques and Standard Values Table 5) Push tip of crankshaft with a hand press, and make a clearance at roller bearing. * For asembly of 6136-81-3120, see 6151-81-3110
8 : 3
003kllV
DISASSEMBLY 6162-83-6600
. . . . . . . S6D 170- 1
6162-83-6800
. . . . . . . S6D170-1
6215-81-3101
. . . . . . . SA12V140-1
6215-81-3201
. . . . . . . SAI 2V140-1
1 Series 1
Before disassembly the air compressor, of oil from the mating surfaces. When disassembling then disassemble.
the cylinder
clean it and check from the outside for damage or leakage
head, connecting
Air pressure from air
rod, and piston,
remove
Air discharge
4,
6
Air intak Port
/ 1
/ 9
A-i
B-i \
\
6
7 Section
B-B
i2
36
Section
16
j5
‘14
A-A
i3 650ACF051
I
”
\
LI
-
26
28
650ACF05i
13-014 0
F
from the engine,
1. Cylinder
head
5. Plate
I ) Remove cylinder head mounting and (41).
bolts (40)
1) Remove hexagon socket head screws (18) installed from top of cylinder head. *
2) Tap cylinder head (6) with a plastic hammer from below to remove it. 3) Remove gasket (34) installed between cylinder (32) and cylinder head (6). 2. Cylinder, piston, piston ring 1) Remove cylinder mounting bolts(33), then remove cylinder (32) from crankcase (30).
2)
Remove snap rings (21) from piston pin holes, then pull out piston pin (22) and
remove piston (23). 3) Using a tool, remove 2 piston rings (19) and oil ring (20) from piston (23).
Do not remove
blind plug (37) of the
water passage plate (8).
in the top surface
2) Remove mounting bolts (39) of plate (38) of water passage in side surface of plate (8), then remove plate. 6.
Inlet valve assembly 11 When cylinder head (6) and plate are . V., removed, inlet valve (l6), inlet valve spring (14), removed.
2)
Remove cylinder
3. Bearing cover, crankshaft Remove oil feed pipe
8 E 3
of
and
bolt (40)
washer installed
(15)
can
from
be
top of
head (6) then remove inlet valve
seat (17). (26)
secured
to
bearing cover (25) and flange (31). * Applicable compressor 6162-83-6600, 6162-83-6800 Remove mounting bolts (24) from bearing 21 cover (25). 3j Tap tip of crankshaft (28) with a plastic hammer, and partially remove crankshaft and bearing cover (25). 4) From the place where cylinder (32) mates with crankcase (30) hold crankshaft (28) and connecting rod (42) by hand, then tap with a plastic hammer from crankcase end to remove bearing cover (25). 5) Using a gear puller, remove ball bearing (27) from crankshaft (28). 6) Remove connecting rod (42) from crankshaft (28), then pull out from mating portin of cylinder (32) in crankcase (30). 7) Using a hand press, pull out outer race of roller bearing (29) from crankcase (30), and inner race from crankshaft (28). 8) Remove hexagon socket head screws tightening flange (31), then remove flange.
7. Delivery valve assembly 1) Remove hexagon socket head screws (36) installed in intermediate plate, then remove stopper (1 I), delivery valve (12), and delivery valve guide (10). * The bushing assembled to the discharge port in the cylinder head is coated with adhesive and press fitted. This bushing forms the cooling water passage and cannot be removed.
4. Unloader valve assembly 11 Remove unloader valve body (5) from top of cylinder head (6). 2) Remove snap ring (1) from inside unloader valve body (5), then pull out washer (9), unloader valve spring (2), and rod (4), and remove O-ring (3).
13-015 3
ASSEMBLY Air pressure from air
6162-83-6600 6162-83-6800 8215-81-3101
4,
5, wvepr
Series
Air discharge Port
6215-81-3201 l
Clean all parts, check for dirt or damage,
and
blow with air to dry. Coat the sliding surfaces and press-fitting portions of all parts with clean engine oil before installing.
/
1
1. Delivery
/A--/
\
9
8
B-l \
7
valve assembly
1) Install
delivery
valve (12), delivery
valve
Section
R-B
Section
A-A
guide (10) and stopper (1 I), then tighten with hexagon socket head screws (36). * Be careful not to let the delivery valve
10
il
j2
and delivery valve guide (10) overlap. Thread: Thread tightener (Three Bond
a
1360) Be careful not to get the thread tightener on the delivery valve.
* m
2.
36
1:
16
i5
‘14
i3 650ACF05
Hexagon socket head screw (36): See tightening Torques and Standard Values Table
Inlet valve assembly 1) Assemble inlet valve seat (17) to cylinder head (6), then tighten mounting bolt (40). &
Thread and washer: Thread tightener
(Three
Bond
1360) sm
Mounting bolt (40): See Tightening Torques Standard Values Table
and
3. Plate 1) Insert washer (15), inlet valve spring (14), and inlet valve plate (16) to plate (8), then assemble gasket (13) and O-ring (7), and tighten with hexagon socket head screws (4 8). * Push inlet valve unloader valve movement. j,
Check that the tip of the hexagon socket head screw does not protrude from the surface of the plate.
13-m 6
0
650ACF052
plate (I 6) from the end to check the
1
&
Thread and seat: Thread
c=
tightener
(Three
Bond
Bearing cover mounting bolt (24): See Tightening Torques and
1360) w
Standard Values
Hexagon socket head screw (18): See Tightening Standard Values
Torques Table
and
insert
unloader valve spring (2) and washer then install snap ring (1).
2) Install
(9),
disulphide
a
cm
Unloader valve: See Tightening Standard
Values
(Three
2) Install oil ring (20) and piston rings (19) to piston (23). * Assemble piston rings (19) with the
Bond *
Torques
and
Table
Mounting bolt thread: Thread tightener 1360) Flange mounting
facing
up, and
make sure that the end gaps of the rings are in different places. There is no top or bottom to oil ring
mounting fid
Bond
bolts (33).
Whole inside surface at bottom cylinder: Coat with engine oil Cylinder
mounting
of
bolt:
See Tightening Standard Values
Torques Table
and
bolt (31):
See Tightening Torques and Standard Values Table 2) Press fit outer race of roller bearing (29) to crankcase (30), and inner race of crankshaft (28) so that both clearance are 0. 3) Insert crankshaft (28) into crankcase (30), insert big end of connecting rod (42) from cylinder mating portion, then push in crankshaft. e-crankshaft
ring surface
(20). 3) Fit O-ring to cylinder (32), then with piston ring (19) press fitted, assemble cylinder to crankcase (30), and tighten with
QKI (Three
rod (42), then push in
Piston pin: Coat with engine oil
stamped
5. ‘Bearing cover, crankshaft 1) Fit O-ring to crankcase (30), then assemble flange (3l), and tighten with mounting bolts. &?&I
a
Thread of unloader valve body: tightener
bearing.
piston pin (22), and secure both ends with snap rings (21 j.
grease
(Dow Corning Corporation [MOLYCOTE 44M]) unloader valve body (5) to cylinder
Thread 1360)
at roller
6. Cylinder, piston, piston pin 1) Align piston pin hole and hole at small end of connecting
head (6)
m
and make a clearance
Sliding surface: Molybdenum
Table
with a hand press,
7) Install oil feed pipe (26) secured to bearing cover (25) and flange (31).
4. Unloader valve assembly 1) Assemble O-ring (3) to rod (4),
a
6) Push tip of crankshaft
pin: Coat with engine
oil
4) Press fit ball bearing (27) to crankshaft (28) with a press. 5) Fit O-ring, then press fit bearing cover (25) to ball bearing, and tighten with mounting bolts (24).
7. Cylinder head 1) Fit gasket to top surface of cylinder (32). 2) Assemble cylinder head (6) to cylinder (32), then tighten with mounting bolts (41). * Tighten the bolts slowly and uniformly to the specified torque. m
Cylinder
head mounting
See Tightening Standard Values
bolt:
Torques Table
and
AIRCOO
1. Cylinder
5. Plate
head
1) Remove
cylinder
head
mounting
(30). 2) Tap cylinder head (1) with hammer from below to remove
bolts
1) Remove installed
a plastic it.
3) Remove gasket (32) installed between cylinder (31) and cylinder head (1).
hexagon from
disassemble
socket
head screws
top of cylinder cylinder
(IO). * Do not remove water passage
head,
(2) and
head (1) and plate
blind plug (49) of the in the top surface of
plate (10). *
2. Cylinder, piston, connceting rod Remove cylinder mounting bolts(48), 1) remove cylinder (31) from crankcase
2)
Remove
mounting
connecting
bolts
rod (42), then
(43) and connecting
at
big
remove
rod from
then (37).
end
of
piston
piston
(43). (46)
3. Bearing cover, crankshaft bolts (36) of bearing 1) Remove mounting cover (35). 2) Pull out bearing cover (35) and crankshaft
3
water then
passage
for
passage remove
in side surface
of plate (lo),
piate.
6. Inlet valve assembly 1) When
(39). 6165-91-100-l 6165-91-1004 Tap the tip of the crankshaft at the flange end with a plastic hammer to remove the crankshaft. bolts (33) of coupling 3) Remove mounting (34) at bearing cover end, then remove coupling. 4) Using a hand press, remove bearing cover (35) from crankshaft (39). Using a hand press, remove ball bearing 5) (38) from crankshaft (39).
cylinder
removed, spring
4) Using a tool, remove 2 piston rings and oil ring (47) from piston (43).
8 :
the water
the cylinder head, so do not remove it. 2) Remove mounting bolts of plate (22) of
crankcase
(37). 3) Remove snap rings (44) from piston pin holes, then pull out piston pin (45) and remove
Link (20) forms
head (1) and plate (10) are
inlet (15),
and
valve
(14),
washer
inlet (16)
valve can
be
removed. 2) Remove bolt (3) installed from top of cylinder head (I), then remove inlet valve seat (I?). 7. Delivery valve assembly 1) Remove hexagon socket head screws (19) installed in plate (IO), then remove stopper (12), delivery valve (1 I), and delivery valve guide (18). 8. Exhaust valve 1) Remove cap (53) tightened from below exhaust valve (50), then pull out rod (51), spring (54), and O-rings (52) and (55). * Applicable compressors 6151-91-1004, 6165-91-1005
4. Unloader valve assembly 1) Remove unloader valve body (4) from top of cylinder head (1). Remove snap ring (9) inside body, then
a
pull out O-ring (6), rod (5), washer unloader valve spring (7). 6165-91-1001 *
Do not disassemble assembly.
the unloader
(8) and
valve
13-019 cc
ASSEMBLY 6165-91-1001
*
6165-91-1004
Push inlet valve (14) from the unloader
Series
valve end to check the movement. *
6165-91-1005
Check that the tip of the hexagon socket head screw does not protrude from the
Clean all parts, check for dirt or damage, and blow with air to dry. Coat the sliding surfaces and press-fitting portions of all parts with
surface of the plate. &
Thread and seat: Thread tightener
clean engine oil before installing. . * Exhaust
m
valve
1) Assemble
O-rings
(52)
(55),
and
spring (54) to rod (51), then tighten
cap
and
(53). &
Slinding
*
*
tightener
Bond ? 360) Be careful not to get tightener on the delivery
CZZZl
3.
valve guide (18) overlap. Thread
(Three
the thread valve plate.
Hexagon socket head screw (19): See Tightening Torques and Standard Values Table
Inlet valve assembly 1) Assemble inlet valve seat (17) to cylinder head (I), then tighten mounting bolts (3). &-L
Thread: Thread tightener 1360)
m
Mounting bolt (3): See Tightening Standard Values
(Three Bond
Torques Table
and
4. Plate 1) Insert washer (16), inlet valve spring (15), and inlet valve (14) to plate (IO), then
13-020 0
(6) to rod (5),
insert (8),
#&
Sliding surface: Grease (NOK Klueber [BARRIERTA JFE5221) 2) Install unloader valve assembly (4) to cylinder head (I ). cm Unloader valve assembly: See Tightening Torques and Standard Values Table
6. Bearing cover, crankshaft 1) Press fit ball bearing (38) to crankshaft (39) with a press. * Only at bearing cover end on 616591-1005. Press fit ball bearing (38) in bearing cover (35) with a press, the assemble O-ring to bearing cover pilot. 3) Assemble coupling (34) at bearing cover (35) end, and tighten mounting bolts (33). 4) Assemble flange (40) to crankcase (37), and tighten with mounting bolts (41). 5) Insert crankshaft (39) from bearing cover (35) end of crankcase, adjust bearing cover so that it is properly centered, then tighten with mounting bolts (36).
a
a
Crankshaft *
assemble gasket (13), and tighten hexagon socket head screws (2).
O-ring
valve spring (7) and washer
then install snap ring (9).
with hexagon socket head screws (19). * Be careful not to let the delivery valve Thread:
Values Table
valve assembly
unloader
2. Delivery valve assembly 1) Install delivery valve guide (18), delivery valve (1 1) and stopper (12) then tighten
ax1
Standard
1) Assemble
Cap (53): See Tightening Torques and Standard Values Table. Applicable compressors 6165-91-1004, 6165-91-1005
and delivery
Hexagon socket head screw (2): See Tightening Torques and
5. Unloader
surface of rod:
Grease (NOK Kluever [BARRIERTA JFE5221) m
(Three Bond
1360)
with
*
pin: Coat with engine
oil
(Front journal on 6165-81-I 005) When installing the bearing cover, check that the O-ring is fitted properly. With 6151-91-1005, fix the washer to the flange with grease.
8 $ 3
&
Bearing cover flange mounting See Tightening Torques Standard Values Table
7. Cylinder, 1) Install
*
bolt: and
%B
piston, connecting rod oil ring (47) and piston rings (46)
stamped
piston
rings (46) with
ring surface
facing
2)
There (47).
Align
piston
pin hole and hole at small rod (42), then push in
piston pin (45), and secure both ends with snap rings (44).
and
Table
005
exhaust
valve
mounting
bracket
(58) at the same time. 9. Exhaust
valve assembly
1) Tighten
mounting
valve assembly
end of connecting
&
Install
up, and
is no top or bottom to oil ring
Values
6165-91-1004
the
make sure that the end gaps of the rings are in different places. *
Cylinder head mounting bolt: See Tightening Torques
6165-91-I
Assemble
the bolts slowly and uniformly
Standard
to piston (43). *
Tighten
to the specified torque.
m
Mounting See
bolts (56) of exhaust
(50). bolt: Tightening
Standard
Values
Torques
and
Table.
Piston pin: Coat with engine oil
3) Insert connecting rod (42) from top of crankcase (37); then tighten mountmg bolts of cap at big end. + Check that, the . . .V match marks on the connecting &Crankshaft &
rod are aligned. pin: Coat with engine
oil
Cap mounting bolt: Coat with engine oil
s-
Connecting rod mounting bolt: See Tightening Torques and Standard Values Table 4) Fit O-ring to cylinder (31), then with piston ring (46) press fitted, assemble cylinder to crankcase (37), and tighten with mounting bolts (48). fi m
Whole inside surface at bottom cylinder: Coat with engine oil Cylinder mounting bolt: See Tightening Torques Standard Values Table 6165-91-I 004 6165-91-1005 Install exhaust
valve
mounting
of
‘53 650ACF055
and
bracket
(57) at the same time. 8. Cylinder head 1) Fit gasket (32) to top surface (31). 2) Assemble cylinder (31), then tighten
of cylinder
head (1) to cylinder with mounting bolts
(30).
13-021 @
14-001 2
14-002 2
14-003 2
14-004 2
l
6165-91-I
001
l
6165-91-1004
l
6165-91-1005
650ACF060
+r Apply for only 6165-91-I items
1
Clearance between cylinder and piston (Measure the outside diameter of the piston at the skirt)
between
piston ring and ring groove
Clearance piston
qemedy
Criteria
No
Clearance
Unit: mm
005
between
Standard
size
Standard
clearance
Clearance
85
0.070
-
0.120
0.25
Piston ring
2
0.020
-
0.050
0.15
Oil ring
4
0.030
-
0.070
0.20
Piston ring
-
0.1 -
0.30
0.6
Oil ring
-
0.15 -
0.35
0.7
ring open-
limit
Replace piston or cylinder Replace piston or pisfnn ripn‘3 .“.I .I
Replace
nings
16
0.006
-
0.026
0.5
Replace piston or piston pin
Clearance between piston pin and connecting rod small end
16
0.006
-
0.026
0.5
Replace connecting rod
Clearance between crankpin and connecting rod big end
35
0.034
-
0.075
0.15
Replace connecting rod
Clearance between front journal and flange inner diameter
45
0.009
-
0.095
0.2
Replace crankshaft or flange
End play of crankshaft
-
Clearance between pin and piston
piston
0.1 -
0.74
0.9
Replace crankshaft or flange
I Drive spline
30 -
connector:
Air inlet port connector: Air discharge connector: 8
8 I!I 0.8 kgm port
I
Unloader port connector: Cooling water connector:
8 f 0.8 kgm 3 I!I 0.3 kgm
port
Retighten
3 f 0.3 kgm
Exhaust valve connector: Air compressor ing bolt:
35 kgm
3 f 0.3 kgm mount-
5 I!I 0.5 kgm
I
14-005 m w
PARTS INSPECTION
l
Be careful
AND JUDGEMENT
not to damage
dry. Check visually
disassembled
particularly
parts.
for the following
Wash
them
Cylinder
in diesel
Part
0 Scuffing, wear, seizure sliding surface l Scratches on head mounting surface l Scratches, dents on O-ring contact surface
of
Bearing cover and flange, oil seal
6i3 0
0
0
0
cl
0
oil, then
blow
with
air to
points.
Check point
Part
STANDARD
Check point 0 Scratches, roughness surface l Scratches, ring contact
degree of of sliding dents on Osurface
0
Piston
and piston
rings
Scuffing, wear, sliding surface Scratches, groove Degree width
dents
seizure
of
in ring
of ring contact
Inlet valve, va Ive
delivery
Scratches, plate
wear
of valve
B Scratches,
wear
of valve
l
l
Connecting
rod
l l
seat Settling
Scratches, cracks, dents Scuffing, wear, seizure of sliding surface
8
2 Unloader
valve
Scratches, dents, wear on sliding surface of rod Settling
Crankshaft
* Scuffing, scratches, wear, discoloration, in rotating parts l
Scratches tact surface
14-006 0
of valve spring
dents
on oil seal con-
of valve spring
a
JUDGEMENT
STANDARDS
FOR REUSE
Judgement Part Name
Position
l
for reuse
of damage A: Can be used as it is
1
category
Sliding
No scuffing, seizure
surface
wear,
B. Can be repaired ’ used again
and
C: Cannot be used again
Scuffing, seizure
-
wear,
2
l
Head mounting surface
No scratches
or dents
-
Scratches
or dents
I
1
l
Sliding piston
surface
of
No scuffing, seizure
wear,
-
Scuffing, seizure
wear,
2
l
Piston
ring groove
No scratches
or dents
-
Scratches
or dents
No scratches
or dents
-
Scratches
or dents
-
Contact than A
-
Scratches, dents
No scratches
-
Scratches
No discoloration
-
Discoloration
-
3
ring SllLdlll~
1;,4;n,
* Piston surface
Normal
contact
width
other
1
l
Overall external appearance
No scratches, dents
cracks,
cracks,
-
1
l
Journal
portion
1
l
O-ring contact surface
No scratches
or dents
Scratches, dents that can be easily removed with an oil stone
Oil seal sliding surface
No scratches, ness
rough-
-
Scratches,
roughness
2
l
Scratches or dents other than A or B
1
l
Valve
seat
Slight
scratches,
wear
-
Scratches,
wear
2
l
Valve
plate
Slight
scratches,
wear
-
Scratches,
wear
spring
No scratches, settling
-
Scratches, wear settling If valve spring is broken, replace cylinder head assembly
-
-
3
* Valve
wear,
-
14-007 co
AIRCOO
Head gasket w h,
Unloader
valve
.
ca
I!.
?
A
PERIODIC
INSPECTION
Carry out the following hours. 1.
Discharge
maintena
nce every 4000
air piping (between
air compres-
sor and wet tank) Remove the discharge the follows.
air piping
and do as collected than 1.5
mm (see diagram below), blow compressed air into the pipe to clean it. If the cannot
be removed,
pipe. If cleaning
agent
41 l-3310
oil
circuit)
(for
is available,
out the carbon. the instructions.)
replace
the
KO: Part No. 600-
cooler
element
oil
it can be used to clean (For details
of use,
see
Carbon tends to stick to restricting portions such as joints and check valves, so check these parts particularly carefully.
inside piping
mm, the pipe rep1 aced. 6206F913
2) If
there
is carbon
Air compressor Remove the head, and carry out the following maintenance. 1) If there
1) If the thickness of the carbon on the inside surface is more
carbon
2.
stuck to the connecting
joints, remove it with a screwdriver, and blow with compressed air to clean it. 3) If there is carbon stuck to the inside of the check valve installed between the air compressor and wet tank, remove it with a screwdriver, and blow with compressed air to clean it. (If the rubber valve seat is broken, replace it.)
are no deep vertical
the cylinder,
and carbon
scratches
is stuck
top surface of the piston, carbon from the top surface
in
to the
remove the of the piston.
Do not use a sharp tool to do this. When doing this, be careful not to let the carbon go through the gap between piston and the cylinder. *
If there
are deep vertical
the cylinder
which
replace the cylinder, ring kit.
the
scratches
in
catch the fingernail, piston,
and piston
2) If there is carbon stuck to the bottom surface of the head, or the air intake and discharge holes, remove it with a screwdriver, and blow with compressed air to clean it. 3) If there is carbon stuck to the delivery valve, intake valve, seat, guide, and spring, remove it with a screwdriver, and blow with compressed air to clean it. 4) If there is carbon stuck to the unloader valve and spring, remove it with a screwdriver, and blow with compressed air to clean it. (If the O-ring is worn, replace the unloader valve assembly.) * When removing the valve with a screwdriver, be careful not to damage the machined surface.
1d-009 3
0
0
El OOddM
II
2 II)
a
/
F
0
W
0
t -I W
3 LL
I
co
P
4
ii e
P
a a ii
k
CONTENTS
No. of page
01
GENERAL ...............................................................~.......~........................ 0%001
11
STRUCTURE
12
TESTING
13
DISASSEMBLY
14
MAINTENANCE
15
OTHERS ................................................................................................... 15-001
00-002
AND FUNCTION
AND ADJUSTING
................................................... 11-001
........................................................ 12-001
AND ASSEMBLY
STANDARD
............................................. 13-001
....................................................... 14-001
: . : *
’ * : * * : : .
: . :
OOddH
FUEL INJECTION SYSTEM OUTLINE
Fig. 1 Fuel injection pump system
Fig. 1 shows a diesel fuel injection pump system. Engine rotation is transmitted to the injection pump camshaft by a coupling or drive gear. The supply pump, driven by the camshaft, sucks fuel oil from the fuel oil tank and supplies it to the fuel oil filter at a pressure of approximately 1.8-2.5 kg/cm*. Filtered fuel oil is then sent to the fuel oil chamber in the injection pump housing. The plunger, raised by camshaft rotation, further increases fuel oil pressure. This fuel oil is then delivered by the injection
01-002
pump through the injection pipe to the nozzle holder, to be injected into the engine combustion chamber. Because the quantity of fuel oil delivered by the supply pump is at least twice the maximum injection quantity of the injection pump, an overflow valve is installed to return excess fuel oil to the fuel oil tank when the fuel oil pressure exceeds a set value. Excess fuel oil from the nozzle (which also lubricates the inside of the nozzle holder) flows through the nozzle holder’s overflow valve and is returned to the fuel oil tank.
cn 2
0 Ia c) E W
c)
n
tn mmJ
a n c)
2
.
OOddM
2 0
It)
z
1
LL
n 2
a
W
: :
OOddM
FIPPOO
2
0 w m a b -_I 0
2 B 2 u
0
To nozzle
t Delivery valve holder
Delivery valve
lilllillA‘il,
type InjectIon
Fig. 3 E(S)-A
I-
When the fuel oil pressure exceeds the nozzle spring set force, fuel oil is sprayed into the engine combustion chamber by the nozzle.
Plunger barrel
Plunger 4
Delivery starts
Pump housing
pump: cut-away view
Helix
4
I --A-
4 Delivery ends
Fig. 4 Plunger: effective stroke
The plunger further ascends, and at the position where the plunger helix meets the suction and discharge port of the plunger barrel, delivery of fuel oil ends. (At the same time, the nozzle spraying ends.) The delivery valve is closed by the force of the delivery valve spring, so that fuel oil is no longer delivered, even though the plunger further ascends. If the plunger is rotated, the effective stroke shown in Fig. 4 is altered, and consequently fuel injection quantity is altered.
1 l-003L
0
%
z?G
Injection
E
8
quantity 2 0
& It: 00000
(mm3/st)E;:
% %
PLUNGER ROTATING MECHANISM
Partial delivery
Non delivery
Fig. 7 Plunger
rotating
Maximum
delivery
mechanisms
Fig. 7 shows the plunger rotating mechanisms. ‘VVith the PE(S)aA pump, the flange at the io’wer portion of the plunger is inserted into the groove of the control sleeve, and teeth on the control sleeve’s upper portion are engaged with the teeth of the control rack. Accordingly, the plunger rotates when the control rack is moved and the injection quantity is therefore altered.
TWO-STEP HELIX PLUNGER I No. 1 helix
o. 2 helix
Combared to the standard helix (No. 2 helix), when using a plunger with a larger helix angle (No. 1 helix) during operation in the low-speed/ low-load range, an increased fuel injection quantity alteration rate can be obtained with only a small movement of the control rack. (Fig. 8) The purpose of this is to improve fuel injection quantity characteristics in the low-speed range.
Fig. 8 Two-step
helix plunger
1 l-005
DELIVERY VALVE ASSEMBLY The delivery valve delivers high pressure fuel oil to the nozzle through the injection pipe. After the plunger finishes delivery of fuel oil, the delivery valve prevents reverse flow of the fuel oil from the injection pipe to the plunger barrel. When the delivery valve descends, fuel oil pressure inside the injection pipe is reduced by the absorbing action of the piston, in order to prevent any leakage of fuel oil after the nozzle is closed. (Fig. 9)
Delivery valve spring -0 Delivery valve
4
O 0
0
0
Fig. 9 Delivery valve
DELIVERY VALVE (for variable retraction piston) Due to the modification of the delivery valve piston the fuel oil retraction effect has been lessened (the retraction quantity has been decreased) in the low-speed range, and as the residual fuel oil pressure inside the injection pipe is increased, stable fuel injection can be obtained. (Fig. IO) However, in the high-speed range the variable retraction piston has scarcely any effect.
t: Retraction piston diameter
“shaved” amount
Fig. 10 Delivery valve (for variable piston)
1 l-006
retraction
8 E E
DAMPING VALVE EQUIPPED DELIVERY VALVE HOLDER A delivery valve holder provided with a damping valve is available. (Fig. 11) Purpose If there is a sudden decrease in fuel oil pressure due to delivery valve retraction during operation in the high-speed/high-load range, negative pressure and air bubbles (cavitation) may be generated in the injection pipe. In extreme cases the injection pipe may be broken. The damping valve is used to prevent the generation of negative pressure and air bubbles. Construction
Open
Closed
The damping valve (ball valve) is installed inside the delivery valve holder. A spring seat and spring are installed in the upper portion of the delivery valve holder. In the lower portion a delivery valve stopper with an orifice is pressfitted. Below this stopper the delivery valve spring and delivery valve a,re ti located. , Operation
8 Fig. 11 Damping delivery valve EL h
At the time of fuel injection from the plunger, the damping valve (ball valve) is opened, and fuel oil is delivered through the delivery valve stopper’s central portion to the nozzle. However, after fuel injection the damping valve (ball valve) closes quicker than the delivery valve, and due to this fuel oil flows through the upper part of the delivery valve stopper orifice. The inside pressure of the injection pipe then decreases only the retraction volume. Because of this, delivery valve movement becomes comparatively slower, and a sudden fuel oil are cavitation and decrease pressure prevented.
1 l-007
CAMSHAFT The camshaft is driven by the engine through a coupling or timing device. Depending on specifications, tangential, convex, or tangential/eccentric combination cams may be used to operate the plungers. (See Fig. 12)
Tangential cam
Convex cam
Eccentric cam
Tangential/ Eccentric cam
In addition to the plunger cams, an eccentric cam is fitted to the camshaft to drive the supply pump.
Fig. 12 Cam profiles
TAPPET ASSEMBLY Standard type
For high-speed
engine
/
Adjusting shim Tappet
The tappet assembly is designed to change rotary camshaft motion into reciprocating motion, therefore raising and lowering the plunger, as well as regulating injection pump timing. Two types of tappets may be used, with their upper construction differing. For ordinary injection pumps the boltadjustable tappet is generally used, while for high-speed injection pumps the shimadjustable type is generally used. (Fig. 13)
Fig. 13 Tappets
SUPPLY PUMP A KS or KE type supply pump is used with the A type injection pump. As their basic construction and function are the same, only the construction and function of the KE type are explained below. Construction Fig. 14 shows the construction supply pump.
Fig. 14 KE type supply pump construction
1 l-008
of the KE type
Camshaft movement is transmitted through a tappet and pushrod to the supply pump piston. The piston spring acts to return the piston. The reciprocating motion of the piston results in alternating suction and discharge of the fuel oil.
8 /$
Operation
Camshaft
Camshaft
Position B
Position A
(A)
w
03
(Cl
Discharge
Regulating
Check valves
Suction
Fig. 15 Supply pump operation
0
za
Fig. T5 shows supply pump operation.
Priming pump
As shown in Fig. 15 (A), when the cam is moving toward position A, fuel is sucked in through the suction port check valve.
A priming pump may be installed on the supply pump to manually supply fuel oil to the fuel injection system from the fuel oil tank during the priming and bleeding operation (See Page 62).
ii
As the cam moves away from position A to position B, the fuel oil is compressed, the suction port check valve is closed, and fuei oil is discharged through the discharge port check valve, as shown in Fig. 15 B. If discharge side fuel oil pressure increases abnormally, the piston spring acts to compress the fuel oil in the pump chamber, therefore closing the suction port check valve and preventing further suction of fuel oil, as shown in Fig. 15 C.
Note:
After using the priming pump ensure the priming pump screw is secured tightly to prevent water and dirt etc., from entering the supply pump. A gauze filter is installed at the suction port to prevent dirt etc., from entering the supply pump.
1 l-009
12 TESTING AND ADJUSTING
SPECIAL TOOLS .............................................. Service tools for adjustment.. ...................... ADJUSTiVlENT .................................................. .................................................... Preparation Setting control rack “0” position ................ Injection timing adjustment ........................ Injection quantity adjustment ...................... Supply pump test ......................................... Injection timing aligning mark .................... PRECAUTIONS .................................................. Fuel oil ........................................................... Fuel filter ........................................................ Bleeding the fuel system .............................. Lubrication ..................................................... procedure ................................. Lubrication
12-002 12-002 12-007 12-007 12-008 12-009 12-014 .12-015 12-017 12-021 .12-021 12-021 12-021 .12-022 .12-023
12-001
SPECIAL TOOLS To service prepared.
the
PE(S)mA(D)
type
injection
pumps,
the
following
special
tools
and general
tools
should
SERVICE TOOLS FOR ADJUSTMENT Key No.
Part Number P/No.
( ): ZEXEL
Tool Name
1
Common tool (105780-2080)
Nozzle
2
Common tool (105780-0000)
Nozzle
Common tool (157805-0520)
Injection
Common tool (157805-3320)
Injection
Common tool (157916-8220) 6
7
10
holder
Q’ty
Application
8
8
pipe
pipe
8
2mmx6mmX600mm, Ml4 x 1.5; Ml2
8
2 mm x 6 mm x 600 mm, Ml4 x 1.5; Ml2 x 1.5
Wrench
1
For purging
Common tool (15781 O-0500)
Stand
2
For mounting PEmA(D) pump (for test stand models 5NP and IONP, shaft center height: 110 mm)
Common tool (105781-0480)
Stand
2
For mounting PEaA pump (for test stand models 7NP and 15NP, shaft center height: 125 mm)
Common tool (105781-0010)
Clamping
1
For fixing PE=A(D) pump models 5NP and IONP)
Common tool (105781-0150)
Stand
1
For mounting PESA(D) pump (for test stand models 5NP and shaft center height: 110 mm)
Common
Stand
1
For mounting PESmA(D) pump (for test stand models 7NP and 15NP, shaft center height: 125 mm)
1
Used together with the mounting stands (key nos. 9 and 10) D: 68 mm and 78 mm
tool
device
(105781-0180)
air from
11
Common tool (15781 I-0620)
Adapter
12
Common tool (105782-6280)
Measuring
device
1
For measuring
13
Common
Measuring
device
1
For measuring installed with compensator
(105782-6130)
12-002
x 1.5
tool
nozzle
holder
(for test
stand
IONP,
control rack travel
control rack travel: driveside mounted boost
be
-
OOddld
C
O
0
b
FIPPOO
OOddlj
d ?
r-
(u
FIPPOO
ADJUSTMENT After reassembling the injection pump, adjust it in the following manner using the injection pump test stand.
Prepare the special service tools described “Service tools for Adjustment”.
in
PREPARATION 1. Mount the injection pump on the test stand as shown in Fig. 86. 2. Connect the fuel pipes and injection pipes.
Fig. 86
Injection stand
pump
installed
on the test
3. Fill the camshaft chamber and governor chamber with injection pump oil. (Fig. 87) Camshaft chamber: Governor chamber:
Fig. 87 Adding
lubricant
20 cc for each cylinder Depends on governor type
to the cam chamber
12-007
z Fir ..
0
0
:
FIPPOO
9. If the pre-stroke is not within the specified range, adjust in the following manner. (1) Rotate the camshaft until the No. 1 cam reaches the T.D.C. position. (2) Insert the plunger spring holder between the lower spring seat and the tappet. (Fig. 96)’
(3) Remove the adjusting shim and adjust the shim thickness so that the desired preshim stroke can be obtained. Adjusting 97) (Fig. steps. mm 0.05 in thickness varies
Fig. 97 Adjusting
shim replacement
Note:
tappet adjustment adFor bolt-type just the position of the adjusting bolt (15791 I-01 00) spanners 2 using (Fig. 98)
If the pre-stroke exceeds the specified value, rotate the adjusting bolt counter clockwise. If less than the specified value, rotate the adjusting bolt clockwise. Remeasure the No. 1 cylinder’s
Fig. 98 Adjusting
pre-stroke.
bolt adjustment
12-011
FIPPOO
0
“0
.I
c-’
.-
OOddM
INJECTION QUANTITY
ADJUSTMENT 1. Check
the (Fig. 104)
Fig. 104
Checking
the control
rack “0”
control
rack
“0”
position.
position
2. Remove the control rack guide screw (68). 3. Attach the lock screw (to secure the control rack) to the pump housing. (Fig. 105)
Fig. 105
Fixing
the control
rack
Set the pump speed, control rack position and plunger strokes as specified in the service data. 5. Measure the fuel injection quantity for each cylinger. If the fuel injection guantity is not as specified, adjust as follows. pinion clamp screw. (1) Loosen the control (Fig. 106)
4.
Fig. 106
12-014
Loosening screw
the control
pinion
clamp
Rotate the control sleeve clockwise or counterclockwise using an appropriate tool. In Fig. 107 the control sleeve is rotated toward the governor side to increase fuel injection. quantity.
Fig. 107
Fuel injection
quantity
adjustment
SUPPLY PUMP TEST 1. Suction test
(1) Attach a pipe (2 m x 8@ mm) to the supply pump suction port and insert the other end into a fuel oil container. (Fig. 108) Note:
Ensure metre.
suction
head
of
approx.
I
(2) Operate the injection pump at 100 rpm. (3) Fuel oil must be discharged seconds.
Fig. 108
Supply
pump
in less than 40
test piping
2. Priming pump test (I) Fully loosen the priming pump’s screw cap. (2) Operate the priming pump using the screw per minute. cap, at 60-I 00 strokes (Fig. 109) (3) Fuel oil must be d ischarged in less than 25 strokes.
Fig. 109
Priming
pump
test
12-015
FIPPOO
INJECTION TIMING ALIGNING
MARK
SA-type timing device 1. Attach
the timing
device
to the injection
pump 2. Attach the coupling (157840-4020) to the timing device. 3. Connect the coupling to the pump test stand. 4. Connect the injection pipes to the delivery valve holder. (Fig. 113)
Fig. 113 Mounting
the injection pump
5. Operate the pump test stand flywheel manually. 6. Place the No. 1 cylinder plunger in the beginning-of-injection position. (Fig. 1 14j
Fig. 114 Confirming the No.1 cylinder’s beginning-of-injection position
Confirm that the injection pump pointer (360A) aligning mark and the flyweight holder aligning mark are aligned. 8. If not aligned, remove the incorrect flyweight holder aligning mark, and remark the position where the pointer aligns with the flyweight holder. (Fig. 115) 7.
