FL Fuel System 1

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 Specification
Injection pump proper Type BOSCH AD BOSCH A NB (EP-9) Improved NB
Turning direction Clockwise ← ← ←

(as viewed from drive side)
Plunger Diameter 9.5 mm ← ø11.5 ø11

Lead R.H. 20 + 50 ← 35W ←
Governor Model, type RLD ← R801 R901

(all speed (all speed mechanical) (all speed
mechanical) mechanical)
Automatic timer Model, type SCZ Type, SBO ←

mechanical mechanical ←
Injection nozzle Type Hole (1 spring) ← Hole (2 spring) ←
No. of orifices 5 ← ← ←
Orifice diameter 0.30 mm 0.285 mm 0.26 mm 0.21 mm
Orifice angle 160° ← 157° 150°
Injection pressure 21.6 MPa ← 1st : 17.65MPa(18kgf/cm2) ←
(220 kgf/cm²) 2nd: 21.6MPa(220kgf/cm²)
Fuel filter Type *Spin-on filter ← ← ←

paper
*Water separator Type Sediment trap ← ← ←

GENERAL FL-3
SERVICE STANDARDS
D4AF/ D4AE/ D4AL [EURO-I] Unit : mm
Nominal value Correction and
Description Limit
[Basic diameter] remarks
Injection pump Overflow valve opening pressure 255 kpa (2.6 kgf/cm²)
proper(D4AF)
Control rack sliding resistance 1.2 N (0.12 kgf)
(when not rotating) or less
Camshaft end play 0.03 to 0.05 0.1 Adjust or replace

Tappet rolter overall clearance Within 0.3 Replace
Tappet to pump housing clearance 0.03 to 0.07 0.2 Replace
Wear on lower spring seat surface in 0.2 Replace
contact with plunger
Squareness Plunger spring 1.5 or less 2 Replace

Delivery valve spring 0.5 or less 1 Replace
Camshaft bend (runout) 0.15
Wear on camshaft surface in contact with 0.2
oil seal
Control rack sliding resistance 20 to 21

(Return stroke)
Prestroke 3.6 ± 0.05 Adjust
Injection start interval 90 ± 30' Adjust
Tappet clearance 0.2 or more Adjust
Fuel injection STD, Cold, Tropical area 9° Adjust
timing(BTDC) High altitude area 12°
Injection pump Overflow valve opening pressure 255 kPa (2.6 kgf/cm²)
proper
Control rack sliding resistance 1.5 N(0.15 kgf)
(D4AL, D4AE)
(when not rotating) or less
Camshaft end play 0.02 to 0.06 0.1 Adjust or replace
Backlash between control rack and pinion 0.15 0.3 Replace
Tappet roller overall clearance 0.2 Replace
Tappet to pump housing clearance [24] 0.03 to 0.07 0.2 Replace
Wer on lower spring seat surface in 0.2 Replace
Plunger driving face to control sleeve 0.02 to 0.08 0.12 Replace

clearance
Control rack full stroke 21 or more

Injection start interval 90° ± 30' Adjust
Fuel injection D4AL 10° Adjust
timing (BTDC) D4AE(STD, Cold area) 9°
(Tropical, high altitude area) 13°

Description Limit
RLD governor Distance between the guide screw top 13.5 to 14.5 Adjust
surface and housing end face
Distance between governor housing end 29 ± 0.2 Adjust

face and shifter pin hole center
Distance between governor cover end Approx. 14 ± 0.5 Adjust

face and guide screw end
Control rack movement (injection pump) 9.5 to 21 Adjust
Boost compensator 24.5 ± 0.5 Adjust
Distance between spacer end face and
push rod end B
* Idle-up set [On-vehicle: actuator 950 to 1,000 rpm

vacuum -47 kPa (-350 mmHg) or below]
* Microswitch set [On-vehicle ; actuator D4AF 2,200 to 2,300 rpm

vacuum -47 kPa (-350 mmHg) or below] D4AE, D4AL 1,900 to 2,000 rpm
Feed pump Airtightness [When 195 kPa (2 kgf/cm²) 0 cc/min. Replace
air pressure is applied]
Priming pump lift capacity 25 or less Replace
(No. of strokes required before lifting
when operated at 60 strokes/min.)
Delivery At 600 rpm D4AF 175 to 215 kPa Replace
pressure (1.8 to 2.2 kgf.cm²)
D4AL, D4AE 335 to 410 kPa

(3.4 to 4.2 kgf.cm²)
Delivery For 1 min. D4AF 900cc or more Replace

amount at 1,000 rpm
through a
1.54 nozzle
For 1 min. D4AL, D4AE 1,620 cc or more
at 1,000 rpm
Lift When operatedat D4AF 45 sec. or less Replace

capacity 150 rpm
When operated D4AL, D4AE 40 sec. or less

at 100 rpm
SCZ automatic timer Injection pump gear thrust clearance 0.01 to 0.2 Adjust
Injection nozzle injection pressure 21.6 to 22.6 MPa 19.6 MPa Adjust
(220 to 230 kgf/cm²) (200 kgf/cm²)
Engine control Accelerator pedal to 0 to 5 Adjust

adjusting bolt clearance
* Accelerator switch operating speed 800 to 950 rpm Adjust

GENERAL FL-5
TIGHTENING TORQUE [EURO-I]
Thread size Tightening torque

Description Remarks
O.D. x pitch mm N·m (kgf·m)
Injection pipe union nut M12 x 1.5 25 (2.5)
Fuel feed pipe and hose eye bolt Injection pump side M14 x 1.5 20 to 29 (2 to 3)
Feed pump side M14 x 1.5 20 to 25 (2 to 2.5)
Fuel filter side M14 x 1.5 25 to 34 (2.5 to 3.5)
Lubrication oil pipe eye bolt 7.8 to 15 (0.8 to 1.5)
Injection pump Delivery valve holder 39 to 44 (4 to 4.5)
Screw plug 54 to 74 (5.5 to 7.5)
Lock plate 7.8 to 11 (0.8 to 1.1.
RLD governor Governor housing bolt 15 to 18 (1.5 to 1.8)
Governor housing bolt 6.9 to 8.8 (0.7 to 0.9)
Adjusting lever shaft nut 9.8 to 14 (1 to 1.4)
Full load set lever nut 9.8 to 14 (1 to 1.4)
U-lever plug 20 to 29 (2 to 3)
Idling screw 25 to 29 (2.5 to 3)
Governor shaft nut 9.8 to 15 (1 to 1.5)
Round nut 49 to 59 (5 to 6)
* Idle-up adjust screw lock nut 7.8 to 8.8 (0.8 to 0.9)
* Microswitch adjust screw lock nut 7.8 to 8.8 (0.8 to 0.9)
Automatic timer Round nut 83 to 98 (8.5 to 10)
Injection pump D4AL, D4AE 7.8 to 12 (0.8 to 1.2)
gear attaching bolt
Timer case nut 29 to 39 (3 to 4)

Injection nozzle Nozzle bridge bolt 25 (2.5)
Retaining nut D4AF 25 to 34 (2.5 to 3.5)
D4AE, D4AL M15 x 0.5 29 to 39 (3 to 4)
Fuel filter Fuel feed hose or pipe connector bolt M14 x 1.5 34 (3.5)
Air vent plug M8 x 1.25 7.8 to 12 (0.8 to 1.2)
* Water separator air plug 7.8 to 9.8 (0.8 to 1.0)
Fuel tank drain plug M16 x 1.5 15 to 25 (1.5 to 2.5)
Fuel tank band nut M8 x 1.25 3.9 to 7.8 (0.4 to 0.8)
5.9 to 9.8 (0.6 to 0.8) 100 lit. tank
Fuel tank bracket to frame bolt M10 x 1.25 59 to 78 (6 to 8) 90 lit. tank
Fuel tank bracket to fuel tank ataching bolt M8 x 1.25 7.8 to 12 (0.8 to 1.2)
Fuel tank bracket to cover attaching M6 x 1.0 4.9 to 6.9 (0.5 to 0.7) 63, 70 lit. tank
Fuel gauge unit screw M4 x 0.7 1.0 to 1.5 (0.10 to 0.15) 56, 63, 70 lit tank
* Fuel cock tightening 15 to 25 (1.5 to 2.5)
D4DA/ D4DB/ D4AL [EURO- ]

Description Limit
Injection pump Overflow valve opening pressure 255 kpa (2.6 kgf/cm²)
proper Control rack sliding resistance 1.2 N (0.12 kgf)
(D4DA,D4DB, (when not rotating) or less
D4AL EURO- ) Camshaft end play 0.03 to 0.05 0.1 Adjust or replace
Tappet rolter overall clearance within 0.3 Replace
Tappet to pump housing clearance 0.03 to 0.07 0.2 Replace
Wear on lower spring seat surface in 0.2 Replace
Squareness Plunger spring 1.5 or less 2 Replace

Delivery valve spring 0.5 or less 1 Replace
Camshaft bend (runout) 0.15
Wear on camshaft surface in contact with 0.2
oil seal
Control rack sliding resistance 20 to 21

(Return stroke)

Injection start interval 90 ± 30' Adjust
Fuel injection D4AL,D4DB(High altitude area) 8° Adjust
timing
D4DA(STD, Cold area) 7°
(BTDC)
D4DA(High altitude, Tropical area) 9°
D4DB [STD(Standard), 7°
Tropical, Cold area]
R801,R901 Distance between the guide screw top 13.5 to 14.5 Adjust
governor surface and housing end face
Distance between governor housing end 29 ± 0.2 Adjust

face and shifter pin hole center
Distance between governor cover end Approx. 14 ± 0.5 Adjust

face and guide screw end
Control rack movement (injection pump) 9.5 to 21 Adjust
Boost compensator 24.5 ± 0.5 Adjust
Distance between spacer end face and
push rod end B
GENERAL FL-7

Description Limit
* Idle-up set [On-vehicle: actuator 950 to 1,000 rpm Replace

vacuum -47 kPa (-350 mmHg) or below]
Feed pump Airtightness [When 195 kPa (2 kgf/cm²) 0 cc/min. Replace
air pressure is applied]
Priming pump lift capacity 25 or less Replace
(No. of strokes required before lifting
when operated at 60 strokes/min.)
Delivery At 600 rpm D4DA,D4DB 175 to 215 kPa Replace
pressure D4AL(II) (1.8 to 2.2 kgf.cm²)
Delivery For 1 min. D4DA,D4DB 900cc or more Replace
amount at 1,000 rpm D4AL(II)
through a
1.54 nozzle
Lift When operatedat D4DA,D4DB 40 sec. or less Replace
capacity 150 rpm D4AL(II)
SBO automatic timer Injection pump gear thrust clearance 0.01 to 0.2 mm Adjust
Injection nozzle injection pressure 1st:17.6(180kgf/cm²) Adjust
2nd:21.6(220kgf/cm²)
Engine control Accelerator pedal to 0 to 5 mm Adjust

adjusting bolt clearance
* Accelerator switch operating speed 800 to 950 rpm Adjust
Tightening Torque [EURO- ]
Thread size Tightening torque

Description Remarks
O.D. x pitch mm Nm (kgf·m)
Injection pipe union nut M14 x 1.5 25 (2.5)
Fuel feed pipe and hose eye bolt Injection pump side M14 x 1.5 14.8 to 19.6 (1.5 to 2)
Feed pump side M14 x 1.5 14.8 to 19.6 (1.5 to 2)
Fuel filter side M14 x 1.5 14.8 to 19.6 (1.5 to 2)
Lubrication oil pipe eye bolt 7.9 to12.7 (0.8 to 1.3)
Injection pump Delivery valve holder 83 to 98 (8 to 10)
Screw plug 54 to 74 (5.5 to 7.5)
R801,R901 Governor housing bolt 15 to 18 (1.5 to 1.8)
governor
Adjusting lever shaft nut 9.8 to 14 (1 to 1.4)
Full load set lever nut 9.8 to 14 (1 to 1.4)
Idling screw 25 to 29 (2.5 to 3)
Governor shaft nut 9.8 to 15 (1 to 1.5)
Round nut 49 to 59 (5 to 6)
*Idle-up adjust screw lock nut 7.8 to 8.8 (0.8 to 0.9)
Automatic timer Round nut 83 to 98 (8.5 to 10)
Injection pump gear attaching bolt 7.8 to 12 (0.8 to 1.2)
Timer case nut 29 to 39 (3 to 4)
Injection nozzle Nozzle bridge bolt 25 (2.5)
Retaining nut 25 to 34 (2.5 to 3.5)
Fuel filter Fuel feed hose or pipe connector bolt M14 x 1.5 34 (3.5)
Air vent plug M8 x 1.25 7.8 to 12 (0.8 to 1.2)
* Water separator air plug 7.8 to 9.8 (0.8 to 1.0)
Fuel tank drain plug M16 x 1.5 15 to 25 (1.5 to 2.5)
Fuel tank band nut M8 x 1.25 3.9 to 7.8 (0.4 to 0.8) 100 lit. tank
5.9 to 9.8 (0.6 to 0.8) 90 lit. tank
Fuel tank bracket to frame bolt M10 x 1.25 59 to 78 (6 to 8)
Fuel tank bracket to fuel tank ataching bolt M8 x 1.25 7.8 to 12 (0.8 to 1.2) 63, 70 lit. tank
Fuel tank bracket to cover attaching M6 x 1.0 4.9 to 6.9 (0.5 to 0.7) 56, 63, 70 lit tank
Fuel gauge unit screw M4 x 0.7 1.0 to 1.5 (0.10 to 0.15)
* Fuel cock tightening 15 to 25 (1.5 to 2.5)
GENERAL FL-9
TROUBLESHOOTING
Fuel Injection Pump
Rough idling
Is idling speed setting normal? No

Adjust idling stopper bolt
(Isn’t it too low?)
Yes
Yes
Is there no air inflow in fuel system? Inspect the faulty cause and repair
No
Yes
Is there no water inflow in fuel system? Drain water from fuel tank, fuel filter,
No and water separator.
Is there no clogging in fuel filter element and feed Yes Replace fuel filter element or clean
pump gauze? gauze.
No
Isn’t injection pump control lever mounting nut loose Yes

