Fuel System of Service Manual

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Laurence Jones
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1 Fuel System of Service Manual for H Series Engine for Generator sets October of

2 Table of Contents 13.1 About System System Diagram Fuel system (4 cylinders) Fuel system (6 cylinders) Tools Notes for Disassembly and Assembly Disassembly High Pressure Fuel Lines Removal (4 Cyinders) High Pressure Fuel Lines Removal (6 Cyinders) Injector Removal Removal of Fuel lines for Application Low Pressure Fuel Lines Removal Fuel Injection Pump Removal Fuel Filter Removal Installation Injector Installation Fuel Injection Pump Installation High Pressure Fuel Lines Installation (4 cyinders) High Pressure Fuel Lines Installtion (6cylinders) Fuel Filter Installation Low Pressure Fuel Lines Installation Installation of Fuel lines for Application

3 13.1 About System The fuel system consists of injectors, fuel injection pump, electronic governor, high and low pressure fuel lines, fuel injection pump brackets, etc. During engine operation, fuel in the tank is pumped first through a primary fuel filter and a secondary fuel filter into the fuel injection pump. The fuel in the fuel injection pump is pressured and then sent to the high pressure fuel pipes. The fuel in the high pressure fuel pipes is supplied to the injectors and then injected into the combustion chambers, providing fuel power for the engine. 3

4 13.2 System Diagram Fuel system (4 cylinders) Fuel system (4 cylinders) (1)Fuel inlet pipe from fuel feed pump to fuel filter (3)Electronic governor (5)Injector clamp (7)Bolt (9)Injector fuel inlet pipe (2)Fuel filter bracket (4)Injector clamp spacer (6)spherical washer (8)Injector (10)Injector fuel inlet pipe nut (11)High pressure fuel pipe (cylinder 1) (12)High pressure fuel pipe (cylinder 2) (13)High pressure fuel pipe (cylinder 3) (14)High pressure fuel pipe (cylinder 4) (15)Bolt (17)Clamp cushion (19)Bolt 4 (16)Clamp (upper half) (18)Clamp (20)Nut

(21)Stud (23)O-ring (25)Bolt (27)Fuel injection pump fuel return pipe (29)Fuel line clamp (31)Rubber coated washer (33)Bolt (35)Fuel injection pump (37)Fuel inlet pipe from fuel filter to fuel

5 (21)Stud (23)O-ring (25)Bolt (27)Fuel injection pump fuel return pipe (29)Fuel line clamp (31)Rubber coated washer (33)Bolt (35)Fuel injection pump (37)Fuel inlet pipe from fuel filter to fuel injection pump (39)Fuel filter (22)O-ring (24)Fuel injection pump flange adapter (26)Joint (28)Banjo bolt (30)Fuel return pipe (32)Bolt (34)Fuel injection pump bracket (36)Fuel injection pump bracket (38)Bolt (40)Fuel filter head bracket Fuel System ( 6 cylinder) Fuel system (6 cylinders) 5

6 (1)Injector clamp spacer (3)Injector clamp (5)Bolt (7)Injector fuel inlet pipe nut (9)High pressure fuel pipe clamp (11)Clamp (upper half) (2)Injector (4)spherical washer (6)Injector fuel inlet pipe (8)Bolt (10)Bolt (12)Clamp cushion (13)Clamp cushion (14)High pressure fuel pipe (cylinder 1) (15)High pressure fuel pipe (cylinder 2) (16)High pressure fuel pipe (cylinder 3) (17)High pressure fuel pipe (cylinder 4) (18)High pressure fuel pipe (cylinder 5) (19)High pressure fuel pipe (cylinder 6) (21)High pressure fuel pipe bracket (23)Electronic governor (25)O-ring (27)O-ring (29)Banjo bolt (31)Fuel return pipe (33)Rubber coated washer (35)Stud (37)Fuel injection pump bracket (39)Bolt (41)Bolt (43)Fuel inlet pipe from fuel filter to fuel injection pump (45)Fuel filter (47)Fuel filter bracket (20)Clamp (22)Bolt (24)Bolt (26)Fuel injection pump flange adapter (28)Joint (30)Fuel line clamp (32)Fuel injection pump fuel return pipe (34)Fuel injection pump (36)Bolt (38)Nut (40)Fuel injection pump bracket (42)Clamp (44)Bolt (46)Bolt (48)Fuel inlet pipe from fuel feed pump to fuel filter 6

