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.
f
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
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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..; ;
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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
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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 .
j
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.
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