Information injection-pump assembly
BOSCH
F 01G 09U 01L
f01g09u01l
ZEXEL
101441-9640
1014419640
Rating:
Service parts 101441-9640 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
16600-43G02
12.
Open Pre:MPa(Kqf/cm2)
9.8{100}
15.
NOZZLE SET
Include in #1:
101441-9640
as INJECTION-PUMP ASSEMBLY
Include in #2:
105856-5410
as _
Cross reference number
BOSCH
F 01G 09U 01L
f01g09u01l
ZEXEL
101441-9640
1014419640
Zexel num
Bosch num
Firm num
Name
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
1404 Test oil ISO4113 or {SAEJ967d}
Test oil temperature
degC
40
40
45
Nozzle and nozzle holder
105780-8140
Bosch type code
EF8511/9A
Nozzle
105780-0000
Bosch type code
DN12SD12T
Nozzle holder
105780-2080
Bosch type code
EF8511/9
Opening pressure
MPa
17.2
Opening pressure
kgf/cm2
175
Injection pipe
Outer diameter - inner diameter - length (mm) mm 6-2-600
Outer diameter - inner diameter - length (mm) mm 6-2-600
Tester oil delivery pressure
kPa
157
157
157
Tester oil delivery pressure
kgf/cm2
1.6
1.6
1.6
Direction of rotation (viewed from drive side)
Right R
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
Right R
Injection order
1-3-4-2
Pre-stroke
mm
2.3
2.25
2.35
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-3 deg. 90 89.5 90.5
Cal 1-3 deg. 90 89.5 90.5
Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5
Cal 1-4 deg. 180 179.5 180.5
Difference between angles 3
Cyl.1-2 deg. 270 269.5 270.5
Cyl.1-2 deg. 270 269.5 270.5
Injection quantity adjustment
Adjusting point
A
Rack position
11.6
Pump speed
r/min
1400
1400
1400
Average injection quantity
mm3/st.
35.8
34.8
36.8
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
9.1+-0.5
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
10
8.9
11.1
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
Adjust only variation between cylinders; adjust governor according to governor specifications.
Timer adjustment
Pump speed
r/min
550--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
500
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
1500
Advance angle
deg.
3
2.5
3.5
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)RACK LIMIT: RAL
(3)Set idle sub-spring
(4)Main spring setting
(5)Rack difference between N = N1 and N = N2
----------
K=18 RAL=15.2+-0.1mm N1=1400r/min N2=800r/min
----------
----------
K=18 RAL=15.2+-0.1mm N1=1400r/min N2=800r/min
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=25deg+-5deg b=23deg+-5deg
----------
----------
a=25deg+-5deg b=23deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=12deg+-5deg b=53deg+-5deg
----------
----------
a=12deg+-5deg b=53deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Position of gear mark 'ZZ' at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=18deg
----------
a=(100deg)
----------
aa=18deg
----------
a=(100deg)
Information:
Indicator Lamps
The MECP indicator lamps provide the following status information:
"SUMMARY SHUTDOWN"
"SUMMARY ALARM"
"PLC FAILURE"
"ENGINE PRELUBE"The lamps activate when the "HORN SILENCE/LAMP TEST" switch is placed in the LAMP TEST.
Illustration 5 g00562727
"SUMMARY SHUTDOWN" Indicator Lamp
The "SUMMARY SHUTDOWN" lamp displays the status of the engine protection shutdown system.A red "SUMMARY SHUTDOWN" lamp indicates that a engine protection shutdown has occurred. The exact shutdown is annunciated on the PC window. A flashing "SUMMARY SHUTDOWN" lamp indicates an shutdown that is not acknowledged. A solid "SUMMARY SHUTDOWN" lamp indicates that the shutdown has been acknowledged.The cause of the shutdown is provided by the display screen. To acknowledge the indicator, turn the "HORN SILENCE/LAMP TEST" switch to the "HORN SILENCE" position. Correct the condition before restarting the engine. The control panel must be reset before the engine can be restarted. To reset the control panel, turn the "OFF/RESET, LOCAL, and REMOTE" switch to the "OFF/RESET" position. The air shutoff is activated for any shutdown. The air shutoff must also be reset before the engine can be restarted. If an overspeed shutdown occurs, the Engine Speed Switch must also be reset.Note: When a shutdown occurs the air damper closes. This secures the intake air. The air damper must be reset in order to start the engine. "SUMMARY ALARM" Indicator Lamp
The "SUMMARY ALARM" lamp provides a summary of the active MMS alarms. A red "SUMMARY ALARM" lamp indicates an alarm condition. Specific information on the alarm is provided on the PC window. A flashing "SUMMARY ALARM" lamp indicates an alarm that has not been acknowledged. A solid "SUMMARY ALARM" lamp indicates that the alarm has been acknowledged. The lamp will remain illuminated until the alarm condition is resolved."PLC FAILURE" Indicator Lamp
