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FUEL & ENGINE CONTROL

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
Items Injection pump proper Turning direction (as viewed from drive side) Plunger Governor Diameter Lead Model, type Type BOSCH AD Clockwise 9.5 mm R.H. 20 + 50
RLD (all speed mechanical)

Specification BOSCH A NB (EP-9) 11.5 35W R801 (all speed mechanical) SBO mechanical Hole (2 spring) Improved NB 11 R901 (all speed mechanical) 0.21 mm 150

Automatic timer Injection nozzle

Model, type Type No. of orifices Orifice diameter Orifice angle Injection pressure Hole (1 spring) 5 0.30 mm 160
21.6 MPa (220 kgf/cm)

SCZ Type, mechanical

0.285 mm 0.26 mm 157 1st : 17.65MPa(18kgf/cm2)


2nd: 21.6MPa(220kgf/cm)

Fuel filter *Water separator

Type Type

*Spin-on filter paper Sediment trap

GENERAL

FL-3

SERVICE STANDARDS
D4AF/ D4AE/ D4AL [EURO-I]
Description Injection pump proper(D4AF) 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 in contact with plunger Squareness Plunger spring Delivery valve spring Camshaft bend (runout) Wear on camshaft surface in contact with oil seal Control rack sliding resistance (Return stroke) Prestroke Injection start interval Tappet clearance Fuel injection timing(BTDC) STD, Cold, Tropical area High altitude area 20 to 21 3.6 0.05 90 30' 0.2 or more 9 12 255 kPa (2.6 kgf/cm) 1.5 N(0.15 kgf) or less 0.02 to 0.06 0.15 [24] 0.03 to 0.07 0.1 0.3 0.2 0.2 0.2 0.02 to 0.08 21 or more 3.6 0.05 90 30' 0.3 or more 10 9 13 Adjust Adjust Adjust Adjust 0.12 Adjust or replace Replace Replace Replace Replace Replace Adjust Adjust Adjust Adjust 1.5 or less 0.5 or less 0.03 to 0.07 Nominal value [Basic diameter] 255 kpa (2.6 kgf/cm) 1.2 N (0.12 kgf) or less 0.03 to 0.05 0.1 Within 0.3 0.2 0.2 2 1 0.15 0.2 Adjust or replace Replace Replace Replace Replace Replace Limit Unit : mm Correction and remarks

Injection pump Overflow valve opening pressure proper Control rack sliding resistance (D4AL, D4AE) (when not rotating) Camshaft end play Backlash between control rack and pinion Tappet roller overall clearance Tappet to pump housing clearance Wer on lower spring seat surface in contact with plunger Plunger driving face to control sleeve clearance Control rack full stroke Prestroke Injection start interval Tappet clearance Fuel injection D4AL timing (BTDC) D4AE(STD, Cold area) (Tropical, high altitude area)

FL-4
Nominal value [Basic diameter] 13.5 to 14.5 29 0.2 Approx. 14 0.5 9.5 to 21 24.5 0.5

FUEL & ENGINE CONTROL


Correction and remarks Adjust Adjust Adjust Adjust Adjust

Description RLD governor Distance between the guide screw top surface and housing end face Distance between governor housing end face and shifter pin hole center Distance between governor cover end face and guide screw end Control rack movement (injection pump) Boost compensator Distance between spacer end face and push rod end B * Idle-up set [On-vehicle: actuator vacuum -47 kPa (-350 mmHg) or below] * Microswitch set [On-vehicle ; actuator vacuum -47 kPa (-350 mmHg) or below] Feed pump D4AF D4AE, D4AL

Limit

950 to 1,000 rpm 2,200 to 2,300 rpm 1,900 to 2,000 rpm 0 cc/min. 25 or less Replace Replace

Airtightness [When 195 kPa (2 kgf/cm) air pressure is applied] Priming pump lift capacity (No. of strokes required before lifting when operated at 60 strokes/min.) Delivery At 600 rpm pressure D4AF D4AL, D4AE Delivery For 1 min. amount at 1,000 rpm through a 1.54 nozzle For 1 min. at 1,000 rpm When operatedat Lift capacity 150 rpm When operated at 100 rpm D4AF

175 to 215 kPa (1.8 to 2.2 kgf.cm) 335 to 410 kPa (3.4 to 4.2 kgf.cm) 900cc or more

Replace

Replace

D4AL, D4AE D4AF D4AL, D4AE

1,620 cc or more 45 sec. or less 40 sec. or less 0.01 to 0.2 Adjust Replace

SCZ automatic timer

Injection pump gear thrust clearance

Injection nozzle injection pressure Engine control Accelerator pedal to adjusting bolt clearance * Accelerator switch operating speed

21.6 to 22.6 MPa 19.6 MPa Adjust (220 to 230 kgf/cm) (200 kgf/cm) 0 to 5 800 to 950 rpm Adjust Adjust

GENERAL

FL-5

TIGHTENING TORQUE [EURO-I]


Description 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 RLD governor Governor housing bolt Governor housing bolt Adjusting lever shaft nut Full load set lever nut U-lever plug Idling screw Governor shaft nut Round nut * Idle-up adjust screw lock nut * Microswitch adjust screw lock nut Automatic timer Round nut Injection pump D4AL, D4AE gear attaching bolt Timer case nut Injection nozzle Nozzle bridge bolt Retaining nut Fuel filter D4AF D4AE, D4AL Fuel feed hose or pipe connector bolt Air vent plug * 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 M16 x 1.5 M8 x 1.25 M10 x 1.25 M8 x 1.25 M6 x 1.0 M4 x 0.7 M15 x 0.5 M14 x 1.5 M8 x 1.25 Thread size O.D. x pitch mm M12 x 1.5 M14 x 1.5 M14 x 1.5 M14 x 1.5 Tightening torque Nm (kgfm) 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) 100 lit. tank 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) 63, 70 lit. tank 1.0 to 1.5 (0.10 to 0.15) 56, 63, 70 lit tank 15 to 25 (1.5 to 2.5) 90 lit. tank Remarks

FL-6 D4DA/ D4DB/ D4AL [EURO]


Nominal value [Basic diameter] 255 kpa (2.6 kgf/cm) 1.2 N (0.12 kgf) or less 0.03 to 0.05 0.03 to 0.07

FUEL & ENGINE CONTROL

Description Injection pump proper (D4DA,D4DB, D4AL EURO- ) Overflow valve opening pressure Control rack sliding resistance (when not rotating) Camshaft end play Tappet rolter overall clearance Tappet to pump housing clearance Wear on lower spring seat surface in contact with plunger Squareness Plunger spring Delivery valve spring Camshaft bend (runout) Wear on camshaft surface in contact with oil seal Control rack sliding resistance (Return stroke) Prestroke Injection start interval Tappet clearance Fuel injection D4AL,D4DB(High altitude area) timing D4DA(STD, Cold area) (BTDC) D4DA(High altitude, Tropical area) D4DB [STD(Standard), Tropical, Cold area] R801,R901 governor Distance between the guide screw top surface and housing end face Distance between governor housing end face and shifter pin hole center Distance between governor cover end face and guide screw end Control rack movement (injection pump) Boost compensator Distance between spacer end face and push rod end B

Limit

Correction and remarks

0.1 within 0.3 0.2 0.2

Adjust or replace Replace Replace Replace Replace Replace

1.5 or less 0.5 or less

2 1 0.15 0.2

20 to 21 3.6 0.05 90 30' 0.2 or more 8 7 9 7 Adjust Adjust Adjust Adjust Adjust Adjust Adjust Adjust Adjust

13.5 to 14.5 29 0.2 Approx. 14 0.5 9.5 to 21 24.5 0.5

GENERAL

FL-7

Description * Idle-up set [On-vehicle: actuator vacuum -47 kPa (-350 mmHg) or below] Feed pump Airtightness [When 195 kPa (2 kgf/cm) air pressure is applied] Priming pump lift capacity (No. of strokes required before lifting when operated at 60 strokes/min.) Delivery At 600 rpm pressure Delivery amount For 1 min. at 1,000 rpm through a 1.54 nozzle D4DA,D4DB D4AL(II) D4DA,D4DB D4AL(II)

Nominal value [Basic diameter] 950 to 1,000 rpm 0 cc/min. 25 or less

Limit

Correction and remarks Replace Replace Replace

175 to 215 kPa (1.8 to 2.2 kgf.cm) 900cc or more

Replace Replace

Lift When operatedat D4DA,D4DB capacity 150 rpm D4AL(II) SBO automatic timer Injection pump gear thrust clearance

40 sec. or less 0.01 to 0.2 mm 1st:17.6(180kgf/cm) 2nd:21.6(220kgf/cm) 0 to 5 mm 800 to 950 rpm

Replace Adjust Adjust Adjust Adjust

Injection nozzle injection pressure Engine control Accelerator pedal to adjusting bolt clearance * Accelerator switch operating speed

FL-8 Tightening Torque [EURO- ]


Description 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 R801,R901 governor Delivery valve holder Screw plug Governor housing bolt Adjusting lever shaft nut Full load set lever nut Idling screw Governor shaft nut Round nut *Idle-up adjust screw lock nut Automatic timer Round nut Injection pump gear attaching bolt Timer case nut Injection nozzle Fuel filter Nozzle bridge bolt Retaining nut Fuel feed hose or pipe connector bolt Air vent plug * 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 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 1.5 M8 x 1.25 Thread size O.D. x pitch mm M14 x 1.5 M14 x 1.5 M14 x 1.5 M14 x 1.5

FUEL & ENGINE CONTROL

Tightening torque Nm (kgfm) 25 (2.5) 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) 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) 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)

Remarks

100 lit. tank 90 lit. tank 63, 70 lit. tank 56, 63, 70 lit tank

GENERAL

FL-9

TROUBLESHOOTING
Fuel Injection Pump
Rough idling

Is idling speed setting normal? (Isnt it too low?) Yes

No

Adjust idling stopper bolt

Is there no air inflow in fuel system? No

Yes

Inspect the faulty cause and repair

Is there no water inflow in fuel system? No

Yes

Drain water from fuel tank, fuel filter, and water separator.

Is there no clogging in fuel filter element and feed pump gauze? No

Yes

Replace fuel filter element or clean gauze.

Isnt injection pump control lever mounting nut loose or missing? No

Yes

Tighten it to the specified value.

Is injection timing of injection pump accurate? Yes

No

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) Yes No

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?

No

Inspect cause of accumulation of rack and repair

FL-10

FUEL & ENGINE CONTROL

Yes

Measure fuel injection timing of each cylinder. Is it regular? Yes

No

Inspect the faulty cause and repair

Is injection interval between cylinders correct? Yes

No

Inspect the faulty cause and repair

Does feed pump output ratio exist within specification?

No

Inspect the faulty cause and repair

GENERAL

FL-11

Hard to start the engine Yes

Is fuel quantity enough? Yes

No

Supply fuel

Is there no air in fuel system? (Engine is not started after bleeding the system) No

Yes

Inspect the following items and repair Loose pipe and connector Feed pump gauze clogged Fuel element clogged Air inflow from feed pump

Yes Is there no water inflow in fuel system? No

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. No

Yes

Repair or replace

Is injection timing of injection pump accurate? Yes

No

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) Yes No

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?

No

Inspect cause of accumulation of rack and repair

FL-12

FUEL & ENGINE CONTROL

Yes

Measure fuel injection timing of each cylinder. Is it regular? Yes

No

Inspect the faulty cause and repair

Is injection interval between cylinders correct? Yes

No

Inspect the faulty cause and repair

Does feed pump output ratio exist within specification?

