NZ SERIES HYDRAULIC GOVERNOR MODEL NZ61/NZ115 SERVICE MANUAL YANMAR CO.,LTD.@ NZ GOVERNOR PREFACE This Service Manual describes the construction and maintenance of and disassembling procedures for Model NZ6LINZ115 Hydraulic Governor and controller. Read this Manual carefully to use the governor correctly. * Keep this Manual under care at a clearly identified place accessible for the operator to refer to it at any time, ‘The text and illustrations of this Manual may partly disagree with the actual product as depended on its specifications. ‘Also note that parts used are subject to change for improving the quality and performance of or for reasons of safety of this product, ‘Use our genuine parts or specified parts for replacement parts. Order a par to your nearest sales agent or YANMAR parts sales agent. When ordering a pat, clearly specify the Part Name (part description), Par No., Engine Name and Governor Model and Serial No. + Should you have lost or damaged this Manual or if you have any question and advice, fel free to contact us or your nearest sales or service agent (shown in the service network list “YANMAR Worldwide Service” appended to the Engine Operation Manual) ‘+ Precautions on Safery + Arnote prefixed withthe or smack in this Manual isa very important part of the text particularly in view of safety as it indicates that there is the possibility of resulting in injury or serious ‘damage to the product when an advice on handling or the proper precaution is not followed. Thus, be sure to follow such anote. ‘© An item prefixed withthe is ‘mark in this Manual is very important for handling of a product. A failure to observe such an item may incur a deterioration of performance ora trouble of this product. Therefore, be sure to observe such an item, ‘An item prefixed withthe BLY mark in this Manual indicates a chapter, section, clause, page or document to be referred to.& NZ GOVERNOR CONTENTS PREFACE ... 7 - CHAPTER I. GENERAL DESCRIPTION... I-1. Specifications of the Governor. 1-2. Hydraulie Oil... — 1-3. Cautions on Handling of the Governor... CHAPTER 2. OUTLINE OF CONSTRUCTION. 2-1. Function of Major Parts cvs 2-2. Operation ofthe GoveMo€ enn 23. Speed Droop Adjusting Mechanism. 24. Compensator Mechanism... CHAPTER 3, MAINTENANCE INSPECTION... Se. Dally Inspection ee snnvenenannisen 32. Change of Hydraulic Oil. 3-3. Air Bleeding of Hydraulic Oil Passage. 3-4. Speed Droop Adjustment 3-5. Adjustment of Needle Valve... 3-6. Cautions in Initial Run 3-7. Troubleshooting, 3-8. Criteria on Parts Replacement CHAPTER 4. REMOTE CONTROLLER. 4-1. Motor Controlie.. 4-2, Pneumatic Controle 4.3. Wire Controller... CHAPTER 5. DISASSEMBLY & REASSEMBLY OF THE GOVERNOR. 5-1. Cautions in Disassembly/Reassembly... $2. $3.@& NZ GOVERNOR CHAPTER 1. GENERAL DESCRIPTION I-L. Specifications of the Governor ‘Specifications of the Models NZ61 & NZ115 Governors are as follows: [Govemor Made Unit Nzst NzuIS o | © [Govemor conrlling force eae Wom (kgf) 59(06) 98(1.0) Ourput shaft argue Wmnikefm | 9801.0) ]1180.2)| 14.7015) Hydraulic of pressure MPa kgdem®) | hacia | arcs) | 14705) Power piston diameter (minorimajon) | __mm 17605 18.627 Sening speed droop adjusment range | ___% 0-10 Dry mass te ‘About 55 (Ap:for Engine Model 6N160 & 6N165 - (B):for Engine Model 6N18 & 6N21 . ‘Sectional view of the governor and nomenclature 1-2. Hydraulic Oil (1) The body of this governor comprises an oil sump ‘chamber, and thas the governor can use an equivalent to the system oil for the engine as govemor hydraulic. oil. Don’t use a synthetic oil as hydraulic oil for this governor. Ifused, it deteriorates ol seals and pack- ings much earlier than the usual. (@) Properly use the hydraulic oil according to the gover- ‘nor oil temperature in a normal run. Gov. Oil Temperarure Hid. Oil Viscosity Below 50°C. SAE20 Between 50°C and 70°C SAE3O Benween 70°C and 80°C SAEAO 2002. 7.108 of its major parts are shawn in Fig. 1-1. 1-3. Cautions on Handling of the Governor (1) Do not install and handle the governor so that a force is applied to or a shock is imparted to the gear shaft, speed control shaft and terminal shafts. Otherwise, the shafts might be bent, and seals or inter- nal parts might be damaged. (@) When attaching the governor tothe engine, attach the govemor to its driving device under the governor's own weight while seting the spline ofthe gear haf, and uniformly tighten tightening nuts.@ NZ GOVERNOR ‘Nomenclature of the Governor Major Parts oe Droop Adjuster Terminal Arm ‘Speed Control Shaft “ ‘Teminal Shaft Floating Lever |___—- Power Piston Governor Weight | —— Housing Governor Spring ‘Compensator Rod Pilot Valve] Compensator Piston Pilot Valve Bushing —— | . Needle Vaive . Fig. 1-1@ NZ GOVERNOR CHAPTER 2. OUTLINE OF CONSTRUCTION This Chapter describes the functions of major part that are constituting the govemor and principle ofits operation 2-1. Function of Major Parts Floating Lever ‘Speed Contr Shat ‘Spring Fork Governor Spring Terminal Saat Droop Adjuster Terminal Arm | Power Piston |__— Compensator Spang Upper) Governos Weight. ‘Compensator Ros Compensator Spring Pict Vale Bushing (Lower) ee = Compensator Paton Piot Valve H i ee \ Gea shat i \ Gear Pump Needle Vaive Fig. 2-1 (1) Gear Shaft Being an input shaft for the governor, the gear shaft serves asa gear to drive the hydraulic oil pump. @) Pilot Vatve Bushing The part