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Doc No. GEK-76749, Rev. -

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Bosch II Fuel-Oil Injection

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7FDM-8/12/16 Diesel Engines
GEK-76749

© 2008 General Electric Company. All rights reserved. The information contained in this
publication is the property of General Electric Company and is disclosed in confidence. This
publication is intended for use by GE customers solely for purposes of operating and
performing routine maintenance of purchased or licensed GE products, and it shall not be
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disclosed to third parties, without the express written consent of GE.

GE and Customer agree that the information contained herein does not purport to cover all

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details or variations in GE products or to provide for every possible contingency with

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installation, operation or maintenance. Should further information be desired or should

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particular problems arise that are not covered sufficiently for the user’s purposes, the matter

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should be referred to General Electric Company. Any applicable Federal, State or local

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regulations or company safety or operating rules must take precedence over any
information or instructions given in the Technical Documentation. GE has no obligation to

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keep the material up to date after the original publication.
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GENERAL ELECTRIC COMPANY EXPLICITLY DISCLAIMS ALL WARRANTIES OF ACCURACY,
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MERCHANTABILITY OR FITNESS FOR ANY PURPOSE IN CONNECTION WITH THIS PUBLICATION

AND USE THEREOF.
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If you are not an authorized recipient of this publication, you are hereby notified that any
perusal, use, distribution, copying or disclosure is strictly prohibited. If you have received this
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publication in error, please immediately return to GE at the following address: GE

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Transportation, Technical Publications Department, Building 14, 2901 East Lake Rd., Erie, PA
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16531.
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 MI–93296–002
GEK–76749

BOSCH II ELECTRONIC FUEL–OIL INJECTION

GE 7FDM–8/12/16 DIESEL ENGINE

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CONTENTS

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Page

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1. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

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1.2. SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. FUEL–OIL FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

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3. ENGINE DRAIN SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
4. RELIEF AND REGULATING VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

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4.1. CHECKING REGULATING VALVE SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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4.2. ADJUSTING REGULATING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4.3. MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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5. FUEL–OIL INJECTION PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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6. FUEL–OIL INJECTION NOZZLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
7. DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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1. GENERAL INFORMATION
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1.1. INTRODUCTION
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This publication covers the BOSCH II Electronic Fuel–Oil Injection (EFI) System for General Electric (GE) 7FDM
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engines.
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1.2. SAFETY INFORMATION

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Safety precautions which must be observed when working on the BOSCH II Electronic Fuel Injection System ap-
pear throughout this publication. WARNINGS indicate the potential for personal injury, and CAUTIONS indicate the
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potential for equipment damage.

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2. FUEL–OIL FILTERS
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The fuel–oil injection equipment is protected from foreign material by a fuel–oil filter. The fuel–oil filter is described
in SMI–86013, Bosch II Pump Diagnostics.

3. ENGINE DRAIN SYSTEM

A slight leakage of fuel–oil from the fuel–oil injection pump and the fuel–oil injector nozzle on each power cylinder is
normal, since this is required to lubricate the pump and nozzle parts. The fuel–oil leakage must then be drained to the
fuel tank.

Copyright 2004 General Electric Company. All rights reserved. This copyrighted document may be reproduced free of charge by General
Electric Company customers, if such reproduction is used exclusively in connection with equipment used in that customer’s internal
operation.

These instructions do not purport to cover all details or variations in equipment nor to provide for every possible contingency to be met in connection with installation, operation, or mainte-
nance. Should further information be desired or should particular problems arise which are not covered sufficiently for the user’s purposes, the matter should be referred to the General
Electric Company. Any applicable Federal, State or local regulations or company safety or operating rules must take precedence over any instructions given in this material. GE has no
obligation to keep the material up to date after the original publication.
THERE ARE NO WARRANTIES OF ACCURACY, MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE.
Verify numbers for parts, tools, or material by using the Renewal Parts or Tool Catalogs, or contact your General Electric
representative for assistance.
Do not order from this publication.
MI–93296–002
GEK–76749, Bosch II Electronic Fuel–Oil Injection System

Fuel–oil is drained from each injector cavity to the return passage. A system of passages within each cylinder
assembly conducts leakage fuel–oil through the upper portion of the cylinder, around the base of the injection pump,
and downward through the pump push–rod cavity.

A passage in each cylinder base is aligned with drilled passages within the engine main frame. A fuel–oil drain
header pipe is attached to each side of the engine main frame and connected to each of these passages to collect
drainage fuel–oil. Each header pipe is constructed with an open standpipe at one end. The other end is connected to
return drainage fuel–oil to the fuel–oil tank.