The "PLC FAILURE" lamp provides status of the PLC timer.The programmable logic control regularly sends a signal to a timer. If the timer fails to receive the signal, the yellow "PLC FAILURE" lamp illuminates. This indicates that the programmable logic control may not be providing full protection for the engine. Running the engine during abnormal conditions may cause engine damage.In the event of a PLC failure, the redundant relay logic shutdown system will provide minimum protection. The PLC failure should be corrected as soon as possible. While the "PLC FAILURE" lamp is illuminated the PC display may not be correct. Use the backup gauges for accurate information. If the programmable logic control is inoperative, the redundant shutdown system will provide minimum protection.PLC failure may be caused by the mode. Loss of the 24 Volt DC power may also cause a PLC failure. The system must be in the run mode.The "PLC FAILURE" lamp is illuminated and the "SUMMARY ALARM" lamp is flashing. Wait for five seconds. Count the number of flashes. The number of flashes corresponds to the slot that contains a faulty module."ENGINE PRELUBE" Indicator Lamp
The "ENGINE PRELUBE" lamp provides the status of engine lubrication.A green "ENGINE PRELUBE" lamp indicates that the engine is prelubed and that the engine is ready to start. Place the "PRELUBE-RUN-START"
The MECP indicator lamps provide the following status information:
"SUMMARY SHUTDOWN"
"SUMMARY ALARM"
"PLC FAILURE"
"ENGINE PRELUBE"The lamps activate when the "HORN SILENCE/LAMP TEST" switch is placed in the LAMP TEST.
Illustration 5 g00562727
"SUMMARY SHUTDOWN" Indicator Lamp
The "SUMMARY SHUTDOWN" lamp displays the status of the engine protection shutdown system.A red "SUMMARY SHUTDOWN" lamp indicates that a engine protection shutdown has occurred. The exact shutdown is annunciated on the PC window. A flashing "SUMMARY SHUTDOWN" lamp indicates an shutdown that is not acknowledged. A solid "SUMMARY SHUTDOWN" lamp indicates that the shutdown has been acknowledged.The cause of the shutdown is provided by the display screen. To acknowledge the indicator, turn the "HORN SILENCE/LAMP TEST" switch to the "HORN SILENCE" position. Correct the condition before restarting the engine. The control panel must be reset before the engine can be restarted. To reset the control panel, turn the "OFF/RESET, LOCAL, and REMOTE" switch to the "OFF/RESET" position. The air shutoff is activated for any shutdown. The air shutoff must also be reset before the engine can be restarted. If an overspeed shutdown occurs, the Engine Speed Switch must also be reset.Note: When a shutdown occurs the air damper closes. This secures the intake air. The air damper must be reset in order to start the engine. "SUMMARY ALARM" Indicator Lamp
The "SUMMARY ALARM" lamp provides a summary of the active MMS alarms. A red "SUMMARY ALARM" lamp indicates an alarm condition. Specific information on the alarm is provided on the PC window. A flashing "SUMMARY ALARM" lamp indicates an alarm that has not been acknowledged. A solid "SUMMARY ALARM" lamp indicates that the alarm has been acknowledged. The lamp will remain illuminated until the alarm condition is resolved."PLC FAILURE" Indicator Lamp
The "PLC FAILURE" lamp provides status of the PLC timer.The programmable logic control regularly sends a signal to a timer. If the timer fails to receive the signal, the yellow "PLC FAILURE" lamp illuminates. This indicates that the programmable logic control may not be providing full protection for the engine. Running the engine during abnormal conditions may cause engine damage.In the event of a PLC failure, the redundant relay logic shutdown system will provide minimum protection. The PLC failure should be corrected as soon as possible. While the "PLC FAILURE" lamp is illuminated the PC display may not be correct. Use the backup gauges for accurate information. If the programmable logic control is inoperative, the redundant shutdown system will provide minimum protection.PLC failure may be caused by the mode. Loss of the 24 Volt DC power may also cause a PLC failure. The system must be in the run mode.The "PLC FAILURE" lamp is illuminated and the "SUMMARY ALARM" lamp is flashing. Wait for five seconds. Count the number of flashes. The number of flashes corresponds to the slot that contains a faulty module."ENGINE PRELUBE" Indicator Lamp
The "ENGINE PRELUBE" lamp provides the status of engine lubrication.A green "ENGINE PRELUBE" lamp indicates that the engine is prelubed and that the engine is ready to start. Place the "PRELUBE-RUN-START"