09080-05841 GOVERNOR ASSY, MEC Denso Cross

Table 1
Revision Summary of Changes
01 Added machines prefixes Introduction
The following Special Instruction gives guidance on troubleshooting and diagnostic on the diesel engine for the machines listed above.Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.Safety Section
Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.
Failure to follow all safety guidelines prescribed in this document and by governing authorities and regulatory agencies may result in severe injury or death of personnel or machine damage.
Personal injury or death can result from improper maintenance procedures. To avoid injury or death, follow the procedures exactly as stated below.
3-Cylinder Diesel Theory and Operation
The KDW 1003 diesel engine has an indirect injection (IDI) fuel delivery system. The fuel injectors are a unit style injector located in the cylinder head and actuated by the camshaft.As the camshaft turns, the adjustable pushrod forces the high-pressure plunger into the injector. The unit injector is then pressurized to 14,000 to 15000 kPa (2030 to 2175 psi) before injection. This process is known as popping pressure. The injection even will take place between 11° and 13° (BTDC) before the piston reaches top dead center.Refer to the engine emissions tag on the engine or the service manual for proper injection timing specifications. Refer to the service manual for the injection timing tool and procedures.The unit injectors are supplied low-pressure fuel from the electric fuel pump in the fuel tank to the injection lines coming through a grommet in the cylinder head. This pressure is between 60 to 70 kPa (8.7 to 10 psi). Fuel supply is hose A and fuel return is hose BCommon Specifications
Compression ratio: 22.8 to 1
Compression: new engine cold 2760 to 3100 kPa (400 to 450 psi) or old engine at 2415 to 2760 kPa (350 to 400 psi)
Compression minimum: 1725 kPa (250 psi) (below this pressure, cylinder misfire will occur)
Compression readingtaken through the glow plug hole, 563-4356 Test Kit
Firing order: 1 - 3 - 2
Supply fuel pressure: 60 to 70 kPa (8.7 to 10 psi)
Popping pressure: 14,000 to 15000 kPa (2030 to 2175 psi)
Thermostat open temperature: 78 to 82 °C (172.4 to 179.6 °F)
Thermostat fully open: 95 °C (203 °F)
Coolant fan on at 100.5 °C (213 °F) and off at 95 °C (203 °F)
Engine oil capacity: approximately 2.8 L (3 qt)
Engine oil (recommended): 5W-50 Synthetic
Engine oil pressure switch minimum opening pressure 30 kPa (4.35 psi) (on valve cover) normally close switch
Engine oil pressure at 120 °C (248 °F): 108 kPa (15.6 psi) at idle speed (800 to 900 rpm)Glow Plug and Thermistor
The KDW 1003 engine uses glow plug temperature sensor, or a thermistor, to adjust glow plug on time. The glow plugs are in the cylinder head precombustion chamber and heat up to 816 °C (1500