7 13.3 Tools The oil/fuel filter tool used for engine maintenance is required Notes for Disassembly and Assembly Use proper tools to disassemble and assemble the fuel system. Disassembly and Assembly must be conducted in the sequences specified in this chapter. All removed O-rings, copper washers, rubber coated washers and non-metal gaskets must be discarded after disassembly, and new ones must be used for assembly. Removed parts must be put in a clean place and must be cleaned before assembly. Use a proper cleaner to clean parts and dry them by compressed or natural air. Do not use a wire brusher to clean the injectors. Cover an injector tip part with a protection cap after cleaning. Take new parts out from their package only after their installations are due. Clean the new parts if they are not clean, Use proper tightening tools to tighten all the bolts and nuts to their required torques. 7

8 13.5 Disassembly High Pressure Fuel Lines Removal (4 Cyinders) 1.Loosen the bolt 1 (2 pcs). 2.Remove the clamp 2 (upper half, 2 pcs), clamp cushion 3 (4 pcs) and clamp 4 (lower half, 2 pcs). 3.Loosen the high pressure fuel pipe nuts. 4.Remove the four high pressure fuel pipes of 1, 2, 3 and High Pressure Fuel Lines Removal (6 Cyinders) 1.Loosen the bolt 1 (5 pcs). 2.Remove the clamp 2 (upper half, 3 pcs), clamp 3, clamp cushion 4 (2 pcs), clamp cushion 5 (6 pcs) and clamp 6 (2 pcs). 3.Loosen the high pressure fuel pipe nuts. 4.Remove the six high pressure fuel pines of 1, 2, 3, 4, 5 and 6 8

9 5.Loosen the bolt 1 (2 pcs). 6.Remove the high pressure fuel pipes bracket Injector Removal 1.Remove the valve cover. Refer to Section for the procedures. 2.Loosen and remove the injector inlet pipe nut 1. 3.Remove the injector inlet pipe 2. Note: Install a high pressure fuel pipe on the injector inlet pipe 2 as a handle to pull out the inlet pipe because there is a setting ball on the inlet pipe that makes it difficult to remove. 4.Loosen and remove the injector clamp bolt 3. 5.Remove the spherical washer 4. 6.Remove the injector 6 with the clamp 5. Use a common tool as an aid to remove the injector with the clamp if necessary. Put the injector in an appropriate clean place. 7.Remove the injector clamp spacer 7. Note: 4-cylinder engine has 4 injectors and 6-cylinder engine 6 ones Removal of Fuel lines for Application 1. Loosen the banjo bolt and remove the fuel inlet pipe Loosen the banjo bolt and remove the fuel return pipe 2. 9

10 Low Pressure Fuel Lines Removal 1. Remove the fuel line clamp Loosen the banjo bolt 1 and the banjo bolt at the fuel injection pump. 3.Remove the injectior fuel return pipe 2 and rubber coated washer 3 (2 pcs). 4.Remove the fuel line clamp 1. 5.Loosen the banjo bolt 2 and injection pump fuel inlet pipe banjo bolt. 6.Remove the low pressure fuel pipe 3 (from fuel feed pump to fuel filter) and rubber coated washer 4 (2 pcs). 7.Loosen the banjo bolt 1 and injection pump fuel inlet pipe banjo bolt. 8.Remove the low pressure fuel pipe 2 (from fuel filter to fuel injection pump) and rubber coated washer 3 (2 pieces) Fuel Injection Pump Removal 1.Loosen and remove the bolt 1 (6 pcs). 10

