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1. Delivery valve Plug Measuring device FEBRUARY 2004 S l 434_8 11 4 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 4 Remove the delivery valve itself 5 Install the measuring device Tool name Part no Remarks 105782 4330 9 680 610 018 6 Remove the overflow valve and install the plug Measuring device Tool name Part no Remarks 029111 4050 9 442 610 325 Plug 7 Fix the control rack in the position specified in the calibration data the example below is 9 1 mm Example Pre stroke No 1 cylinder 2 6 0 05 mm lift After injection quantity adjustment adjust at a rack position of 9 1 mm 8 Turn 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 Test oil
2. EXEL Service Information KOMATSU FEBRUARY 2004 S l 434 1 11 ADJUSTMENT PROCEDURES FOR RSV TYPE HYBRID CAM LOCK GOVERNOR EQUIPPED INJECTION PUMP FOR KOMATSU Adjustment procedures are now available for the RSV type hybrid cam lock governor equipped injection pump for Komatsu assembled with load 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 low load advance type load plungers Lower helix plungers Upper and lower helix plungers Load plungers Starting advance plungers Right helix QA Left helix Low load advance ho AS Right helix 7 N Re Left helix High load advance 9 A4 Right helix ty VN Left helix A Right helix NS Left helix Bosch K K Sales Automotive Aftermarket Division Printed in Japan 2 ADJUSTMENT OUTLINE Preparation Cam lock mechanism adjustment Fuel injection quantity adjustment When fuel injection quantity has been readjusted Injection timing adjustment Fuel injection quantity confirmation Govern
3. Pre stroke adjustment of all cylinders FEBRUARY 2004 S 1 434 9 11 Note When adjusting the injection timing a large quantity of test oil will flow 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 1 mm in the previous example 10 Switch the pump test bench ON and adjust the test oil supply pressure to approx 20 kPa 0 2 kgf cm using the adjusting valve Advice e Operate only the pump test bench test oil supply pressure Do not operate the injection pump e Test oil will flow from the measuring device s spill pipe Prepare a container 11 Turn the pump test bench s flywheel in the specified 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 Confirm that no test oil leaks onto the outside of the injection pump 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
4. 11151 for details Measuring device Delivery valve holder etc Rack position mm Pump speed r min Cy 7 ar OS DEA Pointer FEBRUARY 2004 S 1 434 10 11 14 After the injection timing of all cylinders has been adjusted remove the measuring device and the plug from the No 1 cylinder 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 15 5 Fuel injection quantity confirmation 1 Measure the injection quantities as described in the calibration data and confirm that they are as specified 2 If the injection quantities are not as specified readjust Advice When the injection quantities are readjusted repeat 4 Injection timing adjustment and then 5 Fuel injection quantity confirmation until the specified calibration data values are satisfied 6 Governor adjustment Adjust the governor as described in the calibration data Advice Refer to the service manual RSV Type Governor Construction and Operation Repair and Maintenance Publication No EE13
5. will not rotate 10 Remove the clamp Advice After tightening the flyweight 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 removed Operating the injection pump without 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 governor 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 3 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 Delivery valve spring and stopper WY KO Gm FN 7 Y amp paag QY D gt N VAR we lp QD i ease 2 YY iss aie Os CT da
6. 434_5 11 11 With the flyweight assembly fixed 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 Clam 157927 1620 p 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 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 3 Remove the delivery valve itself Advice Because the delivery valve is a precision part store it so that it is not damaged 4 Install the measuring device Part no 105782 4330 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 Tool name Remarks Measuring device Cam lift s h mm position UCE Pointer Turn flywheel 6 Lever FEBRUARY 2004 S 1 434 6 11 6 Turn the pump test bench s flywheel in the specified direction of rotation using the lever and set the No 1 cylinder s cam lift at h mm refer to the calibration data Note e The control rack can be in any pos
