Rld j Co Rm Ee13e-11141

Pub. No. EE13E-11141

SERVICE MANUAL GOVERNOR MODEL RLD-J

CONSTRUCTION & OPERATION REPAIR & MAINTENANCE

WARNINGS The following definitions and warning signs are used in this service manual. These are extremely important to safe operation. Important points are described to prevent bodily injury and property damage. They must be fully understood before beginning RLD-J governor maintenance. CAUTION!! CAUTION

Improper maintenance can result in injury and property damage.

MEANINGS OF MARKS The following marks are used in this service manual to facilitate correct RLD-J governor maintenance. Advice Note No te

Procedures that must be performed to enable the best possible RLD-J governor maintenance. Info Inform rmat atio ion n assi assist stin ing g in the the bes bestt poss possib ible le RLD RLD-J -J gov gover erno norr main mainte tena nanc nce. e.

WARNINGS The following definitions and warning signs are used in this service manual. These are extremely important to safe operation. Important points are described to prevent bodily injury and property damage. They must be fully understood before beginning RLD-J governor maintenance. CAUTION!! CAUTION

Improper maintenance can result in injury and property damage.

MEANINGS OF MARKS The following marks are used in this service manual to facilitate correct RLD-J governor maintenance. Advice Note No te

Procedures that must be performed to enable the best possible RLD-J governor maintenance. Info Inform rmat atio ion n assi assist stin ing g in the the bes bestt poss possib ible le RLD RLD-J -J gov gover erno norr main mainte tena nanc nce. e.

FOREWORD This service manual describes construction and operation, disassembly and reassembly, and adjustment of the RLD-J type governor. Refer to the separate service manuals listed below to facilitate RLD-J type governor maintenance. This manual is intended for use by vehicle maintenance technicians or persons with an adequate knowledge of injection pumps.

The contents of this manual, including illustrations, drawings and specifications were the latest available at the time of printing. The right is reserved to make changes in specifications and procedures at any time without notice.

Service Manual

Tokyo, Japan

Publication number

PE(S).P TYPE INJECTION PUMP

EE11E-11022

TC(S).MD TYPE INJECTION PUMP

EE11E-11131

TC(S).HD TYPE INJECTION PUMP

EE11E-11170

AUTOMATIC TIMING DEVICES

EE11E-11180

TIMING DEVICE MODEL EC

EE11E-11061

FUEL PUMP TEST STAND MODEL 7NP & 15NP

EC18E-11013

CONTENTS Page

Page

COMPONENT OUTLINE ..................... 1

ADJUSTMENT .................................. 75

CONSTRUCTION ................................ 2

PREPARATION ................................. 75

GOVERNOR HOUSING ...................... 2

INJECTION PUMP INSTALLATION ................................. 75

ADDITIONAL DEVICES ...................... 6 1. BOOST COMPENSATOR ............. 6 2. ANEROID COMPENSATOR.......... 7 3. RACK DAMPER MECHANISM ...... 7 OPERATION ....................................... 8 OUTLINE ............................................. 8 OPERATION...................................... 19 ADDITIONAL DEVICE OPERATION...................................... 26 SPECIAL TOOLS .............................. 32 DISASSEMBLY ................................. 37 PREPARATION ................................. 37 EXPLODED VIEW ............................. 37 INJECTION PUMP INSTALLATION ................................. 38 DISASSEMBLY ................................. 39 EXTERNAL ATTACHMENTS .......... 39 GOVERNOR COVER DISASSEMBLY ................................ 40 BOOST COMPENSATOR DISASSEMBLY ................................ 45 GOVERNOR HOUSING DISASSEMBLY ................................ 47 INSPECTION ..................................... 53

ADJUSTING DEVICE INSTALLATION ................................. 76 MEASURING DEVICE INSTALLATION ................................. 76 SETTING THE CONTROL RACK’S ‘0’ POSITION ..................................... 77 ADJUSTMENT................................... 77 GOVERNOR SPRING SETTING....... 79 FULL LOAD RACK POSITION .......... 82 MAXIMUM SPEED CONTROL ADJUSTMENT................................... 84 BOOST COMPENSATOR ADJUSTMENT................................... 85 ANEROID COMPENSATOR ADJUSTMENT................................... 87 CONFIRMING THE EXCESS FUEL LIMIT FOR STARTING ...................... 89 CONFIRMING THE BLACK SMOKE LIMIT ....................... 89 DAMPER SPRING ADJUSTMENT................................... 89 STOP LEVER ADJUSTMENT ........... 90 PLATE PLUG INSTALLATION .......... 90 HANDLING ........................................ 91

REASSEMBLY ................................. 59

SEALING ........................................... 91 LUBRICATING OIL ............................ 91

GOVERNOR HOUSING REASSEMBLY .................................. 59

TIGHTENING TORQUES .................. 92

GOVERNOR COVER REASSEMBLY .................................. 67

PART NUMBER EXPLANATION ...... 94

COMPONENT OUTLINE OUTLINE The RLD-J type governor can be used with the PE-P, HD-TICS and MD-TICS injection pumps, and was designed to have better control and endurance than the previous RLD type governor. At maximum speed control

Speed control lever

Governor spring At idle speed control

Link mechanism

Sensor lever

P-RLDJ-001

Torque cam

) m m ( n o i t i s o p k c a r l o r t n o C

Pump speed (r/min)

Speed control lever

Guide plate

Ball joint 2nd supporting lever pin

FEATURES 1. Variable speed speed control control governor governor with decreased lever reaction force As with the previous RLD type governor, RLD-J governor control is accomplished using the speed control lever to change the fulcrum of the internal link mechanism. Consequently, as the reaction force of the governor spring does not act directly on the speed control lever, only a very small lever reaction force is exerted on the accelerator pedal. 2. Set torque torque characteristics characteristics through internal torque cam At full load, the tip ti p of the sensor lever traces the face of the torque cam to determine the full load rack position and control the full ful l load injection quantity. Consequently, the torque characteristics demanded by the engine can be freely set by changing the shape of the torque cam face.

P-RLDJ-002

Ball joint

Floating lever

Although the basic construction is identical to that of the RLD type governor, the RLD-J type is larger to match the applicable pumps' larger size.

P-RLDJ-003

3. Improved control through internal guide plate When the speed control lever is operated, the 2nd supporting lever's pin moves along the guide plate. The floating lever connected to the pin thus moves to change the ball joint fulcrum positions. In the intermediate to high speed ranges, the guide plate causes the floating lever to move to increase the lever ratio continuously from 1.1 (idling) 6 (full speed). This increase in the lever ratio in the intermediate to high speed range improves speed droop.

-1-

CONSTRUCTION GOVERNOR HOUSING Full speed stopper bolt

Idling stopper bolt Full load set lever

1st supporting lever

Speed control lever Speed lever shaft

2nd supporting lever

Guide plate Governor spring Sensor lever

Control rack Stop lever

Full load set bolt Guide lever Floating lever

Start spring

Governor shaft U-shaped lever Floating lever cancel spring

Rack connecting link Torque cam

Tension lever

Shifter Idling spring

Flyweight

Tension lever shaft

Sleeve

Rod and spring P-RLDJ-004

T en en si si o n l ev ev e r

T en en si si o n l e ve ve r sh s h a ft ft

The flyweight is mounted on, and turns together with, the camshaft. Camshaft rotation generates centrifugal force at the flyweight so that the flyweight opens around the flyweight pins, and the slider at the end of the flyweight arms pushes the sleeve in an axial direction. The sleeve is connected to the shifter, which in turn is connected to the bottom of the tension lever by a pin. Axial movement of the sleeve moves the bottom of the tension lever around the tension lever shaft.

Slider

Camshaft

Pin Shifter

Pin

Sleeve

Flyweight

P-RLDJ-005

-2-

CONSTRUCTION Governor cover

The tension lever is supported by the tension lever shaft. The governor governor shaft is connected connected to the top of the tension lever. The governor shaft is screwed into the governor cover and supported on the governor housing housing side by a socket. The governor shaft can move axially.

Governor shaft

Socket

Tension lever shaft

Tension lever

P-RLDJ-006

Spring seats are mounted on the governor housing side and the tension lever side of the governor shaft. The governor spring, with no initial set force, is installed between these two spring seats.

Spring seats Tension lever

Governor housing

Governor spring

Governor shaft

P-RLDJ-007

The idling spring is installed on the flyweight axis, and contacts the shifter. The governor spring and idling spring, through the tension lever, balance the flyweight's centrifugal force over the entire speed range to determine the tension lever position with respect to flyweight lift.

Governor spring

Tension lever

Idling spring

Guide lever

Shifter

Ball joint

Flyweight

P-RLDJ-008

The guide lever is supported by the guide lever shaft at the upper part of the tension lever. The guide lever is held by a cancel spring and is assembled so that it moves together with the tension lever. A ball joint at the top of the t he guide lever works to transmit changes in flyweight lift to the floating lever.

Floating lever

Guide lever shaft

Cancel spring Tension lever P-RLDJ-009

-3-

CONSTRUCTION 1st supporting lever

The floating lever is supported by the 2nd supporting lever. One end of the floating lever engages the guide lever ball joint, while the other engages the control rack connecting link's ball joint so that guide lever movement is transmitted to the control rack.

Control rack

Floating lever Ball joint

Rack connecting link Ball joint Guide lever


P-RLDJ-010

The speed control lever is supported by the lever shaft installed in the bushing soldered to the governor cover. The 1st supporting lever is soldered to the lever shaft. The 2nd supporting lever is assembled so that it is moved together with the 1st supporting lever by the force of the cancel spring.

Speed control lever


Bushing Lever shaft 1st supporting lever

Cancel spring


P-RLDJ-011

A pin is soldered to the 2nd supporting lever. (The cancel spring acts to push this pin against the guide plate.) When the speed control lever is operated, the 1st and 2nd supporting levers move together and, because the pin at the floating lever fulcrum moves along the guide plate, each ball joint moment acting on the floating lever changes.

Speed control lever 1st supporting lever

Ball joint

Guide plate Pin Guide lever

Cancel spring

Ball joint P-RLDJ-012

Rack connecting link

One end of the start spring is connected to the plate mounted on the governor housing. The other end is connected to the rack connecting link. The start spring always acts to pull the control rack in the fuel-increase direction.

Control rack Fuel increase direction

Start spring

Plate

P-RLDJ-013

-4-

CONSTRUCTION Rod and spring

The torque cam is mounted on a pin pressfitted to the inside of the governor cover (on the control rack side). The torque cam is connected to the tension lever by a rod, on which a compressed spring is installed. The distance between the torque cam and the tension lever is adjusted by an adjusting nut to determine the portion of the torque cam face utilized by the sensor lever.

Torque cam

Sensor lever

Pin Adjusting nut

Tension lever

P-RLDJ-014

The U-shaped lever is supported by a guide screw and the full load lever shaft. A cancel spring is mounted on the full load lever shaft so that the U-shaped lever and full load lever move together. The sensor lever is attached to the U-shaped lever shaft, and its fulcrum is eccentric to the guide screw axis. The top of the sensor lever engages the rack connecting link, while the bottom is rounded and contacts the torque cam surface.

Rack connecting link Sensor lever Full load lever shaft

U-shaped lever shaft Cancel spring U-shaped lever Torque cam

Full load set lever

Rounded tip

Guide screw P-RLDJ-015

The full load lever shaft is supported by a bushing in the governor housing. The full load set lever is mounted on the full load lever shaft, and is pushed against the full load set bolt by a return spring. The position of the full load set bolt, through the U-shaped lever, determines the prescribed position of the sensor lever fulcrum (and determines the full load rack position).

Full load lever shaft

Bushing

Return spring Full load set bolt

P-RLDJ-016

A full speed stopper bolt, to adjust the engine's maximum speed, and an idling speed stopper bolt, to adjust the engine's idling speed, are mounted in the top of the governor cover. The stopper bolts determine the maximum angle of the speed control lever.

Full speed stopper bolt

Idling stopper bolt Speed control lever

P-RLDJ-017

-5-

CONSTRUCTION The stop lever is mounted on the stop lever shaft, which is supported by bushings in the governor housing. A return spring always acts to hold the stop lever in the normal position (ie, the nonoperation position). When the stop lever is moved to the stop position, the control rack is moved in the fueldecrease direction by the rack connecting link.

Stop lever shaft Bushing Stop position Bushing Lever Fuel decrease direction

Control rack Return spring Stop lever


P-RLDJ-018

ADDITIONAL DEVICES

Governor cover

1. Boost compensator The left hand figure shows an example of boost compensator installation. The boost compensator is mounted directly on the governor cover.

Boost compensator P-RLDJ-019

Boost compensator spring Atmospheric pressure chamber Positive pressure chamber

The diaphragm is installed between the boost compensator cover and the governor cover. The diaphragm separates the boost compensator chamber into an atmospheric pressure chamber and a positive pressure chamber. The boost compensator spring (with a set force) in the atmospheric pressure chamber always acts to push the diaphragm against the boost compensator stroke adjusting screw. One end of pushrod A is attached to the diaphragm, while the other end is attached to the lever assembly. The lever assembly is mounted in the governor cover and pivots to contact pushrod B. The other end of pushrod B contacts the Ushaped lever in the governor. The beginning of boost compensator operation is adjusted by turning the boost compensator spring adjusting nut.

U-shaped lever

Lever assembly

Pivot

Cover

Boost compensator stroke adjusting screw

Pushrod A Diaphragm

Pushrod B P-RLDJ-020

Boost compensator stroke Diaphragm adjusting screw Pushrod A Adjusting nut

U-shaped lever

Pivot Positive pressure chamber Boost compensator spring Atmospheric pressure chamber

L e v e r a s s e m b l y P u s h r o d BP - R L D J - 0 2 1

-6-

CONSTRUCTION 2. Aneroid compensator The left hand figure shows the installation position of the aneroid compensator. The aneroid compensator is screwed directly into the governor cover and fixed by a locknut.

