SEZIONE 3 PAG. 1-14.pdf

7/27/2019 SEZIONE 3 PAG. 1-14.pdf

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3-1

Page

3-2

3-2

GENERAL DESCRIPTION

1-1. Specifications

.3-3

.3-5

.3-5

.3-10

.3-12

.3-15

.3-18

.3-20

2 . S R CNGOFINE CIONUMP-1. Inspectin of ij ctin pump prir to diassembl

2-2. D ssembl of ij ctin pump assembl-3. Inspectin of diassembld parts-4. R as embl of i j cti n pump p arts-5. Aj stment of ij ctjn pump-6. A j stment of R D type governor-7. Fi al adj stment of i j cti n vol me.

3-21

3-21

3-22

3-22

3. SERVICING OF AUTOMA TIC TIMER.-1. Disassembly and inspection of automatic timer

3-2. Reassembly of automatic timer. : ..

3-3. Testing ofautomatictimer

3-233-23

3-24

3-24

4. SERVICINGOFFEEDPUMP-1. Disassembly cf feed pump-2. Inspecticn and reassembly cf feed pump

4-3. Testingcffeed pump

3-25

3-25

3-25

5. SERV/CING OF INJECTION NOZZLES ANO NOZZLE HOLOERS

5-1. Oisassembly-2.lnspectionofinjectionnozzles

6. SERVICING OF FUEL FIL TER-1. Fuef filter servicing procedure 000 3-26

o o o 3-26

7. TROUBLE SHOOTING 3-27

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FUEL SYSTEM

SECTION 3. FUELSYSTEM

GENERAL DESCRIPTION

fuel system is skillfully designed and compactly built tl? withstand continuous high-speed and

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FIG.3-1

Specifications

Main data and specifications

MODEL C240ITEM

NP-PES4A60C

NP-EP/RBD1800L

.NP-EP/SCD500 1750A6L

NP-FP/KS22AC

NP-DNOSD2110

120

Cartridgetype

~-

njecionpumptypeovernortypeutomatic timer typeeed pump typejecion nozzle typejecion sarting pressure kg/cm2

uel fi er type

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FUEL SYSTEM 3-3

2. SERVICING OF INJECTION PUMP

"

14.

16

22 21 20.r

\

17. GASKET

18. JOINT BOL T19. WOODRUFF KEY

20. DISTANCE RING

21. SHIM

22. BEARING

23. OIL SEAL

24. FRDNT BEARING COVER

25. CAMSHAFT

26. CONTROL PINION

27. CLAMP SCREW

28. CENTER SLEEVE

29. UPPER SPRING SEAT

30. PLUNGER SPRING

31. LOWER SPRING SEAT

32. ADJUSTING WASHER

33. T APPET ASSEM8L y34. SCREW PLUG

35. STUD 80L T

36. NUT. SPRING WASHER. PLAIN WASHER

37. NUT, SPRING WASHER

38. OVER FLOW NIPPLE

39. GASKET

40. JOINT BOL T

41. GASKET

42. JOINT BOL T

43. O.RING

44. BRACKET

45. STUD BOL T

46. SCR EW

1. PUMP HOUSING ASSEMBL Y

2. TAPPET CHAMBER COVER3. SETSC1:1EW

4. WASHER

5. CONTROL RACK

6. RACK GUIDE SCREW

7. OIL LEVEL GAUGE

8. AIR BREATHER ASSEMBLY

9. PLUNGER ASSEMBL Y

VALVE ASSEMBL Y

DELIVERY VALVE GASKET

RY VALVE SPRING

RY VALVE HOLDER

AIR BREEDER ASSEMBL Y

LOCK PLATE ASSEMBLY

FIG. 3-2

'---

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3-4 FUEL SYSTEM

1. PLATE PLUG

2. IDLING SPRING GUIDE ASSEMBL Y

3. ROUND NUT

4. HOSE JOINT

5. GOVERNOR HOUSING

6. PNEUMATIC GOVERNOR SPRING ADJUSTING SHIM

7. PNEUMATIC GOVERNOR SPRING

8. DIAPHRAGM ASSEMBL Y

9. MECHANICAL GOVERNOR HOUSING

10. GASKET

11. GUIDE ARM

12. PUSH ROD

13. MECHANICAL GOVERNOR SPRING ADJUSTING SCREW

14. MECHANICAL GOVERNOR SPRING

15. MECHANICAL GOVERNOR SPRING ADJUSTING SHIM

16. STOPPING LEVER

17. STOPPING LEVER18. SLEEVE

19. ROUND NUT

20. SPRING WASHER

21. FLYWEIGHT ASSEMBLY

22. SMORKSET SPRING GUiDE ASSEMBL Y

23. GOVERNOR HOUSING

24. IMPELLER

25. CONTROL LEVER

26. HOSE JOINT

FIG.3-3

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FUEL SYSTEM 3-:

2-1 Inspection of injection pump priorto disassembly .