No

Repair feed pump or replace

GENERAL

FL-13

Output loss Yes Yes

Is there no air in fuel system? (Engine is not started after bleeding the system) No

Inspect the following items and repair Loose pipe and connector Feed pump gauze clogged Fuel element clogged Air inflow from feed pump

Is there no water inflow in fuel system? No

Yes

Drain water from injector pump, fuel filter, fuel tank, and other parts

Is there no sticking or breaking in injection pump overflow valve spring? No

Yes

Replace

Are there no fuel leaks for loose connection and cracks in injection pipes NO

Yes

Repair or replace

Is injection timing of injection pump accurate? Yes

No

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) Yes

No

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? No Inspect cause of accumulation of rack and repair

FL-14

FUEL & ENGINE CONTROL

Yes

Is fuel injection ratio between cylinders regular? Yes

No

Inspect the faulty cause and repair

Is injection interval between cylinders correct? Yes

No

Inspect the faulty cause and repair

Is angular in advance of automatic timer correct?

No

Inspect the faulty cause and repair

GENERAL

FL-15

Excessive smoke in exhaust gas Yes

Is full throttle stopper securely seated onto gavernor control lever? Yes

No

Adjust full throttle stopper bolt

Is injection timing of injection pump accurate? Yes

No

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) Yes No

Correct the first injection pressure as necessary Clean it as necessary and re-check (Replace nozzle tip as necessary)

With injection pump removed, inspect the following item using a pump tester Is injection ratio of injection pump exceed over the specification? Yes

No

Inspect the faulty cause and re-adjust.

Is fuel injection ratio between cylinders regular? Yes

No

Inspect the faulty cause and repair

Is injection interval between cylinders correct? Yes

No

Inspect the faulty cause and repair

Is angular in advance of automatic timer correct?

No

Inspect the faulty cause and repair

FL-16
Knocking noise happens in injection pump surrounding Yes

FUEL & ENGINE CONTROL

Is injection pump connecting part securely connected? Yes

No

Align the timing mark and retighten bolt

Is there no crack and looseness on injection pump and connector? Yes

No

Repair or replace

Is there no abnormal noise in injection pump while rotating engine at low speed?

No

Worn parts surrounding tappet. Disassemble injection pump and replace faulty parts

Knocking noise happens in engine Yes No

Is proper quality of fuel used Yes

Use the specified quality of fuel

Is injection timing of injection pump accurate? Yes

No

Readjust injection timing

With injection pump removed, inspect the following item using a pump tester (Is fuel injection ratio between cylinders regular?) Yes

No

Inspect the faulty cause and repair

Is injection interval between cylinders correct? Yes

No

Inspect the faulty cause and repair

Is angular in advance of automatic timer correct?

No

Inspect the faulty cause and repair

GENERAL
Speed is not smoothly shifted to idle at high speed No

FL-17

From accelerator pedal to governor load control lever, isnt cable clogged? No

Yes

Inspect the faulty part and repair

Isnt load control lever return spring pressed or damaged? No

Yes

Replace return spring

With governor load control lever ring cage disconnected, is load control lever smoothly operating? Yes

No

With injection pump removed, inspect the following item using a pump tester Is injection pump rack smoothly operating? Yes

No

Inspect cause of stiff rack and repair

Inspect cause of stiff governor linkage and repair

Is mounting screw on control pinion securely tightened? Yes

No

Adjust injection pump injection rate and retighten control pinion mounting screw

With injection pump removed, inspect the following item using a pump tester Does the rack move smoothly when pulled by the load control lever?

No

Measure governor idling. If the measured value exceeds the specified value, adjust it

FL-18 Engine control


Excessive accelerator pedal operating effort is required (including unstable pedal return) Yes No

FUEL & ENGINE CONTROL

Is there no rust in pedal arm? No

Clean and apply oil

Is there no rust in cable? No

Yes

Replace

Governor adjusting lever operating resist

Yes

Apply oil to link and shaft

Accelerator control cable broken Yes Yes

Isnt cable end clogged? No

Remove rust and other foreign material

Is cable end installation point vertically correct? Yes

No

Correct

Are cable end and cable vertically correct?

No

Correct or replace

GENERAL
Engine cannot be stopped No Yes

FL-19

Isnt stop cable stretched? No

Adjust

Is stop cable clamp securely tightened? Yes

No

Retighten or replace clamp

Is there no wear in ignition switch cam?

Yes

Replace

Fuel tank
Insufficient fuel supply Yes Yes

Is there no air inflow in fuel tank for cracks in pipes hoses? No

Replace faulty pipes and hoses

Is there no clogging in pipe and hose? No

Yes

Clean or replace

Is there no clogging in bleeder tube? No

Yes

Replace

Is there no water inflow in tank? No

Yes

Remove drain plug and drain water

Is there no clogging in tank by foreign material and rust? No

Yes

Clean

Is there no air inflow in tank due to lack of fuel quantity?

Yes

Supply fuel

FL-20

FUEL & ENGINE CONTROL

DESCRIPTION
Fuel System
Fuel feed pipe

Injection pipe Leak-off hose

Fuel filter

Injection nozzle

Fuel feed pipe Overflow valve

Injection pump

Governor

Feed pump Fuel suction pipe Fuel return pipe Water seperator Fuel tank

EFUMY02A

The fuel system consist of the injection pump assembly (injection pump 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 pump of the injection pump assembly, and then to the fuel filter, injection pump, and injection nozzle. The excess fuel is returned from the injection pump to fuel tank.

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 predetermined stroke to feed fuel under pressure. In so doing, it opens and closes the suction and discharge ports to adjust the fuel injection 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 engine speed.
D4AF0712

Delivery valve holder Stopper Delivery valve spring Delivery valve Delivery valve seat Plunger barrel Plunger Control rack Pump housing Plunger spring

Tappet Camshaft

GENERAL
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 increased until the delivery valve is pushed up against the delivery 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 decreasing the effective stroke. 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.
Suction port

FL-21

a) Bottom b) Starting of c) Pressure d) Completion of dead center compression pressure feed feed (suction) stroke
D4AF2210

Plunger barrel Notch Control rack Pinion Control sleeve Plunger


D4AF2211

FL-22
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 delivery valve is brought back to its original position by the delivery valve spring force to block the fuel passage, thereby preventing back flow of fuel. The delivery valve goes further down until its seat surface is held tight. During this stroke, the fuel is drawn back from the injection pipe side, instantaneously dropping the residual pressure between the delivery valve and nozzle. This draw-back effect improves the end break of an injection from the nozzle and prevents after-injection dripping. A delivery valve stopper is provided on the top of the delivery valve spring. The stopper limits the lift of delivery valve and prevents valve surging during high speed rotation. It also reduces the dead volume between the delivery valve and nozzle, thereby stabilizing the fuel injection rate. 3. Overflow valve The overflow valve, mounted to the top of the pump, stabilizes the fuel temperature in the injection pump and temperature distribution 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.

FUEL & ENGINE CONTROL


Delivery valve spring Delivery valve Valve seat Piston

Injection

a: Retraction stroke Delivery valve seat Completion of injection Completion of (beinginning of retraction retraction) D4AF0713

Spring seat Spring Steel ball

D4AF0714

GENERAL RLD Type Governor [D4AF/D4AE/D4AL (EURO- )]


Supporting lever
Full speed set bolt

FL-23

Adjusting lever

Idling set bolt Floating lever Adjusting lever shaft Control rack

Cancel spring B Start spring Governior spring Guide lever Torque cam Flywheight holder Flyweight Sleeve Idling screw Idling spring Shifter Cancel spring A
D4AF0718

Governor shaft Tension lever

Tension lever shaft

The RLD type governor is an all-speed governor providing smaller lever reaction. 1. Flyweights The flyweight holder is mounted on the injection pump camshaft 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 bearing 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.

FL-24
2. Link

FUEL & ENGINE CONTROL

Control rack

Full speed set bolt

Adjusting lever Idling set bolt Supporting lever


Po

Cancel spring B To increase amount of fuel Ro

Floating lever Start spring Sensor lever Full load set lever Torque cam Cancel spring A Tension lever Flyweight
Qo

Guide lever Governor spring

Idle spring

D4AF1324

The RLD governor link operates as follows to regulate and control 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 putting 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 position 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 becomes fixed to stop the supporting lever at Qb.

Full speed set bolt Cancel spring B Supporting lever Rack connecting link Qb
Ra

Adjusting lever Po Guide lever Floating lever


D4AF2612

GENERAL
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.
To decrease amount of fuel Ra Ra Qa Pa

FL-25

Cancel spring B Ra

L-type lever Qa Qb Supporting lever


D4AF2613

Pa Po

D4AF2614

The governor is so constructed as to allow the lever ratio to become 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 rack moves over a small range. When controlling high speeds with a greater to meet speed variations.
2 1

Adjusting lever
A B

Guide lever

I2 I1

2 1

(Fixed)
Guide lever side ball joint

Lever ratio with adjusting lever at idle position Lever ratio =


2 1

A1 B1
B1 A1

B2 A2

2 1 x = = 1.0 1 2 Lever ratio with adjusting lever at full position Lever ratio = =
2 1

At idling ... Full line At high speed control ... Broken line

A2 B2 = 4.0

D4AF2615

2 2 x 1 1

FL-26
3. Starting the engine With the engine stationary, the flyweights are in closed position and the idling and governor springs remain in the freelength 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 sensor 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 control 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.

FUEL & ENGINE CONTROL


Control rack To increase Cancel amount of fuel spring B Sensor lever Start spring Torque cam Tension lever Idle spring
D4AF1325

Full position

Adjusting lever
Idling position

Adjusting lever shaft Supporting lever Floating lever Guide lever Governor spring

Flyweight

Full position

Adjusting lever Idling position Floating lever Guide lever

Tension lever Idle spring Flywheight


D4AF1326

GENERAL
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 displaces 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.
Sensor lever Full load set lever Torque cam Flywieght Shift Full position

FL-27
Adjusting lever Idling position Supporting lever Floating lever Guide lever Governor spring Governor shaft Tension lever Idle spring

D4AF1327

6. Full speed control With the adjusting lever at full position, the engine speed increases while the fuel injection rates under full load are controlled 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 contacts 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.

Control rack

Full position

Adjusting lever Idling position L-type lever Floating lever Guide lever Governor spring Governor shaft Tension lever

Sensor lever Full load set lever Torque cam

Flywight Idle spring


D4AF1328

7. Stopping the engine Turning the starter switch to "ACC" or "LOCK" with the adjusting lever at idle position causes the stop lever on top of governor 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 position causes the stop device plate to pull the control rack in the direction of smaller fuel delivery.
Return spring Supporting lever

Stop lever Cancel spring B Stop device plate

Stop device plate

Control rack To decrease amount of fuel


D4AF2620

FL-28
This in turn contracts the governor spring. As a result, the control 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".

FUEL & ENGINE CONTROL

8. Boost compensator The boost compensator is a device installed on a turbocharged engine that automatically corrects the fuel injection rate according 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.
Boost compensator
D4AF0719

Lever
Full load set screw Lever Cancel spring

To increase amount of fuel

Push rod A Diaphragm

Sensor lever

U-lever Push rod B Boost pressure Torque cam


D4AF2622

Boost compresator

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.

