rü

NZ SERIES HYDRAULIC GOVERNOR

MODEL NZ61/NZ1 15

SERVICE MANUAL

Be sure to read this Operation Manual for you to use

this product safety and correctly.
Even after reading it, carefully keep it, making clear to
all personnel concerned where it is kept so that the
operator, mechanic or supervisor will have an access
to it whenever he wants to read or refer to it.

YANMAN EO.,LTD.
@
2008.7.4R
PREFACE YA}'NAN lIZ GOI'ER]|OR

PREFACE

This Service Manual describes the construction, maintenance of, and disassembling procedures for Model
NZ61/N2115 Hydraulic Governor and controller. Read this Manualcarefully to use the govemor conectly.

. Keep this Manual under care at a clearly identified place accessible for the operator to refer to it at any
time.

. The text and lustrations 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 rea-
sons of safety of this product.

. Use our genuine parts or specified parts for replacement parts. Order a part to your nearest sales agent
or YANMAR parts sales agent. When ordering a part, clearly specify the Part Name (part description),
Part No., Engine Name and Governor Modeland Serial No.

. Should you have lost or damaged this Manual or if you have any question and advice, feel free to contract
us or your nearest sales or service agent (shown in the service network list "YANMER Worldwide Ser-
vice" appended to the Engine Operation Manual).

. Precautions on Safety

. A note prefixed with the WARNING CAUTION mark in this Manual is a very impor-

tant 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 fol-
lowed. Thus, be sure to follow such a note.

. An item prefixed with the A ma* in this Manual is very important for handling of a product. A failure to

observe such an item may incur a deterioration of performance or a trouble of this product. Therefore, be
sure to observe such an item.

. An item prefixed with the [[fl marf in this Manual indicates a chapter, section, clause, page or docu-
ment to be refened to.
PREFACE YA,trüAn llzGovERlloll
MEMO
 GOI'ERNOR

CONTENTS

Page
PREFACE

CHAPTER 1. GENERAL DESCRIPTION.......... ......1-1

1-1. Specifications of the Governor ........... ......1-1
1-2. Hydraulic Oil ......... .................1-1
1-3. Cautions on Handling of the Governor .....1-1

CHAPTER 2. OUTLINE OF CONSTRUCTION .......2-1

2-1. Function of Major Parts ......... ......,.,..........2-1
2-2. Operation of the Governor .......................2-3
2-3. Speed Droop Adjusting Mechanism .........2-4
2-4. Compensator Mechanism .....2-5

GHAPTER 3. MAINTENANCE 1NSPECT1ON................ .............3-1

3-1. Daily Inspection .....................3-1
3-2. Change of Hydraulic Oil ............. ..............3-1
3-3. Air Bleeding of Hydraulic Oil Passage ......3-2
3-4. Speed Droop Adjustment ......3-3
3-5. Adjustment of Needle Valve .....................3-3
3-6. Cautions in Initial Run .......... ....................34
3-7. Troubleshooting ....................3-6
3-8. Criteria on Parts Replacement ............... .....................3-8

CHAPTER 4. REMOTE CONTROLLER.............. .......................4-1

4-1. Motor Controller .....................4-2
4-2. Pneumatic Controller .............. ..................44
4-3. Wire Controller .......................4-7

CHAPTER 5. DISASSEMBLY & REASSEMBLY OF THE GOVERNOR .....5-1

5-1. Cautions in Disassembly/Reassembly......... ................5-1
5-2. Development of the Governor............ .......5-2
5-3. Disassembly of the Governor............ ........54
54. Checking of Various Parts....... ..................5-9
5-5. Reassembly of the Governor ................. ....................5-12
5-6. Service Data in Servicing .....5-14
CONTENTS Y.AilM,,ß llz GovEllf,oR
CHAPTER 1. GENERAL DESCRIPTION UA'I/'',AN TIZ GOI'EPXOR

CHAPTER 1. GENERAL DESCRIPTION

1-1. Specifications of the Governor

Specifications of the Models NZ61 & N2115 Govemors are as follows:

NZ61
Governor Model Unit N2115
(A) (B)

Governor controlling force (work done) N.m(kgf .m) 5.e (0.6) e.8(1.0)

Output shaft torque N.m(kgf .m) e.8(1.0) 11.8(1.2) 14.7(1.5)

Hydraulic oil pressure MPa (kgf/cm2) 1.18(121 1.47(15) 1.47(15)

Power piston diameter (minor/major) mm 17.6t25 18.6t27

Setting speed droop adjustment range Yo 0-10

Dry mass kg About 5.5

(A): for Engine Model 6N160 & 6N165 .

(B): for Engine Model 6N18 & 6N21.
Sectional view of the governor and nomenclature of its major parts are shown in Fig. 1-1.

1-2. Hydraulic Oil 1-3. Cautions on Handling of the Governor

(1)The body of this governor comprises an oil (1)Do not install and handle the governor so that
sump chamber, and thus the governor can a force is applied to or a shock is imparted to
use an equivalent to the system oil for the the gear shaft, speed control shaft, and
engine as govemor hydraulic oil. terminalshafts.
Othena/se, the shafts might be bent, and
seals or intemal parts might be damaged.
Don't use synthetic oil as hydraulic oil for
(2)When attaching the governor to the engine,
this governor. lf used, it deteriorates oil
seals and packing much earlier than the attach the govemor to its driving device under
usual. the govemor's own weight while setting the
spline of the gear shaft, and uniformly tighten
(2)Properly use the hydraulic oil according to the tightening nuts.
governor oil temperature in a normal run.
Gov. OilTemperature Hyd. OilViscosity

Below 50oC SAE2O

Between 50oC and 70oC SAE3O

Between 70oC and 80oC SAE4O

1-1(Volume:2pages)
CHAPTER 1. GENERAL DESCRIPTION YAmtAE ]lz Gol'ER]loll

Nomenclature of the Governor Major Parts

Droop Adjuster

Speed Control Shafl

Floating Lever

Govemor Weight

Govemor Spring

Compensator Rod

Pilot Valve

Pilot Valve Bushing Compensator Piston

Fig. 1-1

1-2
CHAPTER 2. OUTLINE OF CONSTRUCTION y,AXTüAN lIZ GO\'ERTIOR

CHAPTER 2. OUTLINE OF CONSTRUCTION

This Chapter describes the functions of major parts that are constituting the governor and principle of its
operation.