Governor cover

Locknut

Aneroid compensator

P-RLDJ-022

The left hand figure shows a cross-sectional view of the aneroid compensator and the governor. The inside of the aneroid compensator is at atmospheric pressure. A bellows and aneroid compensator spring inside the case expand and contract in response to changes in the atmospheric pressure. A pushrod is attached to the bellows. Bellows movement is transmitted via the pushrod and lever assembly to pushrod B inside the governor. Pushrod B contacts the governor housing's U-shaped lever.

U-shaped lever Pushrod B

Pushrod

Lever assembly

Aneroid compensator spring

Bellows P-RLDJ-023

Damper capsule

Control rack Spring

Stop lever shaft

Damper spring

Damper lever Rack connecting link

Fuel decrease direction

P-RLDJ-024

3. Rack damper mechanism The damper capsule, which contains a damper spring, is mounted on the top of the governor housing. The damper lever is mounted on the stop lever shaft with a spring so that one end contacts the damper spring and the other end contacts the rack connecting link when it is returned. When the rack connecting link is returned, the damper lever compresses the damper spring to absorb excessive movement of the control rack in the fuel decrease direction caused by rack inertia.

-7-

OPERATION OUTLINE Full speed stopper bolt

Speed control lever Idling stopper bolt


Fuel increase direction

Guide plate Sensor lever

2nd supporting lever Governor spring

Control rack Start spring

Floating lever

U-shaped lever Guide lever Full load set lever

Rack connecting link Governor shaft Torque cam

Flyweight Idling spring

Tension lever

Sleeve P-RLDJ-025

Rack position change F

15 ) m m L ( t f i l t h g i e w y l F

La’ La

) m m R ( n o i t i s o p k c a R

E D Flyweight lift change

C 0 A

B

Na Na’ Pump speed (r/min) P-RLDJ-053

Engine stopped A

1. Relationship between rack position and flyweight lift The left hand figure shows the relationship between rack position and flyweight lift corresponding to pump speed. Initially, the start spring and idling spring have a set force, but the governor spring has no set force and is uncompressed. When speed increases and the centrifugal force generated by the flyweight exceeds the set force of the start spring and idling spring, flyweight lift changes. Flyweight lift is determined by the idling spring and the governor spring over the entire speed range.

Centrifugal force generated by flyweight

Engine starts A ~ B

B ~ D

Start spring & idling spring set force centrifugal force

Start spring & idling spring operate

-8-

D ~ E ~ F Idling spring (B ~ D) Governor spring (D ~ F) operating

OPERATION Speed control lever Idling Guide plate Fuel increase direction

Full speed Cancel spring Ra

Ro Control rack

Qa Qo

Po Guide lever

Pin


Floating lever

P-RLDJ-026

Operate speed control lever

Engine stopped

Idling position

Speed control lever: idling position

Speed control lever Idling

Ra

Full speed

Qa Control rack

Qb Pin Po

Engine stopped

2. No load In the left hand figure the engine is stopped and the speed control lever is moved gradually in the full speed direction from the idling position. The pin soldered to the 2nd supporting lever is held against the guide plate by the force of the cancel spring, and moves along the curved face of the guide plate from Qo to Qa. At this time the floating lever pivots around point Po, and the control rack moves in the fuel increase direction (movement from Ro to Ra).

Floating lever P-RLDJ-027

Partial position

Guide lever fulcrum

Po

Floating lever fulcrum

Qo

Qa

Rack connecting link fulcrum

Ro

Ra

Po Control rack is moved in the fuel increase direction by the floating lever pivoting around guide lever Po.

3. Full load When the speed control lever is moved further in the full direction, the control rack reaches the full load position limited by the torque cam, and Po and Ra can no longer move. When the speed control lever is moved until it contacts the full speed stopper bolt, the floating lever moves in the direction of the arrow, and the 2nd supporting lever pin separates from the guide plate's curved surface and moves from Qa to Qb.

Operate speed control lever

Partial position Guide lever fulcrum

Po


Qa


Ra

-9-

Full speed position

Po 2nd supporting lever’s pin separates from the guide plate

Qb

Ra

OPERATION When the engine is started in the above condition, the flyweight opens and the floating lever pivots around Ra from Po to Pa. When the floating lever pivots around Ra, as the 2nd supporting lever's pin simultaneously separates from the guide plate, the floating lever's pin is moved from Qb to Qc by the cancel spring. When pump speed reaches Na r/min, the guide lever side ball joint moves to Pa, and again, simultaneously, the 2nd supporting lever pin contacts the guide plate at Qc and governor control begins.

Speed control lever Idling

Cancel spring

Full speed

Guide plate

Ra ) k m c a m r ( l n o o r i t i n t o s C o p

Pa

Qc

Na Pump speed (r/min)

2nd supporting lever Qb Pin Floating lever Po Guide lever P-RLDJ-028

Pump speed reaches Na r/min

Pump speed increases

Engine starts Speed control lever: full speed position

Guide lever fulcrum

Lift changes transmitted to guide lever

Centrifugal force generated at flyweight

Qb

Qc


Ra

Ra

Idling

) k m c a m r ( l n o o r i t i n t o s C o p

Fuel decrease direction

Full speed Ra Ra’

Pa’

Na Na’ Pump speed (r/min)

Speed control lever: full speed position

Governor control begins

When pump speed increases further, Pa begins to move, and when pump speed reaches Na' r/min, Pa moves to Pa'. Then, Ra pivots around Qc to Ra', and the control rack moves in the fuel decrease direction.

Speed control lever

Control rack

Pa


Via tension lever

Lift begins

Po

Qc Pa P-RLDJ-029

Pump speed reaches Na' r/min


At Na r/min Guide lever fulcrum

Pa


Qc


Ra

- 10 -

Pa’

Governor control begins

Qc

Ra’

Control rack moves in fuel d e c r e a s e direction

OPERATION 4. Partial load When the speed control lever is maintained in an intermediate position between the idling and full speed positions, the control rack is moved to the full load control rack position Ra (see figure below) through the floating lever, the guide plate and the 2nd supporting lever pin. At this time, the 2nd supporting lever pin moves freely over the guide plate.

Speed control lever Control rack

Idling Full speed

2nd supporting lever Pin Guide plate Floating lever

P-RLDJ-030

When the engine is started in this condition, changes in flyweight lift are transmitted to the guide lever. The position of the guide lever's ball joint changes, and the 2nd supporting lever pin moves until it again contacts the guide plate.

Speed control lever Idling Full speed

2nd supporting lever Pin Guide plate

Guide lever

P-RLDJ-031

When pump speed increases further from this condition to reach Nb r/min, the guide lever side ball joint begins to move from Pb to Pb'. The control rack pivots around the floating lever fulcrum Qd from Ra to Rb to decrease the fuel injection quantity.

Speed control lever Idling Fuel decrease direction Ra

Full speed

Rb Qd

Guide plate Pb’

Pb

Floating lever

Guide lever

P-RLDJ-032

Ra

) k m c a m r ( l n o o r i t i R b n t o s C o p

Na Nb Pump speed (r/min) P-RLDJ-215

- 11 -

OPERATION 5. Variable speed control 1st supporting lever

Guide plate

Speed control lever Control rack

Cancel spring

Idling


Ball joint

Full speed Qo Fuel increase direction

Ra

Start spring Floating lever

Sensor lever

Guide lever Rack connecting link

Full load set lever

Governor spring

Tension lever

Torque cam

Shifter Idling spring

Sleeve

Flyweight P-RLDJ-033

When the speed control lever is moved from the idling position to the full speed position, the floating lever fulcrum moves along the guide plate until it reaches the full rack position Ra determined by the torque cam. The 2nd supporting lever is then canceled and the floating lever fulcrum moves to a random position Qo located on a straight line between the guide lever side ball joint position and the control rack side ball joint position. Pump speed then increases, and when the centrifugal force generated by the flyweight exceeds the start spring and idling spring forces, flyweight lift begins.

- 12 -

The flyweight's centrifugal force increases as pump speed increases, and when the centrifugal force overcomes the forces of the idling spring and the governor spring, flyweight lift increases. This change in lift is transmitted to the tension lever through the shifter. As the guide lever is moved together with the tension lever through the cancel spring, the ball joint position changes. With a change in the position of the guide lever's ball joint, the floating lever fulcrum Qo pivots around the rack connecting link's ball joint Ra to again contact the guide plate.

OPERATION When the speed control lever is maintained in the full speed position and the intermediate speed position, the distance that the guide lever's ball joint moves until the 2nd supporting lever's pin again contacts the guide plate differs. (L1 > L2).

L1

Speed control lever Full speed position At full speed

La

La’

Lift Guide lever ball joint Qa

2nd supporting lever pin

Guide plate

Qo 0 position Control rack ball joint De c r e as e

Speed control lever Intermediate speed position At intermediate speed

I n cr ea s e

L2

P-RLDJ-034

Lb

In other words, 2nd supporting lever pin movement in relation to speed control lever position is as follows. Full speed position: Qo Qa Intermediate position: Qo Qb

Lb’

L1 Qb

Guide plate Qo 0 position

Ra

) ) m m m m L ( R ( n n o o i i t i t i s s o o p p t f k i l c t a r h l g o i r e t w n y o l C F

P-RLDJ-035

La’

La Lb’ Lb

0

Nb Pump speed (r/min)

Na P-RLDJ-053

- 13 -

Because of this, when the beginning of governor control is Nb r/min instead of Na r/ min, and the speed control lever is positioned in the intermediate position, governor control begins at a lower speed range. Also, when the governor spring's set force is compared to the flyweight lift, governor control begins at a lower set force at Lb mm than at La mm. From this it can be seen that the RLD-J type governor is a variable speed mechanical governor in which the speed control lever does not act directly on the governor spring (the lever control force is small), but in which it is possible to change the control speed.

OPERATION Floating lever

Speed control lever f ( f i x e d ) Lg Lr

L2 1st supporting lever

L1

Cancel spring 2nd supporting lever P-RLDJ-036

Floating lever

Pa

Guide lever side ball joint

Po

Full speed

Idling Lg’

Qc

Lg

f (fixed) Lr’ Lr

Qo

Supporting lever

Ro

6. Variable lever ratio mechanism The set force of the cancel spring causes the 1st and 2nd supporting levers to move together. However, as control lever operation through the supporting lever also simultaneously moves the floating lever, the fulcrum at the 2nd supporting lever pin continuously changes between the control lever's idle position and the full speed position. (The ratio of Lr to Lg changes.) The tension lever is assembled so that the tension lever link ratio (L2/L1) is approximately 2. The left hand figure shows the relationship of the idling and full speed positions to the floating lever link ratio. As the 2nd supporting lever's pin moves along the curved surface of the guide plate, the lever ratio changes continuously within the range of 1.1 ~ 6. (Lever ratio is the ratio of the control rack movement to the change in flyweight lift.)

Ra

Control rack side ball joint

P-RLDJ-037

The following shows the floating lever fulcrum positions for each control lever position.

Speed control lever position

Floating lever position

Guide ball joint position

Rack ball joint position

Link ratio

Idling Full speed

Qo Qc

Po Pa

Ro Ra

Lr : Lg Lr' : Lg'

RLD-J type governor lever ratios are shown below.

Speed control lever position

Lever ratio calculation

Lever ratio

Idling Full speed

L2 / L1 x Lr / Lg L2 / L1 x Lr' / Lg'

Approx 1.1 Approx 6

With the speed control lever in a random position, the lever ratio changes within the range shown above.

- 14 -

OPERATION 7. Torque cam control of full load rack position The RLD-J governor is equipped with a torque cam to enable free variations in the full load control rack position to increase or decrease fuel injection quantity in response to variations in pump speed. The torque cam was developed to satisfy recent environmental regulations relating to black smoke emissions, and, moreover, to 1st supporting lever 2nd supporting lever

satisfy demands for maximum control of torque characteristics and output characteristics at full load engine operation. With this mechanism, the control rack position can be finely controlled at full load to match the fuel injection quantity characteristics demanded by the engine.

Speed control lever Control rack Idling

Guide plate Floating lever

Full speed

Fuel increase direction Rack connecting link Sensor lever S

Guide lever Full load set lever

U-shaped lever

Torque cam

P-RLDJ-038

When the speed control lever is moved to contact the full speed stopper bolt at engine speeds exceeding idling, the control rack, through the action of the 2nd supporting lever, the guide plate, and the floating lever, pivots on the guide lever ball joint to move in the fuel increase direction. Consequently, the sensor lever attached to the elongated hole in the control rack's rack Operating conditions Speed exceeding idling Speed control lever position: Full

Control rack moves in fuel increase direction

Refer to variable speed control

- 15 -

connecting link turns around the point S, which is the fulcrum of the top of the Ushaped lever (located in the governor housing) and which fixes the full load set lever (outside the governor housing). The bottom of the sensor lever then moves to contact the torque cam and determine the full load position.

Sensor lever turns

Bottom of sensor lever contacts torque cam

Fulcrum S Determines full load position

OPERATION

Speed control lever Guide plate Idling Pa Po Full speed Control rack Rack connecting link Sensor lever

Guide lever

Torque cam Tension lever Rod Torque cam pin

Tension lever shaft Flyweight P-RLDJ-039

As pump speed increases, the flyweight's centrifugal force and lift increase. Because of this, the tension lever turns around the tension lever shaft and the torque cam is turned around the torque cam pin by the rod connected to the tension lever. That is, the positions of the torque cam and the sensor lever are determined by pump speed. As the sensor lever is attached to the rack

connecting link and the face of the torque cam has been machined so that its shape corresponds to control rack position variations, movement of the bottom of the sensor lever over the torque cam face results in control of full load rack positions. Consequently, the torque cam can be used in a wide range of engines by changing the torque cam profile to match the performance demanded by the particular engine.

