Componente Motor

SEBEKTURB001
TURBOCHARGER
TURBOCHARGER MODEL
KTR100
KTR110
KTR130
KTR150
©2001
All Rights Reserved 00-001
Printed in Japan 02-01(02)
1
CONTENTS
00 INTRODUCTION ........................................................................................ 00-011
01 GENERAL ........................................................................................................ 01-001
11 STRUCTURE AND FUNCTION ....................................................... 11-001
13 DISASSEMBLY AND ASSEMBLY ................................................. 13-001
14 MAINTENANCE STANDARD AND

INSPECTION OF PARTS ................................................................... 14-001
00-002 TURBOCHARGER
1
The affected pages are indicated by the use of the
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Revision Action required
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following
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numberIt is Mark
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tions be taken to these pages according to the table c Page to be newly added Add
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Pages having no marks are those previously re-

vised or made aditions.
LIST OF REVISED PAGES

Revision Revision Revision Revision Revision
Mark Page Mark Page Mark Page Mark Page Mark Page
number number number number number
b 00-001 1
b 00-002 1
c 00-003 1
00-011
01-001
01-002
11-001
11-002
11-003
11-004
11-005
11-006
13-001
13-002
b 13-004 1
b 13-005 1
b 13-006 1
b 13-007 1
b 13-008 1
b 13-009 1
b 13-010 1
b 13-011 1
b 13-012 1
(13-013)
14-001
14-002
14-003
14-004
14-005
14-006
14-007
14-008
14-009
TURBOCHARGER 00-003
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5
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c3
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KTURBO
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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. Blower impeller
13. Blower housing
14. Rock nut
a. Oil inlet (from oil filter)
b. Oil outlet (to oil pan)
c. Air inlet
d. Air outlet
e. Exhaust inlet
f. 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. Ring seal
12. Turbine housing
Air inlet
:: Air outlet
e. Exhaust inlet
61 62F609A f. Exhaust outlet
1 l-002
KTRI 30
1 2 3 4 5 3 6 7 6
1. Blower housing
2. Blower impeller
3. Clamp
4. Center housing
5. Journal bearing
6. Shield
7. Turbine impeller
8. Turbine housing
9. Flinger
IO. Insert
11. Thrust bearing
12. Turbine shaft
Air Jn!e?
Z: Air outlet
Exhaust inlet
e Y. Exhaust outlet
6 162F610
KTRI 50
1. Blower housing
2. Blower impeller
3. Clamp
4. Center housing
5. Journal bearing
6. Turbine impeller
7. Turbine housing
8. Flinger
9. Thrust bearing
10. Turbine shaft
c. Air inlet
d. Air outlet
e. Exhaust inlet
f. Exhaust outlet
8 !i
F6166009
1 l-003
113
m
D
2
-*
3 2
-0
CD c)
=
CD +
3L
5
2
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 com-
pression pressure imposed on the inpeller and the exhaust pressure. Consequently, the shafting is
supported on a floating type cylindrical journal and thrust bearings.
The center housing holds bearings, forming the circuit of oil for lubricating bearings.
The turbine housing contains the turbine impeller, forming the exhaust circuit. The exhaust gases
from the exhaust manifold are led to the turbine impeller at high speed and pressure. Thereby, the
gases which by their expanding 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 the air intake circuit. The
intake air is led to the biower impeiier and compressed by the rotating Impeller. I !tCslli this com-
Than
pressed air is superchanrged 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 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.
l 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 energy as shaft horsepower is
approx. l/3 of the fuel energy. The remainder 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 im-
peller as the rotating power source. Thereby,
the blower impeller on the same shaft with the
turbine impeller is rotated so that the air is com-
pressed 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.
Note Intake
Excess air ratio:
The ratio of the quantity of air necessary
to actually obtain optimum combustion effi-
ciency, assuming that the theoretical quanti- Exhaust gases
ty of air required for complete fuel combus-
tion 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, com-
bustion time limit, etc. If the quantity of air is
less than 1.2 to 1.5 the excess air ratio, in-
complete combustion will take place, re-
sulting in black exhaust smoke and an in- E
- 300
creased heat load. k
is
ln a turbocharged engine, a quantity of air i*
corresponding to the fuel injection quantity is 5

_.c
compressed and supercharged. In an engine of ii
‘i5, 200
the same cylinder capacity, the horsepower can
15
be increased as indicated in the graph at right. If
an after-cooler is used with the turbocharger,
the horsepower can be further improved.
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 00
??
c9c9 c;
FP P
.. ..
.. ..
. .
*. ..
n
KTU R BO
DISASSEMBLY AND ASSEMBLY GENERAL DISASSEMBLY
GENERAL DISASSEMBLY
• Before disassembling the turbocharger, clean its

outside surface and apply match marks to en-
sure that the blower housing and turbine hous-
ing are reassembled in their original positions.
KTR100, KTR130
KTR110, KTR150
13-004 TURBOCHARGER
1
fl Replace the entire rotor assembly, if the dynamic

balance check on the rotor assembly is impracti-
cable.
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 ra-
dial 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 tur-
bine 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 mount-

ing bolts (3), and then remove lock plate.
4) Remove turbine housing (4).
TURBOCHARGER 13-005
1
fl Before removing the blower impellers, measure

the end play and the radial play of the rotor as-
sembly 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 di-
rection.
2) Measurement of the radial play (A play in the

radial direction)
rotor assembly is moved in the radial di-
rection.
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 tur-
bine 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 TURBOCHARGER
1
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.

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
7. Center housing
Pull out center housing (12) from the turbine ro-
tor.
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 TURBOCHARGER
1
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 com-
ponent 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
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 fit-
ted 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)

1) Fit an O-ring and install insert (7).
2) Tighten the insert mounting bolts and then
bend the lock washer.

1) Install the turbine rotor onto the back plate
(7).
2) Tighten the back plate mounting bolts and
bend the lock washer.
13-010 TURBOCHARGER
1
9. Blower impellers
1) Install blower impellers onto the turbine ro-
tor 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 tur-
bine rotor, aligning the match mark.
fl Apply engine oil to the inner face of
the blower impeller and install the im-
peller 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)
rotor assembly is moved in the axial di-
rection.
2) Measurement of the radial play (A play in the

radial direction)
rotor assembly is moved in the radial di-
rection.
TURBOCHARGER 13-011
1
10. Housing
fl Take care not to damage the blower impeller
and turbine impeller when installing the
blower housing and turbine housing.

1) Install the blower housing (4) and turbine
housing (3) into the center housing and
the rotor assembly.
2) Tighten clamp (2), (1).

1) Install the turbine housing (4) into the cen-
ter 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 assem-
bly.
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 di-
rection with a finger.
2) Measure the clearance between the
blower impeller and the housing by us-
ing filler gauge 1.
fl After completing the assembly, rotate the ro-

tor assembly while depressing it lightly and
make sure that the rotor can be rotated
smoothly without binding.
13-012 TURBOCHARGER
1
cl 8
4
z II
a
TURBOCHARGER
KTRI 00
14FOOlA
Unit:mm
No. Check item Criteria Remedy
Standard Repair limit

End play (play in axial Raplacing parts
1
direction) related to thrust
0.06 to 0.11 0.18
Radial play (play in radial Replacing parts re-

2 0.20 to 0.04 0.60
I direction) I I lated to bearing
Tolerance Repair limit

Outside diameter of journal Standard size
3 bearing Shaft Hole Shaft Hole
Inner diameter of center housing -0.040 +0.020
24 -0.060 0 23.91 24.04
Inner diameter of Journal bearing -0.030 +0.020

4 Outside diameter of wheel shaft 16 -0.050 0 15.94 16.05
Bend of wheel shaft Repair limit: 0.010 (Total indicated runout)

Standard size r Replace
Width Groove Width Groove
5 Thickness of thrust bearing
-0.08 0
I I 5.5 -0.17 1 -0.02 1 5.34 , 5.52 I
A
Turbine -0.08 -0.03
side 2 -0.10 -0.04 1.85 2.05
6 Thickness of seal ring -0.08

Blower 2 1.85
-0.10
side
4 -0.12
-0.13 , 4.05
Clearance between blower Replace parts

7 Tolerance: (min.) 0.15
housing and impeller related to bearing
Tightening torque of blower
8 4.25 kO.25 kgm
impeller locknut
Tightening torque of insert
9 mounting bolt 1.25 & 0.25 kgm Tighten
Tightening torque of V band

10 0.9 kO.1 kgm
locknut
14-002
-
2
E
-._
.k
x
ii
- s
?’
co--
Or
dC
I I
KTRI 30
9 6
8 5 2 3 4 10
6162F402
6162F401
Unit: mm
NO. Check item Criteria I Remedy

I
Standard Repair limit Rapiace parts

End play (play in axial
related-to
direction)
0.08 to 0.13 0.18 thrust
Raplace parts
Radial play (play in radial
0.25 to 0.43 0.60 related to
direction) bearing
I I
Standard size
Outside diameter of journal , .Shaft 1 Xo!e Shaft Xo!e 1
bearing.
Inner diameter of center housing.
30 -0.060 +0.020 29.89 30.04
-0.080 0
Inner diameter of journal bearing.

Outside diameter of wheel shaft. 1 2. 1 --;:;;; / +;*‘15 / 19.95 / 20.05 1
4
Bend of wheel shaft I Repair limit: 0.010 (Total indicated runout) I Replace

Standard size
-0.08 +0.02
6 5.86 6.04
-0.11 0
-0.08 -0.03
6 Thickness of seal ring 3 2.85 3.05
-0.10 -0.04
Replace parts
Clearance between blower
Tolerance: (min.) 0.20 related to
7 housing and impeller bearing

8.5 kO.5 kgm
8 impeller locknut
Tightening torque of insert Tighten

9 1.35 kO.15 kgm
mounting bolt

10 0.9 fO.l kgm
locknut I
14-004
KTRI 50
7-
F6166056
Unit: mm
No Check item Criteria Remedy
Standard Repair limit Raplace parts

End play (play in axial related to
1
direction) 0.08 to 0.13 0.18 thrust
I
Radial play (Play in axial Raplace parts
0.25 to 0.43 0.60 related to
direction)
bearing

Outside diameter of journal Standard size
bearing. Shaft Hole Shaft Hole
Inner diameter of center
-0.060 +0.020
housing. 30 29.89 30.04
-0.080 0
Inner diameter of journal bearing. +0.015

20 -0.030 19.95 20.05
Outside diameter of wheel shaft. -0.045 0
4
Bend of wheel shaft Repair limit: 0.010 (Total indicated runout) Replace

Standard size
6 -0.08 +0.02 5.86 6.04

-0.11 0
-0.03
6 Thickness of seal ring 3 -0.08 2.85 3.05
-0.10 -0.04
Replace parts
Clearance between
housing and impeller
blower
Tolerance: (min.) 0.20 I related to

8 9.5 f0.5 kgm
impeller locknut
Tightening torque of insert
9 mounting bolt 6.75 kO.75 kgm
Tighten
Tightening torque of turbine
IO 5.75 kO.25 kgm
housing bolt

0.9 kO.1 kgm
locknut
14-005
Inspection of parts and judgement standards
l In order to make correct diagnoses of faulty parts, first clean the parts, then inspect them, paying
special attention to the following check points.
Part Check points Part Check points
Blower housing 0 Damage or bending of the

l Contact with blower Blower impeller
impeller blade
l Damage or deformation of l Contact with blower housing
the surface fitted with the
center housing
l Deformation or failure at
joints Journal bearing
l Scuffing and seizure
l Wear
Center housing
0 Failure or wear at seal
bore
0 Scratches at bearing bore
Thrust bearing
0 Deformation or failure at
@ Wear and cracks
joints
Turbine housing
l Contact with turbine rotor
Shield
l Corrosion of the inner surfact
l Wear and cracks
Turbine shaft
l Damage or wear of the seal
ring portion of the shaft
Flinger
l Wear, discoloration and
and thrust collar @ Discoloration
seizure of the journal portion
of the shaft @ Wear of the surface in contac
l Bend of the shaft with the back plate
B For criteria about wear and bending, refer to the Maintenance standard
14-006
Standards for Reuse of Parts
l Use the photographs in the shop manual (SEBG4080) as reference when making judgement.
Failure degree
Part Location or type

Use after
name of failure Use again Do not use again
reconditioning
Inner surface of Light contact flaw not Flaws other than use Flaw extending over
1 blower housing extending over the again and do not use the entire inner
entire inner surface. again, surface.
.-F Surface fitted to the No damage or The contacting surface There is clearance with
: 2 center housing. deformation. has a flaw but does not the center housing
r
allow air to leak. caused by deformation.
G
2
m
Connections at air No deformation or Minor deformation More faulty condition
3 cracks. which does not allow than in use after re-
inlet and outlet parts.
air to leak. conditioning.
No scratches. Very thin wear. Large scratches.

Wear.
Corrosion or oxidation
of the inner surface. oxidized surface.
removable oxide film.
inlet flange is less

than 0.3 mm.
14-007
Failure degree
Part Location or type
Use after
name of failure Use again Do not use again
reconditioning
Bending, deformation There is a slight bend Cracks, lack of metal at

1 of the blade. but no cracks at the the tip, easily observ-
tip. able bend.
Flaw due to contact Trace of slight contact Burrs or deformation.

between blade and is on the whole surface
2 housing. of the blade.
However, there are no
burrs.
Seal ring groove. No wear or damage. Deformation to the

3 point that the seal
ring is stuck.
Journal No discoloration. Discolored surface can Discoloration other

c be easily removed with than use after
iscolored)
-!! 4 (d No. 400 to No. 600 reconditioning.
:
._ sandpaper.
+
5 Journal Scratches not One or two flaws Flaws other than use
5 (flaws) detectable by fingernail. which catch on nails after reconditioning.
(Such flaws need not
be repaired.)
6 Journa! (seizure) No seizure. No seizure. Seized bearing metal.
Bend of the shaft. O.Olmm or less T.I.R. Exceeding 0.01 mm

7 (Total indicated T.I.R.
runout)
Surface of fitted No scuffing or flaw. The surface has a flaw

B portion of a blower or scuffed area due to
impeller. the turned impeller,
o Shaft back surface. No trace of contact. There is evidence of

;’ ’
’ contact.
Bend of the blade tip. Slight bending of the Marked bending of the
1 tip.
tip.
Cracks or damage of No cracks or damage. Cracks or damage.

2 the blade.
Contact between blade There is a trace of There is contact that Contact other than use
3 and housing. slight contact. can be easily removed again and use after re-
&
= with sandpaper. conditioning.
g I 41 Con +rrc.+
LabLIv-vt
*;+L.
u, +Lhe back ’ No contact. ’ Ns contact. Contact.
._
& plate.
3
_o Damage of the contact No damage. No damage. Damage.
m
5 surface with nut.
Damage of inner surface No damage. No damage. Damage.

6
of shaft hole.
Flaw on the contact No flaw. No flaw. Flaw.

7 surface with thrust
collar.
14-008
I I I I
.-c
??
5
Gupaq pulnor
©2001
2
CONTENTS
01 GENERAL ........................................................................................................ 01-001
12 TESTING AND ADJUSTING ............................................................ 12-001
14 MAINTENANCE STANDARD AND

INSPECTION OF PARTS ................................................................... 14-001
00-002 AIR COMPRESSOR

2
Revision Indication
Revision
following
Mark marks.
Page
numberIt is Mark
requested
Page that necessary
number
Mark ac-
Page
number
Mark Page
number
Mark Page
number
below.


b 00-001 2 13-014 1
b 00-002 2 13-015 1
b 00-003 2 13-016 1
13-017 1
01-001 13-018 1
01-002 1 13-019 1
01-003 1 13-020 1
01-004 1 13-021 1
01-005 1
01-006 1 b 14-001 2
01-007 1 b 14-002 2
b 14-003 2
11-001 1 b 14-004 2
11-002 14-005 1
11-003 14-006 1
11-004 14-007 1
11-005 14-008 1
11-006 14-009 1
11-007
11-008 1
11-009 1
11-010 1
11-011 1
11-012 1
12-001
12-002 1
13-001 1
13-002 1
13-003 1
13-004 1
13-005 1
13-006 1
13-007 1
13-008 1
13-009 1
13-010 1
13-011 1
13-012 1
13-013 1
AIR COMPRESSOR 00-003

2
.
.
.
003kllV
SPECIFICATIONS
Assembly part number 6206-91-I 100 6136-81-3112 6138-81-3111
Manufacturer’s part number DK408717-0300 DK408717-0251 DK408717-0271
Engine model (S)6D95L- 1 S6D105-1 S(A)GDl 1 O-l
Water cooled - single Water cooled - single Water cooled - single

Type cylinder - double acting cylinder - double acting cylrnder - double acting
Cylinder bore X stroke (mm) 70 x 40 70 x 40 70 x 40
Normal max. pressure (kg/cm2) 8.5 8.5 8.5
Normal max. speed (rpm) 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
Discharge
(Urnin) 800 (rpm) 123.2 123.2 123.2
I
8
::
1,000 (rpm) 154 154 154
3
/ 1,500 0-p-d 231 231 231
2,000 (rpm) - -
6D95L- 1 S6D105-1 S6Dll O-l

l PWI 50-I l LWI 60-I l WA350-1
#50001-
S6D95L- 1 SAGDI IO-I

. PWIOO-3 l WA380-1
l WA400- 1
Application models
l WA420-1
(Note) Normal max. speed and discharge speed are shown in air compressor speed.
w-002
0
8 0
;;;
;;_
m 8 0
ti Y
.
‘c
Lo
-
-_
In 0
ai ;T;;
CD
.!
Al RCOO
Assembly part number 6162-83-6700 6162-83-6800
Manufacturer’s part number DK408738-5102 DK408738-5280
Engine model I S6DI 70
Water cooled - single Water cooled - single

Type cylinder - double acting cylinder - double acting
Cylinder bore X stroke !mm) I 85 X 60 85 X 60

I
Normal max. pressure (kg/cm2) 8.5 8.5
Normal max. speed (rpm) I ,700

I
250 (rpm)
500 (f-pm) 170 170
r---Gz- 204 204
276
340
1,500 (rpm) 510
2,000 (rpm) 680
PC I 000 WD600
Application models
Assembly part number 6165-91-l 001 6165-91-1004 6165-91-I 005
DK408728-5092
Manufacturer’s part number DK408728-5085 DK408728-5093 DK408728-5100
DK408728-5094
Engine model SA8V170-1 SA8V170-1 SA8V170- 1

SA12V170-1 SAI 2V170-1 SAI 2V170-1
Water cooled - two Water cooled - two Water cooled - two

Type cylinder - double actins cylinder - double acting cylinder - double acting
Cylinder bore X stroke (mm) 2 - 85 X 60 2 - 85 X 60 2 - 85 X 60
Normal max. pressure (kg/cm*) 8.5 8.5 8.5
Normal max. speed (rpm) 2,100 2,100 2,100
250 (rpm) - - -
500 (rpm) 340 340 340
600 (rpm) 408 408 408
Discharge
800 (rpm) 544 544 544
(Urnin)
1,000 (rpm) 680 680 680
1,500 (rpm) 1,020 1,020 1,020

r
1 2,000 (rpm) 1,360 1,360 1,360
SA8V170- 1 SA8V170-1 SA8V170-1

l WA800-1 l WA800-1 0 HD785
(Application (Application . WA800-1
Serial No. Serial No.
10246-I 0292) 10294- ) SAI 2V170-1
l HD785-2 l HD785-2 l HD1200-1
(Application (Application
Application !?lC!Ck?iS
Seriai No. Serial No.
10182-I 0230) 10231-J
SA12V170-1 SA12V170-1
l HD1200-1 l HDI 200-I
(Application (Application
Serial No. Serial No.
10004-10009) lOOlO-)
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l 6210-81-3121
1. Cylinder head 7. Crankcase a. Air intake

2. Piston 8. Roller bearing b. Cooling water inlet
3. Piston ring 9. Crankshaft c. Cooling water outlet
4. Piston pin 10. Flange d. Lube oil inlet
5. Connecting rod 11. Ball bearing
6. Cylinder 12. Cover
1 l-004
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AIRCOO
STRUCTURAL FEATURES OF AIR COMPRESSORS
Crankshaft
bearing support
connection
Ball E%Y:’
Separ- Integrat- Split Injection Feed Roller
part number \ 1d” ate type ed type bearing pump pump bearing bearing
6215-81-3201 I I e I I 0 I 0 I 1
*: One sliding bearing
2. Cylinder 5. Piston
l The bottom of cylinder (7) mates with * Two piston rings (6) are installed to the
crackcase (12), and is installed with four top of piston (4), and one oil ring (5) is
bolts. installed to he bottom. To allow for heat
expansion when the piston is operating,
3. Crankcase the outside diameter at the top is smaller
l Crankcase (12) has holes in the side surface than at the bottom, or it forms an oval
for installing the compressor, and has shape.
mounting holes for the oil supply joint. It
has an overflow to allow any excess oil to 6. Connecting rod
flow to the engine crankcase. The face with l There are two types of big end for con-
the holes is put against the appropriate face necting rod (3): a separate type and an
of the timing gear case when installing the integrated type.
compressor. Adjustment of tightening cannot be carried
out using shims, so if there is wear, the
4. Crankshaft connecting rod must be replaced. When
l Crankshaft (2) forms one piece with the assembling the separate type, the match
balance weight. It is supported by two mark is given as a line on the side face.
bearings (I), and at one end it is connected * A steel bushing is used for the small
by taper shaft to the gear. Depending on end of 6165-91-I 005.
the model, it is connected to the injection
pump or feed pump. 7. Lubrication
* 6165-91-1005 lEngine oil is used as the lubricant. The oil
This is supported by one ball bearing and force-fed from the engine to the oil suplly
one sliding bearing: one end is con- joint in the side face of the crankcase is
nected by a taper shaft to the gear, and splashed up by the balance weight of the
the other end is connected to the feed crankshaft and the big end of the connect-
Pump. ing rod, and flows out through the overflow
hole at the engine end.
1 l-009
co
FUNCTION
This equipment is driven by the engine gear, l When the air pressure inside the air tank goes
and is directly connected to the engine, so the below the specified pressure of the air
air compressor is always rotating when the governor, the rod of unloader valve (9) returns
engine is rotating. to its original position, inlet valve (10) starts
its normal operation again, and air is force-
The inlet valve and delivery valve are auto- fed again.
matically opened and closed by the pressure * 6165-91-I 001, 6162-83-6700,
inside the cylinder. On the piston up-stroke, 621 O-81 -3121
the air inside the cylinder is compressed, inlet When the air pressure inside the air tank
valve (10) closes, and delivery valve (11) opens goes below the specified pressure of the
to discharge the compressed air. air governor, the rod of unloader valve (9)
On the down-stroke, the delivery valve closes, returns to its original position, the intake
and the inlet valve opens to suck in air from hole is opened, and air is force-fed again.
the air cleaner. * 6165-91-1004,6215-81-3101,
6165-91-1005,6215-81-3201
There is an air governor to control the amount When the air pressure inside the air tank
of air inside the air tank. When the air pressure goes below the specified pressure of the
inside the air tank reaches the specifierd air governor, unloader valve (9) and the
pressure, the compressed air inside the tank exhaust valve return to their original
passes through the air governor, pushes down position, and air is force-fed again.
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
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 com-
pressed 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 com-
pressed 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
Operation of unloader valve
0 6151-81-3110
Air pressure from

aIt- governor
Intake
Intake
Port 0
port
When intake valve is actuated When intake valve is open
8
l 6210-81-3111
E
3
Air pressure from

air governor
intake Intake
port L I
port
When intake valve is actuated When intake valve is open
11-011
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AIRCOO
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After disassembly, inspection, and assembly, carry out the airtightness test and performance test
as follows.
Division I 1) Testing airtightness I 2) Charging performance
Test method Apply air pressure of 7 k /Cm* Time taken to charge tank pressure of tank with capacity
at the same time to the c?IS- of 35 liters from 0 to 7 kg/cm*
charge port and unloader valve,
and measure the amount of
leakage from the air intake port.
Standard for leakage Rotating speed (rpm) Charging time (set)
6206-91-l 100 450 cc/min max. 1,100 158 max.
6136-81-3112 450 cc/min max. 1,100 158 max.
6138-81-3111 450 cc/min max. 1,100 158 max.
6136-81-3120* 100 cc/min max. 250/I ,500 260 maxY45.5 max.
6151-81-3110~ 450 cc/min max. 250/l ,500 220 max./40 max.
6151-81-3140* 100 cc/min max. 500/l ,500 145 max./60 max.
621 O-81 -3111 j, 100 cc/min max. 500/l ,500 145 max./60 max.
6210-81-3121 * “I 100 cc/min max. 500/l ,500 145 max./60 max.
6162-83-6700 100 cc/min max. 500/l ,500 145 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

98 max.138 max. 8
500/l ,500 198 max./83 max. z
6215-81-3101 * 1500 cc/min max.
6215-81-3201 * 1500 cc/min max. 500/l ,500 198 max./83 max. 3
*: Time taken to charge tank pressure of tank with capacity of 30 liters from 0 to 8 kg/cm*
*? Air tightness test
lWhen 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.
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
13 DISASSEMBLY AND ASSEMBLY
Tightening torque . . . . . . . _. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-002
Disassembly and assembly

6206-91-l 100 ...... (S)6D95L-1
6136-8i -3112 ...... S6D105-1 5 Series
. . . . . . . . . . . . . . . . . 13-006
6138-81-3111 ...... S(A)GDl IO-1
1
6151-&i -31 i 0 ...... (SA)GDI 25-l ,J
6136-81-3120 ...... S6D105-1, S6Dll O-l

6151-81-3140 ...... S6D125-1
6210-81-3111 ...... S6D140-1 Series . .
6210-81-3121 ...... S6D140-1, SAGD140-1
6162-83-6700 ...... S6D170-1 1
6162-83-6600 ...... S6Dl70-1 ’

6162-83-6800 ...... S6D170-1
Series
6215-81-3101 ...... SAl2V140-1
6215-81-3201 ...... SA12V140-1
6165-91-1001 ...... SA8V170-1, SA12V170-1

