Content .. 64 65 66 67 ..

Takeuchi compact excavator TB125, TB135, TB145 / diesel TNE / diesel Yanmar. Service Manual - page 66

4.3.4.

Adjustment of Reverse Angleich

In the case of the governor with reverse angleich mechanism, use the reverse angleich spring
in the assembled state.

Adjustment of Reverse Angleich
Make adjustment of reverse angleich after completing the following processes:

●

Adjustment of fuel volume limiter bolt

●

Adjustment of no-load max, and min. revolutions limiter bolt

①

Shift the control lever to the full load position, and maintain the fuel injection pump revolution to the
specified reverse angleich control revolution number (N

②

In this condition, remove the governor rear cover, and screw the reverse angleich assembly into
the threaded portion of the tension lever until it hits the reverse angleich

lever. If screwing it in

additionally, the reverse angleich lever will shift in the direction of fuel reduction. Screw and set it to
the position of the specified injection quantity (R

③

Tighten the lock nut with specified tightening torque, and attach the governor rear cover.

④

Again, increase the revolution of the fuel injection pump to the rated revolution speed (N

), check

that the control rack will change the position of the reverse angleich stroke smoothly, and confirm
that the rack position (R

) and injection volume are within the specified limits.

N-m (kgf-m)

Lock Nut Tightening Torque

24.5-29.4(2.5-3.0)

4.3.5. Adjustment of Staring Injection Amount

①

Set the engine speed at the starting injection amount adjust
speed and leave the regulator lever at the position in 2
above.

②

Screw in the starting injection amount adjust bolt and adjust
it to obtain the specified injection amount.

③

Set the pump speed at 50 min

-1

and check that the amount

exceeding the specifications is being injected.

4.3.6. Checking the Injection Stop

Leave the regulator lever at the position as before.

①

Checking the Injection Stop: Set the pump speed at the
speed 50min-1 higher than the no load max. speed, and
check that the injection amount reduces to zero.

②

Checking the Stopping: Set the pump speed at the rated
speed, turn off the stop solenoid and check that the
injection amount reduces to zero.

5. Fuel injection Nozzle

When fuel 0il pumped by the fuel injection pump reaches the injection nozzle

，

it pushes up the nozzle valve

（

held down by

spring

），

and is injected into the combustion chamber at high pressure

．

The fuel is atomized by the nozzle to mix uniformly with the air in the combustion chamber. How well the fuel is mixed with
high temperature air directly affects combustion efficiency

，

engine Performance and fuel economy

．

Accordingly, the fuel injection nozzles must be kept in top condition to maintain performance and operating efficiency.

5.1. Functioning of fuel injection nozzle

Fuel from the fuel injection pump passes through the oil port in the nozzle holder and enters the nozzle body reservoir.
When oil reaches the specified pressure

，

it pushes up the nozzle valve

（

held by the nozzle spring

），

and is injected

through the small hole on the tip of the nozzle body

．

The nozzle valve is automatically pushed down by the nozzle spring and closed after fuel is injected.
Oil that leaks from between the nozzle valve and nozzle body goes from the hole on top of the nozzle spring through the oil
leakage fitting and back into the fuel tank.
Adjustment of injection starting pressure is effected with the adjusting shims.

5.2. Type/construction of fuel injection nozzle

There are two types of fuel injection nozzles. Direct injection engines are equipped with the hole type, and indirect injection
engines with the pintle type.
The YPD-MP fuel injection pump is designed for use with both direct and indirect injection engines. The hole type/pintle
type of fuel injection nozzle are used according to the engine type.

+1.0 (+10)

Nozzle opening

pressure

MPa
(kgf/cm

)

21.6

(220)

(0)

Nozzle angle

deg.

162

159

No. of nozzles

dia.

0.16 5

0.17

Identification No.

(Nozzle type)

162P165VAE1 159P175VAD1

Nozzle holder

F.O. return pipe joint

Hole type fuel injection nozzle

Nozzle spring

Nozzle spring seat

Nozzle body identification number

The type of nozzle can be determined from the number

inscribed on the outside of the nozzle body.