Moves together with tension lever through cancel spring’s spring force Tension lever shaft fulcrum Guide lever movement Pump speed increase

Ball joint movement Po Pa

Tension lever movement Torque cam rotation

Sensor lever movement

Via rod

Follows torque cam face

Flyweight lift increase

- 16 -

Controls fuel increase/decrease

OPERATION 8. Starting fuel injection quantity increase mechanism Speed control lever Control rack

Supporting lever Idling Floating lever Full speed


Sensor lever

Sensor lever

Torque cam notch

Tension lever Torque cam

Sleeve

Flyweight

Torque cam

Notch

Sensor lever tip P-RLDJ-040

When the engine is stopped, because the flyweight does not generate centrifugal force, the tension lever is pushed in the direction of zero flyweight lift by the sleeve, and the torque cam is in a raised position. From this condition, if the speed control lever is moved from the idling position (broken line) to the full speed position (solid line), the control rack is moved in the fuel increase direction by the supporting lever. As a result of this, the bottom of the sensor lever engages a notch in the torque cam. That is, when the engine is stopped and the speed control lever is moved to the full speed position,

Engine stopped

Centrifugal force '0'

Speed control lever movement

Idling Full speed

a control rack position enabling an increased fuel injection quantity for starting that exceeds the full load rack position of the torque cam can be obtained, facilitating engine starting. After the engine has started and the speed control lever is returned to the idling position, the floating lever, through the supporting lever, pulls the control rack back and the bottom of the sensor lever separates from the torque cam notch. Following this, the increased fuel injection quantity for starting cannot be obtained despite speed control lever operation, and the governor resumes normal control.

Control rack movement


Torque cam raised

- 17 -

Bottom of sensor lever engages torque cam notch

Increased fuel injection quantity for starting

OPERATION 9. Governor performance diagram Idling stopper bolt

Speed control lever

U

T

A1

n i o t i s o p d e e p s l l u F

i f


I d l i n g p o s i t i o n

C

D E

A2 A4 A 3

F f

I

3

E1

4

G

2

E2 i H 0

E3 Pump speed (r/min)

Full load stopper bolt

P-RLDJ-041

P-RLDJ-217

Idling lever setting ( = i) C ~ D: Pump started; start spring's and idling spring's set forces exceed flyweight's centrifugal force; flyweight lift remains at 0. D ~ E: Start spring's and idling spring's set forces overcome by flyweight's centrifugal force; control rack begins to move. D ~ E1: Idling spring control range. I indicates idling point. D ~ E3: Idling spring and governor spring control range. , 3 and 4 are governor performance 2 curves obtained with the speed control lever positioned at three random points. The closer the speed control lever is inclined to the full speed side, the steeper the performance curve.

- 18 -

Full speed lever setting ( = f) A1 ~ A2 ~ F: Torque cam control range F ~ H: Governor spring control range (G is the no-load maximum speed position.) Increased fuel injection quantity for starting Pump speed increases (from stationary) after speed control lever is set at full speed position. T ~ U: Range of increased fuel injection quantity for starting possible when the sensor lever is engaged with the torque cam notch. Normally, the control rack position T is maintained by the depth of the torque cam notch.

OPERATION OPERATION 1. Engine starting Speed control lever Control rack

Speed control lever shaft Supporting lever

Idling

Cancel spring

Full speed


Governor spring

Start spring Rack position for excessive fuel at starting

Sensor lever

) k a m r ( l n o o r i t i n t o s C o p

T o r q u e c a m n o t c h c m

Idling spring

Torque cam

Pump speed (r/min)

Flyweight P-RLDJ-042

P-RLDJ-218

The flyweight is closed by the forces of the start spring and the idling spring while the engine is stopped, and the governor spring has no set force and is uncompressed. When the operator then fully depresses the accelerator, the speed control lever, through the system of links, is moved to contact the full speed stopper bolt. This movement is simultaneously transmitted through the cancel spring and Flyweight lift '0' Link system

Engine stopped Accelerator pedal position Governor spring

Set force '0,' uncompressed

Speed control lever moved to full position

supporting lever to the lever shaft inside the governor to move the control rack in the fuel increase direction. At this time, the sensor lever tip engages the torque cam notch provided for starting fuel increase, and the control rack moves beyond the full load rack position to reach the starting fuel injection quantity increase position controlled by the depth of the torque cam notch.

Move together via cancel spring

Lever shaft turns

Supporting lever movement


Fully depressed

- 19 -

Control rack moves to starting fuel injection quantity increase position

OPERATION Speed control lever Idling Governor spring Full speed

Start spring

Sensor lever

Torque cam

Tension lever Idling spring

Rod spring

Slider Sleeve

Flyweight

When the engine is first being started, centrifugal force is generated by the flyweight. When this centrifugal force exceeds the set force of the start spring and the idling spring, the flyweight slider, through the sleeve, begins to push the tension lever. If the accelerator pedal is held down after the engine has started, speed increases as the sensor lever continues to engage the torque cam notch, the idling spring and the governor spring are compressed, and the •

P-RLDJ-043

flyweight moves in the direction of maximum lift. During this time the torque cam cannot move and, as the rod between the torque cam and the tension lever is stationary, the tension lever compresses the rod spring as it moves. Once the engine has started, the speed control lever is quickly returned to the idling position so that the bottom of the sensor lever separates from the torque cam and the governor performs normal idling control.

Accelerator pedal held down Engine starting Speed control lever: Full position

Centrifugal force generated by flyweight

Tension lever pushed

Idling spring Governor spring


Via sleeve

Rod cannot move


Tension lever moves

Pump speed increases further

Accelerator pedal depressed, then returned to idling Engine stopped Speed control lever: Full position

Engine starting

Speed control lever quickly returned to idling position

- 20 -

End of increased fuel for starting

By tension lever

Speed increases

While rod spring is compressed



} Compressed

Idling

OPERATION 2. Idling control Speed control lever Control rack Idling Full speed

Floating lever

Fuel decrease direction Start spring

Sensor lever Qo

Torque cam


Flyweight

Idling spring Pump speed (r/min) P-RLDJ-219

After the engine has started and the accelerator pedal is released, the speed control lever returns to the idling position. The floating lever's fulcrum also returns to the idling position (Qo) and idling control begins. In this condition, pump speed decreases, the flyweight's centrifugal force is overcome by the start spring and idling spring force and the flyweight closes. Consequently, the control rack moves about the floating lever fulcrum (Qo) in the fuel increase direction to prevent the engine from stopping.

P-RLDJ-044

Conversely, if the pump speed increases, the flyweight's centrifugal force will overcome the idling spring force, and the control rack will be pulled back in the fuel decrease direction to decrease engine speed. In this way, the governor maintains stabilized idling speed through the balance between the flyweight's centrifugal force and the forces of the start spring and the idling spring. During idling operation the sensor lever does not contact the torque cam.

Centrifugal force start spring & idling spring force

Pump speed decreases Speed control lever: idling position

Centrifugal force decreases

Flyweight closes


Centrifugal force start spring & idling spring force


Centrifugal force increases

Flyweight opens

About floating lever fulcrum (Qo).

Control rack moves in fuel decrease direction

- 21 -

Engine stopping prevented

Engine speed increase prevented

Stable idling

OPERATION 3. Torque cam injection quantity control at full load Speed control lever Guide plate 2nd supporting lever pin

Idling

Full speed

Guide lever

Control rack Sensor lever

Torque cam Tension lever

) k m c a m r ( l n o o r i t t n i o s C o p

Torque cam shaft Rod

Flyweight

Pump speed (r/min) Tension lever shaft

Sleeve

P-RLDJ-219

When the speed control lever is maintained in the full speed position while the engine is under load, the control rack is moved in the fuel increase direction around the guide lever ball joint. Through this movement, the bottom of the sensor lever contacts the torque cam face. If engine speed changes in this condition, flyweight movement is transferred through the sleeve to the tension lever to pivot the tension lever backwards and forwards on the tension lever shaft. Tension lever movement is transferred to the torque cam through the rod

Engine under load

Around guide lever side ball joint



2nd supporting lever pin separates from guide plate

P-RLDJ-039

to turn the torque cam around the torque cam shaft. Torque cam movement is transferred to the sensor lever to increase and decrease the fuel injection quantity as the sensor lever traces the torque cam profile. Even though the tension lever is moved in response to changes in pump speed, the control rack is not moved directly as the 2nd supporting lever pin is separated from the guide plate. Consequently, torque cam movement results in control rack movement (through the sensor lever). Bottom of sensor lever traces torque cam profile

Via rod

Pump speed changes

Flyweight movement transferred to tension lever

Transmitted to torque cam

Not transferred to control rack as 2nd supporting lever pin separated from guide plate

- 22 -

To sensor lever

To control rack

Increases and decreases fuel injection quantity

OPERATION 4. Maximum speed control Speed control lever

Guide plate

Control rack

Cancel spring 2nd supporting lever pin Pa

Idling

Pa’

Floating lever Full speed Fuel decrease direction

Qa

Governor spring

Sensor lever Guide lever


Tension lever Torque cam

Idling spring

Pump speed (r/min) P-RLDJ-220

P-RLDJ-045

When the speed control lever is maintained in the full speed position, pump speed increases, the tension lever moves to compress the idling spring and the governor spring, and full load fuel injection quantity is controlled by the torque cam and the sensor lever. When pump speed increases further, the 2nd supporting lever pin is moved by the cancel

2nd supporting lever pin fulcrum

Refer to 3.


Pump speed increase

spring to contact the guide plate (Qa), and the guide lever ball joint moves from Pa to Pa' around the floating lever fulcrum. The control rack is then pulled back in the fuel decrease direction to perform maximum speed control. With maximum speed control, the sensor lever disengages from the torque cam.

Full load fuel injection quantity control

Floating lever returns

Reaches Qa

2nd supporting lever pin again contacts guide plate

Guide lever ball joint movement

Pump speed increase

Fulcrum Qa

Rack connecting link movement

Control rack movement Sensor lever separates from torque cam face

- 23 -

Fuel injection quantity decrease direction

Maximum speed control

OPERATION Stop lever shaft Bushing Stop side Bushing Lever Fuel decrease direction

Control rack

5. Engine stopping When the stop lever is not operated (ie, is in the normal position), the shaft's lever does not normally contact the rack connecting link. When the stop lever is operated, the shaft's lever moves the control rack in the fuel injection quantity decrease direction so that the engine can be stopped.

Return spring Stop lever Rack connecting link P-RLDJ-018

Stop lever operation

Stop lever shaft’s lever is turned

Via shaft

Control rack moves

Via rck connecting link

- 24 -

Fuel injection quantity decrease

Engine stops

OPERATION

Ra

) k m c a m r ( R a ’ l n o o r i t i n t o s C o p

0

Pump speed (r/min)

Na N a ’ P-RLDJ-221

6. Speed droop Speed droop is the governor's full load maximum speed subtracted from the no load maximum speed, divided by the full load maximum speed and expressed as a percentage. This value is the standard used to determine whether governor control is good or bad. Although usually the smaller the speed droop, the better is governor performance, engine specifications prevent speed droop from being excessively small. The following shows how speed droop is calculated.

Speed droop (%) = No load maximum speed - full load maximum speed Full load maximum speed

x 100

When the above calculation is transposed to the above governor performance graph, the following is obtained. Speed droop (%) = (Na' - Na) / Na x 100 If, for example, the following values for Na and Na' are substituted, the following speed droop is obtained. Na = 1,000 r/min,

Na' = 1,100 r/min

Speed droop = (1,100 - 1,000) / 1,000 x 100 = 10 (%) Speed droop varies with variations in the idling and governor spring constants and set positions. When the governor spring constant is small, speed droop improves (ie, decreases). Important factors in determining whether speed droop is good or bad are lever ratio and the governor spring constant.

- 25 -

OPERATION Rack connecting link

ADDITIONAL DEVICE OPERATION

Damper capsule Damper spring

Pump side

Damper lever

Control rack Decrease

Increase

Injection quantity P-RLDJ-046


With damper capsule

1. Rack damper mechanism The rack damper mechanism prevents the engine from stopping when engine speed suddenly decreases. When the engine speed suddenly decreases, the control rack is pulled back in the fuel injection quantity decrease direction and the rack connecting link contacts the damper lever. The damper lever turns around the damper lever shaft to compress the damper spring in the damper capsule. The damper spring force prevents the control rack from moving too far in the fuel injection quantity decrease direction, as well as facilitating a prompt return to the idling position.

Without damper capsule

Pump speed (r/min)

P-RLDJ-222

2. Boost compensator With an increase in engine speed, the inlet manifold boost pressure (ie, compressed air) pressurized by the turbo charger (utilizing exhaust gas energy) flows through the pipe to the boost compensator's boost pressure chamber.

