FL(Fuel System)[1]

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)



Camshaft end play

Backlash between control rack and pinion

Tappet roller overall clearance


Wer on lower spring seat surface incontact with plunger

Plunger driving face to control sleeveclearance

Control rack full stroke

Prestroke


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


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


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


D4AL,D4DB(High altitude area)

D4DA(STD, Cold area)

D4DA(High altitude, Tropical area)

D4DB [STD(Standard),

Tropical, Cold area]

D4DA/ D4DB/ D4AL [EURO-��]



Camshaft end play

Tappet rolter overall 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


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


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


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


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


Is injection interval between cylinders correct?

Does feed pump output ratio exist within specification?


Yes

Yes

No

No

Measure fuel injection timing of each cylinder.

Is it regular?

No

Yes



FL-11GENERAL


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)


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







inspection)

• Correct the first injection

pressure as necessary







Yes

No

Yes

No

No

Yes

Yes

No

No

Yes

No

No

Yes

Yes



Does feed pump output ratio exist within specification?


Yes

Yes

No

No

Measure fuel injection timing of each cylinder.

Is it regular?

No

Yes


Repair feed pump or replace

FL-13GENERAL


and repair

Output loss

Is there no air in fuel system?

(Engine is not started after bleeding the 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







inspection)


as necessary







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



Is angular in advance of automatic timer correct?


Yes

Yes

No

No

Is fuel injection ratio between cylinders

regular?

No

Yes



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







inspection)


as necessary





• Is injection ratio of injection pump exceed over

the specification?

No

Yes

No

No

Yes




Yes

Yes

No

No

Is fuel injection ratio between cylinders

regular?

No

Yes



Yes

Yes

No


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?



(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


Knocking noise happens in engine


Yes


Yes


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?



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


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


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.


Camshaft

Tappet

Plunger spring

Pump housing

Control rack

PlungerPlunger barrel

Delivery valve seat

Delivery valve


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


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


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


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


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


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


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


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


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


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


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


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


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


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 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


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


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)


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


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


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


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.


Stopper

INJECTION PUMP


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


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


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


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

Valve gasket


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


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

...........


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


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


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


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


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


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


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


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


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


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


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


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


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


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


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


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


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


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)


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


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


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.



5. Adaptor Screw &



NOTE:

For this setting adjustment, the adaptor screws and

are used together.

FL-97

D431023


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.



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


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


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


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


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


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


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


Time requred before liftingwhen operated at 100 rpm.



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)


No. of strokes requiredbefore lifting when operatedat 60 strokes per minute.


<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


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


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


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


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



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


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


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


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

Documents

FL(Fuel System)[1]