6165-91-1004.. .... SA8V170-1, SAI 2V170-1 Series . . . . . . . 13-018
6165-91-1005 ...... SA8V170-1, SAI 2V170-1 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
Inlet valve guide @ 12 + 1.2 12+ 1.2 12+ 1.2 lo+1 lo+1
Delivery valve body @ 105 1 10.1 lOAIl - -
Delivery valve seat @ - - - lo+1 15 X!I 1.5
Unloader valve 04 5 + 0.5 5 XII 0.5 5 + 0.5 5 + 0.5 5 + 0.5
Bearing cover
mounting bolt 05 2.75 f 0.25 0.6 + 0.06 0.6 + 0.06 2.75 + 0.25 2.75 + 0.25
Connectin rod
mounting 1 olt 8 2.5 I+I 0.25 2.5 + 0.25 2.5 f 0.25 2.5 AI 0.25 2.5 + 0.25
0&nder 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 mounting - -
bolt @ 1.5 +0.15 0.6 AI 0.06 0.6 + 0.06
Exhaust valve bracket

mounting bolt 0,o - - - - -
Exhaust valve cap 0 - - - -
Plate mounting bolt @ - - - - -
013
Delivery valve - - - - -
mounting bolt 8
Inlet valve seat

mounting bolt 0,4 _ - - - - 2
,8
i l-
5,
650ACF039 650ACF040 650ACF041
General drawing General drawing
6206-91-l 100 6206-91-l 100 6151-81-3110
13-002
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SL’OT 9’1 91’0 f 9’1 91’0 f 9’1 91’0 f 9’1 91’0 + 9’1 0 1pq 6ugunoLu aIeld
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P’O T P P’O f P 0O1 lay3eJq arilfa vineyxj
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E’O f E E’O f E E’O f E c-0 f & 0L
- 09 1108 Gu!lunow
SZ’O f S’Z SZ’O + S’Z SZ’O f S’Z POJ U!lXHJUO~
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AIRCOO
1. Cylinder head 6. Delivery valve assembly
1) Remove cylinder head mounting bolts 1) Remove delivery valve body (12) from top
(31). of cylinder head.
2) Tap cylinder head (11) with a plastic
hammer from below to remove it.
3) Remove gasket installed between cylinder Air pressuje from
(20) and cylinder head (11). air governor 1 Air discharge
/ port
2. Cylinder, connecting rod, piston

1) Remove cylinder mounting bolts (33), then
Air intake
remove cylinder (20) from crankcase (21). 0
port
2) Remove 2 nuts (34) installing big end of
connecting rod (27).
3) Remove piston (30) and connecting rod
(27) from crankcase (21).
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).
2) If thread portion where delivery valve seat
3. Bearing cover (7) is screwed in and installed to bottom
I) Remove 4 mounting bolts (22) mounting of cylinder head is caulked, remove
bearing cover to crankcase (21), then caulking before removing parts.
remove together with oil seal (23) from 3) Remove delivery valve seat (7), then
crankcase (21). remove delivery valve spring (3), delivery
2) Remove oil seal (23) from bearing cover valve (6), gaskets (5) and (4), and delivery
(26). valve guide (8) from inside delivery valve
seat.
4. Crankshaft
1) Pull out crankshaft (24) in direction of 7. Inlet valve assembly
bearing cover (26), with 2 ball bearings 1) If thread portion where inlet valve guide
(25) still fitted. (1) is screwed in and installed to bottom
2) Using a hand press, remove ball bearings of cylinder head (11) is caulked, remove
(25) from crankshaft (24). caulking before removing parts.
2) Remove inlet valve guide (I), then remove
5. Unloader valve assembly inlet valve spring (2), inlet valve (3), and
1) Remove unloader valve body (10) from top inlet valve seat (4) at the same time.
of cylinder head.
2) Remove snap ring (5) from inside unloader
valve body (IO), then pull out washer (6),
unloader valve spring (7), and rod (9).
13-007
a
ASSEMBLY
6206-91-I 100 1 l 6151-81-3110
6136-81-3112
Series Air pressure from
6138-81-3111 air governor 1 Air discharge 2
6151-81-3110 J 0 / port
A /
l Clean all parts, check for dirt or damage, and

blow with air to dry. Coat the sliding surfaces Air intake
port 0
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 head
(1 I), then fit inlet valve (3) and inlet valve 650ACF048
spring (2), and temporarily tighten inlet
valve guide (1). 1 1 Assemble delivery valve spring (3) to
* Check that inlet valve (3), and inlet valve cylinder head (l), then put delivery valve
spring (2) move smoothly. (6) on top of it.
* If inlet valve guide (1) is protruding from 2) Put gasket (4), delivery valve guide (8), and
the bottom surface of cylinder head (1 I), gasket (5) in position, then temporarily
there is danger that it will interfere with tighten delivery valve seat (7).
the top surface of the piston, so check that * Check that delivery valve (6) moves
it is not protruding. smoothly, then tighten delivery valve seat
* Do not carry out punch caulking on 6151- (7) to the specified tightening torque.
81-3110. m Delivery valve seat thread:
8
& Inlet valve guide thread: Thread tightener (Three Bond
g
Thread tightener (Three Bond 1360) 3
1360) K& Delivery valve seat:
~--LFI Inlet valve guide: See Tightening Torques and
See Tightening Torques and Standard Values Table
Standard Values Table * Check that the seat does not protrude from
the bottom of the cylinder head.
2. Delivery valve assembly
6206-91-I
l 000 3. Unloader valve assembly
6136-81-3112
l
1) Assemble O-ring (8) to rod (9), then intall
6138-81-3111
l inside unloader valve body (10).
Insert gasket into cylinder head (11).
& Sliding surface:
& Delivery valve thread: Molybdenum disulphide grease
Thread tightener (Dow Corning Coorporation
(Three Bond 1360) [MOLYCOTE 44M])
m Inlet valve guide: 2) Insert unloader valve spring (7) and
See Tightening Torques and washer (6), then secure with snap ring
,_*
Standard Values Table (51.
3) Tighten unloader valve body (10) to
cylinder head (11).
m Unloader valve assembly:
See Tightening Torques and
Standard Values Table
* Push rod (9) with a bar, and check the
movement of inlet valve (3).
13-008
0
4. Crankshaft & Crankshaft pin:
1) Using a press, press fit ball bearing (25) Coat with engine oil
to crankshaft (24).
& Cap mounting bolt:
a Oil seal sliding poriton: Coat with engine oil
Coat with engine oil
D Cap mounting bolt:
2) Insert crankshft (24) from bearing cover
(26) end of crankcase (21).
5) Compress piston rings (18) and oil ring
5. Bearing cover
(19), then assemble cylinder (20) to
1) Press fit oil seal (23) to bearing cover (26).
crankcase (21), and tighten with mounting
e, Press-fitting portion of oil seal: bolts.
Adhesive (Loctite hydraulic
m- Whole inside surface at bottom of
seaiant)
cylinder: Coat with engine oil
* Applicable compressors
A Mating surface of cylinder and crank-
6136-81-3112, 6138-81-3111
case: Gasket sealant (LG-4)
2) Press fit bearing cover (26) to ball bearing,
* Applicable compressor
then tighten with mounting bolts (22).
6136-81-3112, 6138-81-3111
/c(l_7L, Mating surface of cover and case:
* For 6206-91-1100 and 6151-81-3110,
Gasket sealant (LG-4)
insert and O-ring in the cylinder skirt.
It Applicable compressors
m Cylinder mounting bolt:
6136-8l-3112,6138-81-3111
* For 6826-91 _11CC and 6J5j_8j_31’jC, See Tightening Torques and
insert an O-ring in the bearing cover, then
install.
7. Cylinder head
w Bearing cover mounting bolt:
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
6. Cylinder, connecting rod, piston
the specified torque.
i) Align piston pin hole and hole at small
m Cylinder head mounting bolt:
end of connecting rod (27), then push in
piston pin (28), and secure both-ends with
snap rings (29).
fln3 Piston pin: Coat with engine oil
2) Install oil ring (19) and piston ring (18).
jt Assemble piston rings (18) with the
stamped ring surface 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 (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, S6Dll O-l
6151-81-3140 ....... S6D125-1
6210-81-3111 ....... S6D140-1 Series
6210-81-3121 ....... S6D140-1, SAGD140-1
6162-83-6700 ....... S6D170-1
. Before disassembly the air compressor, clean it and check from the otitside for damage or leakage
of oil from the mating surfaces.
l When disassembling the cylinder head, connecting rod, and piston, remove from the engine,
then disassemble.
650ACF050
13-010
0
1. Cylinder head 5. Unloader valve assembly
1) Remove cylinder head mounting bolts 1) Remove unloader valve body (8) from top
(20). of cylinder head (11).
2) Tap cylinder head (11) with a plastic 2) Remove rod (7) and O-ring from inside
hammer from below to remove it. unloader valve body (8).
3) Remove gasket installed between cylinder * The unloader valve of 6210-81-3121
(23) and cylinder head (11). and 6162-83-6700 cannot be disas-
sembled.
2. Cylinder, piston, piston ring
11 Remove cylinder mounting bolts (18), then 6. Delivery valve assembly
remove cylinder (23). 1) Remove delivery valve seat (17), then
2) Remove snap rings (33) from piston pin remove delivery valve (16), delivery valve
hoies, then pull out piston pin (32j and spring (15), O-ring (4 3), spring guide (I Oj,
remove piston (34). and O-ring (12).
3) Using a tool, remove 2 piston rings (21)
and oil ring (22) from piston (34). 7. Inlet valve assembly
1) Remove inlet valve guide (I),then remove
3. Bearing cover, crankshaft inlet valve spring (2), inlet valve (3), inlet
1) Remove mounting bolts (25) from bearing valve seat (4), gasket (9), and unloader
cover. valve spring (5).
2) Tap tip of crankshaft (26) with a wooden
hammer, and remove bearing
partiaiiy
cover (27).
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 crank-
shaft (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
6136-81-3120 3. Unloader valve assembly
6151-81-3140 1) Assemble O-ring (6) to rod (7), then install
6210-81-3111 Series inside unloader valve body (8).
621 O-81 -3121 a sliding surface:
6162-83-6700 I Molybdenum disulphide grease
(Dow Corning Corporation
l Clean all parts, check for dirt or damage, and [MOLYCOTE 44M])
blow with air to dry. Coat the sliding surfaces 2) Insert so that rod (7) enters unloader valve
and press-fitting portions of all parts with spring (5), then tighten unloader valve
clean engine oil before installing. body (8).
* For 621 O-81 -3121 and 6162-83-6700,
I. Inlet valve assembly install the unloader valve to the
1) Assemble unloader valve spring (5), cylinder head.
gasket (9), inlet valve seat (4), inlet valve
w Unloader valve body:
(3), and inlet valve spring (2) to cylinder
head (1 I), then tighten inlet valve guide
(1).
* Check that inlet valve (3) moves
4. Flange
smoothly.
Fit O-ring to crankcase (31), then assemble
* Check that inlet valve guide (1) is below
flange (29), and tighten with mounting bolts.
the surface of cylinder head (1 I).
ra Bolt thread: Thread tightener (Three
/cm=-; Inlet valve guide thread:
Bond 1360)
Thread tightener (Three Bond
5~ Mounting bolt:
1360)
See Tightening Torques and 8
m Inlet valve guide: :
Standard Values Table.
See Tightening Torques and 3
5. Bearing cover, crankshaft
1) Press fit outer race of roller bearing (30)
2. Delivery va!ve assembly
to crankcase (31), and inner race to
1) Fit O-ring (12) to spring guide (IO), then crankshaft (26) so that both clearances
install to cylinder head (II).
are 0.
2) Install O-ring (13) and delivery valve
2) Insert crankshaft (26) into crankcase (31),
spring (15).
insert big end of connecting rod (24) from
3) Put delivery valve (16) on top of delivery cylinder mating portion, then push in
valve spring (15), then tighten delivery
crankshaft.
valve seat (17).
-Crankshaft pin: Coat with engine oil
* Check that delivery valve (16) moves
smoothly. 3) Press fit ball bearing (28) to crankshaft (26)
* Check that delivery valve seat (17) is with a press.
below the surface of cylinder head (II). 4) Fit O-ring, then press fit bearing cover (27)
to ball bearing, and tighten with mounting
a Thread of delivery valve seat (15):
bolts (25).
1360) w Bearing cover mounting bolt (25):
m Delivery valve seat:
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
13-012
0
003kllV
DISASSEMBLY
6162-83-6600 . . . . . . . S6D 170- 1

1
6162-83-6800 . . . . . . . S6D170-1
Series
6215-81-3101 . . . . . . . SA12V140-1
6215-81-3201 . . . . . . . SAI 2V140-1 1
Before disassembly the air compressor, clean it and check from the outside for damage or leakage
of oil from the mating surfaces.
When disassembling the cylinder head, connecting rod, and piston, remove from the engine,
then disassemble.
Air pressure
from air Air discharge
4, 6
Air intak
Port
/ / A-i \ B-i \
1 9 6 7
Section B-B
36 i2
Section A-A
16 j5 ‘14 i3
650ACF051
” \ LI
- 26
28
650ACF05i F
13-014
0
1. Cylinder head 5. Plate
I ) Remove cylinder head mounting bolts (40) 1) Remove hexagon socket head screws (18)
and (41). installed from top of cylinder head.
2) Tap cylinder head (6) with a plastic * Do not remove blind plug (37) of the
hammer from below to remove it. water passage in the top surface of
3) Remove gasket (34) installed between plate (8).
cylinder (32) and cylinder head (6). 2) Remove mounting bolts (39) of plate (38)
of water passage in side surface of plate
2. Cylinder, piston, piston ring (8), then remove plate.
1) Remove cylinder mounting bolts(33), then
remove cylinder (32) from crankcase (30). 6. Inlet valve assembly
2) Remove snap rings (21) from piston pin 11 When cylinder head (6) and plate are
holes, then pull out piston pin (22) and . V.,
removed, inlet valve (l6), inlet valve
remove piston (23). spring (14), and washer (15) can be
3) Using a tool, remove 2 piston rings (19) removed.
and oil ring (20) from piston (23). 2) Remove bolt (40) installed from top of
cylinder head (6) then remove inlet valve
3. Bearing cover, crankshaft seat (17).
Remove oil feed pipe (26) secured to
bearing cover (25) and flange (31). 7. Delivery valve assembly
* Applicable compressor 1) Remove hexagon socket head screws (36)
6162-83-6600, 6162-83-6800 installed in intermediate plate, then
21 Remove mounting bolts (24) from bearing remove stopper (1 I), delivery valve (12),
cover (25). and delivery valve guide (10).
3j Tap tip of crankshaft (28) with a plastic * The bushing assembled to the dis-
hammer, and partially remove crankshaft charge port in the cylinder head is
8 and bearing cover (25). coated with adhesive and press fitted.
E
4) From the place where cylinder (32) mates This bushing forms the cooling water
3
with crankcase (30) hold crankshaft (28) passage and cannot be removed.
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
6) Remove connecting rod (42) from crank-
shaft (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.
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
6162-83-6600 from air
Air discharge
6162-83-6800 4, 5, wvepr Port
Series
8215-81-3101
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.
/ /A--/ \ B-l \
1 9 8 7
1) Install delivery valve (12), delivery valve Section R-B
guide (10) and stopper (1 I), then tighten
with hexagon socket head screws (36). 36 10 il j2
* Be careful not to let the delivery valve
and delivery valve guide (10) overlap.
a Thread: Thread tightener (Three Bond
Section A-A
1360)
* Be careful not to get the thread 1: 16 i5 ‘14 i3
tightener on the delivery valve. 650ACF05 1
m Hexagon socket head screw (36):

See tightening Torques and
2. Inlet valve assembly

1) Assemble inlet valve seat (17) to cylinder
head (6), then tighten mounting bolt (40).
& Thread and washer:
1360)
sm Mounting bolt (40):
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). 650ACF052
* Push inlet valve plate (I 6) from the
unloader valve end to check the
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
& Thread and seat: c= Bearing cover mounting bolt (24):
Thread tightener (Three Bond See Tightening Torques and
1360) Standard Values Table
w Hexagon socket head screw (18): 6) Push tip of crankshaft with a hand press,
See Tightening Torques and and make a clearance at roller bearing.
Standard Values Table 7) Install oil feed pipe (26) secured to bearing
cover (25) and flange (31).
1) Assemble O-ring (3) to rod (4), insert 6. Cylinder, piston, piston pin
unloader valve spring (2) and washer (9), 1) Align piston pin hole and hole at small
then install snap ring (1). end of connecting rod (42), then push in
a Sliding surface: piston pin (22), and secure both ends with
Molybdenum disulphide grease snap rings (21 j.
(Dow Corning Corporation a Piston pin: Coat with engine oil
[MOLYCOTE 44M]) 2) Install oil ring (20) and piston rings (19)
2) Install unloader valve body (5) to cylinder to piston (23).
head (6) * Assemble piston rings (19) with the
a Thread of unloader valve body: stamped ring surface facing up, and
Thread tightener (Three Bond make sure that the end gaps of the rings
1360) are in different places.
cm Unloader valve: * There is no top or bottom to oil ring
See Tightening Torques and (20).
Standard Values Table 3) Fit O-ring to cylinder (32), then with piston
ring (19) press fitted, assemble cylinder
5. ‘Bearing cover, crankshaft to crankcase (30), and tighten with
1) Fit O-ring to crankcase (30), then assem- mounting bolts (33).
ble flange (3l), and tighten with mounting fid Whole inside surface at bottom of
bolts. cylinder: Coat with engine oil
&?&I Mounting bolt thread: QKI Cylinder mounting bolt:
Thread tightener (Three Bond See Tightening Torques and
1360) Standard Values Table
m Flange mounting bolt (31):
See Tightening Torques and 7. Cylinder head
Standard Values Table 1) Fit gasket to top surface of cylinder (32).
2) Press fit outer race of roller bearing (29) 2) Assemble cylinder head (6) to cylinder
to crankcase (30), and inner race of (32), then tighten with mounting bolts
crankshaft (28) so that both clearance are (41).
0. * Tighten the bolts slowly and uniformly
3) Insert crankshaft (28) into crankcase (30), to the specified torque.
insert big end of connecting rod (42) from m Cylinder head mounting bolt:
cylinder mating portion, then push in See Tightening Torques and
crankshaft. Standard Values Table
e-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).
AIRCOO
1. Cylinder head 5. Plate
1) Remove cylinder head mounting bolts 1) Remove hexagon socket head screws (2)
(30). installed from top of cylinder head, and
2) Tap cylinder head (1) with a plastic disassemble cylinder head (1) and plate
hammer from below to remove it. (IO).
3) Remove gasket (32) installed between * Do not remove blind plug (49) of the
cylinder (31) and cylinder head (1). water passage in the top surface of
plate (10).
2. Cylinder, piston, connceting rod * Link (20) forms the water passage for
1) Remove cylinder mounting bolts(48), then the cylinder head, so do not remove it.
remove cylinder (31) from crankcase (37). 2) Remove mounting bolts of plate (22) of
2) Remove mounting bolts at big end of water passage in side surface of plate (lo),
connecting rod (42), then remove piston then remove piate.
(43) and connecting rod from crankcase
(37). 6. Inlet valve assembly
3) Remove snap rings (44) from piston pin 1) When cylinder head (1) and plate (10) are
holes, then pull out piston pin (45) and removed, inlet valve (14), inlet valve
remove piston (43). spring (15), and washer (16) can be
4) Using a tool, remove 2 piston rings (46) removed.
and oil ring (47) from piston (43). 2) Remove bolt (3) installed from top of
cylinder head (I), then remove inlet valve
3. Bearing cover, crankshaft seat (I?).
1) Remove mounting bolts (36) of bearing
cover (35). 7. Delivery valve assembly
2) Pull out bearing cover (35) and crankshaft 1) Remove hexagon socket head screws (19)
(39). installed in plate (IO), then remove
8
6165-91-100-l stopper (12), delivery valve (1 I), and
:
3 6165-91-1004 delivery valve guide (18).
Tap the tip of the crankshaft at the flange
end with a plastic hammer to remove the 8. Exhaust valve
crankshaft. 1) Remove cap (53) tightened from below
3) Remove mounting bolts (33) of coupling exhaust valve (50), then pull out rod (51),
(34) at bearing cover end, then remove spring (54), and O-rings (52) and (55).
coupling. * Applicable compressors
4) Using a hand press, remove bearing cover 6151-91-1004, 6165-91-1005
5) Using a hand press, remove ball bearing

1) Remove unloader valve body (4) from top
of cylinder head (1).
a Remove snap ring (9) inside body, then
pull out O-ring (6), rod (5), washer (8) and
unloader valve spring (7).
6165-91-1001
* Do not disassemble the unloader valve
assembly.
13-019
cc
ASSEMBLY
6165-91-1001 * Push inlet valve (14) from the unloader
6165-91-1004 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 surface of the plate.
blow with air to dry. Coat the sliding surfaces & Thread and seat:
and press-fitting portions of all parts with Thread tightener (Three Bond
clean engine oil before installing. 1360)
m Hexagon socket head screw (2):
. * Exhaust valve
1) Assemble O-rings (52) and (55), and
spring (54) to rod (51), then tighten cap
(53).
& Slinding surface of rod:
1) Assemble O-ring (6) to rod (5), insert
Grease (NOK Kluever
unloader valve spring (7) and washer (8),
[BARRIERTA JFE5221)
then install snap ring (9).
m Cap (53): See Tightening Torques and
#& Sliding surface:
Grease (NOK Klueber [BAR-
* Applicable compressors
RIERTA JFE5221)
6165-91-1004, 6165-91-1005
2) Install unloader valve assembly (4) to
cylinder head (I ).
cm Unloader valve assembly:
1) Install delivery valve guide (18), delivery
valve (1 1) and stopper (12) then tighten
Standard Values Table 8
with hexagon socket head screws (19).
$
* Be careful not to let the delivery valve
6. Bearing cover, crankshaft 3
and delivery valve guide (18) overlap.
1) Press fit ball bearing (38) to crankshaft
ax1 Thread: Thread tightener (Three (39) with a press.
Bond ? 360) * Only at bearing cover end on 6165-
* Be careful not to get the thread 91-1005.
tightener on the delivery valve plate.
a Press fit ball bearing (38) in bearing cover
CZZZl Hexagon socket head screw (19): (35) with a press, the assemble O-ring to
See Tightening Torques and bearing cover pilot.
Standard Values Table 3) Assemble coupling (34) at bearing cover
(35) end, and tighten mounting bolts (33).
3. Inlet valve assembly 4) Assemble flange (40) to crankcase (37),
1) Assemble inlet valve seat (17) to cylinder and tighten with mounting bolts (41).
head (I), then tighten mounting bolts (3). 5) Insert crankshaft (39) from bearing cover
&-L Thread: Thread tightener (Three Bond (35) end of crankcase, adjust bearing cover
1360) so that it is properly centered, then tighten
with mounting bolts (36).
m Mounting bolt (3):
See Tightening Torques and a Crankshaft pin: Coat with engine oil
Standard Values Table (Front journal on 6165-81-I 005)
* When installing the bearing cover,
4. Plate check that the O-ring is fitted properly.
1) Insert washer (16), inlet valve spring (15), * With 6151-91-1005, fix the washer to
and inlet valve (14) to plate (IO), then the flange with grease.
assemble gasket (13), and tighten with
hexagon socket head screws (2).
13-020
0
& Bearing cover flange mounting bolt: * Tighten the bolts slowly and uniformly
See Tightening Torques and to the specified torque.
Standard Values Table %B Cylinder head mounting bolt:
7. Cylinder, piston, connecting rod Standard Values Table
1) Install oil ring (47) and piston rings (46) 6165-91-1004
to piston (43). 6165-91-I 005
* Assemble piston rings (46) with the Install exhaust valve mounting bracket
stamped ring surface facing up, and (58) at the same time.
make sure that the end gaps of the
rings are in different places. 9. Exhaust valve assembly
* There is no top or bottom to oil ring 1) Tighten mounting bolts (56) of exhaust
(47). valve assembly (50).
2) Align piston pin hole and hole at small
m Mounting bolt:
end of connecting rod (42), then push in
piston pin (45), and secure both ends with
snap rings (44).
& 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 rod are aligned.
&Crankshaft pin: Coat with engine oil
& Cap mounting bolt:
Coat with engine oil
s- Connecting rod mounting bolt:
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).
‘53
fi Whole inside surface at bottom of
650ACF055
cylinder: Coat with engine oil
m Cylinder mounting bolt:
6165-91-I 004
6165-91-1005
Install exhaust valve mounting bracket
(57) at the same time.
8. Cylinder head
1) Fit gasket (32) to top surface of cylinder
(31).
2) Assemble cylinder head (1) to cylinder
(31), then tighten 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 005 Unit: mm
No items Criteria qemedy
Clearance between cylinder Standard size Standard clearance Clearance limit Replace
and piston (Measure the out- piston
1 or cyl-
side diameter of the piston 0.25
at the skirt) 85 0.070 - 0.120
inder
Piston Replace
Clearance between 2 0.020 - 0.050 0.15
ring piston
piston ring and ring or pis-
groove Oil ring 4 0.030 - 0.070 0.20 fnn
.“.I ripn‘3
.I
Piston
Clearance between - 0.1 - 0.30 0.6
ring
piston ring open- Replace
nings Oil ring - 0.15 - 0.35 0.7
Clearance between piston Replace

pin and piston 16 0.006 - 0.026 0.5 piston or
piston pin
Replace
Clearance between piston pin 0.5 connect-
and connecting rod small end 16 0.006 - 0.026
ing rod
Replace
Clearance between crankpin 0.034 0.075 0.15 connect-
and connecting rod big end 35 -
ing rod
Replace
Clearance between front journal 0.095 0.2 crankshaft
and flange inner diameter 45 0.009 -
or flange
Replace
End play of crankshaft - 0.1 - 0.74 0.9 crankshaft
or flange
I
Drive spline connector: 30 - 35 kgm
Air inlet port

8 I!I 0.8 kgm
connector:
Air discharge port

8 f 0.8 kgm
connector: I
Unloader port 3 I!I 0.3 kgm Retighten
8
connector:
Cooling water port

3 f 0.3 kgm
connector:
Exhaust valve
3 f 0.3 kgm
connector:
Air compressor mount-
5 I!I 0.5 kgm
ing bolt: I
14-005
m
w
PARTS INSPECTION AND JUDGEMENT STANDARD
l Be careful not to damage disassembled parts. Wash them in diesel oil, then blow with air to
dry. Check visually particularly for the following points.
Part Check point Part Check point
Cylinder 0 Scuffing, wear, seizure of Bearing cover and 0 Scratches, degree of

sliding surface flange, oil seal roughness of sliding
Scratches on head surface
6i3
l
0
0
0 mounting surface l Scratches, dents on O-

0
l Scratches, dents on ring contact surface

cl
0
O-ring contact surface
0
Piston and piston rings Scuffing, wear, seizure of

sliding surface
Scratches, dents in ring
groove
Inlet valve, delivery l Scratches, wear of valve
Degree of ring contact va Ive plate
width
B Scratches, wear of valve
seat
l Settling of valve spring
Connecting rod l Scratches, cracks, dents

l Scuffing, wear, seizure of 8
sliding surface 2
a
Unloader valve Scratches, dents, wear
on sliding surface of rod
Settling of valve spring
Crankshaft * Scuffing, scratches,
wear, discoloration, dents
in rotating parts
l Scratches on oil seal con-
tact surface
14-006
0
JUDGEMENT STANDARDS FOR REUSE
Judgement category for reuse

Part
Position of damage
Name
B. Can be repaired and C: Cannot be used again
A: Can be used as it is
’ used again
-
No scuffing, wear, - Scuffing, wear,

1 l Sliding surface seizure
seizure
-
l Head mounting -
2 No scratches or dents Scratches or dents
surface
- I
l Sliding surface of No scuffing, wear, - Scuffing, wear,

1 seizure
piston seizure
-
2 l Piston ring groove No scratches or dents - Scratches or dents
No scratches or dents - Scratches or dents
3
* Piston ring SllLdlll~
1;,4;n,
surface
- Contact width other
Normal contact
than A
-
l Overall external No scratches, cracks, - Scratches, cracks,

1 dents
appearance dents
-
No scratches - Scratches
1 l Journal portion
No discoloration - Discoloration
-
Scratches, dents that
l O-ring contact Scratches or dents
1 No scratches or dents can be easily removed
surface other than A or B
with an oil stone
-
l Oil seal sliding No scratches, rough- -

2 Scratches, roughness
surface ness
-
1 l Valve seat Slight scratches, wear - Scratches, wear
2 l Valve plate Slight scratches, wear - Scratches, wear
-
Scratches, wear set-
No scratches, wear, tling If valve spring is
3 * Valve spring -
settling broken, replace cylinder
head assembly
-
14-007
co
Head
Unloader valve
gasket
A
w h,
.
?
I!.
ca
AIRCOO
PERIODIC INSPECTION
Carry out the following maintena nce every 4000

hours.
1. Discharge air piping (between air compres- 2. Air compressor

sor and wet tank) Remove the head, and carry out the follow-
Remove the discharge air piping and do as ing maintenance.
the follows. 1) If there are no deep vertical scratches in
1) If the thickness of the carbon collected the cylinder, and carbon is stuck to the
on the inside surface is more than 1.5 top surface of the piston, remove the
mm (see diagram below), blow com- carbon from the top surface of the piston.
pressed air into the pipe to clean it. If the Do not use a sharp tool to do this.
carbon cannot be removed, replace the When doing this, be careful not to let the
pipe. If cleaning agent KO: Part No. 600- carbon go through the gap between the
41 l-3310 (for oil cooler element oil piston and the cylinder.
circuit) is available, it can be used to clean * If there are deep vertical scratches in
out the carbon. (For details of use, see the cylinder which catch the fingernail,
the instructions.) replace the cylinder, piston, and piston
Carbon tends to stick to restricting ring kit.
portions such as joints and check valves, 2) If there is carbon stuck to the bottom
so check these parts particularly carefully. surface of the head, or the air intake and
discharge holes, remove it with a screw-
driver, and blow with compressed air to
clean it.
3) If there is carbon stuck to the delivery
inside piping
valve, intake valve, seat, guide, and
spring, remove it with a screwdriver, and
mm, the pipe
rep1 aced. blow with compressed air to clean it.
4) If there is carbon stuck to the unloader
6206F913 valve and spring, remove it with a
screwdriver, and blow with compressed
air to clean it.
2) If there is carbon stuck to the connecting
(If the O-ring is worn, replace the unloader
joints, remove it with a screwdriver, and
valve assembly.)
blow with compressed air to clean it.
* When removing the valve with a
3) If there is carbon stuck to the inside of
screwdriver, be careful not to damage
the check valve installed between the air
the machined surface.
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.)
1d-009
3
II P
2 4
II)
a ii
/
e
0
0
0
F
0
W
El t
-I
W
co
a a
I P
3
LL k ii
OOddM
CONTENTS
No. of page
01 GENERAL ...............................................................~.......~........................
0%001
11 STRUCTURE AND FUNCTION ...................................................