The fuel–oil drain system must remain free of obstructions to permit gravity flow of fuel–oil to the tank. If the system
should become clogged, fuel–oil dilution of the lubricating oil will occur.

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4. RELIEF AND REGULATING VALVES

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The Fuel–oil Relief And Regulating Valves (Figure 1) are different and SHOULD NOT be interchanged. The new
Relief Valves are identified with “8431–2” and the new Regulating Valves are identified with “8431–1” (Figure 2).

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REGULATING
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RELIEF VALVE
VALVE
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E–46446
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Figure 1. Relief and Regulating Valve.

The Relief Valve is located at the fuel–oil sight glass between the fuel–oil transfer pump discharge and the filter of
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the fuel system. This valve is factory set to open at the pressure specified in DATA Section of this publication, and
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return bypassed fuel to the main fuel tank. The valve protects the transfer pump motor against electrical overloading
and protects the system against excessive pressure caused by clogged filters or fuel flow stoppage in the pressure
side of the system.

NOTE: The fuel–oil Relief Valve is factory set and should NOT be adjusted after installation.

The Pressure–regulating Valve is located at the fuel–oil sight glass between the engine header and the fuel–oil tank
return line of the system. This valve is set to maintain the fuel header pressure. Pressure should be as specified in
DATA Section of this publication, and may drop from 4.0 to 20.0 psi (28 to 140 kPa) at full speed and load, depending
on the horsepower rating of the engine. When setting the fuel–oil header pressure, the fuel–oil filter must be clean and
the fuel–oil in the system must be free of air bubbles.

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 MI–93296–002
Bosch II Electronic Fuel–Oil Injection System, GEK–76749

REGULATING
VALVE

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RELIEF
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E–44222
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Figure 2. Relief and Regulating Valve Identification.

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When the fuel–oil header pressure drops slowly over a period of time, it is usually a condition of a clogged fuel–oil
filter rather than an incorrect setting of the pressure–regulating valve. The filter element should be replaced.
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4.1. CHECKING REGULATING VALVE SETTING

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Check Regulating Valve pressure setting as follows:

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NOTE: Ensure a new fuel–oil filter element has been installed in the filter tank.

With the engine operating at IDLE, read the pressure gage in control system. The gage should read the pressure
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specified in DATA Section of this publication.

NOTE: Fuel–oil header pressure at full speed and full load will be lower than the pressure at IDLE. This lower
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pressure varies with the engine horsepower output, and with the condition of the fuel–oil filter and the fuel–
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oil transfer pump.

4.2. ADJUSTING REGULATING VALVE

To adjust the setting of the fuel–oil Regulating Valve:

NOTE: Ensure a new fuel–oil filter element has been installed in the filter tank.

With the engine operating at IDLE, loosen the adjusting locknut on the Regulating Valve and turn the adjusting
screw IN to increase pressure or OUT to decrease pressure as specified in DATA Section of this publication.

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MI–93296–002
GEK–76749, Bosch II Electronic Fuel–Oil Injection System

4.3. MAINTENANCE

If the valve malfunctions, remove the cartridge from the body. Do NOT disconnect piping to the body. Working
through the bottom of the cartridge, check for free movement of the cartridge plunger. If necessary, replace O–rings or
the entire cartridge and readjust the valve; see ADJUSTING REGULATING VALVE Section of this publication.

NOTE: NO ADJUSTMENT is available for the Relief Valve.

5. FUEL–OIL INJECTION PUMP

CAUTION: The fuel–oil injection (high pressure) pump is a Critical Component. Consult the latest revi-
sion of the manufacturer’s Parts Catalog to obtain the correct replacement part.

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NOTE: See SMI–86013, 7FDM CRITICAL COMPONENTS publication for Fuel–Oil Injection (high pres-

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sure) Pump removal and installation.

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6. FUEL–OIL INJECTION NOZZLE

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CAUTION: The fuel–oil injection nozzle is a Critical Component. Consult the latest revision of the
manufacturer’s Parts Catalog to obtain the correct replacement part.

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NOTE: See SMI–90033, 7FDM BOSCH II PUMP DIAGNOSTICS publication for Fuel–Oil Injection Nozzle
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removal and installation.
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7. DATA
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Pump relief valve setting (NO Adjustments Required) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145–5 966–34.5

Pressure regulating valve setting at idle speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60–5 413–34.5
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