GENERAL R801, R901 Type Governor [D4DA/D4DB/D4AL (EUROCutaway view of R801 and R901 governor Sliding plate Adaptor screw Nut Full load stopper housing Full load stopper Stop cam Shackle Control rack Floating arm Control lever Damper spring Return spring

FL-29 )]

Stop lever

Connecting bolt Floating arm spring Stopper arm Start spring Guide shaft Screw plug Sliding block Steering lever Adaptor screw Spring seat Adjusting lever shaft Flyweight holder Flyweight Jointing bolt Bellcrank shaft Bearing bolt Slider Supporting lever Supporting shaft
FIG4-1

Cam plate

Flyweight construction When closed Guide sleeve Control spring Flyweight Spring seat Spring inner seat Camshaft Flyweight holder Mechanical governor spring When wide-opened When wide-opened
FIG4-2

When closed

Adjusting nut Idle outer spring Idle inner spring Bellcrank shaft Jointing bolt Guide sleeve Spring seat Jointing bolt Bellcrank shaft

Bearing bolt

FL-30

FUEL & ENGINE CONTROL

FLYWEIGHT ASSEMBLY
Flyweight holder is securely connected to and driven by the pump camshaft. A pair of flyweights are assembled on this flyweight holder in such a way that they can be swung in either direction about the respective bellcrank shafts which are pressed tight in the flyweight holder. The two flyweights are jointed by the jointing bolt, which transfers the movement of the flyweights to the bearing bolt. As shown in Fig.4-2, the flyweights contain a control spring and two idling springs. The spring seat for retaining these springs has two Vsectioned 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.
Slider Floating lever Bearing bolt Damper Camshaft bushing

Round nut
FIG4-3

Supporting lever

Supporting shaft Shackle

FIG4-4

LINKAGE SYSTEM
The bearing bolt is connected via the slider to the supporting lever and the floating lever. The supporting lever pivots about the supporting shaft and floating lever is linked to the supporting shaft so that the rotational motion of the supporting lever is converted to the up and down motion of the floating lever (Fig.4-4). The floating arm and the control lever are assembled to the upper end of the floating lever. This assembly enables then to move, by the action of their floating arm spring and return spring, with the floating lever. The control lever is connected to the control rack by the shackle and the arm, so that the movement of the floating lever is transmitted to the control rack (see also Fig.4-1). The adjusting lever and steering lever are fixed to the adjusting lever shaft. The steering lever's guide shaft moves along a slot in the cam plate, while the sliding block slides in the cylinder of the floating lever. Movement of the adjusting lever, linked by the adjusting lever shaft to the sliding block, causes the sliding block to slide within the floating 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, is used to move the control rack to shut-off position.

Control lever

Control rack Arm

Floating arm

Floating lever

FIG4-5

Guide shaft Floating lever Sliding block Adjusting lever

Cam plate Steering lever

Adjusting lever shaft

FIG4-6

Sliding plate

Full-load stopper

Adaptor screws Stop cam


FIG4-7

GENERAL SCZ Type Automatic Timer


The SCZ type automatic timer, of the mechanical type, varies automatically 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 applied to the flyweights and the timer spring installed length remains the longest. With the enging running at high speeds, the flyweights move outward 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 turning direction while compressing the timer springs, which moves the pump camshaft in the turning direction to advance the injection timing.
Advacing Injection pump gear pin Flyweights Injection pump gear Timer hub pin

FL-31

Timer hub Injection pump Timer spring gear pin

D4AF0735

Flyweight Curved surface on flyweight Timer hub pin Before advance

Advance

D4AF0737

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.

Priming pump Piston Holder Oil seal

Valve Housing

Gauze filter Piston Connector


D4AF0740

FL-32
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 introduce 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.

FUEL & ENGINE CONTROL

Delivery

Suction

F C B

Suction chamber Pressure chamber

D A

Push rod

Suction

Pressure feed

Stop
D4AF0741

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 decreasing the number of washers in the spring.

<Hole type>

Nozzle holder

Washer Spring Nozzle tip Needle valve Retaining nut

D4AF0742

Fuel Filter
Spin-on type fuel filter is replaced as a filter assembly when the element reguires replacement.

<Spin-on type> Fuel filter head Fuel inlet

Fuel outlet Fuel filter Element


D4AF074A

GENERAL 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 water-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 semitransparent case, making it possible to visually check the water quantity.
To feed pump

FL-33

From fuel tank

Water level ring

D4AF3551

ENGINE CONTROL

Throttle button

Throttle cable

Starting switch Accelerator pedal assembly <D4AF,D4AE,D4AL(EURO- )>

Accelerator control cable <D4DA,D4DB,D4AL(EURO- )>

Injection pump assembly

Engine stop cable


D4AF0664

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.

FL-34 Accelerator Pedal Assmbly

FUEL & ENGINE CONTROL


<Pedal depressed>

31-14A

Depressing the acelerator pedal causes the accelerator control cable to move the adjusting lever toward the full throttle position, thus accelerating the engine speed.

<Pedal released>

31-14B

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.

Throttle button Throttle cable

Accelerator pedal

31-14C

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.
Stop lever

D4AF0668

GENERAL

FL-35

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 allows air to go into the tank, and fuel gauge unit which allows the driver to know the fuel level.

Baffle plate
31-15

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 atmospheric pressure.

Outside air

Breather tube To engine Main pipe

D4AF0688

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.

Fuel tank Fuel guage

Fuel guage unit


D4AF0689

FL-36

FUEL & ENGINE CONTROL

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 can adversely 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 PUMP
BOSH A TYPE

2 6

3 7 4

1. 2. 3. 4. 5. 6. 7. 8.

Injection pipe Fuel suction hose Fuel suction pipe Oil pipe Fuel feed pipe Fuel feed pipe Fuel return pipe Injection pump
EFUMY01A

Removal
Hold 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.
Socket Wrench

D4AF0752

INJECTION PUMP Disassembly [D4AF/D4AE/D4AL(EURO- )]

FL-37

13 14 Deterioration 15

12

Wear, damage 16 Wear, flaws 17 Overflow valve opening pressure NV 255 kPa (2.6 kgf/cm) 19 7

* Sliding resistance (stationary) NV 1.2N (0.12 kgf) or less

20 Bend * Backlash between rack and pinion NV 0.15 mm L 0.25 mm 1

18

3 21 Cracks, damage 11 4 * End play NV 0.03 to 0.05 mm L 0.1 mm 10 9 8 Deterioration 6 Wear 5 2 Disassembly sequence 1 Cover plate 2. Screw plug 3 Bearing cover 4 Camshaft 5 Tappet 6 Lower spring seat 7 Pluger 8. Plunger spring 10. Control sleeve 11. Control pinion NV ... Nominal Value L ... Limit

12 13 14 15 16

17. 18. 19. 20. 21.

Lock plate Delivery valve holder Stopper Delivery valve spring Delivery valve Plunger barrel Control rack cover Rack guide screw Control rack Pump housing

For disassembly of parts with an encircled number, see following pages. Inspection itmes marked with * must be checked before disassembly. NOTE 1. Kep disassembled parts neatly arranced for each cylinder. 2. Keep plunger, plunger barrel, and delivery valve in gas oil.
D4AF0753

FL-38
1. With the automatic timer removed, install the injection pump on Pump Mounting Base and Pump Setting Angle (special tools).

FUEL & ENGINE CONTROL

Pump Setting Angle

Pump Mounting Base


D4AF0754

2. Using box wrench (special tool), remove the feed pump. 3. Remove the governor.

Box Wrench

D4AF0755

4. Measure the control rack sliding resistance. Turn camshaft to ensure that the resistance is up to specification in an position. If the nominal value is exceeded, possible causes are as follows: o o o Damage on control rack and defective tooth Defective pinion tooth, pinion in contact with housing Excessively tightened delivery valve holder
D4AF0756

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.
Coupling and round Nut

Tappet Insert

Tappet Insert Holding Wrench

D4AF0757

6. Mount camshaft clearance gauge (special tool) on the camshaft to mesure the end play.
Angle scale 1/100

Camshaft Clearance Gauge

D4AF0758

INJECTION PUMP
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 contact with the tappet. 2. Install the flyweight round nut at the end of camshaft to protect threads.

FL-39

D4AF0759

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.

Tappet Insert Roller Clamp

D4AF0760

Tappet Clamp

D4AF0761

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.

Plunger Notch Lower spring seat

Plunger Clamp
D4AF0762

10. Remove the lock plate and remove the delivery valve holder with Box Wrench (special tool). Then, remove the stopper, delivery valve, and spring.

Box Wrench

D4AF0763

FL-40
11. Using Delivery Valve Extractor (special tool), remove the delivery valve.

FUEL & ENGINE CONTROL

Delivery Valve Extractor

Delivery valve

D4AF0764

12. Remove the plunger barrel. NOTE Keep a plunger and plunger barrel pair in gas oil.

D4AF0765

Inspection and Correction

Squareness NV 0.5 or less L 1

Sliding condition

Airtightness, wear Bend (Rouout) L 0.15

Use Reaming Cutter to correct pump housing damage, or replace.

Wear on surface contact with oil seal L 0.2

Squarenes NV 1.5 or less L 0.2

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 contact with plunger L 0.2 Unit : mm

NV ... Nominal Value L ... Limit


D4AF0766

INJECTION PUMP
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 o Tilt the plunger barrel approximately 60. Pull the plunger about 10 to 15 mm and let it go.
10 to 15 60

FL-41

o Turn the plunger to check on several more points. Replace the plunger if it does not fall. 2. Delivery valve Clean the valve and valve seat of the delivery valve in gas oil and check for wear. Seal off the bottom of the valve seat with a finger, and press the piston with a finger. If the piston bounces back when released, the valve is in good condition. If not, replace the valve as it must be badly worn. NOTE With the engine provided with the Ungleich cut, the above procedure is not effective since the piston does not spring back. 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.
Roller Roller bushing

D4AF1584

D4AF0767

Dial gauge

Rod
D4AF0768

Measure the clearance between the tappet and pump housing and, if the limit is exceeded, replace parts.

D4AF0769

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.

Wear

D4AF0770

FL-42
5. Plunger spring and delivery valve spring Measure the squareness of the springs and, if the measurement over the limit, replace it.

FUEL & ENGINE CONTROL

Squareness

D4AF0771

6. Replacement of taper roller bearing To remove the inner race from the camshaft, use a gear puller.

Puller

Shims

Adjusting ring
D4AF0772

To remove the outer race on the cover end, use Camshaft Outer Race remover (special tool). Install by using a press.

Camshaft Outer Race Remover


D4AF0773

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.

D4AF0774

INJECTION PUMP Reassembly

FL-43

13 14 15

12 7.8 to 11 Nm (0.8 to 1.1 kgfm) Ensure pump housing locating notch is aligned with pluger barrel knock pin at 21 installation.

16 17

Sliding resistance (when stationary) NV 1.2 N (0.12 kgf) or less 20 Backlash between rack and pinion NV 0.15 mm L 0.25 mm

19

18 1 End play NV 0.03 or 0.05 mm L 0.1 mm 3 4

29 to 39 Nm (3 to 4 kgfm) Face line marking toward timer 11 10 9 8 With control rack set at center, install pinion with its ends facing toward cover plate

7 6 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. 5 2 54 to 74 Nm (5.5 to 7.5 kgfm)
D4AF075C

FL-44
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.