11-001
12 TESTING AND ADJUSTING ........................................................

12-001
13 DISASSEMBLY AND ASSEMBLY 13-001

.............................................
14 MAINTENANCE STANDARD .......................................................

14-001
15 OTHERS ...................................................................................................
15-001
00-002
’ :
* .
: :
: *
. *
- :
: :
* .
OOddH
FUEL INJECTION SYSTEM OUTLINE
Fig. 1 Fuel injection pump system
Fig. 1 shows a diesel fuel injection pump sys- pump through the injection pipe to the nozzle
tem. holder, to be injected into the engine combus-
Engine rotation is transmitted to the injection tion chamber.
pump camshaft by a coupling or drive gear.
Because the quantity of fuel oil delivered by
The supply pump, driven by the camshaft, the supply pump is at least twice the max-
sucks fuel oil from the fuel oil tank and sup- imum injection quantity of the injection pump,
plies it to the fuel oil filter at a pressure of an overflow valve is installed to return excess
approximately 1.8-2.5 kg/cm*. Filtered fuel oil fuel oil to the fuel oil tank when the fuel oil
is then sent to the fuel oil chamber in the pressure exceeds a set value.
injection pump housing.
Excess fuel oil from the nozzle (which also
The plunger, raised by camshaft rotation, furth- lubricates the inside of the nozzle holder) flows
er increases fuel oil pressure. through the nozzle holder’s overflow valve and
This fuel oil is then delivered by the injection is returned to the fuel oil tank.
01-002
cn
2
0
I-
a
c)
E
c)
W
n
tn
mmJ
a
n
c)
2
.
OOddM
2 :
:
0
I-
t)
z
1
LL
n
2
a
W
OOddM
0
2
B
2
u
0
w
m
a
b
-_I
0
2
FIPPOO
To nozzle
Delivery valve holder
Delivery valve
lilllillA‘il, I --A- Pump housing
Fig. 3 E(S)-A type InjectIon pump: cut-away view
When the fuel oil pressure exceeds the nozzle

Helix spring set force, fuel oil is sprayed into the
I-
engine combustion chamber by the nozzle.
The plunger further ascends, and at the
position where the plunger helix meets the
Plunger suction and discharge port of the plunger
barrel
barrel, delivery of fuel oil ends. (At the same
time, the nozzle spraying ends.) The delivery
Plunger 4 valve is closed by the force of the delivery
valve spring, so that fuel oil is no longer
4 4 delivered, even though the plunger further
ascends. If the plunger is rotated, the effective
Delivery starts Delivery ends
stroke shown in Fig. 4 is altered, and
consequently fuel injection quantity is altered.
Fig. 4 Plunger: effective stroke
1 l-003L
Injection quantity (mm3/st)-
2 & It: E;: % %

0 % z?G E 8 0 00000
PLUNGER ROTATING MECHANISM
Non delivery Partial delivery Maximum delivery
Fig. 7 Plunger rotating 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 Combared to the standard helix (No. 2 helix),
No. 1 helix when using a plunger with a larger helix angle
(No. 1 helix) during operation in the low-speed/
o. 2 helix 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,
Delivery valve the delivery valve prevents reverse flow of the
spring fuel oil from the injection pipe to the plunger
-0 4 O barrel. When the delivery valve descends, fuel
Delivery valve 0
0 0
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)
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) 8
E
However, in the high-speed range the variable E
retraction piston has scarcely any effect.
t: Retraction piston diameter “shaved” amount
Fig. 10 Delivery valve (for variable retraction

piston)
1 l-006
DAMPING VALVE EQUIPPED DELIVERY VALVE HOLDER
A delivery valve holder provided with a damp-
ing valve is available. (Fig. 11)
Purpose
If there is a sudden decrease in fuel oil press-

ure 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
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 press-
Open Closed fitted. Below this stopper the delivery valve
spring and delivery valve a,re
ti located.
,
Operation
8 Fig. 11 Damping delivery valve At the time of fuel injection from the plunger,
EL the damping valve (ball valve) is opened, and
h fuel oil is delivered through the delivery valve
stopper’s central portion to the nozzle. How-
ever, 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
pressure decrease and cavitation are
prevented.
1 l-007
CAMSHAFT
The camshaft is driven by the engine through a
coupling or timing device.
Depending on specifications, tangential, con-
vex, or tangential/eccentric combination cams
may be used to operate the plungers. (See Fig.
12)
In addition to the plunger cams, an eccentric
Tangential Convex Eccentric Tangential/
cam is fitted to the camshaft to drive the
cam cam cam Eccentric cam supply pump.
Fig. 12 Cam profiles
TAPPET ASSEMBLY
The tappet assembly is designed to change
Standard type For high-speed engine rotary camshaft motion into reciprocating
motion, therefore raising and lowering the
plunger, as well as regulating injection pump
timing.
Adjusting
shim Two types of tappets may be used, with their
/
Tappet upper construction differing.
8
For ordinary injection pumps the bolt- /$
adjustable tappet is generally used, while for
high-speed injection pumps the shim-
adjustable 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 construc-
tion and function are the same, only the
construction and function of the KE type are
explained below.
Construction
Fig. 14 shows the construction of the KE type
supply pump.
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.
Fig. 14 KE type supply pump construction
1 l-008
Operation
Camshaft Camshaft
Position A Position B
(A) w Check valves 03 (Cl

Regulating
Suction Discharge
Fig. 15 Supply pump operation
Fig. T5 shows supply pump operation. Priming pump

A priming pump may be installed on the supply
As shown in Fig. 15 (A), when the cam is mov- pump to manually supply fuel oil to the fuel in-
0 ing toward position A, fuel is sucked in through jection system from the fuel oil tank during the
za the suction port check valve. priming and bleeding operation (See Page 62).
ii
As the cam moves away from position A to Note: After using the priming pump ensure
position B, the fuel oil is compressed, the the priming pump screw is secured
suction port check valve is closed, and fuei oil tightly to prevent water and dirt etc.,
is discharged through the discharge port check from entering the supply pump.
valve, as shown in Fig. 15 B. A gauze filter is installed at the
suction port to prevent dirt etc., from
If discharge side fuel oil pressure increases entering the supply pump.
abnormally, the piston spring acts to compress
the fuel oil in the pump chamber, therefore
closing the suction port check valve and pre-
venting further suction of fuel oil, as shown in
Fig. 15 C.
1 l-009
12 TESTING AND ADJUSTING
SPECIAL TOOLS .............................................. 12-002

Service tools for adjustment.. ...................... 12-002
ADJUSTiVlENT .................................................. 12-007
Preparation .................................................... 12-007
Setting control rack “0” position ................ 12-008
Injection timing adjustment ........................ 12-009
Injection quantity adjustment ...................... 12-014
Supply pump test ......................................... .12-015
Injection timing aligning mark .................... 12-017
PRECAUTIONS .................................................. 12-021
Fuel oil ........................................................... .12-021
Fuel filter ........................................................ 12-021
Bleeding the fuel system .............................. 12-021
Lubrication ..................................................... .12-022
Lubrication procedure ................................. .12-023
12-001
SPECIAL TOOLS
To service the PE(S)mA(D) type injection pumps, the following special tools and general tools should be
prepared.
SERVICE TOOLS FOR ADJUSTMENT

Part Number
Key No. Tool Name Q’ty Application
( ): ZEXEL P/No.
1 Common tool Nozzle holder 8

(105780-2080)
2 Common tool Nozzle 8

(105780-0000)
Common tool Injection pipe 8 2mmx6mmX600mm,

(157805-0520) Ml4 x 1.5; Ml2 x 1.5
Common tool Injection pipe 8 2 mm x 6 mm x 600 mm,

(157805-3320) Ml4 x 1.5; Ml2 x 1.5
Common tool Wrench 1 For purging air from nozzle holder

(157916-8220)
6 Common tool Stand 2 For mounting PEmA(D) pump

(15781 O-0500) (for test stand models 5NP and IONP,
shaft center height: 110 mm)
7 Common tool Stand 2 For mounting PEaA pump

(105781-0480) (for test stand models 7NP and 15NP,
Common tool Clamping device 1 For fixing PE=A(D) pump (for test stand
(105781-0010) models 5NP and IONP)
Common tool Stand 1 For mounting PESA(D) pump

(105781-0150) (for test stand models 5NP and IONP,
10 Common tool Stand 1 For mounting PESmA(D) pump

(105781-0180) (for test stand models 7NP and 15NP,
11 Common tool Adapter 1 Used together with the mounting

(15781 I-0620) stands (key nos. 9 and 10) D: 68 mm
and 78 mm
12 Common tool Measuring device 1 For measuring control rack travel

(105782-6280)
13 Common tool Measuring device 1 For measuring control rack travel:

(105782-6130) installed with driveside mounted boost
compensator
12-002
O
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FIPPOO
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FIPPOO
ADJUSTMENT
After reassembling the injection pump, adjust Prepare the special service tools described in
it in the following manner using the injection “Service tools for Adjustment”.
pump test stand.
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 pump installed on the test

stand
3. Fill the camshaft chamber and governor

chamber with injection pump oil. (Fig. 87)
Camshaft chamber: 20 cc for each cylinder

Governor chamber: Depends on governor
type
Fig. 87 Adding lubricant to the cam chamber
12-007
z
0
Fir
..
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 pre-
stroke can be obtained. Adjusting shim
thickness varies in 0.05 mm steps. (Fig. 97)
Fig. 97 Adjusting shim replacement
Note: For bolt-type tappet adjustment ad-

just the position of the adjusting bolt
using 2 spanners (15791 I-01 00)
(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 pre-stroke.
Fig. 98 Adjusting bolt adjustment
12-011
FIPPOO
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OOddM
INJECTION QUANTITY ADJUSTMENT
1. Check the control rack “0” position.
(Fig. 104)
Fig. 104 Checking the control rack “0” 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
4. 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 speci-
fied, adjust as follows.
(1) Loosen the control pinion clamp screw.
(Fig. 106)
Fig. 106 Loosening the control pinion clamp

screw
12-014
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 suction head of approx. I
metre.
(2) Operate the injection pump at 100 rpm.

(3) Fuel oil must be discharged in less than 40
seconds.
Fig. 108 Supply pump test piping
2. Priming pump test

(I) Fully loosen the priming pump’s screw cap.
(2) Operate the priming pump using the screw
cap, at 60-I 00 strokes per minute.
(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
7. Confirm that the injection pump pointer

(360A) aligning mark and the flyweight
holder aligning mark are aligned.
8. If not aligned, remove the incorrect fly-
weight holder aligning mark, and remark
the position where the pointer aligns with
the flyweight holder. (Fig. 115)
Fig. 115 Remarking the aligning mark
12-017
Retard/Advance timing device (Eccentric-cam [EC] type timing device)
1. The EC type timing device has retard/

I RI : retard angle value
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.
Pump speed (rpm) - I
Fig. 116 EC type timing device retard-advance

angle characteristics
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)
Mote: Refer to the EC-type timing device
service manual for the measuring
procedure and special tools.
8
k
ii
Fig. 117 Measuring the retard angle
4. Compare the retard angle value measured

Measured value Retard angle value 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)
Fig. 118 Restamping the retard angle value
12-018
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
7. Operate the pump test stand flywheel

manually.
8. Place the No. 1 cylinder plunger in the
beginning-of-injection position. (Fig. 120)
Fig. 120 Confirming the No.1 cylinder’s

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 handling facilities are properly maintained
injection pump and impede performance, use and serviced regularly.
only diesel fuel oils recommended by a Too high a sulphur content in the fuel oil
reputable authority. adversely affects the injection pump; com-
Ensure fuel oil is of the correct viscosity, and is bustion results in the formation of sulphur
clean. oxide which, reacting with any moisture in
As the fuel oil lubricates the plungers, deliv- the fuel oil results in the formation of
ery valves, and nozzles, the correct viscosity sulphuric acid, corroding the internal
fuel oil is necessary to ensure adequate components of the injection pump and the
lubricaton. engine. Use only low sulphur-content fuel
Too low a viscosity may result in seizing of oil.
these parts. Moisture in the fuel oil causes the formation
Too high a viscosity results in poor combus- of rust inside the injection pump, eventually
tion. resulting in seizing of the injection pump’s
Particles of dirt, rust etc. are extremely moving parts.
abrasive to the injection equipment, as the Ensure fuel oil is free of moisture.
moving parts operate with extremely small Excessive carbon residue results in carbon
clearances. deposits in the engine and on the injection
Ensure that the fuei oii is ciean, fuei filters nozzle tips, adversely affecting injection.
are serviced regularly and that storage and Use only low carbon-residue fuel oil.
E FUEL FILTER
As liquid and solid contaminants in fuel oil Observe the manufacturers instructions
adversely affect the injection pump and per- regarding servicing and replacement of fuel
formance, ensure the fuel oil is properly filters.
filtered.
BLEEDING THE FUEL SYSTEM

After installation or reassembly of the injection 3. Continue operating the priming pump until
pump, the fuel system (from the fuel oil tank to there are no air bubbles in the fuel oil flow-
the nozzles) must be properly bled and primed ing from the valve or screw.
to expel all air from the system. Air in the 4. Close the valve or screw.
system may result in reduced engine output, 5. Open the injection pump’s overflow valve
improper idling and difficulty in starting the and continue operating the priming pump
engine. until there are no air bubbles in the fuel oil
The priming pump attached to the supply flowing from the injection pump’s overflow
pump is used to bleed and prime the system. valve.
1. Fully loosen the priming pump’s screw cap. 6. Turn the engine over until it starts.
2. While operating the priming pump open the The fuel injection system is now properly
overflow valve or air bleeder screw on the bled and primed.
fuel oil filter.
12-021
LUBRICATION
Use only specified lubricants and observe the described below and in the following table.
specified lubrication quantities and intervals as
LUBRICATION TABLE
LOCATION LUBRICANT (ZEXEL PART NO.) REMARKS

Injection pump plungers Diesel fuel oil
Delivery valves (as specified by manufacturer)
Injection nozzles etc.
Injection pump camshaft Injection Pump oil: Check: Every 4,000 km
Mechanical governor etc. 131453-0120 x 1,000 cc or 100 hrs.
(independently lubricated Replace: Every 12,000 km
injection pumps) or 300 hrs.
Pneumatic governor Diaphragm oil:
diaphragm 155413-1320 x 60 cc
155413-0220 x 950 cc
Injection pump (engine Engine oil
integrated lubrication (as specified by
system) manufacturer)
Camshaft, mechanical
governor etc.
SCD, SCDM and SBZ type Engine Oil
timing devices (as above)
SAG and SAZ type timing Mobil Oil #20, #3O
devices
SA type timing device Auto timer grease
156118-0120 x 150 a
(Auto Timer Grease)
Fig. 124 Injection pump oil, syringe, diaphragm oil and auto timer grease
12-022
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).
With the engine integrated lubrication sys-
tem, 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.
Fig. 125 Adding injection pump oil
Diaphragm oil
-’ Drain used oil. through the drain plug and
pour 4-5 cc of diaphragm oil onto the
diaphragm blades through the filler plug at
intervals of 4,000 Km, or 100 hours.
:ig. 126 Adding diaphragm 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 the PE(S)-A(D) type injection pumps, the following special tools and general tools should be
prepared.
SERVICE TOOLS FOR DISASSEMBLY AND REASSEMBLY

Part Number
Key No. _ Tool Name Q’ty Application
( ): ZEXEL P/No.
1 Common tool Universal vise 1 Used with bracket (157944-7820 and

(157944-8520) 157944-8720)
2 Common tool Bracket 1 For fixing PESA(D) Pump

(157944-7820)
3 Common tool Bracket 1 For fixing PEaA Pump

(157944-8720)
4 Common tool Ratchet handle 1 Used together with socket wrench

(15791 O-0300)
5 Common tool Handle 1 Used together with socket wrench

(15791 O-l 120)
Common tool Pin 2 For fixing each extractor

(15791 o-51 00) (6 mm diameter)
Common tool Spanner 2 For removing and installing pneumatic

(157911-2100) governor link fixing bolt and nut
(SW 9 mm)
8 Common tooi Box wrench 1 For removing and instaiiing supply

(157913-0100) pump fixing nut (SW 10 mm)
9 Common tool Box wrench 1 For adjusting RSV governor full-load

(157913-3120) stopper bolt (SW 10 mm)
10 Common tool Socket wrench 1 For removing and installing round nuts
(157914-0100) of SA and SCD type timing devices
(SW 14 mm)
11 Common tool Socket wrench 1 For removing and installing standard

(157914-0200) nuts and bolts (SW 17 mm)
12 Common tool Socket wrench 1 For tightening extractor bolts

(157914-0300) (SW 19 mm)
13 Common tool Socket wrench 1 For removing and installing delivery

(157914-0500) valve holder (SW 22 mm)
14 790-l 579150100 Wrench 1 For removing and installing RLD, RSV,

(157915-0100) RAD, RFD governor flyweight fixing
nut (2.9 mm wide tooth)
13-002
s
.-0
5
.-
a
2
OOddM
Part Number
I--
Key No. Tool Name Q’ty Application .
( ): ZEXEL
P/No.
29 790-l 579208700 Seal guide 1 For protecting camshaft oil seal lip
(157920-8700) (for 17 mm dia. camshaft)
790-l 579205400 Seal guide 1 For protecting camshaft oil seal lip
(157920-5400) (for 20 mm dia. camshaft)
Common tool Inserter 1 For removing and installing PE(S)lA

(157921-5620) pump plunger (shim-type tappet
adjustment)
Common tool Tappet holder 6 For holding PE(S)mA high speed type
(157931-2500) pump tappet
79D-1579213020 Tappet inserter 1 For Inserting PE(S) =AD pump tappet

(157921-3020)
79D-1579317320 Tappet holder 10 For holding PE(S)*AD pump tappet

(157931-7320)
35 79D-1579250520 Extractor 1 For removing PE(S)=A(D) pump bearing

(157925-0520) outer race (for 20 mm dia. camshaft)
36 79D-1579256520 Extractor 1 For removing PE(S) -A(D) pump bearing

(157925-6520) inner race (for 20 mm dia. camshaft)
37 Common tool Measuring device 1 For measuring PE(S)=A pump camshaft

(105782-4200) end play (for 17 mm dia. camshaft)
38 Common tool Measuring device 1 For measuring PE(S)lA(D) pump cam-
L (105782-4130)
Common
(157914-2400)
tool Socket wrench 1
shaft end piay (for 20 mm dia. cam-
shaft)
For removing and

type timing device
/
installing SCDM
fixing nut
(SW 12 mm)
Common tool Extractor 1 For removing SCD, SAG type timing

(157926-5820) device (M24 x 1.5)
41 Common tool Extractor 1 For removing SCDM type timing device
I-- 42
(157926-6920)
Common
(157926-7220)
tool Extractor 1
(M22 x 1.5)
For removing SAZ type timing

(M26 x 1.5 and M32 x 1.5)
device
I=
I
43
44
Common
(157916-5320)
Common
(157914-0900)
tool
tool
Spanner
Wrench
1
1
For holding SA, SG type
(installed with laminated
For removing and installing

pump plug (SW 32 mm)
timing device
coupling)
supply
13-004
Part Number
Key No. Tool Name Q’ty. Application
( ): ZEXELP/No.
45 Common tool Guide 1 For installing PE(S) #A pump bearing

(157925-8120) outer race
46 Common tool Guide 1 For installing .PE(S)=A pump bearing

(157925-9120) inner race (for 17 mm dia. camshaft)
47 Common tool Rod 1 For installing PE(S) -AD-S pump

(157925-9300) governor side bearing inner race (used
together with holder: part no. 157925-
9700)
48 Common tool Rod 1 For installing PEW AD-S pump drive

(157925-9400) side bearing inner race (used together
with holder: part no. 157925-9700)
49 Common tool Push rod 1 For installing PE(S) -AD-S pump bearing
(157925-9500) ourter race (used together with bush:
part no. 157925-9600)
50 Common tool Bush 1 For installing PE(S) -AD-S pump bearing

(157925-9600) outer race (used together with push
rod: part no. 157925-9500)
51 Common tool Holder 1 For installing PE(S) =AD-S pump bearing

(I 57925-9700) inner race (used together with rods:
key nos. 47 and 48)
52 Common tool Inserter 1 For removing and inserting PEW AD

(157921-6120) pump plunger
NOTE: The special tool KIT (105790-I 060) for the PE(S) =A, AD pump includes tools with key numbers
4 to 39.
13-005
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EXPLODED VIEW OF THE SUPPLY PUMPS
KS type
77
KE type _-
I t-25
13-012
DISASSEMBLY
PREPARATION
Keep the work bench clean and tidy. Before In the course of disassembly, lay out the dis-
beginning disassembly, record performance assembled parts neatly and sequentially on the
data for later reference. This data will facilitate work bench, labelling if necessary. This will
detection and diagnosis of malfunctions and make the reassembly much easier.
defects, if any, in the disassembled pump.
INJECTION PUMP DISASSEMBLY

Clean the outer surface of the pump before toois are also indicated -with their part numbers
disassembly. Remove grease and dirt, and in brackets.
drain the pump camshaft chamber and
governor chamber. Collect the drained pump This section describes the disassembly of the
oil so that it can be examined. RLD governor mounted on the PE6A type fuel
The number in brackets ( ) are those key injection pump.
numbers described in Fig. 18. Special service
1. Mount bracket (157944-8720) on universal

vise (1&7Q/I4-8520).
\ I"I V-r (Fig. 20)
Fig. 20 Mounting 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
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FIPPOO
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FIPPOO
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 remove the two screws

(96). (Fig. 32)
0
2
n
ii
Fig. 32 Removing the center bearing fixing

screw
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

tappet inserter (A: 157921-0120, 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: Be careful not to let the plungers
contact other parts during remov-
al. Place them in clean fuel oil in
their order of removal.
Fig. 40 Removing the plunger and lower spring

seat
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 spring

seat (for standard type pump)
29.Through the bottom plug hole, remove the

plunger spring (61). (Fig. 42)
Fig. 42 Removing the plunger spring
13-020
OOddM
34. 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)
Fig. 46 Removing the delivery valve 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 Removing the delivery valve and 66

y,,L- _
I ylull yasket
36. Push the plunger barrel by finger to re-

move. Attach them to their corresponding
plungers, and place in fuel oil. (Fig. 48)
Caution: Be sure to keep each plunger with
its corresponding plunger barrel.
If the plungers and barrels are not
matched, the clearances between
them may not meet the standard
values.
Fig. 48 Removing the plunger barrel
13-022
\\ ‘\\\
_i
OOddM
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: Use vise jaw cover to avoid
damaging the pump housing.
Fig. 53 Clamping the 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 the priming pump
13-024
.-cn 0)
LL ii
OOddM
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. (Fig. 59)

13.Draw out the pushrod (1).
Disassembly of the supply pump is now com-
plete. The disassembled parts should be
washed thoroughly in clean fuel oil.
Fig. 59 Removing the tappet
13-026
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 plun-
ger 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 in-
clined 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
I 2. Check the top surface of the tappet adjust-

ing 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.
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 be rotated

manually. (Fig. 72)
Fig. 72 Assembled plunger 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: When the gasket is securely in con-
tact 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.
Fig. 73 Attaching the 66 Nylon gasket
13-031
3. Delivery valve holder installation
(1) After installing the delivery valve spring, fix
the delivery valve holder. (Fig. 74)
Tightening torque:
Nylon gasket: 1) Tighten to 3.0 Kg-m
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
Metal gasket: I) Tighten to 4.0 Kgam
(Delivery valve 2) Loosen to 0 Kg-m
holder: M20x 1.5) 3) Retighten to 4.0 Kgem
4) Loosen to 0 Kg-m
5) Finally retighten to 4.5
Fig. 74 Tightening the delivery valve holder
Kg-m
Metal gasket: 1) Tighten to 5.0 Kg-m
(Delivery valve 2) Loosen to 0 Kg-m
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 hous-
ing.
(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 Positioning the control rack in the centre

Dosition
13-032
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-
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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 per-
form measurement. (Fig. 84)
Note: If the control rack stroke is not within
21 mm reengage the control pinion
with the control rack to obtain the
control rack stroke of 21 mm.
Fig. 84 Measuring the control 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 the lock plate
13-036
a .
:
P
2
a
I-
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W
t)
2
a
z
W
I-
I
z
-
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M6; 0.5-0.7 M20; 3-3.5 (Nylon Gasket)
M20; 4 - 0 - 4 - 0 - 4+“.5 (Metal Gasket)
M24; 6.5 - 0 - 6.5 - 0 - 6.5+“.5 (Metal Gasket)
M4; 0.3 (Minimum Torque) MIA.

