KOMATSU

PUMP OCTOBER 2004

S.I. 461 1 / 11

ADJUSTMENT PROCEDURES FOR RSV TYPE HYBRID

(CAM LOCK) GOVERNOR EQUIPPED INJECTION PUMP
FOR KOMATSU: PART 2
Adjustment procedures are now available for the RSV type hybrid (cam lock) governor equipped
injection pump for Komatsu assembled with lower helix plungers. The details are described
below.
Also refer to service information bulletin S.I. 327.

1. PLUNGER OUTLINE
Plungers are lower helix or upper and lower helix types. The upper and lower helix type
plungers may be further divided into load plunger and starting advance type plungers. The
adjustment procedures described in this bulletin are for lower helix plungers.
Upper and lower helix plungers
Lower helix plungers
Load plungers Starting advance plungers
࡮Low load advance

Right helix Right helix

Right helix

Left helix Left helix

Left helix
࡮High load advance

Right helix

Left helix

Sales Automotive Aftermarket Division Printed in Japan

Bosch K.K.
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2. ADJUSTMENT OUTLINE

Preparation • • • • Install the injection pump on the pump test

bench.
• Remove the governor cover.
• Attach the control rack position measuring
device to the injection pump.
• Remove the flyweight and then reinstall it
loosely to the camshaft so that it turns freely.
• Align the fl yweight pointer and the clamp
groove.

Cam lock mechanism adjustment • • • Perform the following in accordance with the
calibration data.
• Set the No. 1 cylinder's beginning-of-injection
plunger lift and then set the camshaft 'θ°'
from this position.
• In the above position fix the flyweight and
remove the clamp.
CAUTION
Always confi rm that the clamp has been
removed.
Operating the injection pump without
removing the clamp can cause serious injury
and damage the governor.

Injection timing adjustment • • • Adjust the injection timing in accordance with the
calibration data.

Governor adjustment • • • Adjust the governor in accordance with the

calibration data.

Fuel injection quantity adjustment • • • Measure and adjust the fuel injection quantity in
accordance with the calibration data.

Setting the lock pin • • • Align the fl yweight pointer and the lock pin
groove, insert the lock pin and then fix using the
plug.
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Injection pump Injection pipes 3. ADJUSTMENT OUTLINE
[1] Preparation
(1) Attach the injection pump to the pump test
bench.
(2) Attach the test nozzle and nozzle holder
assembly, the injection pipes (except for
the No 1 cylinder's injection pipe), and the
test oil hoses to the injection pump.
Advice
Refer to the calibration data and the
Test oil hoses service manual 'PE(S)-A Type Injection
Pump, Repair and Maintenance (Publication
Governor cover Snap pin
No. EE11E-11151)' for details.
(3) Remove the governor cover.
Advice
• Refer to the service manual 'RSV Type
Governor, Construction and Operation,
Repair and Maintenance (Publication
No. EE13E-11021)' for details.
• Remove the snap pin from the control
rack connection and then remove the
link.

Joint Measuring device

(4) Replace the measuring device joint.
Advice
Because this injection pump's control rack
is short, replace the measuring device joint
with the joint listed below.
Tool name Part no Remarks
157845-5600
Joint
(9 681 610 612)
105782-6180
Measuring device
(9 680 610 144)
Replace the joint only
Note:
All Bosch part numbers are shown in brackets
below RBAJ part numbers.
Measuring device
(5) Attach the measur ing device to the
injection pump.
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(6) Push the control rack against the governor
Setting the dial gauge's '0' position side and zero the measuring device's dial
gauge.

Flyweight Wrench (7) Remove the roundnut fixing the flyweight

using the wrench.
Tool name Part no Remarks
157915-0100
Wrench
(0 986 613 026)

Advice
Fix the pump test bench's flywheel using
the lever so that it will not rotate.

Flyweight assembly Extractor (8) Attach the extractor to the flyweight holder
and remove the flyweight assembly.
Tool name Part no Remarks
157926-9320
Extractor M20x1.5
(9 681 610 403)

Advice
Fix the pump test bench's flywheel using
the lever so that it will not rotate.