intermeshing with the gear shaft constitutes the hydraulic oi! pump gear, the fly weight assembly is fined to the upper par, and the pilot valve is fied to the inner part. Besides, a hydraulic oi! passage hole to the power piston is provided to this bushing. G) Governor Weight Rotating together withthe pilot valve bushing according to the rotation of the gear shaft, the governor weight moves the plot achange in the ‘engine speed (4) Pilot Valve ‘The governor spring is incorporated into the upper part of the pilot valve, and it moves vertically according to a valve vertically according to 2001.2.8 R a change in compressive load of the spring and an opening orclosing of the governor weight, ‘A vertical movement ofthe plot valve controls thehydrau- lic oil which flows tothe lower part of the power piston as, the control land at the central part opens or closes the hydraulic oil passage hole in the pilot valve bushing. () Floating Lever Coupled to the speed control shaft through the spring fork and a fork, the floating lever is connected to the power piston through the droop adjuster and the terminal arm. (©) Power Piston ‘The hydraulic oil pressure bearing area ratio of the power piston upper and lower parts is 1:2, and the power piston is actuated verically by supply of hydraulic oil from the pilot valve bushing central hole or discharge of the oil. Besides, the compensator spring and compensator rod are incorporated in the inner part ofthe piston,& NZ GOVERNOR ©) Terminal Arm Coupled tothe power piston by the guide lever the terminal ‘arm transmits a movement of the power piston to 2 fuel injection pump through the linkage. A droop adjuster to adjust the speed droop is also mounted to this arm. (8) Droop Adjuster Incorporated in the terminal arm, the éroop adjuster changes the speed droop by adjusting its mounting psi- tion. D sec. 23. Speed Droop Adjusting Mechanism (9) Needle Valve ‘The needle valve adjusts the compensator effect by regu- lating the hydraulic oil pressures of the compensator case and the pilot valve lower case. CD sec.2-4, Compensator Mechanism (10) Pressure Regulating Valve Itregulates the hydraulic oil discharged from the hydraulic cil pump tothe specified pressure. 22Fig. 2-2 shows the system diagram on operation of the ‘governor. Balancing a compressive force of the governor spring with 2 centrifugal force of the governor weight, the governor ‘operates to maintain a fuel injection volume corresponding, to the load of the engine. 1) Starting ‘The governor weight is closed by the governor spring, and the control land of the pilot valve is located below the control port. AS the engine is stated, the hydraulic ol is sent into the upper and lower pants of the power piston at the same time. Since the hydraulic oil pressure bearing area ratio of the power piston upper and lower parts is 1 : 2, the power piston shifts upward (in the direction of fuel & NZ GOVERNOR 2) Steady Running Under the stable state of the engine load, a compressive force of the governor spring balances with a centrifugal force of the governor weight, the control land closes the control por, and the power piston holds a fixed position to set the engine rotation, 3) Load Increasing As the load increases, the engine rotation drops, and a centrifugal force of the governor weight decreases to close it ‘The control land shifts below the control port, the hydraulic oil is sent into the lower part ofthe power piston to shift it upward (in the direction of fuel increase). As the power piston shifts upward, the governor spring is also pulled upward through the droop adjuster and the floating lever that are incorporated in the terminal arm, and the control land closes the control port to rise the speedin correspon- dence to the increased load and thus to maintain the equi- {ibrium, 23& NZ GOVERNOR 4) Load Decreasing Contrary to the operation ina load increase. the control land shifts above the control port. The hydraulic oil is dis- ccharged from the lower part of the power piston, and the power piston shifts downward (in the direction of fuel decrease 2-3. Speed Droop Adjusting Mechanism This mechanism purportsto adjust the speed droop and can set any droop within the range of Oto 10 ‘The lever ratio (L1/L2) of the floating lever is changed by ‘changing the position of the droop adjuster, the set load (compressive force) of the governor spring also changes, and consequently, the speed droop undergoes a change AA relation between the set position of the droop adjuster and the speed droop becomes as follows: Sere Sped éroop (arintion) | Desens Inerenes NOTE: The droop adjuster set graduation does not mean to indicate a value of the speed droop. Variation) N2-N * Permanent variation = ——— x 100(%) Itindicates in percentage the difference between the set speed (N2) following the risen speed when the load is shut off (0 %) and the speed(N) in the 100 % load. + Time of stabilize Itrefers to a time required to achieve the set speed from ‘a moment the load is shut off : NI-N + Momentary variation =————x 100(%) It indicates in percentage the difference between the most risen speed(N1) on the way to become the stable speed when the load is shut off (0 %) and the speed (N) inthe 100% load. 24 Speed Cento! hat Droop Aajuster Setscrew rt Droop Adjuster Terminal Arm Fig. 23 boas 100 a ‘ Nt ering ; ‘Speed nt oe Na min“(rpm) : (orFmqveney)| Time