Turbocharger Pipe n o i t c u S

Inlet manifold P-RLDJ-047

- 26 -

OPERATION Cancel spring


U-shaped lever Diaphragm Pushrod A Control rack Sensor lever

Lever

Torque cam Boost pressure acting Boost pressure 0 Boost pressure Boost compensator spring Pushrod B

Boost chamber

P-RLDJ-048

P-RLDJ-223

When the boost chamber pressure exceeds the boost compensator spring force, it begins to push the diaphragm and pushrod A so that the lever contacting pushrod A turns around the lever axis. The U-shaped lever is then turned by the cancel spring to push pushrod B. Because

Boost pressure increases

Sensor lever center fulcrum moves

Pin fulcrum

Diaphragm } move Pushrod A

Control rack moves

Boost compensator stroke

Pump speed (r/min)

the bottom of the sensor lever contacts the torque cam face, this point acts as a fulcrum so that as the U-shaped lever turns, the sensor lever pivots to move the control rack towards the pump in the fuel increase direction.

Boost pressure > boost compensator spring force

Engine speed increases


Lever turns

Through cancel spring force

Pushrod B moves

Fuel injection quantity increased

Towards injection pump

- 27 -

U-shaped lever turns

OPERATION

e r u s s } e r g p H c m i m r { e h a p P s k o m t A

3. Aneroid compensator The left hand figure shows the relationship between atmospheric pressure and altitude. Atmospheric pressure decreases as altitude increases.

{750} 100 {700} 93.3 {650} 86.6 {600} 80.0 {550} 73.3 {500} 66.7 {450} 60.0

0

1,000 2,000 3,000 Altitude (m)

A ir t em pe ra tu re : 2 0

e r {780} u s 104 s } e g r p H { 7 6 0 } c m 1 0 1 i m r { e h a { 7 4 0 } p P 9 8 . 6 s k o m { 7 2 0 } t 96.0 A

0.11

4,000 P-RLDJ-224

C

0.115 0.12 0.125 D e n s i t y ( K g S 2 / m 4 )

0.13 P-RLDJ-225

To prevent the above problems, the full load fuel injection quantity must be adjusted to compensate for altitude, as shown at left. The aneroid compensator moves the U-shaped lever via the pushrod as the atmospheric pressure changes, allowing the control rack to change the full load fuel injection quantity.

100 n o i t ) c % e ( j n y i t i d t a n o a l - u l l q u F

The left hand figure shows the relationship between atmospheric pressure and air density. Air density decreases as the atmospheric pressure decreases. A vehicle with a diesel engine adjusted to function at low altitudes may experience the following problems due to excessive fuel injection when used at high altitudes. 1. Increased black smoke emissions 2. Insufficient engine output, despite increased fuel consumption 3. C a rb o n de p os i ts i n t he c o mb u st i o n chamber, shortening the service life of the engine.

90 80 70 60 50 0

1,000

3,000 2,000 Altitude (m)

4,000 P-RLDJ-226

- 28 -

OPERATION U-shaped lever

Control rack

Lever assembly

Sensor lever

Torque cam


Pushrod B

Pushrod

Aneroid compensator

Bellows P-RLDJ-050

The above figure shows the aneroid compensator prior to operation. At low altitude, the atmospheric pressure is high, and the expansion force of the bellows cannot overcome the set force of the aneroid compensator spring and expand.

Therefore, the pushrod and pushrod B do not move. Pushrod B is positioned so that it does not affect movement of the U-shaped lever, and governor control is normal.

Bellows expansion force aneroid compensator spring force

Low altitude

Atmospheric pressure: high

No bellows expansion

No pushrod B movement

- 29 -

No effect on U-shaped lever operation

Normal governor control


Control rack

Load control lever shaft

Cancel spring


Plate

Pushrod B Pushrod

Bellows P-RLDJ-051

(1)

(2)


Atmospheric pressure kPa {mmHg}

P-RLDJ-227

The above figure shows aneroid compensator operation when there is a small reduction in atmospheric pressure. The bellows expands and pushes against the aneroid compensator spring. Pushrod B moves until it contacts the plate of the U-shaped lever. Despite this movement, however, there is no change in the control rack position [non-reaction range (1)]. The atmospheric pressure may drop further to a point where although pushrod B pushes against the plate of the U-shaped lever, the expansion force of the bellows is still not enough to overcome the force of the aneroid compensator spring and the cancel spring. As a result, the movement of pushrod B stops. This condition continues until the expansion force of the bellows overcomes the force of the aneroid compensator spring and the cancel spring [non-reaction range (2)]. Bellows expansion force aneroid compensator spring force + cancel spring force

Bellows expansion force aneroid compensator spring force

Atmoshpheric pressure: slight increase

Bellows expands

Pushrod B moves to contact the U-shaped lever’s plate

- 30 -

No effect on U-shaped lever operation

Normal governor control


Control rack

Load control lever shaft Sensor lever

Cancel spring


Pushrod B

Pushrod

Bellows P-RLDJ-052

As the atmospheric pressure continues to decrease, the expansion force of the bellows exceeds the force of the aneroid compensator spring and the cancel spring, and therefore the bellows again starts to expand. The U-shaped lever then pivots about the guide screw and the load control lever shaft and moves in the direction of the arrow, as shown above.

Bellows expansion force aneroid compensator spring force + cancel spring force

Atmospheric pressure: continued decrease

Bellows expands

As the sensor lever is attached to the U-shaped lever, U-shaped lever movement is transmitted through the sensor lever to the control rack. The control rack moves in the fuel decrease direction to reduce the fuel injection quantity to match the quantity of intake air. In this way, the system is controlled to provide an optimum balance between the fuel injection quantity and the quantity of intake air (ie, the fuel-air ratio).

Pivots around guide screw and load control lever shaft

Pushrod B moves

Turns Ushaped lever

- 31 -

Via sensor lever

Control rack moved in fuel decrease direction

Governor controls optimum fuel injection quantity

SPECIAL TOOLS The following special tools (in addition to general tools) are required for disassembly, reassembly, and adjustment of the RLD-J type mechanical governor.

The RLD-J type governor is installed on the PE(S)-P, MD-TICS and HD-TICS type injection pumps. Refer to the relevant service manuals for the special tools necessary for the disassembly, reassembly and adjustment of the injection pump and automatic timer. (Titles and publication numbers are listed in the foreword.)

CAUTION

If incorrect tools or attachments are used, the following problems will arise. 1. Governor damage. 2. Lubrication and fuel leaks. 3. Inability to adjust the governor. Key no 1

Part name Guide

Part no

Q’ty

157923-6820

1

assembly

Application For installing control lever shaft oil seal Cap: 157923-6800 Guide: 157923-6900

2

Guide

157923-7000

1

For installing speed control lever shaft snapring

3

Wrench

157913-6220

1

For idling spring adjustment and lock nut removal and installation (idling spring adjustment is possible by inserting a phillips head screwdriver into the center of the wrench).

4

Wrench

157913-6720

1

For torque cam adjustment.

5

Wrench

157923-7220

1

For adjusting boost compensator notch

6

Rod

157923-7300

1

For installing governor shaft plug

7

Rod

157923-7500

1

For installing idle spring assembly plug and converse lever plug on boost compensator equipped governors

8

Rod

157923-7900

1

For installing tension lever shaft plug

9

Guide plate

157923-7622

1

For aligning rack link position (for right hand governor)

10

Guide plate

157923-7822

1

For aligning rack link position (for left hand governor)

11

Guide

157923-6700

1

For installing oil seal to threaded end of stop lever shaft

12

Guide

157923-8000

1

For installing oil seal to unthreaded end of stop lever shaft

13

Guide

157923-7400

1

For pressfitting oil seal on stop lever shaft

14

Wrench

157913-3520

1

For removing boost compensator diaphragm nut

15

Wrench

157923-5321

1

For removing governor shaft locknut

- 32 -

SPECIAL TOOLS Key no

Part name

Part no

Q’ty

Application

16

Wrench

157915-0100

1

For removing flyweight roundnut

17

Extractor

157926-5110

1

For removing flyweight

18

Extractor

157923-8220

1

For removing radial rubber damper equipped flyweight

19

Measuring

105782-6290

1

position

device 20

Measuring

105782-6360

1

Measuring

105782-6370

1

Adjusting

For measuring MD-TICS type pump control rack position

device 22

For measuring HD-TICS type pump control rack position

device 21

For measuring PE(S)-P type pump control rack

105782-6170

1

device

- 33 -

For measuring control lever angle

SPECIAL TOOLS 1.

157923-6820

2.

157923-7000

3.

157913-6220

4.

157913-6720 157913-6620

5.

157923-7220

6.

157923-7300

- 34 -

7.

157923-7500

SPECIAL TOOLS 8.

157923-7900

9.

157923-7622

SW7

12 3

10. 15 157923-7822

12. 157923-8000

20

11. 15 157923-6700

13. 157923-7400

- 35 -

14. 157913-3520

SPECIAL TOOLS 15. 157913-5321

16. 157915-0100

17. 157926-5110

ZW8

18. 15 157923-8220

20. 105782-6360

19. 10 105782-6290

21. 105782-6370

22. 105782-6170

350

- 36 -

DISASSEMBLY PREPARATION Clean the outside of the injection pump before disassembly, disassembly, removing all al l grease and dirt. Keep the work bench and workshop clean and tidy. Before beginning disassembly, record performance data for later reference to facilitate the diagnosis of any governor malfunctions and defects. defects. Drain the oil from the pump chamber and the governor chamber.

Lay out the disassembled parts neatly and sequentially on the work bench, labelling them if necessary, to facilitate later reassembly. The following describes disassembly, inspection, reassembly and adjustment procedures for an RLD-J governor installed on a PE-P type pump equipped with an SP timer. Installation positions and part shapes may differ with the governor type.

EXPLODED VIEW With boost compensator

S t a n d a r d s p e c i f i c a t io io n

P-RLDJ-055

- 37 -

DISASSEMBLY INJECTION PUMP INSTALLATION Note: Refer to the relevant service manual for the necessary tools. (The publication numbers are listed in the foreword.) 1. Mount the bracket on the universal vise.

Brackets

Universal vise

P-RLDJ-227

Injection pump

2. Remove the eye bolt and drain the oil from the injection pump. 3. Secure the injection pump to the bracket.

Bolts (4) Eye bolt

Brackets P-RLDJ-056

4. Remove the timer plug. Note: Loosen the timer plug, remove the spanner, and then remove the plug.

L-shaped Timer plug handle

CAUTION

1. The left hand figure shows the SP type timer. 2. As the oil is lost when the SP(G) type timer is removed, fill the timer with the specified amount of oil at reinstallation.

Spanner P-RLDJ-057

L-shaped handle

5. Remove the timer roundnuts. Note: Loosen the roundnuts, remove the spanner, and then remove the roundnuts.

Roundnut

Spanner

Wrench

P-RLDJ-058

- 38 -

DISASSEMBLY 6. Screw the extractor into the timer and remove the timer.

Timer Extractor L-shaped handle

Wrench

Spanner P-RLDJ-059

7. Attach the coupling to the camshaft.

L-shaped handle Spanner

Coupling P-RLDJ-060

DISASSEMBLY

External attachments Governor cover

After the RLD-J type governor itself is removed from the injection pump, individual components are disassembled. The disassembly sequence is as follows. External attachments Boost compensator

Governor cover Governor housing

(if installed) Governor housing P-RLDJ-061

Microswitch

Bracket

External attachments 1. Remove the return springs. 2. Remove the bracket. 3. Remove the microswitch

Return springs

P-RLDJ-062

- 39 -

DISASSEMBLY Governor cover disassembly

18

Sequence

Part name

1 2 3 4

Plate plug Locknut Locknut Idling spring assembly Speed control lever Oil seal Snapring Shim Governor cover Governor shaft Guide plate Snapring Snapring Tension lever shaft Tension lever Snapring Torque cam Lever shaft Pushrod Cover Nut Diaphragm Lever assembly

12 5

5 6 7 8

16 17

6 7 8 9 10 11 12 13 14

11 10 1

1

13

14

15 2

1

19 9

4 3

1

15 16 17 18 19 20 21 22 23

20

21 23

22 With boost compensator

P-RLDJ-063

1. Remove the plate plugs A, B, C, D (two locations, left and right hand sides) and E (boost compensator equipped only). Note: 1. To remove the plate plugs, hold a screwdriver against the plug and tap lightly with a hammer to pierce the plug. Then, remove the plug. 2. Three types of plate plugs are used at seven locations.

A

Plate plugs

B C

E

D

CAUTION

P-RLDJ-064

1. The governor shaft is located directly behind plate plug B. To avoid shaft damage, do not insert the screwdriver too deeply into the plate plug. 2. Do not damage the area of the governor cover where the plate plugs are pressfitted. - 40 -

DISASSEMBLY 2. Remove the governor shaft locknut using the wrench (157913-5321).

Locknut

Wrench

P-RLDJ-065

3. Remove the idling spring locknut using the wrench (157913-6220).

Wrench P-RLDJ-066

4. Remove the idling spring assembly. Note: Remove the idling spring using a phillips head screwdriver.

Idling spring assembly P-RLDJ-067

5. Remove the speed control lever by removing the nut (SW 14).

Speed control lever Nut L-shaped handle

P-RLDJ-068

- 41 -

DISASSEMBLY Screwdriver

6. Remove the lever shaft oil seal using a screwdriver.

Lever shaft

CAUTION

Do not damage the area where the oil seal is installed, or the lever shaft.

P-RLDJ-069

Oil seal

7. Open the snapring using snapring pliers. 8. Then, with the snapring open, push the lever shaft down to dislodge the snapring from the lever shaft's ring groove. 9. Remove the shim. Note: Shim removal is simplified if the tip of a screwdriver is first held against a magnet, and then used to remove the shim.

Snapring pliers

Snapring

Lever shaft

P-RLDJ-070

Lever shaft

Lever shaft Snapring

Shim

Ring groove Ring groove

Open the snapring and push the lever shaft down P-RLDJ-071

Governor cover

10. Remove the governor cover bolts. Note: First loosening the governor cover bolts using a 10 mm spanner facilitates removal.