2-1. Function of Major Parts

Floating Lever
Speed Control Shaft

Spling Folk Power Piston

Govemor Spring Compensator Rod

GovemorWeight Compensator Spring

(Upper)
Pilot Valve Bushing
Compensator Spring
(Lower)

Pressure Regulating Valve Compensator Piston

Pilot Valve

Needle Valve
Gear Pump
Gear Shafi

Fig.2-1

of the spring and an opening or closing of the gov-

(1) Gear Shaft
ernor weight.
Being an input shaft for the governor, the gear
A vertical movement of the pilot valve controls the
shaft serves as a gear to drive the hydraulic oil
hydraulic oil which flows to the lower part of the
pump.
power piston as the control land at the central part
opens or closes the hydraulic oil passage hole in
(2) Pilot Valve Bushing
the pilot valve bushing.
The part intermeshing with the gear shaft consti-
tutes the hydraulic oil pump gear, the flyweight (5) Floating Lever
assembly is fitted to the upper part, and the pilot
Coupled to the speed control shaft through the
valve is fitted to the inner part. Besides, a hydrau-
spring fork and a fork, the floating lever is con-
lic oil passage hole to the power piston is pro-
nected to the power piston through the droop
vided to this bushing.
adjuster and the terminal arm.
(3) Governor Weight
(6) Power Piston
Rotating together with the pilot valve bushing
The hydraulic oil pressure bearing area ratio of
according to the rotation of the gear shaft the gov-
the power piston upper and lower parts is 1 : 2,
ernor weight moves the pilot valve vertically
and the power piston is actuated vertically by sup-
according to a change in the engine speed.
ply of hydraulic oil from the pilot valve bushing
central hole or discharge of the oil.
(4) Pilot Valve
Besides, the compensator spring and compensa-
The governor spring is incorporated into the tor rod are incorporated in the inner part of the
upper part of the pilot valve, and it moves verti- piston.
cally according to a change in compressive load

2-1(Volume:6pages)
CHAPTER 2. OUTLINE OF CONSTRUCTION YANJüAN lIZ GOYERI|OR

(7) TerminalArm
Coupled to the power piston by the guide lever.
the terminal arm transmits a movement of the
power piston to a 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 droop
adjuster changes the speed droop by adjusting its
mounting position.

üfh s"". 2-3. Speed Droop Adjusting Mechanism

(9) Needle Valve

The needle valve adjusts the compensator effect
by regulating the hydraulic oil pressures of the
compensator case and the pilot valve lower case.

flfll s".. 2-4. Compensator Mechanism

(10) Pressure Regulating Valve

It regulates the hydraulic oil discharged from the
hydraulic oil pump to the specified pressure.

2-2
CHAPTER 2. OUTLINE OF CONSTRUCTION UAX,,AR 1|Z GOVER]IOR

2-2. Operation of the Governor 2) Steady Running

Under the stable state of the engine load, a com-
Fig. 2-2 shows the system diagram on operation pressive force of the governor spring balances
of the governor. with a centrifugal force of the governor weight the
Balancing a compressive force of the governor control land closes the control port and the power
spring with a centrifugal force of the governor piston holds a fixed position to set the engine
weight, the governor operates to maintain a fuel rotation.
injection volume corresponding to the load of the
engine. 3) Load lncreasing
As the load increases, the engine rotation drops,
1) Starting and a centrifugal force of the governor weight
The governor weight is closed by the governor decreases to close it.
spring, and the control land of the pilot valve is The control land shifts below the control port, the
located below the control port. As the engine is hydraulic oil is sent into the lower part of the
started, the hydraulic oil is sent into the upper and power piston to shift it upward (in the direction of
lower parts of the power piston at the same time. fuel increase). As the power piston shifts up-ward,
Since the hydraulic oil pressure bearing area ratio the governor spring is also pulled upward through
of the power piston upper and lower parts is 1 : 2, the droop adjuster and the floating lever that are
the power piston shifts upward (in the direction of incorporated in the terminal arm, and the control
fuel increase) to facilitate starting. land closes the control port to rise the speed in
correspondence to the increased load and thus to
maintain the equilibrium.

|...:

Fig.2-2

2-3
CHAPTER 2. OUTLINE OF CONSTRUCTION Yil|JüAN ]IZ GOVER]IOR

4)Load Deceasing
Contrary to the operation in a load increase, the
control land shifts above the control port. The
hydraulic oil is discharged 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

Droop Adjuster
This mechanism purports to adjust the
speed droop and can set any droop within
the range of 0 to 10 %.

The lever ratio (11/12) of the floating lever change

by changing the position of the droop adjuster, the
set load (compressive force) of the governor Speed Control Shaft
spring also changes, and consequently, the
speed droop undergoes a change.

A relation between the set positions of the droop

adjuster and the speed droop becomes as fol-
lows:

Droop
adjuster set 0 <_>12
graduation

Speed droop
(variation) Decreases..elnCreaSeS

NOTE: The droop adjuster set graduation does

not mean to indicate a value of the speed Fig.2-3
droop (variation).

. Permanent variation x 100 (%)

It indicates in percentage the difference bet-

ween the set speed (N2) following the risen
speed when the load is shut off (0%) and the
speed(N) in the 100% load.
RPM
. Time of stabilize (for Frequency)
It refers to a time required to achieve the set
speed from a moment the load is shut off.

. Momentary variation =
*'i * x 100 (%)

It indicates in percentage the difierence bet-

ween the most risen speed (N1) on the way to
become the stable speed when the load is shut
off (0 %) and the speed (N) in the 100 Yo Fig.24

2-4
CHAPTER 2. OUTLINE OF CONSTRUCTION YA}'NAN lIZ GOVERI|OR

2-4. Compensator Mechan ism

This mechanism consists of the compensator

upper and lower springs and compensator pis-
ton that are incorporated in the power piston
as well as the needle valve. Besides, the com-
pensator case is connected to the pilot valve
lower case with the hydraulic oil passage, 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 mini-
mum overshoot or undershoot.

. As the engine rotational setting is changed or

the load fluctuates, the power piston operates
to change the fuel injection volume.
At that time, the compensator piston also oper-
ates simultaneously, 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
Fig. 2-5
and thus assists in early restoring to the steady
state.

Seed setting Rise Drop

Load fluctuation lncrease Decrease

u
Pilot Valve Fall Rise

Power Piston Rise Fall

Compensator
Positive Negative
CasePilot valve
pressure pressure
lower case

Compensator Lower spring Upper spring

spring compression compression

. The magnitude of a positive or negative pres-

sure of the compensator case and pilot valve
lower case may vary according to the opening
of the needle valve and requires a proper
adjustment of the opening.
.{'-r-L
lltlJll Chapteß, Sec. $5. Adjustment of Needle Valve
lf 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 extensively, the
engine rotation becomes unsteady.

2-5
CHAPTER 2. OUTLINE OF CONSTRUCTION YAr/JüN lIZ GOYER]IOR

2-6
CHAPTER 3. MAINTENANCE INSPECTION YAtt'',An llz GovERlloR

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 a level 2 to 3 mm
above the center of the oil gauge.
. In the case where the oil level fails, check if
there is an oil leakage.
(2)Check for looseness of bolts and nuts of vari-
ous parts and if there is an abnormality of a
linkage that connects the govemor with a fuel
injection pump.

2) Inspection during a run

(1)Measure the temperature of the governor
housing with use of a thermometer.
The temperature becomes stable if the engine
is run for 30 to 40 minutes.
. lf the temperature rises to above 80'c, there
will be an abnormality. Thus, make a check.
(2)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.
An oil volume to reach the specified oil level is Fig. 3-1
about 1.3 liter.

When changing the hydraulic oil, have the

starUstop lever of the engine set in the STOP
position D so as not to start the engine by
mistake.

3-1(Volume:Spages)
CHAPTER 3. MAINTENANCE INSPECTION YA}'TüAN 1|Z GOYER]IOR

O Detacn the drain plugs and needle valve from

the governor base to discharge the oiil hydrau-
lic oil.

