Adjusting throttle linkage

A. Model 123.193 standard version

1st version

Connecting rod (5 in Fig. item 4)

118

Adjusting sleeve (5 in Fig. item 5)

180 072 03 93

30.8-300/1 F 3

1    Check throttle linkage for easy operation and bends. Replace damaged parts, if any.

2   Disconnect all regulating rods.

3   Check whether regulating lever (1) of injection pump rests against idle speed stop (3).

4   Check whether connecting rod (5) is correctly set. For this purpose, push regulating lever (1) against full load stop (2). Actuating lever (8) should have a max. play of 0.5 mm up to full load stop (6). If required, adjust connecting rod (5) by means of adjustable ball head (4).

Connecting rod (5) should be set to 122 mm, measur­ed from center of ball socket to center of linkage.

1    Regulating lever

2    Full load stop

3    Idle speed stop

4    Adjustable ball head

5    Connecting rod

6    Full load stop on vacuum control valve

7    Vacuum control valve

8    Actuating lever for vacuum control valve

5   Plug-on adjusting sleeve (5). Guide lever should rest against sleeve.

6   Set free travel rod (13) in completely pulled out condition to 154 mm, measured from center to center of ball head and connect.

7   Push guide lever (2) against idle speed stop.

8   Adjust pushrod (41) in such a manner that rod can be connected free of tension.

9   Set connecting rod (14) to 140 mm, measured from center to center of ball head and connect.

10   Set regulating lever on injection pump to full load.

Adjust adjustable ball head (13a) in slot, if required.

11 Adjust control pressure rod (12). Guide lever (2) should rest against idle speed stop. Push control pres­sure rod carefully against idle speed stop on transmis­sion, set to tension-free length, connect and secure.

Note: To facilitate assembly, make sure that trade­mark faces in upward direction when end piece is connected.

During longitudinal checkup, hold control pressure rod above test bore adjacent to bolt.

12 Remove adjusting sleeve (5).

30.8-300/3 F2

13 Check full load stop. With engine stopped, push accelerator pedal from inside vehicle up to stop on kickdown switch. Accelerator pedal and regulating lever on injection pump should rest against full load stop. If required, loosen adjusting screw (arrow). Adjust throttle linkage in such a manner that the regulating lever rests against full load stop.

If this adjustment is not enough to attain full load or ^!-Jle speed stop, set pushrod (5) from longitudinal regulating shaft to accelerator pedal to 200 mm, measured from center of ball socket to center of damping ring.

30.8-300/4 F2

14 Adjust cruise control. Check whether actuator rests against idle speed stop of cruise control. For this purpose, disconnect connecting rod (21) and push lever of actuator (4) clockwise against idle speed stop. When attaching connecting rod (21), make sure that the lever of the actuator is pushed away from idle speed stop by approx. 1 mm. Adjust connecting rod, if required.

15 Check operation of emergency stop button. For this purpose, run engine at idle, push emergency stop button (arrow). Engine should stop, readjust pushrod toward injection pump, if required.

Engine regulation

2    Guide lever

3a Longitudinal regulating shaft

4   Washer

5   Corrugated washer

6    Nut

7   Screw 10    Lock

12   Control pressure rod

13    Free travel rod

13a Screw-type ball head

14    Connecting rod 16    Lock

18    Holder

21    Holder

22    Holder

23    Hex. socket screw 41    Pushrod

48    Angle lever

50   Plastic bushing

74    Guide lever

O 1073-8390 1

30.8-300/5 F2

27   Joint

28   Kickdown switch

29   Adjusting nut

32   Copper netting-graphite disk

33   Lock

34   Regulating lever with damper 34a Corrugated washer

35   Bearing bracket 43   Lock

30.8-300/6 F 3

2nd version

Idle travel rod with elastic stop (5)

184

Connecting rod (41)

Adjusting sleeve (05 in Fig. item 1|

182 072 03 93

30.8-300/7 F 3

Adjusting

1 Check full throttle stop and adjust at longitudinal regulating shaft, if required.

Force connecting rod (5) from angle lever (1). Dis­connect control pressure rod (10). Place adjusting sleeve (05) on stop pin.

2 Push angle lever (1) into idle throttle position, so that it will rest against adjusting sleeve (05).

Adjust connecting rod (5) lengthwise in such a manner that it can be pushed in this position free of tension on angle lever (2).