Fig. 115 Remarking the aligning mark
12-017
Retard/Advance
timing device (Eccentric-cam
Pump speed (rpm)
Fig. 116
1. The
EC type timing device has retard/ advance angle characteristics as shown in Fig. 116. (Discrimination can be made by referring to the Bosch-type Number). The retard/advance timing device’s injection timing aligning mark aligning procedure differs from the above, and is explained below.
RI : retard angle value
I
EC type timing device angle characteristics
-
[EC] type timing device)
I
retard-advance
2. Install the coupling between the injection pump and the timing device. 3. Measure the retard angle (RI in Fig. 116) using the timing checker. (Fig. 117) the EC-type timing device service manual for the measuring procedure and special tools.
Mote: Refer to
8 k ii
Fig. 117
Measuring
Measured value
Fig. 118
12-018
Restamping
the retard
angle
Retard angle value
the retard
angle
value
4. Compare the retard angle value measured in Step 3 with the specified retard angle value stamped on the timing device housing. If they are not the same, remove the retard angle vaiue marked on the timing device housing, and restamp the value measured in Step 3. (Fig. 118)
5. Remove the coupling installed between the injection pump and timing device, and attach the timing device to the camshaft. 6. Attach the injection pipes. (Fig. 119)
Fig, 119
Attaching the injection pipes
Operate the pump test stand flywheel manually. 8. Place the No. 1 cylinder plunger in the beginning-of-injection position. (Fig. 120) 7.
Fig. 120 Confirming the No.1 cylinder’s beginning-of-injection position 9. At
this time, the injection pump pointer aligning mark and the timing device housing aligning mark do not match, as shown in Fig. 121, (Injection timing is retarded) The reason for this is that the timing device housing aligning mark has been stamped so that the timing advance angle is “0”, as shown in Fig. 116.
Fig. 121
12-019
FIPPOO
PRECAUTIONS FUEL OIL As inferior quality fuel oil will damage the injection pump and impede performance, use only diesel fuel oils recommended by a reputable authority. Ensure fuel oil is of the correct viscosity, and is clean. As the fuel oil lubricates the plungers, delivery valves, and nozzles, the correct viscosity fuel oil is necessary to ensure adequate lubricaton. Too low a viscosity may result in seizing of these parts. Too high a viscosity results in poor combustion. Particles of dirt, rust etc. are extremely abrasive to the injection equipment, as the moving parts operate with extremely small clearances. Ensure that the fuei oii is ciean, fuei filters are serviced regularly and that storage and
handling facilities are properly maintained and serviced regularly. Too high a sulphur content in the fuel oil adversely affects the injection pump; combustion results in the formation of sulphur oxide which, reacting with any moisture in the fuel oil results in the formation of internal the corroding sulphuric acid, components of the injection pump and the engine. Use only low sulphur-content fuel oil. Moisture in the fuel oil causes the formation of rust inside the injection pump, eventually resulting in seizing of the injection pump’s moving parts. Ensure fuel oil is free of moisture. Excessive carbon residue results in carbon deposits in the engine and on the injection nozzle tips, adversely affecting injection. Use only low carbon-residue fuel oil.
E FUEL FILTER As liquid and solid contaminants in fuel oil adversely affect the injection pump and performance, ensure the fuel oil is properly filtered.
Observe regarding filters.
instructions the manufacturers servicing and replacement of fuel
BLEEDING THE FUEL SYSTEM After installation or reassembly of the injection pump, the fuel system (from the fuel oil tank to the nozzles) must be properly bled and primed to expel all air from the system. Air in the system may result in reduced engine output, improper idling and difficulty in starting the engine. The priming pump attached to the supply pump is used to bleed and prime the system. 1. Fully loosen the priming pump’s screw cap. 2. While operating the priming pump open the overflow valve or air bleeder screw on the fuel oil filter.
3. Continue operating the priming pump until there are no air bubbles in the fuel oil flowing from the valve or screw. 4. Close the valve or screw. 5. Open the injection pump’s overflow valve and continue operating the priming pump until there are no air bubbles in the fuel oil flowing from the injection pump’s overflow valve. 6. Turn the engine over until it starts. The fuel injection system is now properly bled and primed.
12-021
LUBRICATION Use only specified lubricants and observe the specified lubrication quantities and intervals as
described
LUBRICATION LOCATION
below and in the following
TABLE
LUBRICANT (ZEXEL PART NO.)
Injection pump plungers Delivery valves Injection nozzles etc.
Diesel fuel oil (as specified by manufacturer)
Injection pump camshaft Mechanical governor etc. (independently lubricated injection pumps)
Injection Pump oil: 131453-0120 x 1,000
Pneumatic governor diaphragm
Diaphragm oil: 155413-1320 x 60 cc 155413-0220 x 950 cc
Injection pump (engine integrated lubrication system) Camshaft, mechanical governor etc.
Engine oil (as specified by manufacturer)
SCD, SCDM and SBZ type timing devices
Engine Oil (as above)
SAG and SAZ type timing devices
Mobil Oil #20, #3O
SA type timing device
Auto timer grease 156118-0120 x 150 a
REMARKS
Check: cc
Every 4,000 km or 100 hrs. Replace: Every 12,000 km or 300 hrs.
(Auto Timer Grease)
Fig. 124 Injection pump oil, syringe, diaphragm
12-022
table.
oil and auto timer grease
LUBRKATION
PROCEDURE With the independently lubricated injection pump, check oil level and condition using gauge in camshaft chamber; ensure level lies between upper and lower marks. Change oil if dirty or too “thin”. Filling and removal is facilitated by the use of an oil syringe. (Part No. 131499-0320).
Fig. 125 Adding
injection
pump oil
With the engine integrated lubrication system, oil level is checked on the engine side. Ensure engine oil quantity is sufficient by checking engine oil pan. When installing or remounting the injection pump be sure to fill camshaft chamber and governor housing with engine oil.
Diaphragm -’ Drain used pour 4-5 diaphragm intervals of
:ig. 126 Adding
diaphragm
oil oil. through the drain plug and cc of diaphragm oil onto the blades through the filler plug at 4,000 Km, or 100 hours.
oil
4. Auto timer grease After removing the two plugs, screw in the auto timer grease tube and squeeze grease into the timing device.
Fig. 127 Inserting auto timer grease
12-023
OOddM
SPECIAL TOOLS I
To service prepared.
SERVICE Key No.
the
PE(S)-A(D) type
TOOLS _
injection
FOR DISASSEMBLY
Part Number ( ): ZEXEL
pumps,
Tool
P/No.
the
following
special
tools
and general
tools
should
(157944-7820
and
AND REASSEMBLY
Name
Q’ty
vise
1
Used with 157944-8720)
Application
1
Common tool (157944-8520)
Universal
2
Common tool (157944-7820)
Bracket
1
For fixing
PESA(D)
3
Common tool (157944-8720)
Bracket
1
For fixing
PEaA
4
Common tool (15791 O-0300)
Ratchet
1
Used
together
with
socket
wrench
5
Common tool (15791 O-l 120)
Handle
1
Used
together
with
socket
wrench
Common tool (15791 o-51 00)
Pin
2
For fixing each extractor (6 mm diameter)
Common tool (157911-2100)
Spanner
2
For removing and installing pneumatic governor link fixing bolt and nut (SW 9 mm)
8
Common tooi (157913-0100)
Box
wrench
1
For removing and instaiiing supply pump fixing nut (SW 10 mm)
9
Common tool (157913-3120)
Box
wrench
1
For adjusting RSV governor stopper bolt (SW 10 mm)
full-load
10
Common tool (157914-0100)
Socket
wrench
1
For removing and installing of SA and SCD type timing (SW 14 mm)
round nuts devices
11
Common tool (157914-0200)
Socket
wrench
1
For removing and installing standard nuts and bolts (SW 17 mm)
12
Common tool (157914-0300)
Socket
wrench
1
For tightening (SW 19 mm)
13
Common tool (157914-0500)
Socket
wrench
1
For removing and installing valve holder (SW 22 mm)
14
790-l 579150100 (157915-0100)
Wrench
1
For removing and installing RLD, RSV, RAD, RFD governor flyweight fixing nut (2.9 mm wide tooth)
13-002
handle
bracket
Pump
Pump
extractor
bolts
delivery
be
s
.-0
5 .a 2
OOddM
I-Key No.
Part Number P/No.
Tool Name
( ): ZEXEL
Application
Q’ty
.
790-l 579208700 (157920-8700)
Seal
guide
1
For protecting camshaft oil seal (for 17 mm dia. camshaft)
lip
790-l 579205400 (157920-5400)
Seal
guide
1
For protecting camshaft oil seal (for 20 mm dia. camshaft)
lip
Common tool (157921-5620)
Inserter
1
For removing and installing PE(S)lA pump plunger (shim-type tappet adjustment)
Common tool (157931-2500)
Tappet
holder
6
For holding PE(S)mA pump tappet
79D-1579213020 (157921-3020)
Tappet
inserter
1
For Inserting
79D-1579317320 (157931-7320)
Tappet
holder
10
For holding
35
79D-1579250520 (157925-0520)
Extractor
1
For removing PE(S)=A(D) pump bearing outer race (for 20 mm dia. camshaft)
36
79D-1579256520 (157925-6520)
Extractor
1
For removing PE(S) -A(D) pump bearing inner race (for 20 mm dia. camshaft)
37
Common tool (105782-4200)
Measuring
device
1
For measuring PE(S)=A pump camshaft end play (for 17 mm dia. camshaft)
38
Common tool (105782-4130)
Measuring
device
1
For measuring PE(S)lA(D) pump camshaft end piay (for 20 mm dia. camshaft) /
Common tool (157914-2400)
Socket
1
For removing and type timing device (SW 12 mm)
Common tool (157926-5820)
Extractor
1
For removing device (M24
41
I--
Common tool (157926-6920)
Extractor
1
For removing (M22 x 1.5)
42
Common tool (157926-7220)
Extractor
1
For removing SAZ type timing (M26 x 1.5 and M32 x 1.5)
43
Common tool (157916-5320)
Spanner
1
For holding SA, SG type (installed with laminated
44
Common tool (157914-0900)
Wrench
1
For removing and installing pump plug (SW 32 mm)
29
L
I= I
13-004
wrench
high speed
PE(S) =AD
PE(S)*AD
pump
pump
tappet
tappet
installing SCDM fixing nut
SCD, SAG x 1.5) SCDM
type
type
type
timing
timing
device
device
timing device coupling) supply
Key No.
Part Number P/No.
Tool Name
( ): ZEXEL
Application
Q’ty.
45
Common tool (157925-8120)
Guide
1
For installing outer race
46
Common tool (157925-9120)
Guide
1
For installing .PE(S)=A pump bearing inner race (for 17 mm dia. camshaft)
47
Common tool (157925-9300)
Rod
1
For installing PE(S) -AD-S pump governor side bearing inner race (used together with holder: part no. 1579259700)
48
Common tool (157925-9400)
Rod
1
49
Common tool (157925-9500)
Push
50
Common tool (157925-9600)
51
52
NOTE:
For installing side with
bearing holder:
PE(S) #A pump
PEW AD-S
bearing
pump
drive
inner race (used together part no. 157925-9700)
1
For installing PE(S) -AD-S pump ourter race (used together with part no. 157925-9600)
Bush
1
For installing PE(S) -AD-S outer race (used together rod: part no. 157925-9500)
pump bearing with push
Common tool (I 57925-9700)
Holder
1
For installing PE(S) =AD-S inner race (used together key nos. 47 and 48)
pump bearing with rods:
Common tool (157921-6120)
Inserter
1
For removing and pump plunger
The special 4 to 39.
tool
KIT (105790-I
rod
060)
for the
PE(S) =A, AD
pump
includes
inserting
tools
with
bearing bush:
PEW AD
key numbers
13-005
4
;3
,c -__q’
/’
,/-; __\ L.9 l-.1,
FIPPOO
OOddM
co
0
b
8
Y
FIPPOO
V
OOddld
n
a
FIPPOO
r-l
R
CL >
3
.a a
PI
LiJ W
F
x lA 0
W
3 > n W n
I
0 CL X W
261
v901 _ .^A. 8 ?I6
OOddM
EXPLODED VIEW OF THE SUPPLY PUMPS KS type
KE type
0
77 _-
I
13-012
t-25
DISASSEMBLY PREPARATION Keep the work bench clean and tidy. Before beginning disassembly, record performance data for later reference. This data will facilitate detection and diagnosis of malfunctions and defects, if any, in the disassembled pump.
In the course of disassembly, lay out the disassembled parts neatly and sequentially on the work bench, labelling if necessary. This will make the reassembly much easier.
INJECTION PUMP DISASSEMBLY Clean the outer surface of the pump before disassembly. Remove grease and dirt, and drain the pump camshaft chamber and governor chamber. Collect the drained pump oil so that it can be examined. ) are those key The number in brackets ( numbers described in Fig. 18. Special service
toois are also indicated -with their part numbers in brackets. This section describes the disassembly of the RLD governor mounted on the PE6A type fuel injection pump.
1. Mount bracket (157944-8720) (Fig. 20) vise (1&7Q/I4-8520). \ I"I V-r
Fig. 20 Mounting
on universal
the bracket
2. Securely attach the injection pump to the bracket using the four bolts. (Fig. 21)
Fig. 21 Attaching
the injection pump
13-013
FIPPOO
j-
OOddki
4
c7
FIPPOO
A
17. Lay the pump on its side as shown in Fig. 31., and remove the screw plugs (16) using the L-shaped handle. (Fig. 31)
Fig. 31 Removi
!?g
the screw plug
18.With a screwdriver (96). (Fig. 32)
remove the two screws
0
2 n ii
Fig. 32
Removing screw
the center
bearing
fixing
19. Secure
the pump upright in the universal vise and remove the coupling from the camshaft using the socket wrench. (Fig. 33)
Fig. 33
Removing
the coupling
13-017
\
-\\
FIPPOO
23. Remove the camshaft together with the center bearing from the drive side. (Fig. 37)
Fig. 37 Remov,t,,inn the camshaft
24.Again lay the pump on its side. Insert the (A: 157921-0120, tappet inserter AD: 157921-3020) into the bottom plug hole. 25. Push the tappet using the tappet inserter and remove the tappet holder. (Fig. 38)
Fig. 38 Removing
the tappet holder
26. Insert the clamp (157931-6120) through the bearing cover hole, clamp the tappet and remove it from the pump housing. (Fig. 39)
Fig. 39 Removing the tappet
13-019
27. Remove the plunger (30) together with the lower spring seat (63), using inserter (A: 157921-5620, AD: 157921-6120). (Fig. 40) Caution:
Fig. 40 Removing seat
the plunger
and lower
Be careful not to let the plungers contact other parts during removal. Place them in clean fuel oil in their order of removal.
spring
28. In the case of the standard type pump, use inserter (157921-4120). Pinch the plunger as shown in Fig. 41 and remove the plunger from the plunger barrel. (Fig.41)
Fig, 41 Removing the plunger and lower seat (for standard type pump)
spring
29.Through the bottom plug hole, remove the plunger spring (61). (Fig. 42)
Fig. 42 Removing
13-020
the plunger
spring
OOddM
34.
Fig. 46
Removing
the delivery
valve
Remove the delivery valve assy. (36) and gasket (40) using a pair of tweezers. Place the delivery valves in clean fuel oil in their order of removal, as was done with the plungers. (Fig. 46)
and gasket
35. If the delivery valve gasket is 66 nylon, screw the extractor (I 57920-0320) into the delivery valve (36), push the pin down and remove the delivery valve and gasket. (Fig. 47)
Fig. 47
the delivery Removing _ y,,LI ylull yasket
valve
and 66
36. Push the plunger barrel by finger to remove. Attach them to their corresponding plungers, and place in fuel oil. (Fig. 48) Caution:
Fig. 48
13-022
Removing
the plunger
barrel
Be sure to keep each plunger with plunger barrel. its corresponding barrels are not and If the plungers between matched, the clearances them may not meet the standard values.
OOddM
\\ ‘\\\ _i
40. Remove the bearing’s outer race from the bearing cover using extractor (17 mm dia.: 157925-0120, 20 mm dia. : 157925-0520). (Fig. 52) Disassembly of the injection pump is now complete. The disassembled parts should be washed thoroughly with clean fuel oil.
Fig. 52
Removing
the bearing
outer
race
SUPPLY PUMP DISASSEMBLY The numbers in parenthesis following the part names indicate the key numbers in Fig. 19. 1. Clamp the supply pump in a vise. (Fig. 53) Caution:
Fig. 53 Clamping
the
Use vise jaw cover to avoid damaging the pump housing.
supply pump
2. Remove the eye bolts (30, 32), eye and gaskets (35, 36). 3. Using a spanner (SW 24 mm), remove the priming pump (25) and O-ring (18). (Fig. 54)
Fig. 54 Removing
13-024
the priming
pump
.-cn LL
OOddM
0) ii
10. Clamp the supply pump in the vise so that the tappet assembly (10 ) faces upward. 11. Remove the snap-ring (20) holding the tappet. (Fig. 58)
Fig. 58
Removing
the snap-ring
12. Remove the tappet assembly. 13.Draw out the pushrod (1).
(Fig. 59)
Disassembly of the supply pump is now complete. The disassembled parts should be washed thoroughly in clean fuel oil.
Fig. 59
13-026
Removing
the tappet
INSPECTION GASKETS AND O-RINGS Replace all gaskets and O-rings when they are removed. Do not reuse.
PLUNGER 1. Clean the plungers and plunger barrels in fuel oil. Check that the plunger helix is not damaged, that the color of the plungers and plunger barreis has not changed and that the plungers move smoothly in the plunger barrels. If there are problems, replace plunger assemblies. (Fig. 60)
Fig. 60 Plunger
helix
r 2. After cleaning the plunger with clean fuel oil, make sure that the plunger slides smoothly into the barrel under its own weight when the plunger iassembly is inclined 60” as shown in Fig 61. Change the plunger position by rotating it and check plunger movement several times in the above manner. If the plunger slides into the barrel too quickly or does not slide smoothly, replace the plunger assembly.
Fig. 61 Plunger
slide test
13-027
o-l
P
FIPPOO
1. Check the tappet rollers, bushes and pins for excessive wear, flaws or peeling. If found, replace the tappet. (Fig. 65)
Fig. 65 Tappet
Check the top surface of the tappet adjusting bolt or lower spring seat, which contacts th’e lower end of the plunger, for damage. If damaged replace the tappet adjusting bolt or lower spring seat. (Fig. 66) 3. Before replacing the tappet adjusting bolt, measure the distance between the tappet roller and the top surface of the adjusting bolt so that the same distance may be retained after replacement with a new adjusting bolt. This will facilitate later adjustment. 2.
I
Fig. 66 Lower spring
seat and adjusting
bolt
CAMSHAFT AND BEARINGS 1. Check the camshaft for a damaged or worn cam surface. Also check for damage to the thread on both ends of the camshaft, and check that the key groove is not damaged. (Fig. 67)
Fig. 67 Camshaft
13-029
FIPPOO
In generai, reassembly procedure is the reverse of disassembly, so only points requiring special attention are explained below. Plunger barrel installation Install the plunger barrel so that the locating pins in the pump housing correctly contact the grooves in the plunger barrels. (Fig. 71)
Fig. 71
Installing
the plunger
barrel
Ensure that the barrel cannot manually. (Fig. 72)
Fig. 72 Assembled
plunger
be rotated
barrel
Delivery valve installation Place the delivery valve, together with a new gasket, on the plunger barrel. When using the 66 nylon gasket lightly tap the extractor (157926-0120) to secure the gasket against the delivery valve seat. (Fig. 73) Note:
Fig. 73 Attaching
the 66 Nylon
When the gasket is securely in contact with the delivery valve seat the sound generated by tapping the extractor changes. Do not tap the extractor after the gasket is correctly contacting the valve seat.
gasket
13-031
Fig. 74 Tightening
the delivery
valve
holder
3. Delivery valve holder installation (1) After installing the delivery valve spring, fix the delivery valve holder. (Fig. 74) Tightening torque: 1) Tighten to 3.0 Kg-m Nylon gasket: 2) Loosen to 0 Kgam 3) Retighten to 3.0 Kg-m 4) Loosen to 0 Kgsm 5) Finally tighten to 3.5 Kg-m I) Tighten to 4.0 Kgam Metal gasket: 2) Loosen to 0 Kg-m (Delivery valve holder: M20x 1.5) 3) Retighten to 4.0 Kgem 4) Loosen to 0 Kg-m 5) Finally retighten to 4.5 Kg-m 1) Tighten to 5.0 Kg-m Metal gasket: 2) Loosen to 0 Kg-m (Delivery valve holder: M24~1.5) 3) Retighten to 5.0 Kgem 4) Loosen to 0 Kg-m 5) Finally retighten to 5.5 Kg-m 4. Control rack installation (I) Insert the control rack into the pump housing. (2) Screw the guide screw into the back of the pump housing, and ensure the control rack moves smoothly.
0 0 k ii
5. Control sleeve installation (1) Lay the pump housing on its side. (2) Position the control rack referring to the marking lines on both ends of the control rack. Ensure that the distances from the marking lines to the sides of the pump housing are the same. (Fig. 75)
Fig. 75
13-032
Positioning Dosition
the control
rack in the centre
OOddlj
0_
.-c
iD” ..
FIPPOO
Ql
-.
.-0, Ll-
OOddM
.-UI LL
cl,
.-
I I
12. Control rack stroke Ensure control rack stroke is 21 mm, from the position where the control rack is fully pushed toward the governor to the position where it is fully pulled toward the drive side. Use a vernier caliper or depth gauge to perform measurement. (Fig. 84) Note:
Fig. 84
Measuring
the control
If the control rack 21 mm reengage with the control control rack stroke
stroke is not within the control pinion rack to obtain the of 21 mm.
rack stroke
73. Lock plate tightening Secure the lock plate with the specified tightening torque shown below. (Fig. 85) Tightening Torque Rectangular lock plate: 0.45 to 0.6 Kgmm Triangular lock plate: 0.35 to 0.5 Kg-m
Fig. 85 Tightening
13-036
the lock plate
I
a P 2
a
Iv) W
t) 2
a
z W
I-
z
-
. :
OOddkl
By Specified
M6; 0.5-0.7
Torque
(Nylon
Gasket) Gasket)
For Governor
I i
M4; 0.3 (Minimum
Torque)
The torques
M12; M6m
FIPPOO
not specified
z-2.5\
M24; 6.5 - 0 - 6.5 - 0 - 6.5+“.5 (Metal Gasket)
M20; 4 - 0 - 4 - 0 - 4+“.5 (Metal
M20; 3-3.5
5_,,
7-7
5 _._
should
conform
.5 (Copper
MIO; 1.2-I
I
to Standard
Gasket)
Gasket)
(Nylon
(Stud Bolt)
,
MlO; 0.5-0.7
in this drawing
o
, .
MIA. I., .
Tightening
/M12;
Torques.
Unit: Kg-m
6-7
M14; 8.5-10
m
C
13
m
0
-I
2 c)
m
*sanblol
6u!ua~y6!1
p~epuels
laddo
01 LUJO~OD plnoys
(iayseg
6u!~e~p s!y~ u! pa!ywds
/
IOU sanblol
iptm
1 IPL Vu
@uJo:)) 9-Z-Z
uolAN) %I,-&
pue 6uyed
(WsW
OOddM
ayl
M26; 8-9
\ \ \
~18;
FIPPOO
The torques
4-4.5
not specified
\
in this drawing
M16; 4-4.5 -7
M24; 2-2.5
M16; 4-4.5
M8; 0.5-0.8\
M5; 0.5-0.8
should
/
conform
to Standard
Tightening
Torques.
Unit: Kg-m
and Copper Gasket)
: .
m .
.
. . :
.
. .
.
;
:
: .
OOddld
FIPPOO
Malfunctions Engine “knocks”
“Black smoke” and engine “knocks”
Uneven engine output
Causes 1. Injection timing is too early 2. Nozzle opening pressure is excessively high 3. Injection holes are slightly clogged (in case of hole-type nozzle) 4. Nozzle injection function has deteriorated 1. Injection timing adjustment was incorrect 2. Nozzle opening pressure is excessively low 3. Nozzle spring is broken 4. Nozzle injection function has deteriorated 5. Plunger is worn excessively 6. Faulty delivery valve seat 7. Fuel injection quantity is too large, and injection timing is adjusted incorrectly 1. Clogged filter element results in insufficient fuel oil supply 2. Insufficient supply pump delivery 3. Air remains in injection pump 4. Fuel oil contains water 5. Plunger tends to stick and does not reach its full stroke 6. Plunger spring is broken 7. Control rack does not move smoothly 8. Tappet does not move correctly, or one part is worn excessively 9. Delivery valve spring is broken 10. Faulty sealing by delivery valve gasket due to insufficiently secured delivery valve holder 11. Delivery valve does not function correctly 12. Faulty nozzle injection function 13. Nozzle needle valve does not move smoothly 14. Nozzle spring is broken 15.The nozzle opening pressures for each cylinder differ excessively 16. Injection timing is not adjusted correctly 17. Control lever does not contact fullload stopper
Remedies Readjust Readjust Clean or replace Replace Readjust Readjust Replace Clean or replace Replace Replace Readjust
Clean or replace Replace check valve Purge of air Change to high grade fuel Replace Replace Repair or replace Replace Replace Replace gasket and secure delivery valve holder to the specified torque Replace Clean or replace Replace Replace Readjust Readjust Adjust the rod length between accelerator pedal and governor control lever
15003
Engine output is insufficient 1. Insufficient fuel injection quantity
Remedies
Causes
Malfunctions
The governor full-load stopper is not correctly positioned 2. Control lever does not reach fullload position 1.
3. Governor spring is stretched such that the governor starts functioning while the engine operates at a relatively low speed 4. Plunger is worn excessively 5. Delivery valve gasket is damaged, causing leakage (Delivery valve holder is not secured correctly) 6. Delivery valve seat is damaged 7. Delivery valve is damaged 8. Excessive amount of fuel oil leaks from nozzle
15004
Replace Replace
Replace Replace Replace
Readjust
Clean or replace 1. Governor spring force is too weak
Readjust
2. Control lever does not contact fullspeed stopper
Adjust the rod length between accelerator pEXhi and governor control lever Clean or replace
3. Nozzle injection function teriorated Engine maximum speed is excessively high
Adjust the rod length between accelerator pedal and governor control lever Readjust or replace
Replace Readjust
2. Nozzle spring is broken 3. Engine “knocks” due to early injection timing 4. Engine has overheated and “black smoke” is emitted due to late injection timing 5. Nozzle injection function has deteriorated Engine speed does not reach its maximum
Readjust
has de-
1. Control rack does not move
smoothly 2. Governor spring force is too strong 3. Governor flyweight does not operate adequately 4. idling-sub spring or damper spring is not adjusted correctly
Repair or replace Readjust Replace Readjust
OOddM
2
I-.
3 -. Gf & -. 5 -.
0
b .
FIPPOO
c.n ul
0 . . . . . . . . . . coo3\lol
bin
46,
-8-G -8 -8
UludN-~ .. .. .. .. ..
7 2
3
-2 --.
u-l
b.2
cd
cL)cDcn . . . . . .
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P
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E
x
.-5
72 -.-s
E 2
.-5
5t ..3
-is .-al
2
.-5 .-+-J
OOddH
5 7
x
FIPPOO
g
i?
I3
-.
a
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u
L.
cn %-
ET
z
3 -.
co w -.
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0,
cn pl,
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e
e
lil
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.
.
. .
. .
.
.
n cn
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0
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. .
.
.
.
u
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cn
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z --I
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.
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n C
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R
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cn
.
F r-
2 m
c) m
2 -I cn
m
2 -I
0
c)
2 W
w, 0
OOddld
FUEL INJECTION
SYSTEM OUTLINE Injection pipe
Nozzle holder
Overflow
valv
Fig. 1 Diesel engine’s
fuel injection
system
Fig. 1 shows the diesel engine’s fuel injection system. Engine rotation is transmitted to the injection pump camshaft by a coupling or drive gear through the timing device. The supply pump, driven by camshaft rotation, sucks fuel oil from the fuel oil tank and supplies it to the fuel oil filter at a pressure of 1.82.5 kg /cm*. Filtered fuel oil is then sent through the fuei oil chamber in the injection pump housing to the plunger. The plunger, raised by camshaft rotation, further increases the fuel oil pressure, with the fuel oil then being delivered through the injection pipe and the nozzle holder to the nozzle. When the high pressure fuel oil delivered to the nozzle exceeds the specified nozzle opening pressure it is injected into the engine’s combustion chamber.
01-002
/
Because the quantity of fuel oil supplied by the supply pump is at least twice the injection pump’s maximum injection quantity, overflow valves are installed at the top of the filter or on the injection pump to return excess fuel oil to the fuel tank when the fuel oil pressure exceeds a set value. Fuel oil which has lubricated the inside of the nozzie and nozzie holder is returned to the fuei tank or the filter through the nozzle holder’s overflow nipple. The priming pump installed on the supply pump is used to manually bleed air from the fuel pipes and to feed fuel oil from the fuel oil tank to the injection pump. Note: Take care not to bend the injection pipes at too acute an angle (radius: less than 30 mm).
PRINCIPAL SPECIFICATIONS injection pump type
PI
-P3
P-S
Plunger stroke (mm)
10
11
12
21
Control rod travel (mm)
1 to12
I
Number of cylinders
21
Plunger diameter (#mm) & Maximum allowable injection quantity
1 to12
I
I
Plunger diameter
Injection quantity
Plunger diameter
Injection quantity
10.0
235
(I 0.0)
(235)
11.0
285
11.0
285
11.5
310
11.5
310
(mm3/stroke)
12.0
1
Plunger lead (Standard tvoe)
340
I
12.0
1
340
22 mm
INJECTION QUANTITY
CHARACTERISTICS Injection quantity characteristics for the various plunger diameters are shown in Fig. 2.
I
I
I
Plunger dia.: 10 to 12 @mm Plunger lead: 22 mm Cam lift: 10 mm
/
400
5 10 15 Control rod position (mm)
Fig. 2 Injection quantity
I,
20 -+
characteristics
01-003
I I
a 2
a
OOddM
8
I
N
0 0
FIPPOO
0 2
0 2 P 2 u 0 v m
As shown in Figure 4, the plunger and delivery valve etc are fixed in the sleeve flange to form the plunger block assembly. The plunger block assembly is then attached to the pump housing. The plunger barrel is positioned by a knock pin press-fitted to the sleeve flange.
Deliverv valve hol
Sleeve flange
A deflector is attached to the outside of the plunger barrel by a snapring to prevent corrosion of the pump housing caused by the reverse flow of fuel generated at the end of injection. FSucfion-delivery
port
/ Plunger
+
Fig. 4 Plunger
block assembly
O-rings are installed to prevent leakage of the fuel oil from the fuel oil chamber. To increase the oil-tightness of the delivery valve a metal gasket is installed on its highpressure side, while an O-ring is installed on the delivery valve holder (low-pressure side). (Fig. 5)
-ring
Fig. 5 O-ring
and gasket positions
11-003
FI PPOO
A cover is installed at the bottom of the pump housing and is secured by screws. The PE-P type injection pump generally employs an integrated lubrication system to circulate the engine’s lubricating oil. The engine’s lubricating oil is forced, through an inlet adjacent to the tappet’s sliding portion, to the injection pump’s cam chamber to lubricate the cam chamber and the governor chamber before returning to the engine. (Fig. 8)
Fig. 8 Injection pump lubrication
system
OPERATION
Control sleeve
Figure 9 shows the operation of the PE(S)-P type injection pump. Engine rotation is transmitted through a coupling (or drive gear) and timing device to the injection pump camshaft. This rotational movement is changed to reciprocating movement by the tappets to operate each cylinder’s pump element (plunger assembly). The plungers are lifted by the camshaft and returned by the plunger springs in a reciprocating motion. A fuel oil chamber is located in the pump housing, and this chamber is always filled with low pressure fuel oil filtered by, and delivered from, the fuel filter. The plunger barrel’s suctiondelivery ports open onto this fuel oil chamber.
Fig. 9 PE(S)-P type injection pump operation
11-005
C
A Fig. IO Fuel-suction
process
During the camshaft’s downward stroke the plunger is forced down by the plunger spring, and when the plunger’s upper end-face meets the plunger barrel’s suction-delivery port fuel oil is first sucked into the plunger barrel. (Fig. 1 O-A)
Suction is completed when the plunger reaches its lowest position. (Fig. 1 O-B) With further camshaft rotation the camshaft begins its upward stroke and the plunger spring is compressed as the plunger is raised. (Fig. 1O-C)
When the plunger’s upper end-face closes the plunger barrel’s suction-delivery port, compression of fuel oil begins. This closed position is referred to as the beginning of static injection. (Fig. 1 I-A) As the piunger ascends, the fuel oii pressure exceeds the set force of the delivery valve spring and the residual pressure of the fuel oil in the injection pipes, the delivery valve is raised, and delivery of fuel oil to the nozzle holder begins. With further ascent of the plunger, injection continues. (Fig. 1 I-B)
Fig. 11 Fuel-delivery
11-006
process
(I)
As the plunger continues to ascend, the plunger helix meets the plunger barrel’s suctiondelivery port. (Fig. 1Z-A) Because the compressed fuel oil simultaneously escapes to the fuel oil chamber, the pressure inside the plunger barrel suddenly decreases. Then, because the delivery valve is forced down by the delivery valve spring, delivery of fuel oil is completed. (Fig. 12-B)
J
Fig. 12 Fuel-delivery
process (II)
Control rod
i0 in-delivery -
Plunger flange
Control sleeve
I Fig. 13 Mechanism for varying plunger’s effective stroke Effective stroke
Although the plunger may continue to ascend, further delivery of fuel oil can not be performed. Variations in the quantity of fuel delivered by the plunger are performed by varying the plunger’s effective stroke. Figure 13 shows the mechanism for varying the plunger’s effective stroke. The plunger barrel is fixed to the sleeve flange by a knockpin and cannot move. However, the plunger construction is such that it can move both up and down and rotate. Each plunger’s flange is inserted into a control sleeve groove. Balls are welded to the control sleeve and these balls are inserted into grooves in the control rod. Because of this, movement will result in simultaneous cylinders’ plungers, thereby tive stroke and increasing or jection quantity.
of the control rod turning of all the varying the effecdecreasing the in-
The effective stroke indicates the stroke during which fuel is delivered, from the beginning of static injection to the end of injection, and is proportional to the fuel injection quantity. (Fig. 14)
&Plunger
Fig. 14 Plunger’s effective stroke
11-007
INJECTION PUMP: MAIN COMPONENTS Plunger Assembly
I
Fig. 15 Double helix plunger
The plunger can be manufactured with identically shaped helixes in diameterically opposed positions which act to rapidly return the fuel oil at the top of the plunger to the fuel oil chamber following the end-of-injection. (Fig. 15)
Helix
Beginningof-injection
The plunger, which both pressurizes the fuel oil and varies the fuel injection quantity, is the most important component of the injection pump. As the sliding portions of the plunger and the plunger barrel are finished to extremely precise specifications, the components of the plunger/ plunger barrel pair can not be interchanged or used separately. The plunger is manufactured with a helix, and at the edge of the helix is a vertical groove which opens onto the plunger’s upper endface. Two suction-delivery ports are located in the plunger barrel, in diametrically opposed positions.
Delivery
-4
Endof-injection
Fig. 16 Plunger’s effective stroke
When the plunger’s upper end face closes the plunger barrel’s suction-delivery port fuel oil delivery (injection) begins, and when the plunger’s helix meets the plunger barrel’s suctiondelivery port, delivery (injection) simultaneously finishes. This period is referred to as the effective stroke. (Fig. 16) Cutting of the fuel oil delivery (non-injection) is also utilized as one method of stopping the engine, where by operating the control rod, endof-injection may be obtained at the same time as the beginning-of-injection. (Fig. 17)
Non-delivery
Fig. 17 Engine-stopping
11-008
mechanism
8 & h
As shown in Figure 18, plungers or left helix types.
may be right
When right helix type plungers are rotated clockwise (viewed from the bottom of the plunger) the effective stroke is increased, and when left helix plungers are rotated counterclockwise, their effective stroke is increased. The use of either right or left helix plungers is dependant on the installation position of the governor.
Left helix
Right helix
Fig. 18 Plunger helixes
Delivery Valve Assembly
Delivery valve spring
a: retraction stroke
The delivery valve assembly consists of the delivery valve and the delivery valve seat. When high pressure fuel oil delivered from the plunger exceeds the pressure of the delivery valve spring force and the residuai pressure of the fuel oil in the injection pipe, the delivery valve spring is compressed, the delivery valve opens and fuel oil is delivered via the injection pipe to the nozzle holder. Then, when the plunger helix meets the plunger barrel’s suction-delivery port, delivery of fuel oil finishes, and the delivery valve is rapidly closed by the delivery valve spring.