FUEL & ENGINE CONTROL


Control rack

D4AF0775

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).
Delivery Valve Gasket Installer
Knock pin Knock pin
D4AF0776

Pump housing

Plunger barrel Locating notch

D4AF0777

4. Fit the delivery valve spring and stopper into position, and temporarily tighten the delivery valve holer.

Delivery valve holder Stopper Delivery valve spring

D4AF0778

5. With the control rack set at the center, install the control pinion and control sleeve.

Face control pinion joint upward

Equalize the amount of movement to left with that to right

Control pinion

Control sleeve

D4AF0779

INJECTION PUMP
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 number marking faces upward.
Lower spring seat

FL-45
Notch Part number

Plunger clamp

D4AF0780

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.

Tappet Clamp

D4AF0761

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.

Tappet Insert Tappet Insert Shim

Roller Calmp

D4AF076B

9. Tighten the delivery valve holder to the specified torque. Check also the control rack for sliding condition each time the holder is tightened.

Torque wrench

D4AF0781

FL-46
10. Install the camshaft with the marking line at the end of its threads facing toward the drive end.

FUEL & ENGINE CONTROL

Marking line
D4AF0782

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. 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 camshaft in any position. 13. Install governor 14. Install the following parts after adjusting the injection pump: o o o o Control rack cover Feed pump Cover plate Automatic timer
D4AF0756

Bearing Shims

Adjust ring
D4AF0783

INJECTION PUMP Adjustment after Reassembly

FL-47

Prestroke NV 3.6 0.05

Fuel injection start interval NV 90 30'

Control rack sliding resistance NV 20 to 21 (Return stroke o rack when it is pushed all the way and released)

NOTE Feed oil into the injection pump cam chamber.

Tappet clearance NV 0.2 mm or more NV ... Nominal Value


D4AF0784

Injection Rate Adjustment Standards For fuel injection rate adjustment standard, see Service Bulletin separately published.

1. Preparation With the automatic timer removed, install Coupling and Round Nut (special too) and set a tester on the injection pump.

Coupling and Round Nut


D4AF0785

Remove the control rack cover and install Rack Position Measuring 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).

Rack Position Measuring Device

D4AF0786

FL-48
Remove the delivery valve spring and stopper from the delivery valve holder. Feed the engine oil into the injection pump and bleed fuel.

FUEL & ENGINE CONTROL


Stopper Delivery valve spring

D4AF0787

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 return stroke is within specification.

D4AF0786

3. Measurement of prestroke Fix the control rack position at 21mm and set Prestroke Measuring Device (special tool) on the tappet guide of no.1 cylinder. With No.1 cylinder plunger placed at BDC, feed fuel under pressure 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.
Prestroke Measuring Device
D4AF3425

Slowly turn the tester coupling until the fuel stops flowing out of the overflow pipe (static injection starts).

Fuel being sent under pressure (pulger at BDC) D4AF3426

Static injection starts

D4AF3427

INJECTION PUMP
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.
Prestroke

FL-49

D4AF3428

4. Adjustment of prestroke With the tappet at TDC, insert Spring Holder (special tool) between 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 adjustment. Injection sequence : 1 3 4 2

Spring Holder

Adjusting shgims

D4AF0788

Angle scale

D4AF0789

6. Measurement of tappet clearance Intall Prestroke Measuring Device (special tool) and turn the camshaft to bring the tappet to TDC. Using Tappet Clearance Bar (special tool), push up the tappet and measure the lift until the plunger flange top surface comes in contact with the plunger barrel. If the tappet clearance is out of specification, adjust within the allowable limit of the fuel injection start intervals. If adjustment is not possible within the limit, readjust with the No.1 cylinder prestroke at the maximum nominal value. 7. Adjustment of fuel injection rate Measure the fuel injection rate and uneven ratio with the specified rack position and speed. If the injection rate is out of specification, adjust as follows. o Slightly back of the pinion clamp screw. o o With the control rack fixed at a position, turn the control sleeve with the adjusting rod. Tighten the pinion clamp screw.

Tappet Clearance Bar

Clearance
D4AF0790

Prestroke Measuring Device

Decrease Increase

D4AF3472

FL-50
NOTE 1. Use special care to make the correct adjustment. Improper or failure of adjustment greatly affects engine performance. 2. Observe measurement conditions strictly, as the fuel injection rate varies with differen nozzle and pipe 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 injection rate adaptable to the enigne. 9. Inspection of Fuel and Oil leaks o Check the delivery valve mounting position and other parts o for fuel leak. Check oil seals and other parts for oil leak.

FUEL & ENGINE CONTROL

10. Inspection of Unusual Conditions Check 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 Pointer

Pointer

D4AF1253

2. Line up the the marking on the timer case with the notch in the injection pump gear.
Notch

Marking

D4AF0791

INJECTION PUMP
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.

FL-51

Guide bar Guide hole


D4AF0793

4. Make sure that the alignemt mark of the injection pump gear is aligned with that of the timer case. Then, push in the injection pump. At the time, the alignment mark on the gear moves to the end of that on the timer case.

Notch in injection pump gear

Timer case alignment mark

D4AF0794

5. Fix the injection pump to the timing gear case using the Socket Wrench (special tool).
Socket Wrench

D4AF0752

6. Mount the injection pump rear bracket.

Injection pump bracket

D4AF0795

FL-52

FUEL & ENGINE CONTROL

7. Install the fuel hoses, fuel pipes and injection pipes and tighten eye bolts to specified torque.

Injection pipe

Fuel filter 25 to 34 Nm (2.5 to 3.5 kgfm) 25 to 34 Nm (2.5 to 3.5 kgfm) Fuel feed pipe 25 Nm (2.5 kgfm)

Fuel hose

Fuel feed pipe


25 Nm (2.5 kgfm) Overflow valve 20 to 25 Nm (2 to 2.5 kgfm) 20 to 25 Nm (2 to 2.5 kgfm)

20 to 29 Nm (2 to 3 kgfm)

Fuel return pipe


7.8 to 15 Nm (0.8 to 1.5 kgfm) Oil pipe 7.8 to 15 Nm (0.8 to 1.5 kgfm)

Fuel section pipe

EFUMY01A

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.

Priming pump

D4AF0558

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 pump down and turn it clockwise until it fits into position. Then, tighten the air plug. NOTE 1. 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. NOTE Do not operate the starter for more than 15 seconds.
Air plug
D4AF0559

INJECTION PUMP 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 contamination by dust and dirt. 2. Keep the ignition switch at ON and release the governor stop lever.
Stopper Delivery valve spring

FL-53

Injection Pipe

Delivery valve holder

D4AF0796

2. Install a spare injection pipe to No.1 cylinder. Face the other end of the pipe downward for easier observation of fuel flow out condition. 3. Crank the engine to bring the piston in No.1 cylinder at a position 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 normal 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.
D4AF0798

D4AF0797

FL-54
6. Make sure that the crankshaft pulley marker line and pointer indicate the correct fuel injection timing. Fuel injection timing (BTDC):
Area General (standard) Cold Tropical High atitude D4AF D4AE 9 9 9 12 9 9 13 13
Pointer

FUEL & ENGINE CONTROL

D4AL
EURO10 10 10 10 EURO8 8 8 -

D4DA D4DB 7 7 9 9 7 7 7 8
Cranking Handle

If the timing is out of specification, adjust as follows.

Pointer
D4AF1253

To advance To retard

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.

Crankcase

Injection pump

D4AF0799

8. Loosen the injection pump attaching nut with universal Extension (special tool).
Universal Extension

D4AF0800

9. Move the injection pump to the desired direction. A shift of one graduation of the adjustment marker varies the injection timing by 6.

Adjustment mark Pointer


D4AF0801

INJECTION PUMP
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 o Remove only the injection pipe and keep a small amount of fuel remaining at the top of delivery valve holder. Crank the engine to bring the piston in No.1 cylinder to position about BTDC 30C on the compression stroke. Further crank the engine slowly, and the fuel on top of the o delivery valve will begin to move. 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 adjustable range of the injection pump, the engine timing gear and injection pump gear are not probably in proper mesh. In this case, remove the injection pump and reinstall it.
39 to 44 Nm (4.0 to 4.5 kgfm)

FL-55

7.8 to 11 Nm (0.8 to 1.1 kgfm)


D4AF0802

FL-56

FUEL & ENGINE CONTROL

NB(EP-9) TYPE INJECTION PUMP [D4DA/D4DB/D4AL(EURODisassembling


CAUTIONS 1. Wash outside of the pump. 2. Measure and keep record of the fuel delivery characteristics of the pump before disassembling it. When the pump smoothly runs mechanically but contains otherwise misadjusted or malfunctioning parts, the problem can be identified by comparing the fuel delivery characteristics before and after disassembling the pump. 3. Check each part as it is disassembled for the way it was installed, any deformation, broken part, roughness or scratches. 4. Keep parts in groups for each cylinder in an orderly manner. Parts to be renewed and parts to be used again must be kept separately. 5. Each part of the injection pump, especially the pump element and the delivery valve, must be handled most carefully to protect them from damages. 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). 3) Put the 85 mm I.D. ring (SST) around the bearing cover of the injection pump. Fix the injection pump securely at the bearing cover to the pump mounting flange (SST) using two bolts (M10 x 1.5). 4) Remover the feed pump and tilt the pump body to drain lubricating oil from the pump cam chamber. 5) Remove the governor. (This instruction varies by the type of governor used. See appropriate manual of the governor installed). 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 secure it with the fixtures (SST).

)]

Pump mounting flange

DR0503

Governor

Ring

Feed pump
DR0504

Pump holding bracket

Pump holding fixture

DR0505

INJECTION PUMP
3) Remove the feed pump and tilt the pump body to drain lubricating 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).
Feed pump Timer

FL-57

Governor

DR0506

4. Removal of delivery valve holder 1) Remove the nut that is fastening the cylinder.

DR0507

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.

Handle 1 to 2mm approximately Washer Guide

DR0508

3) Turn the SST handle clockwise into the delivery valve holder. Continue until the O-ring in the cylinder comes off the pump housing.

Turn clockwise

Cylinder O-ring

DR0509

4) Pull the delivery valve holder remover (SST) upward to remove the delivery valve group.

Deliver valve holder remover Deliver valve group

DR0510

FL-58
5. Remove the rack guide screw

FUEL & ENGINE CONTROL

DR0511

6. Removal of control sleeve 1) 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. NOTE The sleeve is difficult to remove when the camshaft of the cylinder is at its top dead point.

Control sleeve remover(SST)

DR0512

CAUTION Be extremely careful not to damage the plunger. 7. Remove the control rack

DR0513

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 either 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.

Plunger Lower spring foot seat hole

Lower spring seat

DR0514

INJECTION PUMP
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.

FL-59

Spring compression tool

DR0515

2) Position the guide lever of the spring compression tool (SST) toward you (in parallel to the handle), and put the projected 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.
Handle

SST
Projected part of the spring seat Stopper pin

Guide lever

Plunger spring
DR0516

Guide lever

90

DR0517

10. Remove the upper spring seat, and the plunger spring

Upper spring seat

Plunger spring

DR0518

11. Remove the lower spring seat using the tweezers (SST)
Tweezers Lower spring seat

DR0519

FL-60
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.

FUEL & ENGINE CONTROL

Camshaft

Tappet

DR0520

13. Removal of camshaft 1) Remove the two set screws (49) of the center bearing.

DR0521

2) Remove the four bolts (33) fastening the bearing cover (28), tap the camshaft with a wooden hammer from the governor 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.

Camshaft Bearing cover

DR0522

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 delivery valve holder.
Setting support

DR0523

2) Then, remove parts.

