*ZEXEL: ey _— Service Manual - Operation & Maintenance RHD move. GOVERNOR Excellence inside. ZEXEL. (RHD6 & RHD10)WARNINGS The following definitions and warning signs are used in this service manual. These are extremely important to safe operation. Important points are described to prevent bodily injury and property damage. They must be fully understood before beginning governor maintenance. PNT] = improper maintenance can resuttin injury and property damage. MEANINGS OF MARKS. The following marks are used in this service manual to facilitate correct governor | maintenance. Advice Procedures that must be performed to enable the best possible governor maintenance. Note Information assisting in the best possible governor maintenance.FOREWORD The RHD hydraulic governor is a high performance variable speed governor for use with main and auxiliary marine engines, engines for electric generators and general power engines. This service manual describes the construction and operation, repair and maintenance, and adjustment of the RHD6 and RHD10 hydraulic governors. The contents of the manual, including illustrations, drawings and specifications were the latest available at the time of printing. The right is reserved to make changes in specifications and procedures at any time without notice. Bosch Corporation Automotive Aftermarket Division CONTENTS Page [1] FEATURES .... al [2] SPECIFICATIONS 2 CONSTRUCTION . 6 OPERATION .. 1. ENGINE STARTING 2. NORMAL OPERATION... 3. LOAD DECREASE. 4. LOAD INCREASE 5. ENGINE STOPPING 6. i 8. . AUXILIARY STARTING BOOSTE! SPEED DROOP MECHANISM COMPENSATOR MECHANISM 5] ADDITIONAL DEVICES 1. GOVERNOR MOTOR .. 2, PNEUMATIC CONTROLLER 3. HYDRAULIC CONTROLLER... [6] HANDLING . GOVERNOR INSTALLATION HYDRAULIC FLUID....... AIR BLEEDING & COMPENSATION ADJUSTMENT ........21 LINKAGE CONNECTIONS .. DAILY INSPECTION... . INSERVICE INSPECTION... ero s a 2 1. SPECIAL TOOLS 2. EXPLODED ViE' 3. PART LIST. 4, PREPARATION 5. DISASSEMBLY INSPECTION . REPLACEMENT STANDARDS.. COMPONENT INSPECTION... GOVERNOR MOTOR BRUSH INSPECTION REASSEMBLY .. PNEUMATIC CONTROLLE! GOVERNOR ASSEMBLY. ADJUSTMENT PREPARATION .. OPERATION TEST .... ADDITIONAL DEVICES. TROUBLESHOOTING ... PART NUMBER EXPLANATION 1. MODEL NUMBER... 2. CODE NUMBER ero BEY’ ’-eYr-eFEATURES . The RHD governor has a large controlling force, despite its compact size. As the hydraulic fluid is contained in the governor, piping and sub-tank installation are unnecessary when installing the governor on the engine. As the power piston utilizes a differential system, the operating force is uniform. Moreover, it is not necessary to install a return spring in the fuel control linkage. When play in the linkage system is excessive, however, it is necessary to install a spring at the end of the system to absorb this play. The governor is able to rotate in either direction, and therefore it can be used without modification on engines which rotate in the reverse direction, Because the normal operating speed is low, governor endurance is high, and gearing is simple when installing the governor on jow and intermediate speed engines, The governor has a speed droop mechanism and a compensator mechanism, enabling it to be easily and freely adjusted. The adjustment range is very wide, enabling governor use on a wide range of engines. The governor can also be used as an isochronous governor with 0% speed droop. 7. The governor body’s high tensile aluminum alloy casting makes it extremely lightweight. 8 The governor can be equipped with a governor motor, a pneumatic controller and a hydraulic controller. 9. RHD6 and RHD10 governors are interchangeable. For example, if a higher pressure injection system is required or if the governor's control force is insutficient to cope with the demand for increased engine output, decreased fuel consumption or the use of lower quality fuel oil, then the RHD10 can replace the RHD6. 10. The governor is equipped with a standardized piping connection to enable the installation of an auxiliary starting booster. 11. Of the RHD10 governor's main components, 80% are identical to those of the RHD6. Almost 100% of the remote control device's components are identical to those of the RHDS.2] SPECIFICATIONS (1) RHD6 and RHD10 type governors (Lever type) RHD6 RHD10 Control force 5.9 J {0.6 kgtm} 9.8 J {1.0 kgfm} Output shaft torque 9.8 Nem {1.0 kgtm} 15 Nm {1.5 kgtm} Output shaft operation angle 35° 40° Power piston diameter Small: 917.7; Large: 425 ‘Small: $18.6; Latge: $27 Controlled speed range Standard rating: 600 ~ 2,000 r/min (Normal: 1,700 ~ 2,000 r/min) High speed rating: 800 ~ 2,400 r/min (Normal: 1,900 ~ 2,400 r/min) Maximum allowable speed 2,500 r/min Compensator Needle valve type Speed droop adjustment range 0 ~ approx 10% (rated) Direction of rotation Clockwise & counterclockwise Hydraulic fluid SAE20W~40 (Mobiloil) Dry weight (lever type) 5.5 kg 5.7 kg Governor drive power Max approx 0.2 kW {0.3ps} Applicable engines Low speed: up to approx 1,500 KW {2,000 ps} Intermediate speed: up to approx 1,850 kW {2,500 ps} Low speed: up to approx 2,200 kW {3,000 ps} High speed: up to approx/High speed: up to approx 2,200 kW {3,000 ps} 2,950 kW {4,000 ps} PE (all types) TPE (all types) PF1Z x 18 cyl PFICX x 18 cyl cable injecti PFAC, -1CD x 16 (18) cyl PFIWX x 16 cyl ‘Applicable injection pumps | pew x 12 (16) cyl PFIGX x 12 cyl PF1GD x 8 cyl PF1DX x 8 cyl PFIDD x6 cyl PFIEX x6 cyl The main difference between the RHD6 and the RHD10 is the power piston. The parts adjacent to the power piston also differ. Note: 4. The method of connecting fuel linkages and the amount of corresponding resistance differ depending on the size of the applicable engine and the size and number of the injection pumps. Consequently, engines with little friction loss can be used in high output engine applications and, conversely, engines with large friction loss can only be used in applications equal to or less than those specified above. Simply because the governor has surplus control force does not necessarily mean that stable operation can be ensured. In order to ensure stable operation and to prevent the speed from exceeding the necessary speed, the inertia of the engine and the drive system should be as large as possible.i] SPECIFICATIONS The figure below shows the RHD6 hydraulic governor (lever type). The RHD10 has a special plug (piping connection) for auxiliary starting booster installation located below the center of the name plate. Lever type Approx 34 1675 28 P-RHOR- 004SPECIFICATIONS (2) RHD6 and RHD10 type governors (with MC, -MCL governor motors) MC type with governor motor Approx 118 UIs C2410 250V ype Ae 565 | 2505. g nnn. ove Current Voltage | Cycle Speed consumption OutPut AC100V |50/60 Hz| 1,200/1,450 min] 20W aw em AC220V | 50/60 Hz: 1,200/1,450 r/min | 20W aw pDo24v - 2,200 r/min 20W 3w I DC100V : 2,200 r/min 20W 3w Gear head (speed reduction ratio) Speed setting time Limit switch adjustment range (RHD6, 10 -MCL) 1/18, 1/30, 1/50, 1/75, 1/100, 1/150, 1/300, 1/375, 1/450, 1/600, 1/900, 1/1500 The speed setting time can be determined freely by choosing from any of the above gear heads The standard specified time, however, is approximately that shown below. Main engines: 20 ~ 25 sec dead slow to rated speed Engines for generators: 7 ~ 9 sec/1 Hz ‘Standard specification Lower limit: 600 r/min Upper limit: 2,000 r/min Prior to shipment, the lower limit is set at 600 r/min, and the upper at 1,600 r/min. High speed specification Lower limit: 800 r/min Upper limit: 2,400 r/min Prior to shipment, the lower limit is set at 800 r/min, and the upper at 2,000 rimin. -4-[2) SPECIFICATIONS MCL type with governor motor Speed sting sow or 2 Lower it gitn\ Upper ch P so 3 eG 1 PAN) M : iy tor = Gearhead z tate /| | | Frcion coupling 7 2 ro (LL. —' 3 : | @ ey & poor ue ppr00 161 ci Psvon. 