I., . , 7-7 5
_._
2
c)
M14; 8.5-10
-I
M12; z-2.5\ M6m o 5_,, 0
, . I /M12; 6-7
m
13
C
m
I i
(Stud Bolt)
By Specified Torque For Governor MlO; 0.5-0.7 (Nylon Gasket)

MIO; 1.2-I .5 (Copper Gasket)
Unit: Kg-m
The torques not specified in this drawing should conform to Standard Tightening Torques.
FIPPOO
*sanblol 6u!ua~y6!1 p~epuels 01 LUJO~OD plnoys 6u!~e~p s!y~ u! pa!ywds IOU sanblol ayl
(iayseg laddo pue 6uyed @uJo:)) 9-Z-Z iptm /
(WsW uolAN) %I,-& 1 IPL Vu
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M5; 0.5-0.8
M8; 0.5-0.8\ /
M16; 4-4.5
M24; 2-2.5 \
and Copper Gasket)
M16; 4-4.5
\ -7
\
M26; 8-9
\ ~18; 4-4.5
Unit: Kg-m
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Malfunctions Causes Remedies
Engine “knocks” 1. Injection timing is too early Readjust
2. Nozzle opening pressure is Readjust
excessively high
3. Injection holes are slightly clogged Clean or replace
(in case of hole-type nozzle)
4. Nozzle injection function has Replace
deteriorated
“Black smoke” and 1. Injection timing adjustment was Readjust
engine “knocks” incorrect
2. Nozzle opening pressure is Readjust
excessively low
3. Nozzle spring is broken Replace
4. Nozzle injection function has Clean or replace
deteriorated
5. Plunger is worn excessively Replace
6. Faulty delivery valve seat Replace
7. Fuel injection quantity is too large, Readjust
and injection timing is adjusted
incorrectly
Uneven engine output 1. Clogged filter element results in Clean or replace
insufficient fuel oil supply
2. Insufficient supply pump delivery Replace check valve
3. Air remains in injection pump Purge of air
4. Fuel oil contains water Change to high grade fuel
5. Plunger tends to stick and does Replace
not reach its full stroke
6. Plunger spring is broken Replace
7. Control rack does not move Repair or replace
smoothly
8. Tappet does not move correctly, or Replace
one part is worn excessively
9. Delivery valve spring is broken Replace
10. Faulty sealing by delivery valve Replace gasket and secure
gasket due to insufficiently delivery valve holder to the
secured delivery valve holder specified torque
11. Delivery valve does not function Replace
correctly
12. Faulty nozzle injection function Clean or replace
13. Nozzle needle valve does not Replace
move smoothly
15.The nozzle opening pressures for Readjust
each cylinder differ excessively
16. Injection timing is not adjusted Readjust
correctly
17. Control lever does not contact full- Adjust the rod length
load stopper between accelerator pedal
and governor control lever
15003
Engine output is
insufficient
1. Insufficient fuel 1. The governor full-load stopper is Readjust
injection quantity not correctly positioned
2. Control lever does not reach full- Adjust the rod length be-
load position tween accelerator pedal
3. Governor spring is stretched such Readjust or replace
that the governor starts function-
ing while the engine operates at a
relatively low speed
4. Plunger is worn excessively Replace
5. Delivery valve gasket is damaged, Replace
causing leakage (Delivery valve
holder is not secured correctly)
6. Delivery valve seat is damaged Replace
7. Delivery valve is damaged Replace
8. Excessive amount of fuel oil leaks Replace
from nozzle
3. Engine “knocks” due Readjust
to early injection timing
4. Engine has overheated Readjust
and “black smoke” is
emitted due to late in-
jection timing
5. Nozzle injection func- Clean or replace
tion has deteriorated
Engine speed does not 1. Governor spring force is too weak Readjust
reach its maximum
2. Control lever does not contact full- Adjust the rod length
speed stopper between accelerator pEXhi
3. Nozzle injection function has de- Clean or replace
teriorated
Engine maximum speed 1. Control rack does not move Repair or replace
is excessively high smoothly
2. Governor spring force is too strong Readjust
3. Governor flyweight does not Replace
operate adequately
4. idling-sub spring or damper spring Readjust
is not adjusted correctly
15004
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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 Because the quantity of fuel oil supplied by the
system. Engine rotation is transmitted to the supply pump is at least twice the injection
injection pump camshaft by a coupling or drive pump’s maximum injection quantity, overflow
gear through the timing device. valves are installed at the top of the filter or on
The supply pump, driven by camshaft rotation, the injection pump to return excess fuel oil to
sucks fuel oil from the fuel oil tank and sup- the fuel tank when the fuel oil pressure ex-
plies it to the fuel oil filter at a pressure of 1.8- ceeds a set value.
2.5 kg /cm*. Filtered fuel oil is then sent Fuel oil which has lubricated the inside of the
through the fuei oil chamber in the injection nozzie and nozzie holder is returned to the fuei
pump housing to the plunger. tank or the filter through the nozzle holder’s
The plunger, raised by camshaft rotation, furth- overflow nipple. The priming pump installed on
er increases the fuel oil pressure, with the fuel the supply pump is used to manually bleed air
oil then being delivered through the injection from the fuel pipes and to feed fuel oil from
pipe and the nozzle holder to the nozzle. the fuel oil tank to the injection pump.
When the high pressure fuel oil delivered to Note: Take care not to bend the injection
the nozzle exceeds the specified nozzle open- pipes at too acute an angle (radius:
ing pressure it is injected into the engine’s less than 30 mm).
combustion chamber.
01-002
PRINCIPAL SPECIFICATIONS
injection pump type PI -P3 P-S
Plunger stroke (mm) 10 11 12
Control rod travel (mm) 21 21
Number of cylinders I 1 to12 I 1 to12 I
Plunger Injection Plunger Injection
Plunger diameter (#mm) diameter quantity diameter quantity
& 10.0 235 (I 0.0) (235)
Maximum allowable
injection quantity 11.0 285 11.0 285
(mm3/stroke) 11.5 310 11.5 310
I
12.0 1 340 I 12.0 1 340 I
Plunger lead
22 mm
(Standard tvoe)
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 / I,
5 10 15 20
Control rod position (mm) -+
Fig. 2 Injection quantity characteristics
01-003
8 I
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FIPPOO
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 hous-
Deliverv valve hol ing.
The plunger barrel is positioned by a knock pin
press-fitted to the sleeve flange.
Sleeve flange A deflector is attached to the outside of the

plunger barrel by a snapring to prevent corro-
sion of the pump housing caused by the re-
verse 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 high-
pressure 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 em-
ploys an integrated lubrication system to circu-
late the engine’s lubricating oil. The engine’s
lubricating oil is forced, through an inlet adja-
cent to the tappet’s sliding portion, to the injec-
tion pump’s cam chamber to lubricate the cam
chamber and the governor chamber before re-
turning to the engine. (Fig. 8)
Fig. 8 Injection pump lubrication system
OPERATION
Figure 9 shows the operation of the PE(S)-P
type injection pump.
Engine rotation is transmitted through a cou-
pling (or drive gear) and timing device to the
injection pump camshaft. This rotational move-
ment 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 re-
turned by the plunger springs in a reciprocating
Control sleeve motion.
A fuel oil chamber is located in the pump hous-
ing, and this chamber is always filled with low
pressure fuel oil filtered by, and delivered from,
the fuel filter. The plunger barrel’s suction-
delivery ports open onto this fuel oil chamber.
Fig. 9 PE(S)-P type injection pump operation
11-005
A C
Fig. IO Fuel-suction process
During the camshaft’s downward stroke the Suction is completed when the plunger
plunger is forced down by the plunger spring, reaches its lowest position. (Fig. 1 O-B)
and when the plunger’s upper end-face meets With further camshaft rotation the camshaft
the plunger barrel’s suction-delivery port fuel begins its upward stroke and the plunger
oil is first sucked into the plunger barrel. (Fig. spring is compressed as the plunger is raised.
1 O-A) (Fig. 1O-C)
When the plunger’s upper end-face closes the

plunger barrel’s suction-delivery port, com-
pression of fuel oil begins. This closed position
is referred to as the beginning of static injec-
tion. (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 process (I)
11-006
As the plunger continues to ascend, the plung-
er helix meets the plunger barrel’s suction-
delivery port. (Fig. 1Z-A)
Because the compressed fuel oil simul-
taneously escapes to the fuel oil chamber, the
pressure inside the plunger barrel suddenly de-
creases. Then, because the delivery valve is
forced down by the delivery valve spring, deliv-
ery of fuel oil is completed. (Fig. 12-B)
Although the plunger may continue to ascend,

further delivery of fuel oil can not be per-
formed.
Variations in the quantity of fuel delivered by
J the plunger are performed by varying the
Fig. 12 Fuel-delivery process (II) 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

Control rod by a knockpin and cannot move. However, the
plunger construction is such that it can move
both up and down and rotate.
i0 in-delivery
- 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 of the control rod

Control sleeve will result in simultaneous turning of all the
Plunger flange
cylinders’ plungers, thereby varying the effec-
tive stroke and increasing or decreasing the in-
I jection quantity.
Fig. 13 Mechanism for varying plunger’s
effective stroke
Effective stroke 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
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.
I The plunger is manufactured with a helix, and
Fig. 15 Double helix plunger at the edge of the helix is a vertical groove
which opens onto the plunger’s upper end-
face. Two suction-delivery ports are located in
the plunger barrel, in diametrically opposed
positions.
The plunger can be manufactured with identi-

Helix cally shaped helixes in diameterically opposed
positions which act to rapidly return the fuel oil
at the top of the plunger to the fuel oil cham-
ber following the end-of-injection. (Fig. 15)
8
When the plunger’s upper end face closes the &
plunger barrel’s suction-delivery port fuel oil h
delivery (injection) begins, and when the plung-
Beginning- End- er’s helix meets the plunger barrel’s suction-
of-injection Delivery -4
of-injection delivery port, delivery (injection) simultaneously
Fig. 16 Plunger’s effective stroke finishes. This period is referred to as the effec-
tive stroke. (Fig. 16)
Cutting of the fuel oil delivery (non-injection) is

also utilized as one method of stopping the en-
gine, where by operating the control rod, end-
of-injection may be obtained at the same time
as the beginning-of-injection. (Fig. 17)
Non-delivery
Fig. 17 Engine-stopping mechanism
11-008
As shown in Figure 18, plungers may be right
or left helix types.
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 counter-
clockwise, 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 spring Delivery Valve Assembly
The delivery valve assembly consists of the de-

livery 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
a: retraction stroke 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 sub-
sequent 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-of-
injection 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 pis-
ton’s retraction stroke “a“ (Fig. 19) and the re-
sidual pressure is adjusted, thereby preventing
leakage of fuel oil from the nozzle following the
end-of-injection. (Fig. 19)
11-009
Tangential cam Convex cam Eccentric cam Tangential/eccentric cam
Fig. 20 Camshaft cam shapes
Camshaft
The camshaft is rotated by the engine’s drive tangential/eccentric cams). Cams are chosen
shaft (through the coupling or gear) and the depending on the engine’s specifications.
timing device, while the plungers and the Tangential cams or combination cams (general-
supply pump are operated by the camshaft via ly tangential/eccentric cams) are generally used
the tappets. to operate the plungers.
Cam shapes may be tangential, convex or An eccentric cam is also installed specifically to
eccentric, or a combination of these (e.g. drive the supply pump. (Fig. 20)
Tappet Assembly
The tappet assembly construction is shown in

Lower Fig. 21. Rotational movement of the injection
spring seat pump camshaft moves the plunger up and
down, and is therefore changed to reciprocat-
ing movement.
guide
Roller bush/ W
Fig. 21 Tappet assembly
11-010
-42
16
I8
15
2?
14 1. Housing
5. Piston
6. Piston spring
10. Tappet
14. Check valve
15. Check valve spring
25. Priming pump
30. Eyebolt (filter inlet)
32. Eyebolt
35. Gaskets
36. Gaskets
;
42. Cover
f-g. ee KU rype supply pump: exploded view
KD Type Supply Pump
Fig. 22 shows an exploded view of the KD type the PE-A(D) type injection pump in that the KD
g supply pump, a large number of which are type is a double-action type supply pump with
k used with the PE(S)-P type injection pump. 4 check valves.
E The KD type supply pump differs from the Fig. 23 shows the standard operation of the KD
single-action KE type supply pump used with type supply pump.
Camshaft
/
Piston spring chamber /
A B
Suction Delivery Suction Delivery
Fig. 23 KD type supply pump operation
11-011
As shown in Fig. 23-A, when the camshaft fuel oil tank to the pushrod chamber. Further-
cam pushes the tappet the piston is also more, as the camshaft rotates to the position
pushed via the pushrod, and the fuel oil pres- shown in Fig. 23-B the piston is pushed by the
sure in the piston spring chamber increases. piston spring, the fuel oil in the pushrod cham-
Because of this the suction side check valve ber is fed via the fuel filter to the injection
closes, the delivery side check valve opens, pump, and new fuel oil is sucked from the fuel
and the fuel oil in the piston spring chamber is oil tank to the piston spring chamber.
fed via the fuel filter to the injection pump. In this way one reciprocating movement of the
Meanwhile, because the pushrod chamber’s piston results in two suction and delivery ac-
fuel oil pressure decreases, the delivery side tions, and suction and delivery are continuous
check valve closes, the suction side check during injection pump operation.
valve opens, and fuel oil is sucked from the
11-012
. . . . . .
.. .. .. .. .. .. .: .: :
:
:
:
:
:
:
: :
: :
:
: : : : : : : :
.. .. .. : : : : : .: .: .: .: :- .:
a
a
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KEY Q’TY
PART NO. TOOL NAME APPLICATION
NO.
1 105780-2080 Nozzle holder 12 For adjusting injection timing and
2 105780-0000 Nozzle 12 I injection quantity.
Injection quantity: up to 200 cc/l000 st
(Assembly No: 105780-8140)
3 157805-4720 injection pipe 1 (set) For adjusting injection timing and
injection quantity (set of 12)
4 105780-2090 Nozzle holder 12 1 For adjusting injection timing and
5 105780-0050 Nozzle 12 injection quantity.
Injection quantity: exceeds 200 cc/
1000 st (Assembly No: 105780-8130)
6 157805-5420 Injection pipe 1 For adjusting injection timing and
injection quantity (set of 6)
7 105781-0420 Fixing stand 2 For mounting PE-P type injection pump
(for 15 NP type test stand)
8 15781 I-0920 Flange 1 For mounting PE(S)-P type injection
pump (for 15 NP type test stand)
9 105781-0450 Fixing stand 1 For mounting P.E(S)-P type injection
10 105781-0180 Fixing stand 1 For mounting PE(S)-P type injection
pump (used together with
15781 I-0920)
11 105781-0480 Fixing stand 2 For mounting PE-P type injection pump
(for 10 NP type test stand)
12 157840-3620 Flange 1 For mounting PE(S)+P type injection
13 105781-0160 Fixing stand 1 For PES-P type injection pump
(used together with 157840-3620)
14 157827-6520 Adapter 1 For measuring control rod position
15 ? 57827-6820 , Connecter 1 , For mea.siJring control rod positien
16 105782-4270 Measuring device 1 For measuring plunger pre-stroke
17 157954-3700 Dial gauge 1 For measuring control rod position
18 157912-2000 Spanner 1 For removing delivery valve holder
19 157840-0900 Lever 1 For manual flywheel operation
20 157916-8220 Wrench 1 For operating the nozzle holder
over-flow valve.
21 157970-0500 Measuring cylinder 1 For measuring quantity of test oil
discharged from supply pump.
22 157842-6220 Coupling 1 For driving injection pump (for 25 mm
dia. camshaft)
23 157842-4620 Coupling 1 For driving injection pump (for 20 mm
dia. camshaft)
24 157840-4020 Coupling 1 For driving injection pump
(installation pitch: $66; $72)
25 157916-0200 Box spanner 1 For removing and installing injection
pipes (SW1 9)
Note:
1. The I5 NP type test stand is provided with tools (Key Nos. 1 to 3, 7 to 10, 14, 15, 17, 19,
20, 22 and 23) as standard.
12-002
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 3
A15
M14Xl.5
\”
5 6
14x1.5
.8
MIOXl.S/
Fig. 25-l
12-003
/ \
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co
X
-
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 Adjust-
ment”.
PREPARATION
1. Using the fixing stand, mount the injection
pump on the pump test stand.
Test stand type Fixing Stand Part Number

105781-0420
15NP 15781 I-0920
10578 I-0450
105781-0180
105781-0480
IONP 157840-3620
105781-0160
Fig. 126 Injection pump installed on the test 2. Connect the fuel pipes and the injection
stand pipes. (Fig. 126)
_!I II ” I 3 M IT II I I I I I I I I I I 3. Fill the injection pump cam chamber and 8
the governor chamber with lubricating oil k
(131453-0121). (Fig. 127) iz
Amount: 50-60 cc for each cylinder.
Fig. 127 Adding lukxicating oil
12-006
4. Attach the measuring device to the control
rod tip. (Fig. 128)
Fig. 128 Attaching the measuring 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 adjusted as described
above, operate the load control lever until it
contacts the idling stopper bolt, move the
control rod towards the governor side and
set the measuring device to the “0” posi-
tion. (Fig. 130)
Note: 1. The method of setting the measur-
ing device’s “0” position differs
according to the type of governor.
Refer to the relevant service
manual.
2. If the pump is not operating when
the measuring device is set to
“0”, excessive force will be ap-
plied to the linkage. Be sure to
Fig. 130 Setting the control rack’s “0” position 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 the measuring device
12-008
6. Rotate the test stand’s flywheel in the
specified direction to set the No. 1 cylin-
der’s tappet in the bottom dead centre
(B.D.C.) position. (Fig. 133)
Fig. 133 Setting the tappet’s bottom-dead-

center 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 device’s “0”

position
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 over-
flow pipe. (Fig. ‘135)
Note: 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 fly-
wheel is rotated in the reverse-
rotation direction. The pre-stroke
Fig. 135 Measuring the pre-stroke is then measured when fuel oil
ceases flowing from the measur-
ing device’s overflow pipe.
12-009
2. Pre-stroke indicates the amount of
plunger movement from the bot-
tom 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
Part Thickness Part Thickness Part Thickness Part Thickness

Number (mm) Number (mm) Number (mm) Number (mm)
139400-0900 0.5 139400-2400 0.875 139400-3900 1.25 139400-5400 1.625
-1000 0.525 -2500 0.9 -4000 1.275 -5500 1.65
-1100 0.55 -2600 0.925 -4100 1.3 -5600 1.675
-1200 0.575 -2700 0.95 -4200 1.325 -5700 1.7
-1300 0.6 -2800 0.975 -4300 ? .35 -5800 I .72=
-1400 0.625 -2900 1.o -4400 1.375 -5900 1 .75d
-1500 0.65 -3000 1.025 -4500 1.4 -6000 1.775
-1600 0.675 -3100 1.05 -4600 1.425 -6100 1.8
-1700 0.7 -3200 1.075 -4700 1.45 -6200 1.825
-1800 0.725 -3300 1.I -4800 1.475 -6300 1.85
-1900 0.75 -3400 1.I25 -4900 1.5 -6400 1.87
-2000 0.775 -3500 1.15 -5000 1.525 -6500 1.9
-2100 0.8 -3600 1.I75 -5100 1.55 -6600 1.925
-2200 0.825 -3700 1.2 -5200 1.575 -6700 1.95
139400-2300 0.85 139400-3800 1.225 139400-5300 1.6 139400-6800 1.975
Table 1
12-010
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 the No. 1 delivery valve

holder
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 speci-
fied direction of rotation to raise the plung-
lG&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 adjust-
ment 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: 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.
12-012
1. Confirm the control rod’s “0” position.
2. Operate the injection pump at the specified
speed and fix the control rod in the speci-
fied position. (Fig. 142)
3. Under the above conditions measure the
fuel injection quantity. If not as specified,
loosen the injection pipe and two nuts fix-
ing the sleeve flange and make adjustment
by altering the sleeve flange position. (Fig.
143)
Note: When the sleeve flange is turned
counterclockwise as shown in Fig.
143:-
Right helix plunger
(governor instaiied on right hand
Fig. 142 Fixing the control rod
side): The injection quantity in-
creases.
Left helix plunger
(governor installed on left hand
side): The injection quantity de-
creases.
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 injec-
tion quantity satisfies the specified value.
Fig. 143 Adjusting the sleeve flange

average of injection quantity of all
Injection quantity variation (+) = maximum injection quantity -
cylinders . . . .
Injection quantity variation (-) = average of injection quantity of all cylinders - m’n’mum ‘nJection
quantity
maximum injection - average injection
quantity
Injection quantity variation rate +) = quantity xl00 (%)
average injection quantity
average injection - minimum injection
quantity quantity
Injection quantity variation rate -) = xl00 (%)
average injection quantity
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

the No. 1 cylinder’s plunger in the
beginning-of-injection position. (Fig. 145)
Fig. 145 Adjusting the No. 1 cylinder’s

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

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 align-
ing mark on the new flyweight hold-
er. Therefore, stamp a new aligning
mark on the flyweight holder, align-
ing 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 in-
stalled on the PE(S)-P type injection pump is
explained below.
Preparation
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
Fig. 148 Suction test
(SAE J967d)
Suction Test
1. Loosen the suction side pipe and confirm

that test oil does not flow from the dis-
charge 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
oz I a
io” I r
7
..
CD
I Q
FIPPOO
PRECAUTIONS
FUEL OIL
As inferior quality fuel oil will damage the injec- handling facilities are properly maintained
tion pump and impede performance, use only and serviced regularly.
diesel fuel oils recommended by a reputable 5. Too high a sulphur content in the fuel oil
authority. adversely affects the injection pump; com-
Ensure fuel oil is of the correct viscosity, and is bustion results in the formation of sulphur
clean. oxide which, reacting with any moisture in
1. As the fuel oil lubricates the plungers, deliv- the fuel oil results in the formation of sul-
ery valves and nozzles, the correct viscosity phuric acid, corroding the internal compo-
fuel oil is necessary to ensure adequate lub- nents of the injection pump and the engine.
rication. Use only low sulphur-content fuel oil.
2. Too low a viscosity may result in seizing of Moisture in the fuel oil causes the forma-
these parts. tion of rust inside the injection pump, even-
3. Too high a viscosity results in poor combus- tually resulting in seizing of the injection
tion. pump’s moving parts.
4. Particles of dirt, rust etc. are extremely Ensure fuel oil is free of moisture.
abrasive to the injection equipment, as the Excessive carbon residue results in carbon
moving parts operate with extremely small deposits in the engine and on the injection
clearances. nozzle tips, adversely affecting injection.
Ensure that the fuel oil is clean, fuel filters Use only low carbon-residue fuel oil.
are serviced reguiarly and that storage and
g FUEL FILTER
3
E As liquid and solid contaminants in fuel oil Observe the manufacturer’s instructions re-
adversely affect the injection pump and per- garding servicing and replacement of fuel
formance, ensure the fuel oil is properly filters.
filtered.
BLEEDING THE FUEL SYSTEM

After installation or reassembly of the injection 3. Continue operating the priming pump until
pump, the fuel system (from the fuel oil tank to there are no air bubbles in the fuel oil flow-
the nozzles) must be properly bled and primed ing from the valve or screw.
to expel all air from the system. Air in the 4. Close the valve or screw.
system may result in reduced engine output, 5. Open the injection pump’s overflow valve
improper idling and difficulty in starting the en- and continue operating the priming pump
gine. until there are no air bubbles in the fuel oil
The priming pump attached to the supply flowing from the injection pump’s overflow
pump is used to bleed and prime the system. valve.
1. Fully loosen the priming pump’s screw cap. 6. Turn the engine over until it starts.
2. While operating the priming pump open the The fuel injection system is now properly
overflow valve or air bleeder screw on the bled and primed.
fuel oil filter.
12-017
LUBRICATION
The injection pump cam chamber, the gov- must always be filled with the correct quantity
ernor chamber and the timing device chamber of the specified lubricants.
Lubrication Table
Lubricant Part No. (quantity) Location
Diesel fuel oil As specified by engine manufacturer Injection pump plungers
Delivery valves
Injection nozzles etc.
Auto timer grease 156118-0120 (150 g) SA type timing device
Mobil Oil #20, #30 SP type timing device
Engine oil As specified by engine manufacturer Injection pump cam chamber
Note: When reinstalling the injection Mechanical governor
pump on the engine fill the SPM type timing device
injection pump cam chamber
with injection pump oil (Part
No: 130453-0121; 1000 cc)
until oil overflows from the
overflow nir>de
LUBRICATION PROCEDURE
With the PE-P type injection pump the en-
gine’s lubricating oil is generally circulated
inside the injection pump to lubricate the injec-
‘:
tion 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
engine manufacturer’s specified instructions
should be followed in relation to the inspection
Injection pump oil Syringe
and replacement of the engine oil.
131453-0121 13 1499-0320
However, prior to operation on the pump test
stand or engine, the governor chamber and in-
jection 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.
Auto-timer grease
156118-0120
Fig. 152 Injection pump oil, syringe and autotimer

grease
12-018
(3
2
I
0
0
I:
co
W
ml
m
3
0
PC
OOddkl
4. The nozzle does 5. Injection pipe contains air Bleed of air
not operate 6. Clearance between the nozzle Replace
body and the needle is too great
7:Nozzle nut is improperly tightened Retighten at the specified
torque
Engine starts, but 1. Injection pipes leading to the Clean or replace
operates only for pump are blocked or the filter is
a limited time dirty
2. Air or water is mixed with the fuel Bleed of air or change to high
oil grade fuel and bleed of air
3. Injection pipe contains air Bleed of air
4. Fuel pipe between fuel tank and Replace the fuel pipe, tighten
supply pump is damaged or the the connections, or replace the
connections are not airtight, gasket
allowing air to enter
5. Supply pump is not functioning Inspect the check valve seat
properly, resulting in insufficient and the body/piston clearance
fuel oil supply and replace defective parts
6. The fuel oil tank ventilating device Replace
is blocked
The engine 1. The injection timing is too early Readjust