Flyweight (9) Loosely assemble the flyweight assembly

assembly to the camshaft so that it rotates freely.
Note:
The camshaft and flyweight do not have key
grooves.
(10) Temporarily fix the spring washer and
the roundnut to the flyweight.
Advice
Reconfi rm that the fl yweight assembly
rotates freely.
Spring washer Roundnut
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Clamp Pointer Flyweight assembly (11) W i t h t h e fl y we i g h t a s s e m bl y fi xe d
temporarily as described in procedure
(9) on the previous page, position the
pointer horizontally and assemble the
clamp's groove to the pointer.
Tool name Part no Remarks
157927-1620
Clamp
(9 443 613 006)
Advice
When assembling the clamp's groove to
the pointer, this clamp must be used. Do
not use the lock pin (ie, the original part)
Delivery valve spring and stopper Delivery valve holder as the pin's tooth may be damaged.
[2] Cam lock mechanism adjustment
(1) Remove the No. 1 cylinder's delivery valve
holder (refer to the calibration data).
(2) Remove the delivery valve spring and the
delivery valve stopper.

Delivery valve (3) Remove the delivery valve itself.

Advice
Because the delivery valve is a precision
part, store it so that it is not damaged.

Measuring device Dial gauge's '0' position (4) Install the measuring device.
Tool name Part no Remarks
105782-4330
Measuring device
(9 680 610 018)
(5) Position the No. 1 cylinder's plunger in the
bottom dead center position and zero the
measuring device's dial gauge.
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'Beginning-of-injection plunger lift' position (6) Rotate the pump test bench's flywheel in
the specified direction of rotation using the
lever and set the No. 1 cylinder's plunger
lift to the 'beginning-of-injection position
(pre-stroke)' (refer to the calibration data).
Note:
• The control rack can be in any position.
• It is not necessary to apply pump test
bench oil delivery pressure at this time.

(7) At the 'beginning-of-injection plunger lift'

Pointer
position as set in procedure (6) above, set
the pump test bench's flywheel pointer at
'0' degrees or a suitable position (eg, 100°,
etc) where flywheel markings can be easily
read.

Rotate flywheel θ° (8) Rotate the flywheel 'θ°' in the specified

direction of rotation (refer to the calibration
data).
CAUTION
Remove the lever after operating the
flywheel.
Lever θ° Operating the test bench without removing
the lever can cause serious injury and
damage the test bench.

Example of calibration data sheet's timing indication

54
°5
4'
±3
°

Key groove position at No. 1 cylinder's beginning-of-injection (at B.T.D.C.: 15.5° )

No.1 cylinder's key groove position at B.T.D.C.: 0°

(Fix the governor flyweight at this position using the lock pin before delivery.)

T= 7°45'±30'
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Flyweight Wrench (9) Fix the flyweight to the camshaft in the
'θ°' position set in procedure (8) on the
previous page.
Specified torque:
M14 59 ~ 69 N •m {6 ~ 7 kgf•m}
M12 49 ~ 59 N •m {5 ~ 6 kgf•m}
Advice
Fix the pump test bench's flywheel using
the lever so that it will not rotate.

(10) Remove the clamp.

Advice
After tightening the fl yweight locknut,
confirm that the clamp can be inserted
smoothly onto the pointer at the specified
plunger position [see procedure (9)
above]. (Flyweight pointer position
confirmation)
CAUTION
Always confirm that the clamp has been
Clamp removed.
Operating the injection pump without
Governor cover Snap pin removing the clamp can cause serious
injury and damage the pump.

(11) Assemble the link to the control rack and

attach the snap pin.
(12) Reinstall the gover nor cover in its
original position.
Advice
Refer to the service manual 'RSV Type
Governor, Construction and Operation,
Repair and Maintenance (Publication No.
EE13E-11021)' for details.

Delivery valve spring and stopper Delivery valve holder [3] Injection timing adjustment
(1) Remove the No. 1 cylinder's injection pipe
(refer to the calibration data).
(2) Remove the delivery valve holder.
(3) Remove the delivery valve spring and the
delivery valve stopper.
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Delivery valve (4) Remove the delivery valve itself.