of stabilize Fig. 2-4,2-4, Compensator Mechanism This mechanism consists of the compensator upper and lower springs and compensator piston that are incorporated in the power piston as well as the needle valve. Besides, the compensator case is connected t0 the pilot valve lower case with the hydraulic oil pas- sage, and they are led to the oil sump through the needle valve. ‘When the engine set rotation is changed or the engine load fluctuates, this mechanism stabilizes the governor ‘operation by the minimum overshoot or undershoot. & NZ GOVERNOR Compensatr F Upper Seng oe fl ‘compensator if PRR tT Corer Sng Power Piston | _t compensator 1 Gase i Gompensator A Piston ‘As the engine rotational setting is changed or the load fluctuates, the power piston operates to change the fuel injection volume, Pot Vane Needle Vave ‘At that time, the compensator piston also operates si- multaneously, but a pressure generates temporarily in the compensator case. This pressure acts in the reverse direction to the movements of the power piston and pilot valve and thus assists in early restoring to the steady state. ‘Speed sening Rise Drop Load fiveruation Increase Decrease Pitot valve Fall Rise Power piston Rise Full [Compensator case Positive Negative Pilot valve lower case pressure pressure a Lower spring | Upper spring ee compression | compression ‘+ The magninude of a positive or negative pressure of the ‘compensator case and pilot valve lower case may vary according to the opening of the needle valve and re- quires a proper adjustment ofthe opening. ED sec. 3-5. Adjustment of Needle Valve If the needle valve is closed too firmly, the governor ‘becomes dull and the response by the engine is delayed in a load fluctuation. Moreover, if opened too exten- sively. the engine rotation becomes unsteady. 2s * Pls Valve Lower Case Fig.2-5& NZ GOVERNOR CHAPTER 3. MAINTENANCE INSPECTION ‘This Chapter describes the routine maintenance inspection, basic adjustment and troubleshooting of the governor. 3-1. Daily Inspection 1) Inspection prior to starting (1) Once a day check the oil level of the oil gauge. The specified oil level is alevel 2 to3 mm above the center of the oil gauge. + Inthe case where the oil level falls, check if there is ‘an oil leakage. @) Check for looseness of bolts and nuts of various parts and if there is an abnormality of a linkage which connects the governor witha fuel injection pump. 2) Inspection during a run (1) Measure the temperature of the governor housing with use ofa thermometer. ‘The emperanure becomes stable ifthe engine is run for 30 to 40 minutes. ‘Ifthe temperature rises to above 80°C, there will be ‘an abnormality. Thus, make a check (@) Check for any abnormal noise. 3-2. Change of Hydraulic Oil Change the hydraulic oil first in 1,000 hours or three ‘months and subsequently in 3,000 hours or every six ‘months with the new one. ‘Anool volume to reach the specified oil level is about 1.3, Titer. Fig:34 ‘When changing the hydrau! start/stop lever of the engine set in the STOP posi- tion so as not to start the engine by mistake. 3@ NZ GOVERNOR ® Detach the drain plugs and needle valve from the ‘governor base to discharge the oil hydraulic oi Detach the needle valve only after checking its setting, its position opened from its completely closed state by how many turns. @ Detach the cover, and check if sludge is accumulated in the governor oil sump. @ Attach the drain plugs and needle valve, pour in the new hydraulic oil and atach the cover. ‘When the hydraulic oils changed, be sure to bleed the air. 3-3. Air Bleeding of Hydraulic Oil Passage Bleed the air from the hydraulic oil passage according to the following procedures: (1) Set the needle vaive in the fully opened setting (three tums back from the completely closed state). (@) Tum the control knob to set the speed control shaft pointer with the SPEED graduation 0, and start the engine. (GB) Runthe engine at alow speed tolet hunting orsurging, and nun it further for about 30 seconds. Do not run the engine in the range of torsional vibration critical speed. (A) Stowty close the needle valve to set iti the specified position «in case where air bleeding is insufficient, hunting may not be stopped. In that cas, open the needle valve again o let hunting. + Whenever the governor is replaced, serviced or repaired, adjust the needle valve, ED sce. 3-5. Adjustment of Needle Valve (5) In case where the oil level drops, feed the govemor with hydraulic oi. 323-4, Speed Droop Adjustment ‘Adjust the speed droop to change it according to the fol- lowing procedure: (1) Remove the (controller) cover, and change the set position ofthe droop adjuster. ‘As the adjuster graduation is shifted in the “O" direction, the speed droop lessens. «As the adjuster graduation is shifted in the “10” direction, the speed droop enlarges. (@) Attach the cover, run the engine, and while measuring the speed droop, change the set position of the droop adjuster until the aimed speed droop is reached. ‘© Each time the set position of the droop adjuster is changed, readjust the needle valve. 