Delivery valve holder O-ring Washer Valve spring Delivery valve Valve gasket Delivery valve holder O-ring

DR0524

INJECTION PUMP
15. Removal of bearing 1) Pull out the roller and the inner race using the bearing remover.
Bearing remover

FL-61

DR0525

2) Use the guide, to remove the bearing at the governor side (20f).
Guide Bearing extractor

DR0526

3) Use the outer race puller (SST), to tap out the outer race in the bearing cover.

Outer race puller Bearing cover

DR0527

INSPECTION OF PARTS
Each 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 element 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.
DR0528

Plunger (pulled up by 10 to 15 mm approximately) 60 approximately

FL-62
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. 3. Tappet 1) 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. 3) Check the plunger contact surface for wear. Limit of wear ............................................... 0.2 mm REMEDY If the limit of wear is exceeded, replace.

FUEL & ENGINE CONTROL

Seat face Valve Relief valve Delivery valve Valve seat


DR0016

Tappet roller Roller bushing Roller pin

DR0529

0.2mm max.

Measure wear with a dial gauge and replace if the limit of wear is exceded

DR0530

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.

Key groove

Key groove

Oil seal contact surface


DR0531

INJECTION PUMP
3) Put the camshaft on two V-blocks as illustrated, and measure 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.
V-block

FL-63

DR0532

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. 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 Lshaped ruler, as illustrated. Allowable limit ........... 2 mm for plunger spring. 1 mm for delivery valve spring REMEDY If the allowable limit is exceeded, replace. 8. Delivery valve holder Check the holder for scratch on the surfaces that receive the high-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.
DC05085

DR0533

FL-64

FUEL & ENGINE CONTROL

REASSEMBLING
CAUTIONS 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. 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 Bearing driving tool Outer race

DA3053

CAUTION Put a round nut to the thread at the other end of the camshaft to protect the thread.
SST

Shim

Adjusting ring

Round nut

DR0535

2. Camshaft Put the center bearing on the camshaft, insert the camshaft into the pump housing, and tighten the center bearing in position 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 number (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
Camshaft Center bearing

DR0536

DR0521

INJECTION PUMP
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.

FL-65
Guide rail

DR0537

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
Guide rail
DR0538

3) If the specification is not met, use appropriate shim plates at the governor side until the specification is met.
Guide rail

DR0539

5. Measuring the camshaft clearance Shim plate thickness Part number 090194-0070 090194-0080 090194-0090 090194-0100 Thickness (mm) 0.1 0.15 0.3 0.5

Shim plate
DR0540

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

Camshaft clearance gauge

Guide

DR0541

FL-66

FUEL & ENGINE CONTROL

Camshaft clearance gauge

Guide

DR0542

2) If the specification is not met, use appropriate shim plates at the drive side until the specification is met. Shim plate thickness Part number 090194-0300 090194-0310 090194-0320 090194-0330 Thickness (mm) 0.1 0.15 0.3 0.5
Bearing cover

Shim plate
DR0543

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.

Cir-clip pliers

Tappet

DR0520

7. Lower spring seat Install the lower spring seat using the tweezers. CAUTION Be sure that the flange of the lower spring seat is accurately inside the groove of the tappet. This is very important since and inaccurately positioned seat may cause damage to the pump.

Lower spring seat

DR0544

8. Install the plunger spring


Plunger spring

DR0545

INJECTION PUMP
9. Upper spring seat 1) Insert the upper spring seat with the projected part of the seat coming at the drive side.
Projected part

FL-67

DR0546

2) Attach the upper spring extractor (SST), and place the guide groove on the extractor at the projected part of the upper spring seat.

Guide

Projected part of the upper spring seat Position the projected part in the guide groove.
DR0547

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 inside the pump housing. CAUTIONS 1. Bring the cam of the cylinder at its bottom dead center. 2. For each cylinder worked, check that the spring is accurately 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). 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 clockwise by 90. CAUTIONS 1. When the plunger has only one lead, be sure that the vertical groove faces the spill side. This is very important 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.

Depress the handle

Extractor Housing
Turn 90 Guide groove

Stopper pin

Plunger spring
DR0548

Toward the rack

Projected part Upper spring seat Stopper pin

Pump housing

Plunger spring
DR0549

FL-68
NOTE The plunger can be installed more easily if the cam of the cylinder is at its top dead center.

FUEL & ENGINE CONTROL


Plunger foot

Lower spring seat hole

Lower spring seat

DR0514

11. Control sleeve 1) Insert the control rack.


Control sleeve

Control rack

DR0550

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.

Control rack Housing Control sleeve Upper spring seat Stopper pin

DR0551

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. CAUTIONS The plunger may slip out of its position during installing 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.

Control rack

Plunager

Upper spring seat Control sleeve Plunager spring

DR0552

INJECTION PUMP
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.
O-ring(b) O-ring(c) O-ring(a)

FL-69

Valve holder Shim Valve spring O-ring

Delivery valve Valve gasket

Cylinder

DR0553

2) Secure the pump setting support (SST) in a vice, put the delivery valve group in the support, and tighten the delivery valve holder to the delivery valve group using the torque wrench to the specified torque. Tightening torque ............ .................... 8 to 10 kg-m

Torque wrench

Box

Setting support
DR0554

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 control 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

Marked line

DR05a55

Shim

DR0556

FL-70
2) Put shims under the flange of the cylinder. CAUTIONS 1. Put two counterparts of a shim of the same thickness at sides of each cylinder. Use only one piece on each side. This is very important since, it counterparts 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.
2.5

FUEL & ENGINE CONTROL

Marked thickness(x100)

DR0557

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

DR0558

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 sliding resistance (g) 100 mx.
DR0559

GOVERNOR

FL-71

RLD TYPE GOVERNOR [D4AF/D4AE/D4AL (EURO-I)] Disassembly

1 19 15 18 17 16 10 23 9 8 7 3 40 45 39 38 37 Dimension between guide screw upper end and housing end NV 13.5 to 14.5 29 27 36 26 28 NV ... Nominal Value 25 Disassembly sequence 1 Boost compensator assembly 2. Push rod B 3. Spacer 4 Idling screw 5 Idle spring 6 Governor cover 7 Governor spring 8 Spring seat 9 Governor shaft 10. Rack connecting link 11. Sensor lever 12. Full load set lever 13. U-lever 14. Full load lever shaft 15. Stop lever shaft assembly 6 35 34 43 42 2 44

46

41

22

11

21

31 20 30 32

14 12

13 33 24

5 4

16. 17. 18. 19. 20 21 22. 23. 24. 25. 26. 27. 28 29. 30.

Stop device lever Supporting lever Shim Stop lever Round nut Flyweight assembly Governor housing Start spring Rod Lock screw Plug Cancel spring Tension lever shaft Tension lever shaft assembly Sleeve

31. 32. 33. 34. 35. 36. 37. 38. 39. 40 41. 42. 43. 44. 45. 46

Shifter Shim Torque cam Adjusting lever Adjusting lever section Guide lever Floating lever Supporting lever Adjusting lever shaft Disc Cover Diaphragm Push rod A Boost compensator spring Housing Guide screw

For disassembly of parts with an encircled number, see following pages. NOTE 1. Item numbers 24, 25 and 34 to 39 are not to be disassembled normally. 2. Item number 26 Plug, cannot be reused.
D4AF0873

FL-72
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.
Timer

FUEL & ENGINE CONTROL

Automatic timer

Feed pump

Case

Cover plate

D4AF0719

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.

Boost

D4AF0876

Using Extractor (special tool), lock the camshaft against rotation and remove the round nut using Special Wrench (special tool).

compensator

Governor cover
D4AF3520

6. Using Extractor (special tool), remove the flyweights together with the key.
Extractor

D4AF0877

7. Using Special Wrench (special tool), remove the idling screw and remove the idling spring from the front of the governor cover.

Special Wrench

Extractor Idling spring Idling screw Special Wrench


D4AF3496

GOVERNOR
8. Remove the governor shaft nut using Special Wrench (special tool) and remove the governor shaft, spring seat and governor spring.
Governor shaft Governor spring

FL-73

Spring seat

Special Wrench
D4AF3497

9. Remove the tension lever shaft, applying a rod and striking it.
Rod

D4AF3499

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.

D4AF0879

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.)

D4AF0880

12. Using Special Wrench (special tool), loosen the lock nut to adjust the tightening amount at replacement of parts or adjustment of boost compensator.

Special Wrench

D4AF0881

FL-74 Inspection and Reassembly

FUEL & ENGINE CONTROL

3 19 15 18 17 16 10 23 9 8 7 38 37 39 40 45 35 34 43 42 2 44

46

41

22

32 11 21 20 30

31

29 14 12 13 33 49 to 59 Nm (5 to 6 kgfm) Dimension between governor housing end and center of pin hole in shifter NV 390.2 24

27 26

36 5 28 4

Stake Apply adhesive to cover

25

Assembly sequence 15 (19 18 17 16) 13 11 14 12 10 23 9 8 7 28 27 26 24 25 33 21 20 30 32 31 34 36 35 (39 38 37) 2 42 43 44 40 45 41 46 22

5 4 29 6 3 1

For reassembly of parts with an encircled number, see following pages.


D4AF087F

GOVERNOR
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.

FL-75

Spring support Governor

housing Pump housing 15 to 18 Nm (1.5 to 1.8kgfm)


D4AF3522

2. Install the flyweight and using Special Wrench (special tool), tighten the round nut to specified torque.
Extractor

Special Wrench 49 to 59 Nm (5 to 6 kgfm)


D4AF352D

3. Install the U-lever assembly and spring and tighten the plug to specified torque.

Plug

Spring U-lever

20 to 29 Nm (2 to 3 kgfm)

D4AF351B

4. Install the spring and full load set lever to the full load lever and tighten the nut to specified torque.

9.8 to 14 Nm (1 to 1.4 kgfm) Full load set lever

Full load lever Spring


D4AF3513

5. Install he start spring to the rack connecting link. NOTE Insert the hooked end of the start spring to the connecting link from above.

Start spring Hook

Rack connecting link

D4AF1566

FL-76
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 (seating surface with governor cover) and the shifter pin hole center. Install the shifter assembly to the tension lever. Adjusting shim thickness: 0.2, 0.3, 0.4, 0.5, 1.0, 1.5 7. Assemble the spring seat and spring to the governor shaft and install the assembly to the tension lever. Tighten the nut from the governor cover front using Special Wrench (special tool).

FUEL & ENGINE CONTROL

Adjusting shim

L1=29+0.2

D4AF0883

Governor shaft

Spring seat Spring

Governor shaft Governor spring

Spring seat

Special Wrench
D4AF3529

8. Install the idling spring and using Special Wrench (special tool), tighten the idling screw.

Idling spring Idling screw

Special Wrench

D4AF3496

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.

D4AF3530

GOVERNOR
10. After the governor cover has been installed, slack the governor 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)

FL-77

Adjustment after Reassembly Governor performanace Curves


<Standard>
Rack limit R6/N6

R10 R1 N11 R3 R2 R4

R7

Rack position

R8/N8

R9

R5

N10 N1

N3 N2 N4 N5 Pump speed
D4AF0885

N7 N9

FL-78 Adjsutment for Adaptation to Engine

FUEL & ENGINE CONTROL

Adjusting lever angle Idling set bolt Stopper bolt 2 Idle Full speed set bolt

Full load set lever Full load set bolt

Full

Governor spring adjustment Idling spring adjustment 1 Standard Option 42 3 42 3 2 26 3 26 5


D4AF4409

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 connecting hole. With the handle loosened, turn the lever and make sure that the control rack slides smoothly.