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FIG. 3-5

2) Remove finger from the vacuum nip-

pie quickly after allowing about 5 sec-

onds. Normal condition of the dia-

phragm is indicated by a "pop.. which

accompanies snap action of thediaphragm.

2-2 Disassembly of injection pump

assembly

(1) Preparation for disassembly

Prior to disassembly. wash clean the exterior of

the injection pump. exercising care not to per-

mit detergent oil into the delivery valves. etc.

(2) Automatic timer removal

1) Remove the round nut and spring washer

using socket wrench (57914-010) and L type

handle (57910-112). When turning the round

nut. set special wrench (57916-432) to the

holes in the timer side to prevent turning of

the shaft.NOTE: The numbers in the tool number col-

umn indicate manufacturer.s tool

number (DIESEL KIKI).

Prior to disassembly. check the following

points to determin.e whether or not overhaul-

ing is necessary.

(1) Check the pump hòusing visually forcracking and resulting fuel leaks.

(2) Check the upper face of the pump hous-

ing for a sign of fuel leaks from around

the delivery valve holders. (Leakage of

fuel is mostly due to defective delivery

valve gaskets.)

(3) .Check that the injection pump camshaft

turns smoothly. If rotation of the cam-

shaft is unsmooth. bearing damage or

plunger spring breakage is suspectable.

(4) Check the internai part of the pump for

presence of water with the tappet

chamber cover removed.(5) Check state of oil to see if the fuel is leak-

ing into the cam chamber. (Check viscos-

ity. color and odor of fuel to determine

whether or not fuel is leaking into cam

chamber.) A small amount of fuelleaking

past the cJearance between the injection

pump plungers and plunger barrels is

normal as it serves to lubricate the parts.

Check for fuel leaks from the feed pump

and from around the clearance between

the pump housing and plunger barrels.

(6) Check the pneumatic governor dia-

phragm for damage as defective dia-phragm will prevent smooth engine con-

trolling. To check the diaphragm for

damage, proceed as follows:

1) Tilt the stopper lever ali the way rear-

ward and release the lever with the

vacuum nipple plugged with finger.

FIG. 3-6FIG. 3-4

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FUEL SYSTEM

2) Lock the camshaft with special wrench and

remove the automati~ timer by screwing pro-

jected portion of extractor (57926-581) into

the threaded h aIe at the center of the

flyweight.

(9) Diaphragm hausing remava'

1) Remove the 4 bolts fixing the governor

cover.

2) Remove the adjusting shim and main springtogether with the governor cover and

diaphragm.

FIG. 3-7 FIG.3-9

(10) Mechanical gavernar remavaRemave the mechanical governor cover andsleeve. then pull out the push-rod using care not

to drop the return spring and washer.

pump bracket removal

Take out the 4 nuts fixing the injection pump

bracket and remove the bracket.

Clamp the injection pump in universal vise

(5794-002) securely

Remove the feed pump

the overflow nipple

the tappet chamber cover

Fixing of tappets

1) Connect the automatic timer to the camshaft

and leave the nut semi-tight, then bring one

of the tappets to the uppermost position by

turning the camshaft.

2) Fix the tappet by inserting tappet holder

(57931-250) into the hole in the tappet body.

Repeat the same procedure until the entire

tappets are fixed in elevated position.

(11) Flyweight removal1) Remove the round nut and spring washer

using special wrench (57915-010). Whenturning the round nut. install the timer and

hold it with special wrench to prevent turning

of the camshaft.FIG.3-8

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FUEL SYSTEM 3-7

(13) Governor housing removal

Remove the 5 bolts fixing the governor housing

and remove the governor housing from the

pump housing by tapping on the govern9r hous-

ing lightly with a mallet.

(14) Disassembly of governor housing

1) Remove the bolt fixing the contr?1 lever

shaft, then remove the control lever together

with the return spring. Remove the collar.washer and O ring. " "

NOTE: When removing parts, check the

clearance between collar and

washer far presence of shims which

might have been fitted for

adjustment.

FIG.3-11

2) Remove the flyweight assembly by screwing

the extractor (57926-511) into threaded hole

in the flyweight holder.

