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FUEL &ENGINECONTROL
GENERAL ............................................................................. FL - 2
INJECTION PUMP ................................................................. FL - 36
GOVENOR ............................................................................. FL - 71
TEST AND ADJUSTMENT .................................................... FL - 95
IDLE-UP ADJUSTMENT ........................................................ FL-105
FEED PUMP ........................................................................... FL-106
AUTOMATIC TIMER ............................................................... FL-107
INJECTION NOZZLE ............................................................. FL-111
FUEL FILTER ......................................................................... FL-115
WATER SEPARATOR ............................................................ FL-116
ENGINE CONTROL ............................................................... FL-116
FUEL TANK ............................................................................ FL-119
FL-2 FUEL & ENGINE CONTROL
GENERAL
SPECIFICATIONS
Injection nozzle
Fuel filter
*Water separator
←←←←←0.26 mm
157°1st : 17.65MPa(18kgf/cm2)
2nd: 21.6MPa(220kgf/cm²)
Type
Type
←←←←←0.285 mm
←←←←←←←←←←
*Spin-on filterpaper
Sediment trap
50.30 mm
160°21.6 MPa
(220 kgf/cm²)
←←←←←0.21 mm
150°←←←←←
Injection pump proper
Turning direction(as viewed from drive side)
Plunger
Governor
Automatic timer
Type
No. of orificesOrifice diameter
Orifice angleInjection pressure
Type
DiameterLead
Model, type
Model, type
BOSCH AD
Clockwise
9.5 mmR.H. 20 + 50
RLD
(all speed
mechanical)
Hole (1 spring)
SCZ Type,mechanical
←←←←←
BOSCH A
←←←←←
←←←←←←←←←←
←←←←←
SBOmechanical
Hole (2 spring)
NB (EP-9)
←←←←←
ø11.535W
R801(all speed mechanical)
←←←←←
Improved NB
←←←←←
ø11←←←←←
R901(all speedmechanical)
←←←←←←←←←←
←←←←←
←←←←←
←←←←←
←←←←←
Items Specification
←←←←←
←←←←←
FL-3GENERAL
255 kpa (2.6 kgf/cm²)
1.2 N (0.12 kgf)or less
0.03 to 0.05
0.03 to 0.07
1.5 or less
0.5 or less
20 to 21
3.6 ± 0.05
90 ± 30'
0.2 or more
9°
12°
255 kPa (2.6 kgf/cm²)
1.5 N(0.15 kgf)or less
0.02 to 0.06
0.15
[24] 0.03 to 0.07
0.02 to 0.08
21 or more
3.6 ± 0.05
90° ± 30'
0.3 or more
10°
9°
13°
STD, Cold, Tropical area
High altitude area
Adjust or replace
Replace
Replace
Replace
Replace
Replace
Adjust
Adjust
Adjust
Adjust
Adjust or replace
Replace
Replace
Replace
Replace
Replace
Adjust
Adjust
Adjust
Adjust
Overflow valve opening pressure
Control rack sliding resistance(when not rotating)
Camshaft end play
Tappet rolter overall clearance
Tappet to pump housing clearance
Wear on lower spring seat surface incontact with plunger
Squareness
Camshaft bend (runout)
Wear on camshaft surface in contact withoil seal
Control rack sliding resistance(Return stroke)
Prestroke
Injection start interval
Tappet clearance
Fuel injectiontiming(BTDC)
Overflow valve opening pressure
Control rack sliding resistance(when not rotating)
Camshaft end play
Backlash between control rack and pinion
Tappet roller overall clearance
Tappet to pump housing clearance
Wer on lower spring seat surface incontact with plunger
Plunger driving face to control sleeveclearance
Control rack full stroke
Prestroke
Injection start interval
Tappet clearance
Fuel injectiontiming (BTDC)
SERVICE STANDARDSD4AF/ D4AE/ D4AL [EURO-I]
LimitCorrection and
remarksNominal value
[Basic diameter]Description
Plunger spring
Delivery valve spring
Injection pumpproper(D4AL, D4AE)
0.1
Within 0.3
0.2
0.2
2
1
0.15
0.2
Injection pumpproper(D4AF)
0.1
0.3
0.2
0.2
0.2
0.12
D4AL
D4AE(STD, Cold area)
(Tropical, high altitude area)
Unit : mm
FL-4 FUEL & ENGINE CONTROL
Distance between the guide screw topsurface and housing end face
Distance between governor housing endface and shifter pin hole center
Distance between governor cover endface and guide screw end
Control rack movement (injection pump)
Boost compensatorDistance between spacer end face andpush rod end B
13.5 to 14.5
29 ± 0.2
Approx. 14 ± 0.5
9.5 to 21
24.5 ± 0.5
950 to 1,000 rpm
2,200 to 2,300 rpm
1,900 to 2,000 rpm
0 cc/min.
25 or less
175 to 215 kPa(1.8 to 2.2 kgf.cm²)
335 to 410 kPa(3.4 to 4.2 kgf.cm²)
900cc or more
1,620 cc or more
45 sec. or less
40 sec. or less
0.01 to 0.2
21.6 to 22.6 MPa(220 to 230 kgf/cm²)
0 to 5
800 to 950 rpm
Limit Correction andremarks
Nominal value[Basic diameter]
Description
RLD governor
Feed pump Replace
Replace
Replace
Replace
Replace
Accelerator pedal toadjusting bolt clearance
* Accelerator switch operating speed
19.6 MPa(200 kgf/cm²)
Adjust
Adjust
Adjust
Adjust
D4AF
D4AL, D4AE
D4AF
D4AL, D4AE
D4AF
D4AL, D4AE
D4AF
D4AE, D4AL
* Idle-up set [On-vehicle: actuatorvacuum -47 kPa (-350 mmHg) or below]
* Microswitch set [On-vehicle ; actuatorvacuum -47 kPa (-350 mmHg) or below]
Airtightness [When 195 kPa (2 kgf/cm²)air pressure is applied]
Priming pump lift capacity(No. of strokes required before liftingwhen operated at 60 strokes/min.)
Deliverypressure
Deliveryamount
Liftcapacity
At 600 rpm
For 1 min.at 1,000 rpmthrough a1.54 nozzle
For 1 min.at 1,000 rpm
When operatedat150 rpm
When operatedat 100 rpm
SCZ automatic timer Injection pump gear thrust clearance
Injection nozzle injection pressure
Engine control
Adjust
Adjust
Adjust
Adjust
Adjust
FL-5GENERAL
Round nut
Injection pumpgear attaching bolt
Timer case nut
Nozzle bridge bolt
Retaining nut
25 (2.5)
20 to 29 (2 to 3)
20 to 25 (2 to 2.5)
25 to 34 (2.5 to 3.5)
7.8 to 15 (0.8 to 1.5)
39 to 44 (4 to 4.5)
54 to 74 (5.5 to 7.5)
7.8 to 11 (0.8 to 1.1.
15 to 18 (1.5 to 1.8)
6.9 to 8.8 (0.7 to 0.9)
9.8 to 14 (1 to 1.4)
9.8 to 14 (1 to 1.4)
20 to 29 (2 to 3)
25 to 29 (2.5 to 3)
9.8 to 15 (1 to 1.5)
49 to 59 (5 to 6)
7.8 to 8.8 (0.8 to 0.9)
7.8 to 8.8 (0.8 to 0.9)
83 to 98 (8.5 to 10)
7.8 to 12 (0.8 to 1.2)
29 to 39 (3 to 4)
25 (2.5)
25 to 34 (2.5 to 3.5)
29 to 39 (3 to 4)
34 (3.5)
7.8 to 12 (0.8 to 1.2)
7.8 to 9.8 (0.8 to 1.0)
15 to 25 (1.5 to 2.5)
3.9 to 7.8 (0.4 to 0.8)
5.9 to 9.8 (0.6 to 0.8)
59 to 78 (6 to 8)
7.8 to 12 (0.8 to 1.2)
4.9 to 6.9 (0.5 to 0.7)
1.0 to 1.5 (0.10 to 0.15)
15 to 25 (1.5 to 2.5)
TIGHTENING TORQUE [EURO-I]
M12 x 1.5
M14 x 1.5
M14 x 1.5
M14 x 1.5
M15 x 0.5
M14 x 1.5
M8 x 1.25
M16 x 1.5
M8 x 1.25
M10 x 1.25
M8 x 1.25
M6 x 1.0
M4 x 0.7
Thread sizeO.D. x pitch mm
* Water separator air plug
Fuel tank drain plug
Fuel tank band nut
Fuel tank bracket to frame bolt
Fuel tank bracket to fuel tank ataching bolt
Fuel tank bracket to cover attaching
Fuel gauge unit screw
* Fuel cock tightening
100 lit. tank
90 lit. tank
63, 70 lit. tank
56, 63, 70 lit tank
Description Tightening torqueN·m (kgf·m)
Remarks
D4AF
D4AE, D4AL
D4AL, D4AE
Injection pipe union nut
Fuel feed pipe and hose eye bolt Injection pump side
Feed pump side
Fuel filter side
Lubrication oil pipe eye bolt
Injection pump Delivery valve holder
Screw plug
Lock plate
Governor housing bolt
Governor housing bolt
Adjusting lever shaft nut
Full load set lever nut
U-lever plug
Idling screw
Governor shaft nut
Round nut
RLD governor
* Idle-up adjust screw lock nut
* Microswitch adjust screw lock nut
Automatic timer
Injection nozzle
Fuel filter Fuel feed hose or pipe connector bolt
Air vent plug
FL-6 FUEL & ENGINE CONTROL
D4AL,D4DB(High altitude area)
D4DA(STD, Cold area)
D4DA(High altitude, Tropical area)
D4DB [STD(Standard),
Tropical, Cold area]
D4DA/ D4DB/ D4AL [EURO-����������]
Overflow valve opening pressure
Control rack sliding resistance(when not rotating)
Camshaft end play
Tappet rolter overall clearance
Tappet to pump housing clearance
Wear on lower spring seat surface incontact with plunger
Squareness
Camshaft bend (runout)
Wear on camshaft surface in contact withoil seal
Control rack sliding resistance(Return stroke)
Prestroke
Injection start interval
Tappet clearance
Fuel injectiontiming(BTDC)
255 kpa (2.6 kgf/cm²)
1.2 N (0.12 kgf)or less
0.03 to 0.05
0.03 to 0.07
1.5 or less
0.5 or less
20 to 21
3.6 ± 0.05
90 ± 30'
0.2 or more
8°
7°
9°
7°
LimitCorrection and
remarksNominal value
[Basic diameter]Description
Plunger spring
Delivery valve spring
0.1
within 0.3
0.2
0.2
2
1
0.15
0.2
Adjust or replace
Replace
Replace
Replace
Replace
Replace
Adjust
Adjust
Adjust
Adjust
Injection pump
proper
(D4DA,D4DB,
D4AL EURO-��)
Distance between the guide screw topsurface and housing end face
Distance between governor housing endface and shifter pin hole center
Distance between governor cover endface and guide screw end
Control rack movement (injection pump)
Boost compensatorDistance between spacer end face andpush rod end B
R801,R901
governor13.5 to 14.5
29 ± 0.2
Approx. 14 ± 0.5
9.5 to 21
24.5 ± 0.5
Adjust
Adjust
Adjust
Adjust
Adjust
FL-7GENERAL
Replace
Replace
Replace
Replace
Replace
Replace
Priming pump lift capacity(No. of strokes required before liftingwhen operated at 60 strokes/min.)
950 to 1,000 rpm
0 cc/min.
25 or less
175 to 215 kPa(1.8 to 2.2 kgf.cm²)
900cc or more
40 sec. or less
0.01 to 0.2 mm
1st:17.6(180kgf/cm²)2nd:21.6(220kgf/cm²)
0 to 5 mm
800 to 950 rpm
* Idle-up set [On-vehicle: actuatorvacuum -47 kPa (-350 mmHg) or below]
Feed pump
Limit Correction andremarks
Nominal value[Basic diameter]Description
Airtightness [When 195 kPa (2 kgf/cm²)air pressure is applied]
When operatedat150 rpm
Liftcapacity
Accelerator pedal toadjusting bolt clearance
Adjust
Adjust
Adjust
Adjust
Deliverypressure
Deliveryamount
At 600 rpm
For 1 min.at 1,000 rpmthrough a1.54 nozzle
D4DA,D4DBD4AL(II)
D4DA,D4DBD4AL(II)
D4DA,D4DBD4AL(II)
SBO automatic timer Injection pump gear thrust clearance
Injection nozzle injection pressure
Engine control
* Accelerator switch operating speed
FL-8 FUEL & ENGINE CONTROL
7.9 to12.7 (0.8 to 1.3)
83 to 98 (8 to 10)
54 to 74 (5.5 to 7.5)
15 to 18 (1.5 to 1.8)
9.8 to 14 (1 to 1.4)
9.8 to 14 (1 to 1.4)
25 to 29 (2.5 to 3)
9.8 to 15 (1 to 1.5)
49 to 59 (5 to 6)
7.8 to 8.8 (0.8 to 0.9)
83 to 98 (8.5 to 10)
7.8 to 12 (0.8 to 1.2)
Tightening Torque [EURO-����������]
Thread sizeO.D. x pitch mm
Injection pump
Description Tightening torqueNm (kgf·m)
Remarks
Delivery valve holder
Screw plug
R801,R901governor
Governor housing bolt
Adjusting lever shaft nut
Full load set lever nut
Idling screw
Governor shaft nut
Round nut
*Idle-up adjust screw lock nut
Automatic timer Round nut
Injection pump gear attaching bolt
Timer case nut
Nozzle bridge bolt
Retaining nut
Fuel feed hose or pipe connector bolt
Air vent plug
Injection nozzle
Fuel filter
100 lit. tank
90 lit. tank
63, 70 lit. tank
56, 63, 70 lit tank
* Water separator air plug
Fuel tank drain plug
Fuel tank band nut
Fuel tank bracket to frame bolt
Fuel tank bracket to fuel tank ataching bolt
Fuel tank bracket to cover attaching
Fuel gauge unit screw
* Fuel cock tightening
M14 x 1.5
M8 x 1.25
M16 x 1.5
M8 x 1.25
M10 x 1.25
M8 x 1.25
M6 x 1.0
M4 x 0.7
M14 x 1.5Injection pipe union nut
Fuel feed pipe and hose eye bolt Injection pump side
Feed pump side
Fuel filter side
14.8 to 19.6 (1.5 to 2)
14.8 to 19.6 (1.5 to 2)
14.8 to 19.6 (1.5 to 2)
M14 x 1.5
M14 x 1.5
M14 x 1.5
25 (2.5)
Lubrication oil pipe eye bolt
29 to 39 (3 to 4)
25 (2.5)
25 to 34 (2.5 to 3.5)
34 (3.5)
7.8 to 12 (0.8 to 1.2)
7.8 to 9.8 (0.8 to 1.0)
15 to 25 (1.5 to 2.5)
3.9 to 7.8 (0.4 to 0.8)
5.9 to 9.8 (0.6 to 0.8)
59 to 78 (6 to 8)
7.8 to 12 (0.8 to 1.2)
4.9 to 6.9 (0.5 to 0.7)
1.0 to 1.5 (0.10 to 0.15)
15 to 25 (1.5 to 2.5)
FL-9GENERAL
Inspect cause of accumulation of rack
and repair
TROUBLESHOOTING
Fuel Injection Pump
Rough idling
Is idling speed setting normal?
(Isn’t it too low?)Adjust idling stopper bolt
Is there no air inflow in fuel system?
Is there no water inflow in fuel system?
Inspect the faulty cause and repair
Drain water from fuel tank, fuel filter,
and water separator.
Is there no clogging in fuel filter element and feed
pump gauze?
Replace fuel filter element or clean
gauze.
Isn’t injection pump control lever mounting nut loose
or missing?Tighten it to the specified value.
Is injection timing of injection pump accurate? Readjust injection timing
After removing nozzle, inspect the following items.
• Is the first injection pressure correct?
• Is spray state normal?
(Check nozzle hole part for carbon accumulation,
if it is excessively accumulated, clean it prior to
inspection)
• Correct the first injection pressure
as necessary
• Clean it as necessary and re-check
(Replace nozzle tip as necessary)
With injection pump removed, inspect the following
item using a pump tester
• When control rack is pulled by load control lever,
is it smoothly operating?
Yes
No
No
Yes
Yes
No
No
Yes
Yes
No
No
Yes
No
No
Yes
FL-10 FUEL & ENGINE CONTROL
Is injection interval between cylinders correct?
Does feed pump output ratio exist within specification?
Inspect the faulty cause and repair
Yes
Yes
No
No
Measure fuel injection timing of each cylinder.
Is it regular?
No
Yes
Inspect the faulty cause and repair
Inspect the faulty cause and repair
FL-11GENERAL
Inspect cause of accumulation of rack
and repair
Hard to start the engine
Is fuel quantity enough?Supply fuel
Is there no air in fuel system?
(Engine is not started after bleeding the system)
Is there no water inflow in fuel system?
Inspect the following items and repair
• Loose pipe and connector
• Feed pump gauze clogged
• Fuel element clogged
• Air inflow from feed pump
Drain water from injector pump, fuel
filter, fuel tank, and other parts
Are there no fuel leaks for loose connection and
cracks in injection pipes.Repair or replace
Is injection timing of injection pump accurate? Readjust injection timing
After removing nozzle, inspect the following items.
• Is the first injection pressure correct?
• Is spray state normal?
(Check nozzle hole part for carbon accumulation,
if it is excessively accumulated, clean it prior to
inspection)
• Correct the first injection
pressure as necessary
• Clean it as necessary and re-check
(Replace nozzle tip as necessary)
With injection pump removed, inspect the following
item using a pump tester
• When control rack is pulled by load control lever,
is it smoothly operating?
Yes
No
Yes
No
No
Yes
Yes
No
No
Yes
No
No
Yes
Yes
FL-12 FUEL & ENGINE CONTROL
Is injection interval between cylinders correct?
Does feed pump output ratio exist within specification?
Inspect the faulty cause and repair
Yes
Yes
No
No
Measure fuel injection timing of each cylinder.
Is it regular?
No
Yes
Inspect the faulty cause and repair
Repair feed pump or replace
FL-13GENERAL
Inspect cause of accumulation of rack
and repair
Output loss
Is there no air in fuel system?
(Engine is not started after bleeding the system)
Is there no water inflow in fuel system?
Inspect the following items and repair
• Loose pipe and connector
• Feed pump gauze clogged
• Fuel element clogged
• Air inflow from feed pump
Drain water from injector pump, fuel
filter, fuel tank, and other parts
Is there no sticking or breaking in injection pump
overflow valve spring?Replace
Is injection timing of injection pump accurate? Readjust injection timing
After removing nozzle, inspect the following items.
• Is the first injection pressure correct?
• Is spray state normal?
(Check nozzle hole part for carbon accumulation,
if it is excessively accumulated, clean it prior to
inspection)
• Correct the first injection pressure
as necessary
• Clean it as necessary and re-check
(Replace nozzle tip as necessary)
With injection pump removed, inspect the following
item using a pump tester
• When control rack is pulled by load control lever,
is it smoothly operating?
Yes
Yes
No
No
Yes
Yes
No
No
Yes
No
No
Yes
Are there no fuel leaks for loose connection and
cracks in injection pipesRepair or replace
NO
Yes
FL-14 FUEL & ENGINE CONTROL
Is injection interval between cylinders correct?