“knocks” 2. Nozzle opening pressure is too Readjust
high
3. Some injection holes are blocked Clean or replace
(in hole-type nozzle)
4. Nozzle injection function has Replace
deteriorated
“Black smoke” 1. Injection timing is maladjusted Readjust
and engine 2. Nozzle opening pressure is too Readjust
“knock” low
3. Nozzle spring is broken. Repiace
4. Nozzle injection function has Clean or replace
deteriorated
5. Plunger is worn Replace
6. Faulty delivery valve seat Replace
7. Fuel injection quantity is too large, Readjust
and injection timing is incorrectly
adjusted
Unstable engine I. Clogged filter element results in Ciean or replace

output insufficient fuel oil supply
2. Insufficient supply pump delivery Inspect the check valve seat
and the body/piston clearance
and replace defective parts
3. Injection pump contains air Bleed of air
4. Fuel oil contains water Change to high grade fuel
5. Plunger tends to stick and does Replace
not reach its full stroke
6. Plunger spring is broken Replace
12-020
Engine cannot 1. Governor spring force is too weak Readjust
reach its 2. Control lever does not reach the Readjust
maximum speed full-load position
3. ,Nozzle injection function has Clean or replace
deteriorated
4. Control lever does not contact the Readjust the accelerator rod
full-load stopper bolt
Engine’s 1. Control rack does not move Repair or replace

maximum speed smoothly
is too high
2. Governor spring force is too strong Readjust
3. Governor flyweight does not Replace
operate adequately
Idling speed is
unstable
1. The injection 1. Plunger does not move smoothly Replace
pump’s control or is stuck
rod does not 2. Control rod is improperly Repair
move smoothly connected to the control sleeve
3. Plunger spring does not seat Replace
correctly
4. Clearance between plunger and Replace
lower spring seat is too small
5. Delivery valve holder is Repair (secure delivery valve
overtightened holder at specified torque)
2. Fuel injection Readjust
quantities of
each cylinder
differ
excessively
3. Plunger is worn Replace
excessively
4. Plunger spring Replace
is broken
5. Fuel oil Bleed of air or change to high
contains air or grade fuel
water
6. Governor idling Readjust
spring force is
too weak or
improperly
adjusted
7. Governor links Repair or replace
are twisted re-
sulting in exces-
sive friction
between each
connection or
excessive blav
12-022
OOddkl
OOddlj
SPEClAl TOOLS
The following special tools and general tools tools and attachments may result in damage to
(spanners, hammer etc) are necessary for the injection pump, subsequent fuel oil leaks
PE(S)-P type injection pump disassembly, reas- and an inability to properly perform injection
sembly and adjustment. Non-use of the special pump adjustment.
SERVICE TOOLS FOR DISASSEMBLY AND REASSEMBLY
KEY TOOL NAME Q’TY APPLICATION

PART NO.
NO.
1 157944-8520 Universal Vise 1 For fixing brackets (157944-9420 and
157944-8620)
2 157944-9420 Bracket 1 For fixing PE(S)-P type pump
3 157944-8620 Bracket 1 For fixing PE-P type pump
4 105792-0030 Extractor 1 For removing plunger block assembly
5 105792-0000 O-ring inserter 1 For inserting O-ring in pump housing
6 105782-4130 Measuring device 1 For measuring camshaft end play
(for 20 mm dia. camshaft)
7 105782-4140 Measuring device 1 For measuring camshaft end play
(for 25 mm dia. camshaft)
8 79D-1579156500 Wrench 1 For removing and installing control rod
screw bush
9 157916-4820 Spanner 1 For fixing and rotating timing device
and coupling
10 15792 I-8020 Tappet inserter 1 For removing and installing tappets (for
6-cylinder engine)
11 79D-1579205300 Oil seal guide 1 For protecting bearing cover oil seal
(17 mm dia.)
(20 mm dia.)
I I I I (25 mm dia.)
14 157920-7720 Extractor 1 For removing bearing cover
15 157920-9900 Bracket 1 For removing bearing cover
16 79D-1579252020 Extractor 1 For removing outer race
17 79D-1579257120 Extractor 1 For removing inner race
18 79D-1579265320 Extractor 1 For removing flyweight
19 79D-1579266220 Extractor 1 For removing timing device
(M24x 1.5)
20 79D-1579266120 Extractor 1 For removing timing device
(M45x 1.5; M5Ox 1.5, M30x 1.5)
21 15793 I-4700 Tappet holder 10 For holding tappets (for 10 mm and
1 1 mm cam lift)
22 157828-7100 Plate 1 For installing camshaft (for 17 mm and
20 mm dia. camshaft)
23 157828-7200 Plate I For installing camshaft (for 25 mm and
35 mm dia. camshaft)
24 157944-3520 Plate 1 For removing plunger block assembly
25 15792 I-8900 Shaft 1 For removing and installing tappets
(for 8-12 cylinder engines; used with
157921-8020)
13-002
KEY Q’TY APPLICATION
PART NO. TOOL NAME
NO.
26 157914-0500 Socket wrench 1 For removing delivery valve holder
(SW22)
27 157931-4800 Tappet holder 12 For holding tappets (for 10 mm,
11 mm and 12 mm cam lift)
28 157921-4820 Inserter 1 For removing and installing plunger
29 157921-5620 Inserter 1 For removing and installing control
sleeve and upper spring seat
30 157914-0200 Socket wrench 1 For removing and installing roundnut
(SW1 7)
31 157914-0300 Socket wrench 1 For removing and installing roundnut
(SW1 9)
32 ’ 157916-9520 ’ Spanner 1 For preventing V/T type timing device
rotation (installation pitch: $76)
33 1579 16-5320 Spanner 1 For preventing timing device rotation
(installation pitch: 466; $72; @85)
34 79D-1579267220 Extractor 1 For removing SP type timing device
(M32x 1.5; M26x 1.5)
35 79D-1579267420 Extractor 1 For removing SPM type timing device
(M30x 1.5)
36 79D-1579267620 Extractor 1 For removing SPGH type timing device
(M36x 1.5)
37 157916-2800 Box wrench 1 For removing roundnut (SW1 9)
38 1579 16-2900 Box wrench 1 For removing roundnut (SW1 7)
39 79D-1579150100 Wrench 1 For removing RSV, RAD and
RFD-type governor roundnuts
40 79D-1579150200 Wrench 1 For removing RQ type governor
roundnut
41 79D-1579150300 Wrench 1 For removing roundnut fixing timing
device
42 15791 O-l 120 Handle 1 For socket wrench
43 157914-0090 Socket wrench 1 SW32
44 157991-0100 Inserter 1 For press-fitting camshaft sleeve
(20 mm dia. camshaft)
45 157991-0200 Inserter 1 For press-fitting camshaft sleeve
(25 mm dia. camshaft)
46 157954-l 000 Dial gauge 1 For measuring camshaft axial play
47 157992-l 500 Inserter 1 For installing snap-ring to plunger
barrel (used together with cap:
157992-l 600)
48 157992-l 600 Cap 1 For protecting O-ring groove of
plunger barrel (used when installing
snap-ring)
Note: The special tool kit (105790-7050) for PE-P type injection pump disassembly includes
tools with key nos. 4-26.
13-003
A
a- ILn
FIPPOO
x o-l
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FIPPOO
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R R
FlPPoo
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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
25
Fig. 27 KD type supply pump: exploded view
13-010
DISASSEMBLY
PREPARATION
Keep the work bench clean and tidy. Before
beginning disassembly record performance
data for later reference to facilitate the diagno-
sis of malfunctions and defects, if any, in the
disassembled pump.
In the course of disassembly lay out the dis-
assembled 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 ex-
Fig. 28 Mounting the bracket amined.
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*
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
r
---A--
---
-.
2
0
FIPPOO
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 1 Part Number 1 Remarks

Special 157915-0100 Tooth width:
wrench 2.2 mm
1579 15-0200 Tooth width:
3.9 mm
157915-0300 Tooth width:
5.9 mm
Fig. 34 Removing the flyweight roundnut
10. Remove the flyweight using the extractor

(157926-5320). (Fig. 35)
Note: As various types of mechanical gov-
ernors may be installed on the PE(S)-
P type injection pump, refer to the
relevant governor service manual be-
fore proceeding with governor dis-
assembly.
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
oz
G-
..
FIPPOO
15.Attach the oil seal guide to the camshaft
drive side’s tapered portion. (Fig. 40)
Part Name Part Number Remarks

Oil seal guide 157920-5300 Shaft
diameter:
$17
157920-5400 Shaft
diameter:
020
157920-5500 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: When removing the bearing cover
take care not to lose the shim adjust-
ing the axial end-play of the camshaft
inserted between the pump housing
and the cover.
Fig. 41 Removing the bearing cover
17 Lay the pump on its side and move the

camshaft (71) toward the driveside to re-
move the centre bearing. (Fig. 42)
13-015
l-l
-.
co
.
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3
z
-.
2
s
CD
cn
0
s
3
0
1
0’
5
-.
(a3
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 remov-
ing 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) lubricat-

ing 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 insert-
er (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 up-
per spring seat (43) together. (Fig. 51)
Note: 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 re-
moved.
Fig. 51 Removing the control sleeve and the

upper spring seat
13-018
-
-
OOddH
31.Using two spanners (SW14 and 27), oper-
ate the extractor to extract the plunger
block assembly (7). (Fig. 55)
Ndte: Place the plunger block assembly
together with its previously removed
matching plunger in their correct
order in a container of light oil.
*Refer to paragraph 38 for important points
relating to “Plunger Block Assembly Dis-
assembly. ”
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 on the

pump’s governor-side (Fig. 57)
Fig. 57 Removing the pin
13-020
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s
E
-.-
\ \
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.-6,
LL
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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, 157914-
0500) and remove. (Fig. 65)
-5. Remove the delivery valve spring (7/7).
Fig. 65 Removing the delivery valve holder
-6. Use tweezers to remove the delivery

valve (7/3). (Fig. 66)
=;-
I ly. 66 Removing the delivery valve
13-023
s
CD
FIPPOO
39.When it is necessary to remove the cam-
shaft 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 pump assembly in a vise.

(Fig. 71)
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
0
-’ “3. cn’ 2
.
3
03
s
CD
FIPPOO
Thoroughly 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.
PE-P TYPE PUMP INSPECTION
Plungers
I. If the plunger helix is scratched, worn or

discoloured, replace the plunger assembly.
(Fig. 80)
Fig. 80 Plunger helix
2. After cleaning the plunger thoroughly, en-

sure that the plunger slides smoothly into
the barrel under its own weight when in-
clined 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 assem-
bly. (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
7 N
0
$
..
r-t
5
-
5-
1
-.
cn
2
0
3
0
1
FIPPOO
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
11
-.
LJ CQ
.
6
g
ki
2
3
u
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cn
-.
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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, re-
place 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
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-.
cc2
.
5
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-
-
-.
ra3
7
0
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..
FI PPOO
Install a new O-ring on the delivery valve
I----- 4.
holder,
screw
apply grease to the O-ring and then
the delivery valve holder into the
sleeve flange. (Fig. 98)
Fig. 98 Installing the O-ring
5. 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 hold-
er from the plate.
Fig. 99 Tightening the delivery valve holder
7. Install the washer and deflector. (Fig. 100)

Note: The deflector has a top and a bottom.
Furthermore, the deflector is to be in-
stalled 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.
Fi g. 100 installing th, * \Alasher

.._ and def!ector
13-035
d
3
FIPPOO
0
..
OOddkJ
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 insert-
er (157921-5620). (Fig. 109)
Note: 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.
Fig. 109 Installing the upper spring seat and

plunger spring
13-038
10. Position the plunger helix (or stamping) so
that it faces in the same direction as the
sleeve flange aligning knockpin and then in-
stall 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 hold-
er into the plug hole. (Fig. 112)
Fig. 112 Inserting the tappet holder
13-039
6
P
0
-.
3
FI PPOO
k
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SEBM012702
FUEL INJECTION
PUMP
(With KOMATSU ELECTRONIC GOVERNOR)
FUEL INJECTION PUMP MODEL
KFE
©2001
2
CONTENTS
01 GENERAL ........................................................................................................ 01-001
12 TESTING AND ADJUSTING ............................................................ 12-001
14 ADJUSTING .................................................................................................. 14-001
15 OTHERS ........................................................................................................... 15-001
00-002 FUEL INJECTION PUMP

2
Revision Indication
Revision
following
Mark marks.
Page
numberIt is Mark
requested
Page that necessary
number
Mark ac-
Page
number
Mark Page
number
Mark Page
number
below.


b 00-001 2 12-002 c 14-003 2

b 00-002 2 12-004 1 c 14-004 2
c 00-003 2 12-005 1 c 14-005 2
12-007 1 c 14-006 2
01-001 12-008 1 c 14-008 2
01-002 12-008-1 1 c 14-009 2
01-003 1 12-009 1 c 14-010 2
01-004 12-010 1 c 14-011 2
01-005 12-010-1 1
01-006 12-010-2 1 15-001
01-007 12-010-3 1 15-002 1
12-011 15-003 1
11-001 12-012 15-003-1 1
11-002 12-013 15-004
11-003 15-005 1
11-004 13-001 15-006 1
11-005 13-002
11-006 13-002-1 1
11-007 13-003 1
11-008 13-004 1
11-009 1 13-005 1
11-010 13-006 1
11-011 13-007 1
11-012 13-008
11-013 13-009 1
11-014 13-010 1
11-015 13-011 1
11-016 13-012 1
11-017 13-013 1
11-018 13-014 1
11-019 13-015 1
11-020 13-016
11-021 13-017
11-022 13-018
11-023 13-019
11-024 1 13-020
11-025 13-021
11-026 1 13-022
11-027
c 14-001 2
12-001 1 c 14-002 2
FUEL INJECTION PUMP 00-003

2
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SPECIFICATIONS
Machine model H D785-3, H D985-3
Engine model SA12V140-1 (Mounts 2 fuel injection pumps)
Fuel injection pump type KFE6S135R-1
Dimensions
(length x width x height) I mm
I 526x139x320
Weight 30.0 (Not including flyweight) *I

I kg I
Direction of rotation Clockwise
Firing order l-5-3-6-2-4
Injection interval 60” + 20’
Plunger diameter mm 13.5
Cam lift (plunger stroke)
*2
Prestro ke 4-6
I mm I
1.70
Delivery valve cracking pressure (I 7.3)
Equal pressure valve cracking pressure MPa 9.80
(built into delivery valve) {kg/cm21 {IO01 g
*3 k
Delivery valve retraction volume m m3/st. - L
*I : The flyweight mentioned he:e is the small fly-

weight 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 re-
traction function. However, the abilityto stop
the flow of fuel after the completion of injec-
tion is good in the same way as the equal
volume type.
01-002
.-0
OOddM
FIPPOO
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To cylinder block
FIPPOO
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m
tr
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. .
. .
. .
. .
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.
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. .
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. .
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. .
. .
. .
. .
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. .
. .
. .
. .
. .
.
E
s
26
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FIPPOO
8I
I
.----. I
I
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--- I
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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
U)
8I
_ -. --I
I
I -__
I-
O
Y
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FIPPOO
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FIPPOO
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P
-0
-
FIPPOO
-
0
L
YL
-
0
L
CL
EZ
“C
.-
c-
Y
f
t
OOddM
__-_-----
-7
FIPPOO
OOddM
FIPPOO
II i-l
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0
8
-.
-
7 D
l_LJ n
\: -.
D
m
FIPPOO
[ Hydraulic pump (for KFE6S135R-1) ]
‘pass va I ve
/
E-E (Fuel) B- B (Fuel)
D
D-D (Oil)
A-A
+A
lter
Rel
val
Cd
C-C (Oil) SWE01089
::a 7
Y
FIPPOO
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[ Delivery valve and equal pressure valve 1
Delivery valve holder
A4
Equal Pressure valve
Delivery valve
A-A
11-020
I--
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I’ \\
: \\
I
I
i\
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\ /
\
\ /I
\\
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,/I’
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.--___A
FIPPOO
Function of governor I Mechanical governor I Electronic governor
Basic function of governor Basic functions are governed by The basic functions are governed by the rack
all component parts inside me- position control system (rack position con-
chanical governor (flyweight, trol cylinder, rack position control valve, rack
lever, spring, etc.) position control solenoid built into electronic
Note :For details of the me- governor, and rack position sensor, and con-
chanical governor, see troller outside electronic governor).
“COMPONENTOF ENGINE”
(No. SEBECOMP003).
Function to know when engine It is known that the engine has The electric signal from the starting switch
has started started, from the spring inside passes through the wiring harness and in-
the mechanical governor. forms the controller that the engine has
started.
Function to know angle of ac- This is known from the angle of This is known from the angle sensor installed
celerator pedal the speed control lever installed to the accelerator pedal.
to the mechanical governor.
Function to know engine speed This is known from the fly- This is known from the engine speed sensor
weight inside the mechanical installed to the engine flywheel housing.
governor.
Function to advance fuel injec- The timer governs this function This function is governed by the prestroke
tion timing according to rise in control system (prestroke control cylinder,
engine speed prestroke control valve and prestroke control
solenoid inside electronic governor, and con-
troller and engine speed sensor outside elec-
tronic governor).
Function to know rack position This is known from the rack position sensor.
-
! ! -023
RACK POSITION CONTROL SYSTEM
Rack position Rack position

sensor control cylinder
Rack i-I-1
Rack position
Fuel in_iection
(exclusive for
Pump
electronic
t Hydraulic Pump I
I
I governor)
Controller
Lubricat
---------k---
ina oi I
I
, 1 , %;;;;;d ’
Electronic ,/
Electric signal governor
--____-- --I /._II__p___@
, ~ ,Electric sizl 1 1 Elztric signal, ‘\ ,
Engine speed sensor

I Angle
(installed
sensor
to accelarator Pedal)
(installed to flywheel housing) SWE01205
Note .- “0” and “R” are both connected on the

circumference.
11-024
0
The controller knows the speed desired by the 3) The oil pressure at portion P passes through
operator from the electric signal (output volt- the oil passage and is transmitted to the rack
age) from the angle sensor installed to the position control cylinder. It pushes the spring
accelerator pedal. To obtain the desired inside the cylinder and compresses it to move
speed, it selects the necessary rack position the piston. It stops at the point where the
from the data already stored in the control- hydraulic pressure at portion P is balanced
ler memory. It then selects the value for the with the reaction force of the spring.
solenoid current that matches the rack posi- The hydraulic force at portion P and the
tion from the data and sends the current to change in the position of the piston are pro-
thn
.* .Y rarlr nncitinn
sWY..yvvm..v.. rnntrnl
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II. thn nncitinn
Lll” y”“.‘.“.. nf
VI the
(The above explanation shows the concept of piston means the change in the position of
the system. In fact, it determines the sole- the rack. By controlling the solenoid current,
noid current directly from the voltage output the rack position is controlled indirectly.
from the angle sensor on the pedal.)
4) The controller knows if the rack position is
When the solenoid pushes the rack position being correctly controlled from the rack posi-
control valve spool, it pushes the spring in- tion sensor. If the rack position is not correct,
side the valve and compresses it to move the it corrects it.
spool. The solenoid stops at the point where
the pushing force is balanced with the reac- 5) The amount of fuel injected corresponds to
tion force of the spring. the position of the rack.
The solenoid pushing force and the change If any load is applied to the engine, the con-
in the position of the spool are proportional. troller knows that the engine speed has
The change in the position of the spool and dropped from the engine speed sensor, so it
the hydraulic pressure at portion P are also controls the position of the rack to increase
proportional. the injection volume and prevents the engine
speed from going down.
c
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cz
/ a¶ /
6%
Solenoid current Solenoid pushing force Change in position of

valve spool
0 0.418 0.682 20 25
Solenoid current (A) Rack position (mm)
SWEOlO70
1 l-025
\ I /
I I /
L______----__ _._l
t
-___------
FIPPOO
Operation of prestroke control system
1) The controller knows the engine speed from The solenoid pushing force and the change
the electric signal from the engine speed sen- in the position of the spool are proportional.
sor. It selects the matching value for the angle The change in the position of the spool and
of advance suitable to the engine speed from the hydraulic pressure at portion Y are also
the data already stored in the controller proportional.
memory, then selects the value for the
prestroke that matches the angle of advance 3) The hydraulic force at portion Y passes
from the data, and then selects the value for through the oil passage circuit and is trans-
the solenoid current that matches the value mitted to the prestroke control cylinder inside
of the prestroke from the data, and sends the the plunger. It pushes and compresses the
current to the prestroke control solenoid. (The spring inside the plunger, pushes up the top
above explanation shows the concept of the part of the plunger, and extends to increase
system. In fact, it determines the solenoid the length of the plunger until the hydraulic
current directly from the engine speed.) force and spring force are balanced. The
prestroke becomes shorter by the amount that
2) By controlling the solenoid current, the the plunger becomes longer.
prestroke is controlled indirectly, and as a re- The fuel injection timing is advanced by the
suit it controis the angie of advance. amount that the prestroke becomes shorter.
The current flowing to the solenoid and the That is, the injection angle is advanced.
solenoid pushing force are proportional. As a result of the flow of controls described
When the solenoid pushes the prestroke con- above, if the engine speed is changed, the
trol valve spool, it pushes the spring inside angle of advance is changed as shown in the
the valve and compresses it to move the charts below.
spool. The solenoid stops at the point where
the pushing force is balanced with the reac-
tion force of the spring.
/ /
Solenoid current Solenoid current Oi I pressure at Chanee in prestroke

portion Y J
La rae
t
ln.iec t ion amount
Sma I I
Engine speed
Solenoid current 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
0
0
G;
-.
0
3
-.
0
FIPPOO
r”
CD
-
-.
3
L.
5
-.
0
3
u
u*
5
FIPPOO
Carry out the wiring as shown in the diagram below.
Prestroke current Governor current

adjustment knob adjustment knob
To Power source
Digital meter
Power switch
XEP checker Komatsu fuel injection Pump

with electronic governor
Prestroke current
1
Rack vol tag ee Governor current
Detail of display selector switch TWE00752

PRESTROKE AD.9USTMENT
1. Remove the delivery valve (15) of the No. 1 cylin-

der from the driven end.
2. Remove spring, spring seat (17) and delivery valve 17

(16).
3. Install measuring device T to the plunger barrel,

18
then tighten with the nut.
zm Nut: 49 + IO Mm (5 IL 1 kgm}
4. Set the fuel supply pressure of the locally avail-

able pump stand to 0.05 MPa (0.5 kg/cm2}.
5. Change rack stopper bolt to rack adjusting bolt V.
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 de-
vice 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 sec-
ond as the point where the flow of fuel stops.
Note : The moment where the fuel flow stops is

the moment where the injection starts.
TWE00602
j2-nn7
__I
0
8. If the prestroke is not within the standard value,
adjust the prestroke as follows. Nut
Loosen the nut and pull out the shim between
the plunger barrel and housing (C). Plunger
Change the thickness of shim, then tighten the barrel
nut and measure the prestroke again. Con-

Shim
tinue this process until the prestroke is within
the standard value (see calibration data).
Note : The calibration data is given in each en-
gine shop manual.
After adjusting, match the angle scale of the
test stand to the standard position. (Set the
angle standard for injection interval adjust-
ment 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 de-
livery 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 in-
sert the same thickness of shims on both
sides of the plunger barrel flange to ad-
just.
* Be careful not to get any dirt caught.
9. 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 is not within the

No.2 cylinder 1 239"40' !I240"20'
3 1 119"40' + 120"20'
4 299"40' k 300"20'
5 59"40' f 60"20'
6 179"40' Ifr180"20
standard value, repeat the adjustment proce-

dure for the prestroke and adjust the shim
thickness to bring within the standard value.
1 Z-008
0
. Remove delivery valve holder (15) of the fifth cyl-
inder from the drive side.
. Remove the spring, spring seat (17) and delivery
valve assembly (18).
0 Install measuring device T to the flange sleeve,
then tighten the nut.
. Slowly turn the pump manually in the turning di-
rection and read the turning angle (the angle from
the above standard position) when the fuel stops
flowing from the overflow pipe of measuring de-
vice T (when injection starts).
. Aft,,Or-ad,LKW ‘3, rAW-t-bn\,fi
;I ,c.+in/1 _fi_r\l ,V-:till.-J,..:~- 1-
,GaIIuvc ItlGa~ulllly UGVILG I, +L-“.
LllGll
install the delivery assembly, gasket, seat and
delivery valve holder.
. Adjust the other cylinders according to this pro-
cedure.
12-008-l
0
ADJUSTMENT OF FUEL
INJECTION VOLUME
. After adjusting the fuel injection timing for all the
cylinders, remove the measuring device, as-
semble the delivery valve, and connect the fuel
injection pipe.
. Adjust the fuel injection volume as follows.
1. Preparatory work
1) Loosen the rack adjustment bolt V, and set

the rack position to “0” (the point where there
is no reaction force from the spring).
2) Put a dial gauge in contact with the head of
rack adjustment bolt V and set the scale on
the dial gauge to “0”.
3) Assemble so that the stud bolt is more or less
at the center of the oblong hole for installing
the barrel.
4) 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 Using the prestroke current adjustment knob
on the XEP checker, set the prestroke hydrau- TWE00603
lic pressure to the specified pressure at the
rated point (see calibration data *I).
3) Set the pump speed to the specified speed at
the rated point (see calibration data *I).
4) 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).
5) 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 in-
jection pipe (8) and 2 plunger barrel
mounting nuts (9).
. Using a screwdriver, turn plunger barrel I
(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).
6) The average injection volume may go outside
the specified value when the unequal amount
is adjusted, but in this case, adjust rack ad-
justment bolt V again to bring the average
injection volume within the specified value.
7) Stop the rotation of the injection pump and
oil pump. Shim
After adjusting the injection volume at the
rated point, measure the output voltage of the
rack position sensor with the XEP checker. ,I?\ L +
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). i’l cl -; 9
Measure the rack position (amount rack ad-
Rack position sensor
justment bolt V is pushed in) with the dial
gauge and compare it with the specified po- TWE00753
sition at the rated point (see calibration data