）

Hole type fuel injection nozzles

5.3. Fuel injection nozzle disassembly

Note:

1. Disassemble fuel injection nozzle in a clean area as for fuel injection pump.
2. When disassembling more than one fuel injection nozzle, keep the parts for each injection nozzle separate for each
cylinder (i.e. the nozzle for cylinder 1 must be remounted in cylinder 1).
(1) When removing the injection nozzle from the cylinder head, remove the high pressure fuel pipe, fuel leakage pipe, etc.,
the injection nozzle retainer nut

，

and then the fuel injection nozzle.

(2) Put the nozzle in a vise
NOTE: Use the special nozzle holder for the hole type injection nozzle so that the high pressure mounting threads are
not damaged.

（

）

Remove the nozzle nut

NOTE: Use a special box spanner for the hole type (the thickness of the two nozzle nuts is 15mm(0.5906in.)).
(4) Remove the inner parts
NOTE: Be careful not to loosen the spring seat, adjusting shims or other small parts.

5.4. Fuel injection nozzle inspection

5.4.1. Washing

（

）

Make sure to use new diesel oil to wash the fuel injection nozzle parts.

（

）

Wash the nozzle in clean diesel 0il with the nozzle cleaning kit.

(3) Clean off the carbon on the outside of the nozzle body with a brass brush.
(4) Clean the nozzle seat with cleaning spray.
(5)Clean off the carbon on the tip of nozzle with a piece of wood.

5.4.2. Nozzle inspection

（

）

Inspect for scratches/wear

lnspect oil seals for abnormal scratches or wear and replace nozzle if the nozzle sliding surface or seat are scratched
or abnormally worn.

）

Check nozzIe sliding

Wash the nozzle and nozzle body in clean diesel oil

，

and make sure that when the nozzle is pulled out about half

way from the body

，

it slides down by itself when released.

Rotate the nozzle a little

；

replace nozzle/nozzle body as a set if there are some places where it does not slide smoothly.

（

3) Inspecting stop plate

（

inter-piece

）

Check for scratches/wear in seals on both ends, check for abnormal wear on the surface where it comes in contact with the
nozzle

；

replace if stop plate is excessively worn.

（

）

lnspecting nozzle spring

Replace the nozzle spring if it is extremely bent

，

or surface is scratched or rusted

．

（

）

Nozzle holder

Check oil seal surface for scratches/wear

；

replace if wear is excessive.

5.5. Fuel injection nozzle reassembly

The fuel injection nozzle is reassembled in the opposite order to disassembly.

(1)

Insert the adjusting shims, nozzle spring and nozzle spring seat in the nozzIe holder

，

mount the stop plate with the pin

i nsert the nozzle body/nozzle set and tighten the nut.

(2)

Use the special holder when tightening the nut for the hole type nozzle as in disassembly.

5.6. Adjusting fuel injection nozzle

5.6.1. Adjusting opening pressure

Mount the fuel injection nozzle on the nozzle tester and use the handle to measure injection starting pressure. If it is
not at specified pressure, use the adjusting shims to increase/decrease pressure

（

both hole and pintle types).

Nozzle nut tightening torque

N-m(kgf-m)

Hole type nozzle

39 – 44 ( 4 – 5 )

Injection starting pressure

MPa(kgf/cm

)

19.6 - 20.6 ( 200 – 210 )

Injection starting pressure

21.6 – 22.6 ( 220 – 230 )

Ajusting by 0.1 mm results in a change in the injection starting pressure of about 2 Mpa ( 20 kgf / cm

)

Remark ) Injection starting pressure changes on enjine specifications.

5.6.2. Injection test

After adjusting the nozzIe to the specified starting pressure, check the fuel spray condition and

seat oil tightness.

(1) Check seat oil tightness

After two or three injections, gradually increase the pressure up to1.96MPa (20kg/cm

）

before reading the starting pressure

maintain the pressure for 5seconds, and make sure that no oil is dripping from the tip of the nozzle.

Test the injection with a nozzle tester

；

retighten and test again if there is excessive oil leakage from the overflow coupling.

Replace the nozzle as set if oil leakage is still excessive.

（

）

injection spray condition

Operate the nozzle tester lever once to twice a second and check for abnormal injection.