3-5. Adjustment of Needle Valve The needle valve serves to adjust the response charac- teristics of the governor. If the needle valve is properly adjusted, the engine maintains the fuel injection volume after a change in load with the minimum rotational fluctua tion and time. ‘The needle valve has been adjusted to fit with the engine individually. n the following cases, the needle valve has to be adjusted: + In case where the governor is replaced or serviced. ‘Incase wherethe governor is overhauled (disassem- bled and repaired). ‘+ When the viscosity of hydraulic oil is changed. ‘+ In case where a linkage which connects the gover- nor witha fuel injection pump is altered. ‘© In case where the set position of the droop adjuster is changed, \() After the airbleeding of the governor and setting ofthe droop adjuster are finished, run the engine as well as the governor until they assume the usual running state. ‘© As the engine is ran at the no-load rated speed for 30 to 40 minutes, the viscosity of hydraulic oil stabilize in the usual running state @ NZ GOVERNOR DROOP ADJUSTER 2) Setthe needle valve in the widest opened state possible within a range the engine can run with steady speed. + In case of generator driving, set the needle valve under the rated speed state of the engine. + Incase of amain marine engine or driving a pump, for instance, set the needle valve under the mini- ‘mum speed state of the engine within its normal service range. Ifthe needle valve is closed too firmly, the governor becomes dull and the engine’s response to a load change is delayed. 33& NZ GOVERNOR 3-6. Cautions in Initial Run In he shipping of your engine from our shop, the govemor has been adjusted and fed with hydraulic oil. However, in case ‘where the governor is replaced, serviced or repaired, observe the following matters in the initial run: 1) Mounting of the governor While setting the governor with spline of the gear shaft, ‘mount the governor under its own weight. 2) Oil feeding (1) Feed the governor with new hydraulic oil toa level 2 ‘103mm above the center of the oil gauge. (2) Move the govemor vertically until the terminal arm becomes heavy, and bleed the air from the power piston and hydraulic oil passage. G) Ifthe oll level drops, replenish the hydraulic oil up to the specified oil evel. 3) Connection of the linkage Check if a linkage which connects the governor with a fuel injection pump has been fitted properly. ‘A poor connection ofthe linkage has a possibility of being related to abrupt rotation of the engine. (1) Set the starvstop lever of the engine in the STOP Position. @) Fitthe ourput lever tothe terminal shaft of the gover- nor, and connect a linkage. ) Tum the terminal shaft fully in the FUEL graduation "0" direction, and securely tighten the clamping bolt of the output lever. ‘+ Theterminal shaft pointer should indicates the "0". ‘+The rack of a fue! injection pump should be in the ‘no-injection position. (@) Shift the starvstop lever of the engine in the RUN position, and then check if the output Jever moves lightly when it is sifted from the "0" to "8" terminal shaft graduation, Fig. 364) Setting of speed droop Since the droop adjuster graduation of the new or serviced governor has been set in the "S*, temporarily set the droop adjuster. referring to the former governor or the adjuster _sraduation prior to the repair. 5) Setting of the controller ‘Tum the contro! knob to set the speed control shaft pointer inthe SPEED graduation *0". 6) Start the engine according to Operation Manual for the engine. ‘Be sure to start the engine on the engine side, and have it ready so that it can be stopped at once. Should abrupt rotation break out, there is a possi- bility of amaging the engine or causing an accident resulting in injury or death. 7) Adjustment ofthe droop adjuster and needle valve ‘Adjust the droop adjuster and needle valve. ED sec. 3.4. Speed Droop Adjustment CD sec. 3-5. Adjustment of Needle Valve 35 @ NZ GOVERNOR& NZ GOVERNOR 3-7. Troubleshooting ‘A trouble ofthe governor normally appears as a speed change of the engine, but itis practically impossible to forecast all kinds of troubles. ‘This Chapter outlines the most general troubles of the governor, ‘Aspeod fluctuation and an unsatisfactory control are caused either by atrouble on the engine side ora trouble of the governor or controller. (toe the governor ss alarge numberof pression parts and here isa danger ofoverrunnag ie eagae par are wrongly incorporated or setting is improperly done, do not repair the governor in the field, but consult your nearest sales agent or service agent (shown in the service network list “YANMAR Worldwide Service” appended \ tits maine Overation Manual for repr of your governor. oy ‘Nature of Trouble Probable Cause Engine Side ‘GovernoriControlier Side ‘Countermeasure on Governor/Controller Friction euch slipped Engine rion focused |p Load nflucnation [> Needle va opened to widely [> Adjusmentofihe needle abe aicaly Qumtng) |e Foe fed presute proeay umi) Je Fated presse Foner pin sek or > Oveaal leaning or ening ‘Uneven combustion ioe aed Fuso fite fouled |b Pil vavemalfuncioned[Ovetiaul lanng arson ‘at irded ia feet! ‘At iuded into fel ol OF ated iasde the gover [> Servicing (placement of vom tmalfincioned as) W SS |» Tipof govemor weight (face |» Replacement of the governor exensvely Snacingctmasteasie) | weg |- Linkage wronel connect-| Somamg _ td (mise re govenors : Seached fom tne engine) Compenste piston | Seven tralfenconed | fivaralc ol passage of [> Overaal cleaning Compensaer mechanism biocked vp iRoatonalenoraion |p Engine oveoadcd Needle val cowedioo ight [> Adjunment ofthe necde