Tighten it to the specified value.
or missing?
No
No
Is injection timing of injection pump accurate? Readjust injection timing
Yes
After removing nozzle, inspect the following items. • Correct the first injection pressure
• Is the first injection pressure correct? No as necessary
• Is spray state normal? • Clean it as necessary and re-check
(Check nozzle hole part for carbon accumulation, (Replace nozzle tip as necessary)
if it is excessively accumulated, clean it prior to
inspection)
Yes
With injection pump removed, inspect the following

item using a pump tester No Inspect cause of accumulation of rack
• When control rack is pulled by load control lever, and repair
is it smoothly operating?
Yes
Measure fuel injection timing of each cylinder. No

Inspect the faulty cause and repair
Is it regular?
Yes
No
Is injection interval between cylinders correct? Inspect the faulty cause and repair
Yes
No
Does feed pump output ratio exist within specification? Inspect the faulty cause and repair
GENERAL FL-11
Hard to start the engine

Yes
Is fuel quantity enough? No

Supply fuel
Yes
Yes
Is there no air in fuel system? Inspect the following items and repair
(Engine is not started after bleeding the system) • Loose pipe and connector
No • Feed pump gauze clogged
• Fuel element clogged
• Air inflow from feed pump
Yes Drain water from injector pump, fuel

Is there no water inflow in fuel system? filter, fuel tank, and other parts
No
Are there no fuel leaks for loose connection and Yes

Repair or replace
cracks in injection pipes.
No
No
Yes
After removing nozzle, inspect the following items. • Correct the first injection
• Is the first injection pressure correct? No pressure as necessary
inspection)
Yes

Yes
Measure fuel injection timing of each cylinder. No

Is it regular?
Yes
No
Yes
No
Does feed pump output ratio exist within specification? Repair feed pump or replace
GENERAL FL-13
Output loss
Yes
Yes
Is there no air in fuel system? Inspect the following items and repair
(Engine is not started after bleeding the system) • Loose pipe and connector
No • Feed pump gauze clogged
• Fuel element clogged
• Air inflow from feed pump
Yes Drain water from injector pump, fuel

Is there no water inflow in fuel system?
filter, fuel tank, and other parts
No
Is there no sticking or breaking in injection pump Yes

Replace
overflow valve spring?
No
Are there no fuel leaks for loose connection and Yes

Repair or replace
cracks in injection pipes
NO
No
Yes
inspection)
Yes

Yes
Is fuel injection ratio between cylinders No

regular?
Yes
No
Yes
No
Is angular in advance of automatic timer correct? Inspect the faulty cause and repair
GENERAL FL-15
Excessive smoke in exhaust gas

Yes
Is full throttle stopper securely seated onto gavernor No

Adjust full throttle stopper bolt
control lever?
Yes
No
Yes
inspection)
Yes

item using a pump tester No
Inspect the faulty cause and re-adjust.
• Is injection ratio of injection pump exceed over
the specification?
Yes
Is fuel injection ratio between cylinders No

regular?
Yes
No
Yes
No
Knocking noise happens in injection

pump surrounding
Yes
Is injection pump connecting part securely No Align the timing mark and retighten
connected? bolt
Yes
No
Is there no crack and looseness on injection pump Repair or replace
and connector?
Yes
No
Is there no abnormal noise in injection pump while Worn parts surrounding tappet.
rotating engine at low speed? Disassemble injection pump and re-
place faulty parts
Knocking noise happens in engine

Yes
No
Is proper quality of fuel used Use the specified quality of fuel
Yes
No
Yes
No
With injection pump removed, inspect the following Inspect the faulty cause and repair
item using a pump tester
(Is fuel injection ratio between cylinders regular?)
Yes
No
Yes
No
GENERAL FL-17
Speed is not smoothly shifted to idle

at high speed
No
From accelerator pedal to governor load control Yes Inspect the faulty part and repair
lever, isn’t cable clogged?
No
Yes
Isn’t load control lever return spring pressed or Replace return spring
damaged?
No
With governor load control lever ring cage disconnected, No

is load control lever smoothly operating?
Yes
With injection pump removed, inspect

No
the following item using a pump tester Inspect cause of stiff rack and repair
Is injection pump rack smoothly
operating?
Yes
Inspect cause of stiff governor linkage

and repair
Is mounting screw on control pinion securely No Adjust injection pump injection rate and
tightened? retighten control pinion mounting screw
Yes
With injection pump removed, inspect the following No Measure governor idling. If the mea-
item using a pump tester sured value exceeds the specified
Does the rack move smoothly when pulled by the value, adjust it
load control lever?
Engine control
Excessive accelerator pedal operating effort is

required (including unstable pedal return)
Yes
No
Is there no rust in pedal arm? Clean and apply oil
No
Yes
Is there no rust in cable? Replace
No
Yes
Governor adjusting lever operating resist Apply oil to link and shaft
Accelerator control cable broken

Yes
Yes
Isn’t cable end clogged? Remove rust and other foreign material
No
No
Is cable end installation point vertically correct? Correct
Yes
No
Are cable end and cable vertically correct? Correct or replace
GENERAL FL-19
Engine cannot be stopped

No
Yes
Isn’t stop cable stretched? Adjust
No
No
Is stop cable clamp securely tightened? Retighten or replace clamp
Yes
Yes
Is there no wear in ignition switch cam? Replace
Fuel tank
Insufficient fuel supply

Yes
Yes
Is there no air inflow in fuel tank for cracks in Replace faulty pipes and hoses
pipes hoses?
No
Yes
Is there no clogging in pipe and hose? Clean or replace
No
Yes
Is there no clogging in bleeder tube? Replace
No
Yes
Is there no water inflow in tank? Remove drain plug and drain water
No
Yes
Is there no clogging in tank by foreign material and rust? Clean
No
Yes
Is there no air inflow in tank due to lack of fuel quantity? Supply fuel
DESCRIPTION
Fuel System
Fuel feed pipe Injection nozzle

Injection pipe Fuel filter
Leak-off hose
Fuel feed pipe

Overflow valve
Governor
Injection pump
Feed pump
Fuel suction
pipe
Water
Fuel return pipe 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

Delivery valve holder
The Bosch A type injection pump is used which is constructed as
Stopper
illustrated. Delivery valve spring
The injection pump, that forces fuel into the injection nozzle under Delivery valve
pressure, is provided with a mechanism to increase or decrease Delivery valve seat
the amount of fuel. It has one plunger and delivery valve for each Plunger barrel
Plunger
cylinder. Control rack
The plunger, pushed up by the camshaft and pushed back by the Pump housing
plunger spring, moves up and down in the plunger barrel on a pre- Plunger spring
determined stroke to feed fuel under pressure. In so doing, it opens
and closes the suction and discharge ports to adjust the fuel injec- Tappet
tion rate.
The camshaft is supported two taper roller bearings at its ends, Camshaft
provided with cams operating the plunger and one operating feed
pump.
The camshaft is driven by the injection pump gear at half the en-
gine speed. D4AF0712
GENERAL FL-21
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 a) Bottom b) Starting of c) Pressure d) Completion of
dead center compression feed pressure feed
motion of the plunger. (suction) stroke
With the plunger the suction/discharge port into the plunger barrel. D4AF2210
As the camshaft rotates, the plunger moves up, and when the
plunger top surface and suction/discharge port line up, fuel
begins to be compressed.
When the plunger moves up further, the fuel pressure is in-
creased until the delivery valve is pushed up against the deliv-
ery valve spring. While the delivery valve is pushed up, the fuel
flows through the injection pipe to be pressure-fed to the nozzle.
As the plunger moves further up and the groove cut in plunger
meets the suction/discharge port, the high pressure fuel flows
through the hole in the plunger and runs through the groove
back to the suction/discharge port, completing pressure feed
of fuel.
The plunger stroke during which fuel is fed under pressure is
called the effective stroke. The fuel injection rate is increased
or decreased according to the engine load by turning the plunger
at a certain angle to change the position where the groove
meet the port during its upward stroke, thus increasing or de-
creasing the effective stroke.
The illustration beside shows the mechanism that varies the Plunger barrel
plunger's effective stroke. Suction port Notch
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 Control rack
the accelerator pedal or governor, the control sleeve in mesh

Pinion
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
control sleeve, thus varying the effective stroke to increase or Plunger D4AF2211
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.
2. Delivery valve Delivery valve spring

Delivery
The fuel compressed to a high pressure by the plunger pushes valve
the delivery valve up, spouting out. Valve seat
a
As soon as the pressure feed of fuel completes, the delivery Piston
valve is brought back to its original position by the delivery valve
spring force to block the fuel passage, thereby preventing back Injection Delivery valve seat a: Retraction stroke
flow of fuel. Completion of injection Completion of
(beinginning of retraction
The delivery valve goes further down until its seat surface is retraction) D4AF0713
held tight. During this stroke, the fuel is drawn back from the
injection pipe side, instantaneously dropping the residual pres-
sure 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 re-
duces the dead volume between the delivery valve and nozzle,
thereby stabilizing the fuel injection rate.
3. Overflow valve Spring seat

Spring Steel ball
The overflow valve, mounted to the top of the pump, stabilizes
the fuel temperature in the injection pump and temperature dis-
tribution to make sure that the amount of fuel injected into each
cylinder is maintained constant.
The valve is a ball seal type. When the fuel pressure in the
pump housing exceeds a predetermined level, the valve opens
to allow fuel back into the fuel tank. D4AF0714
GENERAL FL-23
RLD Type Governor [D4AF/D4AE/D4AL (EURO- )]
Supporting
lever
Adjusting lever
Full speed
set bolt
Idling set bolt
Adjusting lever shaft
Floating lever
Control rack
Cancel spring B
Start spring
Governior spring
Guide lever
Torque cam
Flywheight holder
Governor shaft
Tension lever Flyweight

Sleeve
Idling screw
Tension lever shaft
Idling spring Shifter Cancel spring A
D4AF0718
The RLD type governor is an all-speed governor providing smaller

lever reaction.
1. Flyweights
The flyweight holder is mounted on the injection pump cam-
shaft and the flyweights pivot about the pin press-fitted into the
flyweight holder. When the flyweights move outward under
centrifugal force, the sliders on their arm ends pushed the
sleeve in the axial direction. The sleeve is connected via bear-
ing to the shifter which is pinned directly to the bottom of the
tension lever. So, the flyweights impart their motion through
the shifter to the tension lever.
2. Link
Full speed set bolt

Control rack Adjusting lever
Cancel spring B Idling set bolt

To increase
amount of fuel Ro Supporting lever
Po
Floating lever
Start spring
Guide lever
Qo
Sensor lever
Governor spring
Full load set lever
Torque cam
Cancel spring A
Tension lever
Flyweight
Idle spring
D4AF1324
The RLD governor link operates as follows to regulate and con-

Full speed set bolt
trol all speeds.
Among the idling, governor, and start springs, only the start spring Adjusting
Cancel spring B lever
retains the initially set tension. So, the flyweights start to move
out under the centrifugal force more than the set tension of start Supporting Qb
lever Po
Ra
spring. They move further outward as the engine speed increases,
Guide
and the motion is transmitted to the tension lever, gradually put- Rack lever
connecting
ting more tension on the idling and governor springs. The guide link Floating lever
D4AF2612
lever is moved integrally with the tension lever by the set tension
of cancel spring A to displace the ball joint.
By placing the adjusting lever gradually from the idle to full posi-
tion when the guide lever ball joint is located at Po with engine
stationary, the supporting lever moves to cause the floating lever
to pivot about Po. (The point Po is a fixed point since the guide
lever moves integrally with the tension lever by the set tension of
cancel spring A.) This causes the control rack to move from Ro
in the direction of greater fuel delivery. When the rack reaches
Ra, the full load position determined by the torque cam, Ra be-
comes fixed to stop the supporting lever at Qb.
GENERAL FL-25
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 L-type lever
Cancel
flyweight centrifugal force to overcome the tension of idling and spring B Qa Pa
governor springs to move the tension and guide levers. As pump Ra
Po
speed increases, Po moves to Pa and Qb to Qa by the cancel Qb
spring B tension. These movements continue until the L lever

Supporting lever
contacts the supporting lever at Qa. D4AF2613
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 Qa Pa
to Ra'. Ra
The governor can thus control the amount of fuel and engine
Ra
speed by presetting the adjusting lever at any desired position. To decrease
amount of fuel
D4AF2614
The governor is so constructed as to allow the lever ratio to

become greater as the flyweights move further outward. Adjusting lever
When the governor controls idle speed with a low pump speed, B
A
the flyweight centrifugal force is small; under which conditions,
the lever ratio is made smaller to ensure that the control rack
I2
moves over a small range. When controlling high speeds with Guide lever
a greater to meet speed variations. I1

2 2
= (Fixed)
1 1
Guide lever
o Lever ratio with adjusting lever at idle position side ball joint
A1
Lever ratio =
2
x B2
1
B1 B1
A2
A1
2 1
= x = 1.0
1 2
o Lever ratio with adjusting lever at full position At idling ... Full line
At high speed control ... Broken line
D4AF2615
A2
Lever ratio = 2
x
1 B2
2 2
= x = 4.0
1 1
3. Starting the engine Control rack Adjusting lever

To increase Full
Cancel position Idling
amount of fuel Adjusting lever
With the engine stationary, the flyweights are in closed posi- spring B position
shaft
Supporting lever
tion and the idling and governor springs remain in the free- Sensor lever Floating lever
Guide lever
length state free from set tension. Placing the adjusting lever in Start spring
Governor spring
the full position moves the adjusting lever shaft, which causes Torque cam
the cancel spring B force to move the supporting lever. Tension lever
This in turn causes the control rack to move in the direction of Flyweight
Idle spring
greater fuel delivery. At the time, the sensor lever gets into the D4AF1325
groove cut in the torque cam provided to increase the amount

of fuel for startup, and the control rack, past the full load position,
reaches the point to increase the amount of fuel for startup
that is limited by the rack limiter.
By returning the adjusting lever to the idle position after the
engine has started, the control rack is pulled to allow the sen-
sor lever to leave off the groove in the torque cam. Thereafter,
no fuel delivery increase can be obtained for startup even by
moving the adjusting lever to the full position.
4. Idling control Adjusting lever

