Information injection-pump assembly
BOSCH
F 01G 09U 058
f01g09u058
ZEXEL
101607-1330
1016071330
Rating:
Service parts 101607-1330 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
ME076000
12.
Open Pre:MPa(Kqf/cm2)
21.6{220}
15.
NOZZLE SET
Include in #1:
101607-1330
as INJECTION-PUMP ASSEMBLY
Include in #2:
104740-6160
as _
Cross reference number
BOSCH
F 01G 09U 058
f01g09u058
ZEXEL
101607-1330
1016071330
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
Overflow valve
131424-5520
Overflow valve opening pressure
kPa
255
221
289
Overflow valve opening pressure
kgf/cm2
2.6
2.25
2.95
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)
Left L
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
Left L
Injection order
1-5-3-6-
2-4
Pre-stroke
mm
3.3
3.25
3.35
Beginning of injection position
Governor side NO.1
Governor side NO.1
Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5
Cal 1-5 deg. 60 59.5 60.5
Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5
Cal 1-3 deg. 120 119.5 120.5
Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5
Cal 1-6 deg. 180 179.5 180.5
Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5
Cyl.1-2 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5
Cal 1-4 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
-
Rack position
11.4
Pump speed
r/min
700
700
700
Each cylinder's injection qty
mm3/st.
54.5
52.9
56.1
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
D
Rack position
8.7+-0.5
Pump speed
r/min
500
500
500
Each cylinder's injection qty
mm3/st.
7.6
6.5
8.7
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(11.4)
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
54.5
53.5
55.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+0.4
Pump speed
r/min
1450
1450
1450
Average injection quantity
mm3/st.
79.8
75.8
83.8
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
C
Rack position
R1(11.4)
Pump speed
r/min
600
600
600
Average injection quantity
mm3/st.
48.5
44.5
52.5
Fixing the lever
*
Injection quantity adjustment_06
Adjusting point
I
Rack position
14.3+-0.
5
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
73
63
83
Fixing the lever
*
Rack limit
*
Injection quantity adjustment_07
Adjusting point
H
Rack position
9.5+-0.5
Pump speed
r/min
275
275
275
Each cylinder's injection qty
mm3/st.
8.7
7.4
10
Fixing the rack
*
Remarks
(check)
(check)
Timer adjustment
Pump speed
r/min
900--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
850
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
1200
Advance angle
deg.
2.7
2.2
3.2
Timer adjustment_04
Pump speed
r/min
1500
Advance angle
deg.
5
4.5
5.5
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
(2)Tolerance for racks not indicated: +-0.05mm.
(3)RACK LIMIT
----------
T1=D53
----------
----------
T1=D53
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt set position 'H'
----------
----------
a=18.5deg+-5deg b=41deg+-3deg
----------
----------
a=18.5deg+-5deg b=41deg+-3deg
Stop lever angle
N:Engine manufacturer's normal use
S:Stop the pump.
(1)Set the stopper bolt at speed = rated point and rack position = aa. Confirm non-injection at rack position = bb.
(2)After setting the stopper bolt, confirm non-injection at speed = cc.
(3)Rack position = approximately dd
(4)Free (at shipping)
----------
aa=6.7-0.5mm bb=(8.3)mm cc=275r/min dd=17.4mm
----------
a=38.5deg+-5deg b=(27deg) c=17deg+-5deg
----------
aa=6.7-0.5mm bb=(8.3)mm cc=275r/min dd=17.4mm
----------
a=38.5deg+-5deg b=(27deg) c=17deg+-5deg
0000001501 LEVER
(A) Idle
(B) Full speed
(C) Base lever
(D) Accelerator lever
(E) Accelerator lever delivery position
1. Measure speed lever angle
(1)Measure the angle when the accelerator lever (D) contacted the base lever (C) at a.
----------
----------
b=41deg+-3deg c=18.5deg+-5deg
----------
----------
b=41deg+-3deg c=18.5deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Position of timer's tooth at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=16deg
----------
a=(1deg)
----------
aa=16deg
----------
a=(1deg)
Information:
This is a 5.0-hour job
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Rework Procedure
Make sure you have read and understood all of this document before beginning work.
Isolate the generator set before commencing any work on the unit, open generator set breaker, activate Emergency Stop, disconnect the battery cables and either disconnect or open the control circuit breaker for the AC power supply to the battery charger. Ensure all health and safety requirements are adhered to at all times. Also, ensure proper Lock Out-Tag Out procedures are followed at all times while work is being performed on or around the machine. Lock out generator operation and disconnect/lockout all power sources before commencing any work.
1 - Remove the SCR (selective catalyst reduction) side heat shields in order to gain access to the SCR cover. Remove all of the bolts, plates & SCR cover panel. Clean the old gasket material from the Clean Emission Module (CEM) & SCR cover panels.
Reference Image 1.2.1
Image1.2.1
2 - With a new gasket (351-9235) install the SCR cover panel (351-6791), backing plates (351-6794 & 351-6795), washers (7X7729) and original M10 bolts (8T4182) onto the CEM in the following locations:
(7) top center holes
(7) bottom center holes
(1) LH middle hole
(1) RH middle hole
Hand tighten these bolts.
On each corner install a 1" thick plate (512-8186) with (2) washers (7X7729) and (2) longer M10 bolts (8T5005).
Hand tighten these bolts.
Install a nut (5P7970 onto