Is angular in advance of automatic timer correct?
Inspect the faulty cause and repair
Yes
Yes
No
No
Is fuel injection ratio between cylinders
regular?
No
Yes
Inspect the faulty cause and repair
Inspect the faulty cause and repair
FL-15GENERAL
Inspect the faulty cause and re-adjust.
Excessive smoke in exhaust gas
Is full throttle stopper securely seated onto gavernor
control lever?Adjust full throttle stopper bolt
Is injection timing of injection pump accurate? Readjust injection timing
After removing nozzle, inspect the following items.
• Is the first injection pressure correct?
• Is spray state normal?
(Check nozzle hole part for carbon accumulation,
if it is excessively accumulated, clean it prior to
inspection)
• Correct the first injection pressure
as necessary
• Clean it as necessary and re-check
(Replace nozzle tip as necessary)
With injection pump removed, inspect the following
item using a pump tester
• Is injection ratio of injection pump exceed over
the specification?
No
Yes
No
No
Yes
Is injection interval between cylinders correct?
Is angular in advance of automatic timer correct?
Inspect the faulty cause and repair
Yes
Yes
No
No
Is fuel injection ratio between cylinders
regular?
No
Yes
Inspect the faulty cause and repair
Inspect the faulty cause and repair
Yes
Yes
No
FL-16 FUEL & ENGINE CONTROL
Is there no crack and looseness on injection pump
and connector?
Is there no abnormal noise in injection pump while
rotating engine at low speed?
Repair or replace
Yes
Yes
No
No
Is injection pump connecting part securely
connected?
No
Yes
Align the timing mark and retighten
bolt
Worn parts surrounding tappet.
Disassemble injection pump and re-
place faulty parts
Knocking noise happens in injection
pump surrounding
Is injection timing of injection pump accurate?
With injection pump removed, inspect the following
item using a pump tester
(Is fuel injection ratio between cylinders regular?)
Readjust injection timing
Yes
Yes
No
No
Is proper quality of fuel used
No
Yes
Use the specified quality of fuel
Inspect the faulty cause and repair
Knocking noise happens in engine
Is injection interval between cylinders correct?
Yes
Is angular in advance of automatic timer correct?
Yes
Inspect the faulty cause and repair
Inspect the faulty cause and repairNo
No
FL-17GENERAL
Isn’t load control lever return spring pressed or
damaged?
With governor load control lever ring cage disconnected,
is load control lever smoothly operating?
Replace return springYes
No
No
From accelerator pedal to governor load control
lever, isn’t cable clogged?
No
Yes Inspect the faulty part and repair
With injection pump removed, inspect
the following item using a pump tester
Is injection pump rack smoothly
operating?
Speed is not smoothly shifted to idle
at high speed
Inspect cause of stiff rack and repair
Inspect cause of stiff governor linkage
and repair
Is mounting screw on control pinion securely
tightened?
With injection pump removed, inspect the following
item using a pump tester
Does the rack move smoothly when pulled by the
load control lever?
Adjust injection pump injection rate and
retighten control pinion mounting screw
Measure governor idling. If the mea-
sured value exceeds the specified
value, adjust it
Yes
Yes
No
No
No
Yes
No
FL-18 FUEL & ENGINE CONTROL
Is there no rust in cable?
Governor adjusting lever operating resist
ReplaceYes
Yes
No
NoIs there no rust in pedal arm?
No
Yes
Clean and apply oil
Apply oil to link and shaft
Excessive accelerator pedal operating effort is
required (including unstable pedal return)
Is cable end installation point vertically correct?
Are cable end and cable vertically correct?
Correct
Yes
Yes
No
No
Isn’t cable end clogged?
No
Yes
Remove rust and other foreign material
Correct or replace
Accelerator control cable broken
Engine control
FL-19GENERAL
Is stop cable clamp securely tightened?
Is there no wear in ignition switch cam?
Retighten or replace clamp
Yes
Yes
No
No
Isn’t stop cable stretched?
No
Yes
Adjust
Replace
Engine cannot be stopped
Is there no clogging in pipe and hose?
Is there no clogging in bleeder tube?
Clean or replace
Yes
Yes
No
No
Is there no air inflow in fuel tank for cracks in
pipes hoses?
Yes
Replace faulty pipes and hoses
Replace
Insufficient fuel supply
Fuel tank
Is there no clogging in tank by foreign material and rust?
Is there no air inflow in tank due to lack of fuel quantity?
Clean
Yes
Yes
No
No
Is there no water inflow in tank?
No
Remove drain plug and drain water
Supply fuel
Yes
Yes
FL-20 FUEL & ENGINE CONTROL
Injection Pump Proper
The Bosch A type injection pump is used which is constructed as
illustrated.
The injection pump, that forces fuel into the injection nozzle under
pressure, is provided with a mechanism to increase or decrease
the amount of fuel. It has one plunger and delivery valve for each
cylinder.
The plunger, pushed up by the camshaft and pushed back by the
plunger spring, moves up and down in the plunger barrel on a pre-
determined stroke to feed fuel under pressure. In so doing, it opens
and closes the suction and discharge ports to adjust the fuel injec-
tion rate.
The camshaft is supported two taper roller bearings at its ends,
provided with cams operating the plunger and one operating feed
pump.
The camshaft is driven by the injection pump gear at half the en-
gine speed.
Governor
EFUMY02A
Stopper
D4AF0712
Fuel feed pipe
DESCRIPTION
Fuel System
Feed pump
Injection pump
Overflow valve
Leak-off hose
Injection pipe Fuel filter Injection nozzle
Fuel tank
Fuel suctionpipe
The fuel system consist of the injection pump assembly (injectionpump proper, governor, feed pump), automatic timer, fuel filter,water separator, injection nozzle, injection pipe, and other parts.Fuel is fed from the fuel tank through suction pipe to the feed pumpof the injection pump assembly, and then to the fuel filter, injectionpump, and injection nozzle. The excess fuel is returned from theinjection pump to fuel tank.
Delivery valve holder
Camshaft
Tappet
Plunger spring
Pump housing
Control rack
PlungerPlunger barrel
Delivery valve seat
Delivery valve
Delivery valve spring
Waterseperator
Fuel feed pipe
Fuel return pipe
FL-21GENERAL
The illustration beside shows the mechanism that varies the
plunger's effective stroke.
The control rack is coupled to the floating lever in the governor.
As the control rack moves to the right or left by the operation of
the accelerator pedal or governor, the control sleeve in mesh
with the rack turns. Since the bottom of the control sleeve is in
mesh with the claw of the plunger, the plunger turns with the
control sleeve, thus varying the effective stroke to increase or
decrease the fuel injection rate.
The more the control rack is pulled toward the governor, the
less the effective stroke and fuel injection rate.
Each plunger is in mesh with this single control rack and turns
by exactly the same amount.
d) Completion of pressure feed
D4AF2210
D4AF2211Plunger
1. Plunger
The plunger has a groove obliquely cut in its side as shown.
There is a hole at its top which leads to this groove. The plunger
barrel has a suction/discharge port.
The fuel delivered to the injection pump is forced as described
below by the rotating motion of the camshaft or reciprocating
motion of the plunger.
With the plunger the suction/discharge port into the plunger barrel.
As the camshaft rotates, the plunger moves up, and when the
plunger top surface and suction/discharge port line up, fuel
begins to be compressed.
When the plunger moves up further, the fuel pressure is in-
creased until the delivery valve is pushed up against the deliv-
ery valve spring. While the delivery valve is pushed up, the fuel
flows through the injection pipe to be pressure-fed to the nozzle.
As the plunger moves further up and the groove cut in plunger
meets the suction/discharge port, the high pressure fuel flows
through the hole in the plunger and runs through the groove
back to the suction/discharge port, completing pressure feed
of fuel.
The plunger stroke during which fuel is fed under pressure is
called the effective stroke. The fuel injection rate is increased
or decreased according to the engine load by turning the plunger
at a certain angle to change the position where the groove
meet the port during its upward stroke, thus increasing or de-
creasing the effective stroke.
a) Bottom dead center (suction)
b) Starting of compression
c) Pressure feed stroke
Suction port Notch
Plunger barrel
Control rack
Pinion
Control sleeve
FL-22 FUEL & ENGINE CONTROL
3. Overflow valve
The overflow valve, mounted to the top of the pump, stabilizes
the fuel temperature in the injection pump and temperature dis-
tribution to make sure that the amount of fuel injected into each
cylinder is maintained constant.
The valve is a ball seal type. When the fuel pressure in the
pump housing exceeds a predetermined level, the valve opens
to allow fuel back into the fuel tank.
Piston
D4AF0713
Spring
D4AF0714
a
2. Delivery valve
The fuel compressed to a high pressure by the plunger pushes
the delivery valve up, spouting out.As soon as the pressure feed of fuel completes, the deliveryvalve is brought back to its original position by the delivery valvespring force to block the fuel passage, thereby preventing backflow of fuel.The delivery valve goes further down until its seat surface isheld tight. During this stroke, the fuel is drawn back from theinjection pipe side, instantaneously dropping the residual pres-sure between the delivery valve and nozzle. This draw-backeffect improves the end break of an injection from the nozzleand prevents after-injection dripping.A delivery valve stopper is provided on the top of the deliveryvalve spring. The stopper limits the lift of delivery valve andprevents valve surging during high speed rotation. It also re-duces the dead volume between the delivery valve and nozzle,thereby stabilizing the fuel injection rate.
Completion of injection(beinginning ofretraction)
Completion ofretraction
a: Retraction strokeDelivery valve seatInjection
Delivery valve spring
Deliveryvalve
Valve seat
Steel ball
Spring seat
FL-23GENERAL
The RLD type governor is an all-speed governor providing smaller
lever reaction.
1. Flyweights
The flyweight holder is mounted on the injection pump cam-
shaft and the flyweights pivot about the pin press-fitted into the
flyweight holder. When the flyweights move outward under
centrifugal force, the sliders on their arm ends pushed the
sleeve in the axial direction. The sleeve is connected via bear-
ing to the shifter which is pinned directly to the bottom of the
tension lever. So, the flyweights impart their motion through
the shifter to the tension lever.
Full speedset bolt
D4AF0718
RLD Type Governor [D4AF/D4AE/D4AL (EURO-�����)]
Supportinglever
Adjusting lever
Adjusting lever shaft
Control rack
Cancel spring B
Governior spring
Torque camFlywheight holder
Flyweight
Sleeve
Tension lever shaft
Cancel spring AShifter
Guide lever
Governor shaft
Tension lever
Idling screw
Idling spring
Floating lever
Idling set bolt
Start spring
FL-24 FUEL & ENGINE CONTROL
2. Link
Cancel spring B
Guide lever
Ro
D4AF1324
Po
D4AF2612
The RLD governor link operates as follows to regulate and con-
trol all speeds.
Among the idling, governor, and start springs, only the start spring
retains the initially set tension. So, the flyweights start to move
out under the centrifugal force more than the set tension of start
spring. They move further outward as the engine speed increases,
and the motion is transmitted to the tension lever, gradually put-
ting more tension on the idling and governor springs. The guide
lever is moved integrally with the tension lever by the set tension
of cancel spring A to displace the ball joint.
By placing the adjusting lever gradually from the idle to full posi-
tion when the guide lever ball joint is located at Po with engine
stationary, the supporting lever moves to cause the floating lever
to pivot about Po. (The point Po is a fixed point since the guide
lever moves integrally with the tension lever by the set tension of
cancel spring A.) This causes the control rack to move from Ro
in the direction of greater fuel delivery. When the rack reaches
Ra, the full load position determined by the torque cam, Ra be-
comes fixed to stop the supporting lever at Qb.
Control rack
To increaseamount of fuel
Start spring
Sensor lever
Full load set lever
Torque cam
Flyweight
Idle spring
Tension lever
Cancel spring A
Governor spring
Floating lever
Supporting lever
Idling set bolt
Adjusting leverFull speed set bolt
Po
Qo
Full speed set bolt
AdjustingleverCancel spring B
Supportinglever
Rackconnectinglink
Guidelever
Floating lever
QbRa
FL-25GENERAL
The governor is so constructed as to allow the lever ratio tobecome greater as the flyweights move further outward.When the governor controls idle speed with a low pump speed,the flyweight centrifugal force is small; under which conditions,the lever ratio is made smaller to ensure that the control rackmoves over a small range. When controlling high speeds with
a greater to meet speed variations.
=2
1(Fixed)
o Lever ratio with adjusting lever at idle position
Lever ratio =� 1
� 2x
A1
B1
x= = 1.012
21
o Lever ratio with adjusting lever at full position
Lever ratio =� 1
� 2 xA2
B2
x= = 4.012
12
D4AF2613
Cancelspring B
Qb
Qa Pa
D4AF2614
At idling ... Full lineAt high speed control ... Broken line
D4AF2615
When the adjusting lever is further moved, only the L lever
moves, away from the supporting lever. Starting the engine
under this condition increases the pump speed, allowing the
flyweight centrifugal force to overcome the tension of idling and
governor springs to move the tension and guide levers. As pump
speed increases, Po moves to Pa and Qb to Qa by the cancel
spring B tension. These movements continue until the L lever
contacts the supporting lever at Qa.
When the flyweight move further outward as a result of increased
pump speed, the guide lever ball joint moves from Pa to Pa.
This causes the floating lever to pivot about Qa, moving the
control rack from Ra in the direction of smaller fuel delivery up
to Ra'.
The governor can thus control the amount of fuel and engine
speed by presetting the adjusting lever at any desired position.
Po
L-type lever
PaQa
Supporting lever
Ra
To decreaseamount of fuel
Ra
Ra
Adjusting lever
I2Guide lever
Guide leverside ball joint
A B
A1
B1A
2
B2
I1
� 1
� 2
FL-26 FUEL & ENGINE CONTROL
3. Starting the engine
With the engine stationary, the flyweights are in closed posi-
tion and the idling and governor springs remain in the free-
length state free from set tension. Placing the adjusting lever in
the full position moves the adjusting lever shaft, which causes
the cancel spring B force to move the supporting lever.
This in turn causes the control rack to move in the direction of
greater fuel delivery. At the time, the sensor lever gets into the
groove cut in the torque cam provided to increase the amount
of fuel for startup, and the control rack, past the full load position,
reaches the point to increase the amount of fuel for startup
that is limited by the rack limiter.
By returning the adjusting lever to the idle position after the
engine has started, the control rack is pulled to allow the sen-
sor lever to leave off the groove in the torque cam. Thereafter,
no fuel delivery increase can be obtained for startup even by
moving the adjusting lever to the full position.
4. Idling control
Placing the adjusting lever in the idle position with the engine
started makes Q the fulcrum of the floating lever.
As engine speed decreases, the centrifugal force of flyweights
yields to the tension of idling spring, closing the flyweights.
This causes the floating lever to pivot about Q, moving the con-
trol in the direction of greater fuel delivery, thus preventing the
engine from stalling. (condition indicated by solid line)
As engine speed increases, on the other hand, the idling spring
tension yields to the flyweight centrifugal force, causing the
control rack to move the the direction of smaller fuel delivery,
thereby decreasing the speed (Condition indicated by dotted
line)
An idle speed is thus maintained at a point where the flyweight
centrifugal force balances with the set tension of the start and
idling springs.
The torque cam and sensor lever are not in contact with each
other while the engine runs at idle.
Floating lever
D4AF1325
Fullposition
Floating lever
D4AF1326Flywheight
Tension lever
Idle spring
Guide lever
Full position Adjusting lever
Idling position
Idle springTension lever
Flyweight
Torque cam
Start spring
Sensor lever
To increaseamount of fuel
Cancelspring B
Adjusting lever
Adjusting levershaftSupporting lever
Control rack
Idlingposition
Guide leverGovernor spring
FL-27GENERAL
Idling position
Full loadset lever
Shift D4AF1327
5. Control of fuel injection rate at full load by torque cam
When the adjusting lever is placed in the full position under
load, the floating lever pivots about P to move the control rack
in the direction of greater fuel delivery. The sensor lever, at the
same time, comes in contact with the torque cam. As speed
varies, the shifter moves in the axial direction, which causes
the tension lever to be pushed forward and backward around
the tension lever shaft, making the torque cam to rotate around
its shaft.
The sensor lever movement tracing along the cam surface dis-
places the control rack, thereby increasing or decreasing the
fuel injection rate.
The tension lever movement from varying speeds does not,
however, move the point R; it moves only P of guide lever Q of
supporting lever. The control rack is therefore moved through
the sensor lever by the movement of torque cam.
Idle springTension lever
Governor shaftGovernor spring
Flywieght
Torque cam
Sensor lever
Adjusting lever
Supporting leverFloating leverGuide lever
Fullposition
6. Full speed control
With the adjusting lever at full position, the engine speed in-
creases while the fuel injection rates under full load are con-
trolled by the torque cam and sensor lever. This is accomplished
when the centrifugal force of flyweights pushes the idling and
governor springs to push forward the tension lever.
As speed further builds up and as the supporting lever con-
tacts the L lever on the adjusting lever shaft by the cancel spring
B, the floating lever pivots about Q to move the control rack in
the direction of smaller fuel delivery, thus controlling the full
speed.
The sensor lever, on the other hand, leaves the torque cam
surface as this control advances.
7. Stopping the engine
Turning the starter switch to "ACC" or "LOCK" with the adjust-
ing lever at idle position causes the stop lever on top of gover-
nor to move the starter switch. This causes the stop device
plate to forcibly pull the control rack to the position with no fuel
injection, thus stoppint the engine.
Operating the stop lever with adjusting lever at any given posi-
tion causes the stop device plate to pull the control rack in the
direction of smaller fuel delivery.
D4AF1328
L-type lever
Sensor lever
D4AF2620
Stop device plate
Control rackFullposition
Idling positionAdjusting lever
Tension lever
Idle spring
Flywight
Torque cam
Full load set lever Governor shaftGovernor springGuide lever
Floating lever
Stop lever
Cancel spring BReturn spring
Supporting lever
Stop device plate To decreaseamount of fuel
Control rack
FL-28 FUEL & ENGINE CONTROL
This in turn contracts the governor spring. As a result, the con-
trol rack is pulled until the set tensions of cancel and governor
springs balance; after this , the control rack does not move,
only the supporting lever turing as the stop lever moves.
The cancel spring absorbs excessive force being applied to
internal levers when the accelerator pedal is depressed with
the starter switch at "ACC" or "LOCK".
8. Boost compensator
The boost compensator is a device installed on a turbocharged
engine that automatically corrects the fuel injection rate ac-
cording to the boost pressure. It increases the injection rate to
compensate for the increased amount of intake air delivered to
engine cylinders by turbocharger operation.
D4AF0719Boost compensator
D4AF2622
Lever
Lever
Full load set screw Cancel springTo increaseamount of fuel
U-lever
Sensorlever
Torque cam
Push rod B
Boost compresator
Boost pressure
Diaphragm
Push rod A
When the boost pressure in the engine inlet manifold rises by turbocharger operation, it acts on the compression
chamber of the boost compensator.
As the boost pressure overcomes the boost compensator spring tension, the diaphragm and push rod A move to the
right. The motion of push rod A causes the lever to turn clockwise with the push rod B following the lever by the return
spring.At the time, the U-lever in governor housing turns clockwise by the cancel spring force in accordance with the
push rod B motion, which moves the center fulcrum of sensor lever to right. Since the sensor lever is in contact with
the torque cam at its bottom, the control rack moves in the direction of greater fuel delivery as the fulcrum moves of the
sensor lever at the center.