5.6.2.1. Hole type nozzles

Replace hole type nozzles that do not satisfy the following conditions

：

●

Proper spray ang1e

（θ）

●

Correct injection angle

（α）

●

Complete atomization of fuel

●

Prompt starting /stopping of injection

6. Troubleshooting

6.1. Troubleshooting of fuel injection pump

Complete repair means not only replacing defective parts, but finding and eliminating the cause of the trouble as
well. The cause of the trouble may not necessarily be in the pump itself, but may be in the engine or the fuel
system. If the pump is removed prematurely, the true cause of the trouble may never be known. Before removing
the pump from the engine, at least go through the basic check points given here.

Basic checkpoints

Check for breaks or oil leaks throughout the fuel system, from the fuel tank to the nozzle.

Check the injection timings for all cylinders. Are they correctly adjusted? Are they too fast or too slow?

Check the nozzle spray.

Check the fuel delivery. Is it in good condition? Loosen the fuel pipe connection at the injection pump

inlet and test operate the fuel feed pump.

6.2. Major faults and troubleshooting

Fault

Cause

Remedy

(1) No fuel in the fuel tank.

Resupply

(2) Fuel tank cock is closed.

Open

(3) Fuel pipe system is clogged.

Clean

(4) Fuel filter element is clogged.

Disassemble and clean, or
replace element

(5) Air is sucked into the fuel due to defective

connections in the piping from the fuel tank to the
fuel pump.

Repair

(6) Fuel feed pump is damaged.

Replace

Fuel not delivered
to injection pump.

(7) Fuel freeze.

Replace with a fuel for cold
weather.

(1) Defective connection of control lever and accel. rod

of injection pump.

Repair or adjust

(2) Plunger is worn out or stuck.

Repair or replace

(3) Delivery valve is stuck.

Repair or replace

(4) Control rack doesn't move.

Repair or replace

(5) Injection pump coupling is damaged, or the key is

broken.

Replace

(6) Air sucking.

Bleed air.

(7) Plunger/Distribution shaft is seized.

Replace pump.

(8) Tappet is seized.

Replace pump.

(9) Stop solenoid is damaged.

Replace

(10) Cold start device is damaged.

Replace

(11) Low cranking speed.

Replace battery.

(12) Governor is damaged.

Replace

(13) Barrel crack

Replace pump.

1. Engine

won't start.

Fuel delivered to
injection pump.

(14) Transmission shaft is seized. Gear slip.

Replace

(1) Nozzle valve doesn't open or close normally.

Repair or replace

(2) Nozzle seat is defective.

Repair or replace

(3) Case nut is loose.

Inspect and tighten

(4) Injection nozzle starting pressure is too low.

Adjust

(5) Nozzle spring is broken.

Replace

(6) Fuel oil filter is clogged.

Repair or replace

(7) Excessive oil leaks from the nozzle sliding area.

Replace the nozzle assembly

(8) Deformation due to excessive tightening of nozzle

retaining bolt.

Replace or adjust.

Nozzle

doesn't

work.

(9) Strainer is clogged.

Replace or clean

(1) Injection timing is retarded due to failure of the

coupling.

Adjust

(2) Camshaft is excessively worn.

Replace camshaft

(3) Roller tappet incorrectly adjusted or excessively

worn.

Adjust or replace

(4) Plunger is excessively worn.

Replace plunger assembly

(5) Bad installation of injection pump.

Adjust.

(6) Air sucking.

Bleed air.

Injection timing is
defective.

(7) Delivery valve is defective.

Replace.

(1) Fuel pipe is cogged.

Clean

(2) Fuel filter is clogged.

Disassemble and clean, or
replace the element.

(3) Improper air-tightness of the fuel pipe connection,

or pipe is broken and air is being sucked in.

Replace packing; repair pipe

(4) Insufficient fuel delivery from the feed pump.

Repair or replace.

(5) Trochoid pump is defective.

Replace.

(6) Air sucking.

Bleed air or hose check.

(7) Electromagnetic feed pump is clogged.

Replace.

(8) Out of fuel.

Fill the fuel.

(9) Stop solenoid is defective.

Replace.

2. Engine starts,

but immediately stops.

(10) Accumulator is abnormal.

Replace.

(1) Knocking sounds caused by improper (too fast)

injection timing.

Inspect and adjust

(2) Engine overheats or emits large amount of smoke
due to improper (too slow) injection timing.