*I). (Do not make any judgement.)
* Adjust the output voltage of the rack sen-
sor as follows:
INCREASE shim thickness if voltage is too
HIGH
DECREASE shim thickness if voltage is too
LOW
*I :The calibration data is given in each engine

shop manual.
3. Adjusting injection volume at low idling
1) Return rack adjustment bolt V and set the rack

position to “0”.
2) Set the pump speed to the specified value for
low idling (see calibration data *I).
3) Use the prestroke current adjustment knob on
the XEP checker to set the prestroke hydrau-
lic pressure to the specified value for low
idling (see calibration data *I).
4) 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
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 en-

gine shop manual.
6) After adjusting the average ratio, if the av-

erage injection volume is out of the speci-
fied range, adjust the push-in distance of
the rack adjustment bolt V again, then
check the result.
7) Read the rack voltage and rack position
at this time with the XEP checker and dial
gauge respectively.
4. Recheck of injection volume at rated point
1) Using the prestroke current adjustment

knob on the XEP checker, set the variable
prestroke hydraulic pressure to the speci-
fied pressure.
2) Set the pump speed to the specified
speed.
3) Push in the rack adjustment bolt V gradu-
ally and measure the injection volume in
each cylinder, then check the average in-
8 jection volume and average rate.
k 4) Repeat following procedures (5), (6) and
ii
(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 measur-
ing, remove all light oil from the mea-
suring 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. Re-
place the delivery valve in this case.
u
2
3
+ t
3-l n
- -
0 ?
b
cc !2
- -
h -1
iA b
l-t I+
C f’=
k C
a
c c
:: 8
I-l l-t
C c
FIPPOO
v) - .-
.- al 3
PcnuY
OOddM
(v
. .
OOddM
”
Z
?
-
FIPPQO
al
-
a
5:
-
-
.-
4
In
0
m
CL
OOddM
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 pump with electronic gov-
ernor, use the special tools listed below in addition to the normal tools.
Symbol Part No. Part Name Q’tY Remarks
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 202 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
79A-474-1290
13-002
Nm: {kgm}
Model
NO. Item
KFE6S135R-1 KFEGS135L-1
1 I Delivery valve holder I 151.9 + 4.9 {I 5.5 I!I 0.5) I 151.9I!I

4.9 {I 5.5 rf:0.5)
2 Flange holding nut 53.9 f 4.9 (5.5 * 0.5) 53.9 I!I 4.9 (5.5 f 0.5)
3 Governor housing mounting bolt 30.9 I!I 3.4 (3.15 + 0.35) 30.9 It 3.4 (3.15 I!I 0.35)
4 Gear pump cover mounting bolt 30.9 ?I 3.4 (3.15 I!Y0.35) 1, 30.9 * 3.4 (3 15 f n.35)
5 Joint bolt 11.27 f 1.47 (1.15 I!I 0.15) 11.27 f 1.47 (I.15 + 0.15)
I I
6 1 Control solenoid valve mounting bolt I 13.23 I!Z1.47 (1.35 I!I 0.15) I 13.23 ?I 1.47 (I.35 f 0.15)
7 I Rack sensor circuit mounting bolt I 17.2 f 1.47 (1.75 I!I 0.15) 17.2 f 1.47 (1.75 + 0.15)
* 8 Deflector I 17.2 + 2.47 (1.75 z!z0.25) 17.2 f 2.47 (1.75 I!I 0.25)
-__
* 9 Upper seat lock mounting bolt 13.23 + 1.47 (1.35 I!I 0.15) 13.23 f 1.47 (I.35 Z?I0.15)
* 10
I Tappet lock mounting bolt I
13.23 I!I 1.47 (1.35 !I 0.15)
I 13.23 + 1.47 Il.35 +_0.15)
* 11 Bearing stopper mounting bolt 11.27 _+1.47 (1.15 -t 0.15) 11.27 + 1.47 (1.15 Z!I0.15)
I I
8 12 Joint bolt 29.4 f 4.9 (3.0 + 0.5) 29.4 * 4.9 (3.0 z!I0.5)
E
ii * 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)
15 Joint bolt 29.4 f 4.9 (3.0 + 0.5) 29.4 * 4.9 (3.0 I?I0.5)
I I
16 Lock nut 29.4 + 19.6 (3.0 If: 29.4 I!I 19.6 (3.0 f 2)
17 8.82 I!Z0.98 (0.9 + 0.1) 8.82 I!I 0.98 (0.9 I!I 0.1)
I Air bleed bolt (Fuel) I I
18 Control rack sliding resistor 20.6 N {Max. 2.1 kg} 20.6 N {Max. 2.1 kg}
19 Cam shaft end play 0 - 0.02 mm 0 - 0.02 mm
Air bleed bolt

20 (Variable prestroke control oil) 8.82 I!I 0.98 (0.9 +_0.1) 8.82 f 0.98 (0.9 + 0.1)
21 Rack stopper bolt 17.15 3: 2.45 (1.75 f 0.25) 17.15 + 2.45 (1.75 f 0.25)
22 Rack guide bolt 13.23 f 1.47 (1.35 + 0.15) 13.23 I!I 1.47 (1.35 I!I 0.15)
DISASSEMBLY
-k Before disassembling the fuel injection pump,

clean it thoroughly and check that there is no leak-
age of oil from the mating surface of the plug or
gasket.
1. Rack position sensor

1) Remove connector (I), then remove 4 mount-
ing bolts and remove rack position sensor cir-
cuit (2).
2) Loosen nut, then remove rack position sen-

sor (3).
* Confirm the quantity and thickness of
shims, and keep them till reassembly.
Rack bush -b
2. Solenoid and valve
1) Remove mounting bolt, then remove Shi
prestroke control solenoid (4) and rack posi-
tion control solenoid (5). \
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
Fuel relief Screen
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 bolts, then remove plate

(8).
4) Remove gears (9) and (IO).
Oil inlet valve

5) Remove gear pump body (11). valve strainer DWE00243
* The gear pump body, drive gear, and
driven gear are supplied as an assembly,
so when replacing, replace the whole as-
sem bly.
+ HQusiwg (A)
1) Remove 6 mounting bolts, then remove hous-
ing (A) (12).
2) Remove piston (13) of the rack position con-

trol hydraulic cylinder from housing (A).
DWE00123 II OWE00124
DWE00125 \ I DWEOOl 26
13-004
0
-
0-l
-
0
0
w
B
0
OOddM
9. Control sleeve
r
Using pincette, remove control sleeve (23).
10. Plunger 23 24
Using pincette, remove plunger (24).
* When removing the plunger from the lower
spring seat, rotate the plunger approx. 35”
clockwise.
DWE00133 DWE00134
11. Rack
Remove stopper bolts and pull out rack (28)
frontward.
DWE00136
12. Plunger spring, upper spring seat

Fixing nut
1) Using tool E, compress plunger spring, then
remove stopper bolt (29).
Ir If tool E is not used to remove the stop-
per bolt, the thread of the stopper bolt
may be damaged by the tension of the
spring, so always use tool E.
2) Loosen the mounting nuts in turn to release

the tension of the plunger spring, then remove
tool E.
u \
DWE00230
3) Remove upper spring seat (30) and plunger
spring (31).
13. Lower spring seat, tappet assembly

Remove lower spring seat (32) and tappet assem-
bly (33).
Remove tappet guide bolt (33-l).
33-l DWE00235
13-006
0
.-cn .-CIY
.-c, .-+
Y- +
.-
H
L.
OOddld
s
00
FIPPQO
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-‘] Stud bolt : 32 2;: Nm {3.2+$~ kgm}
1. Housing (B)
1) Install oil seal (37) to housing (B). 1 DWE00150
2) When replacing bearing outer race (36), in-

stall new one to housing (C) so that it will pro-
trudes approx. Imm from the ring.
3) Fit the O-rings to housing (B) and housing (C),
then install housing (B).
& Oil seal lip : Grease (G2-LI)
DWE00144 DWE00143
Pump housing
2. Bearing
outer race
If bearings were removed, press fit bearings (46), /
Rine
\
0 ring
(45) to camshaft. DWE00244
* When press fitting the bearing, put special

tool J in contact with the bearing inner race, 45 46
and press fit the bearing with a press fully as
far as the stepped portion of the camshaft.
3. Camshaft
44 DWE00149
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.
2) Replace 4 seal washers with new parts, then
temporarily tighten 4 center bearing mount- 42
ing bolts (42).
* Tighten the mounting bolts fully after ad-
justing the end play.
4. Bearing cover
Using special tool L, install oil seal (41) to bear-
ing cover (38), if bearing outer race (40) is re-
moved, install bearing outer race (40).
38
DUE00241
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 in-
stall bearing cover (38). 3 DUE001 42
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 speci-
fied value.
* Move the camshaft forward and back-
ward from the gear pump drive gear
side.
* End play of camshaft : 0 - 0.2 (mm)
2) Install the shims of correct thickness and at-

tach the O-ring, bearing cover (38) and pointer.
DUE00151
3) Tighten 4 center bearing mounting bolts.
7. Tappet assembly, lower spring seat
Mount tappet guide bolts (33-l) to housing
0.
2) Mount the tappet guide bolts.
Set tappet assembly (33) on lower spring seat
(32), then use tool F-2 to install into housing
(0.
Ir 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 (33-
1j of the pump housing. 33-l DWE00235
&I=, Tappet guide bolt:

Thread tightener (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 hous-
ing (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).
& Stopper bolt : Thread tightener (LT-2)
4) 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 in-
stall.
* Insert the bottom of the plunger into the hole
of the lower spring seat, then turn 35” clock-
wise.
* 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 in-
jection 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 bar-
rel (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,
and use the sam, n +h+ness
,I 1uB of shim at the
left side and right side.
* Check that the control rack slides
smoothly after assembling the plunger
barrel assembly to each cylinder. Plunger
* Check the injection timing with the test barrel
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.
Oblong
hole
DWE00246
13-012
0
13. Rack spring
1) Use tools B and 6 to measure sliding resis-
tance 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 DWEOOt30 DWE00129

delivery valve holder (I 5) temporarily.
Tighten it normally after adjusting the in-
jection timing.
15
15. Deflector
Install deflector (14).
& Deflector : Thread tightener (LT-2) 14
DWE00156
P
FIPPOO
2) Fit O-ring, assemble rack position control so-
lenoid (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 19. Rack sensor
u.
1) Aassemble the disassembled and kept at dis-
assembly shims, then fit rack position sensor
Rack
(3) and tighten nut. senso
core
2) Fit rack sensor circuit (2) to pump body, then

tighten 4 mounting bolts and install connec-
tor (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 and tighten with nut.
QKI Nut:29_+2Nm{30+2kgmI
DWEOOtt8
FIGURE OF SPECIAL TOOLS
SPECIAL TOOL A
Part No. : 79A-474-1410
Part Name : Plate (including 1 bolt)
Material : Iron
100
DWE00161
SPECIAL TOOL B
Part No. : 79A-474-1111
Part Name : Eyebolt
Material : Iron
DWE00162
13-016
t ( P.1)
OOddM
SPECIAL TOOL F-l
Part No. : 79A-474-1270
Part Name : Lifting tool (I)
Material : SWP-A (spring steel)
DWE00166
SPECIAL TOOL F-2

Part No. : 79A-474-1260
Part
* _.. .vame I ifiinn tog! (2)
.- “““.~
Material : SWP-A (spring steel)
DWE00167
13-018
.. .. ..
aI
OOddkl
SPECIAL TOOL J
Part No. : 79A-474-1430
Part Name : Push tool
Material : s43c
Heat treatment : Quenching and tempering of
completed part (KES122501400)
a7
102
DWE00169
Jl: 50 (knurled portion)
SPECIAL TOOL K
Part No. : 79A-4474-l
D-V+ y~-~ . f..:rln
I a#~ I atlm . Gutuc
Material : s43c
DWE00170
13-020
e $_
a
t= i
084’
n
OOddkl
924. 5:“’ _,
FIPPOO
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

2
ADJUSTING ADJUSTING FUEL INJECTION PUMP
ADJUSTING FUEL INJECTION PUMP

PREPARATION WORK
After disassembling and assembling the fuel injec-
tion pump and electronic governor, set the fuel injec-
tion 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.

2
TESTING FUEL INJECTION TIMING (PRE-

STROKE)
• Remove delivery valve holder (3) of the 1st cylin-

der from the drive side.
• Remove stopper (4), spring (5), delivery valve as-

sembly (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 di-
rection and measure the plunger stroke until fuel
stops flowing out of the overflow pipe of measur-
ing 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/sec-
ond to be the starting point of fuel injection.

2
1. Adjusting fuel injection timing (pre-stroke)

If the pre-stroke is out of the standard range, ad-
just 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 bar-
rel flange will be free from foreign mat-
ter.
2. Adjusting fuel injection interval

Measure the injection start interval of the 2nd cyl-
inder 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 240˚ ± 20'
3rd cylinder 120˚ ± 20'
4th cylinder 360˚ ± 20'
fl If any injection start interval is out of the stan-

dard range, adjust it by changing the thick-
ness of shim (7) according to the procedure
for “Adjusting pre-stroke”.

2
MEASURING FUEL INJECTION RATE
• Remove measuring device C and install the de-

livery valve assembly, delivery valve holder (3),
etc. correctly, then connect fuel injection pipe (8).
• Drive the pump at the standard speed and mea-
sure 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 (at-

tached to the test stand) and discharge the all
diesel fuel from it before starting measure-
ment.
1. Adjusting fuel injection rate

If the fuel injection rate is out of the standard
range, adjust it according to the following proce-
dure.
• 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.

2
CALIBRATION DATA
Injection Pump Assembly Number
6553-00-1112 (106682-4751) (Left bank) Applicable Machine Applicable Engine
6553-00-1212 (106684-4013) (Right bank) Model Serial No. Model Serial No.
( ): Injection pump manufacture's part No.
HD785-3 SA12V140-1
Injection Injection Pump
Pump Type Manufactuer HD985-3
(With electronic
PFE6S135 KOMATSU governor)
Injection pump specification Engine Specification

783{1,050}/2,100
Rotating direction Clockwise Flywheel horsepower (kw{HP}/rpm) (HIGH POWER mode, Net)
4,170{425}/1,500
Injection order 1–5–3–6–2–4 Maximum torque (Nm{kgm}/rpm) (HIGH POWER mode, Net)
2,400 – 2,500
Injection interval 59˚30' – 60˚30' High idling speed (rpm) (HIGH POWER mode)
650 – 700
Plunger pre-stroke (mm) 5.95 – 6.05 Low idling speed (rpm) (HIGH POWER mode)
Delivery valve 3
— Pump tester capacity
retraction volume (mm /st) for Service standard Motor: 7.5 KW
Calibration Standard ( ): Injection pump manufactuere's part number

Service standard Manufacturer standard
Conditions Nozzle & nozzle holder part No. (105780-8130)
• Service standard Nozzle part No. (105780-0050)
indicates data
using calibration Nozzle holder part No. (105780-2090)
test parts. Injection pipe (mm)
(Outside dia. ✕ inside dia. ✕ length)
8 ✕ 4 ✕ 1,000
• Manufacture
standard is data Test oil ASTM D975 No.2 diesel fuel or equivalent
for factory test. Oil temperature (ºC) 40 – 45
Nozzle opening pressure (MPa{kg/cm2}) 17.7 – 18.2 {180 – 185}
Transfer pump pressure (kPa[kg/cm2}) —
Injection volume Prestroke Service standard (cc/1,000 st.) Manufacturer standard (cc/1,000 st.)
• Rack positions pressure Rack Rack Pump
Maximum Maximum
B to E are the ref- (kPa voltage position speed
(V) (mm) (rpm) Injection variance Injection variance
erence volume {kg/cm2}) between between
volume volume
when adjusting the cylinder cylinder
injection
volume. Rated 882 2.55 – 12.4 – 1,050 403 – 409 Max. 24
point {9.02} 2.57 13.2
• Marks ★ are
average
volumes. Low
idling 490 Approx. Approx. 300 29 – 35
{5.0} 1.26 5.5 Max. 10
point
Governor performance curve

(Not specified)

2
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 pres-
sure 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.

2
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 en-
ters 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 volt-
age once again.

2
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 speci-
fied 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 cur-

rent after the pre-stroke oil pressure and rack volt-
age were adjusted to the spesified ranges.
fl Governor performance measurement stan-

dard.
Fuel injection
pump speed Rack voltage Governor current
(rpm) (V) (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 mea-
surement using a voltmeter.

2
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.

Measuring item
Set point (specified range)
Fuel injection ª Pre-stroke ª Governor Pre-stroke
pump speed current current oil pressure
(rpm) (A) (A) (MPa{kg/cm2})
0.71 ± 0.03
1 325 ± 5 0.7 ± 0.05 0 {7.2 ± 0.3}
0.89 ± 0.03
2 325 ± 5 0.8 ± 0.05 0 {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.

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
Holder
Valve must slide smoothly inside holder
There must be no scratches or damage to con-

tact surface of spool and seat
SPOOI Install the delivery valve assembly to the holder

for check of valve opening pressure. Apply
pressure with the nozzle opening pressure
Seat tester as shown in the figure at left, and check
HWE00327 the valve opening pressure and sealing perfor-
mance of the two-way delivery valve.
Tube for test
Valve-
Couper
gasket
Holder
nozzle open ine
Pressure test HWE00334
Plunger barrel and plunger assembly There must be no scratches, wear, or discol-
t
oration to outside circumference of plunger
assembly
Pull UP
Wash plunger assembly with cIean diesei oif,

assemble plunger barrel as shown on left, then
assembly 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.
barrel
HWE00328
15002
0
Part Check point
Tappet . There must be no peeling, wear of important

points, or scratches to roller surface
Plunger contact portion
. There must be no play between roller and

Tappet
roller pin
Roller
. Check depth of wear at plunger contact por-
tion
HWE00329
Camshaft There must be no peeling, wear of important

points, or scratches to cam surface
Key groove
There must be no play between key and key
groove
There must be no wear of oil seal contact sur-

face
Oil seal contact surface

HWE00330
* There must be no peeling from surface or ab-

Bearing (taper roller)
normal noise
. There must be no scratches or wear of lip sur-

Oil seal
face
Center bearing d
There must be no peeling, wear, or scratches
to bearing surface
HWE00314
Spool of rack position control hydraulic cylinder . There must be no scratches or wear of surface
. Must slide smoothly inside bushing
HWE00315
FIPPOO
Delivery valve Tappet Camshaft Plunger barrel
F
8
P
0
-.
7
FIPPOO
Part
name
Position of damage r
A: Can be used as it is
Judgment categories
B : Can be repaired
for reuse
and C : Not permitted to use

used again again
-
Injection volume of . lniection volume of a
any cylinder is not cylinder is extremely
extremely little at in- little at injection vol-
jection volume ad- ume adjustment
Opening pressure and justment (particularly when
3 sealing performance of (particularly when - rpm is low).
two-way delivery valve rpm is low). Fuel injection pump
Opening pressure of . Operiing piWSiiii3 zrf
tvwoeway delivery tvwv,“ay delivery
.
More than 8Qkg/cm2 Less’than 80kg/cm2
-
Peeling from surface, luster, No peeling or abnormal - Heavy rotation, abnor-

1
abnormal noise noise mal noise
I Slight rust on outside

2 Rust on bearing No rust on ball or race that can be easily re- There is rust
moved with sandpaper
Threaded portion of hous- No damage or crushing Slight dents or damage Damage, crushing
1
ing of thread to thread other than B
- -
Damage or dents that

2 Damage, cracks in housing No cracks can be easily removed Damage other than B
with oilstone
Damage or dents that

1 Damage, cracks in housing No cracks can be easily removed Damage other than B
with oilstone
Damage that can be

1 Scratches on surface No scratches easily removed with oil- Damage other than B
stone
Slight wear or scratches Damage that can be

Peeling, wear, or scratches Scratches or wear other
1 which are not enough easily removed with oil-
to surface of gear tooth than in A and B
to catch your fingernail stone
Slight wear or scratches Damage that can be

Wear or scratches to surface Scratches or wear other
2 which are not enough easily removed with oil-
of plate than in A and B
to catch your fingernail stone
15-005
0
Judgment categories for reuse
Part Position of damage
name
C : Not permitted to use
used again again
End play of drive shaft Less than 0.075mm - More than 0.075mm
3
Wearorscratchestosurface Slightwearorscratches Damage that can be

Scratches or wear other
4 of oil and fuel relief valve which are not enough easily removed with
than in A and B
seats to catch your fingernail oilstone.
Strainer can be cleaned perfectly by washing in Strainer cannot cleaned

5 Clogging of oil inlet strainer
light oil and blowing air. perfectly.
Filter cannot be used

Filter can be cleaned perfectly by washing in light any more after 4000H.
6 Clogging of screen filter
oil and blowing air before 4000H. Filter cannot cleaned
perfectly before 4000H.
7 Wear of contact surface of Less than o 2mm - More than O.x2mm

drive shaft oil seal
15-006
0
2 0
2
p1
0
w
1
CONTENTS
No. of page
01 GENERAL ...... .............. ...,.........................,. 01-001
11 STRUCTURE AND FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . II-OOI
12 TESTING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-001
13 DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 13-001
14 MAINTENANCE STANDARD ........................... 14-001 , 8

5?
u.
15 OTHERS ... ... ..... .................. ....................... . 15-001
00-002
.
cn
_
C
2
-- 325
m
cn
CD
FIPGOO
II STRUCTURE AND FUNCTION
CONSTRACTION .............................................. 1 I-002

OPERATION ..................................................... .I I-004
Governor spring operation .......................... 1I-004
Performance line drawings
of the governor ............................................ 1 I-005
Control of engine startings .......................... II 1-006
Idling control .................................................. 1 I-007
Maximum speed control .............................. 11-008
Torque control device .................................. 1 I-009
No-load maximum speed operation .......... 1 I-012
Condition at stopping .................................. I I-013
Torque spring operation .............................. 1 I-015
Boost compensator operation .................... II -018
11-001
0
2
FIPGOO
The swivel lever shaft is fitted to the governor An adjustment screw is attached to the oppo-
cover by bushes. One end of the governor site end of the swivel lever through which
spring is connected to the swivel lever, with governor spring tension and therefore the
the other end connected to the tension lever. speed droop can be adjusted.
When the governor spring is extended, the
lower end of the tension lever will contact the The torque control spring regulates fuel injec-
adjustable full-load stopper bolt. The swivel tion quantity (within. a specific range) to assure
lever is so constructed that at the time of optimum fuel injection quantity between idling
stopping the engine it will contact and move speed and maximum speed.
the guide lever. The floating lever attached to
the guide lever will then also move, therefore Constant idling speed is maintained through
placing the control rack in a non-injection the installation of an idling sub-spring, incorpo-
position. rated 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
alter the swivel lever position and
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.
The governor may be equipped with a stopping

device to return the control rack to the stop
\ position when desired, regardless of control
Start spring lever position.
\ Floating lever As shown in Fig. 2, the pin at the bottom of
Control rack the floating lever is inserted into the support-
ing 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
Supporting lever /
Fig. 2 Stop lever mechanism
1 I-003
0
w
FIPGOO
Performance Line Drawings of the Governor
The solid line in Fig. 4 shows control rack posi-

tion 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 con-
trol rack position during injection of excessive
fuel sufficient for the torque control stroke.
D-E shows control rack position at low and

medium speed when the centrifugal force of
Pump speed (rpm)- the flyweights exceeds the torque control
Fig. 4 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, op-
eration at this point is normal)
Point H represents no-load maximum speed;

the maximum speed of the engine. H-l repre-
sents the range where the governor spring and
the idling sub-spring actuate together.
The bold broken line shows control rack posi-

tion 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 de-
creases 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 / i
Shifter and sleeve/
Fig. 5
As shown in Fig. 5, prior to starting, when the roller is held by the shifter and sleeve. As a
control lever is moved to contact the result, the distance between the tension lever
maximum-speed stopper, the swivel lever and shifter is greater than at full-load operation,
--- lln ;
a,,,w,ng an increased fuel injection quantity
(c~~ected to the control lever) extends the
governor spring to move the tension lever, un- and facilitating starting.
til it contacts the full-load stopper bolt. (See
Fig. 5) Immediately after starting the centrifugal force
of the flyweights exceeds the start spring
As the flyweights are not moving at this time, force, resulting in movement of the shifter,
the floating lever is held in the fuel-increase which then contacts the tension lever; conse-
position by the start spring, and the flyweight quently the fuel injection quantity is reduced.
1 l-006
Idling Control
[art .springw ~
.-:
.E
Idling ti
n
-7 Control lever y0
f?
‘ump speed (rpm)
-w
Flyweights/ I
Fig. 6
After starting, the control lever is moved to the If engine speed decreases, the flyweights’
idling position and governor control will begin. centrifugal force will decrease, allowing the
As seen in Fig. 6, with the control lever in the idling sub-spring force to move the tension
idling position the governor spring will be in a lever and shifter, and consequently the guide
completely contracted state, allowing the and floating levers to the left. The control rack
flyweights to open even though engine speed is therefore moved in the fuel-increase
is low. Shifter and sleeve movement will then direction to return the engine to the required
be transmitted to the tension lever, which idling condition. If the engine speed drops
moves to the right to contact the idling sub- further, the start spring acts to quickly move
spring. The floating lever will move to its idling the floating lever and control rack in the fuel-
position, moving the control rack in the fuel- increase direction, preventing the engine from
decrease direction and resulting in a decreased stopping and thus maintaining constant idling.
fuel injection quantity suitable for idling.
1 l-007
Q
00
FIPGOO
Torque Control Device
suction
Increased setting
Fuel requirement ,
ye_;___$L-q
_--- _#--
A?--?---- I
I
&educed setting
I
I I
Na Nb
Engine speed (rpm) ____F
Fig. 8
1 l-009
If full-load fuel injection quantity is set at point This movement, referred to as the torque con-
B’ in order to reduce emission of black smoke, trol stroke, is transferred to the guide/floating
engine output will be reduced at low and in- levers, resulting in control rack movement in
termediate speeds. The torque control device the fuel-increase direction.
operates in such a way that, during full-load
operation the engine satisfies the fuel However, as engine speed increases, the
requirement curve as shown in Fig. 8. flyweights’ centrifugal force will also increase
until it exceeds the force of the torque control
This torque control device is mounted with the spring, which will then be compressed. The
tension lever. However, its use and specifica- shifter will then contact and move the tension
tions depend on the various . engine lever to decrease fuel injection quantity.
applications and range of engine speeds.
Figs. 9 and 10 show torque control device op-

eration. 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
It I
F
2
a
__-____-___------- _-_.----_____f g
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l-
--------_-
I
2
I
I
I
0 0
a-----(LU~J) paads au!Bu~
- (UNU) uo!ysod ycm low03 r-
r-
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3
FIPGOO
Condition at Stopping
Guide lever
stop
Control &j 9
Swivel lever 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 posi-
tion; the engine will then stop.
11-013
Flyweights /
Fig. 15
Where the governor is equipped with a stop-

ping device, operation of the stopping device
results in stopping of the engine regardless of
control lever position.
11-014
Torque Spring Operation
Engines used with construction equipment are

Tension lever n subject to abrupt increases in load, causing
Torque spring
speed to decrease, which may result in the
engine stopping. To prevent this a separate
torque spring is utilized, as shown in Fig. 16.
As engine speed decreases, this torque spring

Adjusting nut 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 tor-
que spring is installed, the control rack moves
along B-C and speed decrease will be Pp.
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 full-
Pump speed (rpm)-!-- ; i 1t---
load 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. Speed decrease will be P2, with the torque
Point B in Fig. 17 represents the control lever spring acting to extend the time taken for this
position suitable for rated output. decrease. As fuel injection quantity is increas-
If the increased load exceeds the rated output, ing during this period, engine torque will
the tension lever will act to move the control increase, the decrease in speed can be felt and
rack in the fuel-increase direction as engine time is available for preventative action (gear
speed decreases, as shown in Fig. 19. change etc) to be taken, and stopping of the
engine is prevented.
However the torque spring will act to retard
the tension lever, and therefore, control rack
movement from point B to C. (See Fig. 17)
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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

directon, and set the minimum-speed
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 con-
trol lever is moved in the stop direction.
(Fig. 74)
Fig. 74 Setting the minimum-speed stopper bolt
h
8. The performance of the governor depends
Rh on the engine specifications.
The performance chart in Fig. 75 is typical
of this type of governor. (Fig. 75)
Na Nb NC NdNeNfNg
Pump speed (rpml-
Fig. 75 Governor performance chart
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If the pump speed is not within the stan-
dard value, adjust the height of the adjust-
ing screw provided on the swivel lever.
Adjusting screw (Fig. 90)
Tightening the adjusting screw de-
creases 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
i the adjusting screw from the swivel
Fig. 90
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.
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 ad-
justing screw. (Fig. 92)
Fig. 92 Setting adjusting screw
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3. Boost compensator stroke adjustment
-.I. 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 control lever in the maximum-
speed 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)
Fig. 1 IO Adjusting boost compensator stroke
I
Na
Pump speed (rpm) -
Fia. 111
12-023
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SPECIAL TOOLS
For service of the RSV type mechanical governor mounted on the PE(S) -A(D) pump, the following spe-
cial tools and general tools should be prepared.
SERVICE TQOLS FOR DISASSEMBLY AND REASSEMBLY

Part Number
Key No. Tool Name Q’ty Application
( ): ZEXEL P/No.
Common tool Universal vise 1 Used with brackets (157944-7820 and

(157944-8520) 157944-8720)
Common tool Bracket 1 For fixing PESA(D) pump

(157944-7820)
Common tool Bracket 1 For fixing PEmA(D) pump

(157944-8720)
Common tool Ratchet handle 1 Used together with socket wrench

(15791 O-0300)
Common tool Handle 1 Used together with socket wrench

(15791 O-l 120)
Common tool Pin For fixing each extractor

(15791 o-51 00) (6 mm diameter)
Common tool Spanner For holding pump side coupling

(157916-5320) (installed with laminated coupling)
Common tool Coupling 1 For camshaft rotation (for 17 mm dia.