Fig. 19 Delivery valve assembly
Thus, the injection pipe’s residual pressure is retained, enabling rapid completion of the subsequent injection operation, with the delivery valve also acting to prevent reverse flow of fuel oil. However, adverse effects may result from the cutting of fuel oil delivery after the end-ofinjection if the residual pressure is too high. To overcome this, the fuel oil in the injection pipe is only retracted an amount equal to the piston’s retraction stroke “a“ (Fig. 19) and the residual pressure is adjusted, thereby preventing leakage of fuel oil from the nozzle following the end-of-injection. (Fig. 19)
11-009
Tangential
Fig. 20 Camshaft
Convex
cam
cam
Eccentric
cam
Tangential/eccentric
cam
cam shapes
Camshaft The camshaft is rotated by the engine’s drive shaft (through the coupling or gear) and the timing device, while the plungers and the supply pump are operated by the camshaft via the tappets. Cam shapes may be tangential, convex or eccentric, or a combination of these (e.g.
tangential/eccentric cams). Cams are chosen depending on the engine’s specifications. Tangential cams or combination cams (generally tangential/eccentric cams) are generally used to operate the plungers. An eccentric cam is also installed specifically to drive the supply pump. (Fig. 20)
Tappet Assembly
Lower spring
The tappet assembly construction is shown in Fig. 21. Rotational movement of the injection pump camshaft moves the plunger up and down, and is therefore changed to reciprocating movement.
seat
guide
Roller bush/
Fig. 21 Tappet assembly
11-010
W
-42
16 I8 15
1. Housing
14
2?
5. 6. 10. 14.
Piston Piston spring Tappet Check valve
15. Check valve spring 25. Priming pump 30. Eyebolt (filter inlet) 32. Eyebolt
;
f-g. ee KU rype supply
pump: exploded
35. Gaskets 36. Gaskets 42. Cover
view
KD Type Supply Pump g k E
Fig. 22 shows an exploded view of the KD type supply pump, a large number of which are used with the PE(S)-P type injection pump. The KD type supply pump differs from the single-action KE type supply pump used with
/
the PE-A(D) type injection pump in that the KD type is a double-action type supply pump with 4 check valves. Fig. 23 shows the standard operation of the KD type supply pump.
Camshaft
Piston spring chamber /
A Suction Delivery
B Suction Delivery
Fig. 23 KD type supply pump operation
11-011
As shown in Fig. 23-A, when the camshaft cam pushes the tappet the piston is also pushed via the pushrod, and the fuel oil pressure in the piston spring chamber increases. Because of this the suction side check valve closes, the delivery side check valve opens, and the fuel oil in the piston spring chamber is fed via the fuel filter to the injection pump. Meanwhile, because the pushrod chamber’s fuel oil pressure decreases, the delivery side check valve closes, the suction side check valve opens, and fuel oil is sucked from the
11-012
fuel oil tank to the pushrod chamber. Furthermore, as the camshaft rotates to the position shown in Fig. 23-B the piston is pushed by the piston spring, the fuel oil in the pushrod chamber is fed via the fuel filter to the injection pump, and new fuel oil is sucked from the fuel oil tank to the piston spring chamber. In this way one reciprocating movement of the piston results in two suction and delivery actions, and suction and delivery are continuous during injection pump operation.
a
a
. .. : ..
. .. : ..
. .. : ..
. .. : :
. .. : :
. .. : : .: : :
.: : :
: : .:
: : .:
: : .:
: : .:
: : :-
OOddld
: : .:
KEY NO.
PART NO.
1 2
105780-2080 105780-0000
Nozzle holder Nozzle
3
157805-4720
injection
4 5
105780-2090 105780-0050
Nozzle holder Nozzle
12 1 12
6
157805-5420
Injection pipe
1
7
105781-0420
Fixing stand
2
8
15781 I-0920
Flange
1
9
105781-0450
Fixing stand
1
10
105781-0180
Fixing stand
1
11
105781-0480
Fixing stand
2
12
157840-3620
Flange
1
13
105781-0160
Fixing stand
1
14 15 16 17 18 19 20
157827-6520 ? 57827-6820 105782-4270 157954-3700 157912-2000 157840-0900 157916-8220
Adapter Connecter Measuring device Dial gauge Spanner Lever Wrench
1
21
157970-0500
Measuring
1
22
157842-6220
Coupling
1
23
157842-4620
Coupling
1
24
157840-4020
Coupling
1
25
157916-0200
Box spanner
1
,
12 12 I 1 (set)
pipe
cylinder
Note: 1. The I5 NP type test stand is provided 20, 22 and 23) as standard.
12-002
Q’TY
TOOL NAME
1
1
1 1 1 1
APPLICATION For adjusting injection timing and injection quantity. Injection quantity: up to 200 cc/l000 st (Assembly No: 105780-8140) For adjusting injection timing and injection quantity (set of 12) For adjusting injection timing and injection quantity. Injection quantity: exceeds 200 cc/ 1000 st (Assembly No: 105780-8130) For adjusting injection timing and injection quantity (set of 6) For mounting PE-P type injection pump (for 15 NP type test stand) For mounting PE(S)-P type injection pump (for 15 NP type test stand) For mounting P.E(S)-P type injection pump (for 15 NP type test stand) For mounting PE(S)-P type injection pump (used together with 15781 I-0920) For mounting PE-P type injection pump (for 10 NP type test stand) For mounting PE(S)+P type injection pump (for 10 NP type test stand) For PES-P type injection pump (used together with 157840-3620) For measuring control rod position , For mea.siJring
control
rod positien
For measuring plunger pre-stroke For measuring control rod position For removing delivery valve holder For manual flywheel operation For operating the nozzle holder over-flow valve. For measuring quantity of test oil discharged from supply pump. For driving injection pump (for 25 mm dia. camshaft) For driving injection pump (for 20 mm dia. camshaft) For driving injection pump (installation pitch: $66; $72) For removing and installing injection pipes (SW1 9)
with tools (Key Nos. 1 to 3, 7 to 10, 14, 15, 17, 19,
2. The adjustment kit (Part No.: 105765-1250) for the PE(S)-P type inject ion pump includes tools with key numbers 16 and 25. 4. The centre height* of the IO NP type test stand is 100 mm. 3. The centre height* of the 15NP type test stand is 125 mm *The centre height is the distance from the pump test stand bent I-I to the centre of flywheel rotation. (SW refers to the width across flats of bolts etc in mm) 2
A15
3 M14Xl.5 \”
5
6
14x1.5
.8
8
MIOXl.S/
Fig. 25-l
12-003
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ADJUSTMENT After reassembling the injection pump, adjust it in the following manner using the injection pump test stand. Prepare the special service tools described in “Service Tools for Adjustment”.
PREPARATION 1. Using the fixing stand, mount the injection pump on the pump test stand. Test stand type 15NP
IONP Fig. 126 Injection pump installed on the test stand _!I
II
” I 3
M IT II I I I I I I I I I
Fig. 127 Adding lukxicating
12-006
oil
I
Fixing Stand Part Number 105781-0420 15781 I-0920 10578 I-0450 105781-0180 105781-0480 157840-3620 105781-0160
2. Connect the fuel pipes and the injection pipes. (Fig. 126) 3. Fill the injection pump cam chamber and the governor chamber with lubricating oil (131453-0121). (Fig. 127) Amount: 50-60 cc for each cylinder.
8 k iz
4. Attach the measuring rod tip. (Fig. 128)
Fig. 128 Attaching
the measuring
device to the control
device
5. Adjust the speed control lever so that the pump’s governed speed is 500-600 r.p.m. (Fig. 129)
Fig. 129 Adjusting
the speed control lever
12-007
6. With the pump above, operate the contacts the idling control rod towards set the measuring tion. (Fig. 130) Note:
Fig. 130 Setting the control rack’s “0” position
as described adjusted load control lever until it stopper bolt, move the the governor side and device to the “0” posi-
1. The method of setting the measuring device’s “0” position differs according to the type of governor. service relevant Refer to the manual. 2. If the pump is not operating when device is set to the measuring “0”, excessive force will be applied to the linkage. Be sure to operate the pump when setting the measuring device to “0”.
INJECTION TIMING ADJUSTMENT 1. Exchange the pump overflow
valve for the
plug (02911 I-4050). 2. Using a socket wrench (SW22) remove the No. 1 cylinder’s (viewed from the drive side or the governor side) delivery valve holder. (Fig. 131) 3. Remove the delivery valve assembly.
Fig. 131 Removing the No. 1 cylinder’s delivery valve holder
4. Screw the measuring device (I05782-4270) onto the sleeve flange. (Fig. 132) 5. Maintain the control lever in the full-load position.
Fig. 132 Attaching
12-008
the measuring
device
6.
Rotate the test stand’s flywheel in the specified direction to set the No. 1 cylinder’s tappet in the bottom dead centre (B.D.C.) position. (Fig. 133)
Fig. 133 Setting the tappet’s bottom-deadcenter position 7. Set
the measuring device’s dial WJge indicator to “0”. (Fig. 134) Then, supply test oil to the injection pump at as low a pressure as possible; eg. 0.2 kg/cm2.
Fig. 134 Setting the measuring position
device’s “0”
8. Rotate the test stand’s flywheel in the specified direction and measure the No. 1 cylinders’ pre-stroke (from the dial gauge reading) at the point where fuel oil ceases flowing from the measuring device’s overflow pipe. (Fig. ‘135) Note:
Fig. 135 Measuring
the pre-stroke
1. Reverse helix plungers are used with some pumps, depending on the pump specifications. In this case the tappet is placed in the top dead centre position, the dial gauge is set to “0” and the flywheel is rotated in the reverserotation direction. The pre-stroke is then measured when fuel oil ceases flowing from the measuring device’s overflow pipe.
12-009
2. Pre-stroke indicates the amount of plunger movement from the bottom dead centre position until the plunger’s end-face closes the plunger barrel’s suction-delivery port (beginning-of-static-injection position). (Fig. 136)
Fig. 136 Beginning-of-static-injection
position
9. If the pre-stroke value measured in 8. above is outside the specified value, the thickness of the shim (23/l) must be altered to adjust the pre-stroke. (Fig. 137) When injection timing is retarded: replace the shim with a thinner shim. When injection timing is advanced: replace the shim with a thicker shim. Table 1 shows the types of adjusting shim.
Fig. 137 Adjusting
the pre-stroke
Thickness (mm) 0.5 139400-0900 -1000 0.525 -1100 0.55 0.575 -1200 -1300 0.6 -1400 0.625 -1500 0.65 -1600 0.675 -1700 0.7 -1800 0.725 0.75 -1900 -2000 0.775 -2100 0.8 -2200 0.825 139400-2300 0.85 Part Number
Part Number
Thickness (mm) 139400-2400 0.875 -2500 0.9 -2600 0.925 -2700 0.95 -2800 0.975 -2900 1.o -3000 1.025 -3100 1.05 -3200 1.075 -3300 1.I -3400 1.I25 -3500 1.15 -3600 1.I75 -3700 1.2 139400-3800 1.225 Table
12-010
Part Number
Thickness (mm) 139400-3900 1.25 -4000 1.275 -4100 1.3 -4200 1.325 -4300 ? .35 -4400 1.375 -4500 1.4 -4600 1.425 -4700 1.45 -4800 1.475 -4900 1.5 -5000 1.525 -5100 1.55 -5200 1.575 139400-5300 1.6 1
Part Number
Thickness (mm) 139400-5400 1.625 -5500 1.65 -5600 1.675 -5700 1.7 -5800 I .72= -5900 1 .75d -6000 1.775 -6100 1.8 -6200 1.825 -6300 1.85 -6400 1.87 -6500 1.9 -6600 1.925 -6700 1.95 139400-6800 1.975
1O.After determining the No. 1 cylinder’s beginning-of-injection position, set the pump test stand flywheel pointer at an arbitary position. (Fig. 138)
Fig. 138 Positioning the pointer
11. Remove the measuring device from the No. 1 cylinder. 12. Install the delivery valve assembly in the sleeve flange and tighten the delivery valve holder to the specified torque. (Fig. 139) Specified tightening torque: 11 kg-m.
Fig. 139 Tightening holder
the No. 1 delivery valve
13. Following the order of injection, position the next cylinder’s tappet in the bottom dead centre position. 14. Using a special wrench (157916-8220), open the nozzle holder overflow valve so that fuel oil flows. (Fig. 140)
Fig. 140 Opening the nozzle holder overflow valve
12-011
15. Rotate the test stand flywheel in the specified direction of rotation to raise the plunglG&ad the pointer indication on the flywheel when fuel oil stops flowing from the nozzle holder overflow valve. (Fig. 141) 17. If the injection interval is not as specified, adjust the pre-stroke using the adjusting shim. 18. Confirm the pre-stroke of all cylinders in the correct order of injection.
Fig. 141 Measuring the beginning-of-injection position
INJECTION QUANTITY ADJUSTMENT Before performing injection quantity adjustment install the specified overflow valve in order to maintain a constant transfer pump pressure, and perform adjustment as follows: Nozzle (105780-OOOO)-injection quantity: up to 200 cc/l000 st. Nozzle (105780-0050)-injection quantity: exceeds 200 cc/l 000 st. Nozzle holder (105780-2080)-injection quantity: up to 200 cc/l 000 st. Nozzle holder (105780-2090)-injection quantity: exceeds 200 cc/l 000 st. Nozzle opening pressure: 175 kg/cm* Transfer pump pressure: 1.6 kg/cm* Test oil: IS0 4113 or SAE standard test oil (SAE J967d) Injection pipes For 15NP test stand: 157805-4720 (set of 12)-injection quantity: up to 200 cc/l000 st. 157805-5420 (set of 6)-injection quantity: exceeds 200 cc/l000 st. For IONP test stand: 157805-2520-injection quantity: up to 200 cc/l 000 st. 157805-2620-injection quantity: exceeds 200 cc/l 000 st. Note:
12-012
These test conditions apply to adjustment of the PE(S)-P type injection pump. As they differ according to the type of pump be sure to confirm the test conditions by referring to the Service Date before performing adjustment.
1. Confirm the control rod’s “0” position. 2. Operate the injection pump at the specified speed and fix the control rod in the specified position. (Fig. 142) 3. Under the above conditions measure the fuel injection quantity. If not as specified, loosen the injection pipe and two nuts fixing the sleeve flange and make adjustment by altering the sleeve flange position. (Fig. 143) Note:
Fig. 142 Fixing the control rod
When the sleeve flange is turned counterclockwise as shown in Fig. 143:Right helix plunger (governor instaiied on right hand The injection quantity inside): creases. Left helix plunger installed on left hand (governor side): The injection quantity decreases.
4. After fixing the injection pipe and sleeve flange repeat the measurement and the adjustment until the specified fuel injection quantities are obtained at the specified pump speed and in the specified control rod position. 5. Next, adjust the injection quantities until the variation between each cylinder’s injection quantity satisfies the specified value.
Fig. 143 Adjusting
the sleeve flange
average of injection quantity of all cylinders . . . . Injection quantity variation (-) = average of injection quantity of all cylinders - m’n’mum ‘nJection quantity Injection quantity variation (+) = maximum
injection quantity
-
maximum injection average injection quantity Injection quantity variation rate +) = quantity average injection quantity average injection - minimum injection quantity quantity Injection quantity variation rate -) = average injection quantity
xl00
(%)
xl00
(%)
12-013
ALIGNING
MARK
1. Attach the timing device to the injection pump. 2. Attach the coupling to the timing device and then connect it to the test stand. 3. Attach the injection pipes and install the fuel oil piping. (Fig. 144) 4. Exchange the pump overflow valve for the plug (02911 I-4050). .
Fig. 144 Attaching the injection pipes and fuel oil piping 5.
Operate the test stand flywheel to position plunger in the the No. 1 cylinder’s beginning-of-injection position. (Fig. 145)
Fig. 145 Adjusting the No. 1 cylinder’s beginning-of-injection position
6, In the above cond i,tion confirm that the pointer and the align ing mark stamped on the timing device’s flyweight holder are aligned. (Fig. 146)
Fig. 146 Confirming the No. 1 cylinder’s beginning-of-injection position
12-014
7. If not aligned, realign the mark with the pointer and stamp the correct position. Erase the old mark so that the new mark can be distinguished. (Fig. 147) Note:
When the flyweight holder has been exchanged, there will not be an aligning mark on the new flyweight holder. Therefore, stamp a new aligning mark on the flyweight holder, aligning it with the pointer’s aligning mark.
Fig. 147 Remarking the aligning mark
KD TYPE SUPPLY PUMP ADJUSTMENT Adjustment of the KD type supply pump installed on the PE(S)-P type injection pump is explained below. Preparation
Fig. 148 Suction test
1. Mount the injection pump on the test stand. 2. Install the fuel piping as specified below. Suction .pipe: $8 (inside dia.)x$lO (outside dia.)x2 m. Suction head: 1 m Test oil: IS0 4113 or SAE standard test oil (SAE J967d) Suction Test 1. Loosen the suction side pipe and confirm that test oil does not flow from the discharge side. Retighten the suction side pipe. 2. Drive the pump at 100 r.p.m. and confirm that test oil flows from the discharge side of the pipe within 40 seconds. (Fig. 148) Priming Pump Suction Test After all the test oil has been discharged from the supply pump, operate the priming pump at 60-100 strokes/minute and confirm that test oil is discharged within 25 strokes. (Fig. 149)
Fig. 149 Priming pump.test
12-015
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PRECAUTIONS FUEL OIL As inferior quality fuel oil will damage the injection pump and impede performance, use only diesel fuel oils recommended by a reputable authority. Ensure fuel oil is of the correct viscosity, and is clean. 1. As the fuel oil lubricates the plungers, delivery valves and nozzles, the correct viscosity fuel oil is necessary to ensure adequate lubrication. 2. Too low a viscosity may result in seizing of these parts. 3. Too high a viscosity results in poor combustion. 4. Particles of dirt, rust etc. are extremely abrasive to the injection equipment, as the moving parts operate with extremely small clearances. Ensure that the fuel oil is clean, fuel filters are serviced reguiarly and that storage and
g 3 E
handling facilities are properly maintained and serviced regularly. 5. Too high a sulphur content in the fuel oil adversely affects the injection pump; combustion results in the formation of sulphur oxide which, reacting with any moisture in the fuel oil results in the formation of sulphuric acid, corroding the internal components of the injection pump and the engine. Use only low sulphur-content fuel oil. Moisture in the fuel oil causes the formation of rust inside the injection pump, eventually resulting in seizing of the injection pump’s moving parts. Ensure fuel oil is free of moisture. Excessive carbon residue results in carbon deposits in the engine and on the injection nozzle tips, adversely affecting injection. Use only low carbon-residue fuel oil.
FUEL FILTER As liquid and solid contaminants in fuel oil adversely affect the injection pump and performance, ensure the fuel oil is properly filtered.
Observe the manufacturer’s instructions garding servicing and replacement of filters.
refuel
BLEEDING THE FUEL SYSTEM After installation or reassembly of the injection pump, the fuel system (from the fuel oil tank to the nozzles) must be properly bled and primed to expel all air from the system. Air in the system may result in reduced engine output, improper idling and difficulty in starting the engine. The priming pump attached to the supply pump is used to bleed and prime the system. 1. Fully loosen the priming pump’s screw cap. 2. While operating the priming pump open the overflow valve or air bleeder screw on the fuel oil filter.
3. Continue operating the priming pump until there are no air bubbles in the fuel oil flowing from the valve or screw. 4. Close the valve or screw. 5. Open the injection pump’s overflow valve and continue operating the priming pump until there are no air bubbles in the fuel oil flowing from the injection pump’s overflow valve. 6. Turn the engine over until it starts. The fuel injection system is now properly bled and primed.
12-017
LUBRICATION The injection pump cam chamber, the governor chamber and the timing device chamber
must always be filled with the correct quantity of the specified lubricants.
Lubrication Table Part No. (quantity)
Lubricant Diesel fuel oil
As specified
Auto timer grease
156118-0120
by engine manufacturer
Injection pump plungers Delivery valves Injection nozzles etc. SA type timing device
(150 g)
SP type timing device
Mobil Oil #20, #30 Engine oil
Location
As specified by engine manufacturer Note: When reinstalling the injection pump on the engine fill the injection pump cam chamber with injection pump oil (Part No: 130453-0121; 1000 cc) until oil overflows from the overflow nir>de
Injection pump cam chamber Mechanical governor SPM type timing device
LUBRICATION PROCEDURE
‘: Injection pump oil 131453-0121
Syringe 13 1499-0320
Auto-timer grease 156118-0120 Fig. 152 Injection pump oil, syringe and autotimer grease
12-018
With the PE-P type injection pump the engine’s lubricating oil is generally circulated inside the injection pump to lubricate the injection pump cam chamber and the governor chamber. Because of this an oil level gauge is not used. inspection of the oil inside the injection pump is not particularly necessary, and instead the specified instructions engine manufacturer’s should be followed in relation to the inspection and replacement of the engine oil. However, prior to operation on the pump test stand or engine, the governor chamber and injection pump cam chamber must be filled with engine oil or injection pump oil (131453-0121; 1,000 cc) until oil overflows from the overflow nipple.
(3 2 I
0 0
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ml
m 3 0
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Malfunctions 4. The nozzle does not operate
Engine starts, but operates only for a limited time
The engine “knocks”
“Black smoke” and engine “knock”
Unstable output
engine
Causes 5. Injection pipe contains air 6. Clearance between the nozzle body and the needle is too great 7:Nozzle nut is improperly tightened 1. Injection pipes leading to the pump are blocked or the filter is dirty 2. Air or water is mixed with the fuel oil 3. Injection pipe contains air 4. Fuel pipe between fuel tank and supply pump is damaged or the connections are not airtight, allowing air to enter 5. Supply pump is not functioning properly, resulting in insufficient fuel oil supply 6. The fuel oil tank ventilating device is blocked 1. The injection timing is too early 2. Nozzle opening pressure is too high 3. Some injection holes are blocked (in hole-type nozzle) 4. Nozzle injection function has deteriorated 1. Injection timing is maladjusted 2. Nozzle opening pressure is too low 3. Nozzle spring is broken. 4. Nozzle injection function has deteriorated 5. Plunger is worn 6. Faulty delivery valve seat 7. Fuel injection quantity is too large, and injection timing is incorrectly adjusted
Clogged filter element results in insufficient fuel oil supply 2. Insufficient supply pump delivery I.
3. Injection pump contains air 4. Fuel oil contains water 5. Plunger tends to stick and does not reach its full stroke 6. Plunger spring is broken
12-020
Remedies Bleed of air Replace Retighten at the specified torque Clean or replace
Bleed of air or change to high grade fuel and bleed of air Bleed of air Replace the fuel pipe, tighten the connections, or replace the gasket Inspect the check valve seat and the body/piston clearance and replace defective parts Replace
Readjust Readjust Clean or replace Replace Readjust Readjust Repiace Clean or replace Replace Replace Readjust
Ciean or replace Inspect the check valve seat and the body/piston clearance and replace defective parts Bleed of air Change to high grade fuel Replace Replace
Engine cannot reach its maximum speed
Engine’s maximum speed is too high
Idling speed is unstable 1. The injection pump’s control rod does not move smoothly
2. Fuel injection quantities of each cylinder differ excessively 3. Plunger is worn excessively 4. Plunger spring is broken 5. Fuel oil contains air or water 6. Governor idling spring force is too weak or improperly adjusted 7. Governor links are twisted resulting in excessive friction between each connection or excessive blav
12-022
1. Governor spring force is too weak 2. Control lever does not reach the full-load position 3. ,Nozzle injection function has deteriorated 4. Control lever does not contact the full-load stopper bolt
Readjust Readjust Clean or replace Readjust the accelerator rod
1. Control rack does not move smoothly
Repair or replace
2. Governor spring force is too strong 3. Governor flyweight does not operate adequately
Readjust Replace
1. Plunger does not move smoothly or is stuck 2. Control rod is improperly connected to the control sleeve 3. Plunger spring does not seat correctly 4. Clearance between plunger and lower spring seat is too small 5. Delivery valve holder is overtightened
Replace Repair Replace Replace Repair (secure delivery valve holder at specified torque) Readjust
Replace Replace Bleed of air or change to high grade fuel Readjust
Repair or replace
OOddkl
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SPEClAl
tools and attachments may result in damage to the injection pump, subsequent fuel oil leaks and an inability to properly perform injection pump adjustment.
The following special tools and general tools (spanners, hammer etc) are necessary for PE(S)-P type injection pump disassembly, reassembly and adjustment. Non-use of the special
SERVICE TOOLS FOR DISASSEMBLY KEY NO.
PART NO.
1
157944-8520
2 3 4 5 6
TOOLS
AND REASSEMBLY Q’TY
APPLICATION
Universal Vise
1
157944-9420 157944-8620 105792-0030 105792-0000 105782-4130
Bracket Bracket Extractor O-ring inserter Measuring device
1 1 1 1 1
7
105782-4140
Measuring
1
8
79D-1579156500
Wrench
1
9
157916-4820
Spanner
1
10
15792 I-8020
Tappet inserter
1
11
79D-1579205300
Oil seal guide
1
12
79D-1579205400
Oil seal guide
1
13
79D-1579205500
Oil seal guide
1
For fixing brackets (157944-9420 and 157944-8620) For fixing PE(S)-P type pump For fixing PE-P type pump For removing plunger block assembly For inserting O-ring in pump housing For measuring camshaft end play (for 20 mm dia. camshaft) For measuring camshaft end play (for 25 mm dia. camshaft) For removing and installing control rod screw bush For fixing and rotating timing device and coupling For removing and installing tappets (for 6-cylinder engine) For protecting bearing cover oil seal (17 mm dia.) For protecting bearing cover oil seal (20 mm dia.) For protecting bearing cover oil seal I (25 mm dia.) For removing bearing cover For removing bearing cover For removing outer race For removing inner race For removing flyweight For removing timing device (M24x 1.5) For removing timing device (M45x 1.5; M5Ox 1.5, M30x 1.5) For holding tappets (for 10 mm and 1 1 mm cam lift) For installing camshaft (for 17 mm and 20 mm dia. camshaft) For installing camshaft (for 25 mm and 35 mm dia. camshaft) For removing plunger block assembly For removing and installing tappets (for 8-12 cylinder engines; used with 157921-8020)
TOOL NAME
device
I
I
I
157920-7720 157920-9900
Extractor Bracket Extractor Extractor Extractor
1
14 15 16 17 18 19
79D-1579252020 79D-1579257120 79D-1579265320 79D-1579266220
20
79D-1579266120
21
15793 I-4700
Tappet holder
22
157828-7100
Plate
1
23
157828-7200
Plate
I
24 25
157944-3520 15792 I-8900
Plate Shaft
1 1
13-002
1
Extractor
1 1 1 1
Extractor
1 10
KEY NO.
PART NO.
26
157914-0500
Socket wrench
1
27
157931-4800
Tappet holder
12
28 29
157921-4820 157921-5620
Inserter Inserter
1
30
157914-0200
Socket wrench
1
31
157914-0300
Socket wrench
1
32
’
157916-9520
TOOL NAME
Q’TY
1
’ Spanner
1
33
1579 16-5320
Spanner
1
34
79D-1579267220
Extractor
1
35
79D-1579267420
Extractor
1
36
79D-1579267620
Extractor
1
37 38 39
157916-2800 1579 16-2900 79D-1579150100
Box wrench Box wrench Wrench
1 1 1
40
79D-1579150200
Wrench
1
41
79D-1579150300
Wrench
1
42 43 44
15791 O-l 120 157914-0090 157991-0100
Handle Socket wrench Inserter
1 1 1
45
157991-0200
Inserter
1
46 47
157954-l 000 157992-l 500
Dial gauge Inserter
1
48
157992-l 600
Cap
1
Note: The special tool kit (105790-7050) tools with key nos. 4-26.
1
APPLICATION For removing delivery valve holder (SW22) For holding tappets (for 10 mm, 11 mm and 12 mm cam lift) For removing and installing plunger For removing and installing control sleeve and upper spring seat For removing and installing roundnut (SW1 7) For removing and installing roundnut (SW1 9) For preventing V/T type timing device rotation (installation pitch: $76) For preventing timing device rotation (installation pitch: 466; $72; @85) For removing SP type timing device (M32x 1.5; M26x 1.5) For removing SPM type timing device (M30x 1.5) For removing SPGH type timing device (M36x 1.5) For removing roundnut (SW1 9) For removing roundnut (SW1 7) For removing RSV, RAD and RFD-type governor roundnuts For removing RQ type governor roundnut For removing roundnut fixing timing device For socket wrench SW32 For press-fitting camshaft sleeve (20 mm dia. camshaft) For press-fitting camshaft sleeve (25 mm dia. camshaft) For measuring camshaft axial play For installing snap-ring to plunger barrel (used together with cap: 157992-l 600) For protecting O-ring groove of plunger barrel (used when installing snap-ring)
for PE-P type injection pump disassembly
includes
13-003
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EXPLODED VIEW OF THE PEmPPUMP AND SUPPLY PUMP Figure 26 shows an exploded view of the PE-P type fuel injection pump, and Figure 27 shows an exploded view of the KD type supply pump. II3 II2 Ill
23/I
Fig. 26 PE-P type fuel injection pump: exploded
view
1
25
Fig. 27 KD type supply pump: exploded view
13-010
DISASSEMBLY PREPARATION
Fig. 28 Mounting the bracket
Keep the work bench clean and tidy. Before beginning disassembly record performance data for later reference to facilitate the diagnosis of malfunctions and defects, if any, in the disassembled pump. In the course of disassembly lay out the disassembled parts neatly and sequentially on the work bench, labelling if necessary, to faciliate later reassembly. Clean the outer surface of the pump before disassembly, removing all grease and dirt. Drain the pump camshaft chamber and the governor chamber and collect the drained pump oil so that it can be examined. The numbers in brackets ( ) following part names and tool names are the key numbers of the parts and the part numbers of the special too!s.
INJECTION
PUMP DISASSEMBLY
1. Mount the bracket (PES-P: 157944-9420; PE-P: 157944-8620) on the universal vise (157944-8520). (Fig. 28) 2. Remove the lubricating oil inlet’s eye bolt (147) and drain the lubricating oil from the pump* Fig. 29 Attaching
the injection pump
3. Securely attach the injection pump to the bracket using the 4 bolts (Fig. 29) 4. Using a hexagon wrench (SW5), remove the plug (96). (Fig. 30)
13-011
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9. Attach the coupling to the camshaft’s driveside and use the spanner (see 8. above) to prevent camshaft rotation. Then, remove the roundnut fixing the flyweight using the special wrench. (Fig. 34) Part Name Special wrench
1 Part
Number
157915-0100 1579 15-0200 157915-0300
Fig. 34 Removing
the flyweight
1
Remarks Tooth width: 2.2 mm Tooth width: 3.9 mm Tooth width: 5.9 mm
roundnut
10. Remove the flyweight using the extractor (157926-5320). (Fig. 35) Note:
As various types of mechanical governors may be installed on the PE(S)P type injection pump, refer to the relevant governor service manual before proceeding with governor disassembly.
Fig. 35 Removing the flyweight
11. Using a spanner (SWIO), loosen the supply pump’s fixing nuts (93) and then remove the supply pump. (Fig. 36)
Fig. 36 Remsving the supply pump
13-013
P
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15.Attach the oil seal guide to the camshaft drive side’s tapered portion. (Fig. 40) Part Name
Part Number
Oil seal guide
157920-5300
157920-5400
157920-5500
Remarks Shaft diameter: $17 Shaft diameter: 020 Shaft diameter: Q25
Fig. 40 Attaching the oil seal guide
16. Using the extractor (157920-7720) and bracket (157920-9900), remove the bearing cover (80) from the pump housing (1). (Fig. 41) Note:
Fig. 41 Removing
the bearing
When removing the bearing cover take care not to lose the shim adjusting the axial end-play of the camshaft inserted between the pump housing and the cover.
cover
17 Lay the pump on its side and move the camshaft (71) toward the driveside to remove the centre bearing. (Fig. 42)
13-015
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(a3
5 -.
0’
1
0
3
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0
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2
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3
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co .
FIPPOO
21 .Operate the tappet inserter lever to raise the tappet, and then remove the tappet holder. (Fig. 46) Note:
Return the lever slowly after removing the tappet holder, as the plunger spring force may cause the tappet assembly to spring out.
Fig. 46 Removing the tappet holder
22. Remove the tappet inserter from the pump housing. 23. Extract the tappet assembly (47) from the pump housing. (Fig. 47)
Fig. 47 Removing the tappet assembly
24. Hook the lower spring seat’s (45) lubricating hole with a . piece. of wire and pull out the plunger and the lower spnng seat to a position where the lower spring seat can be removed. Then, remove the lower spring seat. (Fig. 48)
Fig. 48 Removing the !ower spring seat
13-017
25. Extract the plunger using the plunger inserter (157921-4820). (Fig. 49) Be sure to place the plungers in a container of clean light oil.
Fig. 49 Removing
the plunger
26. Remove the plunger spring (44). (Fig. 50)
Fig. 50 Removing
the plunger spring
27. Using the plunger inserter (157921-5620) remove the control sleeve (41) and the upper spring seat (43) together. (Fig. 51) Note:
Fig. 51 Removing the control sleeve and the upper spring seat
13-018
If the ball attached to the sleeve and the pump housing’s tappet guide groove are not aligned during control sleeve removai, the control sleeve and upper spring seat cannot be removed.
-
-
OOddH
31.Using two spanners (SW14 and 27), operate the extractor to extract the plunger block assembly (7). (Fig. 55) Ndte:
Place the plunger block assembly together with its previously removed plunger in their correct matching order in a container of light oil.
*Refer to paragraph 38 for important points relating to “Plunger Block Assembly Disassembly. ”
Fig. 55 Removing the plunger block assembly
32. Using the special wrenc h (157915-6500), remove the governor side screw bush (34). (Fig. 56)
Fig. 56 Removing
the screw bush
33. Remove the pin (33) installed pump’s governor-side (Fig. 57)
Fig. 57 Removing
13-020
the pin
on
the
~
\ \ \
E -.-
.-6, LL
OOddld
u s
FIPPOO
-3. Remove the ring (7/l 2) and place the plunger block assembly on top of the plate. (Fig. 64) Note:
As the ring is press-fitted to the plunger block’s flange using the separate-type shim, place the plunger block on the plate without removing the ring.
Fig. 64 Positioning the plunger block assembly
-4. Loosen the delivery valve holder (7/4) using a socket wrench (SW22, 1579140500) and remove. (Fig. 65) -5. Remove the delivery valve spring (7/7).
Fig. 65 Removing the delivery valve holder -6. Use tweezers to remove valve (7/3). (Fig. 66)
the delivery
=;Removing the delivery valve I ly. 66
13-023
s
CD
FIPPOO
39.When it is necessary to remove the camshaft sleeve (if equipped), split the sleeve with a chisel and remove it. (Fig. 70) Disassembly of the injection pump is now complete. The disassembled Darts should be Gashed thoroughly in clean’fuel oil.
Fig. 70 Removing the camshaft sleeve
SUPPLY PUMP DISASSEMBLY The numbers in brackets following the part names are the key numbers of -the parts shown in Figure 27. I.
Using a spanner, remove the fuel oil inlet and outlet eyebolts (30,32). Also remove the cover (42) if installed.
2. Fix the supply (Fig. 71)
pump assembly
in a vise.
Fig. 71 Fixing the supply pump
3. Using a wrench (SW19), remove the three plugs (16). (Fig. 72)
Fig. 72 Removing the plugs
13-025
FIPPOO
-
,i
OOddM
FIPPOO
.
-’
0
03
“3.
cn’
CD
s
3
2
clean all disassembled parts in clean gasoline or light oil and inspect them closely for wear, scratches and damage. Exchange all parts that cannot be reused for new parts.
Thoroughly
PE-P TYPE PUMP INSPECTION Plungers I. If the plunger
discoloured, (Fig. 80) Fig. 80 Plunger
helix is scratched, worn or replace the plunger assembly.
helix
2. After cleaning the plunger thoroughly, ensure that the plunger slides smoothly into the barrel under its own weight when inclined 60”. Repeat the above operation several times while rotating the plunger. If the plunger slides into the barrel too quickly or does not slide smoothly, replace the plunger assembly. (Fig. 81)
Fig. 81 Plunger
slide test
Delivery Valves 1.
If the delivery valve’s piston or seat is scratched or worn, replace the delivery valve. (Fig. 82)
Fig. 82 Delivery valve piston/seat
13-029
FIPPOO
1
0
3
0
2
cn
-.
1
5-
5 -
r-t
0
$ ..
7 0
N
Camshaft 1. If the new key is loose in the key groove, replace the camshaft. 2. Inspect the camshaft’s tapered portions, the cam surface and the camshaft’s threaded portions thoroughly. Replace any defective parts. (Fig. 86) 3. If the sleeve press-fitted to the camshaft is worn, replace the sleeve.
Fig. 86 Camshaft
Bearings 1. Inspect the surface of the center bearing, where it contacts the camshaft, for wear. If It is worn, replace the center bearing. 2. If the inner race’s rollers are scratched, or the contact surfaces of the outer race are worn, replace the bearing. (Fig. 87)
Fig. 87 Bearings
r
Oil Seals Check the lip of the oil seal installed in the bearing cover for scratches, wear and damage. Replace the oil seals if defective. (Fig. 88)
I Fig. 88 Oi! sea!