Align this surface

Stand

Square

Lever Adjusting nut Handle Pin Pin Ajusting nut Supporter Stand Adjusting Device

Adjusting lever Adjusting lever shaft

D4AF4442

GOVERNOR
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. NOTE Turning the injection pump at the speed specified above is extremely important. Failure to do so does not allow obtaining he 0 position even with the control pinion pushed hard and can damage governor linkage. Control Rack Locking o With the adjusting lever at idle position, increase the pump speed up to 500 to 600 rpm. Then, move the adjusting lever to the full speed position. Next, set the control rack at full load position plus approx. 3 mm with the full load set bolt. Under these conditions and with the rack fixed at the specified position, make required adjustments. Before moving the adjusting lever to full speed position, make sure that the pump speed is increased to 500 to 600 rpm with the lever at idle position. The torque cam adjusting nut must be locked in position with the lock screw.
Measuring Device

FL-79

D4AF0822

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.
D4AF4449

Idling set bolt

Then, read the adjusting device dial to ensure that the adjusting lever angle is within the specified range. Idling Spring Adjustment
Rack position

R1 R2 R3 R4 R5

N1 N2N3 N4 Pump speed

N5
D4AF0884

FL-80
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.

FUEL & ENGINE CONTROL

D4AF0889

If the control rack position is not R3, adjust with adjusting shim. <Types of shim> 0.1, 0.2, 0.25, 1.0
Idling screw

Outer spring

Inner spring Adjusting shim D4AF3800

After adjustment, tighten the idling screw to specified torque using Special Wrench (special tool).

9.8 to 15 Nm (1 to 1.5 kgfm)

Special Wrench

D4AF3802

Governor Spring Contact adjustment Set the adjusting lever in contact with the idling set bolt and adjust the governor shaft so that the rack position becomes R5 when the pump speed is N . Then, secure the shaft with lock nut. Under this condition, decrease the pump speed to ensure that the speed is N4 when rack position is up o R4. Then, increase the pump speed and ensure that the rack reaches 0. If these specifications are not met, replace the governor spring. After adjustment, tighten the lock nut to specified torque using Special Wrench (special tool).

D4AF0890

Special Wrench

9.8 to 15 Nm (1 to 1.5 kgfm)


D4AF3801

GOVERNOR
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.
Idling set bolt

FL-81

D4AF4449

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.
Full load set lever
D4AF0891

Adjust tightening of full load set bolt so that the rack position becomes R6 when pump speed is kept at N6 with the full load
Rack position

Back off R6 Screw in

set lever at full load position.

N6 Pump speed

N7
D4AF0892

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 N8. 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.

Special Wrench

D4AF0893

If the rack psotiion varies, it means that the torque cam is improperly 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.
Rack position

R8 R6

N6

N8
D4AF0894

Pump speed

FL-82
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
Rack position

FUEL & ENGINE CONTROL

Idling set bolt

D4AF4449

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.

R6 R9

Pump speed

N7 N9
D4AF0895

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.

D4AF0896

Push Rod B Projection Check With the specified rack position obtained, ensure that the dimension L (240.5 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 established 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
Rack position

Spacer

Push rod B

D4AF0897

with a smaller dimenter (5). Boost compensator Activating Point Adjustment Adjust with the screw A so that the oost compensator is activated at Pa. After adjustment, secure with the alock nut. NOTE Do not turn screw A more than four turns from the fully loosened position.

Rb Boost compensator stroke

Ra Pa Pb

Boost pressure

D4AF0898

GOVERNOR
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.
Screw A

FL-83

Screw B

24 0.5

D4AF0899

Ensure that the specified rack position ra is obtained with a boost pressure of Pa. Make also sure that the rack is positioned at Rb when the boost pressure is Pb. NOTE When making the adjustment, raise the boost pressure, and never decrease.
Rb Ra

When boost pressure is applied

Rack position

Boost compensator Boost pressure 0 strok

Pump speed

D4AF0900

Rack position

6. Smoke set assembly operating limit check Set the pump speed slightly above idle N2 and lock the adjusting 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 when the adjusting lever is placed in the full position. NOTE Decreasing the pump speed with the adjusting lever at full position does not permit obtaining the smoke set rack position 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.

Rack limit R1 R2

N2 Pump speed
D4AF091A

R10
Rack position

N10 N11

Pump speed

D4AF0919

FL-84
8. Sealing

FUEL & ENGINE CONTROL

Seal with cap

Seal with wire

Seal with wire 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 o o o Torque cam Tension lever pin Govenor shaft Idling spring
Tension lever pin

Torque cam Governor shaft Idling spring

Tension lever pin

Rod
D4AF3494

Inspection and Adjustment of No-load minimum and Maximum Speeds Perform the following check after the engine has been sufficiently 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 stopper 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.
Full speed set bolt Idling set bolt
D4AF0920

Adjusting lever

GOVERNOR

FL-85

R801, R901 TYPE GOVERNOR [D4DA/D4DB/D4AL (EURO-II)]


Precaution in servicing
Disassembling 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 adjusting 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.

DISASSEMBLY
Prior 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.

Removal of the Governor Cover Assembly


1. Remove the full load stopper housing 32 damper screw 67 and cover plate 45 from the governor cover.

Full load stopper housing 32


Tightening bolt Cover Plate 45 Damper screw 67 Tightening bolt

Control switch

FIG8-1

2. Remove the screw plugs 19 on the sides of the governor housing, then pull out the supporting lever shaft 16 .

Governor cover bolts 28 Supporting lever shaft 16

Screw plug 19

FIG8-2

FL-86
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 governor 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 .

FUEL & ENGINE CONTROL

FIG8-3

CAUTION: Before lifting the governor cover, be sure to pull the supporting lever 15 upwards, as shown by dotted lines in fig.40, so that its lower end does not obstruct the lifting of governor cover.

Floating lever Pull up supporting lever Slider Lever end obstruct governor cover Lift governor cover

FIG8-4

Removal of the Linkage Assembly


1. Remove the floating lever assembly 7 by removing the supporting 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 subassembly 33 from the control rack.
Connecting bolt 37

Cotter pin 65

Floating lever 7 Slider 6 Supporting lever 15

FIG8-5

Arm sub-assembly 33 Start spring 34

FIG8-6

Plate 58
Arm sub-assy 33 Start spring 34

E-ring 14
Steel plate washer 66

Floating lever 7 Sliden 6

Lock washer 56

Connecting bolt 37

Supporting lever 16
FIG8-7

GOVERNOR 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 bearing bolt 61 . 3 -13 and
Jointing bolt 3 -13 Bearing bolt 61

FL-87

Lock nut 3 -18

Lock washer 3 -19


FIG8-8

2. Guide bushing removal Cut the shake-proofing wire for the guide bushing and unscrew the two bolts 3 -14. Then, remove the guide bushing 3 -12. (The shake-prooting wire has been discaded from 1983 production.) CAUION: To remove the guide bushing, it is necessary to keep the camshaft 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.
FIG8-10

Guide bushing 3 -19 Thigtening bolt 3 -18

FIG8-9

Flyweight Round nut wrench (SST)

4. Flyweight assembly removal Remove the flyweight assembly with the flyweight extractor (SST).

Flyweight

Flyweight extractor (SST)

FIG8-11

Damper weights: After removing the flyweights and the dampers, remove the camshaft bushing using the camshaft bushing extractor (SST).
Camshaft bushing Camshaft bushing extractor (SST)
FIG8-12

FL-88
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.

FUEL & ENGINE CONTROL


Idle outer spring Adjusting nut Spring seat Control Washer
spring

Spring inner seat


Mechanical spring

Spring guide
FIG8-13

Idle outer spring

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.

FIG8-14

Removal of the Adjusting Lever Shaft


1. Detach adjusting lever sub-assy 17 , return springs 69 and adjusting lever 20 from the governor cover.

Adjusting lever 20

Return spring 69

Adjusting lever sub-assy 17 Adjusting lever shaft


FIG8-15

2. Remove the taper bolt 9/1 , pull out the adjusting lever shaft and remove the steering lever 9 .

Lever shaft Steering lever 9

E-ring 14 Return spring 13

Stopper Cam plate 12 FIG8-16

3. Leave the cam plate 12 and return spring 13 in the adjusting lever as shown in Fig.8-17. housing.

Return spring

Cam plate

FIG8-17

GOVERNOR 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.

FL-89

Loosen

FIG8-18

2. Measure and record "A" dimension from the edge of the boost compensator housing to the guide bushing as shown in Fig.819. NOTE Make sure to record the dimension A as the guide bushing is put in place based on that length during assembly.
Guide bushing Boost compensator housing FIG8-19

ASSEMBLY
After checking each part, assemble the governor in the following steps of procedure:
Tightening torque: 1.8 ~ 2.0 kgm

Installation of the Governor Housing


With 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 Lever


Install the stop lever 49 as shown in the diagram of Fig.8-21. When installing, adjust by clearance shims 63 (Clearance Tolerance = 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.
Stop lever 49 Spring cover 54
O-ring 51 Bolt with washer 46 Tightening torque: 0.8 ~ 0.9 kgm

FIG8-20

0.05~0.1mm (R801 and R901)

Return spring 53 Stop arm 48 Shim 63

Installation of the Flyweight Assembly


1. 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 face downwards. (Reverse instaalation should be avoided.) 2. The adjusting nut should be tightened so that the projection of the flyweight holder shaft is between -0.4 mm to 0.2 mm (R801 and R901). If the projection exceeds the lower limit (-0.4 mm), the adjusting nut may come in contact the housing. 3. Be sure to insert the adjusting washers on the guide sleeve side.
Governor housing

FIG8-21

Control spring Idle inner spring Spring seat

Idle outer spring

Adjusting nut Guide sleeve

Projection: -0.4 ~ 0.2mm (R801 and R901) Spring inner seat 2.5mm

3.5mm

LAPPED surface should face downwards when installed

FIG8-22

FL-90
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). CAUTION 1. Tighten the round nut 40 with a torque of 5-6 kgm. 2. In tightening, hold the camshaft from rotation by using the holding spanner (SST).

FUEL & ENGINE CONTROL

Tightening torque: 5~6 kgm Round nut socket(STT)

FIG8-23

Flyweigh with Damper


1. Adjustment of the damper clearance This adjustment determines the clearance between the flyweight 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)
Dial gauge
FIG8-25

Clearance adjusting shim


FIG8-24

Flyweight

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 bushing 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 camshaft 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.

Camshaft bushing

Dampers

FIG8-26

Plastic mallet

FIG8-27

GOVERNOR 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).
Washer 3 - 22 On elongated hole side of flyweight

FL-91
Tightening torque : 0.6 ~ 1.0 kgm Guide bushing Lock washer

Bellcrank bolt 3 -13

Nuts 3 -18 Bearing bolt 61

FIG8-28

Bellcrank bolt 3 -13

1.5~2.0mm

Nuts 3 -18

Lock washer 3 -19


FIG8-29

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 - L1 5) Calculate "i" by the following. = 1 + L2 Choose a bearing bolt that has the length "i" from the following table and put it in place.
Adaptor plate Vernier calipers Slider

Bearing bolt

Housing

FIG8-30

FIG8-31

FL-92
R801 governor Parts number 901411-0180 901411-0190 091411-0200 091411-0210 Length () 31.9mm 31.7mm 31.5mm 31.3mm Parts number 901411-0220 901411-0230 091411-0240

FUEL & ENGINE CONTROL

Length () 31.1mm 30.9mm 30.7mm

R901 governor Parts number 901411-0320 901411-0330 091411-0340 091411-0350 Length () 34.54mm 34.34mm 34.14mm 33.94mm Parts number 901411-0360 901411-0370 091411-0380 091411-0450 Length () 33.74mm 33.54mm 33.34mm 37.74mm

4. After the fitting dimension of the bearing bolt has been achieved, lock the nuts by tabbing the lock washer in two opposite directions 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 kgm.
Shake-profing Lock washer

FIG8-32

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.