FL-29GENERAL
R801, R901 Type Governor [D4DA/D4DB/D4AL (EURO-����������)]
FIG4-1
FIG4-2
Cutaway view of R801 and R901 governor
Flyweight construction
Control lever
Full load stopper
Stop cam
Adjusting lever shaft
Floating arm
Cam plate
Guide shaft
Steering lever
Sliding block
Return spring
Damper spring
Floating arm spring
Shackle
Full load stopper housing
Control rack
Sliding plate
Adaptor screw
Connecting bolt
Stop lever
Nut
Start spring
Stopper arm
Spring seat
Screw plug
Jointing boltBellcrank shaft Supporting shaft
Flyweight
Flyweight holder
Adaptor screw
SliderBearing bolt
Supporting lever
Jointing bolt
Bellcrank shaftAdjusting nut
Flyweight
Spring seat
Idle outer spring Guide sleeve
Jointing bolt
Bellcrank shaftIdle inner spring
Bearing bolt
Mechanical governorspring
Spring seat
Camshaft
Flyweight holder
Control spring
Guide sleeve
Spring innerseat
When closed When closed
When wide-openedWhen wide-opened
FL-30 FUEL & ENGINE CONTROL
FLYWEIGHT ASSEMBLY
Flyweight holder is securely connected to and driven by the pump
camshaft. A pair of flyweights are assembled on this flyweight holder
in such a way that they can be swung in either direction about the
respective bellcrank shafts which are pressed tight in the flyweight
holder.
The two flyweights are jointed by the jointing bolt, which transfers the
movement of the flyweights to the bearing bolt.
As shown in Fig.4-2, the flyweights contain a control spring and two
idling springs. The spring seat for retaining these springs has two V-
sectioned arms so that they fit snugly into the V-grooves of the flyweight.
In this design, the idle springs always contact the spring seats evenly.
The mechanical governor spring inside the flyweight absorbs play of
the guide sleeve.
Special weights called damper weights are also available. They have
rubber dampers between the camshaft and the flyweights. Fig.4-3
shows the construction of a typical damper weight assembly. FIG4-4
FIG4-3
FIG4-6
FIG4-5
FIG4-7
LINKAGE SYSTEM
The bearing bolt is connected via the slider to the supporting leverand the floating lever.The supporting lever pivots about the supporting shaft and floatinglever is linked to the supporting shaft so that the rotational motion ofthe supporting lever is converted to the up and down motion of thefloating lever (Fig.4-4).The floating arm and the control lever are assembled to the upper endof the floating lever. This assembly enables then to move, by the actionof their floating arm spring and return spring, with the floating lever.The control lever is connected to the control rack by the shackle andthe arm, so that the movement of the floating lever is transmitted tothe control rack (see also Fig.4-1).The adjusting lever and steering lever are fixed to the adjusting levershaft. The steering lever's guide shaft moves along a slot in the camplate, while the sliding block slides in the cylinder of the floating lever.Movement of the adjusting lever, linked by the adjusting lever shaftto the sliding block, causes the sliding block to slide within the float-ing lever cylinder.The full load stopper housing is located on the top of the governor,It contains :
Stop cam ....Determines the characteristic under full-load
Adaptor screws ....Determine the vertical position of the stop cam
Full-load stopper ....Determines the horizontal position of the stop cam
Sliding plate ....Fixes the stop cam
The stop lever, located on the side of the governor housing, isused to move the control rack to shut-off position.
Full-load stopperSliding plate
Adaptorscrews
Stop cam
Cam plateGuide shaft
Adjustinglever shaft
Steeringlever
Floatinglever
Slidingblock
Adjustinglever
Control leverShackle
Floatingarm
Floating lever
Control rack
Arm
Bearing bolt
Floating lever
Slider
Supporting lever
Supporting shaft
Damper
Camshaftbushing
Round nut
FL-31
Feed pump
The feed pump is driven by the injection pump camshaft.
The priming pump allows manual lift of fuel when the injection pump
is stationary. It may be used when bleeding the system.
The gauze filter removes large particles of dust from the fuel lifted
from the fuel tank, preventing the feed pump from getting clogged.
The filter must be washed in gas oil periodically.
Holder
D4AF0740
D4AF0735
Timer spring
Curved surface on flyweight
D4AF0737
SCZ Type Automatic Timer
The SCZ type automatic timer, of the mechanical type, varies au-
tomatically the injection timing according to the engine speed.
Mounted on the injection pump camshaft with a round nut, it is
driven by the idler gear in mesh with the injection pump gear.
There is a hole provided at one end of each of the two flyweights,
into which the timer hub pins are fitted.
The curved surfaces on the flyweights come in contact with the
injection pump gear pin. Timer springs are mounted on the timer
hub pins and injection pump gear pin.
The automatic timer is forced lubricated by the engine oil being
injected into its center of rotation.
While the engine runs at a low speed, no centrifugal force is ap-
plied to the flyweights and the timer spring installed length remains
the longest.
With the enging running at high speeds, the flyweights move out-
ward under the centrifugal force with the timer hub pins as the
fulcrum. The injection pump gear pin, at the time, is pushed by the
curved surface of the flyweights in the direction to compress the
timer spring; however, it cannot be moved because it is coupled to
the drive end. As a result, the timer hub pins are drawn in the turn-
ing direction while compressing the timer springs, which moves
the pump camshaft in the turning direction to advance the injection
timing.
Priming pump
Piston
Connector
Piston
Gauzefilter
Housing
Valve
Oil seal
Advacing
Advance
Before advance
Timer hub pin
Injection pump gear pin
Flyweight
Timer hub
Timer hub pin
Flyweights
Injection pump gear
Injection pumpgear pin
GENERAL
FL-32 FUEL & ENGINE CONTROL
Fuel Filter
Spin-on type fuel filter is replaced as a filter assembly when theelement reguires replacement.
Suction
A
←←
D4AF0741
Retaining nut
D4AF0742
Fuel filterElement D4AF074A
When the tappet (B) and piston (C) are pushed up by the camshaft
(A), the fuel in the suction chamber opens the outlet check valve
(D) and flows into the pressure chamber.
As the camshaft (A) rotates to produce no cam action, the piston
(C) is pushed back by piston spring (E) to force fuel in the pressure
chamber to the fuel filter. At the time, a vacuum is produced in the
suction chamber allowing the inlet check valve (F) to open to intro-
duce fuel.
When the fuel pressure in the fuel filter or injection pump exceeds
a predetermined level, the piston (C) becomes unable to return to
its original position because of the piston spring (E), stopping the
pressure feed of fuel.
Injection Nozzle
The injection nozzles are of the hole type and the throttle type.
The fuel delivered from the injection pump enters the nozzle holder.
When reaching the specified pressure value, the fuel overcomes
the spring force to push up the needle valve of nozzle tip, sparying
from the injection orifice at the end of the nozzle into cylinder (hole
type).
The injection pressure can be adjusted by increasing or decreas-
ing the number of washers in the spring.
Fuel inlet
Fuel filter head<Spin-on type>
Fuel outlet
<Hole type>
Nozzle holder
Washer
Spring
Nozzle tip
Needle valve
StopPressure feed
Push rod
Delivery Suction
SuctionchamberPressurechamber
E
F
C
B
D
FL-33
The engine control controls the operation of engine by means of
cable connections from the driver's seat.
It consists of the throttle cable, accelerator control cable, engine
stop cable, and other parts.
D4AF3551
To feed pump
D4AF0664
Engine stop cable
<D4AF,D4AE,D4AL(EURO-�)>
Injection pumpassembly
Water Separator
The sedimenter type water separator separates gas oil and water
centrifugally by taking advantage of their difference in specific
gravity.
The fuel that has flowed in from the inlet connector is squeezed by
the fuel path of the head to increase the flow velocity and spins.
The separated water is sedimented in the case, whereas the wa-
ter-separated fuel is drawn through the fuel path in the center of
the head into the feed pump.
The water seaparator sediments not only water but also mud
components.
A red float goes up and down with the water level in the semitrans-
parent case, making it possible to visually check the water quantity.
ENGINE CONTROL
<D4DA,D4DB,D4AL(EURO-��)>
Accelerator pedal assembly
Starting switch
Throttle button
Throttle cable
Acceleratorcontrol cable
Water level ring
From fuel tank
GENERAL
FL-34 FUEL & ENGINE CONTROL
Engine Stop (Cable Type)
Placing the starter switch key in the "ACC" position causes the
engine stop cable to move the stop lever, stopping the engine.
31-14A
31-14B
31-14C
Stop lever
D4AF0668
Throttle cable
Throttle button
Accelerator pedal
<Pedal depressed>
<Pedal released>
Accelerator Pedal Assmbly
Depressing the acelerator pedal causes the accelerator control
cable to move the adjusting lever toward the full throttle position,
thus accelerating the engine speed.
Throttle button
The throttle button is connected via throttle cable to the accelerator
pedal. Operating the button moves the adjusting lever to provide
an optimum idle speed.
FL-35
2. Fuel Gauge Unit
The fuel gauge unit is installed on the top of fuel tank, providing
the fuel level information to the fuel gauge in the meter cluster.
31-15
Main pipe
D4AF0688
Fuel guage unit
D4AF0689
Baffle plate
Fuel guageFuel tank
Outside airTo engine
Breather tube
FUEL TANK
There is a baffle plate installed inside the fuel tank which hampers
fuel movement in the tank while contributing to the rigidity of the
tank body. The tank is also provided with a breather tube that al-
lows air to go into the tank, and fuel gauge unit which allows the
driver to know the fuel level.
1. Breather Tube
A negative pressure is produced when the feed pump draws
fuel, which can deform the tank and pipes. The breather tube
allows air to enter the tank to keep the tank inside at the atmo-
spheric pressure.
GENERAL
FL-36 FUEL & ENGINE CONTROL
1. Injection pipe2. Fuel suction hose3. Fuel suction pipe4. Oil pipe5. Fuel feed pipe6. Fuel feed pipe
7. Fuel return pipe8. Injection pump
EFUMY01A
Socket Wrench
D4AF0752
RemovalHold the injection pump by hand, and remove five injection pump
flange plate attaching bolts.
Then, remove the injection pump, pulling it rearward.
Use of Socket Wrench (special tool) will make the removal of flange
plate attaching bolts easier.
SERVICE PROCEDURES
Wherever possible, test the fuel system parts before disassembly to precisely know their conditions.Select a clean site for disassembly and reassembly work, as even small dust particles on the fuel system parts canadversely affect engine performance.When disassembling the injection pump, keep work bench clean and disassembled parts neatly arranged for each cylinder.Use special care to ensure correct combination of plunger and plunger barrel and of delivery valve and delivery valve seat.Scrupulous care must be exercised when disassembling and reassembling critical parts.Use the specified special tools for disassembly and reassembly; never apply excessive force or handle parts carelessly.
Before disassembly, test the system to know exactly the trouble spots.
INJECTION PUMPBOSH A TYPE
1
2
3
4
5
6
8
7
FL-37
Disassembly [D4AF/D4AE/D4AL(EURO-�����)]
For disassembly of parts with an encircled number, seefollowing pages.Inspection itmes marked with * must be checked before
disassembly.
NOTE1. Kep disassembled parts neatly arranced for
each cylinder.2. Keep plunger, plunger barrel, and delivery valve
in gas oil.
D4AF0753
NV ... Nominal ValueL ... Limit
INJECTION PUMP
Bend
Cracks, damage
Deterioration
Wear
* End playNV 0.03 to 0.05 mmL 0.1 mm
* Backlash between rack and pinion NV 0.15 mm L 0.25 mm
* Sliding resistance(stationary) NV 1.2N (0.12 kgf) or less
1
2
3
4
5
6
7
8
910
11
1213
14
15
16
17
18
19
20
21
Wear, damage
Wear, flaws
Deterioration
Overflow valve opening pressureNV 255 kPa (2.6 kgf/cm²)
Disassembly sequence1 Cover plate2. Screw plug3 Bearing cover4 Camshaft5 Tappet
6 Lower spring seat7 Pluger8. Plunger spring10. Control sleeve11. Control pinion
12 Lock plate13 Delivery valve holder14 Stopper15 Delivery valve spring
16 Delivery valve17. Plunger barrel18. Control rack cover19. Rack guide screw20. Control rack21. Pump housing
FL-38 FUEL & ENGINE CONTROL
PumpMounting Base
D4AF0754
D4AF0755
D4AF0756
Tappet Insert
Tappet Insert
D4AF0757
D4AF0758
6. Mount camshaft clearance gauge (special tool) on the cam-
shaft to mesure the end play.
1. With the automatic timer removed, install the injection pump on
Pump Mounting Base and Pump Setting Angle (special tools).
2. Using box wrench (special tool), remove the feed pump.
3. Remove the governor.
4. Measure the control rack sliding resistance.
Turn camshaft to ensure that the resistance is up to specifica-
tion in an position.
If the nominal value is exceeded, possible causes are as follows:
o Damage on control rack and defective tooth
o Defective pinion tooth, pinion in contact with housing
o Excessively tightened delivery valve holder
5. Remove the cover plate. Then, using coupling and round nut
and holding wrench (special tools), turn the camshaft. With
plunger in each cylinder placed at TDC, install Tappet Insert
(special tool) in the tappet service holes, one by one.
Pump SettingAngle
Box Wrench
Camshaft Clearance Gauge
Anglescale1/100
Coupling andround Nut
Holding Wrench
FL-39
D4AF0759
Tappet Insert
D4AF0760
D4AF0761
Plunger ClampD4AF0762
Box Wrench
D4AF0763
10. Remove the lock plate and remove the delivery valve holder
with Box Wrench (special tool).
Then, remove the stopper, delivery valve, and spring.
7. Remove the camshaft, tapping it with a soft hammer from the
governor end.
NOTE
1. Make sure that the cams on camshaft are not in con-
tact with the tappet.
2. Install the flyweight round nut at the end of camshaft
to protect threads.
8. Take out of tappet
Accessing from the bottom of the pump, insert Roller Clamp
(special tool) to push up the tappet. With the tappet in pushed
position, remove Tappet Insert (special tool) and insert Tappet
Clamp (special tool) into the camshaft hole. Then, clamp the
tappet and take out.
9. Insert plunger clamp (special tool) from the bottom of the pump
and fix its end to the lower spring seat. Then, withdraw the
special tool, which removes the lower spring seat with plunger.
NOTE
When removing, ensure that the groove in the lower spring
seat (for inserting the plunger) faces up to prevent the
plunger from dropping.
Roller Clamp
Tappet Clamp
Lower spring seatNotch
Plunger
INJECTION PUMP
FL-40 FUEL & ENGINE CONTROL
Wear on surface contactwith oil seal L 0.2
Deliveryvalve
Inspection and Correction
11. Using Delivery Valve Extractor (special tool), remove the deliv-
ery valve.
12. Remove the plunger barrel.
NOTE
Keep a plunger and plunger barrel pair in gas oil.
NV ... Nominal ValueL ... Limit
Airtightness, wear
D4AF0766
Use Reaming Cutter to correctpump housing damage, or replace.
Sliding condition
Squareness NV 0.5 or less L 1
Tappet to pump housing clearance NV 0.03 to 0.07 L 0.12
Tappet roller overall clearance L Within 0.3
Wear on surface in contactwith plunger L 0.2
Bend (Rouout) L 0.15
Delivery ValveExtractor
D4AF0764
D4AF0765
Squarenes NV 1.5 or less L 0.2
Unit : mm
FL-41
D4AF1584
D4AF0767
D4AF0768
D4AF0769
Roller bushing
D4AF0770
1. Plunger and plunger barrel
After cleaning in gas oil, check if the plunger falls smoothly in
the plunger barrel under its own weight.
Use the following procedure for the inspection:
o Tilt the plunger barrel approximately 60°.
o Pull the plunger about 10 to 15 mm and let it go.
o Turn the plunger to check on several more points.
Replace the plunger if it does not fall.
Wear
Measure the clearance between the tappet and pump housing
and, if the limit is exceeded, replace parts.
2. Delivery valveClean the valve and valve seat of the delivery valve in gas oiland check for wear.Seal off the bottom of the valve seat with a finger, and pressthe piston with a finger. If the piston bounces back whenreleased, the valve is in good condition. If not, replace the valveas it must be badly worn.
NOTEWith the engine provided with the Ungleich cut, the aboveprocedure is not effective since the piston does not springback.
3. Tappet
Apply a dial gauge to the tappet roller and check for overall
clearance by moving the roller up and down with a rod.
If the clearance exceeds the limit, replace the tappet assembly.
4. Lower spring seat
Check the lower spring seat surface in contact with the plunger
for wear. If the limit is exceeded, replace the lower spring seat.
10 to 15
60°
Dial gauge
Rod
Roller
INJECTION PUMP
FL-42 FUEL & ENGINE CONTROL
D4AF0773
Camshaft Outer Race Remover
D4AF0771
D4AF0772
D4AF0774
7. Camshaft bend (Runout)
Support the camshaft with a V-block at its ends (or the center
holes at both ends), and check for bend at the center with a
dial gauge.
If the limit is exceeded, correct with a press or replace.
5. Plunger spring and delivery valve spring
Measure the squareness of the springs and, if the measure-
ment over the limit, replace it.
6. Replacement of taper roller bearing
To remove the inner race from the camshaft, use a gear puller.
To remove the outer race on the cover end, use Camshaft Outer
Race remover (special tool).
Install by using a press.
Squareness
Puller Adjusting ringShims
FL-43
Reassembly
Assembly sequence
21→ 20 → 19 → 17 → 16 → 15 → 14 → 13 → 12 → 11 →
10 → 9 → 8 → 7 → 6 → 5 → 4 → 3 → 2 → 18 → 1
For assembly of the part with encircled number,see the following pages.
End play NV 0.03 or 0.05 mm L 0.1 mm
Face line markingtoward timer
Ensure pump housinglocating notch isaligned with plugerbarrel knock pin atinstallation.
D4AF075C
54 to 74 N·m(5.5 to 7.5 kgf·m)
7.8 to 11 Nm(0.8 to 1.1 kgf·m)
Backlash betweenrack and pinion NV 0.15 mm L 0.25 mm
29 to 39 N·m(3 to 4 kgf·m)
With control rack set at center,install pinion with its endsfacing toward cover plate
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
INJECTION PUMP
Sliding resistance(when stationary)NV 1.2 N (0.12 kgf)or less
FL-44 FUEL & ENGINE CONTROL
D4AF0775
D4AF0776
Delivery ValveGasket Installer
D4AF0777
D4AF0778
D4AF0779
5. With the control rack set at the center, install the control pinion
and control sleeve.
1. Mount the control rack and rack guide screw.
NOTE
Make sure that the rack moves smoothly. Check also to
ensure that the rack does not turn when so attempted.
2. At installation, ensure that the knock pin fitted into the pump
housing is aligned with the locating notch in the plunger barrel.
Make sure that the knock pin projects by about 0.7 mm from
the housing. If the projection is smaller than that, drive pin out
from the housing side.
NOTE
Note that the pump housing area must be cleaned, into
which the plunger barrel is inserted.
3. With a new gasket installed in the delivery valve, drive the valve
into position until it is heald tightly against the plunger barrel
top surface, using Delivery Valve Gasket Installer (special tool).