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 accu-

mulated in the governor oil sump.
@ nttacn the drain plugs and needle valve, pour
in the new hydraulic oil, and attach the cover.

When the hydraulic oil is changed, be sure to

bleed the air.

Fig. 3-2

3'3. Air Bleeding of Hydraulic Oil Passage

Bleed the air from the hydraulic oil passage Control Knob
according to the following procedures:
(1) Set the needle valve in the fully opened setting
(three turns back from the completely closed
state).
(2) Turn the control knob to set the speed control
shaft pointer with the SPEED graduation 0,
and start the engine.
(3) Run the engine at a low speed to let hunting or
surging, and run it further for about 30 sec-
onds. MOTOR CONTRALLER PENUMATIC CONTROLLER

Do not run the engine in the range of torsional

Contol Knob
vibration critical speed.

(4) Slowly close the needle valve to set it in the

specified position.
. In case where air bleeding is insufficient
hunting may not be stopped. In that case,
open the needle valve again to let hunting.
. Whenever the governor is replaced; ser-
viced or repaired, adjust the needle valve.

Sec. 3-5. Adjustment of Needle Valve

(5) In case where the oil leveldrops, feed the gov-
ernor with hydraulic oil.
Needle Valve

Fig. 3-3

3-2
CHAPTER 3. MAINTENANCE INSPECTION VADüüAB llz GovEniloR

3-4. Speed Droop Adjustment

Adjust the speed droop to change it according to
the following procedure:
Droop Adjuster
(1) Remove the (controller) cover, and change the
set position of the droop adjuster.

@
. As the adjuster graduation is shifted in the "0"
direction, the speed droop lessens.
. As the adjuster graduation is shifted in the
"10" direction, the speed droop enlarges.
(2) 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.
Fig. 3-4

3-5. Adjustment of Needle Valve

The needle valve serves to adjust the response (2) Set the needle valve in the widest opened
,characteristics of the governor. lf the needle valve
state possible within a range the engine can
is properly adjusted, the engine maintains the fuel run with steady speed .
injection volume after a change in load with the . In case of generator driving, set the needle
minimum rotational fluctuation and time. valve under the rated speed state of the
The needle valve has been adjusted to fit with the engine.
engine individually. In the following cases, the . In case of a main marine engine or driving a
needle valve has to be adjusted: pump, for instance, set the needle valve
. In case where the governor is replaced or under the minimum speed state of the
serviced. engine within its normal service range.
. In case where the governor is overhauled
(disassembled and repaired).
. When the viscosity of hydraulic oil is lf the needle valve is closed too firmly, the
changed. governor becomes dull and the engine's
. In case where a linkage which connects the response to a load change is delayed.
governor with a fuel injection pump is
altered.
. In case where the set position of the droop
adjuster is changed.

(1) After the air bleeding of the governor and set-

ting of the droop adjuster are finished, run the
engine as well as the governor until they
assume the usual running state.
. As the engine is run at the no-load rated
speed for 30 to 40 minutes, the viscosity of
hydraulic oil stabilizes in the usual running
state.

3-3
CHAPTER 3. MAINTENANCE INSPECTION UATTJüAN lIZ GOVER]IOR

3-6. Cautions in Initial Run

In the 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) Oilfeeding
(1) Feed the governor with new hydraulic oil to a
level 2 to 3 mm above the center of the oil
gauge.
(2) Move the governor vertically until the terminal
arm becomes heavy, and bleed the air from
the power piston and hydraulic oil passage.
(3) lf the oil level drops, replenish the hydraulic oil
up to the specified oil level. Fig. 3-5

3) Gonnection of the linkage

WARNING
Check if a linkage that connects the govemor
with a fuel injection pump has been fitted
properly.
A poor connection of the linkage has a possi-
bility of being related to abrupt rotation of the
engine.

(1) Set the starUstop lever of the engine in the

STOP position.
(2) Fit the output lever to the terminal shaft of the
governor, and connect a linkage.
(3) Turn the terminal shaft fully in the FUEL
graduation "0" direction, and securely tighten
the clamping bolt oft he output lever.
. The terminal shaft pointer should indicates
the "0". Fig. 3-6
. The rack of a fuel injection pump should be
in the no-injection position.
(4) Shift the starUstop lever of the engine in the
RUN position, and then check if the output
lever moves lightly when it is shifted from the
"0" to "8" terminalshaft graduation.

3-4
CHAPTER 3. MAINTENANCE INSPECTION YAX',,AN ]IZ GOVERTOR

4) Setting Of speed droop

Since the droop adjuster graduation of the new or
serviced governor has been set in the "5", tempo-
rarily set the droop adjuster, referring to the for-
mer governor or the adjuster graduation prior to
the repair.

5) Setting of the controller

Turn the control knob to set the speed control
shaft pointer in the 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
possibility of damaging the engine or causing
an accident resulting in injury or death.

7) Adjustment of the droop adjuster and nee-

dle valve.
Adjust the droop adjuster and needle valve.

flfB S"".3.4. Speed Droop Adjustment

l|fl|| s"". 3-5. Adjustment of Needte Valve

3-5
CHAPTER 3. MAINTENANCE INSPECTION YAXI/|AN ]IZ GOI'ERTOR

3-7. Troubleshooting
A trouble of the governor normally appears as a speed change of the engine, but it is practically impossible
to forecast all kinds of troubles.
This Chapter outlines the most general troubles of the govemor.
A speed fluctuation and an unsatisfactory control are caused either by a trouble on the engine side or a
trouble of the govemor or controller.

Since the govemor uses a large number of precision parts and there is a danger of ovenunning the
engine if parts are wrongly incorporated or setting is improperly done, do not repair the govemor in the
field, but consult your nearest sales agent or service agent (shown in the service network list "YAN-
MAR Worldwide Service" appended to this Engine operation Manual) for repair of your governor.

Nature of Probable Cause Countermeasure on

Trouble Govemor/Controller
Engine Side Governor/Controller Side
Engine . Load in fluctuation . Needle valve opened too widely . Adjustment of the needle valve
rotation . Fuel feed pressure too
fluctuated . Power piston stuck or malfunctioned . Overhaul cleaning or servicing
high (or too low)
periodically . Uneven combustion . Pilot valve malfunctioned . Overhaul cleaning or servicing
(hunting) . Fuel oil filter fouled
. Air intruded into fuel oil . Oil leaked inside the govemor . Servicing (replacement of worn
. Fuel injection pump parts)
rack malfunctioned
. . Tip of govemor weight (face con- . Replacement of the govemor
Linkage twisted or
jolted extensively tacting the thrust washer) worn weight assy.
. Linkage wrongly away
connected (in case the . Compensator piston malfunctioned . Servicing
governor is detached
from the engine) . Hydraulic oil passage of compen- . Overhaul cleaning
sator mechanism blocked up

Rotational Engine overloaded . Needle valve closed too tightly . Adjustment of the needle valve
restoration Fuel oil filter fouled or
lagged . Compensator piston stuck . Overhaul cleaning or servicing
clogged
against the Fuel injection pump . Needle valve clogged . Cleaning oft he needle valve
load fluctu- rack stuck
ation of the Linkage stuck . .
Hydraulic oil passage of compen- Overhaul cleaning
engine or
sator mechanism blocked up
reaction to
a change in . Hydraulic oil pressure dropped . Servicing (replacement of worn
clogged (Side clearance of hydraulic oil pump parts)

