Information injection-pump assembly
BOSCH
9 400 611 282
9400611282
ZEXEL
106682-9593
1066829593
Rating:
Service parts 106682-9593 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
6212-12-3300
12.
Open Pre