3 Pull anlge lever (1) to full load stop. Loosen ball head (8). Displace in slot until angle lever (1) rests against adjusting sleeve (full load stop). Tighten ball head (8) in this position.

4 In idle throttle position, hold control pressure rod (10) above test bore (arrow) in angle lever (1). Adjust lengthwise at end piece (9) in such a manner that the bore in end piece is in alignment with test bore.

Remove adjusting sleeve (05). Connect control pres­sure rod (10) and adjust lock.

30.8-300/8 F 3

Connecting rod (5 in Fig. item 4)

122

Adjusting sleeve (5 in Fig. item 5)

180 072 03 93

30.8-300/9 F 3

1    Check throttle linkage for easy operation and bends. Replace damaged parts, if any.

2    Disconnect all regulating rods.

3    Check whether regulating lever (1) of injection pump rests against idle speed stop (3).

4    Check whether connecting rod (5) is correctly set. For this purpose, push regulating lever (1) to full load stop (2). Actuating lever (8) should have max. 0.5 mm play up to full load stop (6). Adjust connecting rod (5) with adjustable ball head (4), if required. Connecting rod (5) should be set to 122 mm, measur­ed from center of ball socket to center of linkage.

1    Regulating lever

2    Full load stop

3    Idle speed stop

4    Adjustable ball head

5   Connecting rod

6    Full load stop on vacuum control valve

7    Vacuum control valve

8    Actuating lever for vacuum control valve

5    Plug-on adjusting sleeve (5).

6    Adjust free travel rod (1) in fully extended con­dition to 154 mm, measured from center to center of ball head and connect.

1    Free travel rod

2    Connecting rod

3   Control pressure rod

4    Pushrod

5   Adjusting sleeve

6    Regulating lever

30.8-300/10 F 3

7   Push regulating lever (1 and 6) against idle speed stop (Fig. item 3 and 6).

8   Adjust pushrod (4) in such a manner that rod can be connected free of tension (Fig. item 5).

9   Move regulating lever (6) to full load. Regulating lever (1) should also rest against full load stop (2) (Fig. item 3 and 6).

Adjust adjustable ball head (7) in slot, if required.

3 Control pressure rod

6    Regulating lever

7    Adjustable ball head

10 Adjust control pressure rod (3). Regulating lever (6) should rest against idle speed stop. Push control pressure rod carefully against idle stop on transmis­sion, set to tension-free length, connect and secure.

Note: To facilitate assembly, make sure that trade­mark is facing in upward direction when connecting end piece.

For longitudinal checkup, hold control pressure rod above test bore adjacent to bolt.

11    Remove adjusting sleeve (5).

12   Adjust connecting rod (2) to 140 mm, measured from center to center of ball head and connect.

30.8-300/11 F 3

13 Check full load stop. With engine stopped, push accelerator pedal from inside vehicle up to stop on kickdown switch. Accelerator pedal and regulating lever on injection pump should rest against full load stop. Loosen adjusting screw (arrow), if required, adjust throttle linkage in such a manner that regulat­ing lever rests against full load stop.

If throttle linkage is not moving to full throttle, check whether the contour spring for idle speed adjuster has been correctly installed.

The idle speed adjuster is no longer installed starting model year 1980.

If full load or idle speed stop is not attained with this cJjustment, set pull rod (10) from longitudinal regulat­ing shaft to accelerator pedal to 68 mm, measured from center of ball socket to center of damping ring.

If the above adjustment does not attain full load or idle speed stop, set connecting rod (11) from guide lever engine compartment to accelerator pedal to specified length, measured from center to center of ball socket.

10   Pull rod

11    Connecting rod

Adjust regulating lever inside vehicle, if required. For this purpose, loosen fastening screw (arrow), pull accelerator pedal slightly upward and tighten fasten­ing screw again.

30.8-300/12 F 3

14 Adjust Bowden wire for cruise control. For this purpose, push shutoff lever up to stop. Bowden wire should rest free of tension against regulating lever.

If required, adjust Bowden wire by means of adjust­ing nut (arrow). Release shutoff lever (idle speed posi­tion). In this position, Bowden wire has the required play.

15 Check operation of emergency stop button. For this purpose, run engine at idle, push emergency stop button (arrow). Engine should stop, adjust pushrod (4), if required.