13-03 1
ki
6
LJ
P
: cn -. (a3
3 u
2
g
11 -. CQ .
FIPPOO
KD-TYPE SUPPLY PUMP INSPECTION Check Valves The check valves are generally nylon and must not be reused. They must be replaced. If of bakelite construction they must also be replaced. (Fig. 92) Springs If the check valve spring or the piston spring are worn unevenly, bent or rusted, they must be replaced. I
Fig. 92 Check valves
Tappets And Pushrods 1. Inspect the roller, guides and shaft for wear, and replace any defective parts. (Fig. 93) 2. Pushrod Inspection Inspect the pushrod for wear. If worn, replace the supply pump housing assembly. Note:
If pushrod wear is extreme, fuel oil may pass to the pump cam chamber past the pushrod’s outer surface and dilute the lubricating oil, or air may be sucked into the fuel line.
Fig. 93 Tappet assembly
Piston Inspect the portion of the piston contacting the pushrod. Replace the piston if worn. (Fig. 94) Other Parts Check each part carefully. If they are damaged or worn excessively they must be replaced.
Fig. 94 Piston
13-033
ra3
Ql -.
!I
5
%
l-l -. cc2 .
FI PPOO
iD” ..
7 0
I-----
4.
Install holder, screw sleeve
a new O-ring on the delivery valve apply grease to the O-ring and then the delivery valve holder into the flange. (Fig. 98)
I
Fig. 98 Installing
the O-ring
Using a torque wrench, tighten the delivery valve holder to the specified torque. (Fig. 99) Specified tightening torque: 11 kgem. 6. Remove the flange and delivery valve holder from the plate.
5.
Fig. 99 Tightening
the delivery
valve holder
7.
Install the washer and deflector.
Note:
Fi g. 100 installing
(Fig. 100)
The deflector has a top and a bottom. Furthermore, the deflector is to be installed so that the deflector ports do not align with the plunger barrel’s suction-delivery ports. If the ports do align, the reverse fuel oil flow following injection will act to erode the pump housing.
and def!ector th, * \Alasher .._
13-035
FIPPOO
3
d
OOddkJ
0
..
5.
Using a torque wrench, tighten the two plunger block assembly fixing nuts (26) equally to the specified torque. (Fig. 107) Specified tightening torque: 4-4.5 kgem.
Fig. 107 Tightening the plunger block assembly fixing nuts
6. Secure the injection pump on its side in the universal vise. 7. Install the control sleeve (41) so that the control sleeve ball enters the control rod groove. Then, confirm that each cylinder’s control sleeve is moved when the control rod is operated. (Fig. 108)
Fig. 108 Installing the control sleeve
9. Place the upper spring seat (43) on top of the plunger spring (44) and install them in the pump housing using the plunger inserter (157921-5620). (Fig. 109) Note:
Fig. 109 Installing the upper spring seat and plunger spring
13-038
If the upper spring seat and spring are not inserted horizontally, the spring wiii catch during insertion and cannot be withdrawn. Take care not to scratch the housing during the above procedure.
10. Position the plunger helix (or stamping) so that it faces in the same direction as the sleeve flange aligning knockpin and then install the plunger in the plunger barrel using the plunger inserter (157921-4820). (Fig. 1 IO) During this procedure install the lower spring seat to the plunger.
Fig. 110 installing the plunger
11 .Align the tappet guide and the housing guide groove and then install the tappet (47) in the pump housing. (Fig. 111)
Fig. 111 Installing the tappet
12. Using the tappet inserter (157921-8020), push the tappet in and move the control rod a little to insert the plunger flange into the control sleeve. Then, insert the tappet holder into the plug hole. (Fig. 112)
Fig. 112 Inserting the tappet holder
13-039
P 0
6
3
-.
FI PPOO
0
.-
CD c-
.-6, U
OOddM
k
3 CD
FIPPOO
“‘“&;;;$;;;L
0000000
..
OOddld
OOddl3
FIPPOO
C In cn
0 3xI D
2 2 c) -4
ni
n
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..
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s
g
.. : ... : : . : .: : : : .: : :
: .: : : : :. : ;
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SEBM012702
FUEL INJECTION PUMP (With KOMATSU ELECTRONIC GOVERNOR)
FUEL INJECTION PUMP MODEL KFE
©2001 All Rights Reserved Printed in Japan 02-01(02)
00-001 2
CONTENTS
01
GENERAL ........................................................................................................ 01-001
11
STRUCTURE AND FUNCTION
12
TESTING AND ADJUSTING
13
DISASSEMBLY AND ASSEMBLY ................................................. 13-001
14
ADJUSTING .................................................................................................. 14-001
15
OTHERS
00-002 2
....................................................... 11-001
............................................................ 12-001
........................................................................................................... 15-001
FUEL INJECTION PUMP
The affected pages are indicated by the use of the Revision Revision Mark Page Page that necessary Mark acPage following marks. It is Mark requested number number tions be taken to these pages according to the table below.
Revision Mark number
(
Mark
Revision Indication Page number
Revision Action required Page
Mark
number
c
Page to be newly added
Add
b
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Replace
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Discard
)
Pages having no marks are those previously revised or made aditions.
LIST OF REVISED PAGES Mark
b b c
Page
Revision number
00-001 00-002 00-003
2 2 2
01-001 01-002 01-003 01-004 01-005 01-006 01-007 11-001 11-002 11-003 11-004 11-005 11-006 11-007 11-008 11-009 11-010 11-011 11-012 11-013 11-014 11-015 11-016 11-017 11-018 11-019 11-020 11-021 11-022 11-023 11-024 11-025 11-026 11-027
Mark
1
13-001 13-002 13-002-1 13-003 13-004 13-005 13-006 13-007 13-008 13-009 13-010 13-011 13-012 13-013 13-014 13-015 13-016 13-017 13-018 13-019 13-020 13-021 13-022
1
1 1
1
FUEL INJECTION PUMP
Revision number
12-002 12-004 12-005 12-007 12-008 12-008-1 12-009 12-010 12-010-1 12-010-2 12-010-3 12-011 12-012 12-013
c
12-001
Page
c
14-001 14-002
Mark
c
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c c c c c c c
Page
Revision number
14-003 14-004 14-005 14-006 14-008 14-009 14-010 14-011
2 2 2 2 2 2 2 2
15-001 15-002 15-003 15-003-1 15-004 15-005 15-006
Mark
Page
Revision number
Mark
Page
Revision number
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00-003 2
OOddkl
SPECIFICATIONS
Machine
model
H D785-3, H D985-3
Engine model
SA12V140-1
Fuel injection pump type
(Mounts 2 fuel injection pumps)
KFE6S135R-1
Dimensions (length x width x height)
I
Weight
I
mm
kg
I I
526x139x320 30.0 (Not including flyweight)
*I
Clockwise
Direction of rotation
l-5-3-6-2-4
Firing order
60” + 20’
Injection interval mm
Plunger diameter
13.5
Cam lift (plunger stroke) Prestro ke
*2
I
mm
I
1.70 (I 7.3)
Delivery valve cracking pressure Equal pressure valve cracking pressure (built into delivery valve) Delivery valve retraction volume
*3
MPa {kg/cm21 m m3/st.
*I : The flyweight mentioned he:e is the small flyweight connecting the fuel injection pump and the engine. *Z : With this pump, the prestroke automatically varies within the range shown in the chart. (This is called the prestroke control and is a special function of the fuel injection pump with electronic governor.) *3 : The deliverv
valve on this pump is an equal pressure type, so it differs from the normal equal volume type, so it does not have a retraction function. However, the abilityto stop the flow of fuel after the completion of injection is good in the same way as the equal volume type.
01-002
4-6
9.80 {IO01 -
g k L
OOddM
.-0
FIPPOO
OOddkl
FIPPOO
0
To cylinder
block
OOddld
u .-c
m
tr g
h
0
.-c .-
.+P p:
m-
2
3
co
l
: . . . . . .
: . . . . . . . . . .
: * . . . . .
. . . . . . . . . * . . . . . . . . . . .
EG
F?
7’c
45 . . . . . . . . . . . . . . . . . . . . . : . . . . . . . . . . * . . . . . . . . . . . . . .
E s
E
26
OOddlJ
0 N
6
--I
d
FIPPOO
---
OOddM
I .----.
I
I
I
’
I
8I
SWE00989
1. Priming pump (installed to part other than fuel injection pump) 2. Feed pump 3. Bypass valve 4. Relief valve (0.3 MPa (3 kg/cm*}) 5. Filter 6. Fuel gallery 7. Plunger and plunger barrel 8. Overflow valve 9. Komatsu fuel injection pump with electronic governor IO. Fuel tank
1 l-004
IO
Y
I
I
-__
OOddlzl
_ -.
--I
U)
8I
FIPPOO
OOddki
FIPPOO
OOddM
FIPPOO
-0 -
P
Y f t
L
0
YL
L
0
CL
.-
EZ “C
c-
OOddM
__-_-----
FIPPOO
-7
OOddM
FIPPOO
OOddld
II
i-l
8 -. -
0
l_LJ
\:
n -.
D
7
D
D
m
FIPPOO
[ Hydraulic pump (for KFE6S135R-1)
]
‘pass /
E-E
(Fuel)
D-D
(Oil)
+A
Rel val
B-
B
va I ve
(Fuel)
D A-A
lter
Cd C-C
(Oil)
SWE01089
::a
7
FIPPOO
Y
OOddki
[ Delivery
valve and equal pressure valve 1
Delivery
valve
holder
A4
Equal
Delivery
A-A
11-020
Pressure
valve
valve
OOddkJ
I--
F’
FIPPOO
\ \
\
\
\\ \
/I
I’ : i\
‘\
.--___A
/’
/I
/
I I
\\ \\
\
,/I’
\\
Function
of governor
Basic function
of governor
Function to know when has started
Function celerator
to know pedal
angle
Function
to know engine
I
governor
Electronic
I
governor
Basic functions are governed by all component parts inside mechanical governor (flyweight, lever, spring, etc.) Note :For details of the mechanical governor, see “COMPONENTOF ENGINE” (No. SEBECOMP003).
The basic functions are governed by the rack position control system (rack position control cylinder, rack position control valve, rack position control solenoid built into electronic governor, and rack position sensor, and controller outside electronic governor).
It is known that the engine has started, from the spring inside the mechanical governor.
The electric signal from the starting switch passes through the wiring harness and informs the controller that the engine has started.
of ac-
This is known from the angle of the speed control lever installed to the mechanical governor.
This is known from the angle sensor installed to the accelerator pedal.
speed
This is known from the flyweight inside the mechanical governor.
This is known from the engine speed sensor installed to the engine flywheel housing.
The timer
This function is governed by the prestroke control system (prestroke control cylinder, prestroke control valve and prestroke control solenoid inside electronic governor, and controller and engine speed sensor outside electronic governor).
engine
Function to advance fuel injection timing according to rise in engine speed
Function
Mechanical
governs
this function
This is known
to know rack position
from the rack position
sensor.
-
! ! -023
RACK POSITION CONTROL SYSTEM
Rack position control cylinder
Rack position sensor Rack
i-I-1
Rack
I
Fuel in_iection (exclusive for governor)
Pump electronic
Lubricat
Electric --____--
1
,Electric
,
I ’ Electronic governor
%;;;;;d
1
1 Elztric
signal,
‘\
Angle sensor (installed to housing)
Note .- “0” and “R” are both connected circumference.
11-024 0
I
,/
/._II__p___@ sizl
I
Engine speed sensor (installed to flywheel
oi
I I
Pump
signal
--I , ~
ina
Hydraulic
---------k---
Controller
,
t
position
,
accelarator
Pedal) SWE01205
on the
The controller knows the speed desired by the operator from the electric signal (output voltage) from the angle sensor installed to the accelerator pedal. To obtain the desired speed, it selects the necessary rack position from the data already stored in the controller memory. It then selects the value for the solenoid current that matches the rack position from the data and sends the current to thn nncitinn rnntrnl .* .Y rarlr sWY..yvvm..v.. “V..L. V. cnlnnnid Y”.“..“.U. (The above explanation shows the concept of the system. In fact, it determines the solenoid current directly from the voltage output from the angle sensor on the pedal.) When the solenoid pushes the rack position control valve spool, it pushes the spring inside the valve and compresses it to move the spool. The solenoid stops at the point where the pushing force is balanced with the reaction force of the spring. The solenoid pushing force and the change in the position of the spool are proportional. The change in the position of the spool and the hydraulic pressure at portion P are also proportional.
c .-
6%
Solenoid
0
current
0.418 Solenoid
The oil pressure at portion P passes through the oil passage and is transmitted to the rack position control cylinder. It pushes the spring inside the cylinder and compresses it to move the piston. It stops at the point where the hydraulic pressure at portion P is balanced with the reaction force of the spring. The hydraulic force at portion P and the change in the position of the piston are pronnrtinnzal nncitinn nf y-u .I”. .%.a*. Thn . ..V rhanrtn “*nu*my” in II. thn Lll” y”“.‘.“.. VI the piston means the change in the position of the rack. By controlling the solenoid current, the rack position is controlled indirectly.
4)
The controller knows if the rack position is being correctly controlled from the rack position sensor. If the rack position is not correct, it corrects it.
5)
The amount of fuel injected corresponds to the position of the rack. If any load is applied to the engine, the controller knows that the engine speed has dropped from the engine speed sensor, so it controls the position of the rack to increase the injection volume and prevents the engine speed from going down.
Q) >
aaam cz a¶
/
3)
Solenoid
/
pushing
force
Change valve
0.682 current
in position
of
spool
20 25 (A)
Rack
position
(mm)
SWEOlO70
1 l-025
\
-___------
FIPPOO
L______----__
I
I
I
t
/
_._l
/
Operation
of prestroke
control system The solenoid pushing force and the change in the position of the spool are proportional. The change in the position of the spool and the hydraulic pressure at portion Y are also proportional.
1) The controller knows the engine speed from the electric signal from the engine speed sensor. It selects the matching value for the angle of advance suitable to the engine speed from the data already stored in the controller memory, then selects the value for the prestroke that matches the angle of advance from the data, and then selects the value for the solenoid current that matches the value of the prestroke from the data, and sends the current to the prestroke control solenoid. (The above explanation shows the concept of the system. In fact, it determines the solenoid current directly from the engine speed.)
3)
2) By controlling
the solenoid current, the prestroke is controlled indirectly, and as a resuit it controis the angie of advance. The current flowing to the solenoid and the solenoid pushing force are proportional. When the solenoid pushes the prestroke control valve spool, it pushes the spring inside the valve and compresses it to move the spool. The solenoid stops at the point where the pushing force is balanced with the reaction force of the spring.
The hydraulic force at portion Y passes through the oil passage circuit and is transmitted to the prestroke control cylinder inside the plunger. It pushes and compresses the spring inside the plunger, pushes up the top part of the plunger, and extends to increase the length of the plunger until the hydraulic force and spring force are balanced. The prestroke becomes shorter by the amount that the plunger becomes longer. The fuel injection timing is advanced by the amount that the prestroke becomes shorter. That is, the injection angle is advanced. As a result of the flow of controls described above, if the engine speed is changed, the angle of advance is changed as shown in the charts below.
/
Solenoid
current
Solenoid
/ current
Oi I pressure portion Y
at
Chanee
in prestroke J
La rae t ln.iec t ion
amount
Sma I I
Engine Solenoid
current
speed SWEO1072
12 TESTING AND ADJUSTING
SPECIAL TOOLS OF ADJUSTING . . . . . . . . 12-002 PREPARATION. . . . . . . . . . . . . . . . . . . . . . 12-004 PRESTROKE ADJUSTMENT.. . . . . . . . . . . . . . . . . . . 12-007 ADJUSTMENT OF FUEL INJECTION VOLUME. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-009 GOVERNOR PERFORMANCE CHECK.... 12-010-2 PRESTROKE OIL PRESSURE CHECK..... 12-010-3 FIGURE O F SPECIAL TOOLS. . . . . . . . . .12-011
12-001 - 0
FIPPOO
-.
0
-.
3
0
G;
0
0
FIPPOO
3
5 -. 0
3
-.
u*
5
u
L.
CD -
r”
Carry out the wiring as shown in the diagram below.
Prestroke adjustment To
Digital
Power
current knob
Governor adjustment
current knob
source
meter Power
switch
XEP checker
Komatsu fuel with electronic
Prestroke Rack
vol tag
Detail
of
ee
display
injection governor
Pump
current
1 Governor
selector
switch
current
TWE00752
PRESTROKE AD.9USTMENT 1.
2.
Remove the delivery valve (15) of the No. 1 cylinder from the driven end. Remove spring, spring seat (17) and delivery valve
17
(16). 3.
Install measuring device T to the plunger then tighten with the nut. zm
barrel,
18
Nut: 49 + IO Mm (5 IL 1 kgm}
4.
Set the fuel supply pressure of the locally available pump stand to 0.05 MPa (0.5 kg/cm2}.
5.
Change rack stopper bolt to rack adjusting
6.
Fix the control rack at the FULL position, rotate the pump drive coupling by hand, and when the plunger is at the bottom dead center, set the scale of the dial gauge fitted to the measuring device to “0”.
7.
Rotate the pump by hand slowly in the direction of rotation, and read the dial gauge to measure the plunger stroke to the point where fuel stops flowing from the overflow pipe of measuring device T. This is the prestroke. * Prestroke: See calibration data (the calibration data is given in each engine shop manual) * If the fuel flow does not stop properly, use the point where the interval is 1 drop per second as the point where the flow of fuel stops.
bolt V.
Note : The moment where the fuel flow stops is the moment where the injection starts.
TWE00602
j2-nn7 __I 0
8.
9.
If the prestroke is not within the standard value, adjust the prestroke as follows. Loosen the nut and pull out the shim between the plunger barrel and housing (C). Change the thickness of shim, then tighten the nut and measure the prestroke again. Continue this process until the prestroke is within the standard value (see calibration data). Note : The calibration data is given in each engine shop manual. After adjusting, match the angle scale of the test stand to the standard position. (Set the angle standard for injection interval adjustment to O”.) Check that the mark lines of the pointer and flyweight are matched to each other. If these mark lines are not matched to each other, make a new mark line on the flyweight, matching to the mark line of the pointer. Remove measuring device T, then install the delivery valve assembly, gasket, seat and delivery valve holder temporarily. * Adjust the shim thickness as follows: DECREASE shim thickness if prestroke is too LARGE INCREASE shim thickness if prestroke is too SMALL * Fit the shim so that the side where the thickness is stamped is facing up, and insert the same thickness of shims on both sides of the plunger barrel flange to adjust. * Be careful not to get any dirt caught. After determining the start of fuel injection for the No. 1 cylinder, use this as a base to adjust the other cylinders in the firing order, and measure the injection start interval of each cylinder using the angle scale on the test stand. * Injection start interval: +r if the Injection start interval No.2
is not within the
cylinder 1 239"40' !I240"20' 3 4 5 6
1
119"40' + 120"20' 299"40' k 300"20' 59"40' f
60"20'
179"40' Ifr180"20
standard value, repeat the adjustment procedure for the prestroke and adjust the shim thickness to bring within the standard value.
1 Z-008 0
Nut
Plunger barrel Shim
. . 0 .
.
.
Remove delivery valve holder (15) of the fifth cylinder from the drive side. Remove the spring, spring seat (17) and delivery valve assembly (18). Install measuring device T to the flange sleeve, then tighten the nut. Slowly turn the pump manually in the turning direction and read the turning angle (the angle from the above standard position) when the fuel stops flowing from the overflow pipe of measuring device T (when injection starts). _fi_r\l ,V-:till.-J,..:~- 1;I ,c.+in/1 ,GaIIuvc ItlGa~ulllly UGVILG I, +L-“. LllGll Aft,,Or-ad,LKW ‘3, rAW-t-bn\,fi install the delivery assembly, gasket, seat and delivery valve holder. Adjust the other cylinders according to this procedure.
12-008-l 0
ADJUSTMENT OF FUEL INJECTION VOLUME .
.
After adjusting the fuel injection timing for all the cylinders, remove the measuring device, assemble the delivery valve, and connect the fuel injection pipe. Adjust the fuel injection volume as follows.
1.
Preparatory
work
1) Loosen the rack adjustment 2)
3)
4)
bolt V, and set the rack position to “0” (the point where there is no reaction force from the spring). Put a dial gauge in contact with the head of rack adjustment bolt V and set the scale on the dial gauge to “0”. Assemble so that the stud bolt is more or less at the center of the oblong hole for installing the barrel. Remove bolt (20) at the front face of the fuel injection pump, fit joint bolt W (8mm, P=1.25mm), then connect oil pressure gauge
0. 2.
Adjusting
injection volume
at rated point
1) Set the pump speed to low idling.
a
3) 4)
5)
6)
Using the prestroke current adjustment knob on the XEP checker, set the prestroke hydraulic pressure to the specified pressure at the rated point (see calibration data *I). Set the pump speed to the specified speed at the rated point (see calibration data *I). Gradually push in rack adjustment bolt V and set so that the average injection volume for each cylinder is the specified value at the rated point (see calibration data *I). If the amount is not equal, adjust with the oblong hole of the plunger barrel so that it is equal to the specified value at the rated point (see calibration data *I). . If the injection volume for any cylinder is far outside the average value, loosen injection pipe (8) and 2 plunger barrel mounting nuts (9). . Using a screwdriver, turn plunger barrel (IO) a little to adjust. . After completing adjustment, tighten nuts (9) in turn. * When tightening the nuts, be careful not to let the plunger barrel position move. (See tightening torqu table.) . Tighten injection pipe (8). The average injection volume may go outside the specified value when the unequal amount is adjusted, but in this case, adjust rack adjustment bolt V again to bring the average injection volume within the specified value.
TWE00603
I
7)
3.
Stop the rotation of the injection pump and oil pump. After adjusting the injection volume at the rated point, measure the output voltage of the rack position sensor with the XEP checker. Adjust the rack position sensor mount with shims so that the output voltage of the rack position sensor is the specified voltage at the rated point (see calibration data *I). Measure the rack position (amount rack adjustment bolt V is pushed in) with the dial gauge and compare it with the specified position at the rated point (see calibration data *I). (Do not make any judgement.) * Adjust the output voltage of the rack sensor as follows: INCREASE shim thickness if voltage is too HIGH DECREASE shim thickness if voltage is too LOW
*I :The calibration shop manual.
data is given in each engine
Adjusting
volume at low idling
1) 2) 3)
4)
injection
Return rack adjustment bolt V and set the rack position to “0”. Set the pump speed to the specified value for low idling (see calibration data *I). Use the prestroke current adjustment knob on the XEP checker to set the prestroke hydraulic pressure to the specified value for low idling (see calibration data *I). Gradually push in rack adjustment bolt V and set so that the average injection volume for each cylinder is the specified value for low idling (see calibration data *I).
12-010 0
Shim
,I?\
i’l
cl
L
+
-;
9 Rack
position
sensor TWE00753
5)
If the amount is not equal, adjust with the oblong hole at the plunger barrel position so that it is the specified value at low idling (see calibration data *I). :The calibration data is given in each engine shop manual.
6)
7)
4.
After adjusting the average ratio, if the average injection volume is out of the specified range, adjust the push-in distance of the rack adjustment bolt V again, then check the result. Read the rack voltage and rack position at this time with the XEP checker and dial gauge respectively.
Recheck of injection
volume at rated point
1) Using the prestroke current
8 k ii
adjustment knob on the XEP checker, set the variable prestroke hydraulic pressure to the specified pressure. 2) Set the pump speed to the specified speed. 3) Push in the rack adjustment bolt V gradually and measure the injection volume in each cylinder, then check the average injection volume and average rate. 4) Repeat following procedures (5), (6) and (7) until the result is in the specified range. 5) If the recheck result is out of the specified range, push in the rack adjustment bolt V again and barrel fitting position. 6) Adjust and check the injection volume at the low idling again. 7) Adjust and check the injection volume at the rated point again. a
Take care that your clothing, etc. is not caught in the driving sections of the pump. *
*
Use the specified measuring cylinder (having a test stand). Before measuring, remove all light oil from the measuring cylinder. If the injection volume of a cylinder at the low idling is extremely lower than the other cylinders, the delivery valve of that cylinder may be broken. Replace the delivery valve in this case.
I+
l-t
C
I-l
c
l-t
c c :: 8
-
C f’= k C a
-1
b
h
-
-
iA
!2
b
cc
?
-
-
0
n
3-l
2
3 t
u +
FIPPOO
OOddM
v)
-
al
PcnuY
.-
.-
3
(v . .
OOddM
”
FIPPQO
Z ? -
0
m
OOddM
CL
-
al
a 5: .-
4 In
13 DISASSEMBLY AND ASSEMBLY
SPECIAL TOOLS FOR DISASSEMBLY AND ASSEMBLY . . .. . ... . .... . . .. .. . . . . .. .. .. .. . . .. . . . . 13-002 DISASSEMBLY . . .. . .. . .. . ... . ... .. . ... .. . . .. . .. ... . . . . . . . . 13-003 ASSEMBLY . . .. . .. . .. . . ..*..*.............*.................. 13-009 FIGURE OF SPECIAL TOOLS . .. . .. .. . . . .. . .. .. . .. . 13-016
SPECIAL TOOLS FOR DISASSEMBLY
AND ASSEMBLY
When carrying out disassembly and assembly of the Komatsu fuel injection ernor, use the special tools listed below in addition to the normal tools.
Symbol
Part No.
Part Name
pump with electronic
gov-
Remarks
Q’tY
A
79A-474-1410
Plate
1
Remova I of flyweight
B
79A-4474-1111
Eyebolt
1
Measuring
sliding resistance of rack
e
79A-264-0020
Push-pull scale
‘I
D
79A-474-I
Slide hammer
1
Removing
plunger barrel
E
79A-474- 1162
Pusher
1
Holding down plunger spring
F-l
79A-474-1270
Lifting tool (1)
1
Removal and installation of spring
F-2
79A-474- 1260
Lifting tool (2)
1
Removal and installation of tappet
G
79A-474-1130
Puller
1
Removing
gear
M
79A-474-1420
Handle
1
Measuring
camshaft end play
202
79A-474-1290
13-002
Nm: {kgm}
Model Item
NO.
KFE6S135R-1 1
I
Delivery valve holder
I
2
Flange holding nut
3
Governor housing mounting
4
Gear pump cover mounting bolt
5
I
bolt
*
8
bolt
Deflector
bolt
151.9I!I 4.9 {I 5.5 rf:0.5) 53.9 I!I 4.9 (5.5 f 0.5)
30.9 I!I 3.4 (3.15 + 0.35)
30.9 It 3.4 (3.15 I!I 0.35)
11.27 f 1.47 (1.15 I!I 0.15)
6 1 Control solenoid valve mounting
I
53.9 f 4.9 (5.5 * 0.5)
30.9 ?I 3.4 (3.15 I!Y0.35)
Joint bolt
7 I Rack sensor circuit mounting
151.9 + 4.9 {I 5.5 I!I 0.5)
KFEGS135L-1
1,
30.9 * 3.4 (3 15 f n.35)
I
11.27 f 1.47 (I.15 + 0.15)
I
13.23 ?I 1.47 (I.35 f 0.15)
I
13.23 I!Z1.47 (1.35 I!I 0.15)
I
17.2 f 1.47 (1.75 I!I 0.15)
17.2 f 1.47 (1.75 + 0.15)
I
17.2 + 2.47 (1.75 z!z0.25)
17.2 f 2.47 (1.75 I!I 0.25)
13.23 + 1.47 (1.35 I!I 0.15)
13.23 f 1.47 (I.35 Z?I0.15)
-__ *
9
*
10
*
11
Bearing stopper mounting bolt
12
Joint bolt
29.4 f 4.9 (3.0 + 0.5)
29.4 * 4.9 (3.0 z!I0.5)
*
13
Joint lock nut
39.2 * 4.9 (4.0 t- 0.5)
44.1 f 4.9 (4.5 I!I 6.5)
*
14
Joint lock nut
39.2 I!I 4.9 (4.0 + 0.5)
39.2 t- 4.9 (4.0 & 0.5)
Joint bolt
29.4 f 4.9 (3.0 + 0.5)
Lock nut
29.4 + 19.6 (3.0 If:
8 E ii
15 16 17
Upper seat lock mounting bolt
I
I
Tappet lock mounting bolt
I Air bleed bolt (Fuel)
I I
I
13.23 I!I 1.47 (1.35 !I 0.15) 11.27 _+1.47 (1.15 -t 0.15)
8.82 I!Z0.98 (0.9 + 0.1)
I I
I
13.23 + 1.47 Il.35 +_0.15) 11.27 + 1.47 (1.15 Z!I0.15)
29.4 * 4.9 (3.0 I?I0.5) 29.4 I!I 19.6 (3.0 f 2)
I
8.82 I!I 0.98 (0.9 I!I 0.1)
20.6 N {Max. 2.1 kg}
20.6 N {Max. 2.1 kg}
0 - 0.02 mm
0 - 0.02 mm
8.82 I!I 0.98 (0.9 +_0.1)
8.82 f 0.98 (0.9 + 0.1)
Rack stopper bolt
17.15 3: 2.45 (1.75 f 0.25)
17.15 + 2.45 (1.75 f 0.25)
Rack guide bolt
13.23 f 1.47 (1.35 + 0.15)
13.23 I!I 1.47 (1.35 I!I 0.15)
18
Control rack sliding resistor
19
Cam shaft end play
20
Air bleed bolt (Variable prestroke control oil)
21 22
DISASSEMBLY -k
Before disassembling the fuel injection pump, clean it thoroughly and check that there is no leakage of oil from the mating surface of the plug or gasket.
1.
Rack position sensor 1) Remove connector (I), then remove 4 mounting bolts and remove rack position sensor circuit (2). 2)
2.
Loosen nut, then remove rack position sensor (3). * Confirm the quantity and thickness of shims, and keep them till reassembly.
Solenoid and valve 1) Remove mounting bolt, then remove prestroke control solenoid (4) and rack position control solenoid (5).
Rack bush
-b
Shi
\
DWE00242
DWE00121
13-003 0
2)
Using pincette, remove spool (6) and spring (7) from governor body. * Note down if the spring spool is for the prestroke control or for the rack position control, and assemble in the same place when reassembling.
DWE00122
3.
+
Gear pump
1)
Remove the oil relief valve, fuel relief valve and bypass valve.
2)
Remove the oil inlet strainer and screen filter.
3)
Remove 6 mounting (8).
4)
Remove gears (9) and (IO).
5)
Remove gear pump body (11). * The gear pump body, drive gear, and driven gear are supplied as an assembly, so when replacing, replace the whole assem bly.
HQusiwg (A) 1) Remove 6 mounting ing (A) (12). 2)
Fuel relief
Screen
bolts, then remove plate
valve
Oil inlet strainer
valve DWE00243
bolts, then remove hous-
Remove piston (13) of the rack position control hydraulic cylinder from housing (A).
DWE00123
DWE00125
13-004 0
II
\ I
OWE00124
DWEOOl 26
OOddM
-
0 0
0-l -
0
w B
9. Control sleeve Using pincette, remove control sleeve (23). 10. Plunger Using pincette, remove plunger (24). * When removing the plunger from the lower spring seat, rotate the plunger approx. 35” clockwise.
r
23
24
DWE00134
DWE00133
11. Rack Remove stopper frontward.
bolts
and pull
out rack (28)
DWE00136
12. Plunger spring, upper spring seat 1) Using tool E, compress plunger spring, then remove stopper bolt (29). Ir If tool E is not used to remove the stopper bolt, the thread of the stopper bolt may be damaged by the tension of the spring, so always use tool E. 2)
Fixing nut
Loosen the mounting nuts in turn to release the tension of the plunger spring, then remove tool E. u
3) Remove upper spring spring (31).
\
DWE00230
seat (30) and plunger
13. Lower spring seat, tappet assembly Remove lower spring seat (32) and tappet assembly (33). Remove tappet guide bolt (33-l).
33-l
13-006 0
DWE00235
OOddld
.-c,
+ .-
.-CIY .-+
.-cn Y-
H L.
00
s
FIPPQO
A
ASSEMBLY *
*
Wash all parts in clean diesel oil, take care not to get dirt or dust on the parts, replace O-rings and gaskets with new parts, remove all Loctite stuck to the housing deflector holes or other places. Studbolt of housing (C) When replacing studbolt (47) of housing (C), tighten new one so that its tip will be in contact with the bottom of the mounting hole. ~xz-‘]
1.
Stud bolt : 32 2;: Nm {3.2+$~ kgm}
Housing (B) 1) Install oil seal (37) to housing (B). 2) When replacing bearing outer race (36), install new one to housing (C) so that it will protrudes approx. Imm from the ring. 3) Fit the O-rings to housing (B) and housing (C), then install housing (B). &
1
DWE00150
Oil seal lip : Grease (G2-LI)
DWE00143
DWE00144
Pump housing
2.
3.
Bearing If bearings were removed, press fit bearings (46), (45) to camshaft. * When press fitting the bearing, put special tool J in contact with the bearing inner race, and press fit the bearing with a press fully as far as the stepped portion of the camshaft.
Camshaft 1) Put 2 center bearings (44) on camshaft (43 L then fit in pump housing (C). * Coat the inside of the center bearing thinly with grease (G2-LI), and be careful not to let the center bearing slip out of position. * When inserting the camshaft, fit special tool K to the tip of the shaft to prevent damage to the oil seal.
/
Rine
\
outer race
0 ring
DWE00244
46
45
44 \
DWE00149
2)
4.
Replace 4 seal washers with new parts, then temporarily tighten 4 center bearing mounting bolts (42). * Tighten the mounting bolts fully after adjusting the end play.
42
Bearing cover Using special tool L, install oil seal (41) to bearing cover (38), if bearing outer race (40) is removed, install bearing outer race (40).
38
5.
Gear pump drive gear Press fit gear pump drive gear (34) in the hole chamfered more.
6.
Adjustment of camshaft end play 1) Measure end play of camshaft as follows, and adjust with shims so that end play is within specified value. i) Assemble same thickness of shim (39) that was noted during disassembly, then install bearing cover (38). ii) Put probe of dial gauge @ in contact with end face of camshaft, measure end p!ay of camshaft by moving the camshaft frontward and backward, then adjust shim thickness so that end play is within specified value. * Move the camshaft forward and backward from the gear pump drive gear side. * End play of camshaft : 0 - 0.2 (mm) 2)
Install the shims of correct thickness and attach the O-ring, bearing cover (38) and pointer.
3)
Tighten 4 center bearing
DUE00241
3
DUE001 42
DUE00151
mounting
bolts.
7. Tappet assembly, lower spring seat Mount tappet guide bolts (33-l) 2)
Ir *
to housing
0. Mount the tappet guide bolts. Set tappet assembly (33) on lower spring seat (32), then use tool F-2 to install into housing (0. Align the lower spring seat with the dowel pin on the top face of the tappet when installing. Install the tappet assembly by adjusting the side surface groove to tappet guide bolt (331j of the pump housing. &I=,
Tappet guide bolt: Thread tightener
33-l
DWE00235
(LT-2) Fixing nut
8. Plunger spring, upper spring seat 1) Using special tool F-2, install plunger spring (31) and upper split spring seat (30) to housing (C). 2) Fit tool E, tighten mounting nuts in turn, and compress plunger spring. 3) Align with drill hole in upper spring seat, then tighten stopper bolt (29). & 4)
Stopper bolt : Thread tightener
(LT-2)
Loosen the fitting nuts by turns to reduce the tension of the plunger spring, then remove the special tool E.
9. Plunger Align plunger (24) with lower spring seat, and install. * Insert the bottom of the plunger into the hole of the lower spring seat, then turn 35” clockwise. * Hold the head of the plunger and check that it does not come out when it is pulled.
IO. Rack Assemble rack (28) from the front side in pump housing (C), then tighten stopper bolts. fi
Stopper bolt: Thread tightener
(LT-2)
DWE00136
11 Control sleeve Align hollowed part on control sleeve (23) with stamped line on rack, then install. * If the stamped lines on the rack and hollowed part on control sleeve are not aligned, the injection volume for each cylinder will change, so be careful to align accurately.
Hollowed part
Stamped
line Plunger barrel
Control sleeve
DWE00245
DWE00229
12. Plunger barrel assembly 1) Using special tool M, fit O-ring to plunger barrel (21), then insert in cylinder. &
O-ring : Grease (G2-LI)
2) Assemble
same thickness of shim (22) that was checked during disassembly to bottom of flange, then tighten nuts (20) in turn. 5~ *
*
* *
Nut : 54 + 5 Nm (5.5 + 0.5 kgm} Assemble the shim so that the side with the thickness stamped on it, is facing up, of shim at the and use the sam, n +h+ness ,I 1uB left side and right side. Check that the control rack slides smoothly after assembling the plunger barrel assembly to each cylinder. Check the injection timing with the test stand and adjust the shim thickness again. Install the plunger barrel assembly so that the pump housing studbolt will be at the center of the mounting oblong hole.