11 2.Loosen and remove the bolt 1 (2 pcs). 3.Loosen and remove the bolt 2 (2 pcs). 4.Remove the fuel injection pump bracket 3. 5.Loosen and remove the bolt 4 (2 pcs). 6.Remove the fuel injection pump bracket 5. 6.Loosen and remove the nut 1 (4 pcs). 7. Remove the fuel injection pump flange adapter3, O-ring 4 (2 pcs) and O-ring Loosen and remove the stud 2 (4 pcs) when necessary. 9. Remove the assembly of the electronic governor 1 and fuel injection pump If either the electronic governor or fuel injection pump is replaced, disassemble the governor from the injection pump. Refer to the attachment for disassembly procedures Fuel Filter Removal 1. Install the oil/fuel filter tool 1 on the fuel filter 2 and turn the tool in left direction to loosen the fuel filter. 2. Remove the fuel filter 2. 11

12 2.Loosen the bolt 1 (2 pcs). 4.Remove the fuel filter head 2. 5.Loosen the bolt 3 (2 pcs). 6.Remove the fuel filter head bracket 4. 12

13 13.6 Installation Injector Installation 1.Install the injector clamp spacer 1 on the cylinder head. 2.Install the O-ring on the injector and apply proper amount of Vaseline or clean oil to the O-ring. 3.Put the copper sealing washer on the lower part of the injector with Vaseline to prevent the washer from falling during installation. Caution: Do not remove the injector protection cap before installation. 4.Install the injector clamp 2 on the injector 3 from the injector side having the fuel inlet port. Install the injector with the clamp on the cylinder head and settle the injector to its place by manually pressing or by tightening the clamp bolt 5. 5.Install the spherical washer 4 and clamp bolt 5. 6.Put the O-ring on the injector inlet pipe 6 and apply proper amount of Vaseline or clean oil to the O-ring. Install the pipe into the cylinder head to connect the injector fuel inlet port. The injector fuel inlet pipe has a setting ball. Install the pipe with the setting ball facing up and settling in the recess in the pipe bore of the cylinder head. 7.Install the injector fuel inlet pipe nut 7 and tighten it to 15 Nm that is not the final torque. 8.Tighten the bolt 5 to 23±2 Nm. 9.Tighten the nut 7 to 55±2 Nm Note: 4-cylinder engine has 4 injectors and 6-cylinder engine 6 ones. 13

14 Fuel Injection Pump Installation 1.Apply proper amount of Vaseline or clean oil to the O-ring 1 and install it on the fuel injection pump flange adapter 3. Install the 2 pieces of O-ring on the oil hole each side of the adapter 2. If a new fuel injection pump is used, install the stud 4 (4pcs) and tighten them to 40±3Nm alternatively. 3.Install the adapter on the fuel injection pump and tighten stud nut 5 (4 pcs) to 50±5 Nm 4.If the electronic governor 2 has been dismounted from the fuel injection pump 1, refer to the attachment for the assembly procedures when installing the governor onto the pump. 5.Install the pump bracket 1 and tighten the bolt 2 (2 pcs) to 105 Nm alternatively. 6.Install the pump bracket 3 and tighten the bolt 4 (2 pcs) to 60Nm alternatively. 7.Install the fuel injection pump 5 and tighten the bolt 6 (2 pcs) to 40 Nm alternatively. 8. Tighten the bolt 1 (6 pcs) to 60 Nm alternatively. 14