abe lagged gaia telead (0 Fuel ol ite fouled or Fctaprdonemrs eal | “Comper pision sock [> Oretaul cleaning or ering or reaction toa change in |» Fuel injection pump rack [> Needle valve clogged [> Cleaning of the needle valve oaton tagged Suck ; Ee [> Hydraulic ol passage of [> Overhaul cleaning compeasi econ biocked up * Hydraulic oil pressure dropped |» Servicing (replacement of wom (Side clearance of hydraulic oil parts) ‘Pump gear too large) [Pressure relating valve sack > Ovetnal eaing [Motor Conlin ‘Shim adjustment of the friction clutch {Paeumatie Controler) |» Air leaked from diaphragm fe Leakage correction or replace ‘ment of the diaphragm |+_ Push rod malfunctioned [+ Correction ofthe pushrod [Wire Remowe Control) |. Clearance ofthe wire coupling Je Coupling correction ofthe remote to large control wire [Mis-operation) |+ Speed contol shafi bent or je. Servicing ‘malfunctioned |- Terminal shat malfunctioned fe 36& NZ GOVERNOR Nature of Trouble Probable Cause Engine Side ‘Governor/Coniroller Side Countermeasure on Governor/Controller Fuel injection pump rack frequently inched Gigeline)| Backlash of the governor driving system gear 100 large Influenced by torsional |> Governor poorly mounted (Gear shaft and spine coupling, poorly centered) Correction of governor mounting pert |> Governor weightmalfunctioned [+ Replacement of the governor weight assy [No output from the gover- [+ Spline ofthe governor |» Power piston stuck [> Overhaul cleaning Inor (the output lever could | driving device womoff | [Oil pressure ofthe governor not not be moved) le Linkage stuck produced) |+ Output ever clamping fe. Pressure regulating valve stuck |» Overhaul cleaning or replace- bolt loosened cor damaged ‘meat [= Side clearance of the pump gear [+ Overhaul cleaning or servicing too large (replacement of worn parts) [Governor hydaulc oi de- creased [> Oil seal damaged or gear shaft wom away Replacement of the oil seal or gear shaft 37@ NZ GOVERNOR 3-8. Criteria on Parts Replacement ‘Observe the following criteria for replacememt of governor pars: ‘Numbers listed below refer tothe corresponding numbers given in the Development, Fig. 5-1 Replacement Interval ar Deseription No. ey Every disassembly. 2 w 3 yr. PACKING, govemor mig. 5 1 orevery 10.000 hrs. |PACKING, governor mig. 6 1 PACKING, press. regulating valve plug 436 1 PACKING, base incorporating bolt 2 3 PACKING, stopper bolt 3 1 |PACKING, drain plug 54 2 | PACKING, pressure regulating valve 56 1 | WIRE, floating lever 2 2 | SPRING PIN, fork 50 1 COTTER PIN 1 4 (OIL SEAL, base 3 1 ]O-RING, compensator bush 35 2 |O-RING, base 36 1 |O-RING, needle valve 7 1 Every 5 yrs.or20,000 hrs. |GEAR SHAFT 4 1 INEEDLE BEARING 7 1 ‘THRUST WASHER 8 i GUIDE LEVER PIN 2 2 [OIL SEAL. terminal shafvspeed convo shaft 16 4 FLOATING LEVER 2 1 JO GAUGE 6 1 |GOVERNOR WEIGHT ASSY. “ 1 | PRESSURE REGULATING VALVE ASSY. a 1 ‘NOTES: (1) Replace also parts other than the aforementioned with the new ones if the wear, flaw, rust, etc. are found as a result of ‘overhaul inspection, (@) Asa general rule, replace those parts used more than & years or 40,000 hours by the governor assembly.@ NZ GOVERNOR CHAPTER 4. REMOTE CONTROLLER (One of tree types of remote controllers available for remote control of the governor is equipped to a NZ Series Governor according tothe specified specification. (Fig. 4-1 shows the appearances of governors equipped with the respective remote controllers.) ‘This Chapter describes the operation and maintenance of the respective remote controllers. MOTOR CONTROLLER PNEUMATIC CONTROLLER WIRE CONTROLLER ‘Aleversftted to he speed contol sat and remote cones si& NZ GOVERNOR 4-1. Motor Controller ‘Changing the compression of the govemor spring by rota- tion of a motor, the motor cotroler sets the governor in any engine speed. A motor equipped is a reversible, single- phase motor. In the case of regulating the speed manually. regulate it by means of the control knob. Besides, the motor controller ofsuch a specification equip- ping a limit switch to set the upper and lower limits of the ‘engine speedelectrically is also available. 1) Regulation of the speea ‘* The motor tus while the speed setting switch is being ‘pushed on the remote contro side. ‘This rotation is decelerated by the gearhead, transmitted tothe fork ofthe governor through the friction coupling, ‘motor gear, bevel gear, and spindle screw and changes the compression of the governor spring to regulate the engine speed. WO LIMITER Marwal Snat Control Knob Manval Snat Gear (tes ©} ao ‘Motor Gear sah mae ! Fig. 4.2 ‘+ In the case of manual regulation, tuming the control knob intermeshes the manual shaft gear with the motor gear so that the rotation is transmitted tothe governor in the same route as in the case of motor tuming (remote control). Besides, asthe the control knob is tumed during remote control (motor tuning), the friction clutch ofthe friction coupling slips, imparting no adverse effects on the gear head and motor.2) Adjustment of the limit switch ‘The limit switch actuates through a shift based onthe screw action of a limiter incorporated to the manual shaft. The upper and lower limits of the engine speed are set by adjusting the position of the limit switch through a shift of the limiter by turning the control knob. WARNING ‘When working on this adjustment, either cut offthe power or cover the