Plunger barrel
Oblong hole DWE00246
13-012 0
13. Rack spring 1) Use tools B and 6 to measure sliding resistance of rack. Sliding resistance : Max. 21 N (2.1 kg} 2) Assemble stopper and spring (25) to rack, compress spr *ing, and fix with stopper (26).
b\Y/
' DWE00135
14. Delivery valve Fit gasket, then assemble seat (19), delivery valve (18), and spring (17). Using special tool N, give oil to the O-ring and threaded part of delivery vaive holder (15) and fit O-ring, then install delivery valve holder (15). QKI
*
Holder : 152 + 5 Nm (15.5 + 0.5 kgm) lighten in three stages When adjusting after assembling, tighten delivery valve holder (I 5) temporarily. Tighten it normally after adjusting the injection timing.
15. Deflector Install deflector &
Deflector
DWEOOt30
DWE00129
15
(14). : Thread tightener
(LT-2)
14
DWE00156
P
FIPPOO
2)
Fit O-ring, assemble rack position control solenoid (4) and prestroke control solenoid (5) to housing (A), then tighten 4 mounting bolts. * Apply gasket sealant to the surface of each solenoid to contact with the rear housing.
DWE00121
DWEOOl19
8
k
u.
19. Rack sensor 1) Aassemble the disassembled and kept at disassembly shims, then fit rack position sensor (3) and tighten nut.
Rack senso core
2) Fit rack sensor circuit (2) to pump body, then tighten 4 mounting bolts and install connector (1). -k Fit an adiabatic plate at the back of the rack sensor circuit, then tighten bolts. DWE00242
20. Flyweight 1) Fit key in camshaft key groove. 2)
Fit flyweight QKI
and tighten with nut.
Nut:29_+2Nm{30+2kgmI
DWEOOtt8
FIGURE OF SPECIAL TOOLS SPECIAL TOOL
A
Part No. : 79A-474-1410 Part Name : Plate (including : Iron Material
1 bolt)
100
DWE00161
SPECIAL TOOL
B
: 79A-474-1111 Part No. Part Name : Eyebolt : Iron Material
DWE00162
13-016
OOddM
t
( P.1)
SPECIAL TOOL
F-l
: 79A-474-1270 Part No. Part Name : Lifting tool (I) Material : SWP-A (spring steel)
DWE00166
SPECIAL TOOL Part No. Part * _.. .vame Material
F-2
: 79A-474-1260 I ifiinn tog! (2) .- “““.~ : SWP-A (spring steel)
DWE00167
13-018
aI
.. .. ..
OOddkl
SPECIAL TOOL
J
: 79A-474-1430 Part No. Part Name : Push tool : s43c Material Heat treatment : Quenching and tempering of completed part (KES122501400)
a7
102 DWE00169
Jl: 50 (knurled portion)
SPECIAL TOOL Part No. D-V+ I a#~
y~-~ I atlm
Material
K
: 79A-4474-l . : s43c . f..:rln Gutuc
DWE00170
13-020
n
t= 084’
OOddkl
e
a
$_
i
FIPPOO
924.
5:“’ _,
14 ADJUSTING
Adjusting fuel injection pump .................. 14-002 Preparation work ...................................... 14-002 Testing fuel injection timing ................... 14-003 Measuring fuel injection rate .................. 14-005 Calibration data ........................................ 14-006 Adjusting electronic governor .................. 14-008 Adjusting rack sensor .............................. 14-009 Check of governor performance ............ 14-010 Check of pre-stroke oil pressure ............. 14-011
FUEL INJECTION PUMP
14-001 2
ADJUSTING
ADJUSTING FUEL INJECTION PUMP
ADJUSTING FUEL INJECTION PUMP PREPARATION WORK After disassembling and assembling the fuel injection pump and electronic governor, set the fuel injection pump assembly on the test stand and perform various performance tests. •
Connect the fuel outlet and inlet tubes, pre-stroke oil pressure control tube, etc. as shown below.
•
Install stand A to the test stand and set the fuel injection pump assembly, then install pump drive coupling B.
¤
Install the coupling mounting bolts securely.
14-002 2
FUEL INJECTION PUMP
ADJUSTING
ADJUSTING FUEL INJECTION PUMP
TESTING FUEL INJECTION TIMING (PRESTROKE) •
Remove delivery valve holder (3) of the 1st cylinder from the drive side.
•
Remove stopper (4), spring (5), delivery valve assembly (6), and seat (7).
•
Install measuring device C to the flange sleeve and tighten the nut. 3 Nut: 49 ± 9.8 Nm {5 ± 1.0 kgm}
• •
•
Set the fuel supply pressure of the pump stand to 49 KPa {0.5 kg/cm2}. Fix the control rack to the “Full” position and turn the pump drive coupling by hand and set dial gauge 1 to “0” at the bottom dead center of the plunger. Turn the pump slowly by hand in the forward direction and measure the plunger stroke until fuel stops flowing out of the overflow pipe of measuring device C (until fuel injection starts) with dial gauge 1. fl Plunger stroke: 6 ± 0.05 mm fl If fuel does not stop sharply, assume the point at which fuel drops at the rate of 1 drip/second to be the starting point of fuel injection.
FUEL INJECTION PUMP
14-003 2
ADJUSTING
ADJUSTING FUEL INJECTION PUMP
1. Adjusting fuel injection timing (pre-stroke) If the pre-stroke is out of the standard range, adjust it according to the following procedure. •
Loosen the nut and pull out shim (7) between the flange and pump housing.
•
Change the thickness of the shim between the flange and pump housing, then tighten the nut and check to see if the plunger stroke is in the specified range. fl If the pre-stroke is too long, reduce the shim thickness. If the former is too short, increase the latter. fl Set each shim with the side of the stamped thickness up. Insert shims of the same thickness on both sides, one by one. fl Take care that both sides of the shim, top of the housing, and underside of the barrel flange will be free from foreign matter.
2. Adjusting fuel injection interval Measure the injection start interval of the 2nd cylinder and after ones with the angle scale in the injection order on the basis of the injection start time of the 1st cylinder. fl Injection start interval: 2nd cylinder 3rd cylinder 4th cylinder 5th cylinder 6th cylinder
240˚ ± 120˚ ± 360˚ ± 60˚ ± 180˚ ±
20' 20' 20' 20' 20'
fl If any injection start interval is out of the standard range, adjust it by changing the thickness of shim (7) according to the procedure for “Adjusting pre-stroke”.
14-004 2
FUEL INJECTION PUMP
ADJUSTING
ADJUSTING FUEL INJECTION PUMP
MEASURING FUEL INJECTION RATE •
•
Remove measuring device C and install the delivery valve assembly, delivery valve holder (3), etc. correctly, then connect fuel injection pipe (8). Drive the pump at the standard speed and measure the fuel injection rate of each cylinder for the specified stroke.
¤
Take care that your clothes, etc. will not be wound into the pump drive section.
fl Use the specified measuring cylinder (attached to the test stand) and discharge the all diesel fuel from it before starting measurement. 1. Adjusting fuel injection rate If the fuel injection rate is out of the standard range, adjust it according to the following procedure. •
Loosen 2 mounting nuts (9) of the cylinder, the fuel injection rate of which is out of the standard range.
•
Adjust the fuel injection rate by turning flange (10) with screwdriver 2 little by little, then tighten the nuts alternately. fl When tightening the nuts, take care that the cylinder will not shift.
•
Adjust the fuel injection rate of each cylinder into the standard range.
FUEL INJECTION PUMP
14-005 2
ADJUSTING
ADJUSTING FUEL INJECTION PUMP
CALIBRATION DATA Injection Pump Assembly Number
Applicable Machine
6553-00-1112 (106682-4751) (Left bank) 6553-00-1212 (106684-4013) (Right bank) ( ): Injection pump manufacture's part No. Injection Pump Type
Injection Pump Manufactuer
PFE6S135
KOMATSU
Model
Injection order
Serial No.
Model
Engine Specification Clockwise
Flywheel horsepower (kw{HP}/rpm)
1–5–3–6–2–4
Maximum torque (Nm{kgm}/rpm)
59˚30' – 60˚30'
High idling speed
(rpm)
Plunger pre-stroke (mm)
5.95 – 6.05
Low idling speed
(rpm)
Delivery valve 3 retraction volume (mm /st)
—
Injection interval
Calibration Standard Conditions • Service standard indicates data using calibration test parts. • Manufacture standard is data for factory test.
Nozzle & nozzle holder part No. Nozzle part No. Nozzle holder part No. Injection pipe (mm) (Outside dia. ✕ inside dia. ✕ length)
Test oil Oil temperature (ºC) Nozzle opening pressure (MPa{kg/cm2}) Transfer pump pressure (kPa[kg/cm2})
Injection volume Prestroke
Serial No.
SA12V140-1
HD785-3 HD985-3 (With electronic governor)
Injection pump specification Rotating direction
Applicable Engine
Rack Pump • Rack positions pressure Rack voltage position speed B to E are the ref(kPa (V) (mm) (rpm) erence volume {kg/cm2}) when adjusting the injection volume. Rated 882 2.55 – 12.4 – 1,050 point {9.02} 2.57 13.2 • Marks ★ are average Low volumes. 490 Approx. Approx. 300 idling {5.0} 1.26 5.5 point
783{1,050}/2,100 (HIGH POWER mode, Net) 4,170{425}/1,500 (HIGH POWER mode, Net) 2,400 – 2,500 (HIGH POWER mode) 650 – 700 (HIGH POWER mode)
Pump tester capacity for Service standard
Motor: 7.5 KW
( ): Injection pump manufactuere's part number Service standard Manufacturer standard (105780-8130) (105780-0050) (105780-2090) 8 ✕ 4 ✕ 1,000 ASTM D975 No.2 diesel fuel or equivalent 40 – 45 17.7 – 18.2 {180 – 185} — Service standard (cc/1,000 st.) Injection volume
Maximum variance between cylinder
403 – 409
Max. 24
29 – 35
Max. 10
Manufacturer standard (cc/1,000 st.) Injection volume
Maximum variance between cylinder
Governor performance curve (Not specified)
14-006 2
FUEL INJECTION PUMP
ADJUSTING
ADJUSTING ELECTRONIC GOVERNOR
ADJUSTING ELECTRONIC GOVERNOR •
Execute control of the rack device and pre-stroke oil pressure using an XEP checker at the time of testing of a fuel injection pump with elecrtonical governor. Furthermore, make monitoring of the rack position.
Functions of XEP checker • To control the rack position and pre-stroke oil pressure by changing tha current in the range of 0 – 1.0A by means of the control dial on the panel front face. • To take measurement of current and voltage through terminals for measurement of governor, pre-stroke current and rack voltage.
Preparations • Connect the harness of XEP checker (2) to the electronical governor unit (1) of the fuel injection pump before making adjustment of the electronical governor.
14-008 2
FUEL INJECTION PUMP
ADJUSTING
ADJUSTING ELECTRONIC GOVERNOR
ADJUSTMENT OF RACK SENSOR 1. Remove rack stopper bolt (1) and set the rack in position “0” (range in whick motion by the slit on the rear side of the control rack occurs). Make adjustment by shim (3) so that dimension A enters the range indicated below. fl Dimension A: 8.5 ± 0.05 mm 2. Turn in rack adjust bolt (2) and make adjustment by the shim so that the rack voltage enters the range indicated below. fl Rack voltage (when rack position is 14 mm): 2.80 ± 0.01 V fl Shim thickness: 0.1, 0.3, 0.5 mm 3. Remove rack adjust bolt (2), fit rack stopper bolt (1) and check the rack voltage. fl Rack voltage: 0.30 – 0.41 V 4. If the rack voltage is outside of the specified range, replace rack sensor (4) and measure the rack voltage once again.
FUEL INJECTION PUMP
14-009 2
ADJUSTING
ADJUSTING ELECTRONIC GOVERNOR
CHECK OF GOVERNOR PERFORMANCE 1. Rotate the fuel injection pump at the specified speed. 2. Make adjustment by the pre-stroke control dial so thet the pre-stroke oil pressure enters the specified range. 3. Make adjustment by the governor control dial so that the rack voltage enters the specified range.
4. Measure the fuel injection rate and governor current after the pre-stroke oil pressure and rack voltage were adjusted to the spesified ranges. fl Governor performance measurement standard. Fuel injection pump speed (rpm)
Rack voltage (V)
Governor current (A)
1
325 ± 5
1.0 ± 0.01
0.51 ± 0.1
2
325 ± 5
2.2 ± 0.01
0.56 ± 0.1
fl Replace the solenoid, if the measured value fails to enter the specified range. fl The controller is controlled by current and voltage. But conversion is made to “1A/1V” with the EXP checker so as to permit measurement using a voltmeter.
14-010 2
FUEL INJECTION PUMP
ADJUSTING
ADJUSTING ELECTRONIC GOVERNOR
CHECK OF PRE-STROKE OIL PRESSURE 1. Remove bolts from the fuel injection pump front face, connect joint 1 (8 mm, p=1.25) and then connect oil pressure gauge 2. 2. Rotate the fuel injection pump at the specified speed. 3. Make adjustment by the pre-stroke control dial so that the pre-stroke current enters the specified range. 4. Check the pre-stroke oil pressure at this time. Set point Fuel injection pump speed (rpm)
ª Pre-stroke current (A)
1
325 ± 5
0.7 ± 0.05
2
325 ± 5
0.8 ± 0.05
Measuring item (specified range) ª Governor Pre-stroke current oil pressure (A) (MPa{kg/cm2}) 0.71 ± 0.03 0 {7.2 ± 0.3} 0
0.89 ± 0.03 {9.1 ± 0.3}
fl Replace the pre-stroke solenoid if the maximum value of an item wi0th ª mark is outside of the specified range.
FUEL INJECTION PUMP
14-011 2
I-
2
z W
c)
a
B
CL
OOddld
PARTS INSPECTION .
Be careful not to damage the disassembled parts. After washing in diesel oil, blow with compressed air to dry, and make a visual check particularly of the following points.
Part
Check point
Delivery valve
There must be no scratches or damage to seat surface or outside circumference of spool Valve must slide smoothly
Holder
inside holder
There must be no scratches or damage to contact surface of spool and seat SPOOI
Seat HWE00327
Tube
for
Install the delivery valve assembly to the holder for check of valve opening pressure. Apply pressure with the nozzle opening pressure tester as shown in the figure at left, and check the valve opening pressure and sealing performance of the two-way delivery valve.
test
Valve-
Couper gasket Holder nozzle Pressure
open ine test
HWE00334
Plunger barrel and plunger assembly
t
Pull
There must be no scratches, wear, or discoloration to outside circumference of plunger assembly
UP
assembly
barrel
HWE00328
15002 0
Wash plunger assembly with cIean diesei oif, assemble plunger barrel as shown on left, then pull up plunger assembly and check that plunger barrel is not pulled up, and that only plunger comes out. * Change the relative positions of the plunger barrel and plunger assembly (move plunger assembly) and check 2 or 3 times.
Part
Check point
Tappet
.
There must be no peeling, wear of important points, or scratches to roller surface
.
There must be no play between roller pin
.
Check depth of wear at plunger tion
Plunger contact portion Tappet
Roller
roller
and
contact por-
HWE00329
Camshaft
There must be no peeling, wear of important points, or scratches to cam surface
Key groove
There must be no play between groove
key and key
There must be no wear of oil seal contact surface
Oil seal contact surface HWE00330
*
There must be no peeling from surface or abnormal noise
.
There must be no scratches or wear of lip surface
Bearing (taper roller)
Oil seal
Center bearing
d
There must be no peeling, to bearing surface
wear, or scratches
HWE00314
Spool of rack position control hydraulic cylinder
HWE00315
.
There must be no scratches or wear of surface
.
Must slide smoothly
inside bushing
FIPPOO
F 8 P
Delivery
valve
Tappet
FIPPOO
Camshaft
Plunger
barrel
7
0 -.
Part name
Position of damage
r
Judgment
A: Can be used as it is
-
Opening 3
sealing
pressure
and
performance
two-way
delivery
of
valve
categories
for reuse
B : Can be repaired used again
and
C : Not permitted again
.
Injection volume of any cylinder is not extremely little at injection volume adjustment (particularly when rpm is low). Opening pressure of tvwoeway delivery
.
to use
lniection volume of a cylinder is extremely little at injection volume adjustment (particularly when rpm is low). Fuel injection pump Operiing piWSiiii3 zrf tvwv,“ay delivery
.
Less’than
More than 8Qkg/cm2
80kg/cm2
-
1
Peeling from surface, luster,
No peeling
abnormal
noise
noise
or abnormal
Heavy rotation, mal noise
-
abnor-
-
I 2
No rust on ball or race
Rust on bearing
Slight that
rust on outside can be easily
moved
re-
There is rust
with sandpaper
-
1
Threaded ing
portion
of hous-
No damage
or crushing
of thread
Slight dents or damage
Damage,
to thread
other than B
crushing
-
-
2
Damage,
cracks in housing
No cracks
Damage or dents that can be easily removed
Damage
other than B
Damage
other than B
Damage
other than B
with oilstone Damage 1
Damage,
cracks in housing
No cracks
or dents
can be easily
that
removed
with oilstone -
1
Scratches
on surface
No scratches
Damage that easily removed
can be with oil-
stone -
1
Peeling,
wear, or scratches
to surface of gear tooth
Slight wear or scratches
Damage
which
easily removed
are not enough
to catch your fingernail
that
can
be
with oil-
stone
Scratches or wear other than in A and B
-
2
Wear or scratches to surface of plate
Slight wear or scratches
Damage
which
easily removed
are not enough
to catch your fingernail
stone
that
can
be
with oil-
Scratches or wear other than in A and B
-
15-005 0
Judgment Part name
Position
categories
for reuse
of damage C : Not permitted to use again
used again
-
More than 0.075mm
3
End play of drive shaft
Less than 0.075mm
4
Wearorscratchestosurface of oil and fuel relief valve
Slightwearorscratches which are not enough
Damage that can be with easily removed
seats
to catch your fingernail
oilstone.
Clogging of oil inlet strainer
Strainer can be cleaned perfectly by washing light oil and blowing air.
6
Clogging of screen filter
Filter can be cleaned perfectly by washing in light oil and blowing air before 4000H.
7
Wear of contact surface of drive shaft oil seal
5
15-006 0
Less than o 2mm
-
in
Scratches or wear other than in A and B
Strainer cannot cleaned perfectly.
Filter cannot be used any more after 4000H. Filter cannot cleaned perfectly before 4000H.
More than O.x2mm
p1
2
2 0 0
w 1
CONTENTS
No. of page
01 GENERAL
...... .............. ...,.........................,.
11 STRUCTURE
12 TESTING
AND
FUNCTION
01-001
. . . . . . . . . . . . . . . . . . . . . . . . . II-OOI
AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-001
13 DISASSEMBLY
14 MAINTENANCE
AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . .
STANDARD
...........................
13-001
14-001 ,
8 5? u.
15 OTHERS
00-002
... ... ..... .................. ....................... .
15-001
.
cn
FIPGOO
CD
2 --
cn
m
C 325
_
II
STRUCTURE AND FUNCTION
CONSTRACTION .............................................. OPERATION ..................................................... Governor spring operation .......................... Performance line drawings of the governor ............................................ Control of engine startings .......................... Idling control .................................................. Maximum speed control .............................. Torque control device .................................. No-load maximum speed operation .......... .................................. Condition at stopping Torque spring operation .............................. Boost compensator operation ....................
1 I-002 .I I-004 1I-004 1 I-005 II 1-006 1 I-007 11-008 1 I-009 1 I-012 I I-013 1 I-015 II -018
11-001
FIPGOO
2
0
The swivel lever shaft is fitted to the governor cover by bushes. One end of the governor spring is connected to the swivel lever, with the other end connected to the tension lever. When the governor spring is extended, the lower end of the tension lever will contact the adjustable full-load stopper bolt. The swivel lever is so constructed that at the time of stopping the engine it will contact and move the guide lever. The floating lever attached to the guide lever will then also move, therefore placing the control rack in a non-injection position.
An adjustment screw is attached to the opposite end of the swivel lever through which governor spring tension and therefore the speed droop can be adjusted. The torque control spring regulates fuel injection quantity (within. a specific range) to assure optimum fuel injection quantity between idling speed and maximum speed. Constant idling speed is maintained through the installation of an idling sub-spring, incorporated into the governor cover, which at idling rnntwtc VW. I.UV.V
the _*I_ tpncinn _V,.V._. . Ip\/er I_. _. .
Movement of the control lever position will position and swivel lever the alter subsequently governor spring tension, as the centre of revolution of the swivel lever and the tension lever attachment point for the governor spring are mutually eccentric.
\ Start spring Floating lever
\ Control rack
\ Supporting
The governor may be equipped with a stopping device to return the control rack to the stop position when desired, regardless of control lever position. As shown in Fig. 2, the pin at the bottom of the floating lever is inserted into the supporting lever slot. The supporting lever spring is installed to prevent excessive pressure and resultant damage to the lever mechanisms under no-load high-speed conditions.
\ Pin
lever /
Fig. 2 Stop lever mechanism
1 I-003
FIPGOO
0
0 w
Performance Line Drawings of the Governor The solid line in Fig. 4 shows control rack position until contact with the maximum-speed stopper. A-B shows control rack position for engine starting; B-C represents control rack position while the start spring is extended due to the flyweights’ centrifugal force; C-D shows control rack position during injection of excessive fuel sufficient for the torque control stroke.
Pump speed (rpm)-
Fig. 4
D-E shows control rack position at low and medium speed when the centrifugal force of the flyweights exceeds the torque control spring force, with the torque control spring being compressed. E-F represent’s control rack position when the shifter contacts the tension lever at normal-full load operation. At point F the governor spring is actuated; point G is the control lever set point. At point G the rated output of the engine can be obtained. (For construction equipment, which experience extreme load changes, operation at this point is normal) Point H represents no-load maximum speed; the maximum speed of the engine. H-l represents the range where the governor spring and the idling sub-spring actuate together. The bold broken line shows control rack position during idling; the control lever is in the idling position and speed is increased from zero. Point L is the specified idling position; if idling speed decreases below this point the idling sub-spring will move the control rack in the fuel-increase direction.
1 l-005
Control of Engine Starting
stop
(rpm)
Flyweights
/
Shifter Fig.
i and sleeve/
5
As shown in Fig. 5, prior to starting, when the to contact the control lever is moved maximum-speed stopper, the swivel lever --(c~~ected to the control lever) extends the governor spring to move the tension lever, until it contacts the full-load stopper bolt. (See Fig. 5) As the flyweights are not moving at this time, the floating lever is held in the fuel-increase position by the start spring, and the flyweight
1 l-006
roller is held by the shifter and sleeve. As a result, the distance between the tension lever and shifter is greater than at full-load operation, lln ; a,,,w,ng an increased fuel injection quantity and facilitating starting. Immediately after starting the centrifugal force of the flyweights exceeds the start spring force, resulting in movement of the shifter, which then contacts the tension lever; consequently the fuel injection quantity is reduced.
Idling Control
[art
.springw
~
.-: .E
Idling
ti
n
Control lever
-7
y0 f?
‘ump speed (rpm)
-w
Flyweights/
I
Fig. 6
After starting, the control lever is moved to the idling position and governor control will begin. As seen in Fig. 6, with the control lever in the idling position the governor spring will be in a completely contracted state, allowing the flyweights to open even though engine speed is low. Shifter and sleeve movement will then be transmitted to the tension lever, which moves to the right to contact the idling subspring. The floating lever will move to its idling position, moving the control rack in the fueldecrease direction and resulting in a decreased fuel injection quantity suitable for idling.
If engine speed decreases, the flyweights’ centrifugal force will decrease, allowing the idling sub-spring force to move the tension lever and shifter, and consequently the guide and floating levers to the left. The control rack is therefore moved in the fuel-increase direction to return the engine to the required If the engine speed drops idling condition. further, the start spring acts to quickly move the floating lever and control rack in the fuelincrease direction, preventing the engine from stopping and thus maintaining constant idling.
1 l-007
00
Q
FIPGOO
Torque Control Device suction Fuel requirement
Increased setting
,
ye_;___$L-q _--- _#--
A?--?----
I I
&educed setting
I
I
I
Na Engine speed (rpm)
Nb ____F
Fig. 8
1 l-009
If full-load fuel injection quantity is set at point B’ in order to reduce emission of black smoke, engine output will be reduced at low and intermediate speeds. The torque control device operates in such a way that, during full-load satisfies the fuel operation the engine requirement curve as shown in Fig. 8. This torque control device is mounted with the tension lever. However, its use and specificadepend on the various . engine tions applications and range of engine speeds.
This movement, referred to as the torque control stroke, is transferred to the guide/floating levers, resulting in control rack movement in the fuel-increase direction. However, as engine speed increases, the flyweights’ centrifugal force will also increase until it exceeds the force of the torque control spring, which will then be compressed. The shifter will then contact and move the tension lever to decrease fuel injection quantity.
Figs. 9 and 10 show torque control device operation. At low speed the torque control spring force is greater than the flyweights’ centrifugal force and will therefore move the shifter and sleeve in the direction of the arrow ti in Fig. 9.
Pump speed (rpm)-
Fig. 10
11-010
-
I I I I
__-____-___-------
--------_-
(UNU) uo!ysod ycm low03
0
rr-
a-----(LU~J)
_-_.----_____f
paads au!Bu~
009dM
0
l-
z
a g
2
I F
It
2
3
67 -.
. l-l/
z
CE .
FIPGOO
Condition at Stopping
Guide lever
stop
Control
&j
Swivel lever
9
2
Fig. 14
When the control lever is moved to the stop position, the swivel lever will contact and move the guide lever, which in turn moves the floating lever and link, resulting in movement of the control rack to the non-injection position; the engine will then stop.
11-013
Flyweights /
Fig. 15
Where the governor is equipped with a stopping device, operation of the stopping device results in stopping of the engine regardless of control lever position.
11-014
Torque Spring Operation
Tension lever
n
Engines used with construction equipment are subject to abrupt increases in load, causing speed to decrease, which may result in the engine stopping. To prevent this a separate torque spring is utilized, as shown in Fig. 16.
Torque spring
Adjusting
nut
As engine speed decreases, this torque spring operates to slow control rack movement, therefore resulting in increased fuel injection quantity.
stopper bolt
Fig. 16
If the control lever is in the maximum speed position and’ load increases suddenly, without a torque spring the controi rack wiii trace the B-D curve as engine speed decreases, as shown in Fig. 17. Speed decrease wiii be PI. if the torque spring is installed, the control rack moves along B-C and speed decrease will be Pp.
Pump speed (rpm)-!--
; i
1t---
In both cases there is no difference in control rack movement. That is, when the engine experiences an abrupt increase in load from control lever set point B, for control rack movements to the fullload position, there is a greater decrease in speed when the torque spring is utilized.
Fig. 17 Relation between governor performance and engine output
u-015
Control lever
Pump speed (rpm) -
-tt-
Torque spring stroke
Fig. 18
Figs. 18 and 19 show torque spring operation. Point B in Fig. 17 represents the control lever position suitable for rated output. If the increased load exceeds the rated output, the tension lever will act to move the control rack in the fuel-increase direction as engine speed decreases, as shown in Fig. 19. However the torque spring will act to retard the tension lever, and therefore, control rack movement from point B to C. (See Fig. 17)
11-016
Speed decrease will be P2, with the torque spring acting to extend the time taken for this decrease. As fuel injection quantity is increasing during this period, engine torque will increase, the decrease in speed can be felt and time is available for preventative action (gear change etc) to be taken, and stopping of the engine is prevented.
.
/f
\ \
OOSdki
I
00
4
-I-l -.
ON
cn .
FIPGOO
-(UJW)
uo!q!sod ycm lo.quo~
ri E’
-0
s :E -0
u
c-’
s
::
0
t?” _a .-
00!3dlj
a
n 2
a Iv) W
I-
009dM
FIPGOO
--
T
U)
.-s
a_ 2 c-l
n
G’ .
FIPGOO
\ Y
/’
P
n
b 8
I\>
FIPGOO
I-
2 w
3 7 n
0
.-
Et ..
7 0 I N-, . .
1:
u-l
FIPGOO
\
\
-.
--h
-.
‘\
--5
6. Mount the measuring device (105782-6030) to. measure the control lever angle. (Fig. 73)
ig. 73 Mounting
the measuring
cievice
7. Move the control lever fully in the stop and set the minimum-speed directon, stopper bolt (53) so that the control rack position is 0.5-I .O mm, to prevent undue force on the link mechanism when the control lever is moved in the stop direction. (Fig.
Fig. 74 Setting the minimum-speed
h
74)
stopper bolt
8. The performance of the governor depends on the engine specifications. The performance chart in Fig. 75 is typical of this type of governor. (Fig. 75)
Rh
Na
Nb
NC NdNeNfNg
Pump speed (rpml-
Fig. 75 Governor
performance
chart
12-009
-a
-r-l
:
en .
r
--h
1z
HO;
FIPGOO
P J
rack position
__-___________
Control
(mm)-
ll-
\
/
2 uo!ysod yDeA ~OJWO~
1
0
j
---__--__----i’-1 -(UILU)
009dkl
I I I I I
, ,
I
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Es? ---+.LJw)
uo!ysod yDel lo.wo~
0
Control
co
=ii -.
rack position
(mm)-
8
11 -. ccl .
FIPGOO
Control
rack position
(mm) -
-(w.u)
uo!ysod
ycm ~OJJUO~
.-ti
0
LL
00!3dM
Control
FIPGOO
rack position
(mm) -
-
(Sd) P’dJ”O
I 0
(ww)
009dM
I I
n CT
uo!ysod
yx~
lowo~
2 -
Adjusting screw
If the pump speed is not within the standard value, adjust the height of the adjusting screw provided on the swivel lever. (Fig. 90) Tightening the adjusting screw decreases the speed droop. Loosening the adjusting screw increases the speed droop. Note 1: The adjusting screw can be loosened a maximum of 20 notches (5 turns) from the position where it is completely tightened. Loosening further may disengage the adjusting screw from the swivel lever, resulting in damage to the governor. Note 2: Always be sure to tighten the adjusting screw to the point where a click is heard.
i
Fig. 90
3. Remove the plug (4) with the socket wrench (I 57914-1400 SW30). (Fig. 91)
4. Place the adjusting screw below the plug hole of the governor housing. 5. If Ng rpm exceeds the specified value, tighten the adjusting screw; if Ng rpm is iess than the specified vaiue, ioosen the adjusting screw. (Fig. 92)
Fig. 92 Setting
12-016
adjusting
screw
m ii
-
a)
a: (UJUJ)uo!ysod yx.~ lo.wo~
009dkl
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I
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7-l -.
if!2
co .
0
r
Control
rack position ?
(mm)-
FIPGOO
l
l
-
.L
--
009dM
0
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___------
I I I I
I
I I
I
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I I I I I
I
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rack position
rf
----
Control
(mm) -
FIPGOO
a-0
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--as .u
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QE .!=-
-(UJLU)
onm
0
uo!g!sod yBel ~OJJUO=)
CTCTM
FIPGOO
-A
3. Boost compensator stroke adjustment -.I. Connect the compressed-air pipe the cover (268).
to
boost compensator stroke Note: During adjustment it is not necessary to supply compressed air.
Fig. 1 IO Adjusting
boost compensator
-2.
Fix the control lever in the maximumspeed position. (Fig. 109)
-3.
Maintaining pump speed of Na rpm, shift the control rack position from Rb mm to Ra mm using adjusting screw (270) and then lock it with the locknut (271). (Figs. 110 and 111)
stroke
I
Na Pump speed (rpm) -
Fia. 111
12-023
FIPGOO
xl
iD” ..
0
7
Control
rack position
I Iu
(mm)-
P
--_
\’
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3
00!3dM
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:
.
.
SPECIAL TOOLS For service of the RSV type mechanical governor cial tools and general tools should be prepared.
SERVICE Key No.
TQOLS
FOR DISASSEMBLY
Part Number ( ): ZEXEL P/No.
Tool Name
Common tool (157944-8520)
Universal
Common tool (157944-7820) Common
tool
vise
mounted
on the
PE(S) -A(D)
pump,
the following
spe-
AND REASSEMBLY Application
Q’ty 1
Used with 157944-8720)
Bracket
1
For fixing
PESA(D)
Bracket
1
For fixing
PEmA(D)
1
Used
together
with
socket
wrench
1
Used
together
with
socket
wrench
brackets
(157944-7820
and
pump
pump
(157944-8720)
Common tool (15791 O-0300)
Ratchet
Common tool (15791 O-l 120)
Handle
Common tool (15791 o-51 00)
Pin
For fixing each extractor (6 mm diameter)
Common tool (157916-5320)
Spanner
For holding pump side coupling (installed with laminated coupling)
Common tool (157842-4420)
Coupling
1
For camshaft camshaftj
rotation
(for 17 mm
dia.
Common tool (157842-4620)
Coupling
1
For camshaft camshaft)
rotation
(for 26 mm
dia.
10
Common tool (157914-0100)
Socket
wrench
1
For removing and installing fixing nut (SW 14 mm) 1
11
Common tool (I 579?4-0300)
Socket
wrench
1
For tightening mm)
12
Common tool (I 57913-0100)
Box
1
For removing and installing supply pump fixing nuts (SW 10 mm)
13
79D-15793121 (157931-2100)
14
15
13-002
handle
wrench
extractor
coupling
bolt (SW
19
Tappet
holder
8
For holding PE(S) -A pump tappets (bolt-type tappet adjustment)
Common tool (157931-2500)
Tappet
holder
6
For holding PE(S)mA pump tappets
Common tool (157931-7320)
Tappet
holder
10
For holding
Or
PE(S) =AD
high speed
pump
type
tappets
kiz
3
-0
0 .-t
00!3dlj
FIPGOO
P
r
ln
8
I
FIPGOO
a
0
z
a
w > 0 (3 >
to a W
r )I LL 0
s
W >
al W
n
0
n
x
W
009dlj
161 I
0 --.
v)
2 -. c?
009dlj
b
d
FIPGOO
\\ \
\b4
\
b
FIPGOO
19. Lightly tap the governor cover with wooden or plastic hammer to separate from the governor housing. (Fig. 37)
a it
Fig. 37 Separating the goveriior cover
20 Push the link’s (174) leaf spring from above and move the governor cover to the left or right to separate the link from the control rack. (Fig. 38) Idtie Note: T-I
Fig. 38 Separating
care
not to bend
the link.
the link
21 Using long-nose pliers, remove the starting spring (132) from the spring eye. The governor cover can now be removed. (Fig. 39)
Fig. 39 Starting spring removal
13-013
22. Attach the spanner (157916-5420) to the drive side coupling and then remove the roundnut (103) and spring washer (102) using the wrench (I 57915-0100) and handle (15791 O-l 120). (Fig. 40)
Fig. 40 Roundnut
removal
23 Attach the extractor (157926-5110) to the flyweight holder and using the socket wrench (157914-0300) and handle (15791 O11 ZO), remove the flyweight (100) and woodruff key (101). (Fig. 41)
Fig. 41 Removal of the flyweight
24. Remove the seven boits (7 and IO) fixing the governor housing in place. (Fig. 42)
Fig. 42 Removal of the bolts
13-014
b
d
FIPGOO
009dld
6. Remove the two snaprings screwdriver. (Fig. 50)
(153) with
a
Fig. 50 Removal of the snaprings
7. Lightly tap the swivel lever (150) with a wooden or plastic hammer to remove the two bushes (151). (Fig. 51)
Fig. 51 Removal of the bushes
8. After removing the two bushes (15i), the swivel lever (150) can then be removed. (Fig. 52) Note: The swivel lever should not be removed unless it is necessary to repair or replace any parts. If removed, O-rings (152) and oil seals (154) shouid be replaced with negw ones.
Fig. 52 Swivel lever removal
13-018
009dkl
FIPGOO
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FIPGOO
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:
Separate
Type Lever
B !_-
I -
M6; 0.7 - 0.9
The torques
M8; 1 - 1.4
not specified
FIPGOO
in this drawing
~____
should
\Yll%-
M14.: 6 - 7 -
\
(Full Side)
Groove)
@ Bolt after @ Bolt-tightening.
M6. o 5 _ o 7
Tighten
/
M8; 1.5 - 1.8 (Minus
conform
to Standard
Tightening
Torques.
Unit: Kg-m
cn W
Q1 I I-
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FIPGOO
DD
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009dlj
The RSUV mechanical governor is a variable speed governor which has been developed for use with generators, marine engines, construction and industrial machines, which are generally large sized, medium speed diesel engines. The RSUV type governor is the result of modification of the RSV type governor, to which an acceleration gear has been added. By selecting the appropriate gear, the acceleration gear’s gear ratio can be altered and the desired controlled speed range can be obtained. Flyweight speed, and therefore centrifugal force, has been increased, making this governor suitable for use with medium speed diesel engines.