Full position
Placing the adjusting lever in the idle position with the engine Idling position
Floating lever
started makes Q the fulcrum of the floating lever.
Guide lever
As engine speed decreases, the centrifugal force of flyweights
yields to the tension of idling spring, closing the flyweights.
This causes the floating lever to pivot about Q, moving the con- Tension lever
Idle spring
trol in the direction of greater fuel delivery, thus preventing the
Flywheight
engine from stalling. (condition indicated by solid line) D4AF1326
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.
GENERAL FL-27
5. Control of fuel injection rate at full load by torque cam Full Adjusting lever
position Idling position
When the adjusting lever is placed in the full position under Supporting lever
Floating lever
load, the floating lever pivots about P to move the control rack Sensor lever Guide lever
Full load Governor spring
in the direction of greater fuel delivery. The sensor lever, at the set lever Governor shaft
same time, comes in contact with the torque cam. As speed Torque cam
Tension lever
varies, the shifter moves in the axial direction, which causes Idle spring
Flywieght
the tension lever to be pushed forward and backward around
the tension lever shaft, making the torque cam to rotate around Shift D4AF1327
its shaft.
The sensor lever movement tracing along the cam surface dis-
places the control rack, thereby increasing or decreasing the
fuel injection rate.
The tension lever movement from varying speeds does not,
however, move the point R; it moves only P of guide lever Q of
supporting lever. The control rack is therefore moved through
the sensor lever by the movement of torque cam.
6. Full speed control Control rack Adjusting lever

Full Idling position
With the adjusting lever at full position, the engine speed in- position L-type lever
Floating lever
creases while the fuel injection rates under full load are con- Sensor lever Guide lever
trolled by the torque cam and sensor lever. This is accomplished Full load set lever
Governor spring
Governor shaft
when the centrifugal force of flyweights pushes the idling and Torque cam
governor springs to push forward the tension lever. Tension lever
As speed further builds up and as the supporting lever con- Flywight
tacts the L lever on the adjusting lever shaft by the cancel spring Idle spring D4AF1328
B, the floating lever pivots about Q to move the control rack in

the direction of smaller fuel delivery, thus controlling the full
speed.
The sensor lever, on the other hand, leaves the torque cam
surface as this control advances.
7. Stopping the engine Stop lever
Turning the starter switch to "ACC" or "LOCK" with the adjust-

Cancel spring B
ing lever at idle position causes the stop lever on top of gover- Return spring
Stop device plate
nor to move the starter switch. This causes the stop device Supporting lever
plate to forcibly pull the control rack to the position with no fuel
injection, thus stoppint the engine. Control rack
Stop device plate To decrease
Operating the stop lever with adjusting lever at any given posi- amount of fuel
tion causes the stop device plate to pull the control rack in the D4AF2620
direction of smaller fuel delivery.

This in turn contracts the governor spring. As a result, the con-

trol rack is pulled until the set tensions of cancel and governor
springs balance; after this , the control rack does not move,
only the supporting lever turing as the stop lever moves.
The cancel spring absorbs excessive force being applied to
internal levers when the accelerator pedal is depressed with
the starter switch at "ACC" or "LOCK".
8. Boost compensator
The boost compensator is a device installed on a turbocharged
engine that automatically corrects the fuel injection rate ac-
cording to the boost pressure. It increases the injection rate to
compensate for the increased amount of intake air delivered to
engine cylinders by turbocharger operation.
Boost compensator
D4AF0719
Lever
To increase
Full load set screw Cancel spring amount of fuel
Push rod A Lever
Diaphragm
Sensor
lever
U-lever
Push rod B
Boost pressure
Boost compresator Torque cam
D4AF2622
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 FL-29
R801, R901 Type Governor [D4DA/D4DB/D4AL (EURO- )]
Cutaway view of R801 and R901 governor
Sliding plate Nut Full load stopper housing

Full load stopper
Adaptor screw
Stop cam
Shackle
Control rack Floating arm
Control lever
Damper spring
Stop lever
Return spring
Connecting bolt
Floating arm spring
Stopper arm Cam plate

Start spring
Guide shaft
Screw plug
Sliding block
Steering lever
Adaptor screw
Spring seat Adjusting lever shaft

Flyweight holder
Flyweight Bearing bolt
Slider
Jointing bolt Supporting lever
Bellcrank shaft Supporting shaft
FIG4-1
Flyweight construction
When closed When closed
Adjusting nut
Guide sleeve
Idle outer spring Bellcrank shaft
Guide sleeve
Control spring Idle inner spring
Bellcrank shaft Spring seat
Flyweight Jointing bolt
Spring seat Jointing bolt
Spring inner
seat
Camshaft Bearing bolt

Flyweight holder
Mechanical governor
spring
When wide-opened When wide-opened

FIG4-2
FLYWEIGHT ASSEMBLY
Flyweight holder is securely connected to and driven by the pump Damper
camshaft. A pair of flyweights are assembled on this flyweight holder

Camshaft
in such a way that they can be swung in either direction about the bushing
respective bellcrank shafts which are pressed tight in the flyweight
holder.
Round nut
The two flyweights are jointed by the jointing bolt, which transfers the
movement of the flyweights to the bearing bolt. FIG4-3
As shown in Fig.4-2, the flyweights contain a control spring and two

idling springs. The spring seat for retaining these springs has two V- Floating lever
sectioned arms so that they fit snugly into the V-grooves of the flyweight. Bearing bolt
In this design, the idle springs always contact the spring seats evenly.
The mechanical governor spring inside the flyweight absorbs play of
Supporting lever
the guide sleeve.
Slider
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. Supporting shaft FIG4-4
LINKAGE SYSTEM Shackle

Control lever
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 Control rack Floating
the supporting lever is converted to the up and down motion of the arm
Arm
floating lever (Fig.4-4).
The floating arm and the control lever are assembled to the upper end Floating lever
FIG4-5
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 Guide shaft
Floating Cam plate
the arm, so that the movement of the floating lever is transmitted to lever
the control rack (see also Fig.4-1). Sliding
block Steering
The adjusting lever and steering lever are fixed to the adjusting lever 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. Adjusting
lever
Movement of the adjusting lever, linked by the adjusting lever shaft
Adjusting
to the sliding block, causes the sliding block to slide within the float- lever shaft
FIG4-6
ing lever cylinder.
The full load stopper housing is located on the top of the governor,
Sliding plate Full-load stopper
It contains :
Stop cam ....
Determines the characteristic under full-load
Adaptor screws ....
Determine the vertical position of the stop cam
Adaptor
Full-load stopper .... screws
Determines the horizontal position of the stop cam
Stop cam FIG4-7
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.
GENERAL FL-31
SCZ Type Automatic Timer Timer hub pin
The SCZ type automatic timer, of the mechanical type, varies au- Flyweights
tomatically the injection timing according to the engine speed. Injection pump gear
Mounted on the injection pump camshaft with a round nut, it is
driven by the idler gear in mesh with the injection pump gear. Timer hub
There is a hole provided at one end of each of the two flyweights,
into which the timer hub pins are fitted. Injection pump Timer spring
gear pin
The curved surfaces on the flyweights come in contact with the D4AF0735
injection pump gear pin. Timer springs are mounted on the timer
hub pins and injection pump gear pin.
Injection pump gear pin
The automatic timer is forced lubricated by the engine oil being
injected into its center of rotation.
While the engine runs at a low speed, no centrifugal force is ap-
plied to the flyweights and the timer spring installed length remains
the longest. Flyweight
With the enging running at high speeds, the flyweights move out- Curved surface on flyweight Timer hub pin
ward under the centrifugal force with the timer hub pins as the
Before advance
fulcrum. The injection pump gear pin, at the time, is pushed by the
curved surface of the flyweights in the direction to compress the
timer spring; however, it cannot be moved because it is coupled to
the drive end. As a result, the timer hub pins are drawn in the turn-
Advance
ing direction while compressing the timer springs, which moves
the pump camshaft in the turning direction to advance the injection
timing. Advacing
D4AF0737
Feed pump
Priming pump
The feed pump is driven by the injection pump camshaft.
The priming pump allows manual lift of fuel when the injection pump Piston
is stationary. It may be used when bleeding the system. Holder
The gauze filter removes large particles of dust from the fuel lifted
from the fuel tank, preventing the feed pump from getting clogged. Oil seal
The filter must be washed in gas oil periodically.
Valve
Housing
Gauze
filter
Piston
Connector
D4AF0740
When the tappet (B) and piston (C) are pushed up by the camshaft
Delivery Suction
(A), the fuel in the suction chamber opens the outlet check valve ← ←
(D) and flows into the pressure chamber. F
As the camshaft (A) rotates to produce no cam action, the piston E

Suction C
(C) is pushed back by piston spring (E) to force fuel in the pressure chamber D
Push rod
Pressure A
chamber to the fuel filter. At the time, a vacuum is produced in the chamber B
suction chamber allowing the inlet check valve (F) to open to intro- Suction Pressure feed Stop
duce fuel. D4AF0741
When the fuel pressure in the fuel filter or injection pump exceeds
a predetermined level, the piston (C) becomes unable to return to
its original position because of the piston spring (E), stopping the
pressure feed of fuel.
Injection Nozzle <Hole type>

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
Nozzle holder
from the injection orifice at the end of the nozzle into cylinder (hole
type).
The injection pressure can be adjusted by increasing or decreas-
Washer
ing the number of washers in the spring.
Spring
Nozzle tip
Needle valve
Retaining nut
D4AF0742
Fuel Filter <Spin-on type>

Spin-on type fuel filter is replaced as a filter assembly when the Fuel filter head
element reguires replacement.
Fuel inlet
Fuel outlet
Fuel filter
Element D4AF074A
GENERAL FL-33
Water Separator
The sedimenter type water separator separates gas oil and water
centrifugally by taking advantage of their difference in specific
gravity.
To feed pump
The fuel that has flowed in from the inlet connector is squeezed by
the fuel path of the head to increase the flow velocity and spins.
The separated water is sedimented in the case, whereas the wa-
ter-separated fuel is drawn through the fuel path in the center of
From fuel tank
the head into the feed pump.
The water seaparator sediments not only water but also mud
Water level ring
components.
A red float goes up and down with the water level in the semitrans-
parent case, making it possible to visually check the water quantity.
D4AF3551
ENGINE CONTROL
Throttle button
Throttle cable
Starting switch
Accelerator pedal assembly
<D4AF,D4AE,D4AL(EURO- )>
Accelerator
control cable
Injection pump
<D4DA,D4DB,D4AL(EURO- )> 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.
Accelerator Pedal Assmbly <Pedal depressed>
31-14A
Depressing the acelerator pedal causes the accelerator control <Pedal released>
cable to move the adjusting lever toward the full throttle position,
thus accelerating the engine speed.
31-14B
Throttle button
Throttle button
The throttle button is connected via throttle cable to the accelerator
pedal. Operating the button moves the adjusting lever to provide Throttle cable
an optimum idle speed.
Accelerator pedal
31-14C
Engine Stop (Cable Type)

Placing the starter switch key in the "ACC" position causes the Stop lever
engine stop cable to move the stop lever, stopping the engine.
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 al-
lows 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 Breather tube

Outside air
To engine
A negative pressure is produced when the feed pump draws Main pipe
fuel, which can deform the tank and pipes. The breather tube
allows air to enter the tank to keep the tank inside at the atmo-
spheric pressure.
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 unit

Fuel guage
D4AF0689
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
1 5
1. Injection pipe
3 2. Fuel suction hose
3. Fuel suction pipe
7 4. Oil pipe
4 5. Fuel feed pipe
6. Fuel feed pipe
7. Fuel return pipe
8. 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. Socket Wrench
Use of Socket Wrench (special tool) will make the removal of flange
plate attaching bolts easier.
D4AF0752
INJECTION PUMP FL-37
Disassembly [D4AF/D4AE/D4AL(EURO- )]
13
12
14
Deterioration 15 * Sliding resistance

(stationary)
NV 1.2N (0.12 kgf) or less
Wear, damage 16
Wear, flaws 17
20 Bend
Overflow valve opening pressure 7
NV 255 kPa (2.6 kgf/cm²) * Backlash between rack and pinion
19 NV 0.15 mm
L 0.25 mm
18
21
Cracks, damage
11
4 10
9
* End play 8 Deterioration
NV 0.03 to 0.05 mm
L 0.1 mm
6 Wear
NV ... Nominal Value

2 L ... Limit
Disassembly sequence
1 Cover plate 12 Lock plate For disassembly of parts with an encircled number, see
2. Screw plug 13 Delivery valve holder following pages.
3 Bearing cover 14 Stopper Inspection itmes marked with * must be checked before
4 Camshaft 15 Delivery valve spring disassembly.
5 Tappet 16 Delivery valve
NOTE
6 Lower spring seat 17. Plunger barrel
1. Kep disassembled parts neatly arranced for
7 Pluger 18. Control rack cover
each cylinder.
8. Plunger spring 19. Rack guide screw
2. Keep plunger, plunger barrel, and delivery valve
10. Control sleeve 20. Control rack
in gas oil.
11. Control pinion 21. Pump housing
D4AF0753
1. With the automatic timer removed, install the injection pump on

Pump Mounting Base and Pump Setting Angle (special tools).
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 specifica-
tion in an position.
If the nominal value is exceeded, possible causes are as follows:
o Damage on control rack and defective tooth
o Defective pinion tooth, pinion in contact with housing
o Excessively tightened delivery valve holder
D4AF0756
5. Remove the cover plate. Then, using coupling and round nut Tappet Insert
and holding wrench (special tools), turn the camshaft. With
plunger in each cylinder placed at TDC, install Tappet Insert Coupling and
round Nut
(special tool) in the tappet service holes, one by one.
Tappet Insert
Holding Wrench D4AF0757
6. Mount camshaft clearance gauge (special tool) on the cam-

shaft to mesure the end play.
Angle
scale
1/100
Camshaft Clearance Gauge

D4AF0758
7. Remove the camshaft, tapping it with a soft hammer from the

governor end.
NOTE
1. Make sure that the cams on camshaft are not in con-
tact with the tappet.
2. Install the flyweight round nut at the end of camshaft
to protect threads.
D4AF0759
8. Take out of tappet Tappet Insert

Accessing from the bottom of the pump, insert Roller Clamp
(special tool) to push up the tappet. With the tappet in pushed Roller Clamp
position, remove Tappet Insert (special tool) and insert Tappet
Clamp (special tool) into the camshaft hole. Then, clamp the
tappet and take out.
D4AF0760
Tappet Clamp
D4AF0761
9. Insert plunger clamp (special tool) from the bottom of the pump Plunger
and fix its end to the lower spring seat. Then, withdraw the Notch
Lower spring seat
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 Clamp
D4AF0762
10. Remove the lock plate and remove the delivery valve holder Box Wrench
with Box Wrench (special tool).
Then, remove the stopper, delivery valve, and spring.
D4AF0763
11. Using Delivery Valve Extractor (special tool), remove the deliv-
ery valve.
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
Use Reaming Cutter to correct