4. Fit the delivery valve spring and stopper into position, and tem-
porarily tighten the delivery valve holer.
Control pinion
Control sleeve
Equalize the amountof movement to leftwith that to right
Face control pinionjoint upward
Delivery valve holder
Delivery valve springStopper
Control rack
Plunger barrelLocating notch
Pumphousing
Knock pin Knock pin
FL-45
Notch
D4AF0780
Tappet Clamp
D4AF0761
Tappet Insert
D4AF076B
D4AF0781
9. Tighten the delivery valve holder to the specified torque.
Check also the control rack for sliding condition each time the
holder is tightened.
6. Insert of plunger
Fix Plunger Clamp (special tool) into the lower spring seat, and
install the plunger into the lower spring seat.
Insert the plunger into the plunger barrel with care not to allow
the plunger end to hit the pump housing and plunger spring.
NOTE
1. After the plunger has been installed, turn the lower
spring seat to face its notch downward.
This prevents the spring seat from coming off position.
2. Make sure that the plunger flange side with a part num-
ber marking faces upward.
7. Clamp the tappet with tappet clamp (special tool) and, with the
tappet guide aligned with the housing groove, insert it into the
pump housing.
8. Using Roller Clamp (special tool), push the tappet to TDC. Then,
insert Tappet Insert (special tool) and remove Roller Clamp
(special tool).
Make sure that the part number marking on the plunger flange
is positioned on the cover plate side.
For each cylinder, check the control rack for sliding condition
each time Tappet Insert (special tool) is installed.
Torque wrench
Roller Calmp
Shim
Tappet Insert
Plungerclamp
Partnumber
Lower spring seat
INJECTION PUMP
FL-46 FUEL & ENGINE CONTROL
D4AF0782
Bearing
D4AF0783
D4AF0756
12. With Tappet Insert (special tool) removed, measure the sliding
resistance of the control rack.
(When stationary)
Make sure that the resistance is up to specification with cam-
shaft in any position.
13. Install governor
14. Install the following parts after adjusting the injection pump:
o Control rack cover
o Feed pump
o Cover plate
o Automatic timer
10. Install the camshaft with the marking line at the end of its threads
facing toward the drive end.
11. Temporarily mount the bearing cover.
If the camshaft end play measured at disassembly is out of
specification, adjust with shims after temporarily installing the
bearing cover.
Use shims of almost equal thickness for the governor and timer
ends.
After installing the bearing cover in position, measure again
the end play to ensure that it is up to specification.
Marking line
Shims
Adjust ring
FL-47
Injection Rate Adjustment Standards
For fuel injection rate adjustment standard, see Service Bulletin
separately published.
NOTEFeed oil into the injection pump cam chamber.
NV ... Nominal Value
D4AF0784
Adjustment after Reassembly
D4AF0785Coupling and Round Nut
D4AF0786
Remove the control rack cover and install Rack Position Mea-
suring Device (special tool), instead.
Loosen the idling set bolt and full speed set bolt.
Push the control rack all the way to the governor and regard
this position as "0" of the Rack Position Measuring Device
(special tool).
1. Preparation
With the automatic timer removed, install Coupling and Round
Nut (special too) and set a tester on the injection pump.
Rack Position Measuring Device
Tappet clearanceNV 0.2 mm or more
Control rack sliding resistance NV 20 to 21 (Return stroke o rack when it is pushed all the way and released)
Fuel injection start intervalNV 90° ± 30'
INJECTION PUMP
PrestrokeNV 3.6 ± 0.05
FL-48 FUEL & ENGINE CONTROL
Stopper
D4AF0787
D4AF0786
D4AF3426
D4AF3427
Remove the delivery valve spring and stopper from the deliv-
ery valve holder.
Feed the engine oil into the injection pump and bleed fuel.
Slowly turn the tester coupling until the fuel stops flowing out of
the overflow pipe (static injection starts).
3. Measurement of prestroke
Fix the control rack position at 21mm and set Prestroke Mea-
suring Device (special tool) on the tappet guide of no.1 cylinder.
With No.1 cylinder plunger placed at BDC, feed fuel under pres-
sure to the injection pump with high-pressure pump of the pump
tester. Then, let the fuel flow out from the overflow pipe of the
test nozzle.
2. Checking the control rack stroke
Check the control rack for return motion when it is pushed all
the way to the governor and released.
The rack is in good condition if it returns smoothly and the re-
turn stroke is within specification.
D4AF3425Prestroke Measuring Device
Static injection starts
Fuel being sent underpressure (pulger at BDC)
Delivery valve spring
FL-49
D4AF3428
D4AF0788
Angle scale
D4AF0789
PrestrokeMeasuringDevice
Cle
aran
ce
D4AF0790
D4AF3472
7. Adjustment of fuel injection rate
Measure the fuel injection rate and uneven ratio with the speci-
fied rack position and speed.
If the injection rate is out of specification, adjust as follows.
o Slightly back of the pinion clamp screw.
o With the control rack fixed at a position, turn the control
sleeve with the adjusting rod.
o Tighten the pinion clamp screw.
The plunger stroke from BDC until fuel stops flowing is called
the prestroke. Read the prestroke on the dial gauge.
NOTE
When measuring the prestroke, ensure that the adjusting
lever is in full load posiion.
If the prestroke is out of specification, adjust as follows.
4. Adjustment of prestroke
With the tappet at TDC, insert Spring Holder (special tool) be-
tween the lower spring seat and tappet.
Turn camshaft, and you have a clearance between the lower
spring seat and tappet. Increase or decrease shim thickness
to fill the clearance, to adjust the prestroke.
A greater shim thickness makes prestroke smaller.
A smaller shim thickness makes prestroke greater.
5. Measurement of injection start interval
With the static injection start of No.1 cylinder used as a basis,
read the injection start interval of each cylinder according to
the injection sequence using an angle scale of the tester.
If the interval is out of specification, adjust as in prestroke adjust-
ment.
Injection sequence : 1 → 3 → 4 → 2
6. Measurement of tappet clearance
Intall Prestroke Measuring Device (special tool) and turn the cam-shaft to bring the tappet to TDC. Using Tappet Clearance Bar(special tool), push up the tappet and measure the lift until theplunger flange top surface comes in contact with the plunger barrel.If the tappet clearance is out of specification, adjust within theallowable limit of the fuel injection start intervals. If adjustment isnot possible within the limit, readjust with the No.1 cylinderprestroke at the maximum nominal value. Tappet Clearance Bar
Decrease ↔ Increase
Prestroke
Spring Holder
INJECTION PUMP
Adjustingshgims
FL-50 FUEL & ENGINE CONTROL
Pointer
Pointer
D4AF1253
Notch
Marking
D4AF0791
2. Line up the the marking on the timer case with the notch in the
injection pump gear.
NOTE1. Use special care to make the correct adjustment.
Improper or failure of adjustment greatly affectsengine performance.
2. Observe measurement conditions strictly, as thefuel injection rate varies with differen nozzle andpipe used.
3. Uneven ratio = Max. injection rate in each cylinder - Min injection rate in each cylinder
8. Adaptation to Engine
After the governor has been adjusted, measure the fuel injec-
tion rate adaptable to the enigne.
9. Inspection of Fuel and Oil leaks
o Check the delivery valve mounting position and other parts
for fuel leak.
o Check oil seals and other parts for oil leak.
10. Inspection of Unusual ConditionsCheck for unusual noise, heat, and other abnormal conditions.
Installation
1. Bring the piston in No.1 cylinder to TDC on the compression
stroke. To do that, crank the engine with Cranking Handle
(special tool) to align the marking line on "1, 4" side stamped
on the periphery of the crankshaft pulley or pulley flange with
the pointer. If the intake and exhaust valves of No.1 cylinder
are not pushed up by the push rods at the tme, it indicates that
the piston in no.1 cylinder are not pushed up by the push rods
at the time, it indicates that the piston in No.1 cylinder is at TDC
on the compression stroke. If not, turn the crankshaft 360°.Cranking Handle
FL-51
D4AF0793
Notch ininjectionpump gear
D4AF0794
D4AF0752
Injection pump bracket D4AF0795
6. Mount the injection pump rear bracket.
3. Insert the guide bar on the timer case into the guide hole in
front plate. Using this as a guide, push until the injection pump
gear is about to be in mesh with the idler gear.
4. Make sure that the alignemt mark of the injection pump gear isaligned with that of the timer case.Then, push in the injection pump. At the time, the alignmentmark on the gear moves to the end of that on the timer case.
5. Fix the injection pump to the timing gear case using the Socket
Wrench (special tool).
Guide bar
Guide hole
Timer casealignment mark
Socket Wrench
INJECTION PUMP
FL-52 FUEL & ENGINE CONTROL
7. Install the fuel hoses, fuel pipes and injection pipes and tighten eye bolts to specified torque.
EFUMY01A
Priming pump
D4AF0559
Bleeding the Fuel System
Here is the procedure for bleeding the fuel system
1. Turn the injection pump priming pump counterclockwise until it
comes loose.
20 to 25 N·m(2 to 2.5 kgf·m)
Overflow valve
20 to 25 N·m(2 to 2.5 kgf·m)
Oil pipe
7.8 to 15 N·m(0.8 to 1.5 kgf·m)
7.8 to 15 N·m(0.8 to 1.5 kgf·m)
Fuelsectionpipe
25 N·m (2.5 kgf·m)
Fuel hose
Injection pipe
Fuel filter
25 to 34 N·m(2.5 to 3.5 kgf·m)
25 N·m (2.5 kgf·m)
25 to 34 N·m(2.5 to 3.5 kgf·m)
Fuel feed pipe
20 to 29 N·m (2 to 3 kgf·m)
Fuel feed pipe
Fuel return pipe
2. Loosen the air plug of the fuel fillter.3. Move the priming pump up and down by hand to feed fuel until
air bubble doe not come out from the air plug.
4. When no air bubble comes out in fuel, keep the priming pumpdown and turn it clockwise until it fits into position. Then, tighten
the air plug.
NOTE1. The air plug must be tightened after the priming pump
is secured into position.2. Sop up fuel split around.
5. Actuate the starter to discharge air from the injection pump.
NOTEDo not operate the starter for more than 15 seconds.
Air plug
D4AF0558
FL-53
Injection Pipe
Delivery valve holder
D4AF0796
D4AF0797
D4AF0798
Inspection and Adjustment after installation(Fuel Injection Timing)
1. Remove the injection pipe, delivery valve, delivery valve spring,
and stopper from No.1 cylinder of the injection pump. Keep the
delivery valve holder attached.
NOTE
1. Keep disassembled parts in gas oil to prevent contami-
nation by dust and dirt.
2. Keep the ignition switch at ON and release the gover-
nor stop lever.
2. Install a spare injection pipe to No.1 cylinder.
Face the other end of the pipe downward for easier observa-
tion of fuel flow out condition.
3. Crank the engine to bring the piston in No.1 cylinder at a posi-
tion near BTDC 30°.
4. While operating the priming pump to let fuel run out from the
injection pipe, slowly crank the engine in the direction of nor-
mal rotation.
NOTE
Make sure that the stop lever on the governor is not pulled
toward the "STOP" position.
5. Crank the engine even more slowly as the fuel is about to stop
flowing out from the injection pipe.
Stop cranking as soon as no more fuel comes out from the
pipe.
Delivery valve spring
Stopper
INJECTION PUMP
FL-54 FUEL & ENGINE CONTROL
6. Make sure that the crankshaft pulley marker line and pointer
indicate the correct fuel injection timing.
Fuel injection timing (BTDC):
If the timing is out of specification, adjust as follows.
Pointer
D4AF1253
Crankcase
D4AF0799
D4AF0800
Pointer D4AF0801
9. Move the injection pump to the desired direction.
A shift of one graduation of the adjustment marker varies the
injection timing by 6°.
7. To advance the fuel injection timing, move the injection pump
toward the crankcase side.
To retard the timing, move the injection pump away from the
crankcase.
8. Loosen the injection pump attaching nut with universal Exten-
sion (special tool).
Adjustment mark
Universal Extension
To advanceTo retard
Injection pump
Pointer
Cranking Handle
AreaD4AL
D4DA D4DBEURO-� EURO-��
Cold
Tropical
High atitude
General(standard)
10°
10°
10°
8°
8°
-
7°
9°
9°
7°
7°
8°
D4AF D4AE
9°
9°
12°
9°
13°
13°
9° 9° 10° 8° 7° 7°
FL-55
D4AF0802
7.8 to 11 N·m(0.8 to 1.1 kgf·m)
10. With the injection pump attaching nut tightened, measure the
injection start timing again.
11. After the adjustment has been made, install the delivery valve,
delivery valve spring, and stopper and tighten the delivery valve
holdler to specified torque. Then, install the injection pipe.
12. For inspection at dusty locations, proceed as follows.
o Remove only the injection pipe and keep a small amount
of fuel remaining at the top of delivery valve holder.
o Crank the engine to bring the piston in No.1 cylinder to
position about BTDC 30°C on the compression stroke.
Further crank the engine slowly, and the fuel on top of the
delivery valve will begin to move.
o This is the fuel injection start timing. The procedure,
however, involves a delay of approximately 2° behind the
specified timing because of the effect of the valve opening
pressure of the delivery valve spring.
NOTE
If the fuel injection timing is radically different from
the specification and the deviation is beyond the ad-
justable range of the injection pump, the engine tim-
ing gear and injection pump gear are not probably in
proper mesh. In this case, remove the injection pump
and reinstall it.
39 to 44 N·m(4.0 to 4.5 kgf·m)
INJECTION PUMP
FL-56 FUEL & ENGINE CONTROL
1. Preparation
The flange-type and the saddle-type pumps must be secured
differently as shown below prior to disassembling them.
2. Flange-type pump
1) Remove SAZ timer before securing the pump on the pump
mounting vice (See page 00 for detailed instructions).
2) Put the pump mounting flange (SST) on the shaft of the
pump mounting base (SST).
Disassembling
CAUTIONS1. Wash outside of the pump.2. Measure and keep record of the fuel delivery characteris-
tics of the pump before disassembling it. When the pumpsmoothly runs mechanically but contains otherwisemisadjusted or malfunctioning parts, the problem can beidentified by comparing the fuel delivery characteristicsbefore and after disassembling the pump.
3. Check each part as it is disassembled for the way it wasinstalled, any deformation, broken part, roughness orscratches.
4. Keep parts in groups for each cylinder in an orderlymanner. Parts to be renewed and parts to be used againmust be kept separately.
5. Each part of the injection pump, especially the pump ele-ment and the delivery valve, must be handled most care-fully to protect them from damages.
DR0503
DR0504
DR0505
NB(EP-9) TYPE INJECTION PUMP [D4DA/D4DB/D4AL(EURO-����������)]
3. Saddle-type pump
1) Put the pump holding brackets on the shaft of the pump
mounting vice (SST).
2) Mount the injection pump on the holding bracket, and se-
cure it with the fixtures (SST).
3) Put the 85 mm I.D. ring (SST) around the bearing cover ofthe injection pump. Fix the injection pump securely at thebearing cover to the pump mounting flange (SST) usingtwo bolts (M10 x 1.5).
4) Remover the feed pump and tilt the pump body to drainlubricating oil from the pump cam chamber.
5) Remove the governor. (This instruction varies by the typeof governor used. See appropriate manual of the governor
installed).
Pump mounting flange
Governor
Feed pump
Ring
Pump holdingbracket
Pump holdingfixture
FL-57
DR0506
DR0507
DR0508
DR0509
DR0510
3) Remove the feed pump and tilt the pump body to drain lu-
bricating oil from the pump chamber.
4) Remove SP timer.
5) Remove the governor. (This instruction varies by the type
of governor used. See appropriate manual of the governor
installed).
4. Removal of delivery valve holder
1) Remove the nut that is fastening the cylinder.
2) Put the delivery valve holder remover (SST) on the stud
bolts, and turn the guide until the clearance between the
washer and the handle is approximately 1 to 2 mm, to set
the remover.
NOTE
The guide of the delivery valve holder remover (SST)
is left-hand threaded.
3) Turn the SST handle clockwise into the delivery valve
holder. Continue until the O-ring in the cylinder comes off
the pump housing.
4) Pull the delivery valve holder remover (SST) upward to re-
move the delivery valve group.
Timer
Governor
Feed pump
Washer
Handle
Guide
1 to 2mmapproximately
Cylinder
Turn clockwise
O-ring
Deliver valvegroup
Deliver valveholder remover
INJECTION PUMP
FL-58 FUEL & ENGINE CONTROL
8. Remove the plunger
1) Bring the camshaft of the cylinder to its top dead center.
2) Turn the plunger by tweezers by approximately 90° (to ei-
ther direction) until the flange of the plunger foot is in the
same direction as the hole in the lower spring seat, and
pull out the plunger.
NOTES
1. Handle the plunger very carefully not to damage it.
Ex. Cover the tweezers with vinyl tube as shown in
Fig. 36.
2. Keep the removed plungers in a pan containing
clean light oil. Do not mix them as they must be put
back into the same cylinders they are removed from.
DR0511
DR0512
DR0513
DR0514
5. Remove the rack guide screw
6. Removal of control sleeve1) Pull the control rack to the left (viewed from the feed pump)
as far as it goes.2) Hold the top drim of control sleeve with the control sleeve
remover (SST), and remove it.
NOTEThe sleeve is difficult to remove when the camshaft ofthe cylinder is at its top dead point.
CAUTIONBe extremely careful not to damage the plunger.
7. Remove the control rack
Control sleeveremover(SST)
Lower springseat hole
Plungerfoot
Lower spring seat
FL-59
DR0515
DR0516
DR0517
DR0518
DR0519
9. Remove the upper spring seat
1) Attach the spring compression tool (SST) using the stud
bolts located at both ends of the pump housing.
2) Position the guide lever of the spring compression tool (SST)
toward you (in parallel to the handle), and put the pro-
jected part of the upper spring seat accurately into the guide
groove at the end of the extractor.
CAUTION
Bring the cam of the cylinder to its bottom dead point.
The seat cannot be removed if the cam is at its top
dead point.
3) Pushing the handle down to push in the plunger spring,
turn the guide lever by 90° (to either direction) to remove
the upper spring seat from the stopper pin.
10. Remove the upper spring seat, and the plunger spring
11. Remove the lower spring seat using the tweezers (SST)
Spring compressiontool
Handle
Lower spring seat
SST
Guide lever
Upper spring seat
Projected partof the spring seat
Guide lever
90°
Plungerspring
Stopperpin
Plunger spring
Tweezers
INJECTION PUMP
FL-60 FUEL & ENGINE CONTROL
2) Then, remove parts.
DR0520
DR0522
DR0523
DR0524
DR0521
12. Remove the tappet using the cir-clip pliers (SST)
NOTE
The tappet can be removed more easily when the cam of
the cylinder is at its top dead center.
13. Removal of camshaft
1) Remove the two set screws (49) of the center bearing.
2) Remove the four bolts (33) fastening the bearing cover (28),
tap the camshaft with a wooden hammer from the gover-
nor side, and remove the camshaft and the bearing cover
together.
NOTE
Put the round nut of the governor to the camshaft at
the governor side to protect the thread.
14. Disassemble the delivery valve group
1) Secure the setting support (SST) in a vice, put the delivery
valve group on the setting support, and remove the deliv-
ery valve holder.