01-002
The RSUV type governor is identical to the RSV type mechanical governor in regard to the following functions. 1. Speed droop adjustment can be easily performed without governor spring replacement, by adjustment of the swivel lever’s adjusting screw. 2. Engine speed can be maintained automatically at an intermediate level between maximum speed and minimum speed by selecting the appropriate control lever position. 3. The delivery of excess starting is automatic.
fuel for engine
c3 2 Iv) 1 3
n
a
n 2
a
.: .: .: . ** .: .. . .: : : :
. : : .. : .: .: .: : .. .: .. . .: : : :
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u; i 65 P$ g k!o’ CnQ
.. : . . : :. .: .: : .. . : : : *: .. .:
.. . : . : .: : .: .: . .. . : : : .: .. .:
SPECIAL TOOLS
In addition to ordinary tools such as spanners,
hammers, etc., the following special tools and adjustment of the RSUV type governor pump.
are required for disassembly, reassembly mounted on the PES8ZW type fuel injection
Tool No.
No.
Tool Name
Remarks
Q’ty
1
157944-8520
Universal vise
1
Used with bracket (157944-8620)
2
157944-8620
Bracket
1
For fixing PE-Z pump (during disassembly and reassembly)
3
157945-0120
Bracket
1
For fixing PESZW pump
4
157931-7800
Tappet holder
8
For holding tappets
5
157916-4820
Handle
1
For fixing coupling
6 7gD-1579150300 Wrench
1
For removing & installing flyweight roundnut
7 79D-1579266220 Extractor
1
For removing flyweight
1
For removing & installing gear’s fixing nut
157914-1700
8
Socket wrench
(SW27 mm) 9
79D-1579266120 Extractor
1
For removing gear
10
157923-5520
Extractor
1
For removing gear shaft
11
157914-l 200
Socket wrench
1
For removing & installing torque control spring’s locknut (SW24 mm)
12
157915-8300
Wrench
1
13
105782-6350
Measuring device
1
14
105781-0460
Fixing stand
2
For attaching PE.ZW pump (during adjustment)
15
105781-0520
Fixing stand
1
For attaching PESZW pump (during adjustment)
16
157913-3220
Box wrench
1
For adjusting full-load stopper bolt (SW14 mm)
17
157917-0820
Wrench
1
For adjusting torque control spring
18
105780-8130
Nozzle & nozzle
8
Nozzle : 105780-0050 (NP-DNGTDllSNPlT),
holder assembly
For removing & installing rack cap I
For measuring control rack position
Nozzle holder : 105780-2090 (NP-EFFP215)
19
157805-2020
Injection pipe
8
pr4mm~~8mmX1,500mm
20
157843-2720
Coupling
1
For driving PE=ZW pump (during adjustment)
21
157843-3200
Coupling
1
For driving PESZW pump (during adjustment)
Note:
12-002
(M18X1.5-M18~1.5)
The special tool kit (105790-3010) for the PE=Z type pump includes tools with key numbers: 6, 7, 9, 10 and 16.
I.
15794498520 Universal vise
2. 15794418620 Bracket
3. 157945-0120 Bracket 4- Ml OX1 5,
4. 157931-7800 Tappet holder
7. 79D-1579266220 Extractor
5. 157916-4820 Handle
6. 79D-I 579150300 Wrench
8. 157914-1700 Socket wrench
9. 79D-1579266120 Extractor
Ml 2X1.5
SW27
60
:
-lg.
i-1
special tools
12-003
0
L-+---A
FIPGOO
19. 157805-2020
Injection pipe
20. 15784392720 Coupling
I
L’
21. 157843-3200 Coupling
AR3 --._
Fig. 1-3 Special tools
12-005
ADJUSTMENT
Fig. 82
The following adjustments are necessary after reassembly of the RSUV type governor. l Adjustment of the injection pump’s injection timing and injection quantity l Full load adjustment l Maximum speed control adjustment 0 Idling adjustment @ Torque control spring adjustment l Boost compensator adjustment Use the pump test stand for these adjustments, and carefully check the pump speed and control rack position at the same time.
Injection pump installed on the test stand
Preparation 1. Fill
the governor chamber and the injection pump’s cam chamber with lubricating oil (131453-0120). Cam chamber: 30cc/cylinder Governor chamber: 1,200~~ (RSUV for PE-Z
84
Fig. 83
Removing the rack cap
pump) 2. Remove the idling sub-spring (135) and the torque control spring (140). 3. Remove the control rack cap using a spanner (W/21), and then mount the measuring device (105782-6350) on the control rack. (Fig. 83) 4. If a boost compensator is installed, fully screw in the boost compensator stroke adjusting screw and lock it using the locknut. (Fig. 84)
Fig. 84
12-006
Temporarily setting the boost compensator adjusting screw
5. Setting the control rack’s ‘0’ position -1, Maintain the pump speed at 300 rpm. -2, Fully loosen the STOP side stopper screw (407), and set the stop lever in the STOP position. -3, Loosen the minimum speed stopper screw (53) to decrease the governor spring’s set force. (Fig. 85)
Fig. 85
Loosening the minimum speed stopper screw -4. Push the control pinion fully to the drive side using a screwdriver. The position where the control rack does not move any further is the ‘0’ position. -5. In this position, set the measuring device’s scale at ‘0’. (Fig. 86)
Fig. 86
Setting the control rack’s ‘0’ position -6 Confirm that the full control rack stroke exceeds 26 mm by operating the stop lever (404). (Fig. 87) If the control rack does not move through its full stroke, or does not move smoothly, recheck the injection pump and governor.
Fig. 87
Confirming control rack movement
12-007
2” e
E
d, ii
i t
$lI?J
lOJ)UO=)
/’_______
Uo!ysod
I(MU)
009dlzl
Control rack postlion (mm) +
FIPGOO
0
Control rack position (mm) _t
IDLING SUB-SPRING ADJUSTMENT Before adjusting the idling sub-spring, fully loosen the boost compensator stroke adjusting screw. 1. While maintaining a pump speed of 100 rpm, temporarily set the speed control lever so that the control rack is positioned at Rd mm. (Figs. 97 and 98)
Pump speed (rpm) -
i
Fig. 97
Fig. 98
Temporarily setting the speed control lever 2. Increase the pump speed to Ne rpm, and maintain this speed. (Fig. 99) 3. Assemble the idling sub-spring capsule (135) and the nut (136) in the governor cover (35).
0
Ne Pump speed (rpm)
F RSV7006
Fig. 99
12-011
4. Adjust the idling sub-spring
capsule so that the control rack is positioned at Rb mm, and then fix the idling sub-spring capsule . (Fig. 100) 5. Check that the control rack is positioned at Rd mm when the pump speed is decreased to approximately 100 rpm.
Fig. 100 Adjusting the idling sub-spring PUMP SPEED ADJUSTMENT AT THE START OF MAXIMUM SPEED CONTROL 1. Gradually Na rpm.
increase
2. Set the minimum
the pump
speed
speed stopper (53) so that the control rack moving from the Ra mm position fuel decrease direction. (Figs. 101 and 102)
Na
to
screw starts in the
Nb
Pump speed (rpm) i?sv7001
Fig. 101 If Ra is not as specified, adjust it using the boost compensator stroke adjusting screw.
Fig. 102 -Pump speed adJustment at the start of maximum speed controi
SPEED DROOP ADJUSTMENT Engine output performance curve
Speed droop formula:
can be calculated
NC - NbMOO Nb
Governor performance curve RSV7002
Fig. 103 Relation between engine output and governor performance
NC
Pump speed (rpm) RSV7003
Fig. 104
the
(%)
Excessive speed droop increases the engine’s no load maximum speed (NC rpm) over the specified speed, resulting in engine damage. Conversely, too small a speed droop can result in high speed hunting. The speed droop of the RSUV type mechanical governor can be freely adjusted corresponding to engine use. 1. Slowly increase the pump speed. Check that the pump speed is NC rpm when the control rack position is Rb mm. (Fig. 104) 2. If the pump speed is not as specified, adjust the adjusting scre-w provided on the swivel lever. (Fig. 105) e Tightening the adjusting screw decreases the speed droop. e Loosening the adjusting screw increases the speed droop.
Rb
Nb
using
Note 1: The adjusting screw can be loosened a maximum of 24 notches (6 turns) from the position where it is completely tightened. Loosening it further may disengage the adjusting screw from the swivel lever, resulting in governor damage. 2: Always be sure to tighten the adjusting screw to the poin where a ‘click’ is heard.
Fig. 105 Adjusting screw
12-o-l 3
3. Remove the plug (5) using a socket wrench (SW32). (Fig. 106)
~~_
~~
RSV3195
Fig. 106 Removing the plug 4. Loosen the minimum speed stopper screw (53) and position the speed droop adjusting screw below the governor housing’s plug hole. (Fig. 107)
Fig. 107 Loosening the minimum speed stopper bolt 5. Adjusting screw adjustment If NC rpm exceeds the specified value, tighten the adjusting screw; if NC rpm is less than the specified value, loosen the adjusting screw. (Fig. 108)
RSV3197
Fig. 108 Adjusting screw adjustment
12-014
6. Reset the minimum speed stopper screw (53) so that the speed at the start of maximum speed control is Nb rpm. (Fig. 109) 7. Check that the no-load maximum speed is NC rpm (described in item 1. above). Continue the adjustment until the specified value is obtained.
Fig. 109 Pump speed readjustment at the start of maximum speed control SETTING THE MAXIMUM STOPPER SCREW
SPEED
Tighten the maximum speed stopper screw (12) until it contacts the speed control lever (190), and then lock it using the nut (13). (Fig. 110)
Fig. 110 Setting the maximum speed stopper screw
12-015
BOOST COMPENSATOR (when installed)
1. Temporary adjustment of the boost compensator adjusting screw (270) -1. Remove the capnut (276) and loosen the locknut (271).
t
-z
ADJUSTMENT
Perform at Nh rpm
Boost compensalor stroke
Pl Boost
5
.= 2
L----7
p2
pressure (mmHg) +
Rf
Pump speed (rpm) _I)
1
RSV70 10
J
Fig. 111 Boost compensator equipped governor performance chart
0 0
2 ii
-2. Fully screw in the adjusting screw and lock it using the locknut. (Fig. 112) 2. Perform all the previously explained adjustments. NOiC
‘ihe
id
lOad stopper
bdt shdd
be adjusted at a control rack position of Rg mm.
Fig. 112 Temporarily setting the boost compensator screw
12-016
3. Boost compensator stroke adjustment -1. Connect the compressed air pipe to the cover (268).
Note: During boost compensator stroke adjustment, it is not necessary to supply compressed air. -2. Fix the speed control lever in the maximum speed position. -3. Set the stop lever in the NORMAL position. -4. Maintain a pump speed of Nh rpm.
Fig. 113 Adjusting the boost compensator stroke -5‘. Alter the control
rack position from Rg mm to Rf mm using the adjusting screw (270) and then lock it using the locknut (271). (Figs. 113 and 114)
Nh Pump speed (rpm) e RSV70 11
Fig. 114
Pump speed
4. Boost compensator spring adjustment -1. Operate the pump at Nh rpm. -2. Position the speed control lever in the maximum speed position. -3. Position the stop lever in the NORMAL POSITION. -4. Supply compressed air to the boost compensator.
: Nh rpm
Bcost pressure (mmHg) RSV7012
12-017
FIPGOO
-(UJW)
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00!3dM
t--
(UJUJ)
UO!j!SOd
yCN?J lOJWO3
b
FIPGOO
s
m
2.0 to 3.0 mm
Stopper screw &
RSV3209
3. Fully loosen the NORMAL position side stopper screw (407). 4. fvlove the stop lever (404) toward the NORMAL position until the governor’s internal stopper contacts the governor cover. 5. Maintain the stop lever in this position. 6. Adjust the stopper screw so that the clearance between the stopper screw and the stop lever is 2.0 to 3.0 mm. (Fig‘. 125) 7. Fix the stopper screw using the locknut (408) rn
Fig. 125 NORMAL position side stopper screw adjustment CHECKING
THE SPEED CONTROL LEVER AND STOP LEVER ANGLES
Idling
Full-speed
Check that the speed control lever __ aPecified_ _I stop [ever angles are a5
and
(Fig. 126)
SPEED CONTROL LEVER ANGEL
STOP LEVER ANGLE RSV7015
Fig. 1126 Checking the lever angles
CONTROL
RACK LIMITER
ADJUSTMENT
I_ Remove the rack guide screw pump housing. (Fig. 127)
from the
uide screw
12-02 1
~
_
FIPGOO
Control rack positlon (mm) +
.I
F L
m
M
Control rack posltion (mm) --+
FIPGOO
Y
\
\
.$ IA
&I -
n
F
Q
:T
0
n
Control rack poshon (mm)-
O:
Control rack position (mm) -
Screw in the idling spring capsule until the control rack is positioned at Rd mm, and then lock it at this point using a locknut (332) and a wrench (1579170820; SW27 end). (Fig. 141)
Fig. 141 Adjusting the idling spring capsule
0
Nd
NC
Pump speed (rpml RSV702 1
6. Slowly increase the pump speed and ensure that when the control rack the reaches the Rc mm position, corresponding speed is NC rpm. (Fig. 142) e When the pump speed is less than NC rpm, reset the load control lever toward the control rack’s ‘0’ position, but with the control rack position still within the specified range. 7. Make sure the control rack position remains above Rh mm, even when pump speed is decreased to 0 rpm.
Fig. 142
Torque control spring adjustment RQ
t
* --
Ra
F g
7
1. Fully screw in the boost compensator stroke adjusting screw again 2. Set the load control lever at the NORMAL position. 3. While maintaining a pump speed of Na rpm, confirm that the control rack is positioned at Ra mm. 4. Operate the injection pump at a speed slightly less than Nf rpm.
\ \ \
\
5 ._ .5
\ \
8 z
3 e E 8 0
Nf
Na
Pump speed Vpm) A RSV7022
Fig. 143
12-027
Control rack posltion (mm)---+
FIPGOO
Control rack posihon (mm) -
-.
cn
5 -.
3
T-
.
-
.-F 3
2
ci
(WI)
UO!$SOd
y3eJ
lOJ)UO3
P’
.-4”%; !? .cI
X
G=
E 3
E
FIPGOO
L.
Y
3
0
rc -.
0
(D
3
-.
(D
--.
3
%
:
L-.
3
I -.
3
Control rack position (mm)+
5 ._ .= 8 0. 0
x T =
l?
Boost compensator adjustment 1.
I
t
Perform at Nh rpm
2.
0
Pl
p2
Boost pressure (mmHg)----_, Boost compensator stroke
P E S
0
\
I
Nh Pump speed (rpm) -
RSV7030
Fig. 155 Boost compensator equipped governor performance chart
1. Maintain a pump speed of 0 rpm. Ri
2. Confirm that the speed control lever is positioned in the maximum speed position. 3. Hold the load control lever in the full load position. 4. Position the stop lever in the NQRMAL position. Pump speed (rpm) ---+ RSV703 1
Fig. 156
12-032
E
2
0 ii
0
.-c.0
2
-(ww)
uo!qsod ~CELIloquo=)
STOPPERS All adjustment stoppers that directly affect engine performance are lock-sealed after adjustment. Do not readjust any stopper without using the pump test stand or the engine test bench, as this will adversely affect the engine and engine performance. (Fig. 160)
RSV3220
Fig. 160 Stoppers
LUBRICATION Integrated lubrication system In this system, oil is pumped to the injection pump housing (or governor cover) to lubricate the injection pump cam chamber and the governor chamber. After passing through the overflow nipple located on the injection pump or governor, the oil returns to the engine.
12-034
Replenishment or replacement of governor and injection pump oil is not necessary. However, prior to operation on the pump test stand or engine test bench, the governor chamber and the injection pump cam chamber must be filled with engine oil or injection pump oil (Part No 131453-0120) until oil overflows from the overflow nipple.
S t? iT:
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.
.
.
.
: . :
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.
.
.
.
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.
.
.
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: . -.
: .
:
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s
: : : . . : .
.
SPECIAL TOOLS
In addition to ordinary tools such as spanners, hammers, etc., the following special tools are required for disassembly, reassembly and adjustment of the RSUV type governor mounted on the PES8ZW type fuel injection pump.
Tool
NO.
No.
Tool Name
Remarks
Q’ty
1
157944-8520
Universal vise
1
Used with bracket (157944-8620)
2
157944-8620
Bracket
1
For fixing PE.Z pump (during disassembly and reassembly)
3
1579450120
Bracket
1
For fixing PESZW pump
4
157931-7800
Tappet holder
8
For holding tappets
5
157916-4820
Handle
1
For fixing coupling
6 79D-1579150300 Wrench
1
For removing & installing flyweight roundnut
7 79D-1579266220 Extractor
1
For removing flyweight
1
For removing & installing gear’s fixing nut
157914-l 700
8
Socket wrench
(SW27 mm) 9
79D-1579266120 Extractor
1
For removing gear
10
157923-5520
Extractor
1
For removing gear shaft
11
157914-l 200
Socket wrench
1
For removing & installing torque control spring’s locknut (SW24 mm)
12
157915-8300
1
Wrench I
For measuring controi rack position
13
105782-6350
Measuring device
14
105781-0460
Fixing stand
2
For attaching PEmZWpump (during adjustment)
15
105781-0520
Fixing stand
1
For attaching PESZW pump (during adjustment)
16
157913-3220
Box wrench
1
For adjusting full-load stopper bolt (SW14 mm)
17
157917-0820
Wrench
1
For adjusting torque control spring
18 , 105780-8130
, Nozz!e & nozz!e
,
i
For removing & installing rack cap I
8
holder assembly
I
Nozzle : 105780-0050 (NP-DNSTD119NPl T), Nozzle holder : 105780-2090 (NP-EFFP215)
19
157805-2020
Injection pipe
8
~4mmX~8mmx1,500mm
20
157843-2720
Coupling
1
For driving PEmZWpump (during adjustment)
21
157843-3200
Coupling
1
For driving PESZW pump (during adjustment)
Note:
13002
(M18x1.5-M18x1.5)
The special tool kit (105790-3010) for the PEmZtype pump Includes too& with key numbers: 6, 7, 9, 10 and 16.
CL
0
z W > 0
u
W
n
009dM
FIPGOO
111
0
z
3
m
c
0
G)
C 0
c
cn
10
m
-I I
11
0
s
c iii
0
m
0
0
r
m x v
DISASSEMBLY Preparatlon
ism125
Fig. 4
Attaching the brackets
1. Keep the bench and workshop clean. Clean the outside of the governor and injection pump thoroughly before disassembly. 2. Before disassembly record the positions of all adjustable parts to facilitate reassembly, and record governor performance so that a comparison may be made after adjustment. Q LJ. The numbers in parentheses following part names refer to the key numbers in figures 2 and 3, and those following tool names refer to tool part numbers. Disassembly The following is an explanation of the disassembly procedure for the RSUV type mechanical governor mounted on the NPPES8ZW type fuel injection pump. 1. Attach the brackets
RSV3127
Fig. 5
(157944-8620 and 157945-0120) to the universal vise (157944-8520). (Fig. 4) 2. Remove the fuel supply pump and the cover plate. 3. Securely fix the injection pump to the brackets using the six bolts. (Fig. 5)
Attaching the injection pump 4. Rotate the camshaft to position the cams in the top dead center position. 5. Insert a screwdriver between the tappet adjusting bolt and the locknut. 6. Lever the tappet up and insert the tappet holder (157931-7800) into the tappet’s groove, into which the tappet guide is installed. (Fig. 6) When inserting the tappet holder, place a cloth between the screwdriver and the pump housing to prevent damage to the pump housing.
Fig. 6
Inserting the tappet holders
13-005
FIPGOO
14. Remove the flyweight from the gear shaft (107) using an extractor (1579266220). (Fig. IO)
RSV3131
Fig. 10
Removing the flyweight 15. Remove the washer (104).
(Fig. 11)
RSV3132
Fig. 11
Removing the washer
16. Remove the four bolts (IO) fixing the cover (112) using a socket wrench (SW13). (Fig. 12)
RSV3 133
Fig. 12
Removing the bolts
13-007
FIPGOO
4
6, ii 009dM
23.Screw plate.
the extractor (Fig. 19)
bolt
0
into
the
Note: The extractor bolt has a left hand thread.
Fig. 19
Attaching the extractor bolt 24Aount shaft.
Fig. ad
the fixing (Fig. 20)
bolt
@ on the
gear
Attaching the fixing b
25Turn the extractor bolt slowly clockwise using a spanner (SW32) to extract the gear shaft and bearing together from the governor housing. (Fig. 21)
RSV314
Fig. 21
13-010
Extracting the bearing
26.Remove the extractor, gear bearing. (Fig. 22) 27. Remove the washer (11 I).
shaft
and
RSV3142
Fig. 22
Removing the gear shaft and bearing 28.Remove (175).
the link (Fig. 23)
from
the
connector
RSV3143
Fig. 23
Removing the link 29. Disengage the start spring (132) from the governor housing pin. 30.Straighten the two lock washers (178). 31. Remove the bolt (176) and nut (177). (Fig. 24)
Fig. 24
Removing the bolt and nut
13-011
-
FIPGOO
,
35.Lightly tap the governor
housing with a plastic hammer to separate it from the pump housing. (Fig. 28)
148
i
Fig. 28
Removing the governor housing If it is necessary to disassemble the governor cover assembly, the procedure is as follows.
36. Remove the capnut (138; SW32). (Fig. 29)
I
8
2 G
Fig. 29
Removing the capnut
37. Loosen the locknut (136) the idling sub-spring (135).
Fig. 30
and remove (Fig. 30)
Removing the idling sub-spring
13-013
FIPGOO
FIPGOO
49.Pull the tension lever towards the top of the governor cover. (Fig. 40)
Fig. 40
Positioning the tension iever 50.Remove the governor spring and the tension lever together from the swivel lever. (Fig. 41)
Fig. 41
Removing the governor spring and tension lever 51 .Loosen the bolt (SW17) and remove the speed control lever (190) from the swivel lever shaft. (Fig. 42)
Fig. 42
Removing the speed control lever
13-017
FIPGOO
3 P
.
Fl PGOO
d, ii
FIPGOO
FIPGOO
Z
0
Tension lever 1. Replace the tension lever and the shaft when the clearance between the shaft and the tension lever is excessive due to wear. (Fig. 63) 2. Replace the tension lever and the full load adjusting screw when the contact surfaces between the full load adjusting screw, the shifter and the tension lever are worn excessively. (Fig. 63) I
RSV3090
Fig. 63
Tension lever and shaft Inspection Swivel lever Replace the swivel lever and the bushings when the clearances between the swivel lever and the bushings are excessive due to wear. (Fig. 64)
RSV3175
Fig. 64
Swivel lever and bushing inspection Boost compensator 1. Replace the pushrod when the surface of the pushrod is worn excessively. (Fig. 65) 2. Replace the diaphragm if the rubber is damaged (ie, broken or flawed). (Fig. 65)
RSV3092
Fig. 65
Diaphragm and pushrod inspection
13-025
Guide lever 1. Replace the guide lever assembly when the surface of the shifter (where it contacts the tension lever) is worn (ie, the chrome plating is peeling off). (Fig. 66)
RSV3093
Fig. 66
Shifter inspection 2. Worn ball bearings are primarily responsible for excessive axial play between the shifter and the sleeve. If worn, replace the sleeve assembly. Replace the guide lever assembly when the play in the connection between the shifter and the guide lever is excessive. (Fig. 67) 8 2 LL RSV3114
Acceleration gear 1. Replace the gear and the gear shaft when the gear play is excessive due to wear. 2. Replace the four rubber dampers if the gear can be rotated manually while the gear holder is fixed. (Fig. 68)
Fig. 68
13-026
Acceleration gear inspection
1
REASSEMBLY For clockwise rotation (with distinguishing
groove)
For counter clockwise rotation
Because the reassembly procedure is the reverse of the disassembly procedure, only are attention special points requiring explained.
groove
1. Impeller (when installed) Two types of impeller can be used, depending on the direction of pump rotation. (Fig. 71) Counterclockwise rotation: 155412-5600 Clockwise rotation: 155412-5500 RSV31.20
Fig. 71
Impellers 2. When attaching the gear to the camshaft, tighten the nut to the following torque. (Fig. 72)
1 $30 (M20 thread)
1
15.0-17.0
1
RSV3 176
Fig. 72
Tightening the gear nut the cover on the 3. When installing governor housing, tighten the four bolts to the following torque. (Fig. 73) Bolt thread size
Fig. 73
13-028
Tightening the cover bolts
Torque
d CD
LL
x
d, ii
FIPGOO
3
-.
Guide lever
-2. After placing the snapring on the bushing, pressfit the shifter to the bushing. (Fig. 80) Do not alter the thickness of the shim inserted between the bushing and the shifter. Note: Take care not to damage the chrome-plated portion of the shifter.
Shifter
RSV3182
i
Fig. 80
Pressfitting the shifter
e -
RSV3 183
Fig, 81
1
Reassembling the sleeve
-3, Reassemble the inner race, the ball and cage assembly, and the shifter in the sleeve, and fix them using the snapring. (Fig. 8i j -4. After completing reassembly, fix the shifter and confirm that it rotates smoothly when the sleeve is rotated.
I-
: . :
110; 1.2-1.5
/
7
The torques torques
FIPGOO
should
- \
M6; 0.7-0.9 M8; 1.5-1.8
in this drawing
MlO; 1.3- 1.5
conform
M20; 11-12
M14; 6-7
M6; 0.5-0.7
F
M10; 1.2-1.5
_/
M6; 0.7-0.9
1.8-2.2
i
tightening
M3; 0.2-0.3
M5; 0.3-0.45
M6; 0.3-0.5
M6; 0.7-0.97
MlO; 1.2-1.5
M6: 0.5-0.7
MlO; 1.2-1.5
M6; 0.5-0.7
- M20; 2.2-2.5
-M16;
to standard
M8; 1.8-2
M12; 5-6
M8; 1.8-2
M24; 8-- 10
not specified
M8; 1 - 1.4
MlO; 1.5-2 M12; 1.5-2
Mlo; 0.7-
1
RSVlOll
Unit: kg-m
L- M6; 0.7-0.9
L
M30; 2.5-3
M12; 1.2-1.6
M30; 3-3.5
M12: 1.6-2
SEBM024001
FUEL SUPPLY PUMP (COMMON RAIL TYPE)
FUEL SUPPLY PUMP MODEL DENSO CRI TYPE
©2001 All Rights Reserved Printed in Japan 07-01(02)
00-001 1
CONTENTS
01
GENERAL ............................................................................. To be issued next time
11
STRUCTURE AND FUNCTION
12
TESTING AND ADJUSTING
13
DISASSEMBLY AND ASSEMBLY ................................................. 13-001
14
PERFORMANCE TEST
15
OTHERS
00-002
............................ To be issued next time
................................. To be issued next time
.......................................................................... 14-001
................................................................................ To be issued next time
FUEL SUPPLY PUMP
The affected pages are indicated by the use of the Revision Revision Mark Page Page that necessary Mark acPage following marks. It is Mark requested number number tions be taken to these pages according to the table below.
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(
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number
c
Page to be newly added
Add
b
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Discard
)
Pages having no marks are those previously revised or made aditions.
LIST OF REVISED PAGES Mark
b c
b b b b b b
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00-001 00-002 00-003 13-001 13-002 13-003 13-004 13-005 13-006 13-007 13-008 13-009 13-010 13-011 13-012 13-013 13-014 13-015 13-016 13-017 13-018 13-019 13-020 13-021 13-022 13-023 13-024 13-025 14-001 14-002 14-003 14-004 14-005 14-006 14-007 14-008 14-009 14-010 14-011
Revision number
1
Mark
Page
Revision number
Mark
Page
Revision number
Mark
Page
Revision number
Mark
Page
Revision number
14-012
1
1 1 1 1 1 1
1 1 1 1 1 1 1 1 1 1 1 1 1
1 1 1 1 1 1 1 1
FUEL SUPPLY PUMP
00-003 1
13 DISASSEMBLY AND ASSEMBLY
Special tools list ......................................... 13-002 Consumable parts list ................................ 13-003 Sketches of special tools ........................... 13-004 Disassembly of fuel supply pump ............ 13-005 Assembly of fuel supply pump ................. 13-014 Tightening torque table ........................... 13-025
FUEL SUPPLY PUMP
13-001
SPECIAL TOOLS LIST
DISASSEMBLY AND ASSEMBLY
A
B
1
799-609-1010
Puller, PCV
1
2
799-609-1020
Mounting, PCV
1
3
Purchased
Socket, B = 42 mm
1
4
Purchased
Deep socket, B = 22 mm
1
1
799-609-1030
Extractor
1
799-609-1040
Holding spanner
1
799-609-1050
Holding spanner
1
799-609-1310
Pliers
1
1
799-609-1320
Puller
1
2
799-609-1330
Hook set
1
3
799-609-1060
Base (ø100)
1
799-609-1070
Support (ø31)
1
799-609-1080
Support (ø37)
1
2 C
D 4
799-609-1090
Support (ø39)
1
5
799-609-1110
Wear ring stopper
1
1
799-609-1120
Handle
1
2
799-609-1130
Adapter
1
799-609-1140
Replacer (ø34)
1
799-609-1150
Replacer (ø43)
1
799-609-1160
Replacer (ø52)
1
799-609-1170
Replacer (ø60)
1
799-609-1180
Replacer (ø61)
1
799-609-1190
Replacer (ø71)
1
799-609-1210
Replacer (ø81)
1
799-609-1220
Base housing (ø62)
1
3 4 E
5 6 7
F
799-609-1230
Base housing (ø72)
1
8
799-609-1260
Pipe (ø30)
1
9
799-609-1270
Guide pin
1
1
799-609-1240
Oil seal presser
1
2
799-609-1250
Oil seal guide
1
799-609-1340
Guide rail, nut (ø25)
1
799-609-1440
Guide rail, nut (ø30)
1
799-609-1450
Cam clearance measure (ø25)
1
1 G 2 H
I
6UHD
Part name
6HD
Part No.
Symbol
Q’ty
SPECIAL TOOLS LIST Nature of work, remarks
Removal, installation of PCV assembly
Removal, installation of upper spring seat Removal, installation of feed pump Removal of bearing outer race
Removal of bearing inner race Installation of wear ring
Removal, installation of bearing
Installation of oil seal
Installation of camshaft
799-609-1460
Cam clearance measure (ø30)
1
1
799-609-1280
Depth measure
1
2
799-609-1290
Sensor measure
1
1
Purchased
Slide calipers
1
2
Purchased
Hexagon wrench
1
B = 3 mm, 5 mm
3
Purchased
Tweezers
1
L = 100 mm, 150 mm
4
Purchased
Torque wrench
1
Preset type
5
Purchased
Dial gauge
1
Accuracy: 0.01 mm
6
Purchased
Gasket sealant
1
LG-6
7
Purchased
Liquid adhesive
1
LT-2
13-002 1
Installation of G sensor
FUEL SUPPLY PUMP
DISASSEMBLY AND ASSEMBLY
CONSUMABLE PARTS LIST
Part No.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46
094086-0210 094086-0090 094137-0010 094086-0100 949150-3030 949150-3200 094086-0120 094086-0150 094095-0100 094095-0130 094095-0140 094095-0150 094095-0160 094095-0330 094095-0340 094095-0350 094095-0360 094095-0370 094086-0110 094086-0160 094086-0130 094086-0170 949140-6310 094096-0050 094096-0060 094096-0070 094096-0080 090222-0070 090222-0120 095331-0020 090207-0100 094086-0200 094087-0050 092125-0010 090222-0070 094092-0010 094093-0050 094093-0060 094093-0070 094093-0080 094093-0090 094093-0100 094093-0110 094093-0120 949018-0350 949010-3020
FUEL SUPPLY PUMP
Part name O-ring O-ring Gasket O-ring Seal Seal O-ring O-ring Shim Shim Shim Shim Shim Shim Shim Shim Shim Shim O-ring O-ring O-ring O-ring O-ring Shim Shim Shim Shim Washer Washer Stopper Ring O-ring Seal Gasket Washer Washer Washer Washer Washer Washer Washer Washer Washer Washer Washer Washer
Q’ty 1 2 2 6 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 5 2 2 1 1 1 1 6 4 1 1 1 1 1 1 1 1 1 1
6UHD
No.
6HD
CONSUMABLE PARTS LIST Remarks
T = 0.05 T = 0.1 T = 0.2 T = 0.3 T = 0.5 T = 0.05 T = 0.1 T = 0.2 T = 0.3 T = 0.5
T = 0.15 T = 0.20 T = 0.25 T = 0.40
13-003 1
DISASSEMBLY AND ASSEMBLY
SKETCHES OF SPECIAL TOOLS
SKETCHES OF SPECIAL TOOLS Note) Manufacture the bracket according to the following mounting dimensions drawing and the dimensions of the test stand in hand. When manufacturing it, consider that it will be used for the performance test of the pump, too. fl The bracket parts are shown below the drawing for reference. 1 Bracket (Dimensions drawing for mounting fuel supply pump)
6HD 6UHD
A 214.4 239
B 57 59
C 60 60
For reference Bracket 1 on drive shaft side
13-004
D 129±0.15 139.5±0.15
E 11.0 12.5
F 75 75
G 55±0.05 57±0.05
H 54±0.2 70±0.2
I 27 35
J 14.5 14.5
K M12x1.75 M12x1.75
For reference Bracket on feed pump side
FUEL SUPPLY PUMP
DISASSEMBLY AND ASSEMBLY
DISASSEMBLY OF FUEL SUPPLY PUMP
DISASSEMBLY OF FUEL SUPPLY PUMP 1. Securing fuel supply pump 1) Hold bracket 1 with a vise. (Manufacture bracket 1 in the field.)
2) Fix pump assembly (1) to bracket 1 with 4 bolts (M8 or M10).
2. Removal of element assembly 1) Remove the mounting nut of element assembly (2) and install tool A1. Tool: A1 (PCV puller) 799-609-1010
2) Tighten the bolts of tool A1 evenly to remove element assembly (2). • Lift up the element assembly vertically so that its housing will not be damaged.
FUEL SUPPLY PUMP
13-005 1
DISASSEMBLY AND ASSEMBLY
DISASSEMBLY OF FUEL SUPPLY PUMP
3) Pull plunger (3) out of the housing, taking care not to damage it.
3. Removal of PCV 1) Secure tool A2 with the vise and fix removed element assembly (2) to tool A2. Tool: A2 (PCV mounting) 799-609-1020
2) Remove PCV (4) with tool A3. • Use an extension bar about 50 cm long.
3) Remove stopper (5) with tweezers. • Do not reuse stopper (5).
13-006 1
FUEL SUPPLY PUMP
DISASSEMBLY AND ASSEMBLY
DISASSEMBLY OF FUEL SUPPLY PUMP
4) Loosen the vise and change the fixing angle of tool A2, then remove valve holder (6) with tool A4.
5) Remove the stopper, washer, spring, gasket, and valve with magnet 1. • Do not mix the parts of element assembly PCV1 and element assembly PCV2.
4. Removal of upper spring seat 1) Fix tool B1 to housing (35). Tool: B1 (Extractor) 799-609-1030
2) Install tool B2 to the drive shaft end. Tool: B2 (Holding spanner) 799-609-1040 (6UHD) 799-609-1050 (6HD) 3) Turn the shaft with tool B2 to bring the cam of upper spring seat (34) of the cylinder to be removed to the bottom dead center.
FUEL SUPPLY PUMP
13-007 1
DISASSEMBLY AND ASSEMBLY
DISASSEMBLY OF FUEL SUPPLY PUMP
4) Put the pin of tool B1 in the semicircular groove of upper spring seat (34). Pushing it in, turn the handle by 90 degrees and remove upper spring seat (34). fl Do not push in the pin more than necessity since it can cut the housing surface under the seat.
5) Remove the spring, lower spring seat, and tappet (9) with magnet 1.
6) Drain the oil from the pump.
5. Removal of feed pump 1) Remove pump cover (10) with a hexagon wrench (5 mm), then remove the O-ring. • Drain the fuel remaining in the pump with the priming pump.
13-008
FUEL SUPPLY PUMP
DISASSEMBLY AND ASSEMBLY
DISASSEMBLY OF FUEL SUPPLY PUMP
2) Remove four mounting bolts (12) of side plate (11) (outer) with a hexagon wrench (3 mm).
3) Using tool C, remove side plate (11). Tool: C (Pliers) 799-609-1310
4) Remove casing (13). 5) Remove outer rotor (14). 6) Remove inner rotor (15) and key (39).
7) Remove side plate (16) (inner).
FUEL SUPPLY PUMP
13-009 1
DISASSEMBLY AND ASSEMBLY
DISASSEMBLY OF FUEL SUPPLY PUMP
6. Removal of feed pump and crank position sensor 1) Remove the mounting bolts and feed pump housing (17) from housing (35).
2) Remove G sensor (18). • When removing the G sensor, take care not to damage the shim and housing.
7. Removal of camshaft 1) Remove mounting bolts (21) of bearing cover assembly (19) with a hexagon wrench (5 mm).
2) Remove key (20).
13-010
FUEL SUPPLY PUMP
DISASSEMBLY AND ASSEMBLY
DISASSEMBLY OF FUEL SUPPLY PUMP
3) Hit the end of camshaft (22) on the feed pump side with a plastic hammer to remove bearing cover assembly (19) from the housing.