03 (3) Pneumatic controller dimensions QHZ , Yt 3! aoe | 6 eT) 7 asi 7 — i = 2 snp: ne3 CONSTRUCTION Speed control shat Speed increase ‘Speed decrease CH Ay Ci Flyweight — Speeder spring esting vane Sleeve. a Plot vaive Gear pump The above figure shows a cutaway view of the RHD6 hydraulic governor. The governor is installed directly on the engine. Engine crankshaft speed is increased using a Suitable gear ratio, and is then transmitted to the governor gear shaft. This rotation is transmitted to the hydraulic governor's gear pump, which pressurizes the hydraulic fluid. The gear pump pumps hydraulic fluid from the governor's hydraulic fluid tank in through the low pressure side of the regulating vaive, and delivers the high pressure hydraulic fluid to the pilot valve. The regulating valve also regulates the pressure of the fluid pressurized by the i ih —~Asa a | ‘Terminal shat Power piston P-RHOR. 005 gear pump (RHD6: 1.18 MPa {12 kfg/cm*}, RHD10: 1.47 MPa {15 kgf/om’}) and returns excess fluid to the gear pumps intake side. The gear pump has four check valves so that governor performance does not vary, even when the governor rotates in the reverse direction. The gear pump’s driven gear and the sleeve are unified. One end of the sleeve is connected to the governor flyweight. The pilot valve inside the sleeve is moved up and down in response to the flyweight's centrifugal force to control the flow of hydraulic fluid to the power piston, reacting promptly to variations in engine load to rotate the terminal shaftCONSTRUCTION Set screw Set screw om N \ ‘Speeder spring——_ Flyweight assembly —___ ‘Thrust needle roller bearing Bearing Air breather Floating lover ‘Speed droop adjustor i Terminal arm Cover Power piston Ce econparaia se ‘Starting compensation booster init plug Washer Bearing For RHID10 Lower compensating spring — The flyweight’s centrifugal force is transmitted to the pilot valve by the thrust needle roller bearing. The speeder spring's force is always acting against the flyweight’s centrifugal force. The set force of the speeder spring can be changed by moving the control lever. The flyweight assembly is an oil damper type assembly. When sleeve rotation is transmitted to the flyweight, the oil acts to absorb unnecessary high frequency rotation fluctuations and enable stable output. The power piston, which controls the fuel injection quantity to the engine, is a simple —Pushrod: Gear shat Compensating piston Compensating bushing P-AHOR. 06, mechanism which enables high stabilized output. ‘The power piston is operated by the hydraulic fluid to move in both the fuel increase and fuel decrease directions. The power piston rotates the terminal shaft via the guide lever and the terminal arm to directly control fuel injection quantity. In addition to having a larger diameter power piston, the RHD10 is equipped with a piping connection to enable the connection of an auxiliary starting booster to the top of the power piston.[4] OPERATION 1. ENGINE STARTING [ Fyweight —— 8 seam = | GF / = Fuel decrease == Fuslincrease fra fad yori fad [ESE cross section Power piston Plot valve i Gear shatt ‘When the engine is stopped, the flyweight is pushed down and closed by the force of the speeder spring. Consequently, the pilot valve is in its lowermost position. When the control lever is then moved in the fuel increase direction, the engine is rotated by compressed air, etc, the gear pump is ‘operated through the gear shaft and the hydraulic fluid is pressurized. Because the flyweight is pushed down by the speeder spring and the pilot valve does not move, the pressurized hydraulic fluid passage P-BHDR: 007 and the passage to the power piston are open, and the hydraulic fluid pressurized by the gear pump is delivered through the pilot valve to the top and bottom of the power piston. Because the ratio of the areas of the power piston subject to hydraulic pressure is 1:2, the power piston is immediately moved up (in the fuel increase direction) to move the output shaft side lever in the fuel increase direction through the system of links and facilitate engine starting,[4] OPERATION 2. NORMAL OPERATION Control lever ae igh prossre a ta rsa = EEE ow preazy ed When the control lever is moved in the speed increase direction, the speeder spring is compressed by the speed control shaft. When the speeder spring force exceeds the flyweight’ s centrifugal force, the pilot valve is moved down. Because of this, the high pressure hydraulic fluid passage and the top and bottom power piston passages open, and the high pressure hydraulic fluid pressure moves the power piston in the fuel increase direction to increase engine speed. As the engine speed increases, the flyweight's centrifugal force increases and the pilot valve is pulled up. P e-ntoR. 06] At the position where the speeder spring force and the flyweight’s centrifugal force balance, the high pressure hydraulic fluid passage and the bottom power piston passage are closed by the pilot valve land. Because of this, the power piston maintains this position and a constant stable speed is maintained. At this time, excess hydraulic fluid overflows through the regulating valve and is returned to the gear pump’s intake side to maintain a stable hydraulic fluid pressure to the pilot valve.4] OPERATION 3. LOAD DECREASE Contol ever ‘Speed conte, me Terminal shatt a) ©) Floating lever \ > Fuel decrease ZZ High pressure = Fue increase aul fuid rs 5 Low pressure =) ygraute hud [EEE rote section Power piston Pilot valve pS Upper compensating spring Lower compensating soring ese [e Needle valve When engine load decreases, and governor rotation has increased, the flyweight’s centrifugal force increases and moves the pilot valve up. This opens the center pilot port so that the hydraulic fluid in the bottom of the power piston returns to the governor's hydraulic fluid tank. Consequently, the power piston is moved down (in the fuel decrease direction) by the high pressure hydraulic fluid in the top of the cylinder and the speed is decreased to the previous balanced condition. When the power piston moves down, it compresses the speeder spring through the speed droop mechanism's floating lever, the pilot valve moves down, and the land moves to a position where it closes the pilot port. When the power piston moves down, its downward movement is also transmitted to the compensating pushrod and piston through the compensating spring in the power piston, "~ compensating piston Pp PAR. 009] Because of this, the negative pressure generated in the compensator chamber relieves the upward movement of the pilot valve, momentarily applying a force in the downward direction. The compensating effect ends when hydraulic fluid from the governor chamber flows in through the needle valve for a fixed period to restore the negative pressure in the compensator chamber to atmospheric pressure. Consequently, when the pilot port is closed by the speed droop mechanism and the compensator mechanism, the power piston and the terminal shaft stop at a new position where the fuel necessary to operate the engine at normal no-load speed is supplied when the engine load is cut. -10-[4] OPERATION 4, LOAD INCREASE Control over Floating fever 2) ‘Speeder spring —_ Flyweight <> Fuel decrease = Fister igh pram raul fais : Low pressure fs 3 Pyrat id Cross section Upper compensating spring Lower compensating soring Needle valve When the engine load increases, engine speed decreases and the governor's operation is exactly opposite to that at load decrease. Thus, the pilot valve moves down, high pressure hydraulic fluid flows into the chamber below the power piston, and the power piston moves upward in the fuel increase direction to increase the engine speed and return it to the previous balanced condition. When the power piston moves up, the speeder spring is moved upward by