Tappet
Camshaft
Camshaft
Bearing cover
Setting support
Delivery valve holder
Delivery valve
Valve gasket
Delivery valve holder
O-ring
WasherValve spring
O-ring
FL-61
DR0528
DR0525
DR0526
DR0527
15. Removal of bearing
1) Pull out the roller and the inner race using the bearing
remover.
2) Use the guide, to remove the bearing at the governor side
(20f).
3) Use the outer race puller (SST), to tap out the outer race in
the bearing cover.
Guide
Bearing remover
Bearingextractor
Outer race puller
Bearing cover
INSPECTION OF PARTSEach disassembled part must be washed with clean light oil, and
any defective or damaged part must be replaced.
1. Pump element
1) Check the plunger lead and end for wear, scratch, or
discoloration.
2) Wash the pump element well in clean light oil, tilt the ele-
ment to about 60° as illustrated, and pull the plunger by
approximately 10 to 15 mm and release it to see if it slides
down smoothly by its weight. Turn the plunger and repeat
the sliding test several times at different plunger positions.
Remedy
If any defect is found with the plunger, replace the
pump element.
60°approximately
Plunger(pulled up by 10 to 15 mmapproximately)
INJECTION PUMP
FL-62 FUEL & ENGINE CONTROL
3) Check the plunger contact surface for wear.
Limit of wear ............................................... 0.2 mm
REMEDY
If the limit of wear is exceeded, replace.
DR0016
DR0529
3. Tappet1) Check the tappet for peeling, local wear, or scratch in the roller
surface.2) Check total play of the tappet roller, roller bushing and roller
pin.
Allowable limit ............................................... 0.3 mm
REMEDY
If the allowable limit is exceeded, replace.
DR0530
DR0531
4. Camshaft
1) Check play between the key and the key groove. Check
the camshaft for scratch at the tapered portion, peeling,
local wear or scr ......
REMEDY
If any defect is found, replace.
2) Check for wear on the oil seal contact surface.
Limit of Wear ............................................... 0.2 mm
REMEDY
If the limit of wear is exceeded, replace.
2. Delivery valve
1) Check the delivery valve for scratch on the valve seat and
the piston sections.
2) Wash the delivery valve well in clean light oil, pull the valve
up and release it to see if it slides down smoothly until it
touches the valve seat.
REMEDY
If the valve does not fall smoothly, replace the tappet.
Seat face
Relief valve
Valve
Deliveryvalve
Valveseat
Tappet roller
Roller bushing
Roller pin
Oil seal contact surface
Key groove
0.2mm max.
Measure wear with a dial gauge andreplace if the limit of wear is exceded
Key groove
FL-63
7. Plunger spring and delivery valve spring
1) Check them for scratch or rust on the surface.
2) Measure the squareness of the spring at its top with an L-
shaped ruler, as illustrated.
Allowable limit 2 mm for plunger spring.
1 mm for delivery valve spring
REMEDY
If the allowable limit is exceeded, replace.
3) Put the camshaft on two V-blocks as illustrated, and mea-
sure the run out at the center of the shaft with a dial gauge.
Limit of run out .. ........................................ 0.15 mm
REMEDY
Repair to 0.15 mm max. with a press, or replace.
DC05085
DR0532
DR0533
5. Bearing
Check peeling and gloss of the bearing surface, and unusual noise.
REMEDY
If any defect if found, replace.
6. Center bearing
Check the bearing surface for peeling, scratch for wear.
REMEDY
If any unusual condition is found, replace.
V-block
8. Delivery valve holder
Check the holder for scratch on the surfaces that receive thehigh-pressure pipe and delivery valve.
REMEDY
If scratch is found, replace since it causes fuel leakage.
9. Pump housing
Check the housing for scratch on the surface, nick, crack or
rupture.
REMEDY
If any functional defect is found, replace.
10. O-rings, Gaskets and Nipple Washers
REMEDY
Renew every time the part is disassembled washer they
are defective or not.
CAUTION
Re-used parts may cause fuel leakage.
INJECTION PUMP
...........
FL-64 FUEL & ENGINE CONTROL
DA3053
DR0535
DR0536
DR0521
2. Camshaft
Put the center bearing on the camshaft, insert the camshaft
into the pump housing, and tighten the center bearing in posi-
tion with washer (48) and set screw (49).
3. Assembling direction of the camshaft:
Put the larger end of the camshaft to the right or to the left or
the pump according to the rule given below. Pump model num-
ber (example) ND-PES6EP-9/105 R 12LSI-565. If the number
in the box in the pump model number is 3, position the larger
end of the camshaft to the left. If the number in the box is 4, as
in the example above, position the larger end of the camshaft
to the right of the pump. The number is not boxed in the actual
model number.
CAUTION
Position the larger end to the right or left as seen from the
feed pump side.
Measuring the protruding length of the camshaft
REASSEMBLINGCAUTIONS
1. Assemble parts in correct orders to correct standards (tightening torques, assembled dimensions, etc.). See
page 54 for specified tightening torques.
2. Wash parts with clean light oil before assembling them.
3. Do not allow dust or other foreign matter inside the pump when assembling parts.
4. O-rings, gaskets, nipple washers must be renewed each time they are disassembled. Never re-use them.
5. Apply grease to O-rings and oil seals before assembling them.
CAUTION
Put a round nut to the thread at the other end of the
camshaft to protect the thread.
1. Bearing
1) Put the bearing driving tool on the bearing outer race, and
press-fit it into the bearing cover using a hand press, as
illustrated.
2) Install adjust ring, shim and bearing in this order into the 1)
camshaft. Put the bearing driving tool (SST) at the inner
race of the bearing and hammer the bearing to the camshaft.
Hand press
Bearingdriving tool
Outer race
Adjusting ring
Round nut
SST
Shim
Camshaft Center bearing
FL-65
2) Put the hole (25f side) of the guide rail (SST) through the
tapered section of the camshaft drive end, as illustrated in
Figures 42 and 43, then measure dimension L from the
side face of the pump housing to the end face of the guide
rail (at the beginning of the taper on the camshaft).
Specification ............................... L = 16.5 ± 0.5 mm
3) If the specification is not met, use appropriate shim plates
at the governor side until the specification is met.
DR0537
DR0538
DR0539
DR0540
DR0541
1) Screw in the camshaft clearance gauge (SST) for P-type
pumps in the camshaft at the drive side, install the guide
(SST) and a dial gauge, and measure the camshaft thrust
clearance, as illustrated in Figures 45 and 46.
Specification: Clearance ................... 0.03 to 0.05 mm
4. Bearing cover
1) Put the gasket (27) to the bearing cover (28), and tighten
them with four bolts (33).
CAUTION
When return holes are provided in the bearing cover,
position the return holes at the top.
5. Measuring the camshaft clearance
Shim plate thickness
Part number
090194-0070090194-0080090194-0090090194-0100
Thickness (mm)
0.10.150.30.5
Camshaftclearancegauge
Guide
Shim plate
Guide rail
Guide rail
Guide rail
INJECTION PUMP
FL-66 FUEL & ENGINE CONTROL
DR0543
DR0520
DR0544
DR0545
Part number
090194-0300090194-0310090194-0320090194-0330
Thickness (mm)
0.10.150.30.5
8. Install the plunger spring
DR0542
GuideCamshaftclearance gauge
Bearing cover
Shim plate
Cir-clip pliers
Tappet
Lowerspring seat
Plunger spring
2) If the specification is not met, use appropriate shim plates
at the drive side until the specification is met.
Shim plate thickness
6. Tappet
Install the tappet using the cir-clip pliers (SST).
CAUTION
Position the groove provided in the tappet in the axial
direction of the camshaft, and place it accurately so that it
is retained in position by the tappet retainer pin which is
driven inside the pump housing.
7. Lower spring seat
Install the lower spring seat using the tweezers.
CAUTION
Be sure that the flange of the lower spring seat is accu-
rately inside the groove of the tappet.
This is very important since and inaccurately positioned
seat may cause damage to the pump.
FL-67
DR0546
DR0547
DR0548
DR0549
10. Plunger
Put the flange of the plunger leg through the hole provided in
the lower spring seat, with the part number marking coming at
the spill side (opposite from the feed pump), then turn it clock-
wise by 90°.
CAUTIONS
1. When the plunger has only one lead, be sure that the
vertical groove faces the spill side. This is very impor-
tant since the characteristics of injection amount will
be different if the plunger is positioned incorrectly.
2. Hold the plunger at its top, and pull it to check that it
does not come out.
Projected part
Guide
9. Upper spring seat
1) Insert the upper spring seat with the projected part of the
seat coming at the drive side.
2) Attach the upper spring extractor (SST), and place the guide
groove on the extractor at the projected part of the upper
spring seat.
3) Push the handle down to compress the plunger spring, turn
the guide lever by 90° toward you, and install the upper
spring seat underneath the stopper pin which is driven in-
side the pump housing.
CAUTIONS1. Bring the cam of the cylinder at its bottom dead center.2. For each cylinder worked, check that the spring is ac-
curately retained by the stopper pin (See Figure 54).3. Check that the projected part of the upper spring seat
is at the opposite side of the rack (See Figure 54).
Projected part of theupper spring seat
Position the projectedpart in the guide groove.
Stopper pin
Extractor
Guidegroove
Housing
Plunger spring
Depressthe handle
Turn 90°
Toward the rack
Projected partUpper spring seat
Stopper pin
Pump housing Plunger spring
INJECTION PUMP
FL-68 FUEL & ENGINE CONTROL
NOTE
The plunger can be installed more easily if the cam of
the cylinder is at its top dead center.
DR0514
DR0550
DR0551
DR0552
CAUTIONS
The plunger may slip out of its position during install-
ing activities described above. Check the following for
the second time;
1. The vertical groove of the plunger must face the spill
side.
2. The plunger must not come out when it is pulled up.
11. Control sleeve
1) Insert the control rack.
2) Position the flanges of the control sleeve and the plunger,
and the projected part of the upper spring seat correctly
before inserting the control sleeve, as shown in Figure 57.
3) Move the control rack until the ball in the control sleeve is
accurately inside the groove provided in the control rack.
4) Tighten the rack guide screw.
Stopperpin
Housing
Control rack
Lower springseat hole
Control sleeve
Plungerfoot
Lower spring seat
Control rack
Control sleeve
Upper springseat
Control rack
Control sleeve
Upper springseat
Plunager spring
Plunager
FL-69
2) Secure the pump setting support (SST) in a vice, put the
delivery valve group in the support, and tighten the deliv-
ery valve holder to the delivery valve group using the torque
wrench to the specified torque.
Tightening torque ............ .................... 8 to 10 kg-m
DR0553
DR0554
DR05a55
DR0556
12. Delivery valve group
1) Install the valve gasket, delivery valve, valve spring, shim,
and the valve holder in this order inside the cylinder, as
shown in Figure 59.
CAUTIONS
1. Wash each part in clean light oil before installing it.
2. Use new valve gaskets and O-rings. Never re-use
them.
3. Apply grease to each O-ring first to protect if from
damage. Install O-rings (a), (b), and (c) in this order,
as shown in Figure 59.
13. Installing the delivery valve group
1) Apply a small amount of grease to the O-rings and outside
of the cylinder, position the cylinder with the marked line
on its flange coming toward the opposite side of the feed
pump, put the cylinder through the plunger moving the con-
trol rack to right and left, and insert the delivery valve group
inside the housing.
CAUTIONS
1. Put the cylinder in the correct position. This is very
important since, otherwise, the relative position of
the feed hole and the spill port will be reversed and
the characteristics of injection amount will be
different.
2. Each time a cylinder is inserted, move the control
rack to check that it slides smoothly.
3. Install the delivery valve group very carefull so that
no burr is created on the plunger.
Shim
Valve holder
Valve spring
Delivery valve
O-ring
Valve gasket
Cylinder
O-ring(a)
O-ring(b)
O-ring(c)
Box
Setting support
Torque wrench
Shim
Marked line
Shim
INJECTION PUMP
FL-70 FUEL & ENGINE CONTROL
3) Put flat washer (8), spring washer and nut through each
stud bolt in this order, and tighten them temporarily. Then,
tighten them to the specified torque evenly for all stud bolts
alternately using the torque wrench.
Tightening torque ............................... 1.7 to 2.2 kg-m
DR0557
DR0558
DR0559
14. Measuring the sliding resistance of the control rack
After the pump body has been assembled, put a spring scale
to the control rack, as illustrated in Figure 65, and check that
the control rack slides smoothly for the entire stroke.
Pump speed (rpm)
0
Control rack slidingresistance (g)
100 mx.
2) Put shims under the flange of the cylinder.
CAUTIONS
1. Put two counterparts of a shim of the same thick-
ness at sides of each cylinder. Use only one piece
on each side. This is very important since, it coun-
terparts having different thicknesses are used in
one cylinder, the rack will not move smoothly and
hunting and other troubles will result.
2. Put shims with the marked thickness facing above.
(They cannot be put reversed since the valve holder
cover (54) will be in the way.)
3. Push each shim completely until it touches the
cylinder.
Marked thickness(x100)ø2.5
FL-71
31. Shifter32. Shim33. Torque cam
34. Adjusting lever35. Adjusting lever section36. Guide lever37. Floating lever38. Supporting lever39. Adjusting lever shaft
40 Disc41. Cover42. Diaphragm43. Push rod A44. Boost compensator spring45. Housing
46 Guide screw
16. Stop device lever17. Supporting lever18. Shim
19. Stop lever20 Round nut21 Flyweight assembly22. Governor housing23. Start spring24. Rod
25. Lock screw26. Plug27. Cancel spring28 Tension lever shaft29. Tension lever shaft assembly30. Sleeve
Disassembly sequence1 Boost compensator assembly2. Push rod B3. Spacer
4 Idling screw5 Idle spring6 Governor cover7 Governor spring8 Spring seat9 Governor shaft
10. Rack connecting link11. Sensor lever12. Full load set lever13. U-lever14. Full load lever shaft15. Stop lever shaft assembly
RLD TYPE GOVERNOR [D4AF/D4AE/D4AL (EURO-I)]
Disassembly
For disassembly of parts with an encircled number, see following pages.
NOTE1. Item numbers 24, 25 and 34 to 39 are not to be disassembled normally.2. Item number 26 Plug, cannot be reused.
D4AF0873
NV ... Nominal Value
31
32
33
34
35
36
37
38
39
40
4142
43
44
46
1
2
3
4
6
7
89
10
11
12
1314
15
1617
18
19
2021
22
23
24
25
26
27
28
29
30
45
5
Dimension betweenguide screw upper endand housing end NV 13.5 to 14.5
GOVERNOR
FL-72 FUEL & ENGINE CONTROL
6. Using Extractor (special tool), remove the flyweights together
with the key.
D4AF0719
D4AF0876
D4AF3520
D4AF0877
Wrench
D4AF3496
1. Remove the automatic timer and timer case.
2. Remove the feed pump and cover plate. Insert Holder (special
tool) into the holder hole to separate the camshaft from the
tappet.
3. Remove the boost compensator.
4. Loosen adjusting lever clamp nut and remove governor cover.
NOTE
Ready a receiver to receive lubricant that will come out
when removing the governor cover.
7. Using Special Wrench (special tool), remove the idling screw
and remove the idling spring from the front of the governor
cover.
5 Using Extractor (special tool), lock the camshaft against rota-
tion and remove the round nut using Special Wrench (special
tool).
Timer
Feed pump
Case Cover plate
Automatic timer
Boost
compensator
Governor cover
Extractor
Special
ExtractorIdling springIdling screwSpecial Wrench
FL-73
12. Using Special Wrench (special tool), loosen the lock nut to
adjust the tightening amount at replacement of parts or adjust-
ment of boost compensator.
Governor shaft
D4AF3497
D4AF3499
D4AF0879
D4AF0880
SpecialWrench
D4AF0881
8. Remove the governor shaft nut using Special Wrench (special
tool) and remove the governor shaft, spring seat and governor
spring.
9. Remove the tension lever shaft, applying a rod and striking it.
10. Clamp the boost compensator in a vise and remove the nut,
spring washer, and disc from the push rod A.
At the time, apply screwdriver to the push rod and lock it in
position so the diaphragm can be protected from damage.
11. Measure the distance between the guide screw top end face
and housing end face.
(At reassembly, use this dimension as a basis for tightening.)
Rod
SpecialWrench
Spring seat
Governor spring
GOVERNOR
FL-74 FUEL & ENGINE CONTROL
Assembly sequence
15 → (19 → 18 → 17 → 16) 13 → 11 → 14 → 12 → 22
10 → 23
9 → 8 → 7 28 → 27 → 26 → 5 → 4
→ 29 → 6 24 → 25 → 33 → 3→ 1
21 → 20 → 30 → 32 → 3134→ 36→ 35 (39 → 38 → 37)
2 42 → 43 → 44 → 40 → 45
41 → 46
Inspection and Reassembly
Apply adhesive to cover
D4AF087F
For reassembly of parts with an encircled number, see following pages.
49 to 59 N·m(5 to 6 kgf·m)
Dimension between governorhousing end and center ofpin hole in shifterNV 39±0.2
Stake
3132
33
34
35
36
37
38
39
40
41
4243
44
46
1
2
3
4
6
7
89
10
11
12
1314
15
1617
18
19
2021
22
23
24
25
26
27
28
29
30
45
5
FL-75
1. Install the governor housing to the pump housing and tighten
the bolts to specified torque. When installing the governor
housing, install the spring support at illustrated location.
D4AF352D
D4AF3513
Rack connecting linkD4AF1566
D4AF3522
housing
U-lever
D4AF351B
5. Install he start spring to the rack connecting link.
NOTE
Insert the hooked end of the start spring to the connect-
ing link from above.
4. Install the spring and full load set lever to the full load lever and
tighten the nut to specified torque.
3. Install the U-lever assembly and spring and tighten the plug to
specified torque.
2. Install the flyweight and using Special Wrench (special tool),
tighten the round nut to specified torque.
Pump housing15 to 18 N·m(1.5 to 1.8kgf·m)
Spring support
Governor
Extractor
Special Wrench
49 to 59 N·m(5 to 6 kgf·m)
20 to 29 N·m(2 to 3 kgf·m)
Plug
Spring
9.8 to 14 N·m(1 to 1.4 kgf·m)
Full load lever
SpringFull load set lever
Start spring
Hook
GOVERNOR
FL-76 FUEL & ENGINE CONTROL
Adjusting shim
D4AF0883
D4AF3529
Idling spring
D4AF3496
D4AF3530
6. Installation of shifter
With the sleeve fully pressed against the flyweight slider, vary
adjusting shim thickness to obtain the dimension shown at right
for the distance between the governor housing end face (seat-
ing surface with governor cover) and the shifter pin hole center.
Install the shifter assembly to the tension lever.
Adjusting shim thickness:
0.2, 0.3, 0.4, 0.5, 1.0, 1.5
7. Assemble the spring seat and spring to the governor shaft and
install the assembly to the tension lever.
Tighten the nut from the governor cover front using Special
Wrench (special tool).
8. Install the idling spring and using Special Wrench (special tool),tighten the idling screw.
9. Expand the flyweight and install the governor cover to the
governor housing.
When doing so, make sure that the illustrated portion of the
rack connecting link rests in the floating lever groove and that
the sleeve is positioned in center of the flyweight.
