FUSO OHP Sheet Vol.

01

New Canter engine : 4D3

Based on shopmanual : No. TWDE0411

© Copy right PT Krama Yudha Tiga Berlian Motors - Jakarta.

Specifications
Exploded View

Camshaft Cylinder sleeve

Valve spring Cylinder head

Rocker arm
Flywheel

Push rod

Intake valve

Tappet

Timing gear

Crankshaft

Exhaust valve

Piston

Connecting rod
Combustion Chamber

4D34
Injection nozzle

Cylinder head

Piston

Water jacket
 Cylinder Sleeve

4D34, 4D34-T 4D33

Crank case

Cylinder sleeve

0.5mm oversize sleeve is provided Sleeve is provided for overhauling

 Piston-1

4D33, 4D34 4D34-T

Parts number

Mass mark (g)

Oversize mark

Weight mark
(A to F) Oversize mark

Parts number

Front mark
Front mark

Oversize piston – 0.5, 1.0mm (4D34, 4D34-T)

0.5mm (4D33)
Piston-2

EBF - 4D33, 4D34

Ring (Niresist) - 4D34-T

Strut

A>B

Cooling channel – 4D34-T

B
Piston Rings

1st Compression ring

Barrel faced
Full keystone type

2nd compression ring

Taper faced
Inner cut type

Oil ring
Dual type with expander spring

Piston with niresist and iron plated top ring are available as service parts (4D34 N/A)
 Timing Gear Train

Thrust plate

Oil holes

Camshaft gear
Idler shaft

Idler gear Idler bushing

Power steering oil pump gear

Idler gear

Injection pump gear

Oil pump gear

Crankshaft gear
 Injection Pump Installation

4D33, 4D34-T 4D34

Case
Injection pump gear Case

Injection pump gear

Bearing
Connecting Rod-1

4D34-T

4D33, 4D34
Connecting Rod-2

4D33, 4D34

Connecting rod bushing

Upper connecting rod bearing

Connecting rod bolt

Connecting rod

Alignment mark Weight mark

(H to M)

Lower connecting rod bearing Connecting rod cap

Connecting Rod-3

4D34-T

Connecting rod bushing

Connecting rod

Upper connecting rod bearing

Weight mark
(A to G)

Alignment6 mark

Connecting rod cap

Lower connecting rod bearing
Connecting rod bolt
Connecting Rod Bushing

Connecting rod
Special tool MH061891 (4D33, 4D34)
MH062225 (4D34-T)

Bushing

Press Collar B
Oil hole

Puller
Bushing

Bracket Puller
Collar A Bushing

Plate
Collar A

Base
Nut
Angular Tightening

Elastic region Plastic region

Tightening
torque
Small variation

Failure
Axial tension of bolt

Plastic region tightening

Yielding
Large variation point

Axial
tension
Wrench tightening

Angle variation

Torque variation
 Cylinder Head Bolt

Special tool – MH061560

147Nm (15Kgf-m) + 90deg (wet), up to 3 times

5 Rod
Scale
(on socket)

Scale (on holder)

M14 * 2 M14 * 2

9
56mm 50mm
Reusable up to 3 times
L L

L = 122.5 and 180.5mm

 Main Bearing Cap Bolt

Crankshaft
59Nm (6Kgf-m) + 90deg (wet)
Special tool – MH061560 Up to 3 times

Rod

Scale (on holder)

Scale (on socket)

101mm 102mm

M14 * 2 M14 * 2

9 12

Reusable up to 3 times 64mm 45mm

Flywheel Bolt

Bolt

10

Scale (on socket)

Scale (on holder)

Special tool - MH062183

39Nm (4Kgf-m) + 40deg (wet)
Rod
Special tool – MH062356
Connecting Rod Cap Bolt (4D34-T)

29Nm (3Kgf-m) + 90deg (wet) up to 3 times

Special tool – MH061560

Crankshaft

Rod
Scale
(on socket)
5

Scale (on holder)