(157842-4420) camshaftj
Common tool Coupling 1 For camshaft rotation (for 26 mm dia.

(157842-4620) camshaft)
10 Common tool Socket wrench 1 For removing and installing coupling

(157914-0100) fixing nut (SW 14 mm) 1
11 Common tool Socket wrench 1 For tightening extractor bolt (SW 19

(I 579?4-0300) mm)
12 Common tool Box wrench 1 For removing and installing supply

(I 57913-0100) pump fixing nuts (SW 10 mm)
13 79D-15793121 Or Tappet holder 8 For holding PE(S) -A pump tappets

(157931-2100) (bolt-type tappet adjustment)
14 Common tool Tappet holder 6 For holding PE(S)mA high speed type
(157931-2500) pump tappets
15 Common tool Tappet holder 10 For holding PE(S) =AD pump tappets
(157931-7320)
13-002
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19. Lightly tap the governor cover with a
wooden or plastic hammer to separate it
from the governor housing. (Fig. 37)
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)
Note: T-I
Idtie care not to bend the link.
Fig. 38 Separating the link
21 Using long-nose pliers, remove the starting

spring (132) from the spring eye. The gov-
ernor 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) us-
ing 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 O-
11 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
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6. Remove the two snaprings (153) with a
screwdriver. (Fig. 50)
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 re-
moved 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
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Unit: Kg-m
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The RSUV mechanical governor is a The RSUV type governor is identical to the
variable speed governor which has been RSV type mechanical governor in regard
developed for use with generators, marine to the following functions.
engines, construction and industrial
machines, which are generally large sized, 1. Speed droop adjustment can be easily
medium speed diesel engines. performed without governor spring
replacement, by adjustment of the
The RSUV type governor is the result of swivel lever’s adjusting screw.
modification of the RSV type governor, to
which an acceleration gear has been 2. Engine speed can be maintained
added. By selecting the appropriate gear, automatically at an intermediate level
the acceleration gear’s gear ratio can be between maximum speed and minimum
altered and the desired controlled speed speed by selecting the appropriate
range can be obtained. Flyweight speed, control lever position.
and therefore centrifugal force, has been
increased, making this governor suitable 3. The delivery of excess fuel for engine
for use with medium speed diesel engines. starting is automatic.
01-002
. . .. ..
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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.
No. Tool No. Tool Name Q’ty Remarks
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
8 157914-1700 Socket wrench 1 For removing & installing gear’s fixing nut
(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 For removing & installing rack cap
13 105782-6350 Measuring device 1 I For measuring control rack position
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 Nozzle holder : 105780-2090 (NP-EFFP215)
19 157805-2020 Injection pipe 8 pr4mm~~8mmX1,500mm (M18X1.5-M18~1.5)
20 157843-2720 Coupling 1 For driving PE=ZW pump (during adjustment)
21 157843-3200 Coupling 1 For driving PESZW pump (during adjustment)
Note: The special tool kit (105790-3010) for the PE=Z type pump includes tools with
key numbers: 6, 7, 9, 10 and 16.
12-002
I. 15794498520 2. 15794418620 3. 157945-0120
Universal vise Bracket Bracket
4- Ml OX1 5,
4. 157931-7800 5. 157916-4820 6. 79D-I 579150300

Tappet holder Handle Wrench
7. 79D-1579266220 8. 157914-1700 9. 79D-1579266120

Extractor Socket wrench Extractor
Ml 2X1.5
SW27
60
-lg. i-1 special tools
12-003
L-+---A
0
FIPGOO
19. 157805-2020 20. 15784392720 21. 157843-3200
Injection pipe Coupling Coupling
I AR3
--._
L’
Fig. 1-3 Special tools
12-005
ADJUSTMENT
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
Fig. 82 Injection pump installed on the time.
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
pump)
2. Remove the idling sub-spring (135) and
the torque control spring (140).
3. Remove the control rack cap using a
84 spanner (W/21), and then mount the
Fig. 83 Removing the rack cap 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 Temporarily setting the boost

compensator adjusting screw
12-006
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”
I-
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t (MU) Uo!ysod $lI?J lOJ)UO=)
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Control rack postlion (mm) + Control rack position (mm) _t
FIPGOO
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 increase the pump speed to
Na rpm.
2. Set the minimum speed stopper screw
(53) so that the control rack starts
moving from the Ra mm position in the
fuel decrease direction.
(Figs. 101 and 102)
Na 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 can be calculated using the
formula:
NC - NbMOO (%)
Nb
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
Governor performance curve
speed droop can result in high speed
RSV7002 hunting. The speed droop of the RSUV
Fig. 103 Relation between engine output type mechanical governor can be freely
and governor performance 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
Rb the swivel lever. (Fig. 105)
e Tightening the adjusting screw
decreases the speed droop.
e Loosening the adjusting screw
Nb NC
increases the speed droop.
Pump speed (rpm) -
Note 1: The adjusting screw can be
RSV7003
loosened a maximum of 24
Fig. 104 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 SPEED

STOPPER SCREW
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 ADJUSTMENT
(when installed)
1. Temporary adjustment of the boost
t compensator adjusting screw (270)
-z Perform at Nh rpm -1. Remove the capnut (276) and loosen
the locknut (271).
Boost compensalor
stroke
Pl p2
Boost pressure (mmHg) +
L----7
.=
5 Rf
2
Pump speed (rpm) _I)
RSV70 10
1 J
Fig. 111 Boost compensator equipped
0
governor performance chart 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 controlrack 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
4. Boost compensator spring adjustment

-1. Operate the pump at Nh rpm.
Pump speed : 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.
Bcost pressure (mmHg) -

RSV7012
12-017
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3. Fully loosen the NORMAL position side
stopper screw (407).
4. fvlove the stop lever (404) toward the
NORMAL position until the governor’s
Stopper screw &
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
RSV3209
(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 and
__ aPecified_
stop [ever angles are a5 _I
(Fig. 126)
SPEED CONTROL STOP LEVER ANGLE

LEVER ANGEL
RSV7015
Fig. 1126 Checking the lever angles
CONTROL RACK LIMITER ADJUSTMENT

I_ Remove the rack guide screw from the
uide screw
12-02 1
Control rack positlon (mm) +
_
FIPGOO
M
m
.I
F
L
Control rack posltion (mm) --+
FIPGOO
&I
-
Y \ \
.$
IA
Control rack poshon (mm)-
n n
0 Q
O:
F
:T
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 (157917-
0820; SW27 end). (Fig. 141)
Fig. 141 Adjusting the idling spring

capsule
6. Slowly increase the pump speed and

ensure that when the control rack
reaches the Rc mm position, the
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.
0 Nd NC
7. Make sure the control rack position
Pump speed (rpml -
remains above Rh mm, even when
RSV702 1
pump speed is decreased to 0 rpm.
Fig. 142
Torque control spring adjustment

RQ 1. Fully screw in the boost compensator
t Ra * -- 7
stroke adjusting screw again
F \ 2. Set the load control lever at the
\
g \
5 \ NORMAL position.
._
.5 \
\ 3. While maintaining a pump speed of Na
8
z rpm, confirm that the control rack is
3 positioned at Ra mm.
e
E 4. Operate the injection pump at a speed
8
0 Nf Na slightly less than Nf rpm.
Pump speed Vpm) A
RSV7022
Fig. 143
12-027
Control rack posltion (mm)---+ Control rack posihon (mm) -
-.
3
5
-.
cn
FIPGOO
.-4”%;
.-F !? E
3
P’
3 .cI
X
2
G=
E
.
T- ci
- (WI) UO!$SOd y3eJ lOJ)UO3
Control rack position (mm)+
3
I
-.
3
L-.
--.
(D
Y
-.
3
L.
(D
0
rc
-.
0
3
FIPGOO
5
._
.=
80.
x
0
T
=
l?
Boost compensator adjustment
1.
Perform at Nh rpm
t I
2.
0 Pl p2
Boost pressure (mmHg)----_,
Boost compensator stroke
P
E
I \
0 Nh
S
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
.-c.0
0
ii 2
0
2
E
-(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 Replenishment or replacement of governor
pump housing (or governor cover) to and injection pump oil is not necessary. S
lubricate the injection pump cam chamber However, prior to operation on the pump t?
iT:
and the governor chamber. test stand or engine test bench, the
governor chamber and the injection pump
After passing through the overflow nipple cam chamber must be filled with engine oil
located on the injection pump or governor, or injection pump oil (Part No 131453-0120)
the oil returns to the engine. until oil overflows from the overflow nipple.
12-034
ALAR
0000
P5ch5&
rrr-r
.
: . : :
. : : :
-. .* : :
. .
: . .
: . : :
. .
. .
: : . 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.
NO. Tool No. Tool Name Q’ty Remarks
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
8 157914-l 700 Socket wrench 1 For removing & installing gear’s fixing nut
(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 For removing & installing rack cap
I I
13 105782-6350 Measuring device i For measuring controi rack position
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 , 8 I Nozzle : 105780-0050 (NP-DNSTD119NPl T),
holder assembly Nozzle holder : 105780-2090 (NP-EFFP215)
19 157805-2020 Injection pipe 8 ~4mmX~8mmx1,500mm (M18x1.5-M18x1.5)
20 157843-2720 Coupling 1 For driving PEmZWpump (during adjustment)
21 157843-3200 Coupling 1 For driving PESZW pump (during adjustment)
Note: The special tool kit (105790-3010) for the PEmZtype pump Includes too& with
key numbers: 6, 7, 9, 10 and 16.
13002
CL
0
z
W
>
0
u
n
W
009dM
m
x
v
r
0
0
m
0
c
iii
s
0
11
-I
I
m
10
cn
c
C
0
G)
0
c
m
3
z
0
111
FIPGOO
DISASSEMBLY
Preparatlon
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
ism125 part names refer to the key numbers in
Fig. 4 Attaching the brackets 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 NP-
PES8ZW type fuel injection pump.
1. Attach the brackets (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
RSV3127
brackets using the six bolts. (Fig. 5)
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 (157926-
6220). (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
4
FIPGOO
6,
ii
009dM
23.Screw the extractor bolt 0 into the
plate. (Fig. 19)
Note: The extractor bolt has a left hand
thread.
Fig. 19 Attaching the extractor bolt
24Aount the fixing bolt @ on the gear

shaft. (Fig. 20)
Fig. ad 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 Extracting the

bearing
13-010
26.Remove the extractor, gear shaft and
bearing. (Fig. 22)
27. Remove the washer (11 I).
RSV3142
Fig. 22 Removing the gear shaft and

bearing
28.Remove the link from the connector

(175). (Fig. 23)
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 governorhousing with a
plastic hammer to separate it from the
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).
I
(Fig. 29)
2
G
Fig. 29 Removing the capnut
37. Loosen the locknut (136) and remove

the idling sub-spring (135). (Fig. 30)
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
0
Z
FIPGOO
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 Acceleration gear inspection
13-026
1
REASSEMBLY
Because the reassembly procedure is the
For clockwise rotation For counter clockwise
reverse of the disassembly procedure, only
(with distinguishing groove) rotation points requiring special attention are
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
3. When installing the cover on the

governor housing, tighten the four bolts
to the following torque. (Fig. 73)
Bolt thread size Torque
Fig. 73 Tightening the cover bolts
13-028
d
x
CD d,
LL ii
-.
3
FIPGOO
Guide lever Shifter -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.
RSV3182 1
i
Fig. 80 Pressfitting the shifter
-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
e
shifter and confirm that it rotates
-
smoothly when the sleeve is rotated.
RSV3 183
Fig, 81 Reassembling the sleeve

:
.
:
I-
MlO; 1.5-2
M6; 0.7-0.9
M12; 1.5-2
7 M24; 8-- 10 M8; 1.8-2
_/
M8; 1.8-2
F
M12: 1.6-2
M30; 3-3.5
M12; 1.2-1.6
-M16; 1.8-2.2
- M20; 2.2-2.5 M30; 2.5-3
M6; 0.5-0.7
MlO; 1.2-1.5
/ M6: 0.5-0.7 L Mlo; 0.7- 1

110; 1.2-1.5
M6; 0.5-0.7 M12; 5-6 MlO; 1.2-1.5 i
M10; 1.2-1.5 M14; 6-7

M20; 11-12 M6; 0.7-0.97
MlO; 1.3- 1.5
M6; 0.7-0.9 -
M6; 0.3-0.5
M8; 1.5-1.8 - \
M8; 1 - 1.4
M5; 0.3-0.45
L- M6; 0.7-0.9
M3; 0.2-0.3
Unit: kg-m
in this drawing should conform to standard tightening
The torques not specified
torques RSVlOll
FIPGOO
SEBM024001
FUEL SUPPLY PUMP

(COMMON RAIL TYPE)
FUEL SUPPLY PUMP MODEL
DENSO CRI TYPE
©2001
1
CONTENTS
01 GENERAL ............................................................................. To be issued next time
11 STRUCTURE AND FUNCTION ............................ To be issued next time
12 TESTING AND ADJUSTING ................................. To be issued next time
14 PERFORMANCE TEST .......................................................................... 14-001
15 OTHERS ................................................................................ To be issued next time
00-002 FUEL SUPPLY PUMP

Revision Indication
Revision
following
Mark marks.
Page
numberIt is Mark
requested
Page that necessary
number
Mark ac-
Page
number
Mark Page
number
Mark Page
number
below.


b 00-001 1 14-012
00-002
c 00-003 1
13-001
b 13-002 1
b 13-003 1
13-004
b 13-005 1
b 13-006 1
b 13-007 1
13-008
b 13-009 1
13-010
13-011
b 13-012 1
b 13-013 1
b 13-014 1
b 13-015 1
b 13-016 1
13-017
b 13-018 1
b 13-019 1
b 13-020 1
b 13-021 1
b 13-022 1
b 13-023 1
b 13-024 1
b 13-025 1
14-001
b 14-002 1
b 14-003 1
b 14-004 1
b 14-005 1
14-006
b 14-007 1
b 14-008 1
b 14-009 1
14-010
b 14-011 1
FUEL SUPPLY PUMP 00-003

1
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

DISASSEMBLY AND ASSEMBLY SPECIAL TOOLS LIST
SPECIAL TOOLS LIST
6UHD
Q’ty
6HD
Symbol Part No. Part name Nature of work, remarks
1 799-609-1010 Puller, PCV 1

2 799-609-1020 Mounting, PCV 1
A Removal, installation of PCV assembly
3 Purchased Socket, B = 42 mm 1
4 Purchased Deep socket, B = 22 mm 1
1 799-609-1030 Extractor 1
B 799-609-1040 Holding spanner 1 Removal, installation of upper spring seat
2
799-609-1050 Holding spanner 1
C 799-609-1310 Pliers 1 Removal, installation of feed pump
1 799-609-1320 Puller 1
2 799-609-1330 Hook set 1 Removal of bearing outer race
3 799-609-1060 Base (ø100) 1
D 799-609-1070 Support (ø31) 1
4 799-609-1080 Support (ø37) 1 Removal of bearing inner race
799-609-1090 Support (ø39) 1
5 799-609-1110 Wear ring stopper 1 Installation of wear ring
1 799-609-1120 Handle 1
2 799-609-1130 Adapter 1
799-609-1140 Replacer (ø34) 1
3
799-609-1150 Replacer (ø43) 1
799-609-1160 Replacer (ø52) 1
4
799-609-1170 Replacer (ø60) 1
E 799-609-1180 Replacer (ø61) 1 Removal, installation of bearing
5
799-609-1190 Replacer (ø71) 1
6 799-609-1210 Replacer (ø81) 1
799-609-1220 Base housing (ø62) 1
7
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
F Installation of oil seal
2 799-609-1250 Oil seal guide 1
799-609-1340 Guide rail, nut (ø25) 1
1
799-609-1440 Guide rail, nut (ø30) 1
G Installation of camshaft
799-609-1450 Cam clearance measure (ø25) 1
2
799-609-1460 Cam clearance measure (ø30) 1
1 799-609-1280 Depth measure 1
H Installation of G sensor
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
I 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

1
DISASSEMBLY AND ASSEMBLY CONSUMABLE PARTS LIST
CONSUMABLE PARTS LIST
6UHD
6HD
No. Part No. Part name Q’ty Remarks
1 094086-0210 O-ring 1
2 094086-0090 O-ring 2
3 094137-0010 Gasket 2
4 094086-0100 O-ring 6
5 949150-3030 Seal 1
6 949150-3200 Seal 1
7 094086-0120 O-ring 1
8 094086-0150 O-ring 1
9 094095-0100 Shim 1 T = 0.05
10 094095-0130 Shim 1 T = 0.1
11 094095-0140 Shim 1 T = 0.2
12 094095-0150 Shim 1 T = 0.3
13 094095-0160 Shim 1 T = 0.5
14 094095-0330 Shim 1 T = 0.05
15 094095-0340 Shim 1 T = 0.1
16 094095-0350 Shim 1 T = 0.2
17 094095-0360 Shim 1 T = 0.3
18 094095-0370 Shim 1 T = 0.5
19 094086-0110 O-ring 1
20 094086-0160 O-ring 1
21 094086-0130 O-ring 1
22 094086-0170 O-ring 1
23 949140-6310 O-ring 1
24 094096-0050 Shim 1 T = 0.15
25 094096-0060 Shim 1 T = 0.20
26 094096-0070 Shim 1 T = 0.25
27 094096-0080 Shim 1 T = 0.40
28 090222-0070 Washer 5
29 090222-0120 Washer 2
30 095331-0020 Stopper 2
31 090207-0100 Ring 1
32 094086-0200 O-ring 1
33 094087-0050 Seal 1
34 092125-0010 Gasket 1
35 090222-0070 Washer 6
36 094092-0010 Washer 4
37 094093-0050 Washer 1
38 094093-0060 Washer 1
39 094093-0070 Washer 1
40 094093-0080 Washer 1
41 094093-0090 Washer 1
42 094093-0100 Washer 1
43 094093-0110 Washer 1
44 094093-0120 Washer 1
45 949018-0350 Washer 1
46 949010-3020 Washer 1

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 di-
mensions 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)
A B C D E F G H I J K
6HD 214.4 57 60 129±0.15 11.0 75 55±0.05 54±0.2 27 14.5 M12x1.75
6UHD 239 59 60 139.5±0.15 12.5 75 57±0.05 70±0.2 35 14.5 M12x1.75
For reference For reference

Bracket 1 on drive shaft side Bracket on feed pump side

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 assem-
bly (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.

1
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).

1
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 assem-
bly 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.

1
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 neces-
sity since it can cut the housing surface
under the seat.
5) Remove the spring, lower spring seat, and tap-

pet (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.

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).

1
6. Removal of feed pump and crank position sen-

sor
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).

3) Hit the end of camshaft (22) on the feed pump

side with a plastic hammer to remove bear-
ing cover assembly (19) from the housing.
4) Pull out camshaft (22).

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).

1
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)

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 en-
ter 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 bear-

ing 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).

1
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 bear-
ing 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:
2) Press fit bearing (26) on the feed pump side.

Tool: E8 Pipe (ø30): 799-609-1260
2 Inside surface of bearing:

1
3) Using tool D5, set wear ring (25) in the insert-

ing 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:
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.

1
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 with-
out stopping halfway.
7. Installation of delivery valve holder

1) Change the fixing direction of tool A2 and re-
place 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.

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 bear-
ing 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}
• Replace the washer with a new part when
installing the bolt.

1
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 ap-
ply 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.

1
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). Ac-
cordingly, 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 expres-
sion.
t = L1 + L2 (6HD)
t = L1 + L2 + 0.4 (6UHD)
fl If value L2 is positive, the distance be-
tween the sensor fitting face and barrel is
less than the depth of the master pin hole.
Accordingly, select a thicker shim in this
case.

1
fl There is a difference of 0.4 mm in length be-

tween the master pins used for measurement.
Accordingly, if a shim having thickness near-
est to the calculated shim thickness is se-
lected, 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. Thickness (mm)
094096-0050 0.15
094096-0060 0.20
094096-0070 0.25
094096-0080 0.40
5) Apply grease to the O-ring and install crank

position sensor (18) and selected shim to-
gether.
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 po-
sition and push it in with tool B1, then turn
the handle by 90 degrees.

1
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 bot-
tom dead center.
fl Do not push in the upper spring seat with the
extractor too much, since it can cut the hous-
ing 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 fac-
ing down. (UHD)
• Install the plate with the wider groove fac-
ing up. (HD)

1
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).

1
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).

1
TIGHTENING TORQUE TABLE
Tightening torque Tightening torque

No. Item No. Item
Nm {kgm} Nm {kgm}
1 Piston 1.96 – 2.94 {0.2 – 0.3} 13 Bolt 5.88 – 9.8 {0.6 – 1.0}
2 Priming pump (M16) 39.0 – 58.8 {4.0 – 6.0} 14 Bolt 4.4 – 8.3 {0.45 – 0.85}
3 Screw 14.7 – 19.6 {1.5 – 2.0} 15 Screw (M10) 7.8 – 11.8 {0.8 – 1.2}
4 Bolt 6.8 – 11.8 {0.7 – 1.2} 16 Screw 1.96 – 2.9 {0.2 – 0.3}
5 Nut (With washer) 17.6 – 24.5 {1.8 – 2.5} 17 Plug (M16) 39.0 – 58.8 {4.0 – 6.0}
6 PCV 157.0 – 177.0 {16.0 – 18.0} 18 Filter 1.98 – 3.92 {0.2 – 0.4}
7 Holder 137.0 – 167.0 {14.0 – 17.0} 19 Plug (M10) 7.8 – 11.8 {0.8 – 1.2}
8 Bolt 15.7 – 23.5 {1.6 – 2.4} 20 Plug 29.5 – 39.2 {3.0 – 4.0}
9 Overflow valve 21 Air breeder 4.9 – 6.9 {0.5 – 0.7}
(Temporarily tightened) 14.8 – 19.6 {1.5 – 2.0}
10 Screw (Temporarily tightened) 7.9 – 12.7 {0.8 – 1.3}

11 Bolt 9.8 – 11.8 {1.0 – 1.2}
12 Bolt 6.8 – 11.8 {0.7 – 1.2}

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

PERFORMANCE TEST SPECIAL TOOLS LIST
SPECIAL TOOLS LIST

Nos. marked ª are Komatsu part Nos.
6UHD
Q’ty
6HD
Symbol Part No. Part name Nature of work, remarks
1 799-609-5020 Cap nut assembly 1

K Installation of common rail
2 799-609-5030 Joint, nipple assembly 1
799-609-5130 Timer joint (ø25) 1
1
799-609-5140 Timer joint (ø35) 1
L Installation of coupling
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
M Piping for test
3 799-609-5090 Tube (4 x 8 x L 900 inside screw) 2
4 799-609-5110 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
Q 799-609-5170 Cover 1 Coupling cover
R 799-609-5010 Hose 1 Fuel suction hose
1 799-607-4040 Wiring harness 1 Controller wiring harness
S 2 7872-10-910A Controller 1
3 Purchased Electric power supply 1 DC28V/5A
T 799-609-5180 Filter 1
U Purchased Pipe bender 1 For ø8
V 6217-71-1210 Common rail assembly 1

1
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)

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

1
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)

1
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.)

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 com-
mon 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.
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}

1
14) Install pressure gauge, adapter N, and tube

M2 to flow damper (2).
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.
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.