SpecialWrench
L1=29+0.2
Governor shaft
Spring
Spring seat
Governor shaftGovernor spring
Spring seat
Special Wrench
Idling screw
FL-77
Adjustment after Reassembly
Governor performanace Curves
Pump speed
R2
N1 N2 N4 N5 N7 N9
D4AF0885
R3
Rac
k po
sitio
n10. After the governor cover has been installed, slack the gover-
nor spring set tension.
Ensure that the following control rack position is obtained when
the control rack is pushed to the governor from the pump drive
end with the adjusting lever operated to the full load position
without restricting the adjusting lever and full load set lever (by
the stopper bolt).
Control rack movement: 9.5 to 21
Then, check to see if the control rack smoothly reaches to the
following maximum point when it is released.
Injection pump maximum lift: 21
(Control rack entire stroke)
<Standard>
N3
R9
R7
R6/N
6
Rack limit
N11
R8/N
8
N10
R5
R4
R1
R10
GOVERNOR
FL-78 FUEL & ENGINE CONTROL
1. Preparation
Install the injection pump to the pump tester and feed injection
pump oil to the governor and cam chambers.
Remove the idling spring, governor shaft lock nut, and boost
compensator assembly.
Loosen the full speed set bolt, idling set bolt, and full load set
bolt.
Remove the smoke set assembly.
Installation of Adjusting Device
Make the lever run in parallel with the supporter at the portion
indicated in illustration. Set "0" on the dial at the lever pointer
and tighten the lever pointer and tighen the knurled lock nut
under the handle.
Using the adjusting nut, position and fit the pin on the handle
shaft into the center hole in the governor adjusting lever shaft.
Then, fit the pin on the lever into the adjusting lever rod con-
necting hole.
With the handle loosened, turn the lever and make sure that
the control rack slides smoothly.
D4AF4409
D4AF4442
Idling set bolt
Ø2
Ø1
42° ± 3°
42° ± 3°
Ø2
26° ± 3°
26° ± 5°
Pin
Adjsutment for Adaptation to Engine
IdleØ1
Full
Governor spring adjustment
Idling spring adjustment
Full load set bolt
Full load set lever
Stopper bolt
Full speed set bolt
Adjusting lever angle
Standard
Option
Align thissurface
Stand
Supporter
Stand
Ajusting nut
Adjustinglever shaft
Adjusting lever
Pin
Lever
HandleAdjusting nut
Adjusting Device
Square
FL-79
Then, read the adjusting device dial to ensure that the adjust-
ing lever angle is within the specified range.
Idling Spring Adjustment
Measuring Device
D4AF0822
Idlingset bolt
D4AF4449
Rac
kpo
sitio
n
Pump speed D4AF0884
Control Rack 0 Position Setting
Install Measuring Device (special tool) at the end of control
rack.
Secure the adjusting lever near the idle position.
Pressure the governor shaft against the pump housing wall,
increase speed up to 1000 to 1100 rpm, and push the control
rack to the governor. Then, set 0 position on the dial gauge.
NOTETurning the injection pump at the speed specified aboveis extremely important.Failure to do so does not allow obtaining he 0 positioneven with the control pinion pushed hard and can damagegovernor linkage.
Control Rack Locking
o With the adjusting lever at idle position, increase the pumpspeed up to 500 to 600 rpm. Then, move the adjusting le-ver to the full speed position.Next, set the control rack at full load position plus approx. 3mm with the full load set bolt.Under these conditions and with the rack fixed at the speci-fied position, make required adjustments.
o Before moving the adjusting lever to full speed position,make sure that the pump speed is increased to 500 to 600rpm with the lever at idle position.
o The torque cam adjusting nut must be locked in positionwith the lock screw.
2. Governor spring contact adjustment
Idling lever Position Temporary Setting
Using the adjusting device, temporarily fix the adjusting lever at
a position in contact with the idling set bolt.
Tighten the idling set bolt to obtain the rack position R1, with
pump speed N1.
N1
N2N
3 N
4 N
5
R1
R2R3R
4
R5
GOVERNOR
FL-80 FUEL & ENGINE CONTROL
After adjustment, tighten the lock nut to specified torque using
Special Wrench (special tool).
D4AF0889
Inner spring
D4AF3800
D4AF3802Special Wrench
D4AF0890
9.8 to 15 N·m(1 to 1.5 kgf·m)
D4AF3801
With the adjusting lever at idle position, tighten the idling screw
so that the rack position becomes R2 when pump speed is N2.
After adjustment, check that the control rack position becomes
R2 when the pump speed is set at N3.
If the control rack position is not R3, adjust with adjusting shim.
<Types of shim>
0.1, 0.2, 0.25, 1.0
After adjustment, tighten the idling screw to specified torque
using Special Wrench (special tool).
Governor Spring Contact adjustmentSet the adjusting lever in contact with the idling set bolt andadjust the governor shaft so that the rack position becomes R5when the pump speed is N .Then, secure the shaft with lock nut.Under this condition, decrease the pump speed to ensure thatthe speed is N4 when rack position is up o R4. Then, increasethe pump speed and ensure that the rack reaches 0.If these specifications are not met, replace the governor spring.
Special Wrench
Outer spring
Idling screw
Adjusting shim
9.8 to 15 N·m(1 to 1.5 kgf·m)
FL-81
If the rack psotiion varies, it means that the torque cam is im-
properly adjusted. Make readjustment, or if it is impossible,
replace the torque cam. Check the fuel injection rate with the
lever set at the adjusted nominl value. If adjustment is requred,
adjust full load set bolt nd torque cam with the adjusting nut.
Idling setbolt
D4AF4449
Full load set lever
D4AF0891
Pump speedN7
Rac
k po
sitio
n
D4AF0892
Special Wrench
D4AF0893
R8
R6
Rac
k po
sitio
n
D4AF0894
Idling Adjustment
Adjust with the idling set bolt so that the rack position becomes
R1, when pump speed is at N3 with the adjusting lever placed
in contact with the idling set bolt.
After adjustment, amke sure that the adjusting lever angle at
idle is within the specified range.
3. Full load rack position setting
Full Load Control Rack Position Adjustment
Place the full load set lever in contact with the full load set bolt,
and temporarily secure the set bolt so that pump speed is slightly
lower than N7 preventing pump from turning in the governor
control speed range.
Adjust tightening of full load set bolt so that the rack position
becomes R6 when pump speed is kept at N
6 with the full load
set lever at full load position.
Torque cam adjustment
Lock the adjusting lever at full load position.
Adjust the torque cam adjusting nut with Special Wrench (special
tool) so that the rack is positioned at R8 with pump speed at N
8.
Ensure that the rack position becomes R6 when the speed is
reduced down to N6. Make also sure that the torque cam moves
within the adjuste nominal value range with varying pump speeds.
N8
Pump speed
N6
Screw in
Back off
R6
N6
GOVERNOR
FL-82 FUEL & ENGINE CONTROL
Push Rod B Projection Check
With the specified rack position obtained, ensure that the di-
mension L (24±0.5 mm) is obtained for the distance betwen
the spacer end face and push rod B end.
If the specified dimension is not obtained, the governor is
probabley improperly adjusted or wrong parts are installed to
push rod B. Various types of push rods are therefore estab-
lished as shown at under for adjustment of L dimension.
The overall length varies with the length of section with a larger
diameter (∅10). There are two length available for the section
with a smaller dimenter (∅5).
Boost compensator Activating Point Adjustment
Adjust with the screw A so that the oost compensator is acti-
vated at Pa.
After adjustment, secure with the alock nut.
NOTE
Do not turn screw A more than four turns from the fully
loosened position.
Idling setbolt
D4AF4449
Push rod BD4AF0897
Boostcompensatorstroke
Boost pressure
Rac
k po
sitio
n
D4AF0898
Rb
Ra
Pa Pb
N9Pump speed
Rac
k po
sitio
n
D4AF0895
D4AF0896
4. High speed control pump speed adjustment
Lock the adjusting lever at a position in contact with the full
speed set bolt.
With the pump speed increased, adjust full speed set bolt so
that the speed becomes N7 when the rack starts to be pulled
from R7. Then sure with the bolt.
Make sure that the adjusting lever operating angle is within the
specified range by checking with the adjusting device dial.
Gradually increase the pump speed, and ensure that the pump
speed becomes N9 when the rack is pulled to R9. Make also
sure that further increasing the pump speed causes the rack
to be pulled to 0.
5. Boost compensator adjustment
With the adjusting lever placed in the full position and the pump
speed kept at 500 rpm (unless otherwise specified), make the
following adjustments.
R6
R9
N7
Spacer
FL-83
6. Smoke set assembly operating limit checkSet the pump speed slightly above idle N
2 and lock the adjust-
ing lever at a position to obtain rack position R2.
Make sure that the rack position is beyond R1 when pump is
stoppd and that the rack is positioned at the limit position whenthe adjusting lever is placed in the full position.
NOTEDecreasing the pump speed with the adjusting lever atfull position does not permit obtaining the smoke set rackposition at startup.
7. Black smoke prevention limit check
Set the adjusting lever at idle position and decrease the pump
speed down to N10
. Then, ensure that the smoke set is not
activated when the adjusting lever is placed in the full position.
Gradually increase the pump speed and make sure that the
speed N11
allows the rack to leave R10
, at which the smoke set
is obtained, to move in the decreasing direction.
Boost compensatorstrok
Rac
k po
sitio
n
Rb
Rack limit
Rac
k po
sitio
nR
1
N11D4AF0919
D4AF091A
D4AF0899
Boost Compensator Stroke Adjustment
With the boost pressure deactivated, adjust so that the rack
position changes from Rb to Ra with the set screw B. Then,
secure with the lock nut.
Ensure that the specified rack position ra is obtained with a
boost pressure of Pa. Make also sure that the rack is posi-
tioned at Rb when the boost pressure is Pb.
NOTE
When making the adjustment, raise the boost pressure,
and never decrease.
Pump speed
Rac
k po
sitio
n
R10
N10
Pump speed
N2
R2
D4AF0900
24 ± 0.5Screw B
Screw A
When boost pressureis applied
Boost pressure 0
Pump speed
Ra
GOVERNOR
FL-84 FUEL & ENGINE CONTROL
8. Sealing
Seal with wire
D4AF0970
With all adjustments completed, seal the governor as illustrated.
Install the seal cap to illustrated position using Rod (special tool).
<Rod>
o Torque cam
o Tension lever pin
o Govenor shaft
o Idling spring
Inspection and Adjustment of No-load minimum and Maxi-
mum Speeds
Perform the following check after the engine has been suffi-
ciently warmed up.
1) Minimum speed
Make sure that the adjusting lever is in contact with the
idling set bolt. Then, measure to ensure that the minimum
speed is within specification.
If the speed is out of specification, adjust with the idling set bolt.
2) Minimum speed
If the maximum speed is not within specification when the
adjusting lever is in full load position (where it is in contact
with full speed set bolt), adjust with the full speed set bolt.
NOTE
1. Never change the fixed position of full load stop-
per bolt.
2. Ensure that the engine does not stall or hunt when
the adjusting lever is quickly shifted from the full
load to idle position. If abnormal condition is
evident, adjust within the specification.
Torque cam
D4AF3494
D4AF0920
Adjustinglever
Full speedset bolt
Idling set bolt
Tension leverpin
Governor shaft
Idling spring
Tension lever pin
Rod
Seal with cap
Seal with wire
Seal with wire
FL-85
Removal of the Governor Cover Assembly1. Remove the full load stopper housing 32 damper screw 67
and cover plate 45 from the governor cover.
R801, R901 TYPE GOVERNOR [D4DA/D4DB/D4AL (EURO-II)]Precaution in servicingDisassembling
1. During disassembling, as well as re-assembling, the working area and the pump stand should be kept spotlessly
clean with great care exercised.
2. Make a preliminary inspection before disassembling, to determine the extent of governor failure and to make adjust-
ing measurements. This will help pinpoint the cause of the failure by comparing the adjusting measurements before
and after disassembling.
3. Each time a part is removed, check the condition under which it was fitted, and whether or not it has any discoloration,
bruise or any other damages.
4. Arrange the disassembled parts in an orderly fashion and separate the parts to be reused from those to be replaced
to facilitate the subsequent re-assembling procedure.
Assembling
1. Follow the correct procedures and use the recommended standards in assembling; for example, tightening torques,
fitting dimensions, etc.
2. Be sure to wash each part in clean light oil before installation.
3. Special care should be taken in assembly to avoid the entry of foreign material into the governor.
Any small part, such as washer, dropped in the governor may cause a serious problem to the engine in operation.
4. Always discard old nipples, washers, cotter pins, E-rings, gaskets, etc.; DO NOT reuse them.
DISASSEMBLYPrior to governor disassembly, thoroughly clean the exterior of the pump and governor, then mount the pump securely
onto the mounting vice. Unscrew the drain plug on bottom of the governor chamber to drain the lubricating oil.
FIG8-1
2. Remove the screw plugs 19 on the sides of the governor
housing, then pull out the supporting lever shaft 16 .
FIG8-2
Full load stopper housing 32
Control switch
Tightening bolt
Cover Plate 45
Tightening bolt
Damperscrew 67
Screw plug 19
Governor coverbolts 28
Supportinglever shaft 16
GOVERNOR
FL-86 FUEL & ENGINE CONTROL
3. Unscrew six pieces of governor cover bolts 26 . Detach the
return spring 7 -4 from the floating lever sub-assy 7 -1. With
the adjusting lever held in its "idling" position, detach the gov-
ernor cover 2 by lifting it up in such a way that the sliding
block may slide out of the slot in the flating lever 7 .
Removal of the Linkage Assembly1. Remove the floating lever assembly 7 by removing the sup-
porting lever 15 , slider 6 and cotter pin 55 (for shackle).
Then remove the start spring 34.
(On some governors, an E-ring is used in place of the cotter
pin).
CAUTION:
Because the silder 6 is a precision part, great care should
be taken in handling to avoid damage during removal.
2. Unscrew the connecting bolts 37 to remove the arm sub-
assembly 33 from the control rack.
FIG8-3
FIG8-4
Pull upsupportinglever
FIG8-5
FIG8-6
FIG8-7
CAUTION:
Before lifting the governor cover, be sure to pull the sup-
porting lever 15 upwards, as shown by dotted lines in
fig.40, so that its lower end does not obstruct the lifting of
governor cover.
Sliden 6
Slider
Floating lever
Lever end obstructgovernor cover
Lift governor cover
Cotter pin 65
Armsub-assembly 33
Slider 6
Floating lever 7
Supportinglever 15
Start spring 34Connectingbolt 37
Start spring 34
Lock washer 56
Supporting lever 16
Floating lever 7
Steel plate washer 66
E-ring 14Plate 58
Arm sub-assy 33
Connectingbolt 37
FL-87
2. Guide bushing removalCut the shake-proofing wire for the guide bushing and unscrewthe two bolts 3 -14.Then, remove the guide bushing 3 -12.(The shake-prooting wire has been discaded from 1983production.)
CAUION:To remove the guide bushing, it is necessary to keep thecamshaft from rotating by using the holding spanner (SST).
3. Round nut removal
Using the round nut wrench (SST), remove the round nut 3 -
23 which secures the flyweights.
CAUTION:
Use the holding spanner (SST) to keep the camshaft from
rotating.
Removal of the Flyweight Assembly
1. Bearing bolt removal
Untab the lock washer 13 -19 on the jointing bolt and remove
the locknuts 3 -18, pull out the jointing bolt 3 -13 and
bearing bolt 61 .
FIG8-8
FIG8-9
FIG8-10
FIG8-11
FIG8-12
Damper weights:
After removing the flyweights and the dampers, remove the
camshaft bushing using the camshaft bushing extractor (SST).
Flyweight
Round nut wrench(SST)
Flyweight
Flyweight extractor (SST)
Camshaft bushing
Camshaftbushingextractor (SST)
4. Flyweight assembly removal
Remove the flyweight assembly with the flyweight extractor
(SST).
Lock nut 3 -18
Lock washer 3 -19Jointingbolt 3 -13
Bearingbolt 61
Thigtening bolt 3 -18Guide bushing 3 -19
GOVERNOR
FL-88 FUEL & ENGINE CONTROL
2. Remove the taper bolt 9/1 , pull out the adjusting lever shaft and
remove the steering lever 9 .
Removal of the Adjusting Lever Shaft1. Detach adjusting lever sub-assy 17 , return springs 69 and
adjusting lever 20 from the governor cover.
5. Flyweights disassembling
Remove the adjusting nut 3 -11 with weight spring nut wrench
(SST), and disassemble the inner parts of the flyweight
assembly, such as spring guide 3 -8, governor springs, etc.
FIG8-13
FIG8-14
FIG8-15
FIG8-16
FIG8-17
Removal of the Governor Housing
Remove the stop lever 49 . Then unscrew the seven bolts which
sedure the govenor housing 1 , separate the latter from pump
housing by striking it softly with a plastic mallet.
3. Leave the cam plate 12 and return spring 13 in the adjusting
lever as shown in Fig.8-17. housing.
Spring seatWasher
Idle outer spring
Adjusting nutControlspring
Spring inner seat
Idle outer spring
Mechanicalspring Spring guide
Adjusting lever 20
Adjusting lever shaftAdjusting lever sub-assy 17
Return spring 69
Return spring 13E-ring 14
StopperCam plate 12
Steering lever 9Lever shaft
Return springCam plate
FL-89
FIG8-18
FIG8-19
FIG8-20
FIG8-21
FIG8-22
2. Measure and record "A" dimension from the edge of the boost
compensator housing to the guide bushing as shown in Fig.8-
19.
NOTE
Make sure to record the dimension A as the guide bush-
ing is put in place based on that length during assembly.
ASSEMBLYAfter checking each part, assemble the governor in the following
steps of procedure:
Installation of the Governor HousingWith the gasket 30 attached to the fitting surface of the pump housing,
fasten the governor housing ot the pump housing with bolts.
Installation of the Stop LeverInstall the stop lever 49 as shown in the diagram of Fig.8-21.When installing, adjust by clearance shims 63 (Clearance Toler-ance = 0.05 - 0.1 mm) between stop lever and its support shaft.The O-ring 51 should be coated with grease before being fitted
into the lever assembly.
Installation of the Flyweight Assembly1. Flyweight assembling
Refer to Fig.8-22, install the guide sleeve, governor springs,etc. into the flyweight, and then tighten the adjusting nut with
weight spring nut wrench (SST).
CAUTION:1. Be sure to install the spring inner seat in correct
position; namely, its "lapped" surface should facedownwards. (Reverse instaalation should be avoided.)
2. The adjusting nut should be tightened so that the pro-jection of the flyweight holder shaft is between -0.4mm to 0.2 mm (R801 and R901). If the projection ex-ceeds the lower limit (-0.4 mm), the adjusting nut maycome in contact the housing.
3. Be sure to insert the adjusting washers on the guidesleeve side.
Disassembly of the Boost Compensator
1. Loosen the bolts shown in Fig.8-18 first, and then disassemble
the full-load stopper assembly from the governor. Loosen
Boost compensatorhousing
Guide bushing
Tightening torque:1.8 ~ 2.0 kg·m
Spring cover 54
Stop lever 49
Return spring 53
0.05~0.1mm(R801 and R901)
Stop arm 48
O-ring 51
Bolt withwasher 46
Shim63
Governorhousing
Tighteningtorque:0.8 ~ 0.9 kg·m
Adjusting nutGuide sleeve
Spring inner seatControl spring
Idle inner spring
Idle outerspring
Spring seat
2.5mm
“LAPPED” surface shouldface downwards when installed
3.5mm
Projection:-0.4 ~ 0.2mm(R801 and R901)
GOVERNOR
FL-90 FUEL & ENGINE CONTROL
2. Installation of flyweight assembly
Install the spring washer 3 -24 on the camshaft. Then install
and secure the flyweight assembly by tightening the round nut
3 -23 with round nut socket (SST).