Bolts (9)

P-RLDJ-072

- 42 -

DISASSEMBLY Pushrod

11. Tap the governor cover lightly with a plastic hammer and remove it horizontally from the governor housing.

Governor cover

CAUTION

1. Place a pan under the governor cover to catch any oil. 2. A p us h ro d i s i n s ta l l ed o n b o os t compensator-equipped governors. Do not lose the pushrod. P-RLDJ-073

12. Remove the governor shaft together with the governor spring and governor spring seat. Note: The governor shaft is screwed into the governor cover.

Governor shaft

Governor spring Governor spring seat

P-RLDJ-074

13. Remove the guide plate. Note: Because a positioning bushing is located on the back of the guide plate, remove the guide plate horizontally.

Guide plate

Bolts (2) P-RLDJ-075

14. Remove the torque cam rod snapring.

Snapring Torque cam rod

P-RLDJ-076

- 43 -

DISASSEMBLY 15. Remove the tension lever shaft snapring.

Snapring

P-RLDJ-077

16. Remove the tension lever shaft. 17. Clean any adhesive from where the plate plugs were installed (one each side).

Tension lever shaft

Adhesive P-RLDJ-078

18.

Separate the torque cam rod from the torque cam and then remove the tension lever assembly. Note: Refer to Inspection if tension lever-shifter or shifter-sleeve disassembly is necessary.

Torque cam rod

Torque cam Shifter Tension lever assembly

Sleeve

P-RLDJ-079

Guide lever

CAUTION

Screw A

1. Never touch guide lever screw A. 2. The torque cam rod is not normally disassembled. If disassembly is necessary, first measure the amount L that the lock screw is screwed in. Then, maintain this dimension at reassembly to facilitate later governor adjustment.

L Torque cam rod P-RLDJ-080

- 44 -

DISASSEMBLY 19. Remove the snapring and then remove the torque cam.

Snapring

CAUTION

Torque cam face

Remove the torque cam only if the torque cam face or the torque cam-shaft area is worn.

Torque cam P-RLDJ-081

20. Remove the speed control lever shaft. Note: Refer to Inspection if lever shaft disassembly is necessary.

Lever shaft

P-RLDJ-082

Boost compensator disassembly If a boost compensator is installed, boost compensator disassembly follows governor cover disassembly. 1. Remove the pushrod.

Pushrod

P-RLDJ-083

2. Remove the boost compensator cover.

Boost compensator cover Phillips head bolt

Bolts (2; with sealing holes) P-RLDJ-084

- 45 -

DISASSEMBLY Prevent rotation with screwdriver and remove hexagon head nut

Disk

3. Remove the diaphragm mounting nut using the wrench (157913-3520). 4. Remove the spring washer and disk.

Spring washer

Nut

Wrench P-RLDJ-085

5. Remove gasket A, the diaphragm, gasket B and the spring. Spring

Diaphragm Gasket A

Bolts (2)

Gasket B P-RLDJ-086

Spring

6. Remove the lever assembly.

Lever assembly

CAUTION

Remove the lever assembly only if the lever is worn, or if the spring is damaged, rusted or bent.

P-RLDJ-087

7. Remove the adjusting nut using the wrench (157923-7220).

Adjusting nut

CAUTION

Remove the adjusting nut only if it is worn damaged, rusted or bent.

Wrench

L-shaped handle

P-RLDJ-088

- 46 -

DISASSEMBLY Governor housing disassembly Sequence

Part name

1 2

Start spring Rack connecting link Roundnut Flyweight Full load set bolt Full load set lever Snapring Sensor lever Plug U-shaped lever Lever shaft Plate Stop lever Lever Snapring Washer Shaft Oil seal Governor housing

3 4 5 6

13

17

18

16 (

7 8 9 10 11 12 13 14 15 16 17 18 19

) 2

6 15 18

14 8

5

11

7

16 15

1 10 9

(

)

The plate washer is not installed on all governors.

12 19 4 3

P-RLDJ-089

1. Remove the start spring.

Start spring

CAUTION

Do not stretch the start spring more than necessary.

P-RLDJ-090

- 47 -

DISASSEMBLY 2. Remove the rack connecting link. Note: The shape and installation position of the rack connecting link vary, depending on whether the governor is a right hand or left hand governor. (The rack connecting links are symmetrical.)


Allan wrench Socket head bolt

P-RLDJ-091

3. Attach the special tool to the injection pump to prevent drive side coupling rotation (during steps 4 and 5). 4. Remove the roundnut fixing the flyweight. Without radial rubber dampers Use the special wrench (157915-0100). Note: Check the shape of the roundnut to determine whether or not radial rubber dampers are installed.

Special wrench

Roundnut

L-shaped handle

P-RLDJ-092

With radial rubber dampers Use an allan wrench. Note: Check the shape of the roundnut to determine whether or not radial rubber dampers are installed.

Flyweight

Roundnut

Allan wrench

P-RLDJ-093

5. Screw the extractor onto the flyweight and then remove the flyweight. Without radial rubber dampers

Flyweight

Tool name Extractor

Extractor

L-shaped handle

P-RLDJ-094

- 48 -

Part No. 157926-5110

Remarks

DISASSEMBLY With radial rubber dampers

Flyweight

Tool name Extractor

Extractor

Allan wrench

Part No. 157923-8220

Remarks

P-RLDJ-095

6. Remove the full load set bolt.

Full load set bolt Washer

P-RLDJ-096

7. Remove the full load set lever, spring and washer.

Spring

Full load set lever

P-RLDJ-097

8. Remove the snapring and then remove the sensor lever.

Snapring

Sensor lever P-RLDJ-098

- 49 -

DISASSEMBLY 9. Remove the plug supporting the U-shaped lever shaft.

Plug

L-shaped handle

Wrench

U-shaped lever

P-RLDJ-099

10.

Spring

11.

Remove the U-shaped lever, the spring and the lever shaft. Remove the O-ring.

O-ring

Lever shaft P-RLDJ-100

U-shaped lever

Lever shaft

Note: The spring is assembled as shown at left.

Spring

P-RLDJ-101

12. Remove the plate.

Plate

Bolts (2)

P-RLDJ-102

- 50 -

DISASSEMBLY Collar

Spring

13. Remove the stop lever, the spring and the collar.

Stop lever

Nut

P-RLDJ-103

14. Remove the lever. Note: Loosen the lever bolt using a spanner (7 mm), and then remove it using a phillips head screwdriver.

Lever

Bolts (2)

P-RLDJ-104

Washer

15. Remove the snapring and then remove the washer. Note: A plate washer may be installed between the washer and snapring.

Snapring

P-RLDJ-105

Shim

Washer

16.

Shaft

Remove the shaft and related parts.

Without rack damper mechanism Remove the snapring, and then remove the shim, washer and shaft.

Snapring

P-RLDJ-106

- 51 -

DISASSEMBLY Shim

Washer

Shaft

17. Remove the shaft and rack damper related parts. With rack damper mechanism

Damper spring

Spring

Snapring

Washer

Remove the damper spring. Remove the snapring, and then remove the shim, washer, shaft, washer, spring and damper lever.

Damper lever

P-RLDJ-107

18.

Oil seal

Remove both sides’ oil seals. CAUTION

Do not damage the governor housing.

Governor housing

P-RLDJ-108

19. Remove the governor housing mounting bolts.

Governor housing

Bolts (P type: TICS: 8)

6; P-RLDJ-109

Governor housing

20. Lightly tap the left and right hand sides of the governor housing using a plastic hammer and remove it horizontally from the injection pump.

Plastic hammer

P-RLDJ-110

- 52 -

INSPECTION Flyweight

Pin

Wash all parts (except for rubber parts) thoroughly in clean fuel oil, and check for wear, scratches and damage. Always replace all gaskets, O-rings and oil seals when they are removed. Do not reuse them. Flyweight assembly

(Bushing)

Without radial rubber dampers

Flyweight holder

Flyweight assembly

P-RLDJ-111

Slider Pin

1. Secure the flyweight holder and move the flyweight by hand in the direction of the arrow. Replace the flyweight assembly if the pin and flyweight (or pin and bushing) are loose due to excessive wear. 2. Replace the flyweight assembly if the slider's sleeve contact surface is worn or scorched. 3. Replace the flyweight assembly if the slider and pin are loose due to excessive wear.

P-RLDJ-112

Plate

With radial rubber dampers

Plate

1. Inspect the flyweight assembly as described above. 2. Remove the plate, and then remove the rubber dampers.

Rubber dampers (4)

Screwdriver Flyweight P-RLDJ-113

3. Replace the rubber dampers if they are worn excessively, warped or cracked. 4. Replace the flyweight or plate if the flyweight teeth or plate teeth (contacting the rubber dampers) are worn. 5. Following inspection, reassemble the rubber dampers and plate on the flyweight.

Rubber dampers (4)

Tooth

Tooth

Flyweight

Plate

P-RLDJ-114

- 53 -

INSPECTION 0

Tension lever assembly To ensure the correct lever ratio, the center of the tension lever assembly's ball joint is now specified (accurate to within 0.1 mm). The center of the ball joint must align with a straight line running through points A and B as shown at left.

0.1 mm

Ball joint

A

B

Tension lever assembly P-RLDJ-115

CAUTION

Spring

Screw

1. Replace the tension lever assembly when replacing the tension lever, guide lever or guide lever spring. 2. Never touch the screw at the top of the guide lever.

Guide lever

Tension lever

Floating lever

P-RLDJ-116

Spring

C

D

Ball joint Tension lever Guide lever

E

Guide lever pin

A Shaft

Pin

B

Shifter P-RLDJ-117

Torque cam rod

L

1. Check each of the tension lever's moving parts described below. Replace the tension lever assembly if they are worn, damaged, or do not move smoothly. Check the following. A Tension lever and shaft contact surface B Shifter/tension lever and pin contact surface C Location where guide lever ball joint engages the floating lever D Check that the spring is not damaged bent or rusted E Guide lever pin and tension lever contact surface. 2. Replace the torque cam rod if it is bent or if the threads are damaged. Note: When replacing the torque cam rod, first measure dimension L. Maintain this dimension L after replacement to facilitate torque cam adjustment.

P-RLDJ-118

- 54 -

INSPECTION Sleeve Replace the sleeve assembly if the sleeve contact surfaces are worn or scorched. Contact surface

Sleeve assembly

P-RLDJ-119

Sleeve replacement 1. Remove the shifter pin snapring, and then remove the shifter pin. Shifter pin Sleeve assembly

Shifter

Snapring P-RLDJ-120

2. Remove the shifter snapring.

Snapring P-RLDJ-121

Inner ring

3. Remove the shifter-outer ring assembly, ball and cage assembly, inner ring, damper and washer. Note: The damper's rubber face faces the shifter.

Snapring

Damper Shifterouter ring Washer

Sleeve

Ball bearing P-RLDJ-122

- 55 -

INSPECTION 4. Position the shifter-outer ring assembly between two plates on a press. 5. Position a rod on the shifter and operate the press to separate the shifter and outer ring. Discard the outer ring.

Press Plates

Shifter-outer ring

Rod

Shifter Outer ring (discard)

Outer ring

Snapring

P-RLDJ-123

6. Remove the snapring and then the outer ring from the new sleeve. 7. Position the outer ring on the shifter with the adjusting shim and then press fit the outer ring to the shifter using the guide (a metal cylinder, etc). 8. Assemble the shifter-outer ring assembly in the new sleeve and then reinstall the snapring in the sleeve ring groove.

S h i f t e r - o u t er r i n g

Sleeve (new) Sleeve (new)

Guide Adjusting shim

Shifter


Outer ring

P-RLDJ-124

Supporting lever and floating lever 1. Replace the floating lever if there is any play in the floating lever grooves (where they engage the rack connecting link and guide lever ball joints) due to wear. 2. Replace the 2nd supporting lever if the area of the pin that contacts the guide plate is worn excessively.

Lever shaft

Oil seal contact surface

Lever shaft 1. Replace the lever shaft if the area that contacts the oil seal is worn excessively. 2. R e p la c e t h e le ve r s ha f t an d / or t h e supporting lever if the lever shaft or supporting lever moving parts are worn excessively.

Guide plate contact surface

Pin


Floating lever

Grooves P-RLDJ-125

- 56 -

INSPECTION Governor cover

Governor cover 1. Replace the governor cover if the press fitted pins are bent. 2. Replace the governor cover if the bushings supporting the tension lever shaft or the speed control lever shaft are worn. 3. Repair or replace the governor cover if the threads are damaged.

Thread

Bushing

Pin

Bushing

P-RLDJ-126

Governor housing

Governor housing 1. Replace the governor housing if any of the bushings are worn. 2. Repair or replace the governor housing if the threads are damaged.

Bushing

Bushing

Thread

Collar

P-RLDJ-127

Sensor lever and torque cam 1. Replace the sensor lever if the tip is worn. 2. Replace the torque cam if the surface that contacts the sensor lever is worn. 3. Replace the sensor lever if the collar and pin are loose due to wear. 4. Replace the sensor lever and/or the Ushaped lever if the sensor lever does not pivot smoothly around the U-shaped lever pin, or if the pin hole is worn excessively.

Torque cam

Sensor lever

Pin

U-shaped lever pin hole

Tip Contact surface P-RLDJ-128

Guide plate Replace the guide plate if the surface that contacts the supporting lever pin is worn excessively.

Guide plate

Contact surface P-RLDJ-129

- 57 -

INSPECTION Thread

Spring seats

Governor shaft 1. Repair or replace the governor shaft or spring seat if the spring seat does not move smoothly on the governor shaft. 2. Repair or replace the governor shaft if the threads are damaged.