the speed droop mechanism through the floating lever. Consequently, the pilot valve also moves upward until the pilot valve land closes the pilot port. =i] ~ Compensating piston As the power piston moves up, the compensating piston is drawn up by the lower compensating spring, and the compensator chamber pressure becomes positive. Because of this, the speed at which the pilot valve moves down is relieved as this pressure is applied in an upward direction. The compensating effect ends when the hydraulic fluid flows from the governor chamber in through the needle valve for a fixed period to restore the pressure in the compensator chamber to atmospheric pressure, In this way, the pilot valve returns to its regular position and the engine is maintained at the new power piston position, -11-[4] OPERATION 5, ENGINE STOPPING Control over eS High pressure BT EEE gc i ross section Power pion a — Pot valve / r Because the governor's power piston is moved in the fuel decrease direction by the high pressure hydraulic fluid above the power piston, when the control lever is moved to the stop side the pilot valve is moved up by the speeder spring een Fue) decrease j Lp teen / < AS Engine stop handle “Terminal lever \eS cs ay yeaute governor a PANDA. O11 The high pressure hydraulic fluid in the bottom of the power piston is then returned to the governor's hydraulic fluid tank, the power piston moves down (in the fuel decrease direction) and the engine can be forcibly stopped. The engine can also be stopped by remote control by a governor motor or pneumatic controller. These remote control devices are also installed with a synchronizer to enable manual engine stopping. When the engine is not stopped on the governor side as described above, but is instead stopped by a handle which mechanically sets the control rack to the non-injection position, it is necessary to install a spring in the link system to prevent excessive force being applied to the governor. As this governor does not have a load limit device, it is also necessary to install a spring as above when it is necessary to mechanically limit the load. -12-OPERATION 6. AUXILIARY STARTING BOOSTER Control ever == Fuel decrease Fs Fut ineease High pressure aullo fais Low pressure Pyrat Hid Cross secon Compressed air Power piston Compressed alr ce Doster %, Airport p- An auxiliary starting booster can be connected to the RHD10 governor when necessary. The following explains engine operation at starting when a booster has been connected to the governor. When compressed air is supplied to the booster piston to facilitate starting, the piston compresses the spring and the hydraulic fluid in the chamber opposite the compressed air is guided through the discharge side check valve to the chamber above the power piston. As the governor at this time is in the engine starting status, as explained previously, the hydraulic fluid also flows through the pilot valve to the chamber below the power piston. Starting compensation valve As the governor is simultaneously being turned, high pressure hydraulic fluid from the gear pump is also acting on the top and bottom chambers of the power piston. Consequently, hydraulic fluid pressurized by the booster moves the power piston in the fuel increase direction faster than normal, and it arrives at the fuel position necessary for starting faster than normal. The booster is an effective means of assisting starting for engines such as those for emergency power generators, where mis-starting must be avoided, and high output engines where the governor's surplus output is small. Boosters are manufactured especially for the RHD6 and RHD10 governors. -13-[4| OPERATION 7. SPEED DROOP MECHANISM ‘Speod control shaft 3 | Fartoaatexmam e Load Time untit Eatiteaion ‘Speed stoop (%) = No load maximum speed (N,) full load maximum speed (N) Fail load maxirnum epeed (N) With the speed droop mechanism, speed droop can be varied freely from 0% ~ 10% by adjusting the speed droop adjuster. When the speed control shaft position is fixed using the control lever, and the engine speed is maintained at a speed suitable for a fixed load, should the load decrease, the power piston is moved in the fuel decrease direction (ie, down) to prevent an excessive speed increase, With this power piston movement, the speed droop adjuster attached to the terminal arm turns and pivots the floating lever in a clockwise direction around the wire A to compress the speeder spring and apply a new set load. Because the speeder spring's set load is increased, the pilot valve is again moved down to a position where it closes the pilot port, the fiyweight's centrifugal force and the speeder spring are balanced at an engine speed a litle higher than the initial balanced condition, and this engine speed is maintained. Speeder spring Terminal arm ‘Speed dto0p adjuster Floating lever Flyneight IR ~ \ a Power piston / x100 Conversely, when the oad increases, power piston movement in the fuel increase direction extends the speeder spring so that the engine speed is maintained at a speed a little lower than that when the engine speed was originally balanced. Consequently, by adjusting the speed droop adjuster scale, the link lever ratio is changed and, as the speeder spring's set force can be changed, speed droop can be set freely. * Speed droop (stabilizing droop) When load is cut at full-oad maximum speed (N), the speed wili increase and then stabilize at no-load maximum speed (N.).. Speed droop is the no-load maximum speed (N,) expressed as a percentage of the full-load maximum speed (N).. * Momentary droop When the load is cut at full-load maximum speed (N), the maximum speed (N,) attained while the speed is stabilizing expressed as a percentage of the full-load maximum speed (N) is referred to as the momentary droop. -14-4] OPERATION 8. COMPENSATOR MECHANISM Upper compensating spring Pushrod Plot valve — Lower plo valve chamber — _ Power piston Lowor compensating spring “To tid reservoir Compensating piston Nese valve The compensator mechanism is used to prevent hunting, which generally more easily occurs when speed droop is decreased. The compensator mechanism’s upper compensating spring and lower compensating spring are both assembled with a set load. When engine speed increases and the power piston has moved in the fuel decrease direction (ie, down), the power piston and pushrod and the compensating piston first move down together. Because of this, the pressure in the compensating chamber becomes negative. When this negative pressure falls below a certain value, as it overcomes the upper spring’s set load and compresses the spring, the amount of compensating spring movement becomes relatively less than the amount of power piston movement (the rate that negative pressure is generated becomes less than power piston movement). As the compensating chamber is connected to the lower pilot valve chamber, the lower pilot valve chamber pressure also becomes negative, and the pilot valve works to move down against the flyweight’s centrifugal force and close the previously open pilot port. Because of this, power piston movement in response to engine fluctuations can be slowed to a certain extent and hunting prevented. P-AHOR. 015: In other words, providing the compensating spring with a set load and varying the rate at which negative pressure is generated by power piston movement can improve stability by preventing hunting, and improve response (ie, the speed at which the power piston moves in the fuel increase direction) by minimizing momentary droop. Conversely, when engine speed decreases, the power piston moves up. As the lower compensating spring has a set force, however, the compensating piston also initially moves up, and the compensating chamber pressure becomes positive. When this positive pressure exceeds a certain level, the