15 High Pressure Fuel Lines Installation (4 cyinders) 1.Install the four high pressure fuel pipes of 1, 2, 3 and 4. Tighten the pipe nuts manually. 2.Tighten the nuts with to 35 Nm. Caution: When installing the high pressure fuel pipes, first tighten the pipe nuts manually without exerting any stress and then tighten them with tool to the specified torque. 3. Install the clamp 2 (upper half), clamp cushion 3 (2 pcs) and clamp 4 to secure the No. 1 and No. 2 high pressure fuel pipes and tighten the clamp bolt 1 to 9 Nm. 4. Install the clamp 2 (upper half), clamp cushion 3 (2 pcs) and clamp 4 to secure the No. 3 and No. 4 high pressure fuel pipes and tighten the clamp bolt 1 to 9 Nm High Pressure Fuel Lines Installtion (6cylinders) 1. Install the fuel injection pump bracket 1 and tighten the bolt 2 (2 pcs) to 25 Nm. 15

16 2.Install the six high pressure fuel pipes of 1, 2, 3, 4, 5 and 6. Tighten the pipe nuts manually. 3.Tighten the nuts with tool to 35 Nm. Caution: When installing the high pressure fuel pipes, first tighten the pipe nuts manually without exerting any stress and then tighten them with tool to the specified torque. 4.Install the clamp 2 (upper half) and clamp cushion 5 (2 pcs) to secure the No. 1 and No. 2 high pressure fuel pipes to the high pressure fuel pipe bracket, and tighten the clamp bolt 1 to 9 Nm. 5.Install the clamp 3 and clamp cushion 4 (2 pcs) to secure the No. 1, No. 2, No. 3 and No. 4 high pressure fuel pipes to the high pressure fuel pipes bracket, and tighten the clamp bolt 1 (2 pcs) to 9 Nm. 6.Install the clamp 2 (upper half) and clamp cushion 5 (2 pcs) to secure the No. 1 and No. 2 high pressure fuel pipes and tighten the clamp bolt 1 to 9 Nm. 7. Install the clamp 2 (upper half), clamp cushion 5 (2 pcs) and clamp 6 to secure the No. 1 and No. 2 high pressure fuel pipes and tighten the clamp bolt 1 to 9 Nm Fuel Filter Installation 1.Install the fuel filter head bracket 1 and tighten the bolt 2 (2 pcs) to 90±5 Nm alternatively. 2.Install the fuel filter head 3 and tighten the bolt 4 (2 pcs) to 30±3 Nm alternatively. 16

17 3.Apply proper amount of Vaseline or clean oil to the O-ring of the fuel filter 1 and install the filter onto the filter head. Turn the filter until the O-ring contacts the filter head and then tighten the filter with the oil/fuel filter tool to 3/4 circle or Nm Low Pressure Fuel Lines Installation 1. Install the low pressure fuel pipe 1 (from fuel filter to fuel injection pump) with the rubber coated washer 2 ( 2pcs) at the filter end. 2. Tighten the bolt 3 and the banjo bolt at the fuel injection pump end manually first and then tighten them with tool to Nm and18±2 Nm. 3. Install the low pressure fuel pipe 1 (from fuel feed pump to fuel filter) with rubber coated washer 2 (pcs) at the filter end. 4.First tighten the bolt 3 and the banjo bolt at the fuel injection pump end manually and then tighten them with tool to Nm and 18±2 Nm. 5. Install the clamp 4 to secure the low pressure fuel pipe from fuel filter to fuel injection pump and the low pressure pipe from fuel feed pump to fuel filter. 17

18 6.Install the injector fuel return pipe 1 with rubber coated washer 2 (2 pcs) at the cylinder head end. 7.First tighten the bolt 3 and the banjo bolt at the fuel Injection pump end manually and then tighten them with tool to Nm and 10±2 Nm respectively. 8. Install the clamp 4 to secure the fuel return pipe. Caution: When installing the low pressure fuel pipes, first tighten manually without any exerting stress and then tighten with tool to the specified torques Installation of Fuel lines for Application 1. Install the fuel inlet line 1 and tighten the banjo bolt manually first and then tighten it with tool to 18±2 Nm. 2. Install the fuel return pipe 2 and tighten the banjo bolt manually first and then tighten it with tool to 10±2 Nm. Caution: When installing the low pressure fuel pipes, first tighten manually without exerting any stress and then tighten with tool to the specified torques. 18

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