. Pressure regulating valve stuck . Overhaul cleaning

[Motor Controller] . Shim adjustment of the friction

. Friction clutch slipped
clutch

[Pneumatic Controller]
. Air leaked from diaphragm . Leakage correction or replace-
ment of the diaphragm
. Push rod malfunctioned . Correction of the push rod

[Wire Remote Control]

. Clearance of the wire coupling too . Coupling correction of the
large remote control wire

[Miss operation]
. Speed control shaft bent or mal- . Servicing
functioned
. Terminal shaft malfunctioned . Servicing

3-6
CHAPTER 3. MAINTENANCE INSPECTION YAf/'U,ß IIZ GOYER]IOR

Nature of Probable Cause Countermeasure on

Trouble Govemor/Controller
Enqine Side Governor/Controller Side
Fuelinjec- . Backlash of the gover- . Governor poorly mounted . Correction of govemor mount-
tion pump nor driving system gear (Gear shaft and spline coupling ing
rack too large poorly centered )
frequently . Influenced by torsional
inched vibration
. Governor weight malfunctioned . Replacement of the govemor
( jisgling) weight assy.

No output . Spline of the governor . Power piston stuck . Overhaul cleaning

from the driving device worn off [Oil pressure of the governor not
govemor . Linkage stuck producedl
(the output . Output lever clamping . Pressure regulating valve stuck or . Overhaul cleaning or replace-
lever could bolt loosened damaged ment
not be . Side clearance of the pump gear . Overhaul cleaning or servicing
moved) too large (replacement of worn parts)

Governor . Oil seal damaged or gear shaft . Replacement of the oil seal or
hydraulic oil worn away gear shaft
decreased

3-7
CHAPTER 3. MAINTENANCE INSPECTION YAX]TAB NZ GOVER]IOR

3-8. Griteria on Parts Replacement

Observe the following criteria for replacement of governor parts:
Numbers listed below refer to the corresponding numbers given in the Development, Fig. 5-1.

Replacement Inteval Part Description No. Q'ty

Every disassembly, 2 to 3 PACKING, governor mtg. 5 1

yrs. or every 10.000 hrs.

PACKING, governor mtg. 6 1

PACKING, press. regulating valve plug 42-6 1

PACKING, base incorporating bolt 51 3

PACKING, stopper bolt 52 1

PACKING, drain plug 53 2

PACKING, pressure regulating valve 55 1

WIRE, floating lever 22 2

SPRING PlN, fork 49 1

COTTER PIN 50 4

OIL SEAL, base 3 1

O-RlNG, compensator bush 34 2

O-RING, base 35 1

O-RING, needle valve 36 1

Every 5 yrs. or 20,000 hrs. GEAR SHAFT 4 1

NEEDLE BEARING 7 1

THRUST WASHER 8 1

GUIDE LEVER PIN 12 2

OIL SEAL, terminal shaft/speed control shaft 16 4

FLOATING LEVER 21 1

OIL GAUGE 26 1

GOVERNOR WEIGHT ASSY. 43 1

PRESSURE REGULATTING VALVE ASSY. 42 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.
(2) As a general rule, replace those parts used more than 8 years or 40,000 hours by the govemor assem-
blv.

3-8
CHAPTER 4. REMOTE CONTROLLER YAn','Aa llz GovERIloR

CHAPTER 4. REMOTE CONTROLLER

One of three types of remote controllers available for remote control of the governor is equipped to a NZ
Series Govemor according to the specified specification.
(Fig. 4-l shows the appearances of govemors equipped with the respective remote controllers.)
This Chapter describes the operation and maintenance of the respective remote controllers.

MOTOR CONTROLLER PNEUMATIC CONTROLLER WIRE CONTROLLER

A lever is fitted to the speed control

shaft. and remote control is
done cable

Fig.4-1

4-1(Volume:Spages)
CHAPTER 4. REMOTE CONTROLLER YAT'/J',AE ]IZ GOVER]IOR

4-1. Motor Controller

Changing the compression of the govemor spring WITHOUT LIMITER
by rotation of a motor, the motor controller sets
the governor in any engine speed. A motor Manual Shaft Gear Manual shaft
equipped is a reversible, single-phase motor.
In the case of regulating the speed manually, reg-
ulate it by means of the control knob.
Besides, the motor controller of such a specifica-
tion equipping a limit switch to set the upper and
lower limits of the engine speed electrically is also
available.

1) Regulation of the speed

. The motor turns while the speed setting switch

is being pushed on the remote control side.
This rotation is decelerated by the gear head, Gear Belt Filler Plug

transmitted to the fork of the governor through Spindle Screw

the friction coupling, motor gear, bevel gear, Motor Gear Friction Coupling
and spindle screw and changes the compres-
sion of the governor spring to regulate the
engine speed.

GEAR HEAD
I

FRICTION
COUPLING
(FRTCTTON
cLUTCH)
I Fig.4-2
MOTOR GEAR
GEAR
I

BEVEL GEAR . In the case of manual regulation, turning the

I control knob intermeshes the manual shaft gear
SPINDLE SCREW with the motor gear so that the rotation is trans-
I mitted to the governor in the same route as in
GOVERNOR the case of motor tuning (remote control).
Besides, as the control knob is turned during
remote control (motor turning), the friction
clutch of the friction coupling slips, imparting no
adverse effects on the gear head and motor.

4-2
CHAPTER 4. REMOTE CONTROLLER YADt,',An NZ GOVEIIilOR

2) Adjustment of the limit switch

The limit switch actuates through a shift based on Limit Switch Adjusting Bolt
the screw action of a limiter incorporated to the
manual shaft. Adjusting the position of the limit
switch through a shift of the limiter by turning the
control knob sets the upper and lower limits of the
engine speed.

WARNING
When working on this adjustment, either cut
off the power or cover the capacitor with
insulator.
lf you happen to touch it, there is a possibil-
ity of an electric shock or a fire caused by a
short Lower Limite Switch

. 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
position.

Fig.4-3

3) Etectrical connection of the motor controller

RATED POWER APPLICABLE CAPACITOR
Connect the motor controller as shown in Fig. 4-4 AC100-115Y 2.5 uF
Black:
as the motor is a single-phase motor available in Red:AC2OO-220V 0.5 tF
two types of voltage, 110 V and 220V.
As viewed from the gear head side, the sense of
.isp.ä3Ei'l-i
ö
rotation of the motor is as follows with respect to
the rotation of the engine: -19!i!9L - - -.!
. ln acceleration: Glockwise
. ln deceleration: Counterclockwise
Limit Switch Capacitor

Fig.44

4-3
CHAPTER 4. REMOTE CONTROLLER YADr'',An llz GovERlloll

4-2. P neumatic Gontrol ler

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
transmitted to the govemor 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 con-
trol knob.
AIR
cap
Piston
Diaphragm

Diaphragm Sparing
Max. Speed
Limiting Bolt
Push Rod
Filler Plug

Fig.4-5

1) Maintenance of the controller

Replace the O-ring 22 and diaphragm 7 of the

controller cap 6 with the new ones biennially
or every 10,000 hours even if not damaged.