Airtightness, wear pump housing damage, or replace.
Bend (Rouout)
L 0.15
Wear on surface contact

with oil seal
L 0.2
Squarenes Tappet to pump housing clearance

NV 1.5 or less NV 0.03 to 0.07
L 0.2 L 0.12
Wear on surface in contact
with plunger Tappet roller overall clearance
L 0.2 L Within 0.3 NV ... Nominal Value
L ... Limit
Unit : mm
D4AF0766
1. Plunger and plunger barrel

After cleaning in gas oil, check if the plunger falls smoothly in 10 to 15
the plunger barrel under its own weight.
60°
Use the following procedure for the inspection:
o Tilt the plunger barrel approximately 60°.
o Pull the plunger about 10 to 15 mm and let it go.
o Turn the plunger to check on several more points.
Replace the plunger if it does not fall. D4AF1584
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
D4AF0767
procedure is not effective since the piston does not spring
back.
Dial gauge
3. Tappet
Apply a dial gauge to the tappet roller and check for overall Roller
clearance by moving the roller up and down with a rod. Roller bushing
If the clearance exceeds the limit, replace the tappet assembly.
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
Wear
for wear. If the limit is exceeded, replace the lower spring seat.
D4AF0770
5. Plunger spring and delivery valve spring

Squareness
Measure the squareness of the springs and, if the measure-
ment over the limit, replace it.
D4AF0771
6. Replacement of taper roller bearing

To remove the inner race from the camshaft, use a gear puller.
Puller Adjusting ring

Shims
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
Reassembly
13
14
12
7.8 to 11 Nm
15 (0.8 to 1.1 kgf·m)
Ensure pump housing

locating notch is Sliding resistance
16 aligned with pluger (when stationary)
barrel knock pin at NV 1.2 N (0.12 kgf)
17 installation. 21
or less
20
Backlash between
rack and pinion
19 NV 0.15 mm
L 0.25 mm
18
1
End play
NV 0.03 or 0.05 mm 4
L 0.1 mm
29 to 39 N·m
(3 to 4 kgf·m)
11 With control rack set at center,

Face line marking install pinion with its ends
toward timer 10 facing toward cover plate
9
6
Assembly sequence
5
21→ 20 → 19 → 17 → 16 → 15 → 14 → 13 → 12 → 11 →
10 → 9 → 8 → 7 → 6 → 5 → 4 → 3 → 2 → 18 → 1 2
54 to 74 N·m
For assembly of the part with encircled number,
(5.5 to 7.5 kgf·m)
see the following pages.
D4AF075C
1. Mount the control rack and rack guide screw. Control rack
NOTE
Make sure that the rack moves smoothly. Check also to
ensure that the rack does not turn when so attempted.
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 Plunger barrel
Locating notch
the housing. If the projection is smaller than that, drive pin out Pump
housing
from the housing side.
NOTE
Note that the pump housing area must be cleaned, into
Knock pin Knock pin
which the plunger barrel is inserted. D4AF0776
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
D4AF0777
4. Fit the delivery valve spring and stopper into position, and tem-
porarily tighten the delivery valve holer.
Stopper
Delivery valve spring
D4AF0778
5. With the control rack set at the center, install the control pinion Face control pinion
and control sleeve. joint upward
Equalize the amount
of movement to left
with that to right
Control pinion
Control sleeve D4AF0779

6. Insert of plunger Notch

Lower spring seat
Fix Plunger Clamp (special tool) into the lower spring seat, and Part
number
install the plunger into the lower spring seat.
Insert the plunger into the plunger barrel with care not to allow Plunger
clamp
the plunger end to hit the pump housing and plunger spring.
NOTE
1. After the plunger has been installed, turn the lower
D4AF0780
spring seat to face its notch downward.
This prevents the spring seat from coming off position.
2. Make sure that the plunger flange side with a part num-
ber marking faces upward.
7. Clamp the tappet with tappet clamp (special tool) and, with the
tappet guide aligned with the housing groove, insert it into the Tappet Clamp
pump housing.
D4AF0761
8. Using Roller Clamp (special tool), push the tappet to TDC. Then, Tappet Insert
insert Tappet Insert (special tool) and remove Roller Clamp Shim
Tappet Insert
(special tool).
Make sure that the part number marking on the plunger flange Roller Calmp
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.
D4AF076B
9. Tighten the delivery valve holder to the specified torque.

Check also the control rack for sliding condition each time the Torque wrench
holder is tightened.
D4AF0781
10. Install the camshaft with the marking line at the end of its threads
facing toward the drive end.
Marking line
D4AF0782
11. Temporarily mount the bearing cover.

If the camshaft end play measured at disassembly is out of Bearing
specification, adjust with shims after temporarily installing the Shims
bearing cover.
Use shims of almost equal thickness for the governor and timer
ends.
After installing the bearing cover in position, measure again
Adjust ring
the end play to ensure that it is up to specification. D4AF0783
12. With Tappet Insert (special tool) removed, measure the sliding
resistance of the control rack.
(When stationary)
Make sure that the resistance is up to specification with cam-
shaft in any position.
13. Install governor
14. Install the following parts after adjusting the injection pump:
D4AF0756
o Control rack cover
o Feed pump
o Cover plate
o Automatic timer
Adjustment after Reassembly
Fuel injection start interval

NV 90° ± 30'
Prestroke
NV 3.6 ± 0.05
Control rack sliding resistance

NV 20 to 21
(Return stroke o rack
when it is pushed all
the way and released)
Tappet clearance
NV 0.2 mm or more
NOTE NV ... Nominal Value
Feed oil into the injection pump cam chamber.
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 Mea-
Rack Position Measuring Device
suring Device (special tool), instead.
Loosen the idling set bolt and full speed set bolt.
Push the control rack all the way to the governor and regard
this position as "0" of the Rack Position Measuring Device
(special tool).
D4AF0786
Remove the delivery valve spring and stopper from the deliv- Stopper
ery valve holder. Delivery valve spring
Feed the engine oil into the injection pump and bleed fuel.
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 re-
turn stroke is within specification.
D4AF0786
3. Measurement of prestroke
Fix the control rack position at 21mm and set Prestroke Mea-
suring Device (special tool) on the tappet guide of no.1 cylinder.
With No.1 cylinder plunger placed at BDC, feed fuel under pres-
sure to the injection pump with high-pressure pump of the pump
tester. Then, let the fuel flow out from the overflow pipe of the
test nozzle.
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
The plunger stroke from BDC until fuel stops flowing is called
Prestroke
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.
D4AF3428
4. Adjustment of prestroke Spring Holder

With the tappet at TDC, insert Spring Holder (special tool) be-
tween the lower spring seat and tappet.
Turn camshaft, and you have a clearance between the lower Adjusting
spring seat and tappet. Increase or decrease shim thickness shgims
to fill the clearance, to adjust the prestroke.

A greater shim thickness makes prestroke smaller.
A smaller shim thickness makes prestroke greater. D4AF0788
5. Measurement of injection start interval Angle scale
With the static injection start of No.1 cylinder used as a basis,

read the injection start interval of each cylinder according to
the injection sequence using an angle scale of the tester.
If the interval is out of specification, adjust as in prestroke adjust-
ment.
Injection sequence : 1 → 3 → 4 → 2
D4AF0789
6. Measurement of tappet clearance Prestroke

Intall Prestroke Measuring Device (special tool) and turn the cam- Measuring
Device
Clearance
shaft 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
Tappet Clearance Bar
prestroke at the maximum nominal value. D4AF0790
7. Adjustment of fuel injection rate Decrease ↔ Increase
Measure the fuel injection rate and uneven ratio with the speci-
fied rack position and speed.
If the injection rate is out of specification, adjust as follows.
o Slightly back of the pinion clamp screw.
o With the control rack fixed at a position, turn the control
sleeve with the adjusting rod.
o Tighten the pinion clamp screw. D4AF3472
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 injec-
tion rate adaptable to the enigne.
9. Inspection of Fuel and Oil leaks
o Check the delivery valve mounting position and other parts
for fuel leak.
o Check oil seals and other parts for oil leak.
10. Inspection of Unusual Conditions

Check for unusual noise, heat, and other abnormal conditions.
Installation
1. Bring the piston in No.1 cylinder to TDC on the compression Pointer
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
D4AF1253
2. Line up the the marking on the timer case with the notch in the
injection pump gear.
Notch
Marking
D4AF0791
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.
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
Timer case
injection
pump gear 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

7. Install the fuel hoses, fuel pipes and injection pipes and tighten eye bolts to specified torque.
25 to 34 N·m Fuel filter

(2.5 to 3.5 kgf·m)
25 to 34 N·m
Injection pipe Fuel feed pipe (2.5 to 3.5 kgf·m)
25 N·m (2.5 kgf·m)
Fuel hose
Fuel feed pipe

25 N·m (2.5 kgf·m)
Overflow valve
20 to 29 N·m (2 to 3 kgf·m)
20 to 25 N·m
(2 to 2.5 kgf·m)
20 to 25 N·m
(2 to 2.5 kgf·m)
Fuel return pipe Fuel

section
7.8 to 15 N·m pipe
(0.8 to 1.5 kgf·m)
Oil pipe
7.8 to 15 N·m
(0.8 to 1.5 kgf·m)
EFUMY01A
Bleeding the Fuel System Priming pump
Here is the procedure for bleeding the fuel system

1. Turn the injection pump priming pump counterclockwise until it
comes loose.
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 Air plug
1. The air plug must be tightened after the priming pump
D4AF0559
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.
Inspection and Adjustment after installation

(Fuel Injection Timing) Injection Pipe
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
delivery valve holder attached.
Stopper
NOTE
Delivery valve spring
1. Keep disassembled parts in gas oil to prevent contami-
nation by dust and dirt.
2. Keep the ignition switch at ON and release the gover-
nor stop lever.
D4AF0796
2. Install a spare injection pipe to No.1 cylinder.

Face the other end of the pipe downward for easier observa-
tion of fuel flow out condition.
3. Crank the engine to bring the piston in No.1 cylinder at a posi-
tion near BTDC 30°.
4. While operating the priming pump to let fuel run out from the
injection pipe, slowly crank the engine in the direction of nor-
mal rotation. D4AF0797
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
6. Make sure that the crankshaft pulley marker line and pointer
indicate the correct fuel injection timing.
Fuel injection timing (BTDC): Pointer
D4AL
Area D4AF D4AE D4DA D4DB
EURO- EURO-
General
(standard) 9° 9° 10° 8° 7° 7°
Cold 9° 9° 10° 8° 7° 7°
Tropical 9° 13° 10° 8° 9° 7°
High atitude 12° 13° 10° - 9° 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 Crankcase Injection pump
toward the crankcase side.
To retard the timing, move the injection pump away from the
crankcase.
D4AF0799
8. Loosen the injection pump attaching nut with universal Exten-

sion (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
10. With the injection pump attaching nut tightened, measure the 39 to 44 N·m
injection start timing again. (4.0 to 4.5 kgf·m)
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. 7.8 to 11 N·m
(0.8 to 1.1 kgf·m)
o Remove only the injection pipe and keep a small amount
D4AF0802
of fuel remaining at the top of delivery valve holder.
o Crank the engine to bring the piston in No.1 cylinder to
position about BTDC 30°C on the compression stroke.
Further crank the engine slowly, and the fuel on top of the
delivery valve will begin to move.
o This is the fuel injection start timing. The procedure,
however, involves a delay of approximately 2° behind the
specified timing because of the effect of the valve opening
pressure of the delivery valve spring.
NOTE
If the fuel injection timing is radically different from
the specification and the deviation is beyond the ad-
justable range of the injection pump, the engine tim-
ing gear and injection pump gear are not probably in
proper mesh. In this case, remove the injection pump
and reinstall it.
NB(EP-9) TYPE INJECTION PUMP [D4DA/D4DB/D4AL(EURO- )]

Disassembling
CAUTIONS
1. Wash outside of the pump.
2. Measure and keep record of the fuel delivery characteris-
tics 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 ele-
ment and the delivery valve, must be handled most care-
fully to protect them from damages.
1. Preparation Pump mounting flange

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
DR0503
pump mounting base (SST).
3) Put the 85 mm I.D. ring (SST) around the bearing cover of Ring
Governor
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 Feed pump
of governor used. See appropriate manual of the governor

DR0504
installed).
3. Saddle-type pump Pump holding

bracket
1) Put the pump holding brackets on the shaft of the pump
mounting vice (SST).
2) Mount the injection pump on the holding bracket, and se- Pump holding
fixture
cure it with the fixtures (SST).
DR0505
3) Remove the feed pump and tilt the pump body to drain lu- Timer
bricating oil from the pump chamber.
4) Remove SP timer.
5) Remove the governor. (This instruction varies by the type
of governor used. See appropriate manual of the governor
installed). Governor
Feed pump
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 Handle
1 to 2mm
bolts, and turn the guide until the clearance between the approximately
Washer
washer and the handle is approximately 1 to 2 mm, to set
the remover. Guide
NOTE
The guide of the delivery valve holder remover (SST)
is left-hand threaded.
DR0508
3) Turn the SST handle clockwise into the delivery valve Turn clockwise
holder. Continue until the O-ring in the cylinder comes off
the pump housing.
Cylinder
O-ring
DR0509
4) Pull the delivery valve holder remover (SST) upward to re-

Deliver valve
move the delivery valve group. holder remover
Deliver valve
group
DR0510
5. Remove the rack guide screw
DR0511
6. Removal of control sleeve

1) Pull the control rack to the left (viewed from the feed pump) Control sleeve
as far as it goes. remover(SST)
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.
DR0512
CAUTION
Be extremely careful not to damage the plunger.
7. Remove the control rack
DR0513
8. Remove the plunger

Plunger
1) Bring the camshaft of the cylinder to its top dead center. Lower spring foot
seat hole
2) Turn the plunger by tweezers by approximately 90° (to ei-
ther direction) until the flange of the plunger foot is in the
same direction as the hole in the lower spring seat, and Lower spring seat
pull out the plunger.
NOTES
1. Handle the plunger very carefully not to damage it. DR0514
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.
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.
Spring compression
tool
DR0515
2) Position the guide lever of the spring compression tool (SST)