Governor shaft

P-RLDJ-130

Springs Replace the springs if they are damaged, rusted or bent.

P-RLDJ-131

With boost compensator Boost compensator diaphragm Replace the diaphragm if it is worn.

Diaphragm P-RLDJ-132

- 58 -

REASSEMBLY Governor reassembly is the reverse of the disassembly procedure. When reassembling the governor, first reassemble the governor housing, and then reassemble the governor cover.

CAUTION

1. Always replace O-rings, gaskets, oil seals and disassembled snaprings with new ones. 2. Refer to pages 92 93 for the specified tightening torques.

GOVERNOR HOUSING REASSEMBLY

4

2

(

)

19

15 6 4 3 5

13

16

10

14

5 6

11

9 1

1

Governor housing Shaft Lever Oil seal Washer Snapring Stop lever Start spring Plate Lever shaft U-shaped lever Plug Sensor lever Snapring Full load set lever Full load set bolt Flyweight Round nut Rack connecting link

16 17 18 19

8

12

Part name

2 3 4 5 6 7 8 9 10 11 12 13 14 15

7

5

Sequence

(

) T he pl at e wa sh er is not installed on all governors.

17 18

P-RLDJ-089

Governor housing installation Attach the governor housing to the injection pump together with the gasket.

Governor housing

CAUTION

First tighten diagonally opposed governor housing bolts equally. Bolts (P type: 6; TICS: 8) P-RLDJ-133

- 59 -

REASSEMBLY Stop lever installation 1. Install the shaft. Without rack damper mechanism Install the stop lever shaft in the governor housing with the threaded end positioned on the stop lever side.

Shaft

P-RLDJ-134

Shaft

With rack damper mechanism Partially install the stop lever shaft in the governor housing with the threaded end positioned on the stop lever side. Install the washer, spring and damper lever on the shaft, and then install the stop lever in the governor housing. Attach the damper spring to the governor housing.

Damper spring

Spring

Damper lever Washer Lever

P-RLDJ-135

2. Attach the lever to the stop lever shaft. Specified torque: 2 2.5 N.m {0.2 0.25 kgf.m}

Shaft

Bolts (2)

P-RLDJ-136

Guide A

3. Install the oil seal guide A on the unthreaded end of the shaft and install the oil seal.

Oil seal

Tool name Guide A

P-RLDJ-137

- 60 -

Part No. 157923-8000

Remarks L=32.6 mm

REASSEMBLY Guide C

4. Remove guide A and pressfit the oil seal straight into the housing using guide C.

Oil seal

CAUTION

Oil will leak if the oil seal is not pressfitted straight into the housing. Tool name Guide C

Part No. 157923-7400

Remarks

P-RLDJ-138

Oil seal

5. Install guide B on the threaded end of the stop lever shaft and install the oil seal. Tool name Part No. Remarks Guide B 157923-6700 L=53.5

Guide B

P-RLDJ-139

6. Remove guide B and pressfit the oil seal straight into the housing using guide C.

Guide C

CAUTION

Oil will leak if the oil seal is not pressfitted straight into the housing. Tool name Guide C

Part No. 157923-7400

Remarks

P-RLDJ-140

Washer

Snapring

7. Install the washer on the stop lever shaft and then install the snapring in the stop lever shaft's ring groove. Note: Also install the plate washer between the washer and snapring if equipped.

Shaft

P-RLDJ-141

- 61 -

REASSEMBLY Shaft

Collar

8. Install the collar on the stop lever shaft. 9. Fix the spring to the washer and stop lever spring holes and then install the stop lever on the stop lever shaft.

Stop lever

Nut

Spring

Shaft

P-RLDJ-142

10. Install the washer and adjusting shim on the stop lever shaft, and then install the snapring in the stop lever shaft's ring groove.

Washer

Snapring

Adjusting shim

0.1

P-RLDJ-143

11. Measure the stop lever shaft's thrust gap using a thickness gauge. If not as specified, adjust the gap using an adjusting shim. Specified gap: 0.1 0.3 mm Note: Push the stop lever in the direction of the arrow and measure the thrust gap. The gap is satisfactory if a 0.1 mm thickness gauge will fit, and a 0.3 mm thickness gauge will not.

0.3 mm

Adjusting shim

Shaft

Stop lever P-RLDJ-144

Part No

Th/ness (mm)

139408-1300

0.2

139408-1000

0.5

CAUTION

Remarks Shape

Thickness

At least one 0.5 mm shim must be used and the stop lever must move smoothly.

8 16

- 62 -

REASSEMBLY Plate installation Attach the start spring to the plate and attach the plate to the governor housing.

Governor housing

Bolts (2)

Plate

Start spring P-RLDJ-145

Full load set lever installation 1. Install the lever shaft in the governor housing. 2. Install the O-ring in the lever shaft hole.

Lever shaft

O-ring

P-RLDJ-146

3. Attach the spring to the lever shaft's Ushaped groove.

U-shaped groove Spring

Lever shaft

P-RLDJ-147

Plug

U-shaped lever

Lever shaft pin

4. Attach the U-shaped lever to the lever shaft's pin so that the U-shaped lever's portion A is inserted between the spring and the load lever shaft. Then, align the U-shaped lever's hole with the plug and install the plug. CAUTION

Coat the plug with a thread lock adhesive before installation.

Spring

Portion A P-RLDJ-148

- 63 -

REASSEMBLY Snapring

5. Install the sensor lever on the U-shaped lever's pin, and install the snapring in the pin groove.

Sensor lever

For U-shaped lever pin P-RLDJ-149

Washer

6. Attach the spring to the boss, and then install the washer and full load set lever on the load lever shaft. Attach the spring to the full load set lever.

Spring Full load set lever

CAUTION

Adjust the full load set lever's axial clearance to 0.1 mm or less using the washer.

Boss

Lever shaft

P-RLDJ-150

7. Install the full load set bolt.

Full load set bolt

P-RLDJ-096

Flyweight installation Without radial rubber dampers Align the flyweight with the camshaft key groove, and then install the flyweight using the special wrench (157915-0100). Note: Hold the coupling using a spanner to prevent camshaft rotation.

Flyweight

Roundnut

Special wrench

Torque wrench

P-RLDJ-151

- 64 -

REASSEMBLY With radial rubber dampers Align the flyweight with the camshaft key groove, and then install the flyweight using the allan wrench. Note: Hold the coupling using a spanner to prevent camshaft rotation.

Flyweight

Roundnut

Allan wrench

Control rack

P-RLDJ-152

Rack connecting link installation A special tool is used to ensure the accuracy of the rack connecting link's ball joint position in relation to the control rack.

Ball joint

Pump

Tool name Guide plate

Part No. Remarks 157923-7622 For right hand

Guide plate

157923-7822

governor For left hand governor

Control rack Socket head bolt

Use a rack connecting link with the same stamping mark as that removed at disassembly.

Rack connecting link Stamping mark P-RLDJ-153


Collar

Sensor lever

Without rack damper mechanism Insert the sensor lever's collar into the rack connecting link's elongated groove. Loosely install the rack connecting link on the control rack using the socket head bolt.

Groove

Control rack

1. Install the rack connecting link.

Socket head bolt P-RLDJ-154

- 65 -

REASSEMBLY Rack connecting link

Sensor lever

Collar

With rack damper mechanism Insert the sensor lever's collar into the rack connecting link's elongated groove. Attach the rack connecting link's portion A to the rear of the damper lever, and then loosely install the rack connecting link on the control rack using the socket head bolt.

Groove

Portion A

CAUTION Damper lever

Control rack

Control rack

Socket head bolt P-RLDJ-155

2. A l i gn t h e g u id e p la t e wi t h th e r ac k connecting link's ball joint and then secure it to the control rack using the guide plate screw. 3. Tighten the rack connecting link's socket head bolt. Specified torque: 4.9 7 N.m {0.5 0.7 kgf.m} 4. Loosen the guide plate screw and remove the guide plate.

Guide plate Rack connecting link ball joint

Guide plate screw

Socket head bolt

Full load control rack position cannot be obtained if the rack connecting link's portion A is not attached to the rear of the damper lever.

P-RLDJ-156

Start spring installation Attach the start spring to the rack connecting link's hole.

Start spring

Rack connecting link P-RLDJ-157

- 66 -

REASSEMBLY GOVERNOR COVER REASSEMBLY

4

10

18 17 13 12

6 5 11

Sequence

Part name

1 2 3 4 5 6 7 8

Lever assembly Diaphragm Nut Lever shaft Torque cam Snapring Tension lever Tension lever shaft Snapring Snapring Guide plate Shim Snapring Governor shaft Pushrod Governor cover Oil seal Speed control lever Idling spring assembly Locknut Locknut Plate plug Cover

14

22 9

7

8

21 15 16

19 20

23

3

19

1

20 21 22 23

2 With boost compensator

P-RLDJ-063

Shifter shim reassembly Perform the following when the shifter, sleeve or tension lever assembly have been replaced. 1. Remove the snapring and then remove the shifter pin. 2. Insert a 6 mm rod through the shifter. 3. Push the sleeve against the slider and confirm that dimension L1 from the end face of the governor housing to the center of the rod is as specified.

Flyweight

Shifter pin

Sleeve

Snapring

L1

6 rod

9 10 11 12 13 14 15 16 17 18

CAUTION

Shifter P-RLDJ-158

The 6 mm rod must be parallel to the end face of the governor housing. L1 = 29 0.2 mm

Sleeve Adjusting shim

If L1 is not as specified, adjust it using the adjusting shims listed on the next page. Adjusting shim replacement is described on pages 55 56. After adjustment, replace the shifter pin. Shifter

CAUTION

L1 Flyweight P-RLDJ-159

If L1 is not as specified, the specified lever ratio, and thus full performance, cannot be obtained.

- 67 -

REASSEMBLY Part No

Th/ness (mm)

029311-0010

0.2

029311-0180

0.3

029311-0190

0.4

029311-0210

1.0

139410-0000

0.5

139410-0100

1.5

Adjusting shims

Remarks Shape

Thickness

10.1 14

Lever assembly

Boost compensator installation (when equipped) 1. Install the lever assembly in the governor cover (if removed).

Governor cover

Bolts (2)

P-RLDJ-160

2. Install the spring, gasket and diaphragm in the governor cover. Note: Install the diaphragm cover after completing adjustment.

Governor cover Spring Gasket Diaphragm

P-RLDJ-161

Spring washer

3. Assemble the disk and spring washer on the diaphragm rod, and install the nut using the special wrench (157913-3520).

Disk

Rod

Wrench Nut

P-RLDJ-162

- 68 -

REASSEMBLY Governor cover

Governor cover reassembly 1. Install the lever shaft in the governor cover.

Lever shaft

P-RLDJ-163

2. Install the torque cam on the governor cover pin, and then install the snapring in the pin's ring groove (if the torque cam has been removed).

Governor cover

Torque cam

Pin Snapring

P-RLDJ-164

Floating lever

Torque cam rod pin

Torque cam Ball joint

Tension lever assembly

Snapring

Shaft

3. Install the tension lever assembly in the governor cover. At this time, check that: The torque cam rod's pin is inserted into the torque cam's hole. The guide lever's ball joint engages the floating lever groove. 4. Insert the tension lever shaft into the governor cover and tension lever holes.

Tension lever shaft P-RLDJ-165

5. Install the tension lever shaft snapring in the governor cover ring groove. Note: Push the opposite end of the tension lever shaft to confirm that the snapring is properly installed.

Governor cover

P-RLDJ-166

- 69 -

REASSEMBLY 6. Install the snapring in the torque cam rod pin's ring groove.

Snapring

Torque cam rod pin

P-RLDJ-167

7. Attach the guide plate to the governor cover.

Guide plate Governor cover

Bolts (2) P-RLDJ-168

Guide

8. Position the shim and snapring on the lever shaft. 9. Install the snapring in the shaft's ring groove by pushing it down using the guide (1579237000). At this time support the bottom of the shaft using a screwdriver, etc.

Snapring Shim

Lever shaft

P-RLDJ-169

Governor spring Governor cover Governor shaft

10. Screw the governor shaft into the governor cover together with the governor spring and spring seats.

Governor spring seat P-RLDJ-170

- 70 -

REASSEMBLY Boost compensator pushrod installation (when equipped) Insert the pushrod into the rod hole in the governor cover.

Governor cover

Pushrod’s rounded end

CAUTION

The rounded end of the pushrod faces the pump. The rounded end of the pushrod faces the pump P-RLDJ-171

Lever shaft

Gasket

Governor housing

Governor cover Floating lever Knockpins (2)

Ball joint

P-RLDJ-172

Governor cover installation 1. Assemble the governor cover on the governor housing together with the gasket. At this time, ensure the following. Fit the sleeve onto the flyweight. Turn the lever shaft fully towards the full side, and insert the rack connecting link's ball joint into the floating lever groove. Insert the governor shaft into the governor housing socket. Align the governor cover knockpins (2) with the gasket and housing holes. CAUTION

Governor housing socket

Move the lever shaft from idle to full to confirm that the control rack is moving properly.

Governor cover

Governor shaft

Flyweight

Governor cover

Sleeve

P-RLDJ-173

2. Attach the governor cover to the governor housing.

Bolts (9)

CAUTION

First tighten diagonally opposed governor cover bolts equally.

Governor housing P-RLDJ-174

- 71 -

REASSEMBLY 3. Screw the cap (157923-6800) onto the lever shaft.

