KT175-RS-R 175 Series Actuators to

Bosch In-Line Pump with Right Hand

Rack & RS/RSV Governor

1 INSTALLATION PROCEDURE - KT175-RS-R

If the Bosch fuel injection pump with a right hand rack (as viewed from the Gov- 3. Position mounting gasket GA176 onto the cleaned Governor Housing.
ernor end) is equipped with a mechanical governor, it must be removed. GAC Apply a light coat of grease onto the face / sealing surface of the forward
recommends that this modification be performed by a qualified fuel injection ser- governor housing to retain gasket in position during assembly.
vice facility. The following procedure lists the general steps required to remove
the mechanical governor. Slide the adapter plate PL298 over the rack extension and install the 6
M16x18 flat head screws p/n HW05-704, torque to 5.2 - 5.6 Nm (46 - 50
NOTE The mechanical governor will release oil during removal. inch-pounds). Check to make sure the rack moves freely in its bore
through its full stop-to-stop travel (Figure 1-3).
1. Remove the rear housing from the mechanical governor and disconnect
4. Once the pump is prepared with KT175-RS-R, Fuel Rack Return Spring,
the governor linkage from the fuel rack. Remove the flyweight assembly
Spring Seats, Shut-Off Plate and the Locking Nut are assembled, the
with special tools, Bosch part number KDEP-2998 and KDEP-2918, that
actuator can be installed (Figure 1-4).
can be obtained from an authorized Bosch service center (Figure 1-1).
2. Install the rack extension (PN LK175) onto the fuel rack.
Insure the link is horizontal and in line with fuel rack. Torque the retain-
ing screw to 5.2 - 5.6 Nm (46 - 50 inch-pounds) (Figure 1-2).

2 FIGURE 1-1 REMOVE EXISTING GOVERNOR

1 KT175-RS-R Adapter Kit 1-2024 A2 PIB1135

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 3 KT175-RS-R

FIGURE 1-2 RACK LINK INSTALLED FIGURE 1-3 KT175-RS-R INSTALLED

KT175-RS-R Alternate turning the following mounting screws so that the

actuator is aligned properly with the pump adapter plate.

ITEM PART NUMBER DESCRIPTION QTY

NO.
1 GA176 Gasket, Plate 1
2 PL298 Plate, Mounting 1
3 LK175 Link, Rack 1
4 HW05-566 Cap screws, M6x16 4
5 HW05-704 Flat Head M6x18 6

2 KT175-RS-R Adapter Kit 1-2024 A2 PIB1135

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 4 INSTALLING THE ACTUATOR
All hardware needed to attach the actuator to the pump is located in both kits Setting high fuel levels may cause the maximum fuel adjusting
CAUTION
KT283 and KT289, which are supplied with the actuator. The following installa- screw to hit the top cover, which can change the minimum fuel
tion instructions refer to figures located on the next page. position. When setting fuel levels above 17mm, insure that the adjusting screw
does not contact the top cover at minimum level.
1. Place the fuel rack return spring (2) over the fuel rack extension (1)
against the spring seat (6). Place the spring retainer (3) and shut-off With the fuel pump operating on the engine, the maximum fuel setting screw can
plate (4) with the M10 locking nut (5) over the threads on the Rack ex- be adjusted to provide specific horsepower. Once this setting is made torque the
tension. See Figure 1-4. locknut (24) on the fuel adjustment screw to 5-6 N·m (44-53 in-lb)
2. Remove the upper actuator cover (8) and O-ring seal (25). Rotate the manual shut off lever (22) to the stop position and ensure that the fuel
is completely shutoff and the engine stops. With the engine shut down, install
3. Clean the actuator to pump adapter mounting surface so that it is free
the upper chamber cover (8) and O-ring seal (25) by first applying Loctite 222 to
of any debris.
the six screws (26, 27) provided.
4. Insert two M6 X 16 mm long screws (15) and spring washers (16)
through the lower mounting holes inside the upper actuator cavity. See
Figure 1-6.
5. Align the gasket (29) (Figure 1-6) and install it over the two screws and
FIGURE 1-4
carefully slip the actuator over the fuel rack assembly until the two lower
screws just start to meet the fuel pump mounting holes.

IMPORTANT Alternate tightening the following mounting screws so the

actuator aligns properly with the pump adapter plate.

6. Insert a ball end hex wrench through the access point located on the
operating lever (17) and tighten the left lower mounting screw (15) a few
turns. See Figure 1-8.
7. Pull the operating lever outward and slide the ball end hex wrench into 1
the space between the operating lever and the access point in the hous-
ing of the actuator and tighten the right lower mounting screw.
8. Once these two screws are fully engaged (do not tighten at this time)
into the pump housing, insert two additional M6 X 16 mm long screws
(15) and spring washers (16) into the top two mounting holes of the ac-
tuator and thread into the pump housing. See Figure 1-6.
6
9. Torque all four mounting screws to 5-6 N·m (44-53 in-lb)
10. Verify that the fuel rack assembly moves in and out freely inside the
upper cavity of the actuator.
11. Carefully loosen screw (11) and (20) over the slotted portion of the ad-
justment plate so that the operating lever bearing assembly (21) can be
2
moved away from the fuel rack connection link.
12. Ensure that the fuel rack is as far out of the pump as possible.
3
13. Rotate the operating lever (17) out from the actuator until it stops (the
armature of the actuator will be in contact with the lower cover (9) and
4
14.
hold in this position.
Rotate the adjustment plate and lever bearing assembly (21) in towards
5
the fuel rack so that contact between the bearing and rack connection
link is made. Continue to push in an additional 1 to 2 mm. While holding
this position torque the operating lever assembly shaft screw (11) and The engine should be equipped with an independent
screw (20) to 4-6 Nm (35-53 in-lb) WARNING shut down device to prevent overspeed which can
cause equipment damage and personal injury.
15. Inspect the assembly to ensure all screws are tight and the fuel rack
moves smoothly without any binding. Push in the fuel rack manually to
the full fuel position and rotate the fuel shut off lever (22) to the minimum
fuel position to confirm that the shut off lever contacts the metal plate (4) 5 WIRING
on the fuel rack connector assembly and forces the fuel rack to minimum
position.
The 175 Series Integral Electric Actuator is prewired for 12 or 24VDC operation.
16. The operating lever has a maximum fuel adjustment set screw (23) Use the included cable harness or make up a cable harness to connect the
which can be used to restrict the fuel rack travel. actuator to the speed control unit.
Do not use the 175 Series actuator on a 32-volt system.
When installed, the cover must not hit the internal operating lever WARNING
NOTE Contact the factory for assistance.
or the maximum fuel adjustment screw. Torque the cover screws
to 2-3 N·m (18-27 in-lb) Check for any oil leaks. Lock-wire the lower screws for
tamper resistance.

3 KT175-RS-R Adapter Kit 1-2024 A2 PIB1135

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 6 175 SERIES ACTUATOR

FIGURE 1-5 FIGURE 1-7

11
1
FIGURE 1-2
20
1
12
1

17
1

21
1
13
1

24
1 23
1 Adjustment plate

FIGURE 1-6
FIGURE 1-8

Ball End Hex Wrench

M6 x 16 mm
Mounting Screws (15)

FINISHED PRODUCT
Manual stop lever

175 Series
Actuator

4 KT175-RS-R Adapter Kit 1-2024 A2 PIB1135

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