Handle SST
toward you (in parallel to the handle), and put the pro-
jected part of the upper spring seat accurately into the guide Projected part
of the spring seat
groove at the end of the extractor.
Stopper
pin
CAUTION
Bring the cam of the cylinder to its bottom dead point. Plunger
Guide lever spring
The seat cannot be removed if the cam is at its top
dead point. DR0516
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.
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
12. Remove the tappet using the cir-clip pliers (SST)

NOTE Camshaft
The tappet can be removed more easily when the cam of

the cylinder is at its top dead center. 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 gover- Camshaft
nor side, and remove the camshaft and the bearing cover
together. Bearing cover
NOTE
Put the round nut of the governor to the camshaft at
the governor side to protect the thread.
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 deliv-
ery valve holder.
Setting support
DR0523
2) Then, remove parts. Delivery valve holder

O-ring
Washer
Valve spring
Delivery valve
Valve gasket
O-ring
DR0524
15. Removal of bearing Bearing remover

1) Pull out the roller and the inner race using the bearing
remover.
DR0525
2) Use the guide, to remove the bearing at the governor side

(20f).
Bearing
Guide 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 ele- Plunger
ment to about 60° as illustrated, and pull the plunger by (pulled up by 10 to 15 mm
approximately)
approximately 10 to 15 mm and release it to see if it slides
60°
down smoothly by its weight. Turn the plunger and repeat approximately
the sliding test several times at different plunger positions.
Remedy
If any defect is found with the plunger, replace the
pump element. DR0528
2. Delivery valve
1) Check the delivery valve for scratch on the valve seat and Seat face
Valve
the piston sections. Relief valve
2) Wash the delivery valve well in clean light oil, pull the valve Delivery
up and release it to see if it slides down smoothly until it valve
touches the valve seat. Valve

seat
REMEDY
If the valve does not fall smoothly, replace the tappet. DR0016
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 Tappet roller
pin. Roller bushing
Allowable limit ............................................... 0.3 mm
Roller pin
REMEDY
DR0529
If the allowable limit is exceeded, replace.
3) Check the plunger contact surface for wear. 0.2mm max.
Limit of wear ............................................... 0.2 mm
REMEDY
If the limit of wear is exceeded, replace.
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 Key groove Key groove
the camshaft for scratch at the tapered portion, peeling,

local wear or scr ......
REMEDY
If any defect is found, replace.
Oil seal contact surface

2) Check for wear on the oil seal contact surface. DR0531
Limit of Wear ............................................... 0.2 mm
REMEDY
If the limit of wear is exceeded, replace.
3) Put the camshaft on two V-blocks as illustrated, and mea-

sure the run out at the center of the shaft with a dial gauge.
Limit of run out .. ........................................ 0.15 mm
REMEDY
Repair to 0.15 mm max. with a press, or replace.
V-block 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
DR0533
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 L-
shaped ruler, as illustrated.
Allowable limit ........... 2 mm for plunger spring.

1 mm for delivery valve spring
REMEDY DC05085
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.
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
Hand press
1) Put the bearing driving tool on the bearing outer race, and
press-fit it into the bearing cover using a hand press, as
Bearing
illustrated. driving tool
2) Install adjust ring, shim and bearing in this order into the 1)
Outer race
camshaft. Put the bearing driving tool (SST) at the inner
race of the bearing and hammer the bearing to the camshaft.
DA3053
CAUTION
Put a round nut to the thread at the other end of the
Shim
camshaft to protect the thread.
SST
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 posi-
tion with washer (48) and set screw (49).
3. Assembling direction of the camshaft:

Put the larger end of the camshaft to the right or to the left or
the pump according to the rule given below. Pump model num- Camshaft Center bearing DR0536
ber (example) ND-PES6EP-9/105 R 12LSI-565. If the number
in the box in the pump model number is 3, position the larger
end of the camshaft to the left. If the number in the box is 4, as
in the example above, position the larger end of the camshaft
to the right of the pump. The number is not boxed in the actual
model number.
CAUTION
Position the larger end to the right or left as seen from the
feed pump side. DR0521
Measuring the protruding length of the camshaft
4. Bearing cover Guide rail

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.
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 Thickness (mm)

090194-0070 0.1
090194-0080 0.15
090194-0090 0.3
090194-0100 0.5 Shim plate
DR0540
1) Screw in the camshaft clearance gauge (SST) for P-type Camshaft

Guide
pumps in the camshaft at the drive side, install the guide clearance
gauge
(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
DR0541
Guide
Camshaft
clearance gauge
DR0542
2) If the specification is not met, use appropriate shim plates

Bearing cover
at the drive side until the specification is met.
Shim plate thickness
Part number Thickness (mm)

090194-0300 0.1
090194-0310 0.15
090194-0320 0.3 Shim plate
090194-0330 0.5 DR0543
6. Tappet
Install the tappet using the cir-clip pliers (SST).
Cir-clip pliers
CAUTION
Position the groove provided in the tappet in the axial Tappet
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.
DR0520
7. Lower spring seat Lower

Install the lower spring seat using the tweezers. spring seat
CAUTION
Be sure that the flange of the lower spring seat is accu-
rately inside the groove of the tappet.
This is very important since and inaccurately positioned
seat may cause damage to the pump.
DR0544
8. Install the plunger spring

Plunger spring
DR0545
9. Upper spring seat

1) Insert the upper spring seat with the projected part of the
seat coming at the drive side.
Projected part
DR0546
2) Attach the upper spring extractor (SST), and place the guide Guide
groove on the extractor at the projected part of the upper
spring seat.
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 Depress
the handle
the guide lever by 90° toward you, and install the upper Extractor
spring seat underneath the stopper pin which is driven in- Housing
side the pump housing. Guide
groove
Turn 90°
CAUTIONS Stopper pin
1. Bring the cam of the cylinder at its bottom dead center.
2. For each cylinder worked, check that the spring is ac-
Plunger spring
curately retained by the stopper pin (See Figure 54).
3. Check that the projected part of the upper spring seat DR0548
is at the opposite side of the rack (See Figure 54).
10. Plunger Toward the rack

Put the flange of the plunger leg through the hole provided in
the lower spring seat, with the part number marking coming at
the spill side (opposite from the feed pump), then turn it clock- Projected part
Upper spring seat
wise by 90°. Stopper pin
CAUTIONS
1. When the plunger has only one lead, be sure that the Plunger spring
Pump housing
vertical groove faces the spill side. This is very impor- DR0549
tant since the characteristics of injection amount will

be different if the plunger is positioned incorrectly.
2. Hold the plunger at its top, and pull it to check that it
does not come out.
NOTE Plunger
Lower spring foot
The plunger can be installed more easily if the cam of seat hole
the cylinder is at its top dead center.
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
Control rack
before inserting the control sleeve, as shown in Figure 57.
Housing
Control sleeve
Upper spring Stopper

seat pin
DR0551
3) Move the control rack until the ball in the control sleeve is
accurately inside the groove provided in the control rack. Plunager
Control rack
4) Tighten the rack guide screw.
CAUTIONS Upper spring

seat
The plunger may slip out of its position during install-
ing activities described above. Check the following for Control sleeve Plunager spring
the second time;

1. The vertical groove of the plunger must face the spill DR0552
side.
2. The plunger must not come out when it is pulled up.
12. Delivery valve group

1) Install the valve gasket, delivery valve, valve spring, shim, Valve holder
and the valve holder in this order inside the cylinder, as

Shim
shown in Figure 59.
CAUTIONS Valve spring
1. Wash each part in clean light oil before installing it. O-ring
2. Use new valve gaskets and O-rings. Never re-use
them.
3. Apply grease to each O-ring first to protect if from Delivery valve
O-ring(a)
damage. Install O-rings (a), (b), and (c) in this order,
Valve gasket
as shown in Figure 59.
O-ring(b) Cylinder
O-ring(c)
DR0553
2) Secure the pump setting support (SST) in a vice, put the Torque wrench
delivery valve group in the support, and tighten the deliv-
ery valve holder to the delivery valve group using the torque
wrench to the specified torque.
Box
Tightening torque ............ .................... 8 to 10 kg-m
Setting support
DR0554
13. Installing the delivery valve group Marked line

1) Apply a small amount of grease to the O-rings and outside
of the cylinder, position the cylinder with the marked line
on its flange coming toward the opposite side of the feed
pump, put the cylinder through the plunger moving the con-
trol rack to right and left, and insert the delivery valve group
inside the housing.
CAUTIONS DR05a55
1. Put the cylinder in the correct position. This is very

Shim
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. Shim
3. Install the delivery valve group very carefull so that

no burr is created on the plunger. DR0556
2) Put shims under the flange of the cylinder.

ø2.5
CAUTIONS Marked thickness(x100)
1. Put two counterparts of a shim of the same thick-
ness at sides of each cylinder. Use only one piece
on each side. This is very important since, it coun-
terparts having different thicknesses are used in
one cylinder, the rack will not move smoothly and
hunting and other troubles will result. DR0557
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.
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) Control rack sliding

resistance (g)
0 100 mx. DR0559

GOVERNOR FL-71
RLD TYPE GOVERNOR [D4AF/D4AE/D4AL (EURO-I)]

Disassembly
1
19
15 2
18
44
17 3
16 40
45
10 43
39 42
23 35 46 41
9
8 38 34
7 37
22 Dimension between
11 31 guide screw upper end
21 and housing end
20
30 32 NV 13.5 to 14.5
29
13 27 36
14 26 5 4
12 33
28
24
NV ... Nominal Value
6
25
1 Boost compensator assembly 16. Stop device lever 31. Shifter
2. Push rod B 17. Supporting lever 32. Shim
3. Spacer 18. Shim 33. Torque cam
4 Idling screw 19. Stop lever 34. Adjusting lever
5 Idle spring 20 Round nut 35. Adjusting lever section
6 Governor cover 21 Flyweight assembly 36. Guide lever
7 Governor spring 22. Governor housing 37. Floating lever
8 Spring seat 23. Start spring 38. Supporting lever
9 Governor shaft 24. Rod 39. Adjusting lever shaft
10. Rack connecting link 25. Lock screw 40 Disc
11. Sensor lever 26. Plug 41. Cover
12. Full load set lever 27. Cancel spring 42. Diaphragm
13. U-lever 28 Tension lever shaft 43. Push rod A
14. Full load lever shaft 29. Tension lever shaft assembly 44. Boost compensator spring
15. Stop lever shaft assembly 30. Sleeve 45. Housing
46 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
1. Remove the automatic timer and timer case.

Automatic timer Feed pump
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
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
5 Using Extractor (special tool), lock the camshaft against rota-

tion and remove the round nut using Special Wrench (special compensator
tool).
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 Special
and remove the idling spring from the front of the governor Wrench
cover.
Extractor
Idling spring
Idling screw
Special Wrench
D4AF3496
GOVERNOR FL-73
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
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
Special
adjust the tightening amount at replacement of parts or adjust- Wrench
ment of boost compensator.
D4AF0881
Inspection and Reassembly
3 1
19
2
15
18 44
17 40
16
45
43 42
10 39 46
35 41
23
9 8 38 34
7 37
32
22 31
11
21
20 30
29
27 36
13
14 26 5 4
12 33 28
24
49 to 59 N·m
(5 to 6 kgf·m)
25 6
Dimension between governor Stake
housing end and center of Apply adhesive to cover
pin hole in shifter
NV 39±0.2
Assembly sequence
15 → (19 → 18 → 17 → 16)
13 → 11 → 14 → 12 → 22
10 → 23
9 →8 →7
28 → 27 → 26 → 5 → 4
→ 29 →6
24 → 25 → 33 → 3→ 1
21 → 20 → 30 → 32 → 31
34→ 36→ 35 (39 → 38 → 37)
2
42 → 43 → 44 → 40 → 45
41 → 46
For reassembly of parts with an encircled number, see following pages.
D4AF087F
GOVERNOR FL-75
1. Install the governor housing to the pump housing and tighten

the bolts to specified torque. When installing the governor
Spring support
housing, install the spring support at illustrated location.
Governor
housing
Pump housing
15 to 18 N·m
(1.5 to 1.8kgf·m)
D4AF3522
2. Install the flyweight and using Special Wrench (special tool),

tighten the round nut to specified torque. Extractor
Special Wrench
49 to 59 N·m
(5 to 6 kgf·m)
D4AF352D
3. Install the U-lever assembly and spring and tighten the plug to
specified torque. Plug
20 to 29 N·m
Spring (2 to 3 kgf·m)
U-lever
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 N·m
(1 to 1.4 kgf·m)
Full load lever
Full load set lever
Spring
D4AF3513
5. Install he start spring to the rack connecting link. Start spring

NOTE
Hook
Insert the hooked end of the start spring to the connect-
ing link from above.
Rack connecting link

D4AF1566
6. Installation of shifter
Adjusting shim
With the sleeve fully pressed against the flyweight slider, vary
adjusting shim thickness to obtain the dimension shown at right
for the distance between the governor housing end face (seat-
ing surface with governor cover) and the shifter pin hole center.
Install the shifter assembly to the tension lever.
Adjusting shim thickness:
L1=29+0.2 D4AF0883
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 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 FL-77
10. After the governor cover has been installed, slack the gover-
nor spring set tension.
Ensure that the following control rack position is obtained when
the control rack is pushed to the governor from the pump drive
end with the adjusting lever operated to the full load position
without restricting the adjusting lever and full load set lever (by
the stopper bolt).
Control rack movement: 9.5 to 21
Then, check to see if the control rack smoothly reaches to the
following maximum point when it is released.
Injection pump maximum lift: 21
(Control rack entire stroke)
Adjustment after Reassembly

Governor performanace Curves
<Standard>
Rack limit
R6/N6
R10
R1 R7
N11
Rack position
R2 R8/N8 R9
R3
R4
R5
N10 N3
N1 N2 N4 N5 N7 N9
Pump speed
D4AF0885
Adjsutment for Adaptation to Engine
Adjusting lever angle

Idling set bolt Full speed set bolt
Stopper bolt
Ø2
Full Idle
Full load set lever Ø1
Full load set bolt

Governor spring adjustment
Idling spring adjustment

Ø1 Ø2
Standard 42° ± 3° 26° ± 3°
Option 42° ± 3° 26° ± 5°
D4AF4409
1. Preparation Stand Square

Align this
Install the injection pump to the pump tester and feed injection surface
pump oil to the governor and cam chambers.