spring is compressed and the rate at which the positive pressure is generated is slowed. When the compensating chamber pressure becomes positive, the lower pilot valve chamber pressure also becomes positive, and the pilot valve is pushed up to close the pilot port. Because of this, excessive power piston movement and therefore hunting can be prevented. Closing the needle valve increases the pressure generated in the compensating chamber, and thus increases the compensator effect, so that response can be further slowed. -15-(5) ADDITIONAL DEVICES The governor can be equipped with a governor motor and a pneumatic controller. These facilitate remote engine control from a central control room. 1. GOVERNOR MOTOR Their construction and operation are explained below. (1) RHD6 and RHD10 - MC type governor motor ‘Speed setting serow ‘Stopper Gear Fricton coupling Goar head Motor Maximum spoed setting secow k i Guide seraw The governor motor operates when the engine speed set switch in the control room is turned ON. When the motor operates, the speed setting screw is rotated by the friction coupling and gear. As the speed setting screw is screwed into the guide screw, this rotation results in vertical movement. ‘synchronizer knob cover P-AMOR. 16 Because the speed setting screw acts on the speed adjusting mechanism within the governor, speed setting screw movement changes the set ioad of the speeder spring to vary engine speed. The speed can also be changed manually in the same way by turning the synchronizer knob.5] ADDITIONAL DEVICES (2) RHDS and RHD10 - MCL type governor motor (with limit switches) Lower limit switch Speed setting serow v7 Speed adjuster - (cam) Speed adjusting lever Fork This governor motor enables electrical control of the set governor speed's upper and lower limits through limit switches. Three types are available for use with ships’ main engines, pumps, and generators. The control ranges and speed setting times differ depending on the type used. The motor is decelerated by the gear head which, through the friction coupling, turns the speed setting screw to slide the speed agjuster in an axial direction. A pin protruding from the speed adjuster turns the speed adjusting lever fixed to the speed control shaft to vary the set speed. Upper limit switch ‘Synchronizer knob Friction coupling e-DR O17 The upper part of the speed adjuster also serves as a cam to operate the limit switches and move them within the range determined by the slot to enable adjustment of the upper and lower set speeds. When setting the speed manually, the motor side synchronizer can be used to freely vary the speed from the minimum to the maximum irrespective of limit switch control. Also, when an attempt is made to simultaneously change the set speed by remote control, the friction coupling ensures that the speed is first changed on the engine side to prevent any adverse effect on the motor. -17-5] ADDITIONAL DEVICES 2. PNEUMATIC CONTROLLER Fullload oat oan ‘Ai pressure (MPa fglen?) _ (terminal shatt ange at ° Ni, (ing) N Governor speed (vin) (08 = dead slow) ee __— Pushed Cover Pron. o8| The pneumatic controller is used to control engine speed. When air at a specified pressure is supplied to the pneumatic controller, the air pressure acts on the diaphragm and plate, compressing the spring and pushing the pushrod down. The pushrod acts on the speed adjusting link mechanism in the governor to change the set load of the speeder spring. The engine speed can also be freely changed manually in the same way by turning the knob on the top of the controller. -18-ADDITIONAL DEVICES 3. HYDRAULIC CONTROLLER nod mene ay ina t NN Eye bolt eee Cap fee a a i ‘Outer spring =e onion p.ruon- 019 The hydraulic controller is used to control The hydraulic controller's piston displacement engine speed, but utilizes hydraulic pressure is 12 cm’. instead of air pressure, and a piston instead of a diaphragm. -19-[5] HANDLING 1. GOVERNOR INSTALLATION Z| ss "| (ping Smale cia) 9132 | epi araler oy P-RHDR. 020 2. HYDRAULIC FLUID 4. Install the governor vertically to the governor drive case. Use the accompanying gasket at the installation surface. Ensure the governor gear shaft is not subjected to a direct radial load, and that eccentricity and acceleration-gear play are as small as possible. Gear shaft spline coupling dimensions are shown at left. These are the same for RHD6 and RHD10 governors. CAUTION When handling the governor, ensure the end of the governor’s gear shaft is not subject to force or impact. Note: Although the spline is a standard JIS square-shaped spline (6 x 13 x 16), the dimensions shown at left are recommended to avoid even minute eccentricity when installing the coupling. The spline couplings shown at left are standard Bosch Corporation spline couplings, Hydraulic fluid type Fluid charge Inspection Replacement The type of hydraulic |Approx 1,300 cm’, [Check the hydraulic| The fluid must initially fiuid used varies |With the governorfluid daily. lf the |be replaced after 1,000] depending on the governor oil temperature during normal operation. Less than 50°C: horizontal, fill the governor with fluid until the level is slightly above the middle of the governor case ‘SAE20 window. 50°C ~ 70°C: If the fluid charge is SAE30 insufficient, bubbles Over 70°C: will form, performance SAE40 ‘will decrease, and fluid deterioration will be accelerated. charge is less than that specified, check for leaks. If repair is not possible, contact an authorized Bosch Corporation service station. hours or 3 months. Thereafter, the fluid must then be replaced every 3,000 hours or 6 months. -20-6] HANDLING ‘Speed ceoop adjuster Noodle valve loves PeaHoR. a2 ‘Speed droop adjuster Nocse valve PAHOA. 078 3. AIR BLEEDING AND COMPENSATION ADJUSTMENT 1. Set the speed droop at the smallest value possible using the speed droop adjuster (0 ~ 2 on the adjuster scale) and fully open the compensating needle valve (3 turns from the fully closed position) 2. Operate the engine at low speed and cause the engine to ‘hunt! or ‘surge’ for approximately 30 seconds to bleed the air. 3. Stop the engine, set the speed droop to the setting estimated for the particular application (determined from the performance diagram) and then restart the engine. 4, Close the needle vaive until ‘hunting’ stops. Advice The above completes air bleeding and compensation adjustment. If, however, the speed droop adjustment setting is changed during engine adjustment, readjust the needle valve to as open a position as possible at which stabilized engine operation is obtained. 24Fuel pointer scale 7 6] HANDLING fos ieee Ge 7 alt ngauseeet Bet le ac}s \ Eyles i Pr eases Ve eras Sia 7500 1800 Za60 Mins ___Srrererspeestiin) pon ot | FADO Hpe Speed op ais sole 5 == 0 a i Hy =a Hope T Ti ae "500 1,000 ¥,500 2,000 2,600 MsFstim0 Governor speed (nla) pation. os ot ve sun. 08 eon. 4, LINKAGE CONNECTIONS 1. Use a split tightening type lever. After determining the correct position, secure it using a knock pin, etc. 2. The linkage must be as simple and direct as possible. Minimize resistance and the actual mass of the linkage. 3. The figures at left show the recommended relationships for connections between the terminal shaft angle and the injection pump for a static governor. Advice As play in the link system adversely affects performance, ensure play is as small as possible. 5. DAILY INSPECTION 1. Check the fluid level daily before beginning operation. If the level is below the middle of the gauge, add fluid to the governor. 