Reusable up to 3 times
Gasket Selection (4D34-T)
 Valve Mechanism

Adjusting screw

Inner valve spring

Valve cap
Rocker arm Outer valve spring
Valve cotter

Inner valve spring

Upper retainer
Push rod

Valve guide

Valve
Tappet

Camshaft
Valve Guide & Valve Stem Seal

Installation
Removal
Special tool
Special tool MH061293
MH061998
Special tool Lip
MH061066
Valve stem seal
Cylinder head

10mm

Valve guide Cylinder head

Valve guide
Rocker Arm Bushing

Removal Installation

Special tool
MH061378

Rocker bushing
Notch on bushing
Clinch (seam) in bushing

Chamfered
Bushing

Oil hole in bushing

Oil hole in rocker

Valve Clearance Adjustment

0.4mm
Engine cold condition
Crankshaft

Upper main bearing

Thrust plate

Oversize thrust plate

(0.15, 0.30, 0.45mm)

Lower main bearing

Main bearing cap

Undersize Bearings

Journal
Pin
Rear Oil Seal Slinger

Lip

Rear oil seal slinger Special tool

MH062677

Installer
Guide
Main Bearing

Special tool Crankcase side

MH061083

Side seal tips

Main bearing cap

Sealant (1207C)
 Camshaft Bushing

Special tool
Rod
MH061276

ID marks
ID marks

ID marks
Inspection-1

Compression pressure Pressure gauge

Piston projection

Special tool
MH061460

Gasket

Nozzle bridge

Injection nozzle mounting hole

Cylinder head
 Inspections-2
Cylinder head bottom surface distortion

Crankshaft end play

Piston ring end play

Connecting rod end play
Cylinder sleeve

Piston

Piston ring
Inspection-3

Flywheel friction surface distortion

Flywheel friction surface height

Lubrication Diagram (Spin-on Type)
Lubrication Diagram (Spin-on Type, with Turbocharger)
Valve & Switch-1

Oil pump gear

Crankshaft gear

Oil pump

To oil cooler

From oil strainer

Relief valve
Opening pressure
1080kPa (11.0Kgf/cm2)
 Valve & Switch-2

To oil cooler
Bypass valve
To main oil gallery Regulator valve
Opening pressure
390kPa (4.0Kgf/cm2) Opening pressure
590kPa (6.0Kgf/cm2)

To oil pan

To oil filter

Oil filter
 Valve & Switch-3

To main oil gallery

Piston
Main oil gallery
Oil pressure SW

Oil jet

Check valve
Opening pressure
195kPa (2.0Kgf/cm2)
 Oil Filter (Spin-on Type)

To main oil gallery

To oil pan

Bypass filter

Bypass valve
Opening pressure
Special tool 140kPa (1.4Kgf/cm2)
MH061590

Full-flow filter
Inspection of Oil Pressure

Oil pressure SW

Adapter
PT 1/8

Oil quantity – Oil pan 8 liters

Filter 1 liter
Lubrication Diagram (Replaceable Type)
Valves

To oil cooler

From oil cooler

Regulator valve To oil pan

Opening pressure
590kPa (6.0Kgf/cm2)

Bypass valve
Opening pressure
390kPa (4.0Kgf/cm2)

Oil filter
 Valve & Oil Filter

To main oil gallery

To main oil gallery

Oil filter
Oil bypass alarm
Opening pressure
140kPa (1.4Kgf/cm2)
Oil filter
Specification of Fuel System
 Flow of Fuel (4D34)

Fuel filter
Supply fuel
Fuel feed pipe Injection nozzle
Injection pipe Leak-off fuel

Leak-off hose

Fuel feed pipe

Overflow valve Fuel return pipe

Governor

Injection pump

Feed pump
Fuel suction pipe

Water separator Fuel tank

 Flow of Fuel (4D33)

Fuel filter

Injection pipe Fuel feed pipe Injection nozzle Supply fuel

Leak-off fuel
Leak-off pipe

Fuel feed pipe

Overflow valve Fuel return pipe

Governor

Injection pump

Feed pump
Fuel suction pipe

Fuel tank
Water separator
Water Separator

From fuel tank

To feed pump

Screen
Water level ring
 Fuel Filter (Spin-on Type)

4D34
Fuel filter head

From feed pump

Special tool
MH061509

To injection pump

Fuel filter
Fuel Filter (Replaceable Type)