Remove the idling spring, governor shaft lock nut, and boost
compensator assembly.
Lever
Loosen the full speed set bolt, idling set bolt, and full load set
bolt. Adjusting nut
Remove the smoke set assembly. Handle
Pin Adjusting Device
Installation of Adjusting Device
Make the lever run in parallel with the supporter at the portion Pin
indicated in illustration. Set "0" on the dial at the lever pointer Ajusting nut
and tighten the lever pointer and tighen the knurled lock nut Supporter
Adjusting lever
Stand
under the handle.
Adjusting
Using the adjusting nut, position and fit the pin on the handle lever shaft
shaft into the center hole in the governor adjusting lever shaft.
Then, fit the pin on the lever into the adjusting lever rod con-
D4AF4442
necting hole.
With the handle loosened, turn the lever and make sure that
the control rack slides smoothly.
GOVERNOR FL-79
Control Rack 0 Position Setting Measuring Device
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.
D4AF0822
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 le-
ver 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 speci-
fied position, make required adjustments.
o Before moving the adjusting lever to full speed position,
make sure that the pump speed is increased to 500 to 600
rpm with the lever at idle position.
o The torque cam adjusting nut must be locked in position
with the lock screw.
2. Governor spring contact adjustment

Idling lever Position Temporary Setting
Using the adjusting device, temporarily fix the adjusting lever at
a position in contact with the idling set bolt. Idling
set bolt
Tighten the idling set bolt to obtain the rack position R1, with
pump speed N1.
D4AF4449
Then, read the adjusting device dial to ensure that the adjust-
ing lever angle is within the specified range. R1
Idling Spring Adjustment R2

position
R3
R4
Rack
R5
N1 N2N3 N4 N5
Pump speed D4AF0884
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.
D4AF0889
If the control rack position is not R3, adjust with adjusting shim.
Outer spring
<Types of shim> Idling screw
0.1, 0.2, 0.25, 1.0
Inner spring
Adjusting shim D4AF3800
After adjustment, tighten the idling screw to specified torque 9.8 to 15 N·m
using Special Wrench (special tool). (1 to 1.5 kgf·m)
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. D4AF0890
After adjustment, tighten the lock nut to specified torque using

Special Wrench (special tool). Special Wrench
9.8 to 15 N·m
(1 to 1.5 kgf·m)
D4AF3801
GOVERNOR FL-81
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 Idling set
bolt
idle is within the specified range.
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 Back off
becomes R6 when pump speed is kept at N6 with the full load
R6
set lever at full load position.
Rack position
Screw in
N6 N7
Pump speed D4AF0892
Torque cam adjustment Special Wrench

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.
D4AF0893
If the rack psotiion varies, it means that the torque cam is im-
properly adjusted. Make readjustment, or if it is impossible, R8
R6
Rack position
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.
N6 N8
Pump speed D4AF0894
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 Idling set
bolt
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. D4AF4449
Gradually increase the pump speed, and ensure that the pump
speed becomes N9 when the rack is pulled to R9. Make also R6
sure that further increasing the pump speed causes the rack
Rack position
R9
to be pulled to 0.
N7 N9
Pump speed
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 Spacer

With the specified rack position obtained, ensure that the di-
mension L (24±0.5 mm) is obtained for the distance betwen
the spacer end face and push rod B end.
If the specified dimension is not obtained, the governor is
probabley improperly adjusted or wrong parts are installed to
push rod B. Various types of push rods are therefore estab-
lished as shown at under for adjustment of L dimension. Push rod B D4AF0897
The overall length varies with the length of section with a larger
diameter (∅10). There are two length available for the section
with a smaller dimenter (∅5).
Rb
Rack position
Boost compensator Activating Point Adjustment

Boost
Adjust with the screw A so that the oost compensator is acti- compensator
stroke
vated at Pa. Ra
After adjustment, secure with the alock nut.
Pa Pb
NOTE
Boost pressure
Do not turn screw A more than four turns from the fully D4AF0898
loosened position.
GOVERNOR FL-83
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
Screw B
24 ± 0.5
D4AF0899
Ensure that the specified rack position ra is obtained with a When boost pressure
boost pressure of Pa. Make also sure that the rack is posi- is applied
Rb
tioned at Rb when the boost pressure is Pb. Ra
Rack position
Boost compensator
NOTE Boost pressure 0
strok
When making the adjustment, raise the boost pressure,
and never decrease.
Pump speed
D4AF0900
6. Smoke set assembly operating limit check

Set the pump speed slightly above idle N2 and lock the adjust- Rack limit
ing lever at a position to obtain rack position R2. R1
Rack position
Make sure that the rack position is beyond R1 when pump is
R2
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 N2
full position does not permit obtaining the smoke set rack Pump speed
D4AF091A
position at startup.
7. Black smoke prevention limit check

R10
Set the adjusting lever at idle position and decrease the pump
speed down to N10. Then, ensure that the smoke set is not
Rack position
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. N10 N11
Pump speed D4AF0919
8. Sealing
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).
Torque cam
<Rod>
Governor
o Torque cam shaft
Tension lever
Idling spring
o Tension lever pin pin
Tension lever pin
o Govenor shaft
o Idling spring Rod
D4AF3494
Inspection and Adjustment of No-load minimum and Maxi-

mum Speeds
Perform the following check after the engine has been suffi- Adjusting
lever
ciently warmed up.
1) Minimum speed
Make sure that the adjusting lever is in contact with the Full speed
set bolt
idling set bolt. Then, measure to ensure that the minimum
speed is within specification. Idling set bolt
D4AF0920
If the speed is out of specification, adjust with the idling set bolt.
2) Minimum speed
If the maximum speed is not within specification when the
adjusting lever is in full load position (where it is in contact
with full speed set bolt), adjust with the full speed set bolt.
NOTE
1. Never change the fixed position of full load stop-
per bolt.
2. Ensure that the engine does not stall or hunt when
the adjusting lever is quickly shifted from the full
load to idle position. If abnormal condition is
evident, adjust within the specification.
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 adjust-
ing measurements. This will help pinpoint the cause of the failure by comparing the adjusting measurements before
and after disassembling.
3. Each time a part is removed, check the condition under which it was fitted, and whether or not it has any discoloration,
bruise or any other damages.
4. Arrange the disassembled parts in an orderly fashion and separate the parts to be reused from those to be replaced
to facilitate the subsequent re-assembling procedure.
Assembling
1. Follow the correct procedures and use the recommended standards in assembling; for example, tightening torques,
fitting dimensions, etc.
2. Be sure to wash each part in clean light oil before installation.
3. Special care should be taken in assembly to avoid the entry of foreign material into the governor.
Any small part, such as washer, dropped in the governor may cause a serious problem to the engine in operation.
4. Always discard old nipples, washers, cotter pins, E-rings, gaskets, etc.; DO NOT reuse them.
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 Full load stopper housing 32

Tightening bolt
1. Remove the full load stopper housing 32 damper screw 67
and cover plate 45 from the governor cover. 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
3. Unscrew six pieces of governor cover bolts 26 . Detach the

return spring 7 -4 from the floating lever sub-assy 7 -1. With
the adjusting lever held in its "idling" position, detach the gov-
ernor cover 2 by lifting it up in such a way that the sliding
block may slide out of the slot in the flating lever 7 .
FIG8-3
CAUTION:
Floating lever
Before lifting the governor cover, be sure to pull the sup-
porting lever 15 upwards, as shown by dotted lines in Pull up
supporting
fig.40, so that its lower end does not obstruct the lifting of lever
governor cover.
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 sup-
porting lever 15 , slider 6 and cotter pin 55 (for shackle). Cotter pin 65
Then remove the start spring 34.
(On some governors, an E-ring is used in place of the cotter
Floating lever 7
pin).
CAUTION: Slider 6 Supporting
lever 15
Because the silder 6 is a precision part, great care should FIG8-5
be taken in handling to avoid damage during removal.
2. Unscrew the connecting bolts 37 to remove the arm sub-

assembly 33 from the control rack. Arm
sub-assembly 33
Connecting
bolt 37 Start spring 34
FIG8-6
E-ring 14
Plate 58
Steel plate washer 66
Arm sub-assy 33
Start spring 34
Floating lever 7
Sliden 6
Lock washer 56
Connecting
bolt 37 Supporting lever 16
FIG8-7
GOVERNOR FL-87
Removal of the Flyweight Assembly

1. Bearing bolt removal
Untab the lock washer 13 -19 on the jointing bolt and remove Lock nut 3 -18
the locknuts 3 -18, pull out the jointing bolt 3 -13 and
bearing bolt 61 .
Jointing
bolt 3 -13 Lock washer 3 -19
Bearing
bolt 61 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 Guide bushing 3 -19
Thigtening bolt 3 -18 FIG8-9
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. Flyweight
CAUTION: Round nut wrench

(SST)
Use the holding spanner (SST) to keep the camshaft from
rotating.
FIG8-10
4. Flyweight assembly removal

Remove the flyweight assembly with the flyweight extractor
Flyweight
(SST).
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
5. Flyweights disassembling Idle outer spring

Remove the adjusting nut 3 -11 with weight spring nut wrench Spring seat Adjusting nut
Washer Control
(SST), and disassemble the inner parts of the flyweight spring
assembly, such as spring guide 3 -8, governor springs, etc.
Spring inner seat

Mechanical
spring Spring guide
Idle outer spring
FIG8-13
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 Adjusting lever 20

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

Adjusting lever shaft
FIG8-15
2. Remove the taper bolt 9/1 , pull out the adjusting lever shaft and Lever shaft
remove the steering lever 9 . 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 FL-89
Disassembly of the Boost Compensator

1. Loosen the bolts shown in Fig.8-18 first, and then disassemble
Loosen
the full-load stopper assembly from the governor.
FIG8-18
2. Measure and record "A" dimension from the edge of the boost
compensator housing to the guide bushing as shown in Fig.8-
19.
NOTE
Make sure to record the dimension A as the guide bush-
ing is put in place based on that length during assembly.
Guide bushing
Boost compensator
housing FIG8-19
ASSEMBLY
After checking each part, assemble the governor in the following
Tightening torque:
steps of procedure: 1.8 ~ 2.0 kg·m
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 FIG8-20
Install the stop lever 49 as shown in the diagram of Fig.8-21.

Stop lever 49
When installing, adjust by clearance shims 63 (Clearance Toler-
Spring cover 54
ance = 0.05 - 0.1 mm) between stop lever and its support shaft. O-ring 51
The O-ring 51 should be coated with grease before being fitted Bolt with 0.05~0.1mm
washer 46 (R801 and R901)
into the lever assembly. Return spring 53
Tightening
torque:
0.8 ~ 0.9 kg·m Stop arm 48
Installation of the Flyweight Assembly Shim
63
1. Flyweight assembling Governor
Refer to Fig.8-22, install the guide sleeve, governor springs, housing FIG8-21
etc. into the flyweight, and then tighten the adjusting nut with
weight spring nut wrench (SST). Projection:
Adjusting nut -0.4 ~ 0.2mm
Guide sleeve (R801 and R901)
CAUTION: Idle outer
spring Spring inner seat
1. Be sure to install the spring inner seat in correct Control spring
2.5mm
position; namely, its "lapped" surface should face Idle inner spring
downwards. (Reverse instaalation should be avoided.)
Spring seat
2. The adjusting nut should be tightened so that the pro-
jection of the flyweight holder shaft is between -0.4 3.5mm
“LAPPED” surface should
mm to 0.2 mm (R801 and R901). If the projection ex- face downwards when installed FIG8-22
ceeds 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.
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 Tightening torque:
5~6 kg·m
3 -23 with round nut socket (SST).
Round nut socket(STT)
CAUTION
1. Tighten the round nut 40 with a torque of 5-6 kg·m.
2. In tightening, hold the camshaft from rotation by using
the holding spanner (SST).
FIG8-23
Flyweigh with Damper

1. Adjustment of the damper clearance
This adjustment determines the clearance between the fly-
weight assembly and camshaft bushing for proper operation of
the dampers.
1) Install the camshaft bushing on the camshaft.
Clearance
2) Install the flyweight assembly with the campers removed. adjusting shim
3) Install the round nut a tighten to specified torque. FIG8-24
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 Flyweight
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
2. Installation of the dampers Camshaft bushing
1) Install the camshaft bushing on the flyweight assembly.

2) Insert the six dampers between the lip of the camshaft bush-
ing and the flyweight assembly.
Dampers
NOTE:
Smear some labrication oil on the rubber dampers prior
to installation.
FIG8-26
3) Press down on the dampers with fingers and tap the cam-
shaft bushing with a plastic mallet to set the dampers in
place.
CAUTION: Plastic mallet
Be careful not to damage the campers.