2. Check that the governor mounting bolts are not loose and that there are no faults in the linkage connections from the governor terminal shaft to the injection pumps’ control rack. 6. IN-SERVICE INSPECTION 1. Check the governor temperature. The temperature should generally increase to approx 60°C after 30 ~ 40 min of high speed engine operation. If the ambient temperature is high, the temperature may increase to 80°C after continued high speed operation (over 1,800 r/min). ‘Temperatures over 100°C are abnormal. Check for abnormal noises. Wipe any fluid from the outside of the governor and check that no fluid leaks during operation. er -22-[7] DISASSEMBLY 1. SPECIAL TOOLS The following special tools (in addition to general tools) are required for disassembly and reassembly of the RHD hydraulic governor. KeY’ part name | RBUP part no.|Bosch part no. Qty Application 1 |Case 376100-2000 | 9 421 622974] 1 |For tools | 2 |Spanner | 376100-2100 | 9.421.622811| 1 |For removing/installing regulating valve (SW22mm, 24mm) 3 |Screwdriver | 376100-2200 | 9 421 622812] 1 |For removing/installing cover bolts 4 |Screwdriver | 376100-2300 | 9 421 622813] 1 |For speed droop adjuster adjustment 5 |Pliers 376100-2400 | 9421622814) 1 |For removing split pins 6 Spanner 376100-2500 | 9421622815 | 1 |For removing/installing plug (SW17mm) 7 Allan wrench| 376100-2600 9421622816 1 SW3mm 8 Allan wrench, 376100-2700 9.421.622.8171 SW5mm 9 Extractor 376100-2800 9421622818 1 For removing pin 8 0 a 9. 10 “a8 eC -23-(7) DISASSEMBLY 2. EXPLODED VIEW tositg ae vane P-RoR- 026) -24-7| DISASSEMBLY 3. PART LIST (1) RHD-LC type hydraulic governor Key Key Key ee Partname | pad Part name ee Part name 1 [Base 36 [Bolt 89 [Roll pin 2 |Needle roller 50 [Flyweight 95. | Floating lever bearing 51 |Washer 96 |Wire 3 |Oilseal 52 |Thrustneedle roller | 104 |Gasket 7 |Gear shaft bearing 105 |Cover 10 O-ring 53. |Pilot valve 106 |Bolt 11 |Housing assembly 108 |Maximum speed 13 |Sleeve 60 |Guide lever setting screw 18 |Compensator 61 [Pin 109 |Nut assembly 62 |Split pin 110 |Minimum speed 18/1 |Power piston 70 |Terminal arm setting screw 18/3 |Upper compensating assembly 441 Nut spring 70/1 | Terminal arm 112 |Gasket 18/4 |Pushrod 70/2 |Terminal shaft 113 | Air breather 18/5 |Washer 70/3 | Taper pin 118 |Needle valve 18/6 |Lower compensating | 70/4 |Set screw 119 |O-ting spring 70/5 |Speed droop 123 |Gasket 18/7 |Snapring adjuster 124 |Screw plug 18/8 |Compensator 70/6 |Washer 130 |Gasket bushing 70/7 |Lock washer 131 | Regulating valve 18/9. |O-ring 7018 |Screw 135 | Indication plate 18/10 |Compensating piston | 85 Speedcontrol shaft | 136 |Nail 18/11 Roll pin 86 Collar 137 | Indication plate 35__|Gasket washer 88_| Fork 140_|Pointer (2) Pneumatic controller Key Key Key ee Part name ne Part name fe Part name 105 [Pneumatic controller |105/12|Piston 105/25 | Bolt 105/1 | Cover 105/13 |Diaphragm 105/26 | Eye 1085/2 |Cylinder 105/14 | Plate 105/27 |Gasket 105/3 |Screw 105/15 |Nut 105/28| Eye bolt 105/4 | Spring washer 105/16 |Cover 105/30|Nut 105/5 | Spring seat 105/17 |Screw 105/31 | Bolt (set screw) 105/6 |Nut 105/18|O-ring 105/35 | Gasket 105/7 |Washer 105/19|Wing nut 105/36 | Bolt 105/8 | Spring 105/21 |Knob (158) |Pin 105/9 | Spring 105/22| Set screw 105/10 Washer 105/23 |Screw 105/11 | Pushrod 105/24| Spring washer -25-(7) DISASSEMBLY 4. PREPARATION Keep the work bench clean and tidy. Before starting disassembly, record performance data and the positions of adjustable parts for later reference. This data will facilitate the detection and diagnosis of any governor malfunctions and defects, OR 090 + Pilot valve assembly P-RHOR 091 During disassembly, put the disassembled parts neatly and sequentially on the work bench, labelling them if necessary to facilitate later reassembly. Clean the outside of the governor before disassembly. 5. DISASSEMBLY (1) RHD governor disassembly 1. Remove the four bolts using a screwdriver and then remove the cover together with the gasket. 2. Tum the governor upside down and drain the fluid. 3. Remove the two wires connecting the fork to the floating lever and then remove the floating lever. 4, Remove the pilot valve assembly. Advice Put the pilot valve in clean light oil. E265DISASSEMBLY 5. Remove the two split pins and then remove the two pins connecting the terminal arm and the guide lever to the power piston. Terminal arm 6. Remove the bolts using an allan wrench (SW5 mm). t hk Bats () - , Z P-AHOR- 033 7. Tap the base lightly with a plastic hammer to separate it from the housing. Housing P-RHOR. 094 8. Remove the sleeve from the housing and the gear shaft from the base. Advice Put the sleeve in clean light oil. Housing Gar shatt -27-7] DISASSEMBLY 9. Push the power piston down from the top of the governor and then remove the compensator bushing and the compensator assembly. - 4 Fsion- 08 Fok Rolpin 10. Remove the roll pin securing the fork to the speed control shaft, and then remove the speed control shaft, the collars and the fork. Note: PC, MC, and MCL type governors are equipped with a cancel spring on the speed control shaft. Remove the cancel spring when removing the speed control shaft 11. Remove the flyweight assembly together with the thrust needle roller bearing and the washer from the housing. 12. Turn one terminal shaft one half turn and remove the termtinal shafts’ taper pins. Remove the set screws using an allan wrench (SW 3 mm), then remove the terminal shafts and arm, Advice 1. Do not remove the terminal arm assembly unless it is not operating smoothly or it is necessary to replace s > parts. Taper pins (2) Set serene (2) 2. When replacing the terminal shafts L____ en. o29} and arm, they must be replaced as an assembly. -28-7| DISASSEMBLY Taper pin & Set sorew Fogulating ve “at P-RHOR. 040) LS *N ton 009) 13. Remove the needle valve and regulating valve (hexagon head, SW 24 mm) and any other extemal parts. The above completes disassembly of main RHD governor components. Disassemble other components when necessary. The pneumatic controller is the most commonly equipped additional device. Disassembly is described below. (2) Pneumatic controller disassembly 1. Loosen the wing nut. Then, loosen the knob until it can be easily turned. 2. Remove the four bolts using a screwdriver and then remove the cover. -29-7| DISASSEMBLY 3. Remove the diaphragm together with the pushrod, and then remove the two springs. 4. Loosen the nut and then remove the spring seat. The above completes disassembly of main pneumatic controller parts. Disassemble other parts when necessary. P-AHOR. os -30-[8] INSPECTION Record the details of all inspections and 1, REPLACEMENT STANDARDS. repairs. Parts with key numbers marked With parts such as those listed below, first Replace at disassembly or every 2 years check their external appearance to determine Parts with key numbers marked (1: whether further disassembly is necessary. Replace every 4 years or 20,000 hours + Terminal arm assembly In principle, assemblies must be replaced * Pilot valve assembly when any of their component parts have been * Housing assembly used for 8 years or 40,000 hours. + Flyweight assembly Governor motor assembly Wash all parts thoroughly in clean light oil, and check for wear, damage and scratches. Replace any parts that cannot be reused with new parts. 