FIG.3-14

2) Remove the stop lever shaft screw and stop

lever shaft then take out the internaI parts.FIG.3-12

(12) Camshaft removal

Remove the 4 bolts fixing the bearing cover,

then remove the front bearing cover. Remove

the camshaft together with the bearing.

FIG.3-15IG.3-13

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3-8 FUEL SYSTEM

3) Insert tappet pincers (57921-012) into the

pump trom the bottom tace and raise the

handle on the tappet insert, remove the tap-

pet holder and lower the handle.

3) Remove the cap nut and lock nut, then re-

.move the governor spring assembly.

NOTE: Adjust bolt has left-hand threads.

FIG.3-16 FIG.3-18

4) Compress the governor spring and remove

the snap ring. then remove the remaining

parts.5) Remove the screw plug from each end of the

guide arm shaft, pull out the guide arm shaft

and remove the guide arm.

4) When the tappet is pushed outward by the

action of the plunger spring, cfamp the tap-

pet sidewise with the tappet pincers

(57931-612) and remove it from the pump

carefully.

NOTE: When removing the tappet, exercise

care not to drop roller and injection

timing adjusting shim.15) Tappet removal

1) Turn the universal vise to bring the tappet

chamber cover side of the injection pump up.

2) Remove the screw from the bottom face ofthe injection pump using L type handle.

NOTE: Keep the parts removed in the follow-

ing paragraphs separate accordingto each group to prevent inter-

changing. Handle the parts with

meticulous care not to cause

scratching.

FIG.3-19

(16).Plunger and plunger spring removal1) Insert the plunger pincers (57921-562) into

the injectioo pump from the bottom openingand fit it into the hole in the lower springseat, then pull out the plunger together with

the lower spring seat. Keep the parts in cleankerosene in each cylinder group to avoidinterchanging of the parts. Remove the

plunger carefully not to bring it into contact

with the adjacent parts.IG.3-17

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(7) Inspection of plunger barrel to pump housingfitting 1ace .

Check the fitting face for scratches. deformatjon

or roughness and correct as necessary using a

hand milling machine.

(8) Inspection of control pinions

1) Check the gear teeth for wear or damage and

replace as necessary.2) Check the clamp screw for damage and cor-

rect or replace as necessary.

(9) Inspection of control rack

Check the control rack teeth for wear or damage

and control rack for bending by rolling it over a

surface piace. Replace the control rack if found

to be bent.

(10) Inspection of plungers assembly

Check the plungers visuarly for cracking or rust

formation. To check movement of the plungers.

proceed as follows: Lubricate the plunger as-

seA1bly with kerosene and hold it tilted at an

angle of 60 degrees from vertical. Pull the

plunger 213 way out from the plunger barrel and

see if it lowers into the plunger barrel when re-

leased. Repeat the test several times with the

plunger turned slightly.

/

FIG.3-28

(4) Inspection of tappets

1) Check the tappet body and roller for wear or

damage and replace the parts with new ones

as necessary. Aiso check the clearance be-

tween the roller and bushing and between

the rofler and pin.

Replace the parts if the clearance is found to

be excessive.

2) Check the clearance between the injection

pump housing and tappet body and replace

the parts if the measured value is beyond the

limit for use.

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600

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(5) Inspection of plunger springs

Check the springs visually for wear or damage

and replace with new ones as necessary .

(6) Inspection of slit in control sleeves

Che.ck the clearance between the flange of the

plunger and groove in the control sleeve. Re-

piace both of the parts if the measured value is

beyond the limit.

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.:

FIG. 3-29

(11) Inspection of delivery valves

Check the delivery valve piston and seat visually

for cracking or rust formation. To make a test,

proceed as follows: Lubricate the delivery valve

assembly with kerosene and plug the lower end

7/27/2019 SEZIONE 3 PAG. 1-14.pdf


FUEL SYSTEM

of the valve body with finger and insert the valve

carefully into the valve body. If air bubbtes come

out from around the valve seat and gives no re-

sistance when the valv~ is pushed in, the valve

assembly is defective and should be replaced

with a new one.

(2) Delivery valve installation

1) Position the gasket over the delivery valve

body and install the delivery valve and upper

face of plunger barrer must be clean and free

from foreign matter.)

NOTE: Install the delivery "afve. gasket withits heavy-chambered side down into

the delivery valve b.ody..; ;

L1- -

FIG. 3-32

2) Instafl the delivery valve usjng delivery valve

extractor (57296-012), So that it is brought

into firm contact with the plunger barrel.

When installing the delivery valve, hold un-

threaded end of the to01 agajnst the gasket.