After installing the dampers, install the flyweight assembly
onto the camshaft and tighten the round nut.
FIG8-27
GOVERNOR FL-91
Installation of the Bearing Bolt Tightening torque :

0.6 ~ 1.0 kg·m
1. Fasten the guide bushing 3 -12 with the two dmping bolts.
Guide bushing
Tightening torque : 0.6 ~ 1.0 kg· Lock washer
CAUTION
After tightening the clamping bolts, make sure that the
bearing bolt slides in the guide bushing. Bellcrank
bolt 3 -13 Nuts 3 -18
Bearing bolt 61 FIG8-28
2. Install the bearing bolt 61 , and insert the bellcrank bolt 3 -13
through the flyweight arms. Then, install the nuts 3 -18 and
1.5~2.0mm
lock washer 3 -19. The lock washer should not be tabbed yet. Bellcrank
bolt 3 -13
CAUTION
Nuts 3 -18
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 Washer 3 - 22
On elongated Lock washer
on the elongated hole side of flyweight). hole side of 3 -19
flyweight
FIG8-29
3. Fitting dimension of the bearing bolt Bearing bolt
1) Measure the distance L, as shown in Fig.8-32 after the

bearing bolt is put in place. Slider
2) Check whether the length L, is within the fitting dimension.
Adaptor
Fitting dimension L = 50.05 ± 0.2mm (R801) plate
= 49.9 ± 0.2 mm (R901)
Vernier
3) If the length L, is outside the fitting dimension, remove the calipers Housing
FIG8-30
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 fol-
lowing table and put it in place.
FIG8-31
R801 governor
Parts number Length (ι) Parts number Length (ι)

901411-0180 31.9mm 901411-0220 31.1mm
901411-0190 31.7mm 901411-0230 30.9mm
091411-0200 31.5mm 091411-0240 30.7mm
091411-0210 31.3mm
R901 governor
Parts number Length (ι) Parts number Length (ι)

901411-0320 34.54mm 901411-0360 33.74mm
901411-0330 34.34mm 901411-0370 33.54mm
091411-0340 34.14mm 091411-0380 33.34mm
091411-0350 33.94mm 091411-0450 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 direc-
tions indicated by the dotted lines in Fig.8-29. Then, shake-proof
the clamp bolts, which secure the guide bushing, by using a
wire. (Fig.8-32)
NOTE Shake-profing
The shake-proofing wire has been abolished from 1983

Lock washer
production. If a shake-proofing wire was not originally FIG8-32
installed, coat the clamping bolt with adhesive and tighten

them to the specified torque, 0.6 ~ 1.0 kg·m.
Assembling of the Governor Cover

Cam plate 12
1. Fit the cam plate 12 to the governor cover 2 . Allow a play of Bushing 57
0.08 to 0.12 mm (R801 and R901) in the axial direction by Washer 64

Governor
selecting appropriate adjusting washer. cover 2
(From production on August, 1983, the bushing 57 has been E-ring 14

replaced by 4 washers, each of which is 0.5 mm thick. The
0.08~0.12mm
axial clearance can be changed using them.)
FIG8-33
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.
GOVERNOR FL-93
2. Install the steering lever and adjusting lever shaft to the gover- Sliding block
nor cover.
Steering
NOTE lever
Taper bolt
From production in September, 1981, the sliding block has
Tightening
no recess cut in it. Refer to the drawing at right when in- torque:
0.4 ~0.7kg·m 0.5~1.5mm
stalling the sliding block into the floating lever.
(R801 and R901)
Adjusting
lever shaft FIG8-34
Installation of Linkage Assembly

Plate washer
1. Fasten the arm sub-assembly 33 to the control rack with the Shackle 8 Cotter pin
connecting bolts 37 . Hook the start spring 34 to the arm
Washer 56
assembly and the stopper plate. Arm nut
Connecting
NOTE: bolt 37
Control rack
In the above step, be sure to place the arm nut 58 in the
Arm
Start
correct position. (Fig.8-35). sub-assembly 33 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. Floating
leve 7
(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
Supportin
bend its legs after installation. Slider 6 leve 15
2. Make sure that the supporting lever can swing freely FIG8-36
by its own weight when released from lifted position.

(Fig.8-36, 37)
Slider
Supporting lever
Supporting lever
shaft Supporting lever should return
easily by its own weight
FIG8-37
Installation of the Governor Cover

1. To install the governor cover, keep the control rack pulled to-
wards the governor side and place the adjusting lever in its
idling position. Release the return spring from the floating lever
sub-assembly. With the free end of the supporting lever pulled
up, install the governor cover by guiding the sliding block with
your fingers into the slot of the floating lever. Re connect the
return spring to the floating arm sub-assembly. FIG8-38
CAUTION:
Be sure that the sliding block should be inserted with its
concave side facing upwards.
(Refer to Fig.8-36 and "NOTE".)
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 Tightening
governor cover bolts 26 . Torque :
1.0~1.4kg·m
4. Finally, attach the full-load stopper housing 32 and cover
plate 45 .
FIG8-39
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 specifica-
tions sheet for each pump reference number.
FIG8-40
TEST AND ADJUSTMENT FL-95
TEST AND ADJUSTMENT Protractor (SST)

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 Full-load stopper

Adaptor screw
Maximum speed adjusting screw
Damper screw
Screw plug
Adjusting lever
Idle adjusting screw
Adjusting nut
D431003
1. Idle Adjusting Screw

This adjusting screw serves to determine the idling position.
In Fig.D431005, the solid line represents the standard charac-
Rack Screw out
teristic while the dotted and dash-dot lines show the changes travel
in the characteristic when the screw is turned out and in,
respectively. Screw in
Pump speed
D431005
2. Maximum Speed Adjusting Screw

Screw in
This adjusting screw is used to determine the point at which
engine maximum speed is governed.
Rack
The dotted and dash-dot lines show the changes of governing travel
Screw out
characteristic, respectively.
Pump speed
D431007
3. Full Load Stopper

Screw in
Turning this stopper screw changes the quantity of fuel deliv-
ered in the full-load condition.
Rack
The changes of characteristic are shown by the dotted and dash- travel
dot lines, respectively. Screw out
Pump speed D431009
4. Adaptor Screw
Screw in
This screw is used to change the adaptor stroke in medium and
high-speed ranges under full load.
Rack
The changes of characteristic are shown by the dotted and dash- travel Screw out
dot lines, respectively.
Pump speed D431011
5. Adaptor Screw &

Screw out &
The changes of characteristic are shown by the dotted and dash-
Rack
NOTE: travel
Screw in &
For this setting adjustment, the adaptor screws and
are used together.
Pump speed D431013

6. Damper Screw (if installed)

This damper screw prevents engine stalling in rapid deceleration.
By turning in this screw, the rackk travel will change with respcet
Rack
Screw in
to pump speed from the solid line to the dash-dot line. travel
Pump speed
D431015
7. Adjusting Nut
Screw in
This adjusting nut is used to alter the idling and maxmum speed
governing characteristics.
Rack Screw out
The changes of characteristic are shown by the dotted and dash- travel
Fine adjustment for the same purpose can be done by means
of washerss.
Pump speed D431017
PREPARATIONAL PROCEDURE
Prior to governor adjustments, perform the following procedural steps: Rack travel
1. Install the rack travel gauge (SST) on the control rack, and set gauge (SST)
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. D431019
4. Refill the governor and pump camshaft chambers with recom-

mended lubricating oil (engine oil).
NOTE:
Always use a high accuracy type rack position sensor for Ra
Rack Rb
Adjusting
the adjustment of the R901 governor. travel lever set
Rc
Rd
Re
ADJUSTMENT OF IDLING SPEED CONTROL

Na N bNcNd Ne
Pump speed
1. Drive the pump at the speed of Nc*, and turn the idle adjusting D431021
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 .

D431023
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 character- Rack Washer
travel thickened
istic towards the dash-dot line (Fig. D431025). Washer
thickened
4. Drive the pump at Ne, and check rack travel Re. Adjust if neces-
sary by changing washer (Fig. D431027). An increase in
washer thickness will change the characteristic towards the Pump speed
D431025
dash-dot line (Fig. D431025).
Washer Adjusting nut
NOTE: Projection:
Guide sleeve
1. After adjustment, check the projection of the flyweight Idle outer -0.4 ~ 0.2 mm
spring (R801 and R901)
holder shaft. The projection limits of -0.4 to 0.2 (R801 Washer
and R901) mm must be met to prevent interference with Control Spring
inner
the housing. spring
seat
2. Adjusting washer should be inserted on the guide Idle inner
spring
sleeve side.
Spring
seat D431027
5. With the R801 governor with a 3rd idle spring, its characteristic
3rd idle Spring
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.
Larger
NOTE:
Make sure that the 3rd idle spring is installed in the cor-
rect direction. (See Fig.D431029) Guide Bushing
D431029
6. With the R901 governor, all of its springs (idle outer spring, idle <R901 governor>
inner spring, 3rd idle spring and control spring) each have a
washer for adjustment.
Rack
Washer
Washer : For idle outer spring travel
Washer
Washer : For idle inner spring Washer
Washer : For 3rd idle spring
Washer
Washer : For main spring
Pump speed D431031
Washer <R901>
Washer
Washer
Washer
D431033
Washer
PRELIMINARY ADJUSTMENT OF MAXIMUM SPEED Guide sleeve
Adjusting nut
Projection:
Idle outer
CONTROL spring
-0.4 ~ 0.2 mm
(R801 and R901)
For this adjustment place the adjusting lever in its "full" position, Washer
then turn the maximum speed adjusting screw to achieve con- Control Spring
spring inner
trol rack cutback at pump speed Nf (Fig. D431043 & D431045) seat
Idle inner
spring
Spring
seat D431035
ADJUSTMENT OF MEDIUM SPEED CONTROL

Ri Rl
The full load stopper is used to change the adjustment of me-
Rj
dium speed control. (For the changes in characteristics, refer to
Fig.D431009) Rack
travel
1. Drive the pump at Nj, adjust the full load stopper to obtain rack
travel Rj. (For the changes in characteristics, refer to Fig.
D431009) Ni Nj
Pump speed
2. Drive the pump then at Ni, adjust using the adaptor screw to D431037
obtain rack travel Ri. (Refer to Fig.D431011)

3. Drive the pump at Ni, adjust adaptor screws and to obtain
arck travel Ri. (Refer to Fig.D431013)
NOTE:
To adjust the adaptor screw and , loosen the lock nuts.
Turn them using a screwdriver. To lock adaptor screw ,
use the double spanner method.
D431039
ADJUSTMENT OF MAXIMUM SPEED CONTROL Adjusting lever set

1. Perform this adjustment by turning the maximum speed ad-
justing screw to obtain control rack cutback at pump speed
Rack
Nf (Fig. D431007). (For the changes in characteristic, refer to R
travel g
Fig D431007).
Rh
Nf Ng N h
Pump speed D431041
2. Drive the pump then at Ng and Nh, and make sure the rack Maximum speed
travel equals Rg and is less than Rh. adjusting screw
D431043
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 di-
Rack
rection to obtain rack travel Rm (Fig. D431015) (For the changes travel Rm
in characteristic, refer to Fig D431015) Then, drive the pump at Ro
Rn
Nn and check rack travel Rn. Rh
Nm Nn No Np
Pump speed D431045
2. Then place the adjusting lever in its "full" position, check rack
travel Ro and Rp at pump speeds No and Np.
NOTE: Damper screw
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
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.
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
1. Calculate dimension G by the following formula. Rotate the guide

bushing so that G is the same as the required dimension. A
F
G=F-A
NOTE: G
"A" is the dimension measured during the disassembly.
(Refer to Disassembly of the boost compensator)
Guide Boost compensator
bushing 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. Apply
E 1000mmHg
boost
5. Check airtightness by applying 1000 mmHg pressure in the Pressure
diaphragm chamber. Check the pressure drop, if after 10
seconds the pressure is still greater than 980 mmHg, the Screw
compensator is O.K.
D431059
Adjusting Parts and Changes in Rack Travel Characteristics
Adaptor screw
Guide bushing
Stop screw
Full-load stopper
Adaptor screw
Damper screw
Adjusting lever
Screw plug Maximum speed

adjusting screw
Adjusting nut
D431061
For changes in rack travel characteristics by adjusting parts to

Screw in Low boost
,refer to Adjussting parts & changes in goverining characteristics. pressure
(consstant)
Boost compensator function has no affect on their operation.
Rack travel
1. To adjust fuel delivery quantity under full load with low boost
pressure, turn the stop screw . Screw out
Pump speed D431063
2. To adjust boost compensator characteristics, turn the guide

bushing .
Counter
Rack travel
clockwise
In Fig. D431067, the guide bushing is viewed from the stop screw
side. Clock wise
Boost pressure D431065

Preparational Procedure
1. Follow the instructions (1) to (4) given in preparational Three-way
hose
procedure (page 31-91).
2. To measure the pressure to be applied to the boost Air pressure
meter
compensator, use an air pressure meter in which operational
range exceeds 1000 mmHg. Connect the air pressure meter to Handle
the boost compensator port and the vaccum pump on the test
bench using a three-way hose. D431067
The vacuum pump handle must be turned completely counterclock

-wise in order to generate sufficient boost pressure.
SST : Digital air pressure meter
Rack
Preliminary Adjustment of the Stop Cam travel
Follow the instructions given in section 'Adjustment of idling speed
control'
Adjustment of idling speed control Nf

Follow the instructions given in section 'Preliminary adjustment of Pump speed D431069
maximum speed control'
Preliminary Adjustment of Maximum Speed Cotrol

With the specified pressure applied to the boost compensator, turn
Rack R3
the adjusting lever to the "full" position. Turn the maximum speed travel
R2
(mm)
adjusting screw until control rack cutback begins at pump speed Nf
R1
Adjustment of Medium and Maximum Speed Control

With the specified pressure applied, follow the instructions given in P1 P2 P3
Pressure (mmHg) D431071
sections 'Adjustment of maximum speed control' and 'Adjustment
of the damper screw'
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 specifica-
tion table of each governor.
1. Adjustment of the stop screw

With the pressure P1 applied, set the pump speed to the
specification. Turn the stop screw so that the rack travel is R1.
Screw in the stop screw increases rack travel. Stop screw
D431073
IDLE-UP ADJUSTMENT FL-105
2. Adjustment of the guide bushing Flat-blade

With the pressure P2 applied at the specified pump speed, screwdriver
measure fuel delivery quantity. If it deviates from the specified
range, adjust by means of the guide bushing. Guide
bushing
After adjustment, record the rack travel R2 .
Hysteresis check
Compare the rack travel when the pressure is raised to P2 and
conversely, when it is lowered to P2 . Make sure that the differ-
ence is within specification. D431075
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.
IDLE-UP ADJUSTMENT
Idle-up set and microswitch set
[Actuator vacuum: -47kPa (-350 mmHg) or below]
D4AF D4AL
Idle-up set 950 to 1,000 rpm 950 to 1,000 rpm
(on-vehicle)
Idle-up Adjustment Procedure <D4DA, D4DB> Lock nut

7.8 to 8.8 Nm
1. Warm up the engine, keep the transmission in neutral, and (0.8 to 0.9 kgf·m)
Actuator
keep the exhaust brake in "OFF" position. Adjusting screw
2. Activate the actuator by applying a vacuum of -47 kPa (-350
mmHg) or below to it. Adjusting lever
3. With the lock nut loosened, turn the adjust screw to obtain the
specified idle speed.
After adjustment, tighten the lock nut. D4AF0973
4. With the actuator released to the atmosphere, reapply the said
vacuum to it and ensure that the specified idle speed is obtained. <D4AF,D4AE>
If the idle speed is out of specification, repeat steps 2) and 3)
for readjustment.
NOTE Adjusting
lever
1. If the adjust screw does not permit correct adjustment Lock nut
7.8 to 8.8 Nm
on D4AE , move the actuator by loosening the actua- (0.8 to 0.9 kgf·m)
tor attaching bolts.
Adjusting screw
2. For on-vehicle adjustment fo idle-up speed, use spe- Mounting bolt
D4AF0974
cial care not to let the tools be in contact with the B-
terminal of starter.
FEED PUMP
Disassembly, Inspection and Reassembly
4
Deterioration
5
4
Deterioration
5
Seat wear
12
14
Cracks, thread damage 13
Wear
Dirt, clogging
7
Clean or replace
6
8 9 10 11
Disassembly sequence 10. Piston