Filter head

From feed pump

To injection pump

Filter
Fuel Feed Pump-1

Priming pump

To fuel filter

Outlet check valve

Inlet check valve

Feed pump housing

Gauze filter
From water separator
 Fuel Feed Pump-2

At suction At delivery At standstill

Inlet check valve

Piston spring
Suction chamber
Piston
Outlet check valve
Pressure chamber

Camshaft
Push rod
Injection Pump

DENSO PUMP (Type A) Governor (Type R801)

Timer (Type SCZ)

Timer (Type SCZ)-1

Pin

Flyweight

Injection pump gear

Timer hub

Pin Timer spring

 Timer (Type SCZ)-2

At standstill At operation

Flyweight

Timer spring
Timer spring

Advance angle

Flyweight
Pin (Pump gear)
Pin (Timer hub)
 Timer (Type SBO)-1

Large cam

Flyweight

Timer cover Injection pump gear

Small cam
Hub

Timer spring
Timer (Type SBO)-2

At standstill At operation

Advance angle

Small cam

Large cam

Timer spring

Flyweight

Flyweight Timer spring

Injection pump (type A)

Delivery valve holder

Delivery valve spring

Delivery valve

Plunger barrel

Control pinion

Plunger

Control rack

Control sleeve

Plunger spring

Tappet

Camshaft
Delivery of Pressurized Fuel

Suction Start of delivery End of delivery

Inlet / outlet port

Lead

Plunger barrel

Plunger

Tappet

Camshaft
 Injection Quantity Control

Plunger barrel
Effective stroke

Inlet / outlet port

Control rack
Lead

Pinion Plunger

Plunger
Sleeve
Flange
 Delivery Valve-1

A Type NL Type

Delivery valve holder Delivery valve holder

Delivery valve spring

Delivery valve spring

Delivery valve
Delivery valve
 Delivery Valve-2

A B C E D

Delivery valve spring

Delivery valve

A : Start of pressured delivery

B : Injection
C : End of pressured delivery
D : Completion of suction
E : Suction stroke
Injection Pump (type NB)

Delivery valve holder

Delivery valve spring

Delivery valve

Shim

Element cover

Cylinder
Plunger
Upper spring seat

Control rack

Control sleeve

Plunger spring
Lower spring seat

Camshaft

Plunger housing
Tappet
 Delivery of Pressurized Fuel

Suction Start of delivery End of delivery

Outlet port
Inlet port

Lead

Plunger
 Injection Quantity Control

Lead
Outlet port
Inlet port Outlet port
Inlet port

Lead Effective stroke Plunger

Plunger
Control sleeve

Control rod
Delivery Valve

Delivery valve spring

Ball

Spring

Delivery valve
Overflow Valve

Steel ball
Governor (Type R801 & R901)

Nut Full-load stopper housing

Sliding plate
Full-load stopper
Adapter screw
Stop cam
Shackle

Control rack Floating arm

Control lever
Damper spring
Stop lever
Return spring

Connecting bolt

Floating arm spring

Start spring
Cam plate

Guide shaft
Screw plug

Sliding block

Steering lever

Floating lever
Spring seat
Adjusting lever shaft
Flyweight holder
Flyweight Bearing bolt
Slider
Jointing bolt
Supporting lever
Bellcrank shaft Supporting shaft
 Governor Characteristic

2-speed type All-speed type

O : Accelerator pedal opening

O max

Control rack stroke

Control rack stroke

O3
O max
O2
O3
O1 O2

O min O1
O min

Injection pump speed Injection pump speed

All-speed type for truck & bus

Control rack stroke

O max

O min

Injection pump speed

 Governor Operation

Injection quantity

Increased Decreased
Plunger barrel

Floating lever
Control sleeve Shackle
Control pinion Control rack

Plunger
Jointing bolt
Pivot

Cam shaft

Bearing bolt

Flyweight
Spring
 Aneroid Compensator

Decrease Control rack

Bellows

Atmospheric pressure chamber

Push rod
Aneroid compensator

Control rack
1.00
Atmospheric pressure
0.91
0.82
Air density

0.74

Stopper

Compensator lever

0 1000 2000 3000

Altitude (m)
Boost Compensator-1

Adaptor screw
Diaphragm

Boost compensator

Floating arm
Stop cam

Control rack
 Boost Compensator-2

Stopper Adaptor screw

Full-load stopper

Sliding block
Guide bushing
Diaphragm
Push rod

Floating arm

Stop screw
Stop cam

Spring

Push rod
Inspection & Adjustment

Full-load set screw

Speed set screw

Control lever

Idling set screw

Injection Timing

Advance

Retard

Injection pump
Crankcase
Injection Pump installation

Align indent

Indent

Align indent

Indent

Guide bar

Guide hole
Injection Nozzle (1-spring)