1
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 control-
ler.
fl Connect the drive shaft side by the con-
nector of PCV1 and connect the feed
pump side by the connector of PCV2.
fl Connect CN2, CN4, and CN7 to the con-
troller.
3) Connect the wiring harness to the battery or
power supply.
• Take care not to mistake the positive and
negative terminals for each other.

1
Drawing of bench set

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 speci-
fied 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.

1
4) Checking high-pressure discharge 5) Check of display on controller

i) Make sure that the pipes and wires are i) Just after the power switch is turned
connected normally. ON
ii) Turn on the power switch and make The controller displays 88ECAA101100
sure that the source voltage is 28 ± by 2 letters, then displays 00.
0.2 V. ii) While the pump drive shaft is turning
iii) Turn the all knobs of the 4 valves of The controller displays 13.
the pressure regulator to the left end. If 13 is displayed, the signals from the
iv) Operate the pump at the speed of 200 G sensor are normal.
rpm and check for fuel leakage. iii) When the controller displays 74 or 75
v) Raise the pump speed to 1,100 rpm. • If 74 is displayed, the PCV1 circuit
vi) Turn the valve knobs of the pressure is disconnected or shorted. Check
regulator to the right end in the order the wiring harness and connector.
of pressure (No. 1 – No. 4) and set the • If 75 is displayed, the PCV2 circuit
common rail pressure to 120 MPa is disconnected or shorted. Check
{1,224 kg/cm2}. the wiring harness and connector.
• 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 wir-
ing 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)
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

SEBM026200
WATER PUMP
©2001
CONTENTS
01 GENERAL ........................................................................................................ 01-001
14 MAINTENANCE STANDARD AND INSPECTION

OF PARTS ...................................................................................................... 14-001
00-002 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”, “Main-
tenance 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. Water pump 7. Cylinder liner

2. Oil cooler 8. Piston
3. Thermostat 9. Cylinder block
4. Radiator 10. Intake and exhaust valves
5. Fan 11. Injection nozzle or injector
6. Fan belt 12. Cylinder head
WATER PUMP 01-003

GENERAL SPECIFICATIONS
SPECIFICATIONS
Item Speed Water flow Total head
Type increasing amount Remarks
Engine ratio ª (¬/min) (m)
100 5.0 Impeller diameter ø 85
95 Centrifugal, belt-driven 1.0
150 6.5 Impeller diameter ø 90
0.9 95 3.5 Impeller diameter ø 100
105 Centrifugal, belt-driven
0.717 190 6.0 Impeller diameter ø 130
108 Centrifugal, belt-driven 1.19 250 8.0 PC300
110 Centrifugal, belt-driven 0.668 290 7.0
210 5.2 6D125

125 Centrifugal, belt-driven 1.5
375 10.0 S(A)6D125
400 Other than following
6D140 Centrifugal, belt-driven 1.56 14.0
800 WS23-2, HD325
12V140 Centrifugal, gear-driven 1.8 1,500 17.0
480 18.5 S6D155

155 Centrifugal, gear-driven 1.565
820 36.0 SA6D155
6D170 Centrifugal, gear-driven 1.8 800 28.0
1,400 23.0 D475, WA800

8V170 Centrifugal, gear-driven 1.618
2,000 27.5 HD785-2
12V170 Centrifugal, gear-driven 1.618 2,000 27.5
ª 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 105•110 SERIES
1. Pump cover 1. Nut 7. Impeller

2. Impeller 2. Fan pulley 8. Snap ring
3. Water seal 3. Pump shaft 9. Pump cover
4. Pump body 4. Spacer
5. Boss 5. Water seal A. To each part of engine
6. Drive shaft 6. Pump body (Cooling water)
125 SERIES 140 SERIES
1. Alternator drive pulley 6. Pump body

1. Water pump drive gear 5. Water seal 2. Oil seal 7. Water seal
(No. of teeth: 22) 6. Impeller 3. Ball bearing 8. Impeller
2. Pump shaft 7. Pump cover 4. Pump shaft 9. Pump cover
3. Ball bearing 5. Water pump drive gear
4. Pump body (No. of teeth: 23)
11-002 WATER PUMP

12V140 SERIES 155-4 SERIES
1. Cover
2. Impeller
3. Floating seal
4. Water seal
5. Pump body
6. Drive gear (No. of
teeth: 23)
7. Bearing housing
1. Pump shaft 5. Ball bearing 8. Pump shaft
2. Water seal 6. Oil seal 9. V-ring
3. Pump body 7. Impeller A. From radiator
4. Water pump drive gear 8. Pump cover B. From thermostat
(No. of teeth: 25) C. To oil cooler
170 SERIES 8V170 SERIES
1. Pump body 6. Pump shaft (Front) 1. Pump body 6. Pump shaft

2. Impeller 7. Inlet housing 2. Impeller
3. Floating seal 3. Water seal a. Water inlet
4. Water seal a. From radiator 4. Oil seal (From radiator)
5. Pump shaft (Rear) b. To oil cooler 5. Ball bearing b. Water outlet
(To oil cooler)
WATER PUMP 11-003

12V170
1. Pump body Water pump

2. Impeller • Revolving speed: Engine speed x 1.618
3. Floating seal • Flow amount: 2,000 ¬/min (3,235 rpm)
4. Water seal
5. Pump shaft (Rear)
6. Pump shaft (Front)
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. Fan
2. Fan pulley
3. Ball bearing
4. Pump shaft
5. Pump housing
6. Water seal
7. Impeller
8. Cover
A. From thermostat
B. To engine
C. From radiator
Structure and function of water pump Type of water pump

• The drive shaft of the water pump is con- • Almost all the water pumps are centrifugal vo-
nected to the pulley by means of press fitting lute pumps since they have simple structures
or a key, which is driven through V-belts. The and high reliability and can be manufactured
impeller is press fitted to this drive shaft and in various sizes.
rotated to suck and supply the engine cool- • In a centrifugal volute pump, an impeller hav-
ing water forcibly. ing volute guide vanes is rotated to supply
• The drive shaft is usually supported on the cooling water forcibly by utilizing the centrifu-
front and rear ball bearings and lubricated gal force.
with grease.
• The water is sealed in and out of the water
pump (lubricated parts) by the water seal.
WATER PUMP 11-005

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

6D140
155 Series
170 Series
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 Housing mounting bolt

Cover mounting bolt Impeller mounting bolt
or nut or nut
Engine
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}
155 — 76.0 ± 2.5 {7.75 ± 0.25} 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
fl As per KES Tightening Torque Standard.
108 Series
Marked 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
13-002 WATER PUMP

DISASSEMBLY AND ASSEMBLY STANDARD VALUES AND TIGHTENING TORQUE TABLE
Unit: Nm {kgm}
Item Alternator drive pulley

Pulley mounting bolt Shaft mounting nut
Engine mounting nut
95 — — —
105 103.0 ± 14.7 {10.5 ± 1.5} — —
108 — — —
ø25:103.0±14.7{10.5±1.5}
110 — —
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}
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 leak-
age.
95 and 108 Series
1. Mounting bolt and nut

2. Fan pulley
3. Mounting bolt and snap ring
4. Cover
5. Impeller
6. Body
7. Shaft assembly
8. Snap ring
9. Water seal
10. Shaft
11. Boss and ball bearing
12. Ball bearing
13. Floating seal
105 and 110 Series
13-004 WATER PUMP

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 se-
ries.
fl Remove snap ring (3) for 105 and 110 series.
WATER PUMP 13-005

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

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.

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 en-
gine oil to it.
95 and 108 Series
1. Mounting bolt and nut

2. Fan pulley
3. Mounting bolt and snap ring
4. Cover
5. Impeller
6. Body
7. Shaft assembly
8. Snap ring
9. Water seal
10. Shaft
11. Boss and ball bearing
12. Ball bearing
13. Floating seal
105 and 110 Series
13-008 WATER PUMP

1. Shaft assembly
1) Assembly of shaft assembly
Press fit bearings (12) and (11) to shaft (10)
fl Press fit each bearing with the side on
which the balls are seen in.
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 impel-
ler 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

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 simulta-
neously to press fit the water seal.
fl Press fit with the rubber on the impeller side.
fl When replacing the water seal, replace float-
ing 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

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

age.
125 Series
1. Mounting bolt
2. Cover and housing
3. Impeller
4. Gear
5. Spacer
6. Snap ring
7. Shaft assembly
8. Oil seal
9. Water seal
10. Shaft
11. Ball bearing
12. Spacer
13. Bearing
14. Body
15. Floating seal
12V140
13-012 WATER PUMP

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

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).

Remove bearing (11), spacer (12), and bearing (13)
in order from shaft (10) using with push tool 4
and stand 5.
13-014 WATER PUMP

DISASSEMBLY AND ASSEMBLY GENERAL ASSEMBLY (125 AND 12V140 SERIES)
GENERAL ASSEMBLY
125 AND 12V140 SERIES

fl When press fitting each bearing or gear, apply
clean engine oil to it.
125 Series
1. Bolt
2. Cover and housing
3. Impeller
4. Gear
5. Spacer
6. Snap ring
7. Shaft assembly
8. Oil seal
9. Water seal
10. Shaft
11. Bearing
12. Spacer
13. Bearing
14. Body
15. Floating seal
12V140
WATER PUMP 13-015

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 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:
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.
ing seal (15), too.
13-016 WATER PUMP

fl When installing the floating seal to the im-

peller, apply water-soluble lubricant (toilet
soap, etc.) thinly to the inside wall of the im-
peller 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).

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).
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

age.
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

1. Cover
Remove mounting bolts (1) to remove cover (2).
fl The covers of some models (WS23-2) are se-
cured 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

5. Oil seal
13-020 WATER PUMP

DISASSEMBLY AND ASSEMBLY GENERAL ASSEMBLY (6D140 SERIES)
GENERAL ASSEMBLY
6D140 SERIES

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

1. Oil seal
Press fit oil seal (15) to body (16) using with push
tool 3.
sealant)
fl Set the lip of the oil seal toward the gear and
press fit it until it is flush with the fitting part.
around the lip.
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).
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 bear-
ing 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 diam-
eter) under the gear and press fit the shaft until
the flange face touches the bearing face.
13-022 WATER PUMP

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)
around the lip.
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.
ing seal (4), too.
the seat assembly.
WATER PUMP 13-023

4. Impeller
5. Cover
Fit the gasket and install cover (2) and secure it
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)

age.
155 Series
1. Mounting bolt
2. Cover
3. Impeller
4. Mounting bolt
5. Bearing housing shaft
assembly
6. V-ring
7. Oil seal
8. Water seal
9. Nut
10. Lock washer
11. Plate
12. Snap ring
13. Bearing housing as-
sembly
14. Shaft assembly
15. Bearing housing
16. Bearing
17. Shaft
18. Gear
19. Bearing
20. Body
21. Floating seal
WATER PUMP 13-025

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 bear-
ing 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
13-026 WATER PUMP

5. Water seal
6. Disassembly of bearing housing and shaft assembly

Remove nut (9), lock washer (10), plate (11), and
snap ring (12), then remove bearing housing as-
sembly (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.

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

155 Series
1. Mounting bolt
2. Cover
3. Impeller
4. Mounting bolt
5. Bearing housing shaft
assembly
6. V-ring
7. Oil seal
8. Water seal
9. Nut
10. Lock washer
11. Plate
12. Snap ring
13. Bearing housing assembly
14. Shaft assembly
15. Bearing housing
16. Bearing
17. Shaft
18. Gear
19. Bearing
20. Body
21. Floating seal
13-028 WATER PUMP

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)
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 hous-
ing 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.
groove.
fl Bend the lock washer securely.
4. Oil seal
Press fit oil seal (7) to body (20) using with the
push tool.
sealant)
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


around the lip.
5. Bearing housing and shaft assembly

Install bearing housing and shaft assembly (5) and
secure it with mounting bolt (4).
6. Water seal
Press fit water seal (10) using with the push tool.
sealant)
fl Press fit the water seal with the rubber part
on the impeller side.
ing seal (21), too.
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

8. Cover
Fit the O-ring and install cover (2) and secure them
fl After assembling, turn the gear with the hand

to check that it rotates smoothly.
WATER PUMP 13-031

GENERAL DISASSEMBLY
170 SERIES

age.
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

1. Housing
Remove mounting bolts (1), then remove hous-
ing (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 plas-
tic hammer so lightly that it will not be dam-
aged.
5. Water seal
fl Remove the water seal from the bearing side
so that the body will not be damaged.
6. Oil seal
WATER PUMP 13-033

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

GENERAL ASSEMBLY
170 SERIES
• Before assembling, clean the all parts and blow

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

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.
sealant)
around the lip.
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.
sealant)
fl Press fit the water seal with the rubber part
on the impeller side.
ing seal (4), too.
the seat assembly.
13-036 WATER PUMP

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
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 mount-
ing bolts (1).
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
1 Clearance between impel- Standard clearance: 0.30 – 1.00

ler and body
Basic Allowance Standard
Interference between dimension Shaft Hole interference
2 shaft and fan pulley boss
15.9 +0.020 – 0.045 0.050 – 0.080
+0.005 – 0.065
3 Interference between 35 0 – 0.025 0.010 – 0.050

shaft and body – 0.015 – 0.050
4 Interference between 12 0 – 0.045 0.030 – 0.070

shaft and impeller – 0.015 – 0.070
5 Bend of shaft Allowable limit: Facial runout of face A: 0.1
6 Wear of seal ring of water Replace

seal Allowable limit: Dimension A: 0
• 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
Thermostat for 4 – 5 minutes.)
• Fully opening temperature
: 90˚C
• Fully opening lift: Min. 8 (When submerged in water at 90˚C)
7
• Valve opening temperature (Opening fully: Valve must open
: 82 ± 2˚C fully when heated to 95˚C and
Thermostat then submerged in water at 77˚C
(For generators) for 4 – 5 minutes.)
(For ships) • Fully opening temperature
: 95˚C
• Fully opening lift: Min. 8 (When submerged in water at 95˚C)
14-002 WATER PUMP

MAINTENANCE STANDARD AND INSPECTION OF PARTS 105-5 SERIES
105-5 SERIES
(S) 4D105-5 (FOR CONSTRUCTION MACHINERY AND GENERATORS)
Unit: mm
Standard Outside diam- Inside diameter Standard Replace

Inside diameter of impel- dimension eter of shaft of impeller interference Replace impel-
1 ler and outside diameter ler usually
of shaft (Outside diam-
15.9 +0.020 – 0.020 0.025 – 0.070 eter of shaft
+0.005 – 0.050 changes little)
2 Clearance between impel-

ler and body Standard clearance: 0.1 – 0.63 (Including end play)
3 Wear of seal ring of water

seal Allowable limit of dimension A: 0
(Total runout of indicator: Prescribed

4 Bend of shaft Allowable limit: 0.1 mm by facial runout of fan pulley at radius
of 40 mm)
Replace
For
construction Min. 10: Check by submerging in water at 90˚C for 4 – 5 minutes.
Full opening machinery
lift of
thermostat For
generators Min. 10: Check by submerging in water at 95˚C for 4 – 5 minutes.
5
For Valve must close fully when heated to fully opening tempera-
construction ture of 90˚C and then submerged in water at fully closing tem-
machinery perature of 71˚C for 4 – 5 minutes.
Function of
thermostat For Valve must close fully when heated to fully opening tempera-
generators ture of 95˚C and then submerged in water at fully closing tem-
perature of 77˚C for 4 – 5 minutes.
WATER PUMP 14-003

(S) 4D105-5 (FOR SHIPS)
Unit: mm

15.9 +0.020 – 0.020 0.025 – 0.070 eter of shaft

ler and body Standard clearance: 0.1 – 0.63 (Including end play)

Replace
4 Bend of shaft (Total runout of indicator: Prescribed by fa-
Allowable limit: 0.1 cial runout of fan pulley at radius of 40 mm)
Full opening lift of ther- Min. 10: Check by submerging in water at 95˚C for 4 – 5 minutes.
mostat
5
Valve must close fully when heated to fully opening tempera-
Function of thermostat ture of 95˚C and then submerged in water at fully closing tem-
14-004 WATER PUMP

110 SERIES
S(SA) 6D110-1 (FOR CONSTRUCTION MACHINERY AND GENERATORS)
Unit: mm

15.9 +0.020 – 0.020 0.025 – 0.070 eter of shaft

ler and body Standard clearance: 0.2 – 0.6

4 Bend of shaft Allowable limit: 0.1 (Total runout of indicator: Prescribed by fa-
cial runout of fan pulley at radius of 40 mm)
Replace
For
construction Min. 10: Check by submerging in water at 90˚C for 4 – 5 minutes.
Full opening machinery
lift of
thermostat For
generators Min. 10: Check by submerging in water at 95˚C for 4 – 5 minutes.
5
For Valve must close fully when heated to fully opening tempera-
construction ture of 90˚C and then submerged in water at fully closing tem-
Operation of machinery perature of 71˚C for 4 – 5 minutes.
thermostat Valve must close fully when heated to fully opening tempera-
For
generators ture of 95˚C and then submerged in water at fully closing tem-
WATER PUMP 14-005

S(SA) 6D110-1 SERIES (FOR SHIPS)
Unit: mm
Standard Outside diam- Inside diameter Standard Replace im-

dimension eter of shaft of impeller interference peller
Inside diameter of impel-
1 ler and outside diameter Usually (Out-
of shaft +0.020 – 0.020 side diameter
15.9 0.025 – 0.070 of shaft
+0.005 – 0.050
changes little)

ler and body Standard clearance: 0.3 – 0.6

Replace
Bend of shaft (Total runout of indicator: Prescribed by fa-
Allowable limit: 0.1 cial runout of fan pulley at radius of 40 mm)
4 Full opening lift of ther- Allowable range: Min. 10 (Check by submerging in water at
mostat 95˚C for 4 – 5 minutes.)
Valve must close fully when heated to fully opening tempera-
Operation of thermostat ture of 95˚C and then submerged in water at fully closing tem-
14-006 WATER PUMP

125 SERIES
(S) 6D125-1 SERIES
Unit: mm
Basic Allowance Standard Replace

dimension interference Replace impel-
Interference between im- Shaft Hole ler usually
1 peller and shaft (Outside diam-
+0.020 – 0.020 eter of shaft
15.9 +0.005 – 0.050 0.025 – 0.070
changes little)
Interference between drive +0.015 – 0.025 Replace
2 gear and shaft 20.0 0 – 0.055 0.025 – 0.070 (Replace gear
usually)
Clearance between impel-
3 ler and body Standard clearance: 0.31 – 1.10 (Including end play)
Replace
Wear of seal ring of water
4 seal Allowable limit: Dimension A: 1.5
WATER PUMP 14-007

140 SERIES
SA6D140-1 (HD325-5)
Unit: mm

– 0.082 – 0.120 eter of shaft
16 – 0.095 – 0.150 0.025 – 0.068
changes little)
2 gear and shaft 28 +0.002 – 0.053 0.025 – 0.068 (Replace gear
usually)
Interference between flange +0.015 – 0.021

3 25 +0.002 – 0.041 0.023 – 0.056
and shaft
4 Clearance between impel- Standard clearance: 0.6 – 0.9 (Including end play)
ler and body
Replace
5 Wear of seal ring of water Allowable limit of dimension A: 1.5

seal
14-008 WATER PUMP

SA12V140-1 SERIES
Unit: mm

+0.018 – 0.025 eter of shaft
19.0 +0.006 – 0.050 0.031 – 0.068
changes little)
2 gear and shaft 30.0 +0.002 – 0.045 0.020 – 0.060 (Replace gear
usually)
3 ler and body Standard clearance: 0.25 – 1.02 (Including end play)
Replace
Wear of seal ring of water
4 seal Allowable limit of dimension A: 1.5
WATER PUMP 14-009

155-4 SERIES
S4D155-4, S(A) 6D155-4 SERIES
Unit: mm

Interference between im- dimension Shaft Hole interference
1 peller and shaft (Excluding
tapered shaft) +0.070 +0.030
15.85 0.025 – 0.075
+0.055 0 Replace
Standard clearance Allowable clearance
2 ler and connection 0.62 – 1.70 —
Target (Nm {kgm}) Range (Nm {kgm})

Tightening torque of im-
3 peller locknut 76.0 {7.75} 73.6 – 78.5 {7.5 – 8}
Retighten
4 Tightening torque of bear- 196.0 {20} 166.7 – 225.6 {17 – 23}

ing locknut
14-010 WATER PUMP

170 SERIES
S(A) 6D170 SERIES
Unit: mm

dimension Shaft Hole interference
Interference between front
1 shaft and bearing
30 +0.015 0
0 – 0.010 0 – 0.025
Interference between rear +0.010 0

2 shaft and bearing 25 0 – 0.020
0 – 0.010 Replace
3 Interference between rear 19.9 +0.020 – 0.025

shaft and impeller +0.005 – 0.05 0.030 – 0.070

WATER PUMP 14-011

SA 8V170-1, 12V170-1 SERIES
Unit: mm

dimension Shaft Hole interference
Interference between front
1 shaft and bearing
45 +0.018 0
+0.002 – 0.012 0.002 – 0.030
Interference between rear +0.018 0

2 shaft and bearing 35 0.002 – 0.030
+0.002 – 0.012 Replace
3 Interference between rear 25 +0.054 +0.009

shaft and impeller +0.041 – 0.016 0.032 – 0.070

14-012 WATER PUMP

PARTS INSPECTION AND
MAINTENANCE STANDARD AND INSPECTION OF PARTS EVALUATION CRITERIA
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
REUSE CRITERIA
Part name
Division of reuse criteria

Damaged portion
A: Reusable B: Reusable after repair C: Not reusable
Damage which can be re-

Flaw which is not caught moved easily with sand- Damage other than A and
1 Seal contact surface
on nail, slight wear paper B, stepped-type wear
Shaft
Impeller turns and has

2 Impeller fitting part No scuff mark and flaw — flaw or scuff mark on its
surface
Flaking of inside and

1 No flaking — Heavy turning resistance
outside surface, gloss
Bearing
Rust on outside which

Inside and outside of Balls and races are not can be removed easily Rusted, rotation is not
2
bearing rusted with sandpaper smooth
— Abnormal sound is gen-

3 Abnormal sound No abnormal sound
erated
1 Blade tip Slight bend of tip — Clear bend

Impeller
Cracking, damage of
2 No cracking and damage — Cracked, damaged
blade
Contact mark which can

Contact portion of Damage other than A and
3 Slight contact mark at tip be removed easily with
blade and body B
sandpaper
Flaw which can be re-

Flaking, flaw, wear of Flaw which is caught on Damage, wear other than
moved easily with oil-
Drive gear
1 tooth surface nail, slight wear A and B

stone
Wear, flaw, seizure of Flaw which is caught on

2 Very slight scratch —
bearing part nail
Flaking of inside and Turning resistance is

No flaking and abnormal —
1 outside surface, gloss, heavy, abnormal sound is
sound
Bearing housing
abnormal sound generated
Rust on outside which

Inside and outside of Balls and races are not Rusted, rotation is not
2 can be removed easily
bearing rusted smooth
with sandpaper
No damaged or crushed Slight bruise or flaw of Damage or crush other

3 Threads of housing
threads threads than B
1 Tension There is tension — Broken or cracked

Snap ring
Deformation and
2 No deformation and bend — Deformed or cracked
bend
14-014 WATER PUMP

MAINTENANCE STANDARD AND INSPECTION OF PARTS REUSE CRITERIA
Part name
Division of reuse criteria

Damaged portion
A: Reusable B: Reusable after repair C: Not reusable
Crush and wear of No damaged or crushed Slight bruise or flaw of Damage or crush other
1
threads threads threads than B

Cover
Damage and cracking

2 No cracking moved easily with oil- Damage other than B
of cover
stone
Combination of cracking
Corrosion and oxida- No corrosion and oxida- Corrosion which can be
3 and corrosion, oxide film
tion of inside surface tion removed
which cannot be removed
Light contact mark which

Flaw which covers all in-
1 Inside of body does not cover all inside Other than A and C
side surface
surface
Crush and wear of No damaged or crushed Slight bruise or flaw of Damage or crush other
2
threads threads threads than B
Body
Combination of cracking
Corrosion and oxida- No corrosion and oxida- Corrosion which can be
3 and corrosion, oxide film
tion of inside surface tion removed
which cannot be removed

Damage and cracking
4 No cracking moved easily with oil- Damage other than B
of body
stone
WATER PUMP 14-015

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What are the main components of a turbocharger?

What are the main components of a turbocharger?

What is the purpose of each main component?

What is the purpose of each main component?

SEBEKTURB001

00 INTRODUCTION ........................................................................................ 00-011

01 GENERAL ........................................................................................................ 01-001

11 STRUCTURE AND FUNCTION ....................................................... 11-001

13 DISASSEMBLY AND ASSEMBLY ................................................. 13-001

14 MAINTENANCE STANDARD AND

( ) Page to be deleted Discard

Pages having no marks are those previously re-

LIST OF REVISED PAGES

pressed air is superchanrged into the engine.

In a diesel engine, the energy of fuels burnt in

ln a turbocharged engine, a quantity of air i*

corresponding to the fuel injection quantity is 5

Engine speed (rpm)

• Before disassembling the turbocharger, clean its

fl Replace the entire rotor assembly, if the dynamic

• For KTR100, KTR130

• For KTR110, KTR150

3) Staighten the lock washer, remove mount-

fl Before removing the blower impellers, measure

2) Measurement of the radial play (A play in the

3) Extract the bolwer impellers from the turbine

3. Insert (Back plate)

• For KTR110, KTR150.

10. Turbine rotor

• Before assembly parts, wash and clean the parts,

8. Insert (Back plate)

• For KTR110, KTR150.

2) After the blower impellers are cooled, tighten

fl Measure the end play and the radial play of the

2) Measurement of the radial play (A play in the

• For KTR100, KTR130.

• For KTR100, KTR150.

fl Measure the clearance in the radial direction

fl After completing the assembly, rotate the ro-

No. Check item Criteria Remedy

Standard Repair limit

Radial play (play in radial Replacing parts re-

Tolerance Repair limit

Inner diameter of Journal bearing -0.030 +0.020

Bend of wheel shaft Repair limit: 0.010 (Total indicated runout)

Tolerance Repair limit

6 Thickness of seal ring -0.08

Clearance between blower Replace parts

Tightening torque of V band

NO. Check item Criteria I Remedy

Standard Repair limit Rapiace parts

Inner diameter of journal bearing.

Tolerance Repair limit

Tightening torque of blower

Tightening torque of insert Tighten

Tightening torque of V band

No Check item Criteria Remedy

Standard Repair limit Raplace parts

Tolerance Repair limit

Inner diameter of journal bearing. +0.015

Tolerance Repair limit

6 -0.08 +0.02 5.86 6.04

Tightening torque of blower

Tightening torque of V band