4) Pull out camshaft (22).
FUEL SUPPLY PUMP
13-011
DISASSEMBLY AND ASSEMBLY
DISASSEMBLY OF FUEL SUPPLY PUMP
8. Removal of bearing outer race 1) Set tools D1, D2, and D3 and place bearing cover assembly (19) on tool D3. Tools: D1 (Bearing puller) 799-609-1320 D2 (Hook set) 799-609-1330 D3 (Base) 799-609-1060
2) Pull out bearing outer race (24) with a hand press.
9. Removal of oil seal Remove oil seal (30) with tools E3 and E1 and a hand press. Tools: E1 (Handle) 799-609-1120 E3 (Replacer) 799-609-1140 (6HD) 799-609-1150 (6UHD)
10. Removal of wear ring 1) Set shaft (22) to a vise. 2) Break wear ring (25) with a hammer. 3) Pull wear ring (25) out of shaft (22).
13-012 1
FUEL SUPPLY PUMP
DISASSEMBLY AND ASSEMBLY
DISASSEMBLY OF FUEL SUPPLY PUMP
11. Removal of bearing roller Secure the camshaft with tool D4 and pull out bearing rollers (26) (2 pieces, 1 each on both sides). •
Install thread protection nut 1 to the shaft end on the drive side.
Tool: D4 (Support) 799-609-1070 (6HD) 799-609-1080 (6HD) 799-609-1090 (6UHD)
12. Removal of oil seal of feed pump case Using tools D1 and D2, pull out the oil seal with a hand press. Tools: D1 (Bearing puller) 799-609-1320 D2 (Hook set) 799-609-1330
13. Removal of bearing outer race of pump housing Place the housing on tool E7 and assemble the replacers of 2 types, handle, and adapter to make a jig. Remove the bearing outer race with that jig and a hand press. Tools: E1 (Handle) 799-609-1120 E2 (Adapter) 799-609-1130 E4 (Replacer) 799-609-1160 (ø52) (6HD) 799-609-1170 (ø60) (6UHD) E5 (Replacer) 799-609-1180 (ø61) (6HD) 799-609-1190 (ø71) (6UHD) E7 (Base) 799-609-1220 (ø62) (6HD) 799-609-1230 (ø72) (6UHD)
FUEL SUPPLY PUMP
13-013 1
DISASSEMBLY AND ASSEMBLY
ASSEMBLY OF FUEL SUPPLY PUMP
ASSEMBLY OF FUEL SUPPLY PUMP fl When installing each part, clean it in clear diesel fuel and take care that foreign matter will not enter it. Replace O-rings with new ones. fl Prepare the consumable parts indicated in the list. 1. Assembly of bearing outer race 1) Place bearing outer race (27) by using tool E7, then remove tool E7. 2 Outside surface of outer race: Gear oil (SAE #90 or equivalent) Tool: E7 (Base) 799-609-1220 (ø62) (6HD) 799-609-1230 (ø72) (6UHD) 2) After removing tool E7, place tool E6 on bearing outer race (27) and press fit to the end of retainer (28) with a hand press. Tool: E6 (Replacer) 799-609-1210 (ø81)
2. Assembly of feed pump housing 1) Set tool F2 to feed pump housing (17) and insert the oil seal, then press fit with tool F1 with a hand press. 2 Outside surface of oil seal: Adhesive (LT-2) • •
After press fitting, wipe off all projected adhesive. Apply gear oil to the oil seal lip surface. Tool: F1 (Oil seal presser) 799-609-1240 F2 (Oil seal guide) 799-609-1250
2) Install camshaft clearance adjustment shim (29).
13-014 1
FUEL SUPPLY PUMP
DISASSEMBLY AND ASSEMBLY
ASSEMBLY OF FUEL SUPPLY PUMP
3) Fit the O-ring to camshaft housing (35) and install feed pump housing (17). 3 Mounting bolt: 6.8 – 11.8 Nm {0.7 – 1.2 kgm}
3. Press fitting of bearing outer race Assemble the replacers of 2 types, handle, and adapter to make a press fitting jig. Press fit bearing outer race (27) on the feed pump side to the feed pump housing end with the press fitting jig and a hand press. Tools: E1 (Handle) 799-609-1120 E2 (Adapter) 799-609-1130 E4 (Replacer) 799-609-1160 (ø52) (6HD) 799-609-1170 (ø60) (6UHD) E5 (Replacer) 799-609-1180 (ø61) (6HD) 799-609-1190 (ø71) (6UHD)
4. Installation of bearing roller 1) Press fit bearing (26) on the drive side. Tool: E8 Pipe (ø30): 799-609-1260 • Do not receive the press fitting force with the cam at part a but receive it with the shaft end. 2 Inside surface of bearing: Gear oil (SAE #90 or equivalent)
2) Press fit bearing (26) on the feed pump side. Tool: E8 Pipe (ø30): 799-609-1260 2 Inside surface of bearing: Gear oil (SAE #90 or equivalent)
FUEL SUPPLY PUMP
13-015 1
DISASSEMBLY AND ASSEMBLY
ASSEMBLY OF FUEL SUPPLY PUMP
3) Using tool D5, set wear ring (25) in the inserting position and press fit it with a press. Tool: D5 (wear ring stopper) 799-609-1110
5. Installation of bearing outer race 1) Press fit bearing outer race (24) to bearing cover (19). Tool: E1 (Handle) 790-609-1120 E2 (Adapter) 790-609-1130 E4 (Replacer) 790-609-1160 (ø52) (6HD) 790-609-1170 (ø60) (6UHD) E5 (Replacer) 790-609-1180 (ø61) (6HD) 790-609-1190 (ø71) (6UHD) 2 Outside surface of outer race: Gear oil (SAE #90 or equivalent)
2) Press fit oil seal (30) to the bearing cover end. 2 Outside surface of oil seal: Adhesive (LT-2) • •
After press fitting, wipe off all projected adhesive. Apply gear oil to the oil seal lip surface.
6. Installation of PCV 1) Install new stopper (5) with tweezers.
13-016 1
FUEL SUPPLY PUMP
DISASSEMBLY AND ASSEMBLY
ASSEMBLY OF FUEL SUPPLY PUMP
2) Fit the new O-ring to element (4) and apply grease to them.
3) Fix element (2) to tool A2 and install PCV (4) to element (2). 3 PCV: 157 – 177 Nm {16 – 18 kgm} •
Using a limit-type torque wrench, tighten the element to the specified torque without stopping halfway.
7. Installation of delivery valve holder 1) Change the fixing direction of tool A2 and replace gasket (36) with new one, then install check valve (31) and washer (37A). 2) Install spring (32), washer (37B), and stopper (38). 3) Replace the O-ring with new one and apply grease to it and the threads of delivery valve holder (6), then assemble them temporarily.
FUEL SUPPLY PUMP
13-017
DISASSEMBLY AND ASSEMBLY
ASSEMBLY OF FUEL SUPPLY PUMP
4) Using tool A4, install delivery valve holder (6). 3 Delivery valve holder: 137 – 167 Nm {14 – 17 kgm} •
Use a limit-type torque wrench.
5) Fit O-ring (40).
8. Installation of camshaft and bearing cover 1) Install camshaft (22) to pump housing (1), then install guide pin E9 and bearing cover (19) and camshaft clearance adjustment shim without fitting the O-ring. Tool: E9 (Guide pin) 799-609-1270 • When installing the camshaft and bearing cover, take care not to damage the oil seal on the feed pump side and bearing cover side.
2) Using a hand press, press fit bearing cover (19) and secure it with the bolt. Tool: E8 (Pipe) 799-609-1260 Tightening torque for bolt of bearing cover (19) 3 : 9.8 – 11.8 Nm {1.0 – 1.2 kgm} •
13-018 1
Replace the washer with a new part when installing the bolt.
FUEL SUPPLY PUMP
DISASSEMBLY AND ASSEMBLY
ASSEMBLY OF FUEL SUPPLY PUMP
9. Measuring camshaft clearance • Hit both ends of camshaft (22) lightly with a plastic hammer to fit the camshaft.
1) Install guide rail G1 to the camshaft end and measure the projection of the camshaft in the axial direction. If the projection is out of the standard range, change the thickness of adjustment shim (29) [See 2.2)]. Tools: G1 (Guide rail) 799-609-1340 (ø25) (6HD) 799-609-1440 (ø30) (6UHD) Standard projection: 16.5 ± 0.3 mm (6HD) 13.5 ± 0.3 mm (6UHD) 2) Install camshaft clearance measure G2 to the camshaft and measure the clearance. Standard clearance: 0.03 ± 0.03 mm Tool: G2 (Camshaft clearance measure) 799-609-1450 (ø25) (6HD) 799-609-1460 (ø30) (6UHD) • If the clearance is out of the standard range, change the thickness of adjustment shim [See 8.1)]. If the clearance is in the standard range, fit the O-ring to bearing cover (19) and apply grease to them and install them. Then, measure the clearance again. fl If the clearance is “0”, reduce the turning torque of the camshaft to 0.6 Nm {0.06 kgm} or below.
FUEL SUPPLY PUMP
13-019 1
DISASSEMBLY AND ASSEMBLY
ASSEMBLY OF FUEL SUPPLY PUMP
10. Installation of G sensor 1) Install a dial gauge to tool H2 and insert the attached master pin. Tool: H2 (Measure sensor) 799-609-1290 • Push master pin 1 into measure sensor 2 firmly and set dial gauge 3 to “0”.
2) Push in G sensor (18) firmly and read the value of the dial gauge (L1). fl If the sensor is longer than the master pin, the dial gauge indicates a positive value (L1) (the pointer moves clockwise). Accordingly, select a thicker shim in this case.
3) Install the dial gauge to tool H1 and press it against attached master pin 4 firmly and set the dial gauge to “0”. Tool: H1 (Depth measure) 799-609-1280
4) Insert tool H1 in the mounting hole of the G sensor and read the value of the dial gauge (L2). • Calculate the thickness (t) of the air gap adjustment shim by the following expression. t = L1 + L2 (6HD) t = L1 + L2 + 0.4 (6UHD) fl If value L2 is positive, the distance between the sensor fitting face and barrel is less than the depth of the master pin hole. Accordingly, select a thicker shim in this case.
13-020 1
FUEL SUPPLY PUMP
DISASSEMBLY AND ASSEMBLY
ASSEMBLY OF FUEL SUPPLY PUMP
fl There is a difference of 0.4 mm in length between the master pins used for measurement. Accordingly, if a shim having thickness nearest to the calculated shim thickness is selected, the air gap is set in the standard range. fl Standard air gap: • 0.4 +– 0.20 0.05 mm (6HD) • 0.8 +– 0.15 0.05 mm (6UHD) •
Shim size Part No. 094096-0050 094096-0060 094096-0070 094096-0080
Thickness (mm) 0.15 0.20 0.25 0.40
5) Apply grease to the O-ring and install crank position sensor (18) and selected shim together. 3 : 4.4 – 8.34 Nm {0.45 – 0.85 kgm}
11. Installation of tappet 1) Insert tappet (9) in pump housing (35). 2) Insert lower spring seat (8). 3) Install plunger spring (7).
12. Installation of upper spring seat 1) Set upper spring seat (34) in the inserting position and push it in with tool B1, then turn the handle by 90 degrees.
FUEL SUPPLY PUMP
13-021 1
DISASSEMBLY AND ASSEMBLY
ASSEMBLY OF FUEL SUPPLY PUMP
fl When installing the upper spring seat, set the cam at the bottom dead center. • Install tool B2 to the drive shaft end and turn the shaft to bring the cam to the bottom dead center. fl Do not push in the upper spring seat with the extractor too much, since it can cut the housing end. Tool: B1 (Extractor) 799-609-1030 B2 (Holding spanner) 799-609-1040 (6HD) 799-609-1050 (6UHD)
13. nstallation of element 1) Install plunger (3). • Install plunger (3) so that its bottom will be at the cut of lower spring seat (8).
2) Install element assembly (2), taking care not to damage the plunger, then tighten the nuts alternately. 2 O-ring: Grease (G2-LI) 3 Nut: 15.7 – 23.5 Nm {1.6 – 2.4 kgm}
14. Installation of feed pump 1) Install side plate (16) (inner). • Install the plate with the wider groove facing down. (UHD) • Install the plate with the wider groove facing up. (HD)
13-022 1
FUEL SUPPLY PUMP
DISASSEMBLY AND ASSEMBLY
ASSEMBLY OF FUEL SUPPLY PUMP
2) Install the inner rotor. Fit key (39) to camshaft (22) and install inner rotor (15). • Make sure that the inner rotor is inserted smoothly.
3) Install casing (13). • The position of the hole is off center to the bottom, so when installing, set the eccentric side at the bottom (UHD) or top (HD).
•
Install inner rotor (15) and outer rotor (14) with their ends having punch marks a on this side.
4) Install outer rotor (14).
FUEL SUPPLY PUMP
13-023 1
DISASSEMBLY AND ASSEMBLY
ASSEMBLY OF FUEL SUPPLY PUMP
5) Install side plate (11) (outer). • Assemble the plate so that the face with wider groove b is at the bottom (UHD) or top (HD). • Install the plate with hole a on the left side. 3 Screw: 1.96 – 2.94 Nm {0.2 – 0.3 kgm}
6) Fit the O-ring to housing (17) and install cover (10). 3 Bolt: 5.88 – 9.8 Nm {0.6 – 1.0 kgm}
15. Refilling with oil Pour lubricating oil in the fuel supply pump to oil filler (41).
13-024 1
FUEL SUPPLY PUMP
DISASSEMBLY AND ASSEMBLY
ASSEMBLY OF FUEL SUPPLY PUMP
TIGHTENING TORQUE TABLE
No.
Item
Tightening torque Nm {kgm}
1 2 3 4 5 6 7 8
Piston Priming pump (M16) Screw Bolt Nut (With washer) PCV Holder Bolt
1.96 – 2.94 {0.2 – 0.3} 39.0 – 58.8 {4.0 – 6.0} 14.7 – 19.6 {1.5 – 2.0} 6.8 – 11.8 {0.7 – 1.2} 17.6 – 24.5 {1.8 – 2.5} 157.0 – 177.0 {16.0 – 18.0} 137.0 – 167.0 {14.0 – 17.0} 15.7 – 23.5 {1.6 – 2.4}
9
Overflow valve (Temporarily tightened)
14.8 – 19.6 {1.5 – 2.0}
10 11 12
Screw (Temporarily tightened) 7.9 – 12.7 {0.8 – 1.3} Bolt 9.8 – 11.8 {1.0 – 1.2} Bolt 6.8 – 11.8 {0.7 – 1.2}
FUEL SUPPLY PUMP
No. 13 14 15 16 17 18 19 20 21
Item Bolt Bolt Screw (M10) Screw Plug (M16) Filter Plug (M10) Plug Air breeder
Tightening torque Nm {kgm} 5.88 – 9.8 {0.6 – 1.0} 4.4 – 8.3 {0.45 – 0.85} 7.8 – 11.8 {0.8 – 1.2} 1.96 – 2.9 {0.2 – 0.3} 39.0 – 58.8 {4.0 – 6.0} 1.98 – 3.92 {0.2 – 0.4} 7.8 – 11.8 {0.8 – 1.2} 29.5 – 39.2 {3.0 – 4.0} 4.9 – 6.9 {0.5 – 0.7}
13-025 1
14 PERFORMANCE TEST
Special tools list ......................................... 14-002 Sketches of special tools ........................... 14-003 Performance test on fuel supply pump .... 14-004 1. Preparation ........................................... 14-004 2. Bench setting ........................................ 14-005 3. Electrical wiring .................................... 14-009 4. Performance test .................................. 14-011
FUEL SUPPLY PUMP
14-001
SPECIAL TOOLS LIST
PERFORMANCE TEST
SPECIAL TOOLS LIST
K
M
799-609-5020
Cap nut assembly
1
2
799-609-5030
Joint, nipple assembly
1
799-609-5130
Timer joint (ø25)
1
799-609-5140
Timer joint (ø35)
1
2
799-609-5150
Coupling (ø25)
1
3
799-609-5160
Coupling (ø35)
1
1
799-609-5070
Tube (4 x 8 x L 500 outside screw)
2
2
799-609-5080
Tube (4 x 8 x L 500 inside screw)
2
3
799-609-5090
Tube (4 x 8 x L 900 inside screw)
2
4
6UHD
Part name
1
1 L
Part No.
6HD
Symbol
Q’ty
Nos. marked ª are Komatsu part Nos. Nature of work, remarks Installation of common rail
Installation of coupling
Piping for test
799-609-5110
Nozzle, Nozzle holder
2
N
799-609-5050
Pressure gauge (with adapter)
1
Pressure gauge
P
799-609-5040
Pressure regulator assembly
1
Pressure regulator
799-609-5170
Cover
1
Coupling cover
Q
799-609-5010
Hose
1
Fuel suction hose
1
799-607-4040
Wiring harness
1
Controller wiring harness
2
7872-10-910A
Controller
1
3
Purchased
Electric power supply
1
R S T
799-609-5180
U
Purchased
V
6217-71-1210
14-002 1
Filter
1
Pipe bender
1
Common rail assembly
1
DC28V/5A For ø8
FUEL SUPPLY PUMP
PERFORMANCE TEST
SKETCHES OF SPECIAL TOOLS
SKETCHES OF SPECIAL TOOLS Note) The shapes of the tools shown in the following drawings depend on the shapes of the fuel filter and bench. Accordingly, when manufacturing these tools in the field, confirm the actual parts in advance. 6 Common rail mounting channel (Reference drawing)
FUEL SUPPLY PUMP
14-003 1
PERFORMANCE TEST
PERFORMANCE TEST ON FUEL SUPPLY PUMP
PERFORMANCE TEST ON FUEL SUPPLY PUMP 1. Preparation 1) Remove 2 flow damper assemblies (2) from common rail assembly (1). 2) Install blind plug 8. • Blind plug 8 is a component part of tool K1. Tool: K1 (Cap nut assembly) 799-609-5020
3) Taking care not to damage the sealing surface of flow damper assembly (2), insert pin puller rod 1 (ø3 – L = 100) to drive out the internal parts.
4) Install 2 empty flow damper assemblies (2) to common rail (1) again. 3 Flow damper: 98.1 ± 5.0 Nm {10.0 ± 0.5 kgm}
5) Fit the steel ball of tool K1 and secure it from above with the cap nut (4 places). 3 Cap nut: 44.1 ± 5.0 Nm {5.0 ± 0.5 kgm} Tool: K1 (Cap nut assembly) 799-609-5020
14-004 1
FUEL SUPPLY PUMP
PERFORMANCE TEST
PERFORMANCE TEST ON FUEL SUPPLY PUMP
2. Bench setting 1) Install bracket 1 to the bench temporarily.
2) Install tool L to the bench. Tool: L (Timer joint) 799-609-5130 (6HD) 799-609-5140 (6UHD)
3) Install supply pump (3) to bracket 1.
4) Install coupling 2 to supply pump (3). Tool: B2 (Holding spanner) 799-609-1040 (6HD) 799-609-1050 (6UHD) 3 Coupling: 176 – 196 Nm {18 – 20 kgm} (6UHD) 127 – 147 Nm {13 – 15 kgm} (6HD)
FUEL SUPPLY PUMP
14-005 1
PERFORMANCE TEST
PERFORMANCE TEST ON FUEL SUPPLY PUMP
5) Connect the couplings on the bench side and pump side. • Connect by joint 3. (Tighten temporarily.)
6) Tighten bracket 1 to the bench permanently. 7) Install rear bracket 4. (Prepare rear bracket 4 in the field.)
8) Turning the drive shaft, align the camshaft and coupling. • Limit the turning speed of the drive shaft to 20 rpm. After aligning, tighten the nut for coupling joint 3.
9) Installation of filter i) Install fuel filter fixing bracket 5. ii) Install the fuel filter. (Prepare filter fixing bracket 5 in the field.)
14-006
FUEL SUPPLY PUMP
PERFORMANCE TEST
PERFORMANCE TEST ON FUEL SUPPLY PUMP
10) Install hose T between the pump and filter. T (Filter): 799-609-5180 • Insert the copper tubes for blinding the port in the pipe fitting parts (2 places) on the pump side.
11) Install channel 6 to common rail (1). (Prepare channel 6 in the field.) 12) Install tube M1 between delivery valve holder (5) (High-pressure discharge check) and common rail (1). • When installing the tube, bend it to match it the other parts. M1 (Tube): 799-609-5070 3 Tube: 39.2 – 49.0 Nm {4.0 – 5.0 kgm} 13) Install tube M1 between delivery valve holder (6) (discharge pressure check side) and nozzle M4 and M5. • When installing the tube, bend it to match it the other parts. M1 (Tube) : 799-609-5070 M4 (Nozzle) : 799-609-5110 3 Tube: 39.2 – 49.0 Nm {4.0 – 5.0 kgm}
FUEL SUPPLY PUMP
14-007 1
PERFORMANCE TEST
PERFORMANCE TEST ON FUEL SUPPLY PUMP
14) Install pressure gauge, adapter N, and tube M2 to flow damper (2). • When installing the tube, bend it to match it the other parts. N (Pressure gauge) : 799-609-5050 M2 (Tube) : 799-609-5080 3 Tube: 39.2 – 49.0 Nm {4.0 – 5.0 kgm}
15) Install tube M2 between pressure regulator P (IN side) and flow damper (2a). P (Pressure regulator) : 799-609-5040 M2 (Tube) : 799-609-5080 3 Tube: 39.2 – 49.0 Nm {4.0 – 5.0 kgm}
16) Install tube M3 between pressure regulator P (OUT side) and nozzle M4 and M5. • When installing the tube, bend it to match it the other parts. M3 (Tube) : 799-609-5090 M4 (Nozzle) : 799-609-5110 3 Tube: 39.2 – 49.0 Nm {4.0 – 5.0 kgm}
17) Install hose 6 between overflow valve (7) and bench “TO TANK”. • Use the hose attached to the bench as hose 6.
14-008 1
FUEL SUPPLY PUMP
PERFORMANCE TEST
PERFORMANCE TEST ON FUEL SUPPLY PUMP
18) Install hose 7 between common rail pressure limit (8) and bench “LEAKAGE”. • Use the hose attached to the bench as hose 7. • Install tool K2 on the pressure limit side. K2 (Joint nipple): 799-609-5030 19) Install cover Q. Q (Cover): 799-609-5170
20) Install hose R between feed pump inlet (9) and fuel tank. R (Hose): 799-609-5010
3. Electrical wiring • Prepare controller (13) and a battery (DC 24 V) or a DC 24 V power supply (purchased). Controller: 7872-10-910A 1) Turn off the power switch of wiring harness (14). Wiring harness: 799-607-4040 2) Connect the PVC and G sensor to the controller. fl Connect the drive shaft side by the connector of PCV1 and connect the feed pump side by the connector of PCV2. fl Connect CN2, CN4, and CN7 to the controller. 3) Connect the wiring harness to the battery or power supply. • Take care not to mistake the positive and negative terminals for each other.
FUEL SUPPLY PUMP
14-009 1
PERFORMANCE TEST
PERFORMANCE TEST ON FUEL SUPPLY PUMP
Drawing of bench set
14-010
FUEL SUPPLY PUMP
PERFORMANCE TEST
PERFORMANCE TEST ON FUEL SUPPLY PUMP
4. Performance test 1) Testing condition • Test oil: ISO 4113 test oil • Oil temperature: 40 +50 ˚C (104 – 113˚F) • Lubricating oil: 10W30 • Set source voltage: 28 ± 0.2 V • Make sure that the fuel supply pump is filled with lubricating oil up to the specified level.
2) Checking priming pump i) Drain the oil between the tank and feed pump (11). ii) Disconnect discharge pipe T on the filter side and prepare a measuring cylinder to receive the fuel.
iii) Operate priming pump (12) at the rate of 1 stroke/sec and make sure that the fuel is sucked up by 55 strokes or less. (Revolution of pump: 0 rpm)
3) Checking discharge of feed pump i) Drain off the fuel between than tank and feed pump (11) again. ii) Disconnect discharge pipe T on the filter side and prepare a measuring cylinder to receive the fuel. iii) Operate the pump at the speed of 400 rpm and make sure that the discharge is 120 cc in 20 revolutions or more.
FUEL SUPPLY PUMP
14-011 1
PERFORMANCE TEST
4) Checking high-pressure discharge i) Make sure that the pipes and wires are connected normally. ii) Turn on the power switch and make sure that the source voltage is 28 ± 0.2 V. iii) Turn the all knobs of the 4 valves of the pressure regulator to the left end. iv) Operate the pump at the speed of 200 rpm and check for fuel leakage. v) Raise the pump speed to 1,100 rpm. vi) Turn the valve knobs of the pressure regulator to the right end in the order of pressure (No. 1 – No. 4) and set the common rail pressure to 120 MPa {1,224 kg/cm2}. • No. 1, No. 2, No. 3, and No. 4 are stamped on the knob fitting parts. vii) Measure the discharge of PCV2 (high pressure side). viii)Turn off the power switch of the wiring harness and lower the pump speed slowly to 0. ix) Turn the all knobs of the pressure regulator valves to the left end. x) Replace the fuel tube connected to PCV1 and PCV2, then connect PCV1 to the pressure regulator valve. xi) Repeat steps ii), iii), iv), and v) shown above. xii) Measure the discharge of PCV1 (high pressure side)
PERFORMANCE TEST ON FUEL SUPPLY PUMP
5) Check of display on controller i) Just after the power switch is turned ON The controller displays 88ECAA101100 by 2 letters, then displays 00. ii) While the pump drive shaft is turning The controller displays 13. If 13 is displayed, the signals from the G sensor are normal. iii) When the controller displays 74 or 75 • If 74 is displayed, the PCV1 circuit is disconnected or shorted. Check the wiring harness and connector. • If 75 is displayed, the PCV2 circuit is disconnected or shorted. Check the wiring harness and connector.
Standard value: • HD pump (6217-71-1120): 172.5 ± 15 cc/100 revolutions Difference between PCV1 and PCV2: 9 cc/100 revolutions • UHD pump (6217-71-1110): 240 ± 15 cc/100 revolutions Difference between PCV1 and PCV2: 9 cc/100 revolutions
14-012
FUEL SUPPLY PUMP
SEBM026200
WATER PUMP
©2001 All Rights Reserved Printed in Japan 10-01(02)
00-001
CONTENTS
01
GENERAL ........................................................................................................ 01-001
11
STRUCTURE AND FUNCTION
13
DISASSEMBLY AND ASSEMBLY ................................................. 13-001
14
MAINTENANCE STANDARD AND INSPECTION OF PARTS
00-002
....................................................... 11-001
...................................................................................................... 14-001
WATER PUMP
01 GENERAL
Introduction ................................................ 01-002 Cooling system ........................................... 01-003 Specifications ............................................. 01-004
WATER PUMP
01-001
GENERAL
INTRODUCTION
INTRODUCTION
The cooling system employs a highly reliable centrifugal volute pump to keep the engine at proper operating temperature, reduce the cooling loss, and give full play to the engine performance. To keep the function of the water pump, “proper maintenance and inspection” and “repair work” must be carried out. This Shop Manual describes “Outline”, “Structure and function”, “Disassembly and assembly”, “Maintenance standard”, and “Parts inspection” of the water pump which are necessary to the inspection and repair works that are performed mainly in repair shops among the above works. Since this Shop Manual is so made that it will help you learn the correct knowledge and repair method of the water pump and make proper judgment to improve the quality of the repair, understand its contents sufficiently and use it positively.
01-002
WATER PUMP
GENERAL
COOLING SYSTEM
COOLING SYSTEM
1. 2. 3. 4. 5. 6.
Water pump Oil cooler Thermostat Radiator Fan Fan belt
WATER PUMP
7. 8. 9. 10. 11. 12.
Cylinder liner Piston Cylinder block Intake and exhaust valves Injection nozzle or injector Cylinder head
01-003
GENERAL
SPECIFICATIONS
SPECIFICATIONS Item Type Engine
Speed increasing ratio ª
Water flow amount (¬/min)
Total head (m)
Remarks
100
5.0
Impeller diameter ø 85
150
6.5
Impeller diameter ø 90
95
3.5
Impeller diameter ø 100
0.717
190
6.0
Impeller diameter ø 130
Centrifugal, belt-driven
1.19
250
8.0
PC300
110
Centrifugal, belt-driven
0.668
290
7.0
125
Centrifugal, belt-driven
1.5
6D140
Centrifugal, belt-driven
1.56
12V140
Centrifugal, gear-driven
1.8
155
Centrifugal, gear-driven
1.565
6D170
Centrifugal, gear-driven
1.8
8V170
Centrifugal, gear-driven
1.618
12V170
Centrifugal, gear-driven
1.618
95
Centrifugal, belt-driven
105
Centrifugal, belt-driven
108
ª
1.0 0.9
210
5.2
375
10.0
400 800
14.0
6D125 S(A)6D125 Other than following WS23-2, HD325
1,500
17.0
480
18.5
S6D155
820
36.0
SA6D155
800
28.0
1,400
23.0
D475, WA800
2,000
27.5
HD785-2
2,000
27.5
Water pump speed = Engine speed x Speed increasing ratio
01-004
WATER PUMP
11 STRUCTURE AND FUNCTION
General structure ........................................ 11-002 Structure and function ............................... 11-005
WATER PUMP
11-001
STRUCTURE AND FUNCTION
GENERAL STRUCTURE
GENERAL STRUCTURE PUMP 95 SERIES
1. 2. 3. 4. 5. 6.
105•110 SERIES
1. 2. 3. 4. 5. 6.
Pump cover Impeller Water seal Pump body Boss Drive shaft
125 SERIES
1. Water pump drive gear (No. of teeth: 22) 2. Pump shaft 3. Ball bearing 4. Pump body
11-002
Nut Fan pulley Pump shaft Spacer Water seal Pump body
7. Impeller 8. Snap ring 9. Pump cover A. To each part of engine (Cooling water)
140 SERIES
5. Water seal 6. Impeller 7. Pump cover
1. 2. 3. 4. 5.
Alternator drive pulley Oil seal Ball bearing Pump shaft Water pump drive gear (No. of teeth: 23)
6. 7. 8. 9.
Pump body Water seal Impeller Pump cover
WATER PUMP
STRUCTURE AND FUNCTION
GENERAL STRUCTURE
12V140 SERIES
155-4 SERIES
1. 2. 3. 4. 5. 6. 1. 2. 3. 4.
Pump shaft Water seal Pump body Water pump drive gear (No. of teeth: 25)
5. 6. 7. 8.
170 SERIES
1. 2. 3. 4. 5.
Pump body Impeller Floating seal Water seal Pump shaft (Rear)
WATER PUMP
7. 8. 9. A. B. C.
Ball bearing Oil seal Impeller Pump cover
Cover Impeller Floating seal Water seal Pump body Drive gear (No. of teeth: 23) Bearing housing Pump shaft V-ring From radiator From thermostat To oil cooler
8V170 SERIES
6. Pump shaft (Front) 7. Inlet housing a. From radiator b. To oil cooler
1. 2. 3. 4. 5.
Pump body Impeller Water seal Oil seal Ball bearing
6. Pump shaft a. Water inlet (From radiator) b. Water outlet (To oil cooler)
11-003
STRUCTURE AND FUNCTION
GENERAL STRUCTURE
12V170
1. 2. 3. 4. 5. 6.
Pump body Impeller Floating seal Water seal Pump shaft (Rear) Pump shaft (Front)
Water pump • Revolving speed: Engine speed x 1.618 • Flow amount: 2,000 ¬/min (3,235 rpm)
A. Water inlet (From radiator) B. Water outlet (To oil cooler)
11-004
WATER PUMP
STRUCTURE AND FUNCTION
STRUCTURE AND FUNCTION
STRUCTURE AND FUNCTION
1. 2. 3. 4. 5. 6. 7. 8.
Fan Fan pulley Ball bearing Pump shaft Pump housing Water seal Impeller Cover
A. From thermostat B. To engine C. From radiator
Structure and function of water pump • The drive shaft of the water pump is connected to the pulley by means of press fitting or a key, which is driven through V-belts. The impeller is press fitted to this drive shaft and rotated to suck and supply the engine cooling water forcibly. • The drive shaft is usually supported on the front and rear ball bearings and lubricated with grease. • The water is sealed in and out of the water pump (lubricated parts) by the water seal.
WATER PUMP
Type of water pump • Almost all the water pumps are centrifugal volute pumps since they have simple structures and high reliability and can be manufactured in various sizes. • In a centrifugal volute pump, an impeller having volute guide vanes is rotated to supply cooling water forcibly by utilizing the centrifugal force.
11-005
13 DISASSEMBLY AND ASSEMBLY
Standard values and tightening torque table ............................ 13-002 95, 105, 108, and 110 Series General disassembly ................................ 13-004 General assembly ..................................... 13-008 125, 12V140 Series General disassembly ................................ 13-012 General assembly ..................................... 13-015 6D140 General disassembly ................................ 13-018 General assembly ..................................... 13-021 155 Series General disassembly ................................ 13-025 General assembly ..................................... 13-028 170 Series General disassembly ................................ 13-032 General assembly ..................................... 13-035
WATER PUMP
13-001
DISASSEMBLY AND ASSEMBLY
STANDARD VALUES AND TIGHTENING TORQUE TABLE
STANDARD VALUES AND TIGHTENING TORQUE TABLE Unit: Nm {kgm} Item
Body mounting bolt or nut
Cover mounting bolt
Impeller mounting bolt
Housing mounting bolt or nut
95
fl
24.5 ± 4.9 {2.5 ± 0.5}
—
—
105
fl
—
—
—
108
See drawing below
See drawing below
—
—
110
fl
—
—
—
125
fl
30.9 ± 3.4 {31.5 ± 0.35}
—
—
6D140
fl
fl
—
—
12V140
fl
—
—
—
M10: 65.7±6.9{6.7±0.7} M12: 112.8±9.8{11.5±1.0}
—
6D170
fl
—
—
fl
8V170
fl
—
—
fl
12V170
66.2 ± 7.4 {6.75 ± 0.75}
—
—
fl
Engine
155
76.0 ± 2.5 {7.75 ± 0.25} M10: 65.7±6.9 {6.7±0.7}
fl As per KES Tightening Torque Standard.
108 Series
Marked
13-002
18.6±9.8 Nm {1.9±1.0 kgm} Cover mounting 18.6±9.8 Nm {1.9±1.0 kgm} bolt 18.6±9.8 Nm {1.9±1.0 kgm} fl 66.2±7.4 Nm {6.75±0.75 kgm} Body mounting bolt
WATER PUMP
DISASSEMBLY AND ASSEMBLY
STANDARD VALUES AND TIGHTENING TORQUE TABLE
Unit: Nm {kgm} Item
Pulley mounting bolt
Shaft mounting nut
Alternator drive pulley mounting nut
95
—
—
—
105
103.0 ± 14.7 {10.5 ± 1.5}
—
—
108
—
—
—
110
ø25:103.0±14.7{10.5±1.5} ø30:171.6±24.5{17.5±2.5}
—
—
125
—
—
—
6D140
—
—
—
12V140
—
—
—
155
—
198.1 ± 29.4 {20.2 ± 3.0}
—
6D170
—
—
—
8V170
—
—
588.4 ± 29.4 {60 ± 3.0}
12V170
—
—
588.4 ± 29.4 {60 ± 3.0}
Engine
WATER PUMP
13-003
DISASSEMBLY AND ASSEMBLY
GENERAL DISASSEMBLY (95, 105, 108, AND 110 SERIES)
GENERAL DISASSEMBLY 95, 105, 108, AND 110 SERIES fl Before disassembling, clean the pump thoroughly and check it for outside damage and water leakage.
95 and 108 Series 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
Mounting bolt and nut Fan pulley Mounting bolt and snap ring Cover Impeller Body Shaft assembly Snap ring Water seal Shaft Boss and ball bearing Ball bearing Floating seal
105 and 110 Series
13-004
WATER PUMP
DISASSEMBLY AND ASSEMBLY
GENERAL DISASSEMBLY (95, 105, 108, AND 110 SERIES)
1. Pulley Remove bolt or nut (1), then remove fan pulley (2) with puller 1.
2. Cover Remove mounting bolt or snap ring (3) to remove cover (4). fl Remove mounting bolt (3) for 95 and 108 series.
fl Remove snap ring (3) for 105 and 110 series.
WATER PUMP
13-005
DISASSEMBLY AND ASSEMBLY
GENERAL DISASSEMBLY (95, 105, 108, AND 110 SERIES)
3. Impeller Remove impeller (5) with gear puller 2. fl For 108 series, use forcing screws (8 mm, P = 1.25) to remove the impeller.
4. Shaft assembly Remove shaft assembly (7) from body (6) using with push tool 3.
fl For 105 and 110 series, remove snap ring (8) before pulling out shaft assembly (7).