3) Oil seal 23) Gasket Gear shaft 480) Gasket i O-ring 1477) Oilseal || @ ome IB) ot wetoage ! Pin (BO) Flyweight Roll pin HE Washer a 2 aterbeng Gasket Pin Gasket [95] Floating lever | oning [rar] Feguieting If parts other than the above are worn or svon-ou damaged, replace them with new ones, -31-8] INSPECTION Sloove contact surface Gear shaft contact surface Power piston contac surace P.BHOR. 047 ‘Bustings 2) Power piston contact ure Housing holes Sleeve contact surface Gear shatt| ‘contac sutace P-RMOA. O48 Gearshet Spline p-pyoR-o40 ‘Compensator bushing A Lon. 20 2. COMPONENT INSPECTION (1) Base assembly and housing Replace the base if the power piston, gear shaft or sleeve contact surfaces are worn of damaged. Replace the housing if the power piston, gear shaft or sleeve contact surfaces, or the housing holes, are warn or damaged Replace the housing if the pressfitted terminal arm bushings are worn or loose, (2) Gear shaft and sleeve Replace the gear shatt if the outside, spline, oil seal contact surface or gear is worn or damaged, Replace the sleeve if the gear, pilot ports or lands are worn or damaged. (3) Compensator assembly Assemble the compensator assembly's power piston, pushrod and compensator bushing in the housing and check that they move smoothly up and down under their own weight when the housing is moved. Repair or replace them if they do not move smoothly. Note: If the power piston does not move smoothly, hunting or excessive speed droop will prevent engine adjustment. -32-INSPECTION ‘Speed control shat Floating lever ‘Terminal arm Power piston 98 Pin Guide lever P-RHOR. 052 Washer Spring Regulating vaive (4) Flyweight assembly Foreign matter in the flyweight will prevent smooth flyweight movement. Check that the flyweight moves smoothly. Wash the flyweight thoroughly. (5) Power piston, guide lever and terminal arm + Replace the guide lever if the pin holes are worn, Replace the pins if they are worn. Replace the power piston if the inside is worn, * Replace the speed control shatt if its bent or the shaft journals are worn. (6) Regulating valve Check that the piston moves smoothly. Repair or replace the piston if it is worn or does not move smoothly. (7) Other parts + Check all other parts for cracks, damage, damaged threads and rust. Repair or replace them if necessary. + Replace all O-rings and gaskets. + Replace springs that are damaged, bent or rusted -33-INSPECTION (2) Brush inspection Remove brush (one side) Confirm overall length ‘Overall length is 4mm or less YES _® Arr orlss (replace) Brush 3. GOVERNOR MOTOR BRUSH INSPECTION (MC, MCL TYPES) Advice motors. (1) Brush inspection intervals Brush inspection intervals are shown below. Inspection applies only to direct current (DC) type motors. The following is not necessary for alternating current (AC) gH 15 Inspection £108 15] Part name peta Remarks When overall Brush Monthly | lengthis 4 mm. or less Note: Overall length of new brushes: 10 mm. Remove motor and replace both brushes Reinstall brush in original position cover. P-RADR. 106) -34- (3) Brush removal 1. Remove the screw and then remove theSpring P-RHOR. 100 Brush Bish P-RHOR. 109 Knob Cie S f Soren a) [8] INSPECTION 2. Loosen and then remove the cap. 3. Remove the brush from the motor. Advice Do not stretch the brush spring during removal. 4. Measure the overall length of the brush Advice + When overall brush length still exceeds the wear limit of 4 mm, reverse the removal procedure to reinstall the brush. (Inspection is complete.) + When overall brush length is 4 mm or less, continue with the following steps. (Replace both brushes at the same time.) (4) Motor removal 1. Loosen the screw and then remove the knob. Note: Screw: SW3 -35-BI INSPECTION Serews () P-AHOR 112 Caps 2) Covers (2) Seraws (2) Paton. 1] 2. Remove the screws and then remove the motor horizontally. Advice The motor is connected to a harness. Do not pull the harness excessively. (8) Brush replacement 1. Remove the knob-side brush using the same procedure as above. 2. Replace both brushes with new ones and then reinstall the motor and knob by reversing the removal procedure. Advice + When reinstaiting the motor, install the motor so that the side with the nameplate is facing up. + Tighten diagonally opposed motor fixing screws (4) gradually and evenly. Tightening torque: 2 ~ 2.2 Nm {0.2 ~ 0.22 kgfm} Brush part numbers Zevel part no. Partname | (girehParino. | Remarks 58901-4500 (9421 622899) | Forbceav Brush 15890-4600 am eceen, | ForDcr0ov | -36-Spring seat PAHOA. 054 PIRMOR. 055 <— Se Wing nut P.RHOR. 057 REASSEMBLY ©} Governor reassembly is described below. 1. PNEUMATIC CONTROLLER (if installed) 1. Screw the locknut onto the spring seat, then screw the spring seat into the cylinder. 2. Install the diaphragm and pushrod together with the two springs. 3. Install the cover and secure it using the four bolts, 4. Install the knob and wing nut. -37-9] REASSEMBLY Regulating valve 2. GOVERNOR ASSEMBLY 1. Install the regulating valve. Tightening torque: 25 ~ 29 N-m {2.5 ~ 3.0 kgfm} 2. Install the terminal shafts and arm. Align each terminal shaft’s and terminal arm's taper hole. Coat the taper pins with an adhesive and install the taper pins A\CAUTION When installing the two taper pins in the terminal shafts, support the terminal arm and terminal shafts to avoid damaging the bushings pressfitted to the housing. arise ara “Terminal shafts (2) P-RHOR. 050 3. Coat the set screws with an adhesive and “Taper pin esta install the two set screws. Tightening torque: 3.9 ~ 4.9 N-m {0.4 ~ 0.5 kgfm} P-RHOR. 040) 4. Caulk the two taper pins after final tightening -38-9] REASSEMBLY Flyweight assorbly P-AHOR: 051 Compensator bushing ! Ranon- os ‘Sloove Gear shatt P-RHDR 059 5. Install the flyweight assembly, thrust needle roller bearing and washer in the housing. 6. Install the speed control shaft, collars and fork, and then install the roll pin. Advice PC, MC, and MCL governors are equipped with a cancel spring. Install the cancel spring when installing the speed contro! shaft. 7. Install the power piston, the compensator assembly and the compensator bushing. 8. Install the gear shaft in the base, and the sleeve in the housing.[8] REASSEMBLY High pressure uid passageway Prossfit bearing until it abgns wih aa end faco P-Bon- oss| Bolts (2) Gaskeis (3) P-RHDR. 66: ouide lever P-BHOR. 067 } Pitot vaive assembly P.BHOn. 86 Advice When pressfitting the gear shaft bearing into the base, pressfit the bearing to al with the base face, as shown. If the bearing is pressfitted too deep, the bearing will block the high pressure fluid passageway. 9. Install the base to the housing using the bolts and gasket washers. Tightening torque: 10 ~ 15 Nm {1.0 ~ 1.5 kgfm} OT WI securing the base to the housi check that the gear shaft turns smoothly. If the gear shaft does not turn smoot! the oil delivery gear may be damaged. 10. Attach the guide lever to the terminal arm and the power piston using the two pins and two split pins, Then, bend the spit pins over. 11. Install the pilot vaive assembly. -40-9] REASSEMBLY Wies Foaingiver ~~*+|~«‘12._‘Install the floating lever and secure it to the fork and pilot valve using the two wires. Advice Bend the ends of the wires to prevent them from loosening. A e-ruoe-or ‘Connecter 13. After assembling the governor's inner Senn components, thoroughly wash the inside +49kPa (0.5 kgtlem’} and then instail the cover using the bolts. Air tightness test -1. Before filling the governor with hydraulic Light fluid, remove the air breather and install the connector, gaskets and eye bolt. Then, supply compressed air at 49 kPa {0.5 kgf/om’} to the governor through the connector, and immerse the governor in light oil. ee ___pauon-on| 2 Operate the speed control shaft and check that no air leaks from the governor. If air leaks, repair the governor. Advice If the governor is equipped with an overflow valve, seal it using a blind plug. If the governor is equipped with booster connections, remove them and seal the openings with blind plugs. Remove the blind plugs and reinstall all components after adjustment. [Speed contro! shaft -41-9] REASSEMBLY Thang | 14. Remove the connector, gaskets and eye cover rbreatner | feats) Ear Reinstall the air breather, then remove the cover. -42-{i] ADJUSTMENT In addition to general tools, the following special tools are necessary for governor adjustment. 