Cam plate 12 Bushing 57 Washer 64 Governor cover 2 E-ring 14 0.08~0.12mm


FIG8-33

GOVERNOR
2. Install the steering lever and adjusting lever shaft to the governor cover. NOTE From production in September, 1981, the sliding block has no recess cut in it. Refer to the drawing at right when installing the sliding block into the floating lever.
Taper bolt Tightening torque: 0.4 ~0.7kgm Adjusting lever shaft Sliding block

FL-93

Steering lever

0.5~1.5mm (R801 and R901)


FIG8-34

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).
Shackle 8 Washer 56 Connecting bolt 37 Arm sub-assembly 33

Plate washer Cotter pin Arm nut

Control rack
Start spring 34

FIG8-35

2. Connect the shackle 8 to the arm subassembly 33 with the plate washer, and secure the shackle by using a E-ring 14 . Then, install the slider 6 and supporting lever 15 on the floating 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)

Floating leve 7

Slider 6

Supportin leve 15
FIG8-36

Slider Supporting lever

Supporting lever shaft

Supporting lever should return easily by its own weight

FIG8-37

FL-94 Installation of the Governor Cover


1. To install the governor cover, keep the control rack pulled towards 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".)

FUEL & ENGINE CONTROL

FIG8-38

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 .
FIG8-39

Tightening Torque : 1.0~1.4kgm

Preliminary Adjustment of Stop Cam


Remove the full load stopper assembly. Measure the L1, L2 and L3 distances with vernier calipers and adjust to meet specified amount on test plan. NOTE For the specifications, refer to the injection pump specifications sheet for each pump reference number.

FIG8-40

TEST AND ADJUSTMENT

FL-95
Protractor (SST)

TEST AND ADJUSTMENT


After 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:

D431001

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

ADJUSTING PARTS & CHANGES IN GOVERNING CHARACTERISTICS


Adaptor screw Adaptor screw Full-load stopper

Maximum speed adjusting screw Damper screw

Screw plug Adjusting lever

Idle adjusting screw Adjusting nut

D431003

FL-96
1. Idle Adjusting Screw This adjusting screw serves to determine the idling position. In Fig.D431005, the solid line represents the standard characteristic while the dotted and dash-dot lines show the changes in the characteristic when the screw is turned out and in, respectively.
Rack travel

FUEL & ENGINE CONTROL

Screw out

Screw in Pump speed


D431005

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.
Screw in Rack travel

Screw out

Pump speed

D431007

3. Full Load Stopper Turning this stopper screw changes the quantity of fuel delivered in the full-load condition. The changes of characteristic are shown by the dotted and dashdot lines, respectively.
Rack travel Screw out Screw in

Pump speed

D431009

4. Adaptor Screw This screw is used to change the adaptor stroke in medium and high-speed ranges under full load. The changes of characteristic are shown by the dotted and dashdot lines, respectively.
Rack travel Screw in

Screw out

Pump speed

D431011

5. Adaptor Screw

&
Screw out Rack travel &

The changes of characteristic are shown by the dotted and dashdot lines, respectively. NOTE: For this setting adjustment, the adaptor screws are used together. and

Screw in

&

Pump speed

D431013

TEST AND ADJUSTMENT


6. Damper Screw (if installed)

FL-97

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.
Rack travel Screw in

Pump speed

D431015

7. Adjusting Nut This adjusting nut is used to alter the idling and maxmum speed governing characteristics. The changes of characteristic are shown by the dotted and dashdot lines, respectively. Fine adjustment for the same purpose can be done by means of washerss.

Screw in

Rack travel

Screw out

Pump speed

D431017

PREPARATIONAL PROCEDURE
Prior 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 recommended lubricating oil (engine oil). NOTE: Always use a high accuracy type rack position sensor for the adjustment of the R901 governor.
Ra Rb Rc Rd Re D431019

Rack travel gauge (SST)

Rack travel

Adjusting lever set

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 Rc is out of specification, adjust using washer .

Na N bNcNd

Pump speed

Ne

D431021

Idle adjusting screw


D431023

FL-98
2. Drive the pump then at Na and check rack travel R. 3. Drive the pump at Nd, and check rack travel Rd. If Rd is out of specification, adjust by changing washer shown in Fig. D431027 Use of a thicker washer will move the characteristic towards the dash-dot line (Fig. D431025). 4. Drive the pump at Ne, and check rack travel Re. Adjust if necessary 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.
Rack travel

FUEL & ENGINE CONTROL

Washer thickened

Washer thickened

Pump speed

D431025

Washer Guide sleeve Idle outer spring Washer Control spring Idle inner spring Spring seat

Adjusting nut Projection: -0.4 ~ 0.2 mm (R801 and R901) Spring inner seat

D431027

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 correct direction. (See Fig.D431029)

3rd idle Spring

Larger

Guide Bushing
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. : For idle outer spring Washer Washer Washer Washer : For idle inner spring : For 3rd idle spring : For main spring
Rack travel Washer Washer Washer

<R901 governor>

Washer Pump speed


D431031

Washer Washer

Washer Washer

<R901>

D431033

TEST AND ADJUSTMENT

FL-99
Washer Guide sleeve Idle outer spring Washer Control spring Idle inner spring Spring seat Adjusting nut Projection: -0.4 ~ 0.2 mm (R801 and R901) Spring inner seat

PRELIMINARY ADJUSTMENT OF MAXIMUM SPEED CONTROL


For this adjustment place the adjusting lever in its "full" position, then turn the maximum speed adjusting screw to achieve control rack cutback at pump speed Nf (Fig. D431043 & D431045)

D431035

ADJUSTMENT OF MEDIUM SPEED CONTROL


The full load stopper is used to change the adjustment of medium 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
Ni Nj Ri Rj Rl

Rack travel

travel Rj. (For the changes in characteristics, refer to Fig. D431009) 2. Drive the pump then at Ni, adjust using the adaptor screw to obtain rack travel Ri. (Refer to Fig.D431011) 3. Drive the pump at Ni, adjust adaptor screws arck travel Ri. (Refer to Fig.D431013) NOTE: To adjust the adaptor screw and , loosen the lock nuts. , and to obtain

Pump speed

D431037

Turn them using a screwdriver. To lock adaptor screw use the double spanner method.

D431039

ADJUSTMENT OF MAXIMUM SPEED CONTROL


1. Perform this adjustment by turning the maximum speed adjusting screw to obtain control rack cutback at pump speed Nf (Fig. D431007). (For the changes in characteristic, refer to Fig D431007).
Rh

Adjusting lever set

Rack R travel g

Nf Ng N h

Pump speed

D431041

2. Drive the pump then at Ng and Nh, and make sure the rack travel equals Rg and is less than Rh.

Maximum speed adjusting screw

D431043

FL-100

FUEL & ENGINE CONTROL

ADJUSTMENT OF THE DAMPER SCREW


1. With the adjusting lever set at its "idle" position, drive the pump at Nm and adjust by turning the damper screw in either direction 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 Rn.
Rack travel

Rm Ro Rn Rh Nm Nn No Np D431045

Pump speed

2. Then place the adjusting lever in its "full" position, check rack travel Ro and Rp at pump speeds No and Np. 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.
D431047

Damper screw

ADJUSTMENT OF FUEL DELIVERY QUANTITY UNDER FULL LOAD


Perform 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.

D431049

CHECK THE STOP LEVER OPERATION


With 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.

TEST AND ADJUSTMENT

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 Compensator


Before installing the boost compensator and the full-load stopper housing, make the following adjustments.

Guide bushing

Push rod

Screw

Stop screw

D431051

FL-102
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)
Guide bushing

FUEL & ENGINE CONTROL

Boost compensator housing D431053

2. Screw in the stop screw until it contacts the push rod. Screw it in further by half turn to get the correct position.

Stop screw Push rod


D431055

3. Obtain correct dimension of "C" by turning the screw. Fix it by means of the lock nut.
Lock nut

Screw C
D431057

4. Apply 1000 mmHg pressure through the port D The screw should travel E cm. If the travel is too much or too less, check the parts for correct installation.
E

5. Check airtightness by applying 1000 mmHg pressure in the diaphragm chamber. Check the pressure drop, if after 10 seconds the pressure is still greater than 980 mmHg, the compensator is O.K.

Apply 1000mmHg boost Pressure

Screw

D431059

TEST AND ADJUSTMENT Adjusting Parts and Changes in Rack Travel Characteristics
Adaptor screw Guide bushing Stop screw

FL-103

Full-load stopper

Adaptor screw Damper screw

Adjusting lever

Screw plug

Maximum speed adjusting screw

Idle adjusting screw

Adjusting nut
D431061

For changes in rack travel characteristics by adjusting parts to ,refer to Adjussting parts & changes in goverining characteristics. 1. To adjust fuel delivery quantity under full load with low boost pressure, turn the stop screw .
Rack travel

Screw in

Boost compensator function has no affect on their operation.

Low boost pressure (consstant)

Screw out

Pump speed

D431063

2. To adjust boost compensator characteristics, turn the guide bushing . In Fig. D431067, the guide bushing is viewed from the stop screw side.
Rack travel

Counter clockwise Clock wise

Boost pressure

D431065

FL-104 Preparational Procedure


1. 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
Rack travel Three-way hose

FUEL & ENGINE CONTROL

Air pressure meter Handle

D431067

Preliminary Adjustment of the Stop Cam


Follow the instructions given in section 'Adjustment of idling speed control'

Adjustment of idling speed control


Follow the instructions given in section 'Preliminary adjustment of maximum speed control'
Pump speed

Nf D431069

Preliminary Adjustment of Maximum Speed Cotrol


With 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
Rack travel (mm)
R3 R2 R1

Adjustment of Medium and Maximum Speed Control


With the specified pressure applied, follow the instructions given in sections 'Adjustment of maximum speed control' and 'Adjustment of the damper screw'
P1

Pressure (mmHg)

P2

P3 D431071

Adjustment of the Boost Compensator


Turn 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 specification 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.
Stop screw

D431073

IDLE-UP ADJUSTMENT
2. Adjustment of the guide bushing With the pressure P2 applied at the specified pump speed, measure fuel delivery quantity. If it deviates from the specified range, 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 difference 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 R2 + (specified value). 4. With pressure released and pump speed of 100 rpm, make sure that the rack is in the start position. For other operations (9), (10) and (11), see sections 'Adjustment of 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 these adjustments, install the exterior parts and seal each of the adjustments.
Flat-blade screwdriver Guide bushing

FL-105

D431075

IDLE-UP ADJUSTMENT
Idle-up set and microswitch set [Actuator vacuum: -47kPa (-350 mmHg) or below] D4AF Idle-up set (on-vehicle) 950 to 1,000 rpm D4AL 950 to 1,000 rpm

Idle-up Adjustment Procedure


1. Warm up the engine, keep the transmission in neutral, and keep the exhaust brake in "OFF" position. 2. Activate the actuator by applying a vacuum of -47 kPa (-350 mmHg) or below to it. 3. With the lock nut loosened, turn the adjust screw to obtain the specified idle speed. After adjustment, tighten the lock nut. 4. With the actuator released to the atmosphere, reapply the said vacuum 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 actuator attaching bolts. 2. For on-vehicle adjustment fo idle-up speed, use special care not to let the tools be in contact with the Bterminal of starter.