When disassembling the pneumatic controller,

refer to the Development in Fig. 4-10 and the fol-
lowing procedures:
An encircled numeral appended to a part descrip-
tion appearing in the following text refers to the
corresponding numeral given in Fig. 4-10, Devel-
opment.
(1) Detach the compressed air inlet pipe, loosen
the lock handle 15 of the controller, and
loosen also the control knob 3 until it turns
lightly.
(2) Loosen the clamping bolts 24 and setscrews Fig.4-6
26 of the cap 6 with use of a wrench and a
Phillips screwdriver, and remove the cap.

4-4
CHAPTER 4. REMOTE CONTROLLER UAf/JüAR lIZ Go\'ERIIOII
(3) Take out the diaphragm assembly, and re-
move the spring seat 13 and springs 11 & 12.

Diaphragm Assy.

't3

12

11

(4) Lightly insert the width across flats of the tip of

the push rod 8 in a vice stand, loosen the nut
27, and then take out the upper plate 18, dia-
phragm 7 and piston 17.

Disassembly of major parts of the pneumatic

controller is ended with the aforementioned.
Disassemble other parts when and if needed. Fig.4-7

27
GE_19
@-,,
Ig
--€.
2) Reassemble the pneumatic controller in the
reverse sequence of the aforementioned
disassembling procedures.

In this Sub-section, cautions to be taken in reas- 17

sembling are set forth.
(1) Incorporate the pertinent parts (parts having
asterisked reference numbers in Fig. 4-10)
upon coating the following spots with molyb-
denum disulfide:
. Outer periphery of the adjust screw {4,
. Both faces of the spring seat 13 and 024678 - 001

. (10 mm<D) shaft part of the push rod 8.

Fig.4-8

(2)Pay your attention to the following points when

incorporating the diaphragm:
. Coat the base fabric side of the diaphragm
with molybdenum disulfide.
. Parallel the width across flats of the tip of the
push rod with the floating lever of the gover-
nor, and then mount the diaphragm on the
cylinder 5.
Base Fabric Side
. Set the protrusion on the outer periphery of (molybdenum disulfi de coated)
the diaphragm in the groove of the cylinder
5.
. Making sure there is no twist nor wrinkle to
the diaphragm, tighten the cap 6.
. Don't tighten the nut 27 excessively.

Fig.4-9

4-5
CHAPTER 4. REMOTE CONTROLLER Y.A'''I|AN IIZ GCDI'ER]IOR

Development & Nomenclature of the Pneumatic Controller

----]

-29

13*

1",

fl
I
16

t_
21
ll
tql -g*
I

__)
* NOTE: Incorporate this part upon coating it with seizure inhibitor (molybdenum disulfide).

Fig.4-'10

No. Part Description o'ty No. Part Description o'ty

,|
1 BOLT, max. rotation limiting 1 17 PI STON
2 NUT. lock 1 18 PLATE upper 1

3 KNOB. control 1 19 WASHER, spring 8

4 COVER 1 20 PlN, spring 1

5 CYLINDER 1 21 GASKET. copper 1

6 CAP 1 22 O-RING 1

7 DIAPHRAGM 1 23 BOLT M6x20, collar 4

8 ROD, push 1 24 BOLT M6x95 2

I ADJUSTER, spring 1 25 SCREW M6x16 3

10 NUT.lock 1 26 SCREW M6x25 2

11 SPRING, diaphragm (outer) 1 27 NUT M6 1

12 SPRINC, diaphragm (inner) 1 28 JOINT, swivel pipe 1

13 SEAT. spring 2 29 BOLT, pipe joint 1

14 SCRLW, adjust 1 30 GASKET 2

15 HANDLE.lock I
16 PLVG filler 1

4-6
CHAPTER 4. REMOTE CONTROLLER r,AnnAn ]lz GovERlloR
4-3. Wire Controller
With a lever attiached to the speed control shaft of
the governor, the wire controller regulates the
Speed Control Shafl
engine rotation.
Moreover, turning the control knob can also
change the engine speed in the same way as the
controlcable.

Fig.4-'11
Development & Nomenclature of the Wire Controller

@- 10

.€
3--@
7

I
h
+
11

Fig.4-12

No. Part Description o'tv No. Part Description o'tv

1 BREEDER ASSY.. filler port combined I 7 SCREW, adjust 'l
,|
2 GASKET, rubber 1 8 SCREW, guide
3 NUT,lock 1 I NUT, lock 1

4 BOLT, max. rotation limiting I 10 PlN, spring 'l

5 COVER 1 11 GASKET I
6 KNOB, control 1 12 BOLT 4

4-7
CHAPTER 4. REMOTE CONTROLLER YAnttAn ilz GovERIloR

4-8
CHAPTER 5. DISASSEMBLY & REASSEMBLY OF THE GOVERNOR YAffüAN lIZ GOVER]IC'R

CHAPTER 5. DISASSEMBLY & REASSEMBLY OF THE GOVERNOR

5-1. Cautions in Disassembly/Reassembly

(1) Do not disassemble the govemor unnecessarily except in the case of a special repair.
(2) In the case of a repair, have the replacement parts ready in advance.
(3) Prior to the disassembly, have the governor 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.
(4) When taking out the govemor and after it is 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 or a damage of internal parts.)
(5) After the govemor is removed cover it so that dust and foreign matter will not enter the governor-driv-
ing device.
(6) Before disassembling the governor, clean its exterior to get rid of adhering dust etc.
(7) Keep a disassembling workbench clean, and use clean light oil for cleaning fluid.
(8) The following tools are necessary for disassembly & reassembly of the govemor:

ToolDescription Applieation Ref. No. in Fig.S-l

For detaching & attaching the (controller)

Wrench (10 mm width across fiats)
cover

Wrench (12 mm width across flats) For detaching & attaching the stopper bolt 25

Wrench (17 mm width across fiats) For detaching & attaching plugs 54,42-3
For detaching & attaching the pressure
Wrench (24 mm width across fiats) 42
regulating valve

Pliers or pincers For drawing out a cotter pin and wire 50,22

Screwdriver, Phillips For adjusting the droop adjuster 60

Screwdriver. blade For adjusting the needle valve 41

Hex. wrench key

For detaching & attaching the base 57
(5 mm width across flats)

Hex. wrench key For detaching & attaching the terminal

61
(3 mm width across fiats) arm setscrew

Extractor (3.89x59 tt1 For drawing out the fork spring pin 49

(9) Be sure to change cotter pins, spring pins, wire, copper gaskets and other gaskets with the respective
new ones at time of disassembly.
Refer to Chapter 3 for periodically replacing parts.

llfBl ctt"pter 3, Sec. 3-8. criteria on Parts Replacement

5-1 (Volume: l Spages)

CHAPTER 5. DISASSEMBLY & REASSEMBLY OF THE GOVERNOR
y/AmüAE llz GovEllxoll

5-2. Development of the Governor

60
45
44
15

47-----tl
U
€P--u t3

a
61

1,7 39

6=i

a\26
31

30
29
33
46
34

51

36 53 54

Fig. 5-1

5-2
CHAPTER 5. DISASSEMBLY & REASSEMBLY OF THE GOVERNOR YAITIUAN NZ G(oVER]I(oR

Governor Parts List

No. Part Description o'tv No. Part Description o'tv
1 HOUSING 1 36 O-RING needle valve 'l