Inspect and adjust

(3) Insufficient fuel delivery from feed pump.

Repair or replace

(4) Torochoid pump is defective.

Replace.

(5) Type of fuel is incorrect.

Check and refill proper fuel.

Defective
injection
timing, and other
failures.

(6) Fuel tempererture is high.

Cool.

(1) Case nut loose.

Inspect and retighten

(2) Defective injection nozzle performance.

Repair or replace nozzle

(3) Nozzle spring is broken.

Replace

Nozzle
movements
is defective

(4) Excessive oil leaks from nozzle.

Replace nozzle assembly

(1) Max. delivery limit bolt is screwed in too far.

Adjust

(2) Plunger is worn.

Replace

(3) Injection amount is not uniform.

Adjust

(4) Injection timings are not even.

Adjust

(5) The 1st and 2nd levers of the governor and the control rack

of the injection pump are improperly lined up.

Repair

(6) Delivery holderr is loose

Inspect and retighten

(7) Delivery packing is defective.

Replace packing

(8) Delivery valve seat is defective.

Repair or replace

(9) Delivery spring is broken.

Replace

(10) Carbon deposit is adhered.

Clean

(11) Spray pattern is abnormal.

Replace

(12) Nozzle crack.

Replace

3.Engine's

output

insufficient.

Injection pump is
defective.

(13) Plunger barrel crack.

Replace fuel injection pump.

(1) Movement of central rack is defective.
1) Stiff plunger movement or sticking.

Repair or replace

2) Rack and pinion fitting is defective.

Repair

3) Movement of governor is improper.

Repair

4) Delivery holder is too tight.

Inspect and adjust

(2) Uneven injection volume.

Adjust

(3) Injection timing adjustment failure.

Adjust

(4) Plunger is worn and fuel injection adjustment is

difficult.

Replace

(5) Governor spring is too weak.

Replace

(6) Feed pump can't feed oil at low speeds.

Repair or replace

(7) Fuel supply is insufficient at low speeds due to

clogging of fuel filter.

Disassemble and clean, or
replace element

(8) Weight abnormality.

Replace

(9) Shifter is worn.

Replace governor.

(10) Air sucking.

Check piping.

(11) Torochid pump is defective.

Replace

4. Idling is rough.

(12) Governor is worn.

Replace or adjust.

(1) The wire or rod of the accel is caught.

Inspect and repair

(2) Control rack is caught and can't be moved.

Inspect and repair

5. Engine runs at high speeds,

but cuts out at low Speeds.

(3) Low idling stopper bolt is abnormal.

Replace or adjust.

(1) Governor spring is broken or excessively worn.

Replace

(2) Injection performance of nozzle is poor.

Repair or replace

(3) Trochiod pump is defective.

Replace

(4) Accumulator is abnormal.

Replace

(5) Filter and pipe are clogged.

Check piping.

6. Engine doesn't reach max,

rpm.

(6) Governor is abnormal.

Replace

(1) Injection timing is too fast or too slow.

Adjust

(2) Injection from nozzle is improper fuel drips after each

infection.

Adjust

(3) Injection nozzle starting pressure is too high.

Adjust

(4) Uneven injection.

Adjust

7. Loud knocking.

(5) Engine overheats, or insufficient compression.

Repair

(1) Injection timing is too fast.

Adjust

(2) Air volume intake is insufficient.

Inspect and repair

(3) The amount of injection is uneven.

Adjust

When exhaust
smoke is black:

(4) Injection from nozzle is improper.

Repair or replace

(1) Injection timing is too slow.

Adjust

(2) Water is mixed in fuel.

Inspect fuel system, and
clean

(3) Shortage of lube oil m the engine.

Repair

8.Engine
exhausts too
much smoke.

When exhaust
smoke is white:

(4) Engine is over-cooled.

Inspect

7. Tightening torques for main bolts and nuts

7.1. Pump part

7.2. Mechanical governor part

8. Tools

Name of tool

Shape and size

application

Nozzle plate
158090-51700

Bottom clearance gauge

158090-51800 : MP2
158090-51810 : MP4

Plunger SP seat extractor

158090-51900

Bottom clearance gauge

Content .. 64 65 66 67 ..