Engine regulation

30.8-300/13 F 3

Chassis regulation

no longer required starting model year 1980

30.8-300/14 F 3

Length of regulating rods in mm

Engine regulation

51 Bowden wire for cruise control

53    Longitudinal regulating shaft

54   Washer

55    Corrugated washer

56    Nut

57    Screw

58    Angle lever

59    Holder

60    Lock 61a Holder

62    Control pressure rod

63    Free travel rod

63a Screw-type ball head 64a Switchover valve 64b Switchover valve

65    Pull rod

66    Lock

67    Plastic bushing

68    Guide lever

69    Plastic hub

70    Push rod

71    Holder

72    Holder

73    Hex. socket screw

30.8-300/15 F 3

Chassis regulation

1    Check regulating linkage for easy operation and bends. Replace damaged parts, if any.

2    Disconnect all regulating rods.

3    Check whether regulating lever (1) of injection pump rests against idle speed stop (3).

30.8-300/16 F 3

4 Check whether connecting rod (5) is correctly set. For this purpose, push regulating lever (1) to full load stop (2). Actuating lever (8) should have max. 0.5 mm play up to full load stop (6). Adjust connecting rod (5) with adjustable ball head (4), if required. Connect­ing rod (5) should be set to 122 mm, measured from center of ball socket to center of linkage.

1    Regulating lever

2    Full load stop

3    Idle speed stop

4   Adjustable ball head

5   Connecting rod

6    Full load stop on vacuum control valve

7    Vacuum control valve

8    Actuating lever for vacuum control valve

5   Plug adjusting sleeve on locating pin (arrow) of holder.

6   Set free travel rod (63) in fully extended condition to 154 mm, measured from center to center of ball head and connect.

63 Free travel rod 65 Pull rod 70 Pushrod

7 Adjust pushrod (70) in such a manner that max. 0.5 mm play is available between control cam lobe of guide lever (68) and link (arrow) of switchover valve (64a). Regulating lever on injection pump should rest against idle speed stop.

62 Control pressure rod

63a Adjustable ball head

64a Switchover valve idle speed shutoff EGR

64b Switchover valve full throttle shutoff EGR

68 Guide lever

60 Lock

30.8-300/17 F 3

8 Push guide lever (68) in direction of full load. Adjust ball head (63a) in slot of guide lever (68) in such a manner that guide lever rests against adjusting sleeve and regulating lever on injection pump against full load stop.

9   Adjust control pressure rod (62). Regulating lever on injection pump should rest against idle speed stop (free travel rod should be extended). Carefully push control pressure rod on idle speed stop on transmis­sion.

10    Hold control pressure rod (62) above check bore adjacent to bolt. Adjust end piece lengthwise in such a manner that bore in end piece is in agreement with test bore.

11    Connect control pressure rod (62), tighten counter-nut and secure with lock (60).

Note: When connecting end piece, trademark should face in upward direction.

12    Remove adjusting sleeve.

13   Adjust pull rod (65 in Fig. item 5) to 137 mm, measured from center to center of ball head and connect.

14 Check full throttle stop. With the engine stopped, push accelerator pedal from inside vehicle up to stop on kickdown switch. Accelerator pedal and regulating lever on injection pump should rest against full throttle stop. Loosen adjusting screw (arrow) if re­quired. Adjust throttle linkage in such a manner that regulating lever rests against full throttle stop.

30.8-300/18 F 3

15 If full throttle stop is not attained with this adjustment, set pull rod (5) from longitudinal regu­lating shaft to accelerator pedal to 68 mm, measured from center of ball socket to center of damping ring.

16 If the full throttle or idle speed stop is not attain­ed with the above adjustment, set connecting rod (21) from guide lever engine compartment to accelerator pedal to 122 mm, measured from center to center of ball socket. Adjust regulating lever inside vehicle, if required. For this purpose, loosen fastening screw (arrow), pull accelerator pedal slightly up and tighten fastening screw again.

17 Set Bowden wire for cruise control. For this pur­pose, push shutoff lever up to stop. Bowden wire should rest free of play against regulating lever.

If required, adjust Bowden wire by means of adjust­ing screw (arrow). Release shutoff lever (idle speed position). In this position, Bowden wire has the re­quired play (arrow).