2 BASE 1 37 NAME PLATE 1

3 SEAL. oil 1 38 NAME PLAT& L, side shaft 1

4 SHAFT, gear 1 39 NAME PLAT& R, side shaft 1

5 GASKET. base 1 40 VALVE ASSY., pilot 1

6 GASKET, cover 1 40-1 BUSHING, pilot valve (1)

7 BEARING thrust 1 40-2 VALVE, pilot (1)
I WASHER. thrust 1 41 VALVE. needle 1

9 SPRING govemor 1 42 VALVE, pressure regulating 1

10 FORK spring 1 42-1 BODY (1)

11 LEVER, guide 2 42-2 PISTON (1)
12 PlN, guide lever 2 42-3 PLUG (1)
13 ARM. terminal 1 42-4 SPRING (1)
14 SHAFT, terminaUoutput 2 42-5 PIN (1)
15 ADJUSTER, droop 1 42-6 GASKET (1)
16 SEAL, oil 4 43 WEIGHT ASSY., govemor 'l

17 BUSH 4 44 WASHER, droop adjuster 1

18 SHAFT, speed control 1 45 WASHER, droop adjuster toothed 1

19 COLLAR 2 46 RING, compensator lower spring snap 1

20 FORK 1 47 PlN, terminal arm taper 2

21 LEVER, floating 1 48 PlN, compensator piston 1

22 WIRE 2 49 PlN, fork spring 1

23 POINTER 4 50 PlN, guide lever pin cotter 4

24 SPRING 1 51 GASKET, base incorporating bolt 3
25 STOPPER 1 52 GASKET, stopper bolt 1

26 GAUGE. oil 1 53 GASKET, drain plug 2

27 BUSH, compensator 1 54 PLUG drain 2
28 PISTON, compensator 1 55 GASKET, pressure regulating valve 1

29 SPRING, compensator lower 1 56 BEARING needle 1

30 ROD, compensator 1 57 BOLT, base-incorporating hex. socket 3

31 SPRING, compensator upper 1 58 SCREW pointer 2
32 PISTON, power 1 59 NUT, pointer 2
33 SPACER, compensator lower spring 2 60 SCREW droop adjuster 1

34 O-RlNG, compensator bush 2 61 SETSCREW terminalarm hex. socket 2

35 O-RING. base 1

5-3
CHAPTER 5. DISASSEMBLY & REASSEMBLY OF THE GOVERNOR YAmüAn tlz GovERIloR

5-3. Disassembly of the Governor

In time of disassembling (or reassembling) the governor, refer to Fig. 5-1, " Development of the Governor"
and the following procedures:

An encircled numeral given in a figure of this Chapter or that appended to a part description appear-
ing in the following text refers to the corresponding numeral given in Fig. 5-1, "Development of the
Governor".

1) Loosen four cover clamping bolts with use of

a wrench having 10 mm width across flats,
and remove them together with gasket 6.
2) Turn the governor upside down to discharge
the hydraulic oil.
3) Remove a drain plug on the oil gauge side
from the base 2, and insert the base into the
vice stand for fixing.
4) Straighten with pliers one side of two wires 22
that are coupling the floating lever 21.

Replace the wires 22 with the new ones when

reassembling the governor.

Fig.5-2

5) Holding the spring fork 10, take out the gover-

nor spring 9 together with the pilot valve 40-2.

(1) Keeping the spring fork and governor

spring not removed from the pilot valve,
soak them in clean light oil.
(2) When taking out the pilot valve pay your
attention not to lose the thrust bearing 7
and thrust washer 8 that might fall out
together.

Fig.5-3

5-4
 CHAPTER 5. DISASSEMBLY & REASSEMBLY OF THE GOVERNOR YAxnAn llz GovERlloP

6) Draw out the cotter pins 50 from the guide

lever pins 12 that are coupling the terminal
arm 13 with the power piston 32, and remove
the guide levers 11 and guide lever pins 12.

A
. As two verticallylocated cotter pins are
drawn out one at a time, the guide levers
and guide lever pins can be removed.

Fig. 5-4

7) Remove the governor from the vice stand,

o place the governor upside down, and using a
hexagonal wrench key having Smm width
across flats, detach the clamping bolts 57
from the base 2.

When placing the governor upside down, pay

your attention not to lose the thrust bearing 7
and thrust washer 8 in case they are still
remaining inside the governor weight assem-
bly.

Ell pig. s-ro.

Fig. 5-5

8) Tap the side of the base 2 with a plastic ham-

mer (or mallet), and as it is disjoined from the
housing 1, raise the base straight up to
remove it.
After removing the base, detach the needle
valve 41 from the base by using a blade

'-{g;
screwdriver.

Fig. 5-6

5-5
CHAPTER 5. DISASSEMBLY & REASSEMBLY OF THE GOVERNOR YAXNAN TIZ GO\'ERTOR

9) Remove the pilot valve bushing 4O-1 and

gear shaft 4 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.

Fig. 5-7

10) Push down the power piston below the gov-

ernor upper part, and remove this piston
together with the compensator bush 27.

Do not disassemble the compensator un it

unless the compensator piston 28 operates
un-smoothly.
3Y
@ö

Itl
tl
Fig. 5-8

11) Using an extractor, draw out the spring pin

49 inside the governor, and remove the
speed control shaft 18, collar 19, fork 20 and
spring 24.

. Draw out the speed control shaft as the -'(.-=.')

pointer 23 kept intact on the shaft
. When drawing out the spring pin, pay your
attention so that the speed control shaft
would not bend.
. Be careful not to flaw the mating surfaces of
the housing and base.

Fig. 5-9

5-6
CHAPTER 5. DISASSEMBLY & REASSEMBLY OFTHE GOVERNOR
y.AT'/IüAN TIZ GOVEIITOR

12) Unscrew the stopper bolt 25, and remove

the governor weight assembly 43.
lf the thrust bearing 7 and thrust washer 8
are remaining inside the assembly, remove
t 43

them from it.

024692-O0X

Fig. 5-10

13) Disassembly of the terminal shaft unit

Do not disassemble the terminal shaft unit

unless the terminal shaft operates un-
smoothly or its parts have to be replaced.

When replacing parts of the terminal shaft unit,

disassemble this unit according to the following
procedures:
(1) Turn the terminal arm 13 half around, and
hammer the minor diameter side of a taper
pin 47 to remove it.
(2) Using a hexagonalwrench key (having 3 mm
width across flats), unscrew the setscrews
61.
(3) Draw out the terminal shafts 14 , 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. Fig. 5-11

5-7
CHAPTERs.DISASSEMBLY&REASSEMBLYOFTHEGOVERNOR UA'JrüAN ]|Z GOVER]IOR

14) Using a wrench (having 24 mm width across

flats), remove the pressure regulating valve
assembly 42 .

n
n o
Disassembly of major parts of the governor is no @n
\-/
ended with the aforementioned. Disassemble @ n
other parts when and if needed. 4o^
ov

Fig. 5-12

5-8
CHAPTER 5. DISASSEMBLY & REASSEMBLY OF THE GOVERNOR YATITUAN ]IZGOYEII]IOR

5-4. Ghecking of Various Parts

1) Glean
. Clean (wash) the disassembled parts in clean cleaning fluid (light oil).
. During cleaning, pay your attention not to impart hit marks particularly to the pilot valve, pilot valve
bushing, power piston. needle bearing, thrust washer, etc.
. Either wipe the cleaned parts with a clean cloth or blow the dry air against them to dry them.
. Check if the holes for hydraulic oil 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, correct or replace such a part.
. Arrows given in the following figures refer to checking points.