Inspection item
1. Needle valve opening pressure
2. Splay condition
3. Leakage

Nozzle tester

Adjusting shim

Spring

Nozzle tip

Needle valve

Variation of 0.5mm thickness in adjusting shim

causes a difference of 735 kPa (7.5kgf/cm2) of
Pressure. (1 kg/cm2 / 0.0067mm thickness)
 Injection Nozzle-1 (2-spring)

From injection pipe

To leak-off pipe

Spring seat
No.1 spring (for total lift adjustment)

1st opening pressure

adjustment shim

Pressure pin

2nd opening
pressure
No.2 spring
adjustment shim

Total lift Pre-lift

Spring seat

4D34-T4
0.075 (+0.01 -0.01) mm
Washer

Washer
(for pre-lift adjustment)
Needle valve
Injection Nozzle-3 (2-spring)

T
P
C

Spring set force (Kg)

Injection rate (mm3/deg)

B
A

P
Cam angle (deg)
T

T : Needle valve total lift (mm)

P : Needle valve pre-lift (mm)
A to B : No.1 spring set force
B to D : No.1 + No.2 spring set force
Cooling System

Reservoir tank

Pressure cap

Radiator

High
temperature Cylinder head
Heater
Thermostat
Low
temperature

Cylinder block
Water pump
Thermostat
Low water temperature High water temperature

To radiator

From cylinder head

To water pump

At engine standstill At engine in operation

Air Air

Water pressure
Pressure Cap

Pressure building-up Pressure spring

To reservoir tank

Vacuum

From reservoir tank

Vent valve
 Coolant Boiling Temperature

Pressure cap valve opening pressure

4300 0.60

3750 0.65
Atmospheric pressure (Kg/cm2)

1.1 Kg/cm2
3000 0.70
0.8
Altitude (m)

2250 0.75 0.6

0.5

0.80
0.3

1500 0.85
Free

0.90

750 0.95
85 90 95 100 105 110 115 120 125

Boiling temperature (deg Celsius)

Water Pump

Water pump case

Unit seal

Water pump shaft

Impeller
Flange
Unit bearing

Drain hole
 Auto-cooling Fan

Oil port

Rotor Case

Cooling fan speed

Valve

Shaft

Counter weight

Bimetal

Air temperature
Cover (Bimetal temperature)
 Automatic Fan Coupling

At air temperature is low At air temperature is rising At air temperature is high

Case
Cover Operational chamber

Pump hole

Oil port
Storage chamber

Rotor
Valve

Bimetal
 Turbocharger with Waste Gate

Thrust bearing
Thrust sleeve Bearing
Type : TD05H-14G
Bearing housing

Turbine back plate

Compressor wheel

Compressor cover

Turbine housing

Actuator
Shaft and turbine wheel

Piston ring
Thrust ring
Inserter
Oil deflector
 Function of Waste Gate

Waste gate valve is closed Waste gate valve is opened

Compressor wheel
Compressor cover Turbine wheel

Intake air

Boost pressure
Waste gate
valve

Actuator

Pressure chamber
Exhaust gas
Opening pressure – 715 mmHg
Over Boost Valve

Boost pressure Over boost valve

Intake air Exhaust gas

Boost pressure

Opening pressure – 860mmHg

Inspection-1

MH061366

Hose

Boost compensator
 Inspection-2

Correction value (Pa)

Boost pressure
Coefficient (kt)

Boost pressure
Engine speed (rpm)
Air temperature
(Difference between the median of the no-load
Maximum engine speed and the actual engine
Speed used for boost pressure measurement)
Unloader Valve

Air cleaner assembly

Air box

Unloader valve