1. PREPARATION (1) Special tools ne Part name Part no. Remarks 1 |Driving stand 307610-0050 For driving RHD governor 2 [Adjusting device 307610-1010 For measuring lever angle Hydraulic fag ® A ll gauge P-AHOR- 073 (2) Inspection following reassembly 1. Attach the driving stand to the pump tester and install the governor on the driving stand. Fill the governor with the specified amount of hydraulic fluid (approx 1,300 cm*; the fluid should be a little over the middle of the gauge). -43-(i) ADJUSTMENT ‘Terminal ann Fustinewease rection ‘Adjusting device lover ‘Speed increase direcion| ‘Adjusting deviee ‘Speed conta shat | ~~ | 2 Move the terminal arm by hand until it becomes difficult to move to bleed the air from the governor. 3. Turn the flywheel by hand and check that the gear shaft can be turned easily, and that the flyweight turns together. Note: It the gear shaft does not turn easily, it will heat up during operation and adversely affect endura eile) y Remove the lever after operating the flywheel. Operating the test bench without removing the lever can cause serious injury and damage the test benc! 4. Set the speed control shaft in the speed increase position, rotate the gear shaft and check that the terminal shaft moves in the fuel increase direction 5. Attach the adjusting device to the driving stand and then attach the adjusting device lever to the terminal shaft.(0) ADJUSTMENT rection >p.RHOR. o7@ ‘Speed contol shaft Th p-aion. 072 O poston Stop positon ‘Speed control shaft 6. Set the speed control shaft in the speed decrease position, rotate the gear shaft and check that the terminal shaft moves in the fuel decrease direction. Note: If the cover is installed, the terminal shaft may not return in the fuel decrease direction, depending on the set position of the speed control shaft. 7. Install the governor cover. (3) Warming-up operation Run the governor at 1,000 r/min for 20 mins and check that no fiuid leaks. (4) Air bleeding Fully open the needle valve (approx 3 turns from the fully closed position) and run the governor at 1,000 t/min. Operate the speed control shaft so that the power piston moves through its full stroke. Do this at least 10 times to bleed afl air from the governor's hydraulic system. (8) Terminal shaft pointer adjustment 1. Run the governor at approx 1,000 r/min and move the speed control shaft to the stop position. 2. in the above condition, align the terminal shaft side pointer with the indication plate’s (fuel side) 0 position and fix it using the screw. 3. This position is the terminal shaft angle’s 0 position. Align the adjusting device's 0 position with this position.i) Terminal ‘Spe droop aduster For RHDB rerminal shat ant c Pointer ADJUSTMENT ‘Speed control shaft Governor s8ed (HN) ryuoa, 114-18 4. Run the governor at approx 600 r/min (with the needle valve fully open, ie, returned 3 turns from the fully closed position) and turn the speed contro! shaft. Check that the terminal shaft moves easily from 0° ~ 35° (RHD10: 0° ~ 40°) when the power piston moves through its full stroke. At this time, check that the terminal shatt operating torque is 9.8 Nm {1 kgtm} for the RHD6 or 14.7 Nm {1.5 kgm} for the RHD10 using a spring balance attached to the adjusting device. 2. OPERATION TEST The operation test is the same for LC, PC, MC, and MCL type governors. Perform the operation test with the needie valve fully open. (1) Speed control shaft pointer angle adjustment 1. Remove the governor cover and set the droop adjuster pointer at the specified value. 2. Run the governor at 2,000-10 r/min and secure the speed control shaft at the position (A) where the terminal shaft angle is 30° (ie, 6 on the scale). Then, align the speed control shaft pointer at 8 (on scales graduated from 0 ~ 8) and tighten the screw. Note: -1 On PC, MC and MCL governors, the terminal shatt is fixed (at A) by a knob. On RHD10 governors, when the terminal shaft angle is 32° (ie, 8 on the scale), align the speed control shaft pointer at 10 using the screw.For RHDS NON: Governor speed (cin) ‘Speed droop adjuster i ADJUSTMENT (2) Speed droop adjustment 1. Temporarily fix the droop adjuster pointer at the specified position. 2. Operate the governor at N, r/min and then fix the speed control shaft when the terminal shaft angle is 30° for the RHD6 or 82° for the RHD10. 3. Gradually increase governor speed and further adjust the speed droop adjuster so that governor speed is No r/min when the terminal shaft angle is returned to 10° for the RHD6 or 8° for the RHD10, Note: When the speed droop adjuster pointer is moved toward 0, speed droop decreases. When the speed droop adjuster is moved toward 10, speed droop increases. Advice Confirm that N, is within the allowable speed when the speed droop adjuster is exactly as specified. Note: If the lever attached to the terminal shaft deviates more than =1° during high speed operation (ie, at approx 1,800 r/min), check as follows. Regular deviation: Check compensator related parts (housing, base, assembly, tegulating valve). Replace them if necessary. Irregular deviation: Check the flyweight assembly. Replace it if necessary. Perform the following adjustments with the governor adjusted as described above. -47-{i] ADJUSTMENT Governor speed (min) —— ‘avium speed setting screw P-RHOR- 098 ‘Speed contol shat ‘ P-AHOR. 089 (3) Maximum speed setting screw adjustment (not necessary on MCL type governors) 4. Install the governor cover. Operate the governor at N, r/min, adjust the maximum speed setting screw until the terminal shaft angle is 30° for the RHD6 or 32° for the RHD10, and then fix the screw using the locknut. (4) Minimum speed setting screw adjustment (not necessary on PC, MC or MCL type governors) 1. With the governor stopped, move the speed control shaft as far as possible to the low speed side (0 or less on the scale), and then temporarily set the minimum speed setting screw. 2. Operate the governor at Ny r/min and adjust the minimum speed setting screw so that the terminal shaft angle does not exceed 10° (RHD6) or 8° (RHD10). Then, fix the screw using the locknut. (6) Compensator chamber high pressure hydraulic fluid flow The flow of a large quantity of hydraulic fluid 10 the compensator is not desirable. To check for this, perform the following test. 1. Fully open the needle valve (approx 3 turns from the fully closed position) and maintain governor speed at approx 1,000 min, 2. Fix the speed control shaft so that the terminal shaft angle is approx 20° (4 on the scale). -48-{f] ADJUSTMENT 3. Fully close the needle valve and check that the terminal shaft does not move more than 1° in the G direction. Advice If the terminal shaft moves more than 1° in the 0 direction, check for the following. * Clearance between the sleeve and base. + The base-housing contact surfaces may not be even, or may be scratched. + The needle valve escape ports (9 0.4 and 6 0.8) and the base escape ports (01.5) may be blocked. + The compensator bushing O-ring may be damaged. (6) Governor control confirmation Under the following conditions, operate the speed control shaft to move the terminal shaft in the fuel inctease direction (RHD6: 0° > 35°; RHD10: 0° — 40°) and in the fuel decrease direction (RHDS: 35° = 0°; RHD10: 40° — 0°) and check that the lever resistance is as specified. Measurement conditions Governor speed: 600 r/min Needle valve position: fully open R (see fig at left): 100 mm Note : If the lever resistance is not as specified, replace the following parts. + Regulating valve assembly * Check for openings or leaks in the gear pump or hydraulic fluid system and replace faulty or damaged parts. (7) Reverse operation The RHD governor is constructed so that identical performance is obtained whether it is operating clockwise or counterclockwise. To confirm this, operate the governor in the reverse direction and check governor control as described above under the exact same conditions and procedures, and check that performance is as specified. -49-i ) nal shalt angle ( ADJUSTMENT — kro ~ Outer spring 3. ADDITIONAL DEVICES (1) Pneumatic controller adjustment 1. Before adjustment, check that the outer and inner springs’ distinguishing colors are as specified 2. Temporarily position the manual knob as shown at left and connect a compressed air source capable of supplying 0 ~ 0.49 MPa {0 ~ 5 kgf/cm’ } to the eye bolt. Note : Perform the following adjustments and confirmations based on the individual test standards, 3. Point [adjustment Example: 1,680~ 0.37 MPa ~ 3020.5 {3.8 kgt/om’} (speed) (air pressure) (terminal shaft angle) ‘Operate the governor at 1,680 r/min and adjust the spring seat so that the terminal shaft angle is 30+0.5° when 0.37 MPa {3.8 kgf/cm’} air pressure is supplied. Then, secure the spring seat using the nut. Advice When adjusting point I, return the air pressure to 0 and the manual speed adjusting knob to its original position to prevent diaphragm damage. 