Cap Lever shaft

P-RLDJ-175

Oil seal

4. Fit the oil seal onto the cap.

Cap

P-RLDJ-176

5. Hold the guide (157923-6900) against the oil seal and tap it lightly with a plastic hammer to pressfit the oil seal straight onto the shaft. Then, remove the cap.

Guide

CAUTION

Oil will leak if the oil seal is not installed straight onto the shaft.

P-RLDJ-177

6. Install the speed control lever using the nut (SW 14).

Speed control lever

L-shaped handle

Nut

P-RLDJ-178

- 72 -

REASSEMBLY 7. Install the idling spring assembly and tighten it temporarily.

Idling spring assembly P-RLDJ-179

8. Temporarily install the idling spring locknut using the wrench (157913-6220).

Locknut P-RLDJ-180

9. Temporarily install the governor shaft locknut using the wrench (157913-5321).

Locknut

Wrench Plate plugs (one each side)

P-RLDJ-181

10.

Rod

A

B

Loosely install the plate plugs in the governor cover. Hold the rod (1579237900; 17.95) against the plate plugs and tap it lightly with a plastic hammer to pressfit the plugs (one each side). Ensure the edges are equidistant from the outside. CAUTION

Plate plugs A, B, C and E are installed after adjustment.

C E

P-RLDJ-182

- 73 -

REASSEMBLY 11.

Plate plugs (one each side)

Coat the areas where the plugs are pressfitted with an adhesive. CAUTION

Oil will leak if adhesive is not used.

Adhesive

Phillips head bolt

P-RLDJ-183

12.

Boost compensator cover Governor cover

When a boost compensator is installed, temporarily install the boost compensator cover and gasket on the governor cover.

Bolts (2) Gasket P-RLDJ-184

Microswitch

Bracket

Return springs

External attachments 1. Install the bracket. 2. Install the return springs. 3. Install the microswitch.

P-RLDJ-062

- 74 -

ADJUSTMENT PREPARATION In addition to general tools (spanners, hammer, etc), special tools are required for adjustment of the RLD-J type governor. Refer to the special tool list on page 32 and 33 and the relevant data sheet.

INJECTION PUMP INSTALLATION

Injection pipes

Injection pump

Refer to the relevant service manual for the special tools required for injection pump adjustment. (Publication numbers are listed in the foreword.)

1. Mount the injection pump on the pump test stand. CAUTION

Before tightening the pump test stand bolts (marked with arrows), rotate the flywheel 2 3 times using the handle to confirm that the coupling is properly centered.

Fuel hoses

Coupling

P-RLDJ-185

Injection pump oil

2. Connect the fuel hoses and injection pipes to the injection pump. 3. Fill the injection pump camshaft chamber and governor chamber with injection pump oil and then reinstall the cap to where the feed pump was removed. Pump oil part no: 131453-0121 Volume: Pump cam chamber 50 60 cm3 /cyl Governor chamber Approx 200 cm3

Add approx 200 cm3

P-RLDJ-186

Idling stopper bolt

4. Loosen the full speed stopper bolt, the idling stopper bolt and the full load set bolt. 5. Loosen the idling spring and the governor shaft lock nut. 6. Remove the boost compensator cover (if installed).


Boost compensator cover Locknut

Locknut

Full load set bolt P-RLDJ-187

- 75 -

ADJUSTMENT ADJUSTING DEVICE INSTALLATION

Adjusting device

1. Attach the adjusting device (105782-6170) to the pump test stand.

P-RLDJ-188

Stand

2. Position the lever at right angles to the supporter and then fix it. 3. Align the scale's '0' position with the lever pointer and then fix it using the locknut under the handle.

Set square

Pointer

These faces must be parallel

Lever

Scale plate Supporter Adjusting bolt

Handle

P-RLDJ-228

4. Align pin A with the center of the lever shaft. 5. Insert pin B into the hole in the speed control lever. 6. Loosen the handle, move the speed control lever between the full and idle positions and confirm that the lever and control rack move smoothly.

Locknut

Pin A

Handle Pin B Scale plate Adjusting bolt

Speed control lever

Stand

Lever shaft

P-RLDJ-229

Spacer

MEASURING DEVICE INSTALLATION Joint A

(The left hand figure shows a PE-P pump.) 1. Attach the spacer to the pump housing. 2. Assemble joint A and the bushing, and then screw them into the control rack. 3. Attach the bushing to the spacer and tighten it temporarily. CAUTION

Control rack

Hole

Bushing

P-RLDJ-189

As the bushing’s hole for joint A is eccentric, fix the bushing so that joint A moves smoothly.

- 76 -

ADJUSTMENT Joint B

4. Attach joint B to the dial gauge. 5. Assemble the dial gauge in the holder and attach the holder to the bushing.

Dial gauge

Tool name Measuring device

Bushing

Holder

Part No.

Remarks

105782-6290

For PE-P type

105782-6360

For HD-TICS

105782-6370

For MD-TICS

P-RLDJ-190

SETTING THE CONTROL RACK'S '0' POSITION

Dial gauge

1. Fix the speed control lever in the idling position. 2. Lightly but fully screw in the governor shaft. 3. Increase pump speed to 1,000 1,200 r/ min, pull the control rack fully towards the governor side and zero the measuring device. Then, fix the measuring device.

Allan wrench

P-RLDJ-191

ADJUSTMENT The following precautions must be observed during RLD-J type governor adjustment. Adjustment precautions 1. Fixing the control rack Injection timing adjustment and injection quantity adjustment are performed before governor adjustment. At this time it is necessary to fix the control rack. To do this, maintain the speed control lever in the idling position, increase the pump speed to 500 600 r/min, and move the speed control lever to the full speed position. Then, set the control rack at a position approximately 3 mm beyond the full load position using the full load setting bolt. Under the above conditions the control rack can then be fixed in the specified position for each injection quantity adjustment.

2. Torque cam adjustment The torque cam adjusting nut must be fixed using the lockscrew. 3. Speed control lever operation Before moving the speed control lever to the full speed position, position the speed control lever in the idling position and increase pump speed to 500 600 r/min. This prevents the sensor lever tooth from disengaging from the torque cam. 4. Idling and full load adjustment When adjusting idling, attach a return spring to the speed control lever so that it contacts the idling stopper bolt. When adjusting full load, attach a return spring to the speed control lever so that it contacts the full speed stopper bolt.

- 77 -

ADJUSTMENT Governor performance graphs Although governor performance graphs vary with engine specifications, the graphs below are representative of governor performance. Full speed


0


n i o t i s o p d e e p s l l u F

Pump speed (r/min)

Idling

0


0

Pump speed (r/min)

Adjustment

2

I d l i n g p o s i t i o n

Pump speed: 500 r/min (when not indicated) Boost compensator stroke

Boost pressure (kPa {mmHg}) P-RLDJ-192

Adjusting point

Governor spring setting Temporary idling lever setting Idling spring adjustment Governor spring setting Idling adjustment Full load rack position Full load rack position adjustment Torque cam adjustment Maximum speed control adjustment Boost compensator adjustment Operation stroke adjustment Beginning of boost compensator operation Aneroid compensator adjustment Aneroid compensator kit adjustment Aneroid compensator adjustment Confirming the excess fuel limit for starting Confirming the black smoke limit Damper spring adjustment

Location

Page No

Idling stopper bolt Idling spring Governor spring Idling stopper bolt

79 79 80 81

Full load set bolt Torque cam adjusting nut Full speed stopper bolt

82 83 84

Rack adjusting screw Adjusting nut

85 86

87 87 89

Damper spring

- 78 -

89 89

ADJUSTMENT

Allan wrench

GOVERNOR SPRING SETTING

Adjusting device

Idling stopper bolt

Speed control lever

P-RLDJ-193

Temporary idling lever setting 1. Hold the speed control lever against the idling stopper bolt. 2. Operate the pump at Na r/min (80 100 r/ min) and adjust the idling stopper bolt until the control rack position is Ra mm. Then, fix the idling stopper bolt using the locknut. Note: At this time, confirm from the adjusting device scale that the speed control lever angle is as specified in the data sheet.

) k m c a m R a r ( l n o o r i t i n t o s C o p

0

Na(80

100) Pump speed (r/min) P-RLDJ-230

Idling spring adjustment 1. Hold the speed control lever against the idling stopper bolt. 2. Operate the pump at Nc r/min and adjust the idling spring until the control rack position is Rc mm. Then, fix the Iocknut using the wrench (157913-6220).

Phillips head screwdriver

Wrench

P-RLDJ-194

) k m c a m r ( l n o o R c r i t i n t o s C o p

0

Nc Pump speed (r/min) P-RLDJ-231

- 79 -

ADJUSTMENT 3. Operate the pump at Nb r/min and confirm that the control rack position is Rb mm. ) k m c a m r ( l n o o R b r i t i n t o s C o p

0

CAUTION

If Rb mm cannot be obtained, replace the idling spring adjusting shim until Rb can be obtained and then repeat adjustment 2. above.

Nb


Part No

Th/ness (mm)

Remarks

029311-0010

0.2

Shape

029311-0180

0.3

029311-0190

0.4

029311-0210

1.0

139410-0000

0.5

139410-0100

1.5

139410-3000

2.0

139410-3100

3.0

139410-3200

4.0

Adjusting shims

Thickness

10.1 14

Governor spring setting adjustment 1. Hold the speed control lever against the idling stopper bolt. 2. Adjust the governor shaft until the control rack position is Rd mm at Nd r/min, and then fix the locknut using the wrench (1579135321). (See figures at left and below left.)

Wrench

Allan wrench

P-RLDJ-195

3. Operate the pump at Ne r/min and confirm that the control rack position is Re mm. CAUTION

) k m c a m r ( l n o o r i t i R d n t o s C o p

If Re mm cannot be obtained, readjust Rd within the allowable range as described in 2. above until Re mm can be obtained.

Re

0

Nd

Ne Pump speed (r/min) P-RLDJ-233

- 80 -

ADJUSTMENT 4. Increase pump speed and confirm that pump speed is Nf r/min when the control rack reaches '0'. ) k m c a m r ( l n o o r i t i n t o s C o p

0

Nf Pump speed (r/min)

Idling stopper bolt

Allan wrench

) k m c a m r ( l n o o r i t i R c 1 n t o s C o p

P-RLDJ-234

Adjusting device

Speed control lever P-RLDJ-193

Idling adjustment 1. Hold the speed control lever against the idling stopper bolt. 2. Operate the pump at Nc1 r/min and adjust the idling stopper bolt until the control rack position is Rc1 mm. Then, fix the idling stopper bolt using the locknut. (Point H) 3. Increase pump speed and confirm that the control rack position reaches '0'. 4. After adjustment, confirm from the adjusting device scale that the speed control lever angle at idling is within the range specified in the data sheet.

H

Nc1


- 81 -

ADJUSTMENT FULL LOAD RACK POSITION


When a boost compensator is installed, the full load rack position is adjusted by adjusting the rack position at boost compensator operation. Full load rack position adjustment 1. Hold the speed control lever against the full speed stopper bolt. 2. Adjust the full speed stopper bolt until the pump speed is a little less than No r/min, and then fix it temporarily using the locknut. Speed control lever

P-RLDJ-196


0

No Pump speed (r/min)

P-RLDJ-236

Full load set bolt

3. Operate the pump at N r/min and adjust the full load set bolt until the control rack position is Rh3 mm. Then, fix the full load set bolt using the locknut. Tightening the full load set bolt deceases the control rack position. Loosening the full load set bolt increases the control rack position.

P-RLDJ-197

) k m c a m r ( l n R h 3 o o r i t i n t o s C o p

0

N Pump speed (r/min)

P-RLDJ-237

- 82 -

ADJUSTMENT Torque cam adjustment 1. Hold the speed control lever against the full speed stopper bolt. 2. Operate the pump at Nj r/min and adjust the torque cam adjusting nut until the control rack position is Rh2 Then, fix the adjusting nut using the special wrench.


Lockscrew

Adjusting nut

CAUTION

Screwdriver

Wrench


Torque cam adjustment procedure Loosen the torque cam lock screw using the screwdriver. Adjust the torque cam using the wrench (157913-6720). After adjustment, fix the torque cam lock screw using the screwdriver. Specified torque: 2.9 3.4 N.m {0.3 0.35 kgf.m}

) k m c a m r ( l nR h 2 o o r i t i n t o s C o p

0

As the torque cam adjusting points (Nj r/ min and Rh2) vary with pump specifications, refer to the pump data sheet.

Nj Pump speed (r/min)

P-RLDJ-238

3. Increase pump speed to Nn r/min from a speed approx 100 r/min less than Ni r/min and check that the control rack positions and pump speeds coincide as specified in the governor performance graph.

) m m (

Rh

4 n oR h i 3 t i s oRh 2 p kR h 1 c a r l o r t n o C

Pump speed Rack position

0

N i Nj N k Nm Nn Pump speed (r/min)

Ni Nj Nk Nm Nn Rh1 Rh2 Rh3 Rh3 Rh4

4. If the pump speeds and control rack positions do not coincide, repeat adjustment 2. above P-RLDJ-239

CAUTION

If the pump speeds for the corresponding control rack positions cannot be obtained, replace the torque cam and repeat adjustment.

- 83 -

ADJUSTMENT ) m m ( n o i t i s o p k c a r l o r t n o C

5. Confirm that the injection quantities at the adjusting points (A C) for the basic lever settings are as specified. If the injection quantity is as specified for the rack setting but not for the lever setting, adjust the full load set bolt and torque cam by turning the adjusting nut a small amount.

B

A C

CAUTION

Basic fuel injection quantity adjusting points 0



Adjusting device

If not performed correctly, the specified fuel injection quantity cannot be obtained, resulting in decreased engine output and black smoke.