Reassembly of injection pump

parts

reassembly. wash clean the parts paying

to the fuel ports. Discard deliverygaskets. oil seals and O rings and instalf new

Installation of plunger barrelsInstall the plunger barrel by aligning its pin

groove with the pin on the pump housing. theninsert fingers into the pump housing from the

tappet chamber cover opening and see if the

plunger turns. If the plunger cannot be turned

with fingers. it indicates that the pin is fittedproperfy into the pin groove. -

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FIG. 3-33

3) Position the delivery valve spring over the de-

livery valve.4) Torque the delivery vaJve holder to specifica-

tion in the following manner: First tighten the

valve holder to 3 m-k9 and loosen it com-

pletely. Reti9hten the valve holder to 3 m-kgand loosen it again, then tighten it to the final

torque of 3.5 m-k9.5) Install the delivery valve holder lock plate.

(3) Control rack installation1) Apply a thin coat of en9ine oil to the control

rack and insert it into the pump housing from

the governor side, so that its end with the

I

FIG.3-31

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FUEL SYSTEM 3-13

(7} Plunger Insta/1ation

Combine the plunger with the lower spring seat

and insert these parts into the plunger barrel. so

that the p/unger lead or flange with numerai is

turned toward ~he tappet chamber cover .

diaphragm fittjng hole is turned to the gov-

ernor side and rack teeth are brought to the

tappet chamber cover side, respectively.

2) Install the control I'ack gujde screw on the

rear face of the pump housing.

3) Set the control rack to even out the distancebetween the notched lines and outer edges

of the pump. The control rack can also be set

correctly by adjusting the projectjon of the

rack beyond the timer sjde face of the pump

body to 17.5 mm.

FIG. 3-35

(8) Tappet instaJlation

1) Clamp the lower part of the tappet body with

the tappet ctamp and insert the tappet into

the body through the camshaft ho/e.t,;";."'..'- ,

{4) Contrai pinion and contrai 51eeve in5tallation

1) Hold the control rack in position as de-

5cribed in the foregoing paragraph and en-

gage the control pinion with the rack teeth by

turning the slotted face of the pinion toward

the tappet chamber side (top).

Direction of slot in the control sleeve is not

important at this stage of operation.

2) Measurement of control rack stroke.

Measure the fufl stroke of the control rack

from the timer side to the governor side. If

the measured value deviates from the

specified range. recheck setting of the con-

trai rack and adjust by disengaging and

reengaging the pinion with the control rackteeth.

FIG. 3-362) Align the flange of plunger with the slot in

the control sleeve and depress the handle on

the tappet insert untjl tappet holder fittinghole in the tappet body appears to the tappet

chamber cover opening. then install the tap-pet holder .

Upper spring seat installationInstall the upper spring seat. so that its flat faceis turned to the defivery vafve.

Plunger spring insta/1ationInsert the plunger spring into position throughthe screw plug fitting hole in the bottom face ofthe pump housing. . FIG. 3-37

7/27/2019 SEZIONE 3 PAG. 1-14.pdf


3-14 FUEL SYSTEM

(9) 5crew plug installation

Instalf the screw plug after applying liquid gas-

ket to the threaded portion.

(10) Governor housing installation

Reassemble the governor housing by followingthe disassembly procedure in reverse order and

install it on the pump housing using gasket.(11) "Camshaft installation

Install the impeller on the marked side end of

,the camsh.aft. then insert the camshaft into the

'pump housing from the timer side. so that its

end with themark is turned to the governor side.

FIG. 3-38

{12) Front bearing cover installation

Install the front bearing cover on the pump

housing in the following manner: Install seal

cover {57920-870) on the tapered portion of the

camshaft to protect the oil against damage in

contact with the sharp edge of the key groove as

scratches on the oil seal can cause oil leaks.

2) Install the automatic timer and leave the nut

semi-tight. Remove the tappet holders by

turning the camshaft gradually, then check

operation of tappets.

(14) Mechanical governor installation

1) Install the key on the camshaft, then install

the flyweights by aligning its key groove with

the key. Install and torque the nut.

2) Install the push-rod. spring and plain washer

3) Install the sleeve and governor cover.

(15) Inspection of control rack sliding resistance

With a pull scale check the sliding resistance of

the control rack with each plunger set at the

uppermost position corresponding to top dead

center .

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FIG. 3-39

(13) Measurement of camshaft end play

1) Check the camshaft end play using measur-

ing device (5782-420). If the end play deviates

from the specified range, adjust by usingshims between the camshaft bearing and dis-

tance piece.

SEZIONE 3 PAG. 1-14.pdf

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