1. Priming pump 11. Push rod
2. Eye bolt 12. Snap ring
3. Valve support 13. Tappet
4. Spring 14. Housin
5. Check valve
6. Eye bolt For reassembly, reverse the order of disassembly.
7. Gauze filter NOTE
8. Plug Know the trouble spots thoroughly by making tests before
9. Spring disasembly.
D4AF0978
AUTOMATIC TIMER FL-107
Test and Adjustment
Airtightness
No leaks from push
rod sliding surface
Air
Lift capacity pressure
<D4AL> Conditions 195 kPa
Delivery pressure No. of strokes required Feed pump
(2 kgf.cm²)
Condition 600 rpm before lifting when operated
NV 335 to 410 kPa at 60 strokes per minute.
(3.4 to 4.2 kgf/cm²) NV 25 strokes or more
Delivery
Condition
For 1 min, at 1,000 rpm
NV 1,620 cc or more
<D4AF>
Delivery pressure
Condition 600 rpm
NV 175 to 215 kPa
(1.8 to 2.2 kgf/cm²)
Lift capacity
Delivery Conditions
Condition Time requred before lifting
Trough ∅1.54 nozzle when operated at 150 rpm.
for min. at 1,000 rpm NV 45 strokes or more
NV 1,620 cc or more
Test conditions
Fuel pipe Lift capacity
I.D. 8 mm Conditions
Length 2,000 mm Time requred before lifting
Cam lift 6 when operated at 100 rpm.
<D4AF> NV 40 strokes or more
(Eccentric cam) 8 mm
<D4AE> NV ... Nominal Value
Height from oil level 1,000 mm
Test oil JIS No.2 light oil
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
2. Disassembly and inspection
Flaws in curved surface

6
Wear of pin
3
5
4
5 Deterioration
1. Circlip
2. Shim
3. Injection pump gear
4. Timer spring
5. Shim
For disassembly of parts with an encircled number, 6. Flyweight
see following pages. 7. Timer hub
D4AF0982
Remove the circlip and shim.
D4AF0984
Raise the injection pump gear while turning it in the direction to Injection pump gear
compress the time spring. Then remove the injection pump
gear.
NOTE
Use cre not to let the timer spring spring out.
D4AF0985
AUTOMATIC TIMER FL-109
3. Reassembly
8
Apply engine oil
when installed
Thrust clearance 7
NV 0.01 to 0.2 mm
4
3
2
6 Assembly sequence
5 7→6→3→4→5→2→1
6
For reassembly of parts with an encircled
number, see following pages.
1 NV ... Nominal
D4AF0982
1) Instal the timer hub.

Timer hub
D4AF0986
2) With the flyweight mounted on the timer hub, install the

Timer hub keyway Injection pump
injection pump gear in the direction of the illustration. gear
Flyweight
Gear marking
D4AF0987
3) While turning the injection pump gear in the direction to

Injection pump
compress the timer spring, fit the injection pump gear pin gear
into the curved surface of the flyweight.
D4AF0985
4) Check the spring for installed condition.
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. Socket Wrench
Then, tighten the round nut to the specified torque using Socket
93 to 98 N·m(8.5 to10kgf·m) :
D4AF,D4AE,D4AL(EURO- )
128 to 147 N·m(13 to15kgf·m) :
D4DA,D4DB,D4AL(EURO- ) D4AF0991
5. Test and Adjustment Advance angle adjusting shim

Whenever the automatic timer is disassembled, its advance
angle must be measured with the manufacturer's mesuring in-
strument and readjusted.
Automatic Timer Advance Characteristics
To adjust the advance characteristics of the automatic timer,
add or reduce the adjusting shims or replace the spring. Advance angle adjusting shim
D4AF0992
To reducethe advance angle, increase the shim thickness.
Shim thickness: Stopper
0.5, 0.6, 0.7, 0.8, 0.9, 1.0
Advance angle (deg)
Output point
6.5±0.5
Automatic Timer Advance Characteristics Curves
1,000 1,750
Pump speed (rpm)
D4AF0993
INJECTION NOZZLE FL-111
INJECTION NOZZLE Replace 3

2
25 N·m
Removal and Installation (2.5 kgf·m)
To remove and install the injection nozzle, use socket wrench and
1
Handle (special tools).
1. Bridge
2. Injection nozzle
3. Nozzle tip gasket
D4AF1004
If the nozzle tip gasket is hard to remove because of seizure, use

a gasket pliers (special tool).
NOTE
Cover pipes, injection nozzle, and injection pump to prevent
entry of dust and dirt. If the injection nozzle is removed, pro-
vide adequate means to prevent entry of dust into the cylinder.
Gasket Pliers
D4AF1007
Disassembly
7 Wear
6 Deterioration, cracks
Disassembly sequence 5 Wear

1. Retaining nut
2. Nozzle
4
3. Needle valve
4. Packing
3 Wear, damage
5. Pressure pin6. Spring
7. Washer
8. Nozzle holder 2 Carbon deposits
NOTE 1
Make sure that the combination of
the nozzle and needle valve is not
changed.
D4AF1008
Cleaning and Inspection

Nozzle Cleaning Tool
1. Cleaning
After cleaning the nozzle with gas oil, remove carbon deposits
with nozzle cleaning tool (special tool).
Proceed as follows.
D4AF7002
Remove the needle valve from the nozzle and clean the needle
Needle valve
valve with the needle valve cleaning wood piece. 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. clean-
ing needle and then finish with following:
D4AF D4AE D4AL D4DA D4DB D4AL(EURO- )

0.26 0.30 0.30 0.26 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 FL-113
Reassembly
NOTE
1. Never touch the sliding surfaces of the needle valve by
hand.
2. When replacing the nozzle tip with a new one, remove the 8
seal peel (synthetic resin film) and move the needle valve
in nozzle in a clean gas oil to completely remove the anti-
rust oil. 7
6
5
4
2
25 to 34 Nm
3 (2.5 to 3.5 kgf·m) <D4AF>
29 to 39 Nm
1 (3 to 4 kgf·m)
Assembly sequcne
8→7→6→5→4→3→2→1
D4AF1010
Test and Adjustment

1. Injection Pressure
Injection pressure
Install a nozzle to the nozzle tester. 21.6 to 22.6 MPa
(220 to 230 kgf/cm²)
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.
D4AF1012
Shim thickness:
0.95 to 1.25 in 0.05 increments
A 0.05 variation in shim thickness varies the injection pressure
by 0.49 MPa (5 kgf/cm²).
With a correct shim selected, recheck the injection pressure.
NOTE
Never let yourself exposed directly to the atomized fuel
injected from the nozzle.
2. Spray Condition
1 2 3 4 5 6
Good Good Poor Poor Poor Poor
Good spray
1. Evenly sprayed 3. Asymetricl
from five 4. Branched
injection orifices 5. Thin
2. Even and symmetrical 6. Irregular
Poor soray
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 Test pressure
19.6 to 206 MPa
specified pressure, to the nozzle tester and slowly increase (200 to 210 kgf·cm²)
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
FUEL FILTER FL-115
FUEL FILTER <Spin-on type>

1. Fuel feed pipe or hose
2. Fuel feed or hose
Removal and Installation 3. Fuel filter
34 N·m
(3.5 kgf·m)
2
34 N·m
(3.5 kgf·m)
1 3 D4AF1015
On the double-cab model, first remove the rear inspection cover.
D4AF1016
When removing the spin-on type fuel filter, use Filter Wrench <Spin-on type>
(special tool).
To install, tighten additional 3/4 to a full turn after the element gas-
ket is seated on the filter head.
Filter Wrench
NOTE
After installation, run the engine and check for fuel leaks.
D4AF1017
Disassembly, Inspection and Reassembly <Spin-on type>
7.8 to 12 N·m 3
(0.8 to 1.2 kgf·m)
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
WATER SEPARATOR
CAUTION
Red line
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, Drain plug
immedidately loosen the drain plug to discharge water.
It is not necessary to completely remove the drain plug as
water is discharged gradually through the groove of the loos-
CUBFL201
ened plug.
NOTE
After draining, tighten firmly the drain plug before bleeding
the fuel system
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 FL-117
Accelerator Pedal Assembly

Disassembly
3 4 2 1
Disasembly sequence
1. Split pin
5 4
2. Washer
7 6 3. Accelerator pedal arm
4. Bushing
5. Return spring
8 11
6. Accelerator lever
13 12 7. Bushing
8. Accelerator switch
9. Snap ring
10 10. Clevis pin
11. Accelerator pedal
12. Adjusting bolt
12. Adjusting bolt
13. Lock nut
9
D4AF0675
Reassembly
2 4
5 Apply grease to
inner surface
1 7
Section A-A
6 Apply grease
Apply grease to 9
3 10
sliding surface
11 Apply grase to Assembly sequence

8 accelerator pedal
12 arm sliding surface 7→6→5→3→2→1→8
13 4
12→13→11→10→9
D4AF0677
Installation and Adjustment of Cables Turn all the way
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.
D4AF0679
3. Routing radius for each cable must be 150 mm or more.
With the throttle knob turned fully in the direction opposite to
the arrow mark, install the throttle cable to the accelerator pedal
arm or accelerator lever, where the inner cable projects most.
Make sure that the inner cable projects most with the least
engine speed.
2. Accelerator control cable

Clip
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 Accelerator Adjusting
control cable lever
cable end on the engine side with a clip.
NOTE
When installing the accelerator control cable, do not move
D4AF0680
the adjusting lever on the engine side.
3. Stop cable
Connect the stop cable ends to the stop lever on the engine
Nut Stop lever
side and that on the starter switch side. With the starter switch
in "ACC" or "LOCK" position and the lever on the engine side Stopper
bolt
moved to the stop position to bring it in contact with the stopper Stop cable
bolt, tighten the nut to secure the stop cable. After adjustment,
make sure that the engine stops when the starter switch is
operated. D4AF0681
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 Accelerator
pedal
obtain clearance of dimension A between the accelerator pedal
A
Adjusting bolt
and adjusting bolt. Lock nut
Dimension A 0 to 5 mm
D4AF0682
FUEL TANK FL-119
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 Accelerator
pedal arm
the accelerator pedal. Make sure that the exhaust brake
oepration indicator lamp in the meter cluster goes of when the Accelerator
switch D4AF0684
engine speed reaches 800 to 950 rpm
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
15~25N·m(1.5~2.5kgf·m)
Bracket assembly
CW31-101
Airtightness Test for Fuel Tank

Apply air pressure
Fuel Tank Airtightness Test [29 kPa (0.3 kgf/cm²)]
When no return Connect tube
Apply soapsuds to the fuel tank surface and feed air 29 kpa (0.3 pipe is provided or the like
kgf/cm²) from the air vent tube.

Parts requiring periodic replacement : Fuel hose
Install plug
D4AF0697

FL Fuel System 1

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

FL Fuel System 1

Uploaded by

Copyright:

Available Formats

FUEL &

Turning direction Clockwise ← ← ←

Plunger Diameter 9.5 mm ← ø11.5 ø11

Governor Model, type RLD ← R801 R901

Automatic timer Model, type SCZ Type, SBO ←

Fuel filter Type *Spin-on filter ← ← ←

*Water separator Type Sediment trap ← ← ←

Camshaft end play 0.03 to 0.05 0.1 Adjust or replace

Squareness Plunger spring 1.5 or less 2 Replace

Control rack sliding resistance 20 to 21

Plunger driving face to control sleeve 0.02 to 0.08 0.12 Replace

Control rack full stroke 21 or more

Nominal value Correction and

Distance between governor housing end 29 ± 0.2 Adjust

Distance between governor cover end Approx. 14 ± 0.5 Adjust

* Idle-up set [On-vehicle: actuator 950 to 1,000 rpm

* Microswitch set [On-vehicle ; actuator D4AF 2,200 to 2,300 rpm

D4AL, D4AE 335 to 410 kPa

Delivery For 1 min. D4AF 900cc or more Replace

Lift When operatedat D4AF 45 sec. or less Replace

When operated D4AL, D4AE 40 sec. or less

Engine control Accelerator pedal to 0 to 5 Adjust

* Accelerator switch operating speed 800 to 950 rpm Adjust

TIGHTENING TORQUE [EURO-I]

Thread size Tightening torque

Timer case nut 29 to 39 (3 to 4)

D4DA/ D4DB/ D4AL [EURO- ]

Nominal value Correction and

Squareness Plunger spring 1.5 or less 2 Replace

Control rack sliding resistance 20 to 21

Prestroke 3.6 ± 0.05 Adjust

Distance between governor housing end 29 ± 0.2 Adjust

Distance between governor cover end Approx. 14 ± 0.5 Adjust

Nominal value Correction and

* Idle-up set [On-vehicle: actuator 950 to 1,000 rpm Replace

Engine control Accelerator pedal to 0 to 5 mm Adjust

Tightening Torque [EURO- ]

Thread size Tightening torque

Is idling speed setting normal? No

Isn’t injection pump control lever mounting nut loose Yes

With injection pump removed, inspect the following

Measure fuel injection timing of each cylinder. No

Hard to start the engine

Is fuel quantity enough? No

Yes Drain water from injector pump, fuel

Are there no fuel leaks for loose connection and Yes

With injection pump removed, inspect the following

Measure fuel injection timing of each cylinder. No

Yes Drain water from injector pump, fuel

Is there no sticking or breaking in injection pump Yes

Are there no fuel leaks for loose connection and Yes

With injection pump removed, inspect the following

Is fuel injection ratio between cylinders No

Excessive smoke in exhaust gas

Is full throttle stopper securely seated onto gavernor No

With injection pump removed, inspect the following

Is fuel injection ratio between cylinders No

Knocking noise happens in injection

Knocking noise happens in engine

Speed is not smoothly shifted to idle

With governor load control lever ring cage disconnected, No

With injection pump removed, inspect

Inspect cause of stiff governor linkage