Plug Measuring device (5) Install the measuring device.

Tool name Part no Remarks
105782-4330
Measuring device
(9 680 610 018)
(6) Remove the overflow valve and install the
plug.
Tool name Part no Remarks
029111-4050
Plug
(9 442 610 325)

(7) Fix the control lever in the full speed

Dial gauge's '0' position
position.
(8) Rotate the pump test bench flywheel in the
specified direction of rotation and position
the No. 1 cylinder's plunger in the bottom
dead center position.
(9) Zero the pre-stroke measuring device's
dial gauge.

Note:
When adjusting the injection timing, a
large quantity of test oil will fl ow from the
measuring device's spill pipe when the test
bench is switched ON when the plunger lift
is small. To prevent this, it is better to have
the camshaft lift at approximately 0.5 mm
before the specified pre-stroke position (ie, at
approximately 2.0 mm when the pre-stroke is
2.5 mm).
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Test oil (10) Switch the pump test bench ON and
adjust the test oil supply pressure to
approx 20 kPa {0.2 kgf/cm2} using the
adjusting valve.
Advice
• Operate only the pump test bench test
oil supply pressure. Do not operate the
injection pump.
• Test oil will flow from the measuring
device's spill pipe. Prepare a container.

Pre-stroke (11) Rotate the pump test bench's flywheel

in the specifi ed direction (refer to the
calibration data) and measure the
pre-stroke from the dial gauge when
test oil stops flowing from the measuring
device spill pipe.
Note:
Test oil has stopped flowing when only 2 ~ 3
drops of oil per second drip from the spill pipe.
Advice
Confi rm that no test oil leaks onto the
outside of the injection pump.
Pre-stroke adjustment of all cylinders (12) If pre-stroke in procedure (11) above
is not as specified, adjust until it is as
specified.
(13) Adjust the remainder of the cylinders in
the order of injection.
Advice
Refer to the service manual 'PE(S)-A Type
Injection Pump, Repair and Maintenance
(Publication No. EE11E-11151)' for details.

Plug Measuring device Delivery valve holder, etc (14) After the injection timing of all cylinders
has been adjusted, remove the
measuring device and the plug from the
No. 1 cylinder.
(15) Reinstall the delivery valve, delivery
valve spring, etc, and then reinstall the
injection pipe and the test oil hoses in
their original positions.
Advice
Refer to the service manual 'PE(S)-A Type
Injection Pump, Repair and Maintenance
(Publication No. EE11E-11151)' for details.
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Example of calibration data sheet's governor graph [4] Governor adjustment
Adjust the governor as described in the
Boost compensator stroke
calibration data.
E F
Advice
Rack position (mm)

A
Refer to the service manual 'RSV Type
Governor, Construction and Operation,
C Repair and Maintenance (Publication No.
EE13E-11021)' for details.
If equipped with a boost compensator,
refer to service information bulletin S.I.
0
Pump speed (r/min)
327.

No. 1 cylinder [5] Fuel injection quantity adjustment

(1) Reinstall the No. 1 cylinder's delivery
valve, delivery valve stopper, delivery
valve spring and delivery valve holder, and
connect the injection pipe.
(2) Reconfirm that the control rack measuring
device's dial gauge is in the '0' position.
(3) Measure the fuel injection quantity and
adjust it so that it is as specified in the
calibration data.
Advice
Refer to the 'PE(S)-A Type Injection Pump,
Repair and Maintenance (Publication No.
EE11E-11151)' for details.
Lock pin Pointer [6] Setting the lock pin
(1) After completing adjustment, rotate the
fl ywheel using the lever to position the
flyweight assembly's pointer horizontally.
Note:
Check through the plug's hole to confirm that
the pointer is horizontal.
(2) Disconnect the injection pump from the
pump test bench's drive coupling and
disassemble the coupling from the pump.
(3) Align the lock pin groove (original part)
with the pointer and then securely
assemble the lock pin to the pointer.
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Plug Caution plate (4) Assemble the caution plate to the plug and
install the plug to the governor housing.

• Caution plate