capacitor with insulator. Ifyou happen to touch it, there is a possibility of an electric shock or a fire caused by a short. (© Loosen the limit switch adjusting bolts, and shift the limit switch in the direction of an elongate hole of the limit switch guide to adjust the switch posit 3) Electrical connection of the motor controller ‘Connect the motor controller as shown in Fig, 4-4 as the motor is a single-phase motor available in two types of voltage, 110 V and 220 V. ‘As viewed from the gear head side, the sense of rotation of the motor is as follows with respect to the rotation of the ‘engine: ‘+ In acceleration: Clockwise ‘+ In deceleration: Counterclockwise @ NZ GOVERNOR Limit Switch Adjusting Bott Lower Limit Swit Limit Swi Upper Limit Contrt Knob Gg seew RATED POWER APPLICABLE CAPACITOR Back ACTO-1SV 25 uF Red: AC 200-220 O5)F 43& NZ GOVERNOR 4-2. Pneumatic Controller ‘The compressed air having the specified pressure is sent into the controller by remote control. ‘The pressure of the air acted on the diaphragm is transmit- ted to the governor spring through the piston and spindle to change the engine RPM. ‘The engine RPM can be changed. in the same way as by the compressed air, by tuming the control knob. 1) Maintenance of the controller Replace the O-ring @ and diaphragm © of the controllercap © withthe new ones biennuallyor every 10,000 hours even if not damaged When disassembling the pneumatic controller, refer to the Development in Fig. 4-10 and the following procedures: ‘An encircled numeral appended to a part description ap- pearing in the following text refers to the correspor numeral given in Fig. 4-10, Development. (1) Detach the compressed air inlet pipe, loosen the lock handle @ of the controller, and loosen also the contro! knob @ until tums lightly (2) Loosen the clamping bolts @ and setscrews @ of the cap © with use of a wrench and a Phillips screw- driver, and remove the cap. 2001.2.8 R Contra Kno Adjust Serew o-ring + COMPRESSED AIR cap Piston = Diaprvagm Max. Rot | |i vag Cesta | Desnag Sing \ Push Rod Filler Plug Fig. 46(3) Take out the disphragm assembly, and remove the spring seat @ and springs @ & @ (4) Lightly insert the width across flats of the tip of the push rod © in a vice stand, loosen the mut @ , and ‘then take out the upper plate @ , diaphragm ® and piston @. Disassembly of major parts of the pneumatic con- troller is ended with the aforementioned. Disas- semble other parts when and if needed. 2) Reassemble the pneumatic controller in the reverse sequence ofthe aforementioned disassembling pro- cedures. In this Sub-section, cautions to be taken in reassembling are set forth. (1) Incorporate the pertinent pars (parts having aterisked reference numbers in Fig. 4-10) upon coating the fol- lowing spots with molydenum disulfide: © Outer periphery ofthe adjust screw @, ‘= Both faces of the spring seat @ and * (10mmé) shaf part ofthe push rod ®. @) Pay your attention othe following points when incor- Porating the diaphragm: © Coat the base fabric side of the diaphragm with rmolydenum disulfide. + Parallel the width across flats of the tip ofthe push rod withthe floating lever of the governor, and then mount the diaphragm on the cylinder ©, ‘Set the promusion on the outer periphery of the diaphragm in the groove ofthe cylinder ©. ‘© Making sure thee is no twist nor wrinkle to the iaphragm, tighten the cap ©. + Don’ttighten the mut @ excessively 45 & NZ GOVERNOR cap Den"tghten it excessively aA Base Fabre Sie’ ((molydenum disutide coated) [ 1 Parallel this face with the foating lever Fig. 49& NZ GOVERNOR Development &: Nomenclature of the Pneumatic Controller * NOTE: Incorporate this part upon coating it with seizure inhibitor (molydenum disulfide). Fig. 410 ‘No. Part Description Q'ty | No. Part Description oy 1 BOLT, max rotation limiting 1 [17 [Piston 1 2. |NUT, lock 1 | 18 |PLATE, upper 1 3 |KNOB, control 1 19 | WASHER, spring 8 4 [cover 1 | 20 |PIN, spring 1 5 [CYLINDER 1 | 21 |PACKING, copper 1 6 |caP 1 | 2 Jorme 1 7 [DIAPHRAGM 1 | 23 [BOLT M6x20, colar 4 8 |ROD, push 1 | 24 [pour mexes 2 9 |ADJUSTER, spring 1 | 25 |scREWMexis, 3 10 NUT, tock 1 | 26 |scrEw mex2s, 2 11. | SPRING, diaphragm (outer) 1 | 27 |NurM6 1 12. |SPRING, diaphragm (inner) 1 | 28 [JOMNT, swivel pipe i 13 |SEAT, spring 2 | 29 |BOLT, pipe joint 1 14 |SCREW, adjus 1 | 30 Jrackinc 2 15 |HANDLE, lok 1 16 |PLUG, fier 143. Wire Controller ‘With a lever attached to the speed control shaft of the governor, the wire controller regulates the engine rotation. Moreover, turing the contol knob can also change the ‘engine speed in the same way as the control cable. Development & Nomenclature of the Wire Controller & NZ GOVERNOR Control Knob ‘Speed Control Shaft Fig. 412 No. Part Description Qty [No Part Description ey 1 [BREEDER ASSY,, filler port combined 1 | 7 [scrEW, adjus i 2. |PACKING, rubber 1 | 8 |SCREW, guide 1 3. INUT, lock 1 | 9 |NUT, lock 1 4 [BOLT, max. rotation limiting, 1 | 10 Jpn, spring 1 5 |COVER 1 | ar packinG 1 6 |KNOB, contro! 