<D4DA, D4DB>

Lock nut 7.8 to 8.8 Nm (0.8 to 0.9 kgfm) Actuator Adjusting screw

Adjusting lever

D4AF0973

<D4AF,D4AE>

Adjusting lever Lock nut 7.8 to 8.8 Nm (0.8 to 0.9 kgfm) Adjusting screw Mounting bolt
D4AF0974

FL-106

FUEL & ENGINE CONTROL

FEED PUMP
Disassembly, Inspection and Reassembly

2 1

3 4 Deterioration 4 Deterioration 5 Seat wear 12 14 Cracks, thread damage 13 Wear 5

Dirt, clogging Clean or replace

6 8 9 10 11

Disassembly sequence 1. Priming pump 2. Eye bolt 3. Valve support 4. Spring 5. Check valve 6. Eye bolt 7. Gauze filter 8. Plug 9. Spring

10. 11. 12. 13. 14.

Piston Push rod Snap ring Tappet Housin

For reassembly, reverse the order of disassembly. NOTE Know the trouble spots thoroughly by making tests before disasembly.
D4AF0978

AUTOMATIC TIMER Test and Adjustment

FL-107

<D4AL> Delivery pressure Condition 600 rpm NV 335 to 410 kPa (3.4 to 4.2 kgf/cm) Delivery Condition For 1 min, at 1,000 rpm NV 1,620 cc or more

Lift capacity Conditions No. of strokes required before lifting when operated at 60 strokes per minute. NV 25 strokes or more

Air pressure 195 kPa (2 kgf.cm)

Airtightness No leaks from push rod sliding surface

Feed pump

<D4AF> Delivery pressure Condition 600 rpm NV 175 to 215 kPa (1.8 to 2.2 kgf/cm) Delivery Condition Trough 1.54 nozzle for min. at 1,000 rpm NV 1,620 cc or more Test conditions Fuel pipe I.D. 8 mm Length 2,000 mm Cam lift 6 <D4AF> (Eccentric cam) 8 mm <D4AE> Height from oil level 1,000 mm Test oil JIS No.2 light oil

Lift capacity Conditions Time requred before lifting when operated at 150 rpm. NV 45 strokes or more Lift capacity Conditions Time requred before lifting when operated at 100 rpm. NV 40 strokes or more NV ... Nominal Value

D4AF0979

AUTOMATIC TIMER
SCZ Type Automatic Timer
1. Removal Loosen the round nut with Socket Wrench (special tool).
Socket Wrench

D4AF0980

Using Timer Extractor (special tool), remove the automatic timer from the injection pump.

Timer Extractor

D4AF0981

FL-108
2. Disassembly and inspection

FUEL & ENGINE CONTROL

Flaws in curved surface 6 Wear of pin 3 2 1

5 4 5 Deterioration

For disassembly of parts with an encircled number, see following pages.

Disassembly sequence 1. Circlip 2. Shim 3. Injection pump gear 4. Timer spring 5. Shim 6. Flyweight 7. Timer hub
D4AF0982

Remove the circlip and shim.

D4AF0984

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.

Injection pump gear

D4AF0985

AUTOMATIC TIMER
3. Reassembly

FL-109

Apply engine oil when installed Thrust clearance NV 0.01 to 0.2 mm 4 3 2 7

6 1

Assembly sequence 7634521 For reassembly of parts with an encircled number, see following pages.
D4AF0982

NV ... Nominal

1) Instal the timer hub.

Timer hub

D4AF0986

2) With the flyweight mounted on the timer hub, install the injection pump gear in the direction of the illustration.

Timer hub keyway

Injection pump gear Flyweight

Gear marking

D4AF0987

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 pump gear

D4AF0985

FL-110
4) Check the spring for installed condition.

FUEL & ENGINE CONTROL

D4AF0989

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.

D4AF0990

4. Intallation Mount the automatic timer aligning it with the camshaft key. Then, tighten the round nut to the specified torque using Socket Wrench (special tool).

Socket Wrench

93 to 98 Nm(8.5 to10kgfm) : D4AF,D4AE,D4AL(EURO- ) 128 to 147 Nm(13 to15kgfm) : D4DA,D4DB,D4AL(EURO- )

D4AF0991

5. Test and Adjustment Whenever the automatic timer is disassembled, its advance angle must be measured with the manufacturer's mesuring instrument 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:
Advance angle (deg)

Advance angle adjusting shim

Advance angle adjusting shim

D4AF0992

Stopper Output point 6.50.5

0.5, 0.6, 0.7, 0.8, 0.9, 1.0 Automatic Timer Advance Characteristics Curves

1,000 1,750 Pump speed (rpm)


D4AF0993

INJECTION NOZZLE

FL-111
2 25 Nm (2.5 kgfm) 1 1. Bridge 2. Injection nozzle 3. Nozzle tip gasket
D4AF1004

INJECTION NOZZLE
Removal and Installation
To remove and install the injection nozzle, use socket wrench and Handle (special tools).

Replace 3

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, provide adequate means to prevent entry of dust into the cylinder.
Gasket Pliers
D4AF1007

Disassembly

8 7 Wear 6 Deterioration, cracks Disassembly sequence 1. Retaining nut 2. Nozzle 3. Needle valve 4. Packing 5. Pressure pin6. Spring 7. Washer 8. Nozzle holder NOTE Make sure that the combination of the nozzle and needle valve is not changed. 5 Wear 4 3 Wear, damage 2 Carbon deposits 1

D4AF1008

FL-112 Cleaning and Inspection


1. Cleaning After cleaning the nozzle with gas oil, remove carbon deposits with nozzle cleaning tool (special tool). Proceed as follows.

FUEL & ENGINE CONTROL

Nozzle Cleaning Tool

D4AF7002

Remove the needle valve from the nozzle and clean the needle valve with the needle valve cleaning wood piece.

Needle valve cleaning wood piece

D4AF7003

Insert, while turning a cleaning needle into the injection orifice of the nozzle to remove carbon. Use first a 0.25 mm-dia. cleaning needle and then finish with following: D4AF 0.26 D4AE 0.30 D4AL 0.30 D4DA 0.26 D4DB D4AL(EURO- ) 0.22 0.21

To remove burnt and hardened carbon.


D4AF7004

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.
D4AF7005

INJECTION NOZZLE 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 antirust oil.
7 6 5 4 2 8

FL-113

3 (2.5 to 3.5 kgfm) <D4AF> 1 (3 to 4 kgfm)


Assembly sequcne 87654321
D4AF1010

25 to 34 Nm 29 to 39 Nm

Test and Adjustment


1. Injection Pressure Install a nozzle to the nozzle tester. Operate the nozzle tester to inject several times. This allows the tester to be bled of air. Operate the nozzle tester at the specified speed. Then, vary shims to obtain the specified injection pressure. Shim thickness: 0.95 to 1.25 in 0.05 increments 1.275 to 1.775 in 0.025 increments 1.80 to 2.15 in 0.05 increments A 0.05 variation in shim thickness varies the injection pressure by 0.49 MPa (5 kgf/cm). With a correct shim selected, recheck the injection pressure. NOTE Never let yourself exposed directly to the atomized fuel injected from the nozzle.
D4AF1012

Injection pressure 21.6 to 22.6 MPa (220 to 230 kgf/cm)

FL-114
2. Spray Condition

FUEL & ENGINE CONTROL

1 Good

2 Good

3 Poor

4 Poor

5 Poor

6 Poor

Good spray 1. Evenly sprayed from five injection orifices 2. Even and symmetrical Poor soray

3. 4. 5. 6.

Asymetricl Branched Thin Irregular


D4AF1013

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. 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.
D4AF1012

Test pressure 19.6 to 206 MPa (200 to 210 kgfcm)

FUEL FILTER

FL-115
<Spin-on type>
1. Fuel feed pipe or hose 2. Fuel feed or hose 3. Fuel filter

FUEL FILTER
Removal and Installation

2
34 Nm (3.5 kgfm)

34 Nm (3.5 kgfm)

D4AF1015

On the double-cab model, first remove the rear inspection cover.

D4AF1016

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 gasket is seated on the filter head. NOTE After installation, run the engine and check for fuel leaks.

<Spin-on type>

Filter Wrench

D4AF1017

Disassembly, Inspection and Reassembly

<Spin-on type>

7.8 to 12 Nm 3 (0.8 to 1.2 kgfm)

1 Cracks and thread damage


Apply thin coat of oil when installed

2 Clogging, breakage

1. Fuel filter head 2. Element 3. Air plug


D4AF1018

FL-116

FUEL & ENGINE CONTROL

WATER SEPARATOR
CAUTION 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 loosened plug. NOTE After draining, tighten firmly the drain plug before bleeding the fuel system
CUBFL201

Red line Drain plug

ENGINE CONTROL
Components

Throttle

Starting switch

Engine stop cable

Broken cable, worn covering, damaged bolt

Accelerator switch

Accelerator control cable

Engine stop cable

CUBFL032

ENGINE CONTROL Accelerator Pedal Assembly Disassembly

FL-117

2 1

5 7 8 6

11 13 12 10

Disasembly sequence 1. Split pin 2. Washer 3. Accelerator pedal arm 4. Bushing 5. Return spring 6. Accelerator lever 7. Bushing 8. Accelerator switch 9. Snap ring 10. Clevis pin 11. Accelerator pedal 12. Adjusting bolt 12. Adjusting bolt 13. Lock nut
D4AF0675

Reassembly

2 4 5 Apply grease to inner surface

1 Section A-A

Apply grease

Apply grease to sliding surface 11 Apply grase to accelerator pedal arm sliding surface

10

8 12 13

Assembly sequence 7653218 4 121311109


D4AF0677

FL-118 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.

FUEL & ENGINE CONTROL


Turn all the way

D4AF0679

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. 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 0 to 5 mm
D4AF0682 D4AF0681 D4AF0680

Clip

Accelerator control cable

Adjusting lever

Nut

Stop lever Stopper bolt

Stop cable

Adjusting bolt Lock nut

Accelerator pedal

FUEL TANK
5. Accelerator switch Place the accelerator switch screw end face in tight contact with the accelerator pedal arm with the arm in contact with stopper. Then, back off approximately 1-1/4 turns and secure with the nut. Next, turn ON the exhaust brake switch and slowly depress the accelerator pedal. Make sure that the exhaust brake oepration indicator lamp in the meter cluster goes of when the engine speed reaches 800 to 950 rpm

FL-119

Accelerator pedal arm Accelerator switch

D4AF0684

FUEL TANK
Removal and Installation
1. 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.

Fuel hose Fuel hose Sender

Fuel cut-off valve

Fuel tank Drain plug 15~25Nm(1.5~2.5kgfm) Bracket assembly

CW31-101

Airtightness Test for Fuel Tank Fuel Tank Airtightness Test


Apply soapsuds to the fuel tank surface and feed air 29 kpa (0.3 kgf/cm) from the air vent tube. Parts requiring periodic replacement : Fuel hose
Install plug When no return pipe is provided Connect tube or the like

Apply air pressure [29 kPa (0.3 kgf/cm)]

D4AF0697