13-006
WATER PUMP
DISASSEMBLY AND ASSEMBLY
GENERAL DISASSEMBLY (95, 105, 108, AND 110 SERIES)
5. Water seal Remove water seal (9).
6. Disassembly of shaft assembly • For 95 and 108 series Remove boss (11) from shaft (10) using with the push tool.
•
For 105 and 110 series Remove bearings (11) and (12) from shaft (10) using with push tool 4 and stand 5.
WATER PUMP
13-007
DISASSEMBLY AND ASSEMBLY
GENERAL ASSEMBLY (95, 105, 108, AND 110 SERIES)
GENERAL ASSEMBLY 95, 105, 108, AND 110 SERIES fl Before assembling, clean the all parts and blow compressed air against them. fl When press fitting each bearing, apply clean engine oil to it.
95 and 108 Series 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
Mounting bolt and nut Fan pulley Mounting bolt and snap ring Cover Impeller Body Shaft assembly Snap ring Water seal Shaft Boss and ball bearing Ball bearing Floating seal
105 and 110 Series
13-008
WATER PUMP
DISASSEMBLY AND ASSEMBLY
GENERAL ASSEMBLY (95, 105, 108, AND 110 SERIES)
1. Shaft assembly 1) Assembly of shaft assembly • For 105 and 110 series Press fit bearings (12) and (11) to shaft (10) using with push tool 6 and stand 7. fl Press fit each bearing with the side on which the balls are seen in. • For 95 and 108 series Press fit shaft (10) to boss (11) using with the push tool. fl Press fit the shaft until its end is flush with the boss end. fl Receive the shaft end from the impeller side.
2) Install shaft assembly (7) to body (6). fl Press fit the shaft until its end is flush with the body end.
fl For 105 and 110 series, install snap ring (8) after press fitting the shaft assembly.
WATER PUMP
13-009
DISASSEMBLY AND ASSEMBLY
GENERAL ASSEMBLY (95, 105, 108, AND 110 SERIES)
2. Fan pulley 1) Press fit fan pulley (2). fl Perform this procedure for only 105 and 110 series.
2) Secure the fan pulley with nut or mounting bolt (1). 3 Nut: See standard values and tightening torque table.
3. Water seal Press fit water seal (9) using with push tool 8. 8 Periphery of outer cylinder of water seal: ThreeBond No. 110 (Nondrying gasket sealant) fl Receive the shaft end and body end simultaneously to press fit the water seal. fl Press fit with the rubber on the impeller side. fl When replacing the water seal, replace floating seal (13), too. fl Apply water-soluble lubricant (toilet soap, etc.) thinly to the periphery of the rubber part of the seat assembly.
13-010
WATER PUMP
DISASSEMBLY AND ASSEMBLY
GENERAL ASSEMBLY (95, 105, 108, AND 110 SERIES)
4. Impeller Press fit impeller (5) to the shaft assembly using with push tool 9. fl Press fit the impeller until its end is flush with the shaft end.
5. Cover Fit the gasket or O-ring and secure cover (4) with mounting bolt or snap ring (3). 3 Mounting bolt: See standard values and tightening torque table.
fl For 105 and 110 series, secure the cover with the snap ring. fl After assembling, turn the fan pulley with the hand to check that it rotates smoothly.
WATER PUMP
13-011
DISASSEMBLY AND ASSEMBLY
GENERAL DISASSEMBLY (125 AND 12V140 SERIES)
GENERAL DISASSEMBLY 125 AND 12V140 SERIES Special tools
•
Symbol
Part No.
Part name
Q’ty
Remarks
A
790-475-1100
Impeller
1
Impeller puller tap (6D125, 6 mm, P = 1.0)
Before disassembling, clean the pump thoroughly and check it for outside damage and water leakage.
125 Series 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.
Mounting bolt Cover and housing Impeller Gear Spacer Snap ring Shaft assembly Oil seal Water seal Shaft Ball bearing Spacer Bearing Body Floating seal
12V140
13-012
WATER PUMP
DISASSEMBLY AND ASSEMBLY
GENERAL DISASSEMBLY (125 AND 12V140 SERIES)
1. Cover Remove mounting bolts (1) to remove cover or housing (2). fl For 12V140, remove housing (2) using with forcing screws 1 (12 mm, P = 1.75).
2. Impeller Remove impeller (3) using with tool A or gear puller 2. fl Impeller puller tap For 125 series: 6 mm, P = 1.0 For 12V140 : 10 mm, P = 1.5
3. Gear 1) Remove gear (4) using with gear puller 3. fl Gear puller tap for 12V140: 10 mm, P = 1.5. 2) Remove spacer (5). fl The spacer is not used for 12V140. 3) Remove snap ring (6).
WATER PUMP
13-013
DISASSEMBLY AND ASSEMBLY
GENERAL DISASSEMBLY (125 AND 12V140 SERIES)
4. Shaft assembly Remove shaft assembly (7). fl Lightly hit the shaft end on the impeller side using with a hammer to push out the shaft.
5. Oil seal Remove oil seal (8).
6. Remove water seal (9).
7. Disassembly of shaft assembly Remove bearing (11), spacer (12), and bearing (13) in order from shaft (10) using with push tool 4 and stand 5. fl The spacer is not used for 12V140.
13-014
WATER PUMP
DISASSEMBLY AND ASSEMBLY
GENERAL ASSEMBLY (125 AND 12V140 SERIES)
GENERAL ASSEMBLY 125 AND 12V140 SERIES fl Before assembling, clean the all parts and blow compressed air against them. fl When press fitting each bearing or gear, apply clean engine oil to it.
125 Series 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.
Bolt Cover and housing Impeller Gear Spacer Snap ring Shaft assembly Oil seal Water seal Shaft Bearing Spacer Bearing Body Floating seal
12V140
WATER PUMP
13-015
DISASSEMBLY AND ASSEMBLY
GENERAL ASSEMBLY (125 AND 12V140 SERIES)
1. Assembly of shaft assembly Press fit bearing (13), spacer (12), and bearing (11) in order to shaft (10) using with push tool 6 and stand 7. fl The spacer is not used for 12V140. fl Press fit the above parts until the shaft flange face is flush with the bearing face.
2. Oil seal Press fit oil seal (8) to body (14) using with push tool 6. 8 Periphery of fitting part of oil seal: ThreeBond No. 1102 (Nondrying gasket sealant) 8 Oil seal lip: Grease (G2-LI) fl Set the lip of the oil seal toward the gear and press fit it until it is flush with the fitting part. fl Take care that dirt and chips will not stick around the lip. fl Take care not to damage the lip in handling. 3. Shaft assembly Install shaft assembly (7).
4. Water seal Press fit water seal (9) to the body using with push tool 7. 8 Periphery of metallic ring fitting part of water seal: ThreeBond No. 1102 (Nondrying gasket sealant) fl Press fit with the rubber on the impeller side. fl When replacing the water seal, replace floating seal (15), too.
13-016
WATER PUMP
DISASSEMBLY AND ASSEMBLY
GENERAL ASSEMBLY (125 AND 12V140 SERIES)
fl When installing the floating seal to the impeller, apply water-soluble lubricant (toilet soap, etc.) thinly to the inside wall of the impeller seat fitting part. 5. Gear 1) Install snap ring (6). fl For 12V140, install the snap ring with the tapered side out. fl Check that the snap ring is fitted to the groove.
2) Install spacer (5). fl The spacer is not used for 12V140. 3) Press fit gear (4) using with push tool 8.
6. Impeller Press fit impeller (3) using with push tool 9. fl Position of impeller vanes 125 series: Inside of body 12V140 : Outside of body
7. Cover Fit the gasket and install cover or housing (2) and secure it with mounting bolts (1). 3 Mounting bolt: See standard values and tightening torque table. fl After assembling, turn the gear with the hand to check that it rotates smoothly.
WATER PUMP
13-017
DISASSEMBLY AND ASSEMBLY
GENERAL DISASSEMBLY (6D140 SERIES)
GENERAL DISASSEMBLY 6D140 SERIES Disassembly of water pump assembly •
Before disassembling, clean the pump thoroughly and check it for outside damage and water leakage.
6D140 Series
Water pump assembly 1. Bolt 2. Cover 3. Impeller 4. Floating seal 5. Shaft 6. Sleeve 7. Water separator 8. Oil seal 9. Ball bearing 10. Spacer 11. Gear 12. Spacer 13. Snap ring 14. Ball bearing 15. Oil seal 16. Body
13-018
WATER PUMP
DISASSEMBLY AND ASSEMBLY
GENERAL DISASSEMBLY (6D140 SERIES)
1. Cover Remove mounting bolts (1) to remove cover (2). fl The covers of some models (WS23-2) are secured with snap rings.
2. Impeller Remove impeller (3) using with gear puller 1.
3. Shaft Remove shaft (5) using with push tool 2. fl Remove sleeve (6), water seal (7), oil seal (8), bearing (9), spacer (10), gear (11), and spacer (12) in order.
4. Snap ring and bearing 1) Remove snap ring (13). 2) Remove bearing (14).
WATER PUMP
13-019
DISASSEMBLY AND ASSEMBLY
GENERAL DISASSEMBLY (6D140 SERIES)
5. Oil seal Remove oil seal (15).
13-020
WATER PUMP
DISASSEMBLY AND ASSEMBLY
GENERAL ASSEMBLY (6D140 SERIES)
GENERAL ASSEMBLY 6D140 SERIES fl Before assembling, clean the all parts and blow compressed air against them. fl When press fitting each bearing or gear, apply clean engine oil to it.
6D140 Series
Water pump assembly 1. Bolt 2. Cover 3. Impeller 4. Floating seal 5. Shaft 6. Sleeve 7. Water separator 8. Oil seal 9. Ball bearing 10. Spacer 11. Gear 12. Spacer 13. Snap ring 14. Ball bearing 15. Oil seal 16. Body
WATER PUMP
13-021
DISASSEMBLY AND ASSEMBLY
GENERAL ASSEMBLY (6D140 SERIES)
1. Oil seal Press fit oil seal (15) to body (16) using with push tool 3. 8 Periphery of fitting part of oil seal: ThreeBond No. 2 (Nondrying gasket sealant) 8 Oil seal lip: Grease (G2-LI) fl Set the lip of the oil seal toward the gear and press fit it until it is flush with the fitting part. fl Take care that dirt and chips will not stick around the lip. fl Take care not to damage the lip in handling. 2. Bearing and snap ring 1) Press fit bearing (14) to body (16) using with push tool 4.
2) Snap ring Secure the bearing with snap ring (13). fl Check that the snap ring is fitted to the groove.
3. Shaft Install spacer (10) and gear (11) in order to the body, then press fit shaft (5) using with push tool 5. fl Set the thinner side of the shaft up and press fit it until it is projected a little from the bearing face. (If the shaft is inserted too deeply, gear (11) cannot be installed. Take care.) fl Place a stand (100 mm in length, 45 mm in outside diameter, and 30 mm in inside diameter) under the gear and press fit the shaft until the flange face touches the bearing face.
13-022
WATER PUMP
DISASSEMBLY AND ASSEMBLY
GENERAL ASSEMBLY (6D140 SERIES)
fl If the thinner part of the shaft is pressed, it may be bent. Accordingly, be sure to press the flange face. 1) Bearing Install spacer (12), then press fit bearing (9) using with push tool 6.
2) Oil seal Press fit oil seal (8) using with the push tool. 8 Lip: Grease (G2-LI) fl Take care that dirt and chips will not stick around the lip. fl Take care not to damage the lip in handling.
3) Sleeve Press fit sleeve (6) using with push tool 7.
4) Water seal Press fit water seal (7) to the body using with push tool 8. 8 Periphery of outer cylinder of water seal: ThreeBond No. 1102 (Nondrying gasket sealant) fl Press fit water seal with the rubber part on the impeller side. fl When replacing the water seal, replace floating seal (4), too. fl Apply water-soluble lubricant (toilet soap, etc.) thinly to the periphery of the rubber part of the seat assembly.
WATER PUMP
13-023
DISASSEMBLY AND ASSEMBLY
GENERAL ASSEMBLY (6D140 SERIES)
4. Impeller Press fit impeller (3) using with push tool 9.
5. Cover Fit the gasket and install cover (2) and secure it with mounting bolts (1). 3 Mounting bolt: See standard values and tightening torque table. fl After assembling, turn the gear with the hand to check that it rotates smoothly.
13-024
WATER PUMP
DISASSEMBLY AND ASSEMBLY
GENERAL DISASSEMBLY (155 SERIES)
GENERAL DISASSEMBLY 155 SERIES Special tools
•
Symbol
Part No.
Part name
Q’ty
Remarks
A
790-475-1100
Remover
1
Impeller puller tap (8 mm, P = 1.25)
Before disassembling, clean the pump thoroughly and check it for outside damage and water leakage.
155 Series
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21.
WATER PUMP
Mounting bolt Cover Impeller Mounting bolt Bearing housing shaft assembly V-ring Oil seal Water seal Nut Lock washer Plate Snap ring Bearing housing assembly Shaft assembly Bearing housing Bearing Shaft Gear Bearing Body Floating seal
13-025
DISASSEMBLY AND ASSEMBLY
GENERAL DISASSEMBLY (155 SERIES)
1. Cover Remove mounting bolts (1), then remove cover (2) using with forcing screws 1 (8 mm, P = 1.25).
2. Impeller Remove impeller (3) using with tool A. fl Impeller puller tap (8 mm, P = 1.25)
3. Bearing housing and shaft assembly 1) Remove mounting bolt (4), then remove bearing housing and shaft assembly (5). fl Lightly hit the shaft end on the water seal side with a hammer to push out the shaft. 2) Remove V-ring (6).
4. Oil seal Remove oil seal (7).
13-026
WATER PUMP
DISASSEMBLY AND ASSEMBLY
GENERAL DISASSEMBLY (155 SERIES)
5. Water seal Remove water seal (8).
6. Disassembly of bearing housing and shaft assembly Remove nut (9), lock washer (10), plate (11), and snap ring (12), then remove bearing housing assembly (13) and shaft assembly (14) using with push tool 2 and stand 3.
7. Disassembly of bearing housing assembly Remove bearing (16) from bearing housing (15) using with the push tool.
8. Disassembly of shaft assembly 1) Remove gear (18) from shaft (17) using with the push tool. 2) Remove bearing (19) using with push tool 4 and stand 5.
WATER PUMP
13-027
DISASSEMBLY AND ASSEMBLY
GENERAL ASSEMBLY (155 SERIES)
GENERAL ASSEMBLY 155 SERIES fl Before assembling, clean the all parts and blow compressed air against them. fl When press fitting each bearing or gear, apply clean engine oil to it.
155 Series
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21.
13-028
Mounting bolt Cover Impeller Mounting bolt Bearing housing shaft assembly V-ring Oil seal Water seal Nut Lock washer Plate Snap ring Bearing housing assembly Shaft assembly Bearing housing Bearing Shaft Gear Bearing Body Floating seal
WATER PUMP
DISASSEMBLY AND ASSEMBLY
GENERAL ASSEMBLY (155 SERIES)
1. Assembly of shaft assembly 1) Press fit bearing (19) to shaft (17) using with the push tool. fl Press fit the bearing until its face is flush with the flange face. 2) Press fit gear (18) using with push tool 6 and stand 7, matching it to the shaft key.
2. Assembly of bearing housing assembly 1) Press fit bearing (16) to bearing housing (15) using with push tool 8 and stand 9. fl Press fit the bearing until its face is flush with the bearing housing face.
3. Assembly of bearing housing and shaft assembly 1) Press fit shaft assembly (14) to bearing housing assembly (13) using with the push tool and stand 0, then install plate (11) and lock washer (10) and secure them with nut (9) and snap ring (12). 3 Nut: See standard values and tightening torque table. fl Check that the snap ring is fitted to the groove. fl Bend the lock washer securely.
4. Oil seal Press fit oil seal (7) to body (20) using with the push tool. 8 Periphery of fitting part of oil seal: ThreeBond No. 1102 (Nondrying gasket sealant) 8 Oil seal lip: Grease (G2-LI) fl Set the lip of the oil seal toward the impeller and press fit it until it is flush with the fitting part.
WATER PUMP
13-029
DISASSEMBLY AND ASSEMBLY
GENERAL ASSEMBLY (155 SERIES)
fl Take care that dirt and chips will not stick around the lip. fl Take care not to damage the lip in handling.
5. Bearing housing and shaft assembly Install bearing housing and shaft assembly (5) and secure it with mounting bolt (4). 3 Mounting bolt: See standard values and tightening torque table.
6. Water seal Press fit water seal (10) using with the push tool. 8 Periphery of outer cylinder of water seal: ThreeBond No. 1102 (Nondrying gasket sealant) fl Press fit the water seal with the rubber part on the impeller side. fl When replacing the water seal, replace floating seal (21), too. fl Apply water-soluble lubricant (toilet soap, etc.) thinly to the periphery of the rubber part of the seat assembly. 7. Impeller Press fit impeller (3) using with push tool B. fl Press fit the impeller until its face is flush with the shaft end.
13-030
WATER PUMP
DISASSEMBLY AND ASSEMBLY
GENERAL ASSEMBLY (155 SERIES)
8. Cover Fit the O-ring and install cover (2) and secure them with mounting bolts (1). 3 Mounting bolt: See standard values and tightening torque table.
fl After assembling, turn the gear with the hand to check that it rotates smoothly.
WATER PUMP
13-031
DISASSEMBLY AND ASSEMBLY
GENERAL DISASSEMBLY (170 SERIES)
GENERAL DISASSEMBLY 170 SERIES •
Before disassembling, clean the pump thoroughly and check it for outside damage and water leakage.
170 Series (6D170, 8V170, 12V170)
Water pump assembly 1. Bolt assembly 2. Housing cover 3. Impeller 4. Floating seal 5. Snap ring 6. Shaft 7. Shaft assembly 8. Water seal 9. Oil seal 10. Retainer ring 11. Ball bearing 12. Ball bearing 13. Body
13-032
WATER PUMP
DISASSEMBLY AND ASSEMBLY
GENERAL DISASSEMBLY (170 SERIES)
1. Housing Remove mounting bolts (1), then remove housing (2) using with forcing screws 1 (12 mm, P = 1.75). fl If the forcing screws do not go in, repair the screw holes with a tap.
2. Impeller 1) Remove impeller (3) using with gear puller 2. fl If the forcing screw holes of the impeller are corroded, repair them with a tap. 2) Remove floating seal (4).
3. Snap ring Remove snap ring (5). 4. Shaft assembly Remove shaft assembly (7). fl Hit the shaft from the impeller side with a plastic hammer so lightly that it will not be damaged.
5. Water seal Remove water seal (8). fl Remove the water seal from the bearing side so that the body will not be damaged. 6. Oil seal Remove oil seal (9).
WATER PUMP
13-033
DISASSEMBLY AND ASSEMBLY
GENERAL DISASSEMBLY (170 SERIES)
8. Retainer ring Remove retainer ring (10) using with snap ring puller 3.
9. Bearings Remove bearings (11) and (12) from shaft (6).
13-034
WATER PUMP
DISASSEMBLY AND ASSEMBLY
GENERAL ASSEMBLY (170 SERIES)
GENERAL ASSEMBLY 170 SERIES •
Before assembling, clean the all parts and blow compressed air against them. fl When press fitting each bearing or gear, apply clean engine oil to it.
170 Series (6D170, 8V170, 12V170)
Water pump assembly 1. Bolt assembly 2. Housing 3. Impeller 4. Floating seal 5. Snap ring 6. Shaft 7. Shaft assembly 8. Water seal 9. Oil seal 10. Retainer ring 11. Ball bearing 12. Ball bearing 13. Body
WATER PUMP
13-035
DISASSEMBLY AND ASSEMBLY
GENERAL ASSEMBLY (170 SERIES)
1. Bearings Press fit bearings (12) and (11) to shaft (6) using with push tools 4 and 5.
2. Retainer ring Secure the bearings with retainer ring (10). fl Check that the retainer ring is fitted to the groove.
3. Oil seal Press fit oil seal (9) to the body using with push tool 6. 8 Periphery of fitting part of oil seal: ThreeBond No. 2 (Nondrying gasket sealant) 8 Oil seal lip: Grease (G2-LI) fl Take care that dirt and chips will not stick around the lip. fl Take care not to damage the lip in handling. fl Set the lip of the oil seal toward the bearing and press fit it until it is flush with the fitting part. 4. Water seal Press fit water seal (8) to the body using with push tool 7. 8 Periphery of outer cylinder of water seal: ThreeBond No. 2 (Nondrying gasket sealant) fl Press fit the water seal with the rubber part on the impeller side. fl When replacing the water seal, replace floating seal (4), too. fl Apply water-soluble lubricant (toilet soap, etc.) thinly to the periphery of the rubber part of the seat assembly.
13-036
WATER PUMP
DISASSEMBLY AND ASSEMBLY
GENERAL ASSEMBLY (170 SERIES)
5. Shaft assembly Press fit shaft assembly (7). fl Press fit the shaft by hitting it lightly with a plastic hammer. 6. Snap ring Secure the shaft with snap ring (5). fl Check that the snap ring is fitted to the groove.
7. Impeller Press fit impeller (3) using with push tool 8. fl Press fit the impeller to the standard position. fl Replace floating seal (4).
8. Housing Fit the O-ring and secure housing (2) with mounting bolts (1). 3 Mounting bolt: See standard values and tightening torque table. fl After assembling, turn the gear with the hand to check that it rotates smoothly.
WATER PUMP
13-037
MAINTENANCE STANDARD AND 14 INSPECTION OF PARTS
Maintenance standard 95 Series .................................................. 14-002 105 Series .................................................. 14-003 110 Series .................................................. 14-005 125 Series .................................................. 14-007 140 Series .................................................. 14-008 155 Series .................................................. 14-010 170 Series .................................................. 14-011 Parts inspection and evaluation criteria ... 14-013 Reuse criteria .............................................. 14-014
WATER PUMP
14-001
MAINTENANCE STANDARD AND INSPECTION OF PARTS
95 SERIES
95 SERIES 3 (4) D95S, (SA) 4D95L, (SA) 6D95L
Unit: mm
No.
Check item
Criteria
1
Clearance between impeller and body
Standard clearance: 0.30 – 1.00
2
Interference between shaft and fan pulley boss
Basic dimension
Remedy
Allowance
Standard interference
Shaft
Hole
15.9
+0.020 +0.005
– 0.045 – 0.065
0.050 – 0.080
3
Interference between shaft and body
35
0 – 0.015
– 0.025 – 0.050
0.010 – 0.050
4
Interference between shaft and impeller
12
0 – 0.015
– 0.045 – 0.070
0.030 – 0.070
5
Bend of shaft
6
Wear of seal ring of water seal
Allowable limit: Facial runout of face A: 0.1
Allowable limit: Dimension A: 0
Thermostat
• Valve opening temperature (Opening fully: Valve must open : 76 ± 1.5˚C fully when heated to 95˚C and then submerged in water at 71˚C for 4 – 5 minutes.) • Fully opening temperature : 90˚C • Fully opening lift: Min. 8 (When submerged in water at 90˚C)
Thermostat (For generators) (For ships)
• Valve opening temperature (Opening fully: Valve must open : 82 ± 2˚C fully when heated to 95˚C and then submerged in water at 77˚C for 4 – 5 minutes.) • Fully opening temperature : 95˚C • Fully opening lift: Min. 8 (When submerged in water at 95˚C)
Replace
7
14-002
WATER PUMP
105-5 SERIES
MAINTENANCE STANDARD AND INSPECTION OF PARTS
105-5 SERIES (S) 4D105-5 (FOR CONSTRUCTION MACHINERY AND GENERATORS)
Unit: mm
No.
1
Check item
Inside diameter of impeller and outside diameter of shaft
2
Clearance between impeller and body
3
Wear of seal ring of water seal
4
Bend of shaft
Full opening lift of thermostat 5 Function of thermostat
WATER PUMP
Criteria Standard dimension 15.9
Remedy
Outside diam- Inside diameter eter of shaft of impeller +0.020 +0.005
– 0.020 – 0.050
Standard interference 0.025 – 0.070
Standard clearance: 0.1 – 0.63 (Including end play)
Allowable limit of dimension A: 0
(Total runout of indicator: Prescribed Allowable limit: 0.1 mm by facial runout of fan pulley at radius of 40 mm) For construction machinery
Min. 10: Check by submerging in water at 90˚C for 4 – 5 minutes.
For generators
Min. 10: Check by submerging in water at 95˚C for 4 – 5 minutes.
For construction machinery For generators
Replace Replace impeller usually (Outside diameter of shaft changes little)
Replace
Valve must close fully when heated to fully opening temperature of 90˚C and then submerged in water at fully closing temperature of 71˚C for 4 – 5 minutes. Valve must close fully when heated to fully opening temperature of 95˚C and then submerged in water at fully closing temperature of 77˚C for 4 – 5 minutes.
14-003
105-5 SERIES
MAINTENANCE STANDARD AND INSPECTION OF PARTS
(S) 4D105-5 (FOR SHIPS)
Unit: mm
No.
1
Check item
Inside diameter of impeller and outside diameter of shaft
2
Clearance between impeller and body
3
Wear of seal ring of water seal
Criteria Standard dimension 15.9
Remedy
Outside diam- Inside diameter eter of shaft of impeller +0.020 +0.005
– 0.020 – 0.050
Standard interference 0.025 – 0.070
Replace Replace impeller usually (Outside diameter of shaft changes little)
Standard clearance: 0.1 – 0.63 (Including end play)
Allowable limit of dimension A: 0 Replace
4
Bend of shaft
(Total runout of indicator: Prescribed by faAllowable limit: 0.1 cial runout of fan pulley at radius of 40 mm)
Full opening lift of thermostat
Min. 10: Check by submerging in water at 95˚C for 4 – 5 minutes.
Function of thermostat
Valve must close fully when heated to fully opening temperature of 95˚C and then submerged in water at fully closing temperature of 77˚C for 4 – 5 minutes.
5
14-004
WATER PUMP
110 SERIES
MAINTENANCE STANDARD AND INSPECTION OF PARTS
110 SERIES S(SA) 6D110-1 (FOR CONSTRUCTION MACHINERY AND GENERATORS)
Unit: mm
No.
1
Check item
Inside diameter of impeller and outside diameter of shaft
2
Clearance between impeller and body
3
Wear of seal ring of water seal
4
Bend of shaft
Full opening lift of thermostat 5 Operation of thermostat
WATER PUMP
Criteria Standard dimension 15.9
Remedy
Outside diam- Inside diameter eter of shaft of impeller +0.020 +0.005
– 0.020 – 0.050
Standard interference 0.025 – 0.070
Replace Replace impeller usually (Outside diameter of shaft changes little)
Standard clearance: 0.2 – 0.6
Allowable limit of dimension A: 0
Allowable limit: 0.1 (Total runout of indicator: Prescribed by facial runout of fan pulley at radius of 40 mm) Replace
For construction machinery
Min. 10: Check by submerging in water at 90˚C for 4 – 5 minutes.
For generators
Min. 10: Check by submerging in water at 95˚C for 4 – 5 minutes.
For construction machinery For generators
Valve must close fully when heated to fully opening temperature of 90˚C and then submerged in water at fully closing temperature of 71˚C for 4 – 5 minutes. Valve must close fully when heated to fully opening temperature of 95˚C and then submerged in water at fully closing temperature of 76˚C for 4 – 5 minutes.
14-005
MAINTENANCE STANDARD AND INSPECTION OF PARTS
110 SERIES
S(SA) 6D110-1 SERIES (FOR SHIPS)
Unit: mm
No.
1
Check item
Inside diameter of impeller and outside diameter of shaft
2
Clearance between impeller and body
3
Wear of seal ring of water seal
Criteria Standard dimension 15.9
Remedy
Outside diam- Inside diameter eter of shaft of impeller +0.020 +0.005
– 0.020 – 0.050
Standard interference 0.025 – 0.070
Replace impeller Usually (Outside diameter of shaft changes little)
Standard clearance: 0.3 – 0.6
Allowable limit of dimension A: 0 Replace
4
Bend of shaft
(Total runout of indicator: Prescribed by faAllowable limit: 0.1 cial runout of fan pulley at radius of 40 mm)
Full opening lift of thermostat
Allowable range: Min. 10 (Check by submerging in water at 95˚C for 4 – 5 minutes.)
Operation of thermostat
Valve must close fully when heated to fully opening temperature of 95˚C and then submerged in water at fully closing temperature of 76˚C for 4 – 5 minutes.
14-006
WATER PUMP
125 SERIES
MAINTENANCE STANDARD AND INSPECTION OF PARTS
125 SERIES (S) 6D125-1 SERIES
Unit: mm
No.
1
Check item
Interference between impeller and shaft
2
Interference between drive gear and shaft
3
Clearance between impeller and body
4
Wear of seal ring of water seal
Criteria
Remedy
Allowance
Basic dimension
Shaft
Hole
Standard interference
15.9
+0.020 +0.005
– 0.020 – 0.050
0.025 – 0.070
20.0
+0.015 0
– 0.025 – 0.055
0.025 – 0.070
Replace Replace impeller usually (Outside diameter of shaft changes little) Replace (Replace gear usually)
Standard clearance: 0.31 – 1.10 (Including end play)
Replace
WATER PUMP
Allowable limit: Dimension A: 1.5
14-007
140 SERIES
MAINTENANCE STANDARD AND INSPECTION OF PARTS
140 SERIES SA6D140-1 (HD325-5)
Unit: mm
No.
1
Check item
Interference between impeller and shaft
Criteria
Remedy
Allowance
Basic dimension
Shaft
Hole
Standard interference
16
– 0.082 – 0.095
– 0.120 – 0.150
0.025 – 0.068
2
Interference between drive gear and shaft
28
+0.015 +0.002
– 0.023 – 0.053
0.025 – 0.068
3
Interference between flange and shaft
25
+0.015 +0.002
– 0.021 – 0.041
0.023 – 0.056
4
Clearance between impeller and body
Replace Replace impeller usually (Outside diameter of shaft changes little) Replace (Replace gear usually)
Standard clearance: 0.6 – 0.9 (Including end play) Replace
5
Wear of seal ring of water seal
14-008
Allowable limit of dimension A: 1.5
WATER PUMP
140 SERIES
MAINTENANCE STANDARD AND INSPECTION OF PARTS
SA12V140-1 SERIES
Unit: mm
No.
1
Check item
Interference between impeller and shaft
2
Interference between drive gear and shaft
3
Clearance between impeller and body
4
Wear of seal ring of water seal
Criteria
Remedy
Allowance
Basic dimension
Shaft
Hole
Standard interference
19.0
+0.018 +0.006
– 0.025 – 0.050
0.031 – 0.068
30.0
+0.015 +0.002
– 0.018 – 0.045
0.020 – 0.060
Replace Replace impeller usually (Outside diameter of shaft changes little) Replace (Replace gear usually)
Standard clearance: 0.25 – 1.02 (Including end play)
Replace
WATER PUMP
Allowable limit of dimension A: 1.5
14-009
155-4 SERIES
MAINTENANCE STANDARD AND INSPECTION OF PARTS
155-4 SERIES S4D155-4, S(A) 6D155-4 SERIES
Unit: mm
No.
Check item
1
Interference between impeller and shaft (Excluding tapered shaft)
2
Clearance between impeller and connection
3
Tightening torque of impeller locknut
4
Tightening torque of bearing locknut
14-010
Criteria Allowance
Basic dimension 15.85
Remedy
Shaft
Hole
Standard interference
+0.070 +0.055
+0.030 0
0.025 – 0.075
Standard clearance
Allowable clearance
0.62 – 1.70
—
Target (Nm {kgm})
Range (Nm {kgm})
76.0 {7.75}
73.6 – 78.5 {7.5 – 8}
196.0 {20}
166.7 – 225.6 {17 – 23}
Replace
Retighten
WATER PUMP
170 SERIES
MAINTENANCE STANDARD AND INSPECTION OF PARTS
170 SERIES S(A) 6D170 SERIES
Unit: mm
No.
1
Check item
Interference between front shaft and bearing
Criteria
Remedy
Allowance
Basic dimension
Shaft
Hole
Standard interference
30
+0.015 0
0 – 0.010
0 – 0.025
2
Interference between rear shaft and bearing
25
+0.010 0
0 – 0.010
0 – 0.020
3
Interference between rear shaft and impeller
19.9
+0.020 +0.005
– 0.025 – 0.05
0.030 – 0.070
4
Clearance between impeller and connection
WATER PUMP
Standard clearance
Allowable clearance
0.23 – 0.66
—
Replace
14-011
MAINTENANCE STANDARD AND INSPECTION OF PARTS
170 SERIES
SA 8V170-1, 12V170-1 SERIES
Unit: mm
No.
1
Check item
Interference between front shaft and bearing
Criteria
Remedy
Allowance
Basic dimension
Shaft
Hole
Standard interference
45
+0.018 +0.002
0 – 0.012
0.002 – 0.030
2
Interference between rear shaft and bearing
35
+0.018 +0.002
0 – 0.012
0.002 – 0.030
3
Interference between rear shaft and impeller
25
+0.054 +0.041
+0.009 – 0.016
0.032 – 0.070
4
Clearance between impeller and connection
14-012
Standard clearance
Allowable clearance
0.43 – 1.41
—
Replace
WATER PUMP
PARTS INSPECTION AND EVALUATION CRITERIA
MAINTENANCE STANDARD AND INSPECTION OF PARTS
PARTS INSPECTION AND EVALUATION CRITERIA •
Handle the removed parts carefully not to damage them. Clean them in diesel fuel oil, then dry them by blowing compressed air against them. In particular, check the following points visually. Part
Checkpoints
Shaft
• •
Damage and wear of shaft Bend of shaft
Ball bearing
• •
Damage and wear of inside and outside surfaces Rusting
Impeller
• •
Damage and wear of inside surfaces Wear of surfaces
Drive gear
• •
Damage and wear of gear Damage and wear of inside surface of gear
Bearing housing
• •
Damage and wear of inside surfaces Wear of surfaces
Snap ring
• •
Lowering of tension Bend and deformation
Cover
•
Corrosion and bend
Body
• • •
Damage and wear of inside surfaces Damage and distortion of threads Cracking of corrosion of whole body
fl Replace the oil seal and water seal with new ones.
WATER PUMP
14-013
MAINTENANCE STANDARD AND INSPECTION OF PARTS
REUSE CRITERIA
Part name
REUSE CRITERIA Division of reuse criteria Damaged portion A: Reusable
C: Not reusable
1
Seal contact surface
Damage which can be reFlaw which is not caught moved easily with sand- Damage other than A and B, stepped-type wear on nail, slight wear paper
2
Impeller fitting part
No scuff mark and flaw
1
Flaking of inside and No flaking outside surface, gloss
2
Rust on outside which Inside and outside of Balls and races are not can be removed easily Rusted, rotation is not smooth rusted bearing with sandpaper
3
Abnormal sound
No abnormal sound
—
Abnormal sound is generated
1
Blade tip
Slight bend of tip
—
Clear bend
2
Cracking, damage of No cracking and damage blade
—
Cracked, damaged
3
Contact mark which can Damage other than A and Contact portion of Slight contact mark at tip be removed easily with B blade and body sandpaper
1
Flaw which can be reDamage, wear other than Flaking, flaw, wear of Flaw which is caught on moved easily with oilA and B nail, slight wear tooth surface stone
2
Wear, flaw, seizure of Very slight scratch bearing part
—
Flaw which is caught on nail
1
Flaking of inside and No flaking and abnormal outside surface, gloss, sound abnormal sound
—
Turning resistance is heavy, abnormal sound is generated
2
Rust on outside which Rusted, rotation is not Inside and outside of Balls and races are not can be removed easily smooth rusted bearing with sandpaper
3
Threads of housing
No damaged or crushed Slight bruise or flaw of Damage or crush other threads than B threads
1
Tension
There is tension
—
Broken or cracked
2
Deformation bend
No deformation and bend
—
Deformed or cracked
Shaft Bearing Impeller Drive gear Bearing housing Snap ring
B: Reusable after repair
14-014
and
—
Impeller turns and has flaw or scuff mark on its surface
—
Heavy turning resistance
WATER PUMP
REUSE CRITERIA
Division of reuse criteria Damaged portion A: Reusable
B: Reusable after repair
C: Not reusable
1
Crush and wear of threads
No damaged or crushed Slight bruise or flaw of Damage or crush other than B threads threads
2
Damage and cracking of cover
No cracking
3
Corrosion and oxidation of inside surface
Combination of cracking No corrosion and oxida- Corrosion which can be and corrosion, oxide film tion removed which cannot be removed
1
Inside of body
Light contact mark which does not cover all inside Other than A and C surface
2
Crush and wear of threads
No damaged or crushed Slight bruise or flaw of Damage or crush other threads threads than B
3
Corrosion and oxidation of inside surface
Combination of cracking No corrosion and oxida- Corrosion which can be and corrosion, oxide film tion removed which cannot be removed
4
Damage and cracking of body
No cracking
Body
Cover
Part name
MAINTENANCE STANDARD AND INSPECTION OF PARTS
WATER PUMP
Flaw which can be removed easily with oil- Damage other than B stone
Flaw which covers all inside surface
Flaw which can be removed easily with oil- Damage other than B stone
14-015
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