1 | 22 [pour 4 47& NZ GOVERNOR CHAPTER 5. DISASSEMBLY & REASSEMBLY OF THE GOVERNOR 5-1. Cautions in Disassembly/Reassembly (1) Do not sassemble the governor unnecessarily except in the case ofa special repair. (@) Inthe case of a repair, have the replacement parts ready in advance. (G) Prior tothe disassembly, have the govemor performance and its adjusting spots put on recorded. ‘Comparing the adjusting values before and after the disassembly makes easy to find out the cause of a trouble. © Speed droop ‘+ Droop adjuster set graduation * Adjusting value of needle valve ‘Terminal shaft pointer graduation ‘+ Speed control shaft pointer graduation Have a linkage to connect the terminal shaft with the fuel injection pump given with the set mark. (@) When taking out the governor and after itis removed, pay your attention not to impart a shock to the terminal shaft, speed control shaft and gear shaft. (Such a shock may cause a bend of the shaft, a positional deviation of a shaft bush (ora damage of internal parts.) (8) Afier the govemor is removed, cover it so that dust and foreign matter will not enter the governor driving device. (©) Before disassembling the governor, clean its exterior to get rid of adhering dus, etc. (D Keep a disassembling workbench clean, and use clean light oil for cleaning fluid. (8) The following tools are necessary for disassembly & reassembly of the governor: “Tool Description ‘Applicaton RefNo. inFig. $1 [Wrench (10 mm width across fas) |For deaching & ataching the (conwoller) cover Wrench (I2 mm width across fats) [For detaching & anaching the stopper bolt 25 Wrench (17 mm width across flats) |For detaching & anaching plugs 35,433 ech 4m with acess fas) [FF desing aching teresa resning . Pliers o pincers For drawing out aconer pin and wire / 3.2 Screwdriver, [For adjusting the droop adjuster i Screwdriver, bade For adjusting the needle valve a2 ag) en Emm widths Ir er detaching &anaching the base 38 Rag) nC mm wis Troe etching & amaching the minal arm sesrew @ Exacior (3.8 ¢ x 50 mm) For drawing out the fork spring pin i 30 (9) Be sure to change coter pins, spring pins, wire, copper packings and other packings with the respective new ones at time of disassembly. Refer to Chapter 3 for periodically replacing pars. CD chapter 3, Sec.3-8. Criteria on Parts Replacement s1& NZ GOVERNOR 5-2, Development of the GovernorGovernor Parts List & NZ GOVERNOR No. Pant Description Ory | No. Part Description ey 1 |HousiN 1 | 37 JO-RING. needle valve 1 2 [BASE 1 | 38. [NAMEPLATE 1 3. [SEAL cit 1 | 39° [NAMEPLATE L side shaft 1 4 | SHAFT. gear 1 | 40. [NAMEPLATE R side shaft 1 5 |PACKING, base 1 | 41 |VALVEASSY. pilot 1 6 | PACKING, cover 1 | 41-1 [BUSHING, pitt valve a 7 |BEARING, thrust 1 | 412 |VALVE. pio: a 8 |WASHER, thrust 1 | 42. |VALVE. needte 1 9 |SPRING, governor 1 | 43. |VALVE. pressure regulating 1 10. | FORK. spring 1 | 434 |Bopy @ 11 |LEVER. euide 2 | 432 [PISTON a 12 | PI, guide lever 2 | 433 |pLuc wo 13, |ARM.terminal 1 | 434 fsprING ” 14 | SHAFT, terminaVourput 2 | 435 [pm ® 15. | ADJUSTER, droop 1 | 436 [PACKING ® 16 {SEAL oil 4 | 44 |WEIGHTASSY., governor 1 17 [pus 4 | 45. [WASHER droop adjuster 1 18 |SHAFT, speed conto! 1 | 46. | WASHER, droop adjuster toothed 1 19 [COLLAR 2 | 47 |RING, compensator lower spring snap 1 20 |FORK 1 | 48 |My terminal arm taper 2 21 {LEVER foating 1 | 49. |PIN, compensator piston spring 1 22 |WIRE 2 | 50. |PIN, fork spring 1 23 [POINTER 4 | 51 |PIN, guide lever pin coner 4 24 |SPRING 1 | 52. | PACKING, base incorporating bolt 3 25. |STOPPER 1 | 53. |PACKING, stopper boit 1 26 |GAUGE, oit 1] 54 |PACKING, drain plug 2 27. | BUSH, compensator 1 | 55° |PLUG, drain 2 28 PISTON. compensator 1 | 56 |PACKING, pressure regulating valve 1 29 | SPRING, compensator lower 1 | 57. |BEARING, needle 1 30. ROD, compensator 1 | 58° |BOLT, base incorporating hex. socket 3 31 | SPRING, compensator upper 1 | 59. |SCREW, pointer 2 32. | PISTON, power 1 | 60. [NUT poimer 2 33. |SPACER, compensator lower spring. 1 | 61 |SCREW, droop adjuster ' 34 |SEAT, spring 2 | 62 |SETSCREW, terminal arm hex. socket 2 35 O-RING, compensator bush 2 36 |O-RING, base 1& NZ GOVERNOR 5-3. Disassembly of the Governor In time of disassembling (or reassembling) the governor, refer to Fig. $-1, the Development and the following proceudures: ‘An encircled numeral given in a figure ofthis Chapter or that appended to 2 part description appearing in the following, text refers to the corresponding numeral given in Fig. 5-1, Development. 1) Loosen four cover clamping bolts with use of a wrench having 10 mm width across flats, and remove them together with packings ©, 2) Tum the governor upside down to discharge the hy- raulic oi. 3) Remove a drain plug on the oil gauge side from the base ©, and insert the bast into the vice stand for fixing 4) Straighten with pliers one side of two wires @ that are coupling the floating lever @ Replace the wires @ with the new ones when reassembling the governor. 5) Holding the spring fork ®, take out the governor spring © together with the pilot valve G3) GQ) Keeping the spring fork and governor spring ‘not removed from the pilot valve, soak them in clean light oil. @) When taking out the pilot valve, pay your at- tention not to lose the thrust bearing © and thrust washer ® that might fall out together.6) Draw out the cotter pins @ from the guide lever pins @ that are coupling the terminal arm @ with the power piston @ , and remove the guide levers @ and guide lever pins. @ ‘+ When drawing out the guide lever pins, be care- fal not to lose the compensator upper spring @ and spring seats. @ that might spring out of the power piston @ where they are incorpo- rated in, ‘+ As two vertically located cotter pins are drawn out one ata time, the guide levers and guidelever pins can be removed. 