(1) Base
Replace those gear shaft and pilot valve
bushing that have scratch or sliding flaw or
hit mark trace at the gear fit part with the new
ones.
/t^\o
vo
ol

Fig.5-13
(2) Housing
. Replace those gear shaft and pilot valve
bushing that have a flaw at the gear slide
part or those power piston and pilot valve
bushing that have a flaw at the fitting hole
with the new ones. a'\
. Replace those terminal shafts and speed IJ

control shaft of which bearing bushes 17

N
r')
6)n o
turn as fitted loosely or are wom off by the
housing assembly.
oo ?
6)
+)
\J^o
uo o

Fig. 5-14

5-9
CHAPTER 5. DISASSEMBLY & REASSEMBLY OF THE GOVERNOR YAD//',AA ]IZ GOVERilOR

(3) Gear shaft and pilot valve bushing

Replace the gear shaft of which oil seal con-
tacting part is worn off as stepped or of
which the spline part is damaged and pilot Pilot Valve Bushing
valve bushing of which the outer diameter
(18 mmq) is flawed with the new one.
Besides, replace also those parts of which
tooth surface is flawed with the new ones.

Check also whether the spline fit hole on the

governor driving device side is abnormally
worn off or not Gear Shafl

Fig. 5-15

(4) Governor weight assembly

. Check if the govemor weight moves
Governor Weight
smoothly.
. Check the face sliding with thrust washer at
the weight tip part. lf the bearing width is
found to be greater than I mm, replace it by
the weight assembly.
. Check that the fitting with the pilot valve
bushing is smooth.
. lf there is a hit mark, burr, etc., correct such
a part.

Pilot Valve Bushing

Fig.5-16

(5) Power piston and compensator piston

Incorporate the power piston (in the state of
incorporating the compensator piston 28 and
compensator bushing 27) in the housing, and
check if the power piston operates vertically
under its own weight. Exchange pin (48) for
the new one when servicing. When the col-
lapsing pin is used again, it causes the pin to
slip out. lf operations of the power piston and
compensator piston are un-smooth and do o" ?vG
not improve even after they are cleaned, ^ou
replace the power piston and compensator
rod 30.

lf operations of the power piston and com-

pensator piston are found bad, this causes a
Fig. 5-17
hunting, excessive s peed droop or bad con-
dition in the engine run.

5-1 0
CHAPTER 5. DISASSEMBLY & REASSEMBLY OF THE GOVERNOR UA''/TüAN lIzZ GOVERilOR

(6) Guide levers and speed control shaft

Replace the guide levers 11 and terminal
arm 13 of which 8 mmg hole or the guide
lever pins 12 is or are worn off with the new
ones.
Besides, replace the speed control shaft 18,
which is found bent, or the shaft supporting
parts or bushes 17 are found wom off with
the new ones. l--'''

Fig.5-18

(7) Pressure regulating valve

Detach the plug 42-3,take out the spring
424 , and check if the piston 42-2 operates
smoothly. lf its operation is found catchy or it
is worm off excessively, correct or replace it.

Incorporate the piston with a hole on its end

set at the back.

Fig.5-19

5-1 1
CHAPTER 5. DISASSEMBLY & REASSEMBLY OF THE GOVERNOR YArrM,,ß llz GoVERIIOR

5-5. Reassembly of the Governor

. Reassemble the governor in the reverse
sequence of the aforementioned disassembling
procedures.
. In this Sub-section, cautions to be taken in reas-
sembly of the govemor are set forth.
. Replace the O-rings, cotter pins, spring pins,
and gaskets with the respectively new ones, not
use them again.

1) Oil seal and needle bearing

(1) When press fitting the oilseal 3, be careful of
its fiüing orientation (in which do not make a
mistake). Needle Bearing
End
(2) When press fitting the needle bearing 56,
position it on the end of the oil seal fitting hole.

lf the needle bearing is press fitted exces-

sively, this will block up the hydraulic oil pas-
sage. Fig. 5-20

2) Incorporation of the terminal shafts

ln the case where the terminal shafts are disas-
sembled or replaced with the new ones, incorpo-
rate them according to the following procedures:
(1) When driving in the taper pins 47, hold the ter-
minal arm 13 by hand, and be careful not to
impart a shock to a bush press fitted to the
housing.

Fig. 5-21

(2) After driving in the taper pins, caulk four points

around taper pin holes.

lf taper pin driving in and caulking are done

with a strong force, the terminal shafts 14
may bend and cause them to malfunction so
pay your attention to this regard.

Fig.5-22

5-12
CHAPTER 5. DISASSEMBLY & REASSEMBLY OF THE GOVERNOR uADtruAR llzGovElllloll

3) Incorporation of the fork

When incorporating the fork 20 to the speed con-
trol shaft 18, insert the spring pin 49 with the
stepped pan of the fork faced up.

Fig.5-23

4) Stopping of wires from slipping out

i--------iöärä---i
After incorporating two wires to couple the fork 20 i---lFi ---l
with the floating lever 21 as well as the spring im'-r-.i
i i

fork 10, bend the ends of these wires for stopping

them from slipping out of place.

Bend about 10 mm of the straight part of

wires in 20 to 30 degrees. Round the bend to
the smallest possible radius.
lf the bending angle or rounding is large, this
may cause a malfunction of the floating lever.

Fig,5-24

5) Incorporation of the base

When incorporating the base 2, tighten bolts 57
uniformly only after checking that the gear shaft 4
can be lightly turned by hand.

lf the gear shaft could not be tumed lightly by

hand, note that this might damage the
hydraulic oil pump gear, base, etc.

Fig. 5-25

5-1 3
CHAPTERs.DISASSEMBLY&REASSEMBLYOFTHEGOVERNOR UA}'/',AN ]IZ GOI'ER]|OR

5-6. Service Data in Servicing

This Section sets forth the adjusting (confirming) items at the test stand in time of servicing the governor
as follows:
. Set the following items with the droop adiuster set to graduation 5.
(Pay your attention so that the droop adjuster does not contact with the side of the floating lever.)
. Make the following adjustments (excluding No. 10 & No. 11) with the needle valve fully opened (set to
open at a position 3 turns back from the completely closed position).