MAXIMUM SPEED CONTROL ADJUSTMENT 1. Hold the speed control lever against the full speed stopper bolt. 2. Operate the pump at Np r/min and adjust the full speed stopper bolt until the control rack position is Rp mm. Then, fix the full speed stopper bolt using the locknut. 3. Operate the pump at Nq r/min and confirm that the control rack position is Rq mm.


CAUTION

If Rq cannot be obtained, readjust Rp within the allowable range as described in 2. above until Rq can be obtained.

) m m ( n o i t i s o p R p k c a r R q l o r t n o C

4. Increase pump speed and confirm that the control rack is pulled back to the '0' position.

0

Np Pump speed (r/min)

Nq P-RLDJ-241

5. Gradually increase pump speed from a speed less than No r/min and confirm that the control rack begins to move back from Rh4 at No r/min. 6. After adjustment, confirm from the adjusting device scale that the speed control lever angle at full load is within the range specified in the data sheet.

) m m ( n o R h i 4 t i s o p k c a r l o r t n o C

0

No Pump speed (r/min) P-RLDJ-242

- 84 -

ADJUSTMENT BOOST C O M P E N S AT O R ADJUSTMENT

Boost compensator cover

Gasket

When installed CAUTION

Air hose

Remove the aneroid compensator if installed. Bolts (2)

Phillips head bolt

P-RLDJ-199

Rack position adjusting screw

Wrench


P-RLDJ-200

4. Increase the boost pressure to the pressure specified in the data sheet and confirm that the control rack position is R2 at a boost pressure of P2.

Boost compensator stroke R2 R1

0

Air hose installation 1. Install the boost compensator cover and gasket on the governor cover. 2. Connect the air hose (for supplying boost pressure) to the boost compensator. Operation stroke adjustment 1. Hold the speed control lever against the full speed stopper bolt. 2. At a boost pressure of '0', operate the pump at N1 r/min. 3. Adjust the control rack position adjusting screw using the wrench (157913-3520) so that the control rack moves from R2 to R1.

N1 Pump speed (r/min)

R2 P u m p s p e e d N 1 r / m i n R1 0 P1 P2 Boost pressure (kPa {mmHg})

P-RLDJ-243

Governor cover Full boost pressure

Governor housing Depth gauge

P-RLDJ-201

Pushrod selection 1. Increase the boost pressure to full boost pressure as described in fuel injection quantity adjustment in the data sheet. 2. Then, check using a depth gauge that the depth from the end face of the housing to the lever is as specified. (See figure, next page.) Specified depth: 37.5 0.5 mm If not as specified, replace the pushrod B with a pushrod from the following table. Note: The governor cover must be removed to replace the pushrod B.

- 85 -

ADJUSTMENT Full boost pressure

Depth from housing end face to lever

U-shaped lever

Lever Pushrod 37.5

0.5 mm

P-RLDJ-202

Pushrods Part no

Length (mm)

Part no

Length (mm)

Part no

Length (mm)

159274-5100

72.5

159274-6300

78.5

159274-7500

84.5

159274-5200

73.0

159274-6400

79.0

159274-7600

85.0

159274-5300

73.5

159274-6500

79.5

159274-7700

85.5

159274-5400

74.0

159274-6600

80.0

159274-7800

86.0

159274-5500

74.5

159274-6700

80.5

159274-7900

86.5

159274-5600

75.0

159274-6800

81.0

159274-8000

87.0

159274-5700

75.5

159274-6900

81.5

159274-8100

87.5

159274-5800

76.0

159274-7000

82.0

159274-8200

88.0

159274-5900

76.5

159274-7100

82.5

159274-8300

88.5

159274-6000

77.0

159274-7200

83.0

159274-8400

89.0

159274-6100

77.5

159274-7300

83.5

159274-8500

89.5

159274-6200

78.0

159274-7400

84.0

159274-8600

90.0

) k m c a mR r ( 2 l n o o r i t i R 1 n t o s 0 C o p

Beginning of boost compensator operation 1. Hold the speed control lever against the full speed stopper bolt. 2. Remove the plug from the adjusting hole. 3. Increase the boost pressure and adjust the nut so that the control rack begins to move from R1 mm at a boost pressure of P1.

Pump speed N 1 r / m i n

P2 P1 Boost pressure (kPa {mmHg})

CAUTION

When using the screwdriver, do not damage the adjusting hole threads. Screwdriver

Adjusting nut

P-RLDJ-203

4. Following adjustment, reinstall the plug and cap in their original positions.

- 86 -

ADJUSTMENT A N E R O I D C O M P E N S AT O R ADJUSTMENT

Locknut

Cap

Pushrod

When installed CAUTION

The aneroid compensator must be adjusted at conditions equal to sea level. L Set screw P-RLDJ-204

Locknut

Air hose

Aneroid compensator P-RLDJ-205

) m m R ( 2 n o i t i s o p k c R 1 a r l o r t n o C

Aneroid compensator kit adjustment 1. Measure the distance L between the snapring and the aneroid compensator body. Refer to the data sheet for the specified value. 2. If L is not as specified, remove the cap, loosen the locknut and adjust L using the set screw. Then, tighten the locknut and reinstall the cap.

Aneroid compensator adjustment 1. Hold the speed control lever against the full speed stopper bolt. 2. Increase pump speed to the speed specified in the data sheet. 3. C o nn e ct t h e ai r h os e t o th e a ne r oi d compensator. 4. Loosen the locknut. 5. Supply negative pressure P1 to the aneroid compensator and turn the aneroid compensator body until the control rack position is R1 mm. Confirm that the fuel injection quantity is Q1 cm3 /1,000 st.

Q 2 c m 3 / 1 0 0 0 s t

Q 1 c m 3 / 1 0 0 0 s t

P2 P1 Negative pressure (kPa {mmHg}) P-RLDJ-244

- 87 -

ADJUSTMENT ) m m R ( 2 n o i t i s o p k c R 1 a r l o r t n o C

Q 2 c m 3 / 1 0 0 0 s t

Q 1 c m 3 / 1 0 0 0 s t

P2

P1 Negative pressure (kPa {mmHg}) P-RLDJ-245

6. Temporarily reduce the negative pressure from P1 to less than P2, and then increase the negative pressure to P2. Confirm that the fuel injection quantity at control rack position R2 is Q2cm3 /1,000 st. 7. Tighten the locknut. Note : The following explains the relationship between negative pressure as shown in the left hand figure and absolute pressure. Zero point (ie, the intersection of the axes) equals absolute pressure at sea level (ie, 101 kPa {760 mmHg}). In relation to the negative pressure, for example, the change from 0 to P1 kPa on the horizontal axis is an increase in negative pressure. In terms of absolute pressure, however, the above equals a reduction in pressure, from 101 kPa to the point 101 kPa - P1 kPa. In other words, an increase in negative pressure is actually a decrease in absolute pressure. Therefore, 'supply negative pressure' actually means 'reduce the pressure.'

- 88 -

ADJUSTMENT ) m m (

CONFIRMING THE EXCESS FUEL LIMIT FOR STARTING

Rs

n o i t i s o p k c a r l o r t n o C

J Ra’ Rc1

0

Nc2

Pump speed (r/min)

Sensor lever

P-RLDJ-246

Torque cam

1. Operate the pump at Nc2 r/min (a speed a little more than idling) and fix the speed control lever so that the control rack position is Rc1 (ie, position J). 2. In the above condition, stop the pump and confirm that the control rack position is Ra' or more. 3. Move the speed control lever fully to the full speed side and confirm that the control rack position is Rs mm (ie, the excess fuel limit for starting). This is the condition in which the tip of the sensor lever engages the bottom edge of the torque cam. CAUTION

Even if pump speed is decreased from the condition with the speed control lever in the full speed position, the excess fuel limit for starting Rs cannot be obtained unless the pump is stopped. Excess fuel limit for starting P-RLDJ-206

CONFIRMING THE BLACK SMOKE LIMIT

) m m (

H

Rh1

n o i t i s o p k c a r l o r t n o C

1. Hold the speed control lever in the idling position H and operate the pump at Ng r/ min. 2. Move the speed control lever to the full speed side (at 10 /1 2 secs) and confirm that the control rack does not move beyond the excess fuel limit for starting (Rh1). 3. Gradually increase pump speed and confirm that the control rack moves from Ni r/min.

Rc1

0 Ng

Nc1

Ni Pump speed (r/min) P-RLDJ-247

DAMPER SPRING ADJUSTMENT

Damper spring

When rack damper is installed 1. Hold the speed control lever against the idling stopper bolt. 2. Increase pump speed to Nx r/min and adjust the damper spring so that the control rack position is Rx mm. Then, tighten the locknut. (Refer to figure on following page.)

Speed control lever

P-RLDJ-207

- 89 -

ADJUSTMENT Damper spring setting ) m m ( n o i t i s o p R x k c a r l o r t n o C

Damper spring setting

Nx

0

Pump speed (r/min)

P-RLDJ-248

STOP LEVER ADJUSTMENT

Stop lever

Adjust the stop lever, referring to the data sheet for the stop lever angle. At this time, adjust the stopper bolt to adjust the control lever position when the stop lever is contacting the stopper bolt.

Stopper bolt

P-RLDJ-208

PLATE PLUG INSTALLATION

Plate plugs

B

1. Install the plate plugs at locations A, B, C and E (E: boost compensator equipped only). Then, hold the rod against the plate plugs and tap it lightly to pressfit the plugs. Ensure the edges are equidistant from the outside.

A

Rod

C

E

P-RLDJ-209

Tool name Rod

Part No. Remarks 157923-7300 For A & B;

Rod

157923-7500

21.95 For C & E; 29.95

2. Coat the areas where the plate plugs (A, B, C and E) are installed with an adhesive.

Plate plugs (4 positions) A

CAUTION

Oil will leak if an adhesive not used. B

C

E

Adhesive

P-RLDJ-210

- 90 -

HANDLING SEALING

Seals

Each governor stopper bolt is set after adjustment on the pump test stand or engine test bench. The set positions of these stopper bolts must only be adjusted on the pump test stand or engine test bench. If the set positions are changed, engine performance will be adversely affected. All exposed stopper bolts are sealed at delivery from the engine maker or at adjustment on the pump test stand to indicate that they have been adjusted. The positions of these seals are shown at left.

Seals

Seals

P type injection pump P-RLDJ-211

LUBRICATING OIL Name plate

P-RLDJ-212

The governor and the injection pump cam chamber are filled with lubricating oil. The RLDJ type governor utilizes a forced lubrication system in which oil is forcefully supplied by the engine. With this system there is no particular need to maintain injection pump oil as long as the engine manufacturer's instructions regarding inspection and replacement of the engine oil are followed. When replacing the injection pump, however, supply the pump cam chamber with the quantity of oil specified on the nameplate.

- 91 -

TIGHTENING TORQUES Unit: N

m { kg f

SW7 2.0 2.5 {0.2 4.9

SW14 6.9 10.8 {0.7

1.1}

SW17 12 15 {1.2

6.9 {0.5

m}

0.25}

0.7}

SW10 6.9 8.8 {0.7 0.9} SW17 1.5} 1 4 . 7 1 9 . 6 {1 . 5

SW14 9.8 13.7 {1.0

1.4} Apply thread lock adhesive and tighten

2.0}

SW14 9.8 13.7 {1.0 1.4}

SW10 6.9 8.8 {0.7 SW14 1 4 . 7 1 9 . 6 {1 . 5

SW10 4.9 6.9 { 0.5

0.7}

SW14 9.8 13.7 { 1.0

2.0} SW10 4.9 6.9 {0.5

1.4}

0.9}

0.7}

SW17 9.8 13.7 {1.0 1.4}

2.9 3.4 {0.3 0.35}

9.8 14.7 {1.0 1.5}

39.2 58.8 {4.0 6.0} M12 49.0

5 8 . 8 {5 . 0

SW10 6.9 8.8 {0.7

6.0}

0.9}

P-RLDJ-213

- 92 -

TIGHTENING TORQUES Unit: N 4.9

6.9 { 0.5

SW17 1 1 . 8 1 5 . 7 {1 . 2

0.7}

SW17 1 5 . 7 1 9 . 6 {1 . 6

m { kg f

m}

1.6}

2.0}

SW27 39.2 58.8 {4.0 6.0} SW8 3.43

4.90 {0.35

0.5}

SW24 2 4 . 5 3 4 . 3 {2 . 5

3.5} e p c a f m u d P n e

SW10 2.45 4.41 {0.25 0.45} SW10 2.9 3.9 {0.3

0.4}

SW17 21.6 27.5 {2.2 2.8}

SW10 2.94 4.9 {0.3 0.5}

SW10 4.9 6.9 {0.5

SW10 2 . 4 5 4 . 4 1 {0 . 2 5

0.45}

0.7}

P-RLDJ-214

- 93 -

PART NUMBER EXPLANATION CODE NUMBER 1

0

5

9

3 -

RLD-J type mechanical governor Governor installation position 2: right hand side of pump 3: left hand side of pump Specific number Modification code

BOSCH NUMBER NP - EP / RLD * * *

****

P 1 J F R

Manufactured by Bosch Automotive Systems Corporation Governing speed range and type of control *** **** Specified speed Variable speed type Idling speed Applicable pump size P: P type T: TICS (MD, HD) Design symbol Governor type RLD-J type mechanical governor Additional functions F: Torque cam and stopping device X: Torque cam, stopping device and boost compensator B: Torque cam, stopping device and aneroid compensator Y: X above, and aneroid compensator (ie, aneroid-boost compensator or ‘ABCS’) Governor installation position R: right hand side L: left hand side

- 94 -

Rld j Co Rm Ee13e-11141

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