7) Remove the governor from the vice stand, place the ‘govemor upside down, and using a hexagonal wrench key having Smm width across flats, detach the clamp- ing bolts @ from the base @. ‘When placing the governor upside down, pay your attention not to lose the thrust bearing © and thrust washer © in case they are stil remaining inside the governor weight assembly. rig. so. 8) Tap the side of the base © with a plastic hammer (or ‘mallet, andas itis disjoined from the housing ©, raise the base straight up to remove it. As the base is removed, remove the needle valve @ from the base with use of a blade screwdriver. 55 @ NZ GOVERNOR& NZ GOVERNOR 9) Remove the pilot valve bushing @)_and gear shaft © from the housing and base respectively. ‘Temporarily reassemble the removed pilot valve bushing with already removed pilot valve,and soak them in clean light oil. 10) Push down the power piston below the govemor upper ‘part, and remove this piston together with the compen- sator bush @ Do not disassemble the compensator unit unless the compensator piston @ operates unsmoothly. 11) Using an extractor, draw outthe springpin @ inside the govemor, and remove the speed control shaft G collar @ , fork @ andspring @ ‘© Draw out the speed control shaft as the pointer @ kept intact on the shaft. ‘© When drawing out the spring pin, pay your at- tention so that the speed control shaft would not bend. ‘© Be careful not to flaw the mating surfaces of the housing and base.12) Unscrew the stopper bolt @ , and remove the gover- nor weight assembly @ If the thrust bearing @ and thrust washer ® are remaining inside the assembly, remove them from it. 13) Disassembly of the terminal shaft unit Do not disassemble the terminlal shaft unit unless the terminal shaft operates unsmoothly or its parts have to be replaced. ‘When replacing parts ofthe terminal shaft unit, disassem- ble this unit according to the following procedures: (1) Tum the terminal arm @ half around, and hammer the minor diameter side ofa taper pin @ toremove i. @) Using a hexagonal wrench key (having 3 mm width across flats), unscrew the setserews @. G) Draw out the terminal shafts @ , and remove the terminal arm. ‘When replacing the shafts and arm, be sure to replace them as a set since they have been taper bored together. s7 & NZ GOVERNOR& NZ GOVERNOR 14) Using a wrench (having 24 mm width across flats), remove the pressure regulating valve assembly @ Disassembly of major pans of the governor is ended with the aforementioned. Disassemble other parts when and if needed 2002.7.108 58@ NZ GOVERNOR 5-4. Checking of Various Parts 1) Clean + Clean (wash) the disassembled pat in clean cleaning uid (light oil) + During clee-ing, pay your atention not to impart hit marks particularly to the pilot valve, pilot valve bushing, power piston, ne:4™ bearing, trust washer, ec. + Either wipe the cleaned parts witha clean cloth o blow the dry air against them to dry them. + Check ifthe holes for hydraulic ol passage in the base and housing have been cleaned neatly. 2) Parts check ‘© Check each parts for crack, damage and rust; and if found defective, corrector replace such a part. ‘© Arrows given in the following figures refer to checking points. () Base Replace those gear shaft and pilot valve bushing that have scratch o sliding law or hit mark trae atthe gear fitpart with the new ones. @) Housing ‘Replace those gear shaft and pilot valve bushing ‘thathave a flaw atthe gear slide part or those power piston and pilot valve bushing that have a flaw at the fitting hole withthe new ones. ‘+ Replace those terminal shafis and speed control ‘shaft of which bearing bushes @_ tum as fined loosely or are worn off by the housing assembly. 59& NZ GOVERNOR @) Gear shaft and pilot valve bushin Replace the gear shaft of which ol seal contacting part {is wom off as stepped or of which the spline part is damaged and pilot valve bushing of which the outer diameter (18 mms) is flawed with the new one, Be- sides, replace also those pars of which tooth surface is flawed with the new ones. ‘Check also whether the spline fit hole on the gover- nor driving device side is abnormally worn off or not (4) Governor weight assembly + Check ifthe governor weight moves smoothly + Check the face sliding with thrust washer at the ‘weight tip part. Ifthe bearing width is found to be seater than I rom, replace it by the weight assem- by. ‘+ Check that the fiting withthe pilot valve bushing is smooth + If there is ait mark, bur, ete, correct such a part. (©) Power piston and compensator piston Incorporate the power piston (in the state of incorpo- rating the compensator piston @ and compensator bushing @ ) in the housing, and check if the power piston operates vertically under its own weight. More- over, incorporate the upper spring @, spring seats @ and guide lever pins @ in the power piston; and ‘check that the compensator piston moves smoothly. If ‘operations ofthe power piston and compensator piston are unsmooth and do not improve even after they are ‘leaned, replace the power piston and compensator rod ®@ Ifoperations of the power piston and compensator piston are found bad, this causes a hunting, exces- sive speed droop or bad condition in the engine run. 2002.7.108 5-10 Gear Shaft Pilot Valve Bushing Spine Part Fig. S15, PILOT VALVE BUSHING Fig. 516