No. Item The PoinVProcedures F(emafl(S

1 Hydraulic oil . SAE#30
. Oil volume: Abt. 1.3 ltr.
. Oil temperature: 55 to 65"C
2 Mountrng ol tne governor . Paying your attention so that the center of the gear shaft
does not deviate from the center of the driving stand,
tighten tightening nuts uniformly.
. Attach the (controller) cover, and have the control knob
loosened fully.
3 Air bleeding'from the . Govemor speed: 1.000 t10 min-r (rpm)
hydraulic oil line . Operate the speed control shaft to actuate the power pis-
ton in full stroke more than ten times
4 Running-in . Drive the governor under the No. 3 state for 20 minutes,
and check that no hydraulic oil is
leaking to the exterior.
(Check that there is no change in oil level of the oil
gauge.)
5 Setting of the terminal shaft . Govemor speed: 1.000 t10 min-1 (rpm)
pointer in the . Turn the speed control shaft in the direction of decelera-
"0" position tion (in the SPEED "0" direction)
. Set the terminal shaft pointer to the FUEL
"0" position, and tighten the pointer screw
6 Checking of the rotation . Governor speed: 600 t10 min'l (rpm)
range of the terminal shafis . When the speed control shaft in the + and - direction,
the terminal shaft should turn promptly and operate over
the full range of the FUEL graduations. [Engen Model]
NZ61: FUEL graduations "0 to 7" (0 to 35 deg.) [6N160,6N165]
NZ61: FUEL graduations "0 to 8" (0 to 40 deg.) [6N18,6N21]
N2115: FUEL graduations'0 to 10" (0 to 40 deg.)

5-1 4
CHAPTER 5. DISASSEMBLY & REASSEMBLY OF THE GOVERNOR y,A}'JUAE lIZ GOYER]IOR

NO. Item The PoinUProcedures Remarl(S

7 Measurement of the operat- . Govemor speed: 600 t10 min{ (rpm)
ing torque of the terminal . Lever length: 200mm
shafts . Measure with a spring balancer the reaction force of the Fig. $26
lever when the terminal shafts turn by one graduation in Operating
the FUEL + and - directions. torque =
reaction force
Governor öpecrneo pressure Operating torque
N(kgf)xg.21m;
Model MPa (kgf./cm2) N.m (kgf.m)
[Engen Model]
Greater than
NZ61 1.18(12) [6N160,6N165]
e.8 (1.0)
[6N18,6N21]
Greater than
NZ61 1.47(15)
11.8 (1.2)
Greaterthan 14.7
N2115 1.47(15)
1.5

Should the operating torque not satisfy value, check

the following parts, and conect or replace them.

O Pressure regulating valve stuck.

@ The clearance of the power piston and housing
too large.
@ Tne clearance of the power piston and( 5 mmg)
compensator rod too large.
@ Side clearance of the hydraulic oil pump gear too
large.
@ Foreign matter bit in the check valve.
@The clearance of the (18 mmg) pilot valve bushing
and housing too large.
6 Positional setting of the Govemor speed: 2000 !10 min-l (rpm)
speed control shaft pointer . Turn the control knob, and set the terminal shaft pointer
to the following FUEL graduation: [Engen Model]
NZ61: FUEL "6" [6N160,6N165]
NZ61: FUEL "7" [6N18,6N21]
N2115: FUEL "9'
. Set the speed control shaft pointer to the following
SPEED graduation, and tighten the pointer screw: [Engen Model]
NZ61: SPEED "8" [6N160,6N165]
NZ61: SPEED "10" [6N18,6N21]
N2115: SPEED'10"
9 Checking of the "O" position . Lower the governor speed from the No. 8 state so that
ofthe speed control shaft the terminal shaft pointer assumes the following FUEL
pointer graduation: [Engen Model]
NZ61: FUEL "6" [6N160,6N165]
NZ61: FUEL "7" [6N18,6N211
N2115: FUEL.9"
. Check the speed when the speed control shafi pointer
indicates the SPEED "0"
NZ61: 500 to 700 min-1 (rpm)
N2115: 400 to 600 mini (rpm)

Should the govemor speed run out of the aforementioned

range, check the following parts.

O Checking of the droop adjuster graduation.

@ Positional setting of the speed control shaft pointer.
@ Incorporation of the govemor spring.
@ Governor weight assembly.

5-1 5
CHAPTERs.DISASSEMBLY&REASSEMBLYOFTHEGOVERNOR UAMUM ]IZ G(oVER]IOR

No Item The PoinUProcedures Remarks

10 GhecKing ot presence or . Govemor speed: 1.000 t10 min-l (rpm)
absence of a high-pressure . Set the terminal shaft pointer to the FUEL "4".
hydraulic oil inflow into the (Adjust this setting by tuming the control knob.)
compensator case . When the needle valve is changed to the completely Fig.$l7
closed state from the fully opened state the terminal
shafts should not turn to the FUEL "0" side by no more
than one degree.

Should the terminal shafts turn more than 1 degree, check

the following parts. and conect or replace them.

O Compensator bush O-rings damaged or dust biting in

of the O-ring grooves, presence or absence or flaw.
@ me clearance of the(18 mmg) pilot valve bushing and
the sliding part of the base too large.
@ Flaw on the mating surfaces of the base and housing or
biting in of foreign matter.
@ (0.3 mmgand 0.8 mmg) escape holes of the needle
valve clogged.
@ (3 mmq) escape hole of the base clogged.
@ The clearance of the (5 mmg) compensator rod and
compensator bush too large.
1'l LihecKrng or anillrgglrng . Terminal shaft pointer graduation: FUEL'2".
performance (Adjust this by tuming the control knob.)
. Needle valve: One tum back from the completely closed
position.
. Govemor speed: 600. 1,000. 1,500 & 2,000 mini (rpm). Fig. $28
. The angle of deflection of the terminal shafts should be
within 0.4

Should the angle of deflection exceed 0.4 degree, check

the following parts, and conect or replace them.

O me dearance between the power piston and the hous-

ing too large.
@ Compensator rod malfunctioned.
@ Pilot valve control land damaged.
@ Govemor spring incorporated wrongly.
@Jiggte of the fork. spring fork and floating lever coupling
part too large.
@ Side gap of the speed control shafi and terminal shafts
too large.

5-1 6
 CHAPTER 5. DISASSEMBLY & REASSEMBLY OF THE GOVERNOR YANI',ß lIZ GOVEII]IOR

Procedures for Inspecting the Terminal Shaft Anti-jiggling Performance Inspecting Procedures
Operating Torque
Reading of dial Deflection angle: within 0.4 deg.
gauge: Wthin 0.14 mm
<+ FUEL + Dir.
-

Fig.5-26
FUEL 2 Graduations

Fig.5-28

o Procedures for lnspecting the Presence or

Absence of High-pressure Hydraulic Oil Inflow
into the Compensator Case

gauge: Within 0.35 mm +Shift angle: Within 1 Deg.

FUEL 4 Graduations 024a5?-ooE

Fig.*27

5-1 7
CHAPTER 5. DISASSEMBLY & REASSEMBLY OF THE GOVERNOR YA}']üAN IIZ GCDVERIIOR

MEMO

5-1 I
 NZ Series Hydraulic Governor
Model tZ6l /]il,Zlls
SERVICE MANUAL
YAN}'AN EO.,LTO.
1st edition : June, 1997
1st revision : July,2002
2nd revision : July, 2005
2nd edition : July,2008

lssued by : Precision
Equipment Division
Power system Operations Division
ano
Quality Assurance Dept.,
Large Power Products Operations Division
Yanmar Co..Ltd.

Edited by : Yanmar Technical Service Co.,Ltd.

l.B.C.No. | 0BNZ6-G00100
2008.7.4R