4. Point I adjustment Example: 1,055~ 0.16 MPa ~ (Approx 16.5) {1.6 kgf/cm*} (speed) (air pressure) (terminal shaft angle) Operate the governor at 1,055 r/min and confirm that the terminai shaft angle is 16.5° when 0.16 MPa {1.6 kgf/cm} air pressure is supplied. 5. Point Ill adjustment Example: 700 ~ O~ 8.5+1.5 (speed) (air pressure) (terminal shaft angle) Operate the governor at 700 r/min and adjust the manual speed adjustment knob so that the terminal shaft angle is 8+1.5° at an air pressure of 0. Then, secure the knob using the wing nut. -50-ADJUSTMENT Example ‘Test electrical crcuit Governor motor assembly f ‘Motor spe0. 'Spoed increase Maximum speed seting serew Fork Speed setting screw __p.ntnon 097, Friction coupling (2) Governor motor operation confirmation (MC type} 1. Specification confirmation Confirm from the individual standards that the specifications of individual parts are correct. + Motor specification (voltage) * Condenser capacity * Speed reduction ratio 2. Operation confirmation (using manual speed adjustment knob) Tum the knob manually, and confirm that the speed setting screw turns smoothly over the whole range by observing speed control shaft pointer movement. If it does not move smoothly over the whole range, loosen the friction coupling set screw, adjust the positions of the bevel gear teeth and recheck screw movernent. 3. Operation confirmation (using the motor) Connect the governor motor assembly to the electrical test circuit in accordance with the particular motor’s specifications, as shown at left. 4. Operation test + Turn the governor motor’s speed switch ON in the speed increase direction to operate the motor. Then, operate the motor until the fork contacts the maximum speed setting screw adjusted above and the friction coupling is rotating freely. -51-ADJUSTMENT ‘Speed seting soraw PRR. 098 ‘Spoed setting sero P-nHoR. 99] Speed seting screw P-RHOR. 100. * Then, turn the switch OFF and then ON in the speed decrease direction, and confirm that the speed setting screw begins moving smoothly. * Operate the governor motor until the ‘speed setting screw contacts the stopper and the friction coupling is rotating freely. * Then, turn the switch OFF and then ON in the speed increase direction and confirm that the speed setting screw moves smoothly. Advice During the above operation test, if the friction coupling rotates freely in other than the following two cases, check the alignment of the bevel gear teeth. + When the maximum speed setting screw is contacting the fork + When the speed setting screw is contacting the stopper (3) Governor motor operation test and limit switch adjustment (MCL type) 1. Specification confirmation Confirm from the data sheet that the specifications of individual parts are correct. + Motor specification (voltage) + Condenser capacity + Speed reduction ratio -52-[i] ADJUSTMENT 2. Operation confirmation (using the manual speed adjustment knob) Confirm operation as described below before adjusting the terminal shaft side pointer. Operate the knob manually and confirm that the speed setting screw rotates smoothly over the full range. If it does not move smoothly in some places, check the installation of the holder or the speed setting screw. came 3. Governor motor operation test ont slchlal ke ernor motor assem (limit switch adjustment) << Gasca Connect the governor motor assembly to spot inzease Lio the electrical test circuit in accordance with a Hi To} o oreo Sar 3 @ the particular motor’s specifications, as I “Tred Re si) shown at left eS ack Then, adjust each limit switch. we | (overt For RHDG * Maximum speed limit switch adjustment Operate the governor at the specified speed (N, r/min), and the governor motor in the speed increase direction, Adjust the limit switch’s upper limit position so that the governor motor stops at the terminal shaft angle of 303° for the RHD6 or 323° for the RHD10. shaft ange) soale y[10] ADJUSTMENT Low A Hoa. 196 er lint witch / / Scat Minimum speed limit switch adjustment Operate the governor at the specified speed (N. r/min), and the governor motor in the speed decrease direction. Adjust the limit switch’s lower limit position so that the governor motor stops at the terminal shaft angle of 103° for the RHD6 or 83° for the RHD10. Set the governor speed at 1,500 r/min and confirm that the governor motor operates correctly between the upper and lower operation limits and that the friction coupling does not rotate freely.TROUBLESHOOTING Of the phenomena listed below, some originate solely in the governor, and some solely in the engine. + Faulty starting Hunting Insufficient engine output Engine will not operate at maximum speed Excessive momentary speed droop, or inability to control speed First, check the engine for the following faults. If engine faults are found, perform repairs in accordance with the engine maker's instructions. * Compression pressure of each cylinder is extremely uneven + Excessive play in fuel control and speed adjustment linkage + Excessive resistance in injection pump control rack and fuel control linkage + Excessive play because of worn governor drive system gear or rubber damper + Relative positions of linkages incorrect + Dashpot spring in fue! control linkage bent or damaged If no engine faults are found, check the governor. As the governor uses many precision parts, there is a danger of the engine overrunning if these parts are incorrectly assembled. PROT Never attempt to repair the governor on-site. Always consult your nearest Bosch Corporation representative. -55-[2] PART NUMBER EXPLANATION 1. MODEL NUMBER Example: RHD 6 L C (1) (2) (3) (4) (1) Independent type hydraulic governor, manufactured by Bosch Corporation (2) Control force (work load) Indicates 10 times the controlling force (work load) in kgfm. 3) & lever type M: with governor motor P: with pneumatic controller (4) C: with compensator Note: No symbol ‘C’ indicates that a compensator is not used, 2. CODE NUMBER Example: 10585 6 - 0 000 (1) (2) @)(4) 5) 6) (1) 10: Assembly part number (2) 58: Hydraulic governor manufactured by Bosch Corporation (3) Type 5: RHD6 type 6: RHD10 type (4) Direction of pump rotation and governor installation position a 1 ; al Dinection es Pump ee Sas 0 |Clockwise Right side ) 1 |Clockwise Left side eae 2 |Counterclockwise Right side 3 |Counterclockwise Left side 4 | Clockwise - 5 |Counterclockwise - 6 | Reversible : Note: With in-line pumps, the direction of pump rotation is viewed from the pump's drive side. Governor installation position is viewed from the pump’s cover plate side. (6) Remote control device installation 3: LC type without remote contral device 4: PC type 5: MC type 6 MC type & Noe ee with remote control device 8: MCL type 9: HC type, others Characteristic number (6) -56-Pub. No: EE74E-11017 GOVERNOR MODEL RHD (RHD6 & RHD10) Service Manual Operation & Maintenance Printing: July 2008 Published by: Bosch Corporation Automotive Aftermarket Division Printed in Japan © Copyright 2008, Bosch Corporation + WRGGS-O1EE74E-11017 JAITSS5: 7.2008 Printed in Japan SZEXM EL: tetme neon