CAUTION1. Tighten the round nut 40 with a torque of 5-6 kg·m.2. In tightening, hold the camshaft from rotation by using
the holding spanner (SST).FIG8-23
FIG8-24
FIG8-25
FIG8-26
FIG8-27
Flyweigh with Damper1. Adjustment of the damper clearance
This adjustment determines the clearance between the fly-
weight assembly and camshaft bushing for proper operation of
the dampers.
1) Install the camshaft bushing on the camshaft.
2) Install the flyweight assembly with the campers removed.
3) Install the round nut a tighten to specified torque.
4) Move the needle of the dial gauge to contact the flyweight
assembly and take the reading.
5) Insert shims between the camshaft bushing and the round
nut and take another reading. Subtract the first reading from
the second. Repeat this until the desired clearance is
obtained.
Clearance: L = 0.02 ~ 0.10mm
(R801 and R901)
2. Installation of the dampers
1) Install the camshaft bushing on the flyweight assembly.
2) Insert the six dampers between the lip of the camshaft bush-
ing and the flyweight assembly.
NOTE:
Smear some labrication oil on the rubber dampers prior
to installation.
3) Press down on the dampers with fingers and tap the cam-
shaft bushing with a plastic mallet to set the dampers in
place.
CAUTION:
Be careful not to damage the campers.
After installing the dampers, install the flyweight assembly
onto the camshaft and tighten the round nut.
Tightening torque:5~6 kg·m
Clearanceadjusting shim
Round nut socket(STT)
Flyweight
Dial gauge
Camshaft bushing
Dampers
Plastic mallet
FL-91
Installation of the Bearing Bolt
1. Fasten the guide bushing 3 -12 with the two dmping bolts.
Tightening torque : 0.6 ~ 1.0 kg·
CAUTION
After tightening the clamping bolts, make sure that the
bearing bolt slides in the guide bushing.
2. Install the bearing bolt 61 , and insert the bellcrank bolt 3 -13
through the flyweight arms. Then, install the nuts 3 -18 and
lock washer 3 -19. The lock washer should not be tabbed yet.
CAUTION
1. The free play of the bellcrank bolt in an axial direction
should be between 1.5 and 2.0mm.
2. The washer should be placed on the bolt head side (or
on the elongated hole side of flyweight).
3. Fitting dimension of the bearing bolt
1) Measure the distance L, as shown in Fig.8-32 after the
bearing bolt is put in place.
2) Check whether the length L, is within the fitting dimension.
Fitting dimension L = 50.05 ± 0.2mm (R801)
= 49.9 ± 0.2 mm (R901)
3) If the length L, is outside the fitting dimension, remove the
bearing bolt and measure i, shown in Fig.8-33.
4) Calculate L2 by the following.
L2 = L - L
1
5) Calculate "i" by the following.
=
Choose a bearing bolt that has the length "i" from the fol-
lowing table and put it in place.
FIG8-28
FIG8-29
FIG8-30
Bearing bolt
FIG8-31
1 + L
2
Tightening torque :0.6 ~ 1.0 kg·m
Bellcrankbolt 3 -13 Nuts 3 -18
Bearing bolt 61
Guide bushing
Lock washer
Bellcrankbolt 3 -13
1.5~2.0mm
Washer 3 - 22On elongatedhole side offlyweight
Lock washer3 -19
Housing
Slider
Adaptorplate
Verniercalipers
Nuts 3 -18
GOVERNOR
FL-92 FUEL & ENGINE CONTROL
Parts number
901411-0320
901411-0330
091411-0340
091411-0350
Length (ι)
33.74mm
33.54mm
33.34mm
37.74mm
R801 governor
Parts number
901411-0180
901411-0190
091411-0200
091411-0210
Length (ι)
31.9mm
31.7mm
31.5mm
31.3mm
Parts number
901411-0220
901411-0230
091411-0240
Length (ι)
31.1mm
30.9mm
30.7mm
R901 governor
Length (ι)
34.54mm
34.34mm
34.14mm
33.94mm
Parts number
901411-0360
901411-0370
091411-0380
091411-0450
FIG8-32
FIG8-33
Assembling of the Governor Cover
1. Fit the cam plate 12 to the governor cover 2 . Allow a play of
0.08 to 0.12 mm (R801 and R901) in the axial direction by
selecting appropriate adjusting washer.
(From production on August, 1983, the bushing 57 has been
replaced by 4 washers, each of which is 0.5 mm thick. The
axial clearance can be changed using them.)
CAUTION
Be sure to place the 0.5 mm thick washer 64 next to the
E-ring and insert the adjusting washer between the washer
64 and the bushing.
4. After the fitting dimension of the bearing bolt has been achieved,
lock the nuts by tabbing the lock washer in two opposite direc-
tions indicated by the dotted lines in Fig.8-29. Then, shake-proof
the clamp bolts, which secure the guide bushing, by using a
wire. (Fig.8-32)
NOTE
The shake-proofing wire has been abolished from 1983
production. If a shake-proofing wire was not originally
installed, coat the clamping bolt with adhesive and tighten
them to the specified torque, 0.6 ~ 1.0 kg·m.
Shake-profing
Cam plate 12
Lock washer
Governorcover 2
Bushing 57
Washer 64
E-ring 14
0.08~0.12mm
FL-93
Installation of Linkage Assembly
1. Fasten the arm sub-assembly 33 to the control rack with the
connecting bolts 37 . Hook the start spring 34 to the arm
assembly and the stopper plate.
NOTE:
In the above step, be sure to place the arm nut 58 in the
correct position. (Fig.8-35).
2. Connect the shackle 8 to the arm subassembly 33 with theplate washer, and secure the shackle by using a E-ring 14 .Then, install the slider 6 and supporting lever 15 on thefloating lever.(Some governors use a cotter pin instead of the E-ring 14 .)
CAUTION:1. To prevent the cotter pin from falling out, be certain to
bend its legs after installation.2. Make sure that the supporting lever can swing freely
by its own weight when released from lifted position.(Fig.8-36, 37)
FIG8-35
FIG8-36
FIG8-37
FIG8-34
2. Install the steering lever and adjusting lever shaft to the gover-
nor cover.
NOTE
From production in September, 1981, the sliding block has
no recess cut in it. Refer to the drawing at right when in-
stalling the sliding block into the floating lever.
Steeringlever
0.5~1.5mm(R801 and R901)
Adjustinglever shaft
Sliding block
Taper bolt
Tighteningtorque:0.4 ~0.7kg·m
Floatingleve 7
Plate washer
Cotter pin
Arm nut
Shackle 8
Washer 56
Connectingbolt 37
Armsub-assembly 33
Startspring 34
Control rack
Supportinleve 15Slider 6
Slider
Supporting lever
Supporting levershaft Supporting lever should return
easily by its own weight
GOVERNOR
FL-94 FUEL & ENGINE CONTROL
2. Insert the supporting lever shaft 16 . Then, coat the screw
plug 19 with adhesive and screw it in.
3. Fasten the governor cover to the governor housing with six
governor cover bolts 26 .
4. Finally, attach the full-load stopper housing 32 and cover
plate 45 .
Installation of the Governor Cover
1. To install the governor cover, keep the control rack pulled to-
wards the governor side and place the adjusting lever in its
idling position. Release the return spring from the floating lever
sub-assembly. With the free end of the supporting lever pulled
up, install the governor cover by guiding the sliding block with
your fingers into the slot of the floating lever. Re connect the
return spring to the floating arm sub-assembly.
CAUTION:
Be sure that the sliding block should be inserted with its
concave side facing upwards.
(Refer to Fig.8-36 and "NOTE".)
FIG8-39
FIG8-40
Preliminary Adjustment of Stop CamRemove the full load stopper assembly. Measure the L
1, L
2 and L
3
distances with vernier calipers and adjust to meet specified amount
on test plan.
NOTE
For the specifications, refer to the injection pump specifica-
tions sheet for each pump reference number.
FIG8-38
Tightening Torque :1.0~1.4kg·m
FL-95
TEST AND ADJUSTMENTAfter governor assembling has been completed, test the governor
for its working performance and make necessary adjustments,
accordingly. Prior to testing, check each connections and sliding
smoothness.
Perform the governor testing and adjustment using the following
sequential order:
1. Preparational Procedure
2. Preliminary adjustment of stop cam
3. Adjustment of idling speed control
4. Preliminary adjustment of maximum speed control
5. Adjustment of medium speed control
6. Adjustment of maximum speed control
7. Adjustment of damper screw
8. Adjustment of fuel delivery quantity under full load
9. Checking for stop lever operation
D431001
Protractor (SST)
D431003
Adjusting lever
Adaptor screw Full-load stopper
Idle adjusting screw
Damper screw
Maximum speed adjusting screw
Adjusting nut
Adaptor screw
Screw plug
ADJUSTING PARTS & CHANGES IN GOVERNING CHARACTERISTICS
TEST AND ADJUSTMENT
FL-96 FUEL & ENGINE CONTROL
D431005
D431007
D431009
D431011
Screw out
1. Idle Adjusting Screw
This adjusting screw serves to determine the idling position.
In Fig.D431005, the solid line represents the standard charac-
teristic while the dotted and dash-dot lines show the changes
in the characteristic when the screw is turned out and in,
respectively. Screw in
Racktravel
Pump speed
2. Maximum Speed Adjusting Screw
This adjusting screw is used to determine the point at which
engine maximum speed is governed.
The dotted and dash-dot lines show the changes of governing
characteristic, respectively.
Racktravel
Pump speed
Screw out
Screw out
Screw out
Racktravel
Racktravel
Racktravel
D431013
Screw out &
Pump speed
Pump speed
Pump speed
Screw in
Screw in
Screw in
Screw in &
3. Full Load Stopper
Turning this stopper screw changes the quantity of fuel deliv-
ered in the full-load condition.
The changes of characteristic are shown by the dotted and dash-
dot lines, respectively.
4. Adaptor Screw
This screw is used to change the adaptor stroke in medium and
high-speed ranges under full load.
The changes of characteristic are shown by the dotted and dash-
dot lines, respectively.
5. Adaptor Screw &
The changes of characteristic are shown by the dotted and dash-
dot lines, respectively.
NOTE:
For this setting adjustment, the adaptor screws and
are used together.
FL-97
D431023
Idle adjusting screw
D431015
D431017
D431019
6. Damper Screw (if installed)
This damper screw prevents engine stalling in rapid deceleration.
By turning in this screw, the rackk travel will change with respcet
to pump speed from the solid line to the dash-dot line. Screw in Racktravel
Pump speed
7. Adjusting Nut
This adjusting nut is used to alter the idling and maxmum speed
governing characteristics.
The changes of characteristic are shown by the dotted and dash-
dot lines, respectively.
Fine adjustment for the same purpose can be done by means
of washerss.
Racktravel
Pump speed
Screw out
Screw in
PREPARATIONAL PROCEDUREPrior to governor adjustments, perform the following procedural steps:
1. Install the rack travel gauge (SST) on the control rack, and set
zero of the gauge.
2. Install the protractor (SST) for the adjusting lever on the test
stand. (Zero position is perpendicular to the bed.)
3. Remove the full-load stopper housing cover, damper screw,
full-load stopper cap and control switch from the governor.
4. Refill the governor and pump camshaft chambers with recom-
mended lubricating oil (engine oil).
NOTE:
Always use a high accuracy type rack position sensor for
the adjustment of the R901 governor.
Rack travelgauge (SST)
ADJUSTMENT OF IDLING SPEED CONTROL
1. Drive the pump at the speed of Nc*, and turn the idle adjusting
screw in either direction to obtain the rack travel Rc*. (For the
changes in characteristics, refer to (1) Idle Adjusting Screw
* If specification has Nb, Rb, use this setting to change the
idle adjusting screw. Then check N, Rc. If R
c is out of
specification, adjust using washer .
D431021
Racktravel
Pump speed
Adjustinglever set
Ra Rb
Rc
Rd Re
Na NbNcNd Ne
TEST AND ADJUSTMENT
FL-98 FUEL & ENGINE CONTROL
2. Drive the pump then at Na and check rack travel R.
3. Drive the pump at Nd, and check rack travel R
d. If R
d is out of
specification, adjust by changing washer shown in
Fig. D431027 Use of a thicker washer will move the character-
istic towards the dash-dot line (Fig. D431025).
4. Drive the pump at Ne, and check rack travel R
e. Adjust if neces-
sary by changing washer (Fig. D431027). An increase in
washer thickness will change the characteristic towards the
dash-dot line (Fig. D431025).
NOTE:
1. After adjustment, check the projection of the flyweight
holder shaft. The projection limits of -0.4 to 0.2 (R801
and R901) mm must be met to prevent interference with
the housing.
2. Adjusting washer should be inserted on the guide
sleeve side.
5. With the R801 governor with a 3rd idle spring, its characteristic
curve controlled by that spring, i.e. the broken line portion in
Fig.D431027, cannot be adjusted. Replace the spring if the
idling speed is not with in the standard range.
NOTE:
Make sure that the 3rd idle spring is installed in the cor-
rect direction. (See Fig.D431029)
6. With the R901 governor, all of its springs (idle outer spring, idle
inner spring, 3rd idle spring and control spring) each have a
washer for adjustment.
Washer : For idle outer spring
Washer : For idle inner spring
Washer : For 3rd idle spring
Washer : For main spring
Pump speedD431025
Washerthickened
Washerthickened
Racktravel
D431027
D431029
Guide Bushing
3rd idle Spring
Larger
Racktravel
Pump speed
WasherWasher
Washer
Washer
Washer Adjusting nutProjection:-0.4 ~ 0.2 mm(R801 and R901)
Springinnerseat
Springseat
Idle innerspring
Washer
Controlspring
Guide sleeveIdle outerspring
<R901 governor>
<R901>
D431031
D431033
Washer
WasherWasher
Washer
FL-99
PRELIMINARY ADJUSTMENT OF MAXIMUM SPEED
CONTROLFor this adjustment place the adjusting lever in its "full" position,
then turn the maximum speed adjusting screw to achieve con-
trol rack cutback at pump speed Nf (Fig. D431043 & D431045)
ADJUSTMENT OF MEDIUM SPEED CONTROLThe full load stopper is used to change the adjustment of me-
dium speed control. (For the changes in characteristics, refer to
Fig.D431009)
1. Drive the pump at Nj, adjust the full load stopper to obtain rack
travel Rj. (For the changes in characteristics, refer to Fig.
D431009)2. Drive the pump then at N
i, adjust using the adaptor screw to
obtain rack travel Ri. (Refer to Fig.D431011)
3. Drive the pump at Ni, adjust adaptor screws and to obtain
arck travel Ri. (Refer to Fig.D431013)
NOTE:
To adjust the adaptor screw and , loosen the lock nuts.
Turn them using a screwdriver. To lock adaptor screw ,
use the double spanner method.
ADJUSTMENT OF MAXIMUM SPEED CONTROL1. Perform this adjustment by turning the maximum speed ad-
justing screw to obtain control rack cutback at pump speed
Nf (Fig. D431007). (For the changes in characteristic, refer to
Fig D431007).
2. Drive the pump then at Ng and N
h, and make sure the rack
travel equals Rg and is less than R
h.
D431035
Washer Adjusting nutProjection:-0.4 ~ 0.2 mm(R801 and R901)
Springinnerseat
Springseat
Idle innerspring
Washer
Controlspring
Guide sleeveIdle outerspring
D431037
D431039
D431043
Racktravel
Pump speed
Maximum speedadjusting screw
Adjusting lever set
Ni Nj
Ri
Rj
Rl
D431041
Racktravel
Pump speed
Nf Ng Nh
Rg
Rh
TEST AND ADJUSTMENT
FL-100 FUEL & ENGINE CONTROL
D431045
ADJUSTMENT OF THE DAMPER SCREW1. With the adjusting lever set at its "idle" position, drive the pump
at Nm and adjust by turning the damper screw in either di-
rection to obtain rack travel Rm (Fig. D431015) (For the changes
in characteristic, refer to Fig D431015) Then, drive the pump at
Nn and check rack travel R
n.
2. Then place the adjusting lever in its "full" position, check rack
travel Ro and R
p at pump speeds N
o and N
p.
NOTE:
Some governors do not have a damper screw. Others need
no damper screw adjustment even if it is installed. Refer
to the test specification for details.
ADJUSTMENT OF FUEL DELIVERY QUANTITY
UNDER FULL LOADPerform this adjustment to achieve the required quantities of fuel
delivery at the specified pump speeds. Adjust using the full load
stopper for this adjustment under full load.
CHECK THE STOP LEVER OPERATIONWith the adjusting lever placed in its "idling" position and the pump
speed of "0" rpm, check the rack travel. It should be less than 5.5
mm when the stop lever is operated.
For the correct rack travel, refer to the pump's test specification.
This completes the necessary governor adjustments. After these
adjustments, install the exterior parts and seal each of the
adjustments.
D431047
Damper screw
D431049
Racktravel
Pump speed Nm Nn NoNp
Rm
Ro
Rn
Rh
FL-101
ADJUSTMENT OF R801 & R901 WITH BOOST COMPENSATOR
Make adjustments in the following order after disassembly and assembly operation.
1. Preliminary adjustment of boost compensator
2. Proportional procedure
3. Preliminary adjustment of stop can
4. Adjustment of idling speed control
5. Preliminary adjustment of maximum speed control
6. Adjustment of medium speed control
7. Adjustment of maximum speed control
8. Adjustment of the boost compensator
9. Adjustment of the damper screws
10. Adjustment of fuel delivery quantity under full load
11. Checking stop lever operation
Preliminary Adjustment of Boost CompensatorBefore installing the boost compensator and the full-load stopper housing, make the following adjustments.
D431051
Guide bushing
Screw
Push rod
Stop screw
TEST AND ADJUSTMENT
FL-102 FUEL & ENGINE CONTROL
1. Calculate dimension G by the following formula. Rotate the guide
bushing so that G is the same as the required dimension.
G = F - A
NOTE:
"A" is the dimension measured during the disassembly.
(Refer to Disassembly of the boost compensator)
2. Screw in the stop screw until it contacts the push rod. Screw it
in further by half turn to get the correct position.
D431053
D431055
Guidebushing
Boost compensatorhousing
Pushrod
Stop screw
AF
G
3. Obtain correct dimension of "C" by turning the screw. Fix it by
means of the lock nut.
4. Apply 1000 mmHg pressure through the port “D” The screwshould travel E cm. If the travel is too much or too less, checkthe parts for correct installation.
5. Check airtightness by applying 1000 mmHg pressure in thediaphragm chamber. Check the pressure drop, if after 10seconds the pressure is still greater than 980 mmHg, thecompensator is O.K.
D431057
D431059
C
E
Screw
Lock nut
Apply1000mmHgboostPressure
Screw
FL-103
Adjusting Parts and Changes in Rack Travel Characteristics
D431061
Damper screw
Stop screw
Guide bushing
Adaptor screw
Maximum speed adjusting screw
Full-load stopper
Adjusting lever
Adaptor screw
Screw plug
Adjusting nut
Idle adjusting screw
D431063
Low boostpressure(consstant)
Screw in
Screw out
Pump speed
Rac
k tr
avel
D431065Boost pressure
Rac
k tr
avel
Clock wise
Counterclockwise
For changes in rack travel characteristics by adjusting parts to
,refer to Adjussting parts & changes in goverining characteristics.