51 Bowden wire for cruise control

30.8-300/19 F 3

(usa) starting 1981 Federal and California version

3    Longitudinal regulating shaft

14    Lock

15    Roller

21    Connecting rod for electro cruise control

32    Plastic spacing ring

41     Pushrod

42    Lock

44    Hex. screw

45    Bearing

47    Hex. socket screw

48    Angle lever

50    Plastic bushing

54    Washer

55    Spring washer

56    Nut

57    Screw

60    Pushrod

61    Pull rod

62    Bowden wire for automatic transmission 63a  Adjustable ball head

64a  Switchover valve idle speed shutoff — EGR 64b Switchover valve full throttle shutoff — EGR

66a  Hex. socket screw

68    Guide lever

69    Valve plate

70    Cap

71     Central plug

72    Cable holder

73    Hex. socket screw

74    Guide lever

75    Drag lever

76    Plastic bushing

77    Spring

78    Holder

79    Guide lever

80    Connecting rod

81     Lever

82    Stop

83    Corrugated washer

84    Lock

30.8-300/20 F 3

3   Longitudinal regulating shaft

4   Adjusting screw

5   Pushrod

6   Washer

10   Screw

11    Rubber grommet

12   Plastic spacing ring 1 3   Return spring

14   Accelerator pedal lever

18   Hex. screw

19   Corrugated washer

20   Washer

21    Bearing

22   Gasket

24   Accelerator pedal

25   Clip

26   Fastening plate

27   Joint

28   Kickdown switch

29   Adjusting nut

32   Copper netting-graphite disk

33   Lock

34   Regulating lever with damper 34a Conugated washer

35   Bearing bracket

43   Lock

44   Guide lever

83   Corrugated washer

84   Lock

30.8-300/21 F 3

Two switchover valves (64a, 64b) are mounted on a valve plate (69) to control EGR. Connection is made by means of a central plug (71). A cap (70) is fitted to prevent dirt from settling on plastic running sur­face.

64a   Switchover valve idle speed shutoff-EGR

64b   Switchover valve full throttle shutoff-EGR

68     Guide lever

69     Valve plate

70     Cap

71      Central plug

1    Check throttle linkage for easy operation and bends. Replace damaged parts.

2   Disconnect all regulating rods and bowden wire (62).

3   Check whether regulating lever (1) of injection pump rests against idle speed stop (3).

4 Check whether connecting rod (5) is correctly set. For this purpose, push regulating lever (1) to full throttle stop (2). Actuating lever (8) should have max. 0.5 mm play up to full throttle stop (6). Adjust con­necting rod (5) with adjustable ball head (4), if re­quired.

The connecting rod (5) should be set to 122 mm, measured from center of ball socket to center of linkage.

1    Regulating lever

2    Full throttle stop

3    Idle speed stop

4   Adjustable ball head

5    Connecting rod

6    Full throttle stop on vacuum control valve

7    Vacuum control valve

8    Actuating lever for vacuum control valve

30.8-300/22 F 3

5 Set pushrod (41) to 184 mm measured from center to center of ball socket and connect.

6 Adjust guide lever (68):

a)  Idle speed position: Set pushrod (60) in such a manner that roller (15) in guide lever (68) rests free of tension against end stop.

b)  Full throttle position: Push guide lever (68) to full throttle, roller (15) should have approx. 1 mm distance in guide lever (68).

Set adjustable ball head (63a), if required. When adjusting ball head, readjust pushrod (41). (Fig. engine regulation).

Regulating lever on injection pump should also rest against full throttle stop.

7 Check full throttle stop. With engine stopped, step on accelerator pedal from inside vehicle up to stop on kickdown switch. Regulating lever on injection pump should rest against full throttle stop. Loosen adjust­ing screw (arrow), if required. Set throttle linkage in such a manner that regulating lever rests against full throttle stop.

If full throttle or idle speed stop is not attained with this adjustment, set pushrod (5) from longitudinal regulating shaft to accelerator pedal to 222 mm, measured from center of ball socket to center of damping ring.

30.8-300/23 F 3

8   Set pull rod (61) to 100 mm, measured from center to center of ball socket and connect.

9   Adjust Bowden wire (62). Guide lever (68) should rest against idle speed stop and drag lever (75) against stop (82). Pull Bowden wire (62) against noticeable idle speed stop on transmission, adjust to tension-free length and connect.

10 Adjust cruise control. Check whether actuator rests against idle speed stop of cruise control. For this purpose, disconnect connecting rod (21) and push lever of actuator (4) clockwise to idle speed stop. When attaching connecting rod (21), make sure that lever of actuator is pushed away from idle speed stop by approx. 1 mm. Adjust connecting rod, if required.

30.8-300/24 F 3