7. E 11021 for details If equipped with a boost compensator refer to service information bulletin S I 327 7 Setting the lock pin 1 After completing adjustment turn the flywheel 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 Plug gt C A SO A Coo AAT L PI Caution plate amp 2E ar T YT EE CA HELD IN T SGEENTHET UTION MING POSITION FEBRUARY 2004 S 1 434 11 11 4 Assemble the caution plate to the plug and install the plug to the governor housing e Caution plate
8. ion pump W Injection pipes 3 2 Test oil hoses Governor cover Snap pin 0 L065 za h Joint FEBRUARY 2004 S l 434 3 11 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 service manual PE S A Type Injection Pump Repair and Maintenance Publication No EE11E 11151 for details 3 Remove the governor cover Advice e Refer to the service manual RSV Type Governor Construction and Operation Repair and Maintenance Publication No EE13E 11021 for details e Remove the snap pin from the control rack connection and then remove the link 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 Joint 157845 5600 9 681 610 612 Measuring device 105782 0160 9 680 610 144 Note All Bosch part numbers are shown in brackets below RBAJ part numbers 5 Attach the measuring device to the injection pump 9 A Ko Flyweight assembly Extractor LNN
9. ition e It is not necessary to apply pump test bench oil delivery pressure 7 At the h mm position set in procedure 6 above set the pump test bench s flywheel pointer at 0 or at any position where 100 markings can be easily read 8 Turn the flywheel 6 in the specified direction of rotation refer to the calibration data N CAUTION Remove the lever after operating the flywheel Operating the test bench without removing the lever can cause serious injury and damage the test bench 0 5 30 30 Key groove position at cam lift h 2 6 0 01 B T D C 11 Key groove position after injection q ty adjustment adjust at rack position A Fix the governor flyweight at this position using the lock pin before delivery Key groove position at B T D C 0 Flyweight Wrench Governor cover Snap pin P 3 L 0 D o m LENE Zz Sot a Voy 0 o 0 lt F 10 N SSN No 1 cylinder q SS 2 z O BH Wy y x x O 8 0 LY Di 0j o AE OS FEBRUARY 2004 S I 434 7 11 9 Fix the flyweight to the camshaft in the 9 position set in procedure 8 on the previous page Specified torque M14 59 69N m 6 7 kgfm M12 49 59N m 5 6 kgfm Advice Fix the pump test bench s flywheel using the lever so that it
10. ni id ESIA O KOH NOC 2 ZN Spring washer Roundnut FEBRUARY 2004 S I 434 4 11 6 Push the control rack against the governor side and zero the measuring device s dial gauge 7 Remove the roundnut fixing the flyweight using the wrench Tool name Part no 157915 0100 0 986 613 026 Remarks Wrench Advice Fix the pump test bench s flywheel using the lever so that it will not rotate 8 Attach the extractor to the flyweight holder and remove the flyweight assembly Tool name Part no Remarks 157926 9320 Extractor 9 681 610 403 M20x1 5 Advice Fix the pump test bench s flywheel using the lever so that it will not rotate 9 Loosely assemble the flyweight 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 Reconfirm that the flyweight rotates freely Clamp Pointer Flyweight assembly Delivery valve spring and stopper Delivery valve holder p D J wg le S wW Delivery valve Measuring device Dial gauge s 0 position FEBRUARY 2004 S l
11. or adjustment Setting the lock pin FEBRUARY 2004 S 1 434 2 11 e Install the injection pump on the pump test bench e Remove the governor cover e Attach the control rack position measuring device to the injection pump e Remove the flyweight and then reinstall it loosely to the camshaft so that it turns freely e Align the flyweight pointer and the clamp groove Perform the following in accordance with the calibration data e Set the No 1 cylinder s cam lift at h mm and then set the camshaft from the h mm position e In the above position fix the flyweight and remove the clamp N CAUTION Always confirm that the clamp has been removed Operating the injection pump without removing the clamp can cause serious injury and damage the governor Measure and adjust the fuel injection quantity in accordance with the calibration data After adjusting the fuel injection quantity adjust the injection timing in accordance with the calibration data Confirm the fuel injection quantity in accordance with the calibration data Advice When the fuel injection quantity has been adjusted adjust the injection timing until it is as specified in the calibration data and confirm the fuel injection quantity Adjust the governor in accordance with the calibration data Align the flyweight pointer and the lock pin groove insert the lock pin and then fix using the plug Inject

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