Boost compensator function has no affect on their operation.
1. To adjust fuel delivery quantity under full load with low boost
pressure, turn the stop screw .
2. To adjust boost compensator characteristics, turn the guide
bushing .
In Fig. D431067, the guide bushing is viewed from the stop screw
side.
TEST AND ADJUSTMENT
FL-104 FUEL & ENGINE CONTROL
D431067
Preparational Procedure1. Follow the instructions (1) to (4) given in preparational
procedure (page 31-91).
2. To measure the pressure to be applied to the boost
compensator, use an air pressure meter in which operational
range exceeds 1000 mmHg. Connect the air pressure meter to
the boost compensator port and the vaccum pump on the test
bench using a three-way hose.
The vacuum pump handle must be turned completely counterclock
-wise in order to generate sufficient boost pressure.
SST : Digital air pressure meter
Preliminary Adjustment of the Stop CamFollow the instructions given in section 'Adjustment of idling speed
control'
Adjustment of idling speed controlFollow the instructions given in section 'Preliminary adjustment of
maximum speed control'
Preliminary Adjustment of Maximum Speed CotrolWith the specified pressure applied to the boost compensator, turn
the adjusting lever to the "full" position. Turn the maximum speed
adjusting screw until control rack cutback begins at pump speed Nf
Adjustment of Medium and Maximum Speed ControlWith the specified pressure applied, follow the instructions given in
sections 'Adjustment of maximum speed control' and 'Adjustment
of the damper screw'
Adjustment of the Boost CompensatorTurn the adjusting lever to the "full" position and follow the steps
below.
In the steps below, adjustments are based on the specified pump
speed. On some governors, however, the pump speed may vary
from one adjustment to the other. For details, refer to the specifica-
tion table of each governor.
1. Adjustment of the stop screw
With the pressure P1 applied, set the pump speed to the
specification. Turn the stop screw so that the rack travel is R1.
Screw in the stop screw increases rack travel.
D431069
D431071
Racktravel
Three-wayhose
Air pressuremeter
Pump speed
P1
P2 P
3
R3
R2
R1
Racktravel(mm)
Pressure (mmHg)
D431073
Stop screw
Handle
Nf
FL-105
IDLE-UP ADJUSTMENTIdle-up set and microswitch set
[Actuator vacuum: -47kPa (-350 mmHg) or below]
D4AF D4AL
Idle-up Adjustment Procedure
1. Warm up the engine, keep the transmission in neutral, andkeep the exhaust brake in "OFF" position.
2. Activate the actuator by applying a vacuum of -47 kPa (-350mmHg) or below to it.
3. With the lock nut loosened, turn the adjust screw to obtain thespecified idle speed.After adjustment, tighten the lock nut.
4. With the actuator released to the atmosphere, reapply the saidvacuum to it and ensure that the specified idle speed is obtained.If the idle speed is out of specification, repeat steps 2) and 3)
for readjustment.
NOTE
1. If the adjust screw does not permit correct adjustment
on D4AE , move the actuator by loosening the actua-
tor attaching bolts.
2. For on-vehicle adjustment fo idle-up speed, use spe-
cial care not to let the tools be in contact with the B-
terminal of starter.
D4AF0974Mounting bolt
Actuator
D4AF0973
<D4AF,D4AE>
2. Adjustment of the guide bushingWith the pressure P
2 applied at the specified pump speed,
measure fuel delivery quantity. If it deviates from the specifiedrange, adjust by means of the guide bushing.
After adjustment, record the rack travel R2 .
Hysteresis check
Compare the rack travel when the pressure is raised to P2 and
conversely, when it is lowered to P2 . Make sure that the differ-
ence is within specification.
If it deviates too much, replace the boost compensator spring.
3. With the pressure P3 applied at the specified pump speed, make
sure that the rack travel R3 is equal to R
2 + (specified value).
4. With pressure released and pump speed of 100 rpm, makesure that the rack is in the start position.
For other operations (9), (10) and (11), see sections 'Adjustmentof fuel delivery quantity under full load', 'Check the stop operation'and 'Adjustment of R801 & R901 with boost compensator'
This completes the necessary adjustments. After completing theseadjustments, install the exterior parts and seal each of theadjustments.
D431075
Flat-bladescrewdriver
Guidebushing
Idle-up set(on-vehicle)
950 to 1,000 rpm 950 to 1,000 rpm
Adjusting lever
Adjusting screw
<D4DA, D4DB> Lock nut7.8 to 8.8 Nm(0.8 to 0.9 kgf·m)
Lock nut7.8 to 8.8 Nm(0.8 to 0.9 kgf·m)
Adjusting screw
Adjustinglever
IDLE-UP ADJUSTMENT
FL-106 FUEL & ENGINE CONTROL
FEED PUMPDisassembly, Inspection and Reassembly
Disassembly sequence1. Priming pump2. Eye bolt3. Valve support
4. Spring5. Check valve6. Eye bolt7. Gauze filter8. Plug9. Spring
D4AF0978
10. Piston11. Push rod12. Snap ring13. Tappet
14. Housin
For reassembly, reverse the order of disassembly.
NOTEKnow the trouble spots thoroughly by making tests beforedisasembly.
Wear
Deterioration
Deterioration
Seat wear
Cracks, thread damage
1
2
3
4
5
6
7
8 9 10 11
12
1314
Clean or replace
Dirt, clogging
4
5
FL-107
Test and Adjustment
AUTOMATIC TIMER
SCZ Type Automatic Timer
1. Removal
Loosen the round nut with Socket Wrench (special tool).
Lift capacity Conditions
Time requred before liftingwhen operated at 150 rpm.
NV 45 strokes or more
Lift capacity Conditions
Time requred before liftingwhen operated at 100 rpm.
NV 40 strokes or more
NV ... Nominal Value
D4AF0979
Socket Wrench
D4AF0980
D4AF0981
Using Timer Extractor (special tool), remove the automatic timer
from the injection pump.
Timer Extractor
Feed pump
AirtightnessNo leaks from pushrod sliding surface
Airpressure195 kPa(2 kgf.cm²)
Lift capacity Conditions
No. of strokes requiredbefore lifting when operatedat 60 strokes per minute.
NV 25 strokes or more
<D4AF>Delivery pressure Condition 600 rpm NV 175 to 215 kPa (1.8 to 2.2 kgf/cm²)
Delivery Condition Trough ∅1.54 nozzle for min. at 1,000 rpm NV 1,620 cc or more
Test conditionsFuel pipe
I.D. 8 mmLength 2,000 mm
Cam lift 6 <D4AF>
(Eccentric cam) 8 mm <D4AE>
Height from oil level 1,000 mmTest oil JIS No.2 light oil
AUTOMATIC TIMER
<D4AL>Delivery pressure Condition 600 rpm NV 335 to 410 kPa (3.4 to 4.2 kgf/cm²)
Delivery Condition For 1 min, at 1,000 rpm NV 1,620 cc or more
FL-108 FUEL & ENGINE CONTROL
Disassembly sequence
1. Circlip2. Shim3. Injection pump gear4. Timer spring5. Shim6. Flyweight
7. Timer hub
D4AF0982
D4AF0984
Injection pump gear
D4AF0985
2. Disassembly and inspection
Raise the injection pump gear while turning it in the direction to
compress the time spring. Then remove the injection pump
gear.
NOTE
Use cre not to let the timer spring spring out.
Remove the circlip and shim.
Deterioration
Flaws in curved surface
Wear of pin
For disassembly of parts with an encircled number,see following pages.
1
2
3
45
6
7
5
FL-109
1) Instal the timer hub.
D4AF0982
Timer hub
D4AF0986
Timer hub keyway
D4AF0987
D4AF0985
Assembly sequence
7→6→3→4→5→2→1
For reassembly of parts with an encirclednumber, see following pages.
NV ... Nominal
3. Reassembly
2) With the flyweight mounted on the timer hub, install the
injection pump gear in the direction of the illustration.
3) While turning the injection pump gear in the direction to
compress the timer spring, fit the injection pump gear pin
into the curved surface of the flyweight.
Injection pumpgear
Injection pumpgear
Flyweight
Gear marking
AUTOMATIC TIMER
Apply engine oilwhen installed
Thrust clearanceNV 0.01 to 0.2 mm
1
2
3
4
56
7
8
6
FL-110 FUEL & ENGINE CONTROL
5. Test and Adjustment
Whenever the automatic timer is disassembled, its advance
angle must be measured with the manufacturer's mesuring in-
strument and readjusted.
Automatic Timer Advance Characteristics
To adjust the advance characteristics of the automatic timer,
add or reduce the adjusting shims or replace the spring.
To reducethe advance angle, increase the shim thickness.
Shim thickness:
0.5, 0.6, 0.7, 0.8, 0.9, 1.0
Automatic Timer Advance Characteristics Curves
D4AF0989
D4AF0990
Socket Wrench
D4AF0991
Advance angle adjusting shim
D4AF0992
1,000
Adv
ance
ang
le (
deg)
D4AF0993
4) Check the spring for installed condition.
5) Install the shim and circlip.
Then, measure the thrust clearance of the injection pump
gear.If the clearance is out of specification, adjust with
shims.
4. Intallation
Mount the automatic timer aligning it with the camshaft key.
Then, tighten the round nut to the specified torque using Socket
Wrench (special tool).
6.5±0.5Output point
Stopper
Pump speed (rpm)1,750
Advance angle adjusting shim
93 to 98 N·m(8.5 to10kgf·m) :D4AF,D4AE,D4AL(EURO-�)128 to 147 N·m(13 to15kgf·m) :D4DA,D4DB,D4AL(EURO-��)
FL-111
Disassembly
Disassembly sequence
1. Retaining nut2. Nozzle3. Needle valve4. Packing5. Pressure pin6. Spring7. Washer
8. Nozzle holder
NOTEMake sure that the combination ofthe nozzle and needle valve is notchanged.
Replace
1. Bridge2. Injection nozzle3. Nozzle tip gasket
D4AF1004
Gasket PliersD4AF1007
Carbon deposits
D4AF1008
Wear
Deterioration, cracks
Wear
Wear, damage
25 N·m(2.5 kgf·m)
INJECTION NOZZLE
Removal and InstallationTo remove and install the injection nozzle, use socket wrench and
Handle (special tools).
If the nozzle tip gasket is hard to remove because of seizure, use
a gasket pliers (special tool).
NOTE
Cover pipes, injection nozzle, and injection pump to prevent
entry of dust and dirt. If the injection nozzle is removed, pro-
vide adequate means to prevent entry of dust into the cylinder.
1
23
1
2
3
4
5
6
7
8
INJECTION NOZZLE
FL-112 FUEL & ENGINE CONTROL
Insert, while turning a cleaning needle into the injection orifice
of the nozzle to remove carbon. Use first a 0.25 mm-dia. clean-
ing needle and then finish with following:
To remove burnt and hardened carbon.
2. Inspection
Clean and immerse the nozzle in gas oil, slide the needle valve,
and ensure that it moves smoothly.
Next, pull up the needle valve vertically about 1/3 of its entire
stroke and check if it falls under its own weight. If it does not
fall, replace the nozzle.
Nozzle Cleaning Tool
D4AF7002
D4AF7003
D4AF7004
D4AF7005
Cleaning and Inspection
1. Cleaning
After cleaning the nozzle with gas oil, remove carbon deposits
with nozzle cleaning tool (special tool).
Proceed as follows.
Remove the needle valve from the nozzle and clean the needle
valve with the needle valve cleaning wood piece.Needle valvecleaning woodpiece
D4AF
0.26
D4AL(EURO-��)
0.21
D4AE
0.30
D4AL
0.30
D4DA
0.26
D4DB
0.22
FL-113
Reassembly
NOTE
1. Never touch the sliding surfaces of the needle valve by
hand.
2. When replacing the nozzle tip with a new one, remove the
seal peel (synthetic resin film) and move the needle valve
in nozzle in a clean gas oil to completely remove the anti-
rust oil.
Assembly sequcne
8→7→6→5→4→3→2→1
25 to 34 Nm(2.5 to 3.5 kgf·m) <D4AF>29 to 39 Nm(3 to 4 kgf·m)
D4AF1010
Injection pressure21.6 to 22.6 MPa(220 to 230 kgf/cm²)
D4AF1012
Test and Adjustment
1. Injection Pressure
Install a nozzle to the nozzle tester.
Operate the nozzle tester to inject several times. This allows
the tester to be bled of air.
Operate the nozzle tester at the specified speed. Then, vary
shims to obtain the specified injection pressure.
Shim thickness:
0.95 to 1.25 in 0.05 increments
1.275 to 1.775 in 0.025 increments
1.80 to 2.15 in 0.05 increments
A 0.05 variation in shim thickness varies the injection pressure
by 0.49 MPa (5 kgf/cm²).
With a correct shim selected, recheck the injection pressure.
NOTE
Never let yourself exposed directly to the atomized fuel
injected from the nozzle.
1
2
3
456
7
8
INJECTION NOZZLE
FL-114 FUEL & ENGINE CONTROL
When adjusting the pressure with a nozzle tester, check also
for clogged injection orifices, spray condition, and fuel leaks
from the orifices. Replace the nozzle if defective.
Good spray1. Evenly sprayed
from fiveinjection orifices
2. Even and symmetricalPoor soray
Poor
D4AF1013
Test pressure19.6 to 206 MPa(200 to 210 kgf·cm²)
D4AF1012
2. Spray Condition
3. Tighteness test
Mount a nozzle, that has been adjusted to start injection at the
specified pressure, to the nozzle tester and slowly increase
the pressure to the test pressure.
Keeping this condition, check for fuel leaks from the bottom of
the nozzle. The nozzle is in good condition if there is no leak.
Good Good Poor Poor Poor1 2 3 4 5 6
3. Asymetricl4. Branched5. Thin6. Irregular
FL-115
Disassembly, Inspection and Reassembly
34 N·m(3.5 kgf·m)
D4AF1015
D4AF1016
Filter Wrench
D4AF1017
<Spin-on type>
D4AF1018
When removing the spin-on type fuel filter, use Filter Wrench
(special tool).
To install, tighten additional 3/4 to a full turn after the element gas-
ket is seated on the filter head.
NOTE
After installation, run the engine and check for fuel leaks.
FUEL FILTER
Removal and Installation
On the double-cab model, first remove the rear inspection cover.
7.8 to 12 N·m(0.8 to 1.2 kgf·m)
1. Fuel filter head2. Element3. Air plug
Clogging,breakage
Cracks and thread damage
Apply thin coat ofoil when installed
34 N·m(3.5 kgf·m)
<Spin-on type>1. Fuel feed pipe or hose2. Fuel feed or hose3. Fuel filter
1
2
3
<Spin-on type>
1
2
3
FUEL FILTER
FL-116 FUEL & ENGINE CONTROL
Drain plug
CUBFL201
Accelerator control cable
CUBFL032
WATER SEPARATORCAUTION
If the water level ring in the translucent case rises to the level
of the red line marked on the outer circumference of the case,
immedidately loosen the drain plug to discharge water.
It is not necessary to completely remove the drain plug as
water is discharged gradually through the groove of the loos-
ened plug.
NOTE
After draining, tighten firmly the drain plug before bleeding
the fuel system
ENGINE CONTROL
Components
Red line
Throttle Starting switchEngine stop cable
Broken cable,worn covering,damaged bolt
Accelerator switch
Engine stop cable
FL-117
Accelerator Pedal Assembly
Disassembly
Reassembly
Disasembly sequence1. Split pin2. Washer3. Accelerator pedal arm
4. Bushing5. Return spring6. Accelerator lever7. Bushing8. Accelerator switch9. Snap ring
10. Clevis pin11. Accelerator pedal12. Adjusting bolt12. Adjusting bolt13. Lock nut
D4AF0675
Assembly sequence
7→6→5→3→2→1→8 4
12→13→11→10→9
Apply grase toaccelerator pedalarm sliding surface
D4AF0677
Apply grease
Section A-A
Apply grease toinner surface
Apply grease tosliding surface
123 4
5
67
8
9
10
11
1213
4
1
2
3
4
5
6
7
8
9 10
11
1213
ENGINE CONTROL
FL-118 FUEL & ENGINE CONTROL
4. Accelerator pedal stopper
With the starter switch in "ON" position and the adjusting lever
on the engine side in contact with the full stopper, adjust to
obtain clearance of dimension A between the accelerator pedal
and adjusting bolt.
Dimension A
Turn all the way
D4AF0679
Clip
D4AF0680
Nut
D4AF0681
D4AF0682
Installation and Adjustment of Cables
1. Throttle cable
CAUTION
1. This adjustment must be made with the cab tilted down
and also with the tilt steering wheel down.
2. Cables must be routed so they may not be in contact
with the metal edges.
3. Routing radius for each cable must be 150 mm or more.
With the throttle knob turned fully in the direction opposite to
the arrow mark, install the throttle cable to the accelerator pedal
arm or accelerator lever, where the inner cable projects most.
Make sure that the inner cable projects most with the least
engine speed.
2. Accelerator control cable
Turn throttle knob fully in the direction opposite to the arrow
mark and ensure that the accelerator pedal does not move. Fit
the accelerator contol cable to the adjusting lever and fix the
cable end on the engine side with a clip.
NOTE
When installing the accelerator control cable, do not move
the adjusting lever on the engine side.
3. Stop cable
Connect the stop cable ends to the stop lever on the engine
side and that on the starter switch side. With the starter switch
in "ACC" or "LOCK" position and the lever on the engine side
moved to the stop position to bring it in contact with the stopper
bolt, tighten the nut to secure the stop cable. After adjustment,
make sure that the engine stops when the starter switch is
operated.
Lock nutAdjusting bolt
Acceleratorpedal
Stopperbolt
Stop lever
Stop cable
Adjustinglever
Acceleratorcontrol cable
0 to 5 mm
A
FL-119
Airtightness Test for Fuel Tank
Fuel Tank Airtightness Test
Apply soapsuds to the fuel tank surface and feed air 29 kpa (0.3
kgf/cm²) from the air vent tube.
Parts requiring periodic replacement : Fuel hose
CW31-101
Install plug
D4AF0697
Acceleratorpedal arm
D4AF0684
FUEL TANK
Removal and Installation1. Remove fuel from the tank.
2. Remove the fuel gauge unit harness suction pipe and return
pipe.
CAUTION
Keep out of open flame, or explosion will result.
5. Accelerator switch
Place the accelerator switch screw end face in tight contactwith the accelerator pedal arm with the arm in contact withstopper. Then, back off approximately 1-1/4 turns and securewith the nut.Next, turn ON the exhaust brake switch and slowly depressthe accelerator pedal. Make sure that the exhaust brakeoepration indicator lamp in the meter cluster goes of when theengine speed reaches 800 to 950 rpm
When no returnpipe is provided
Connect tubeor the like
Apply air pressure[29 kPa (0.3 kgf/cm²)]
Acceleratorswitch
FUEL TANK
Drain plug15~25N·m(1.5~2.5kgf·m)
Fuel tank
Fuel hose
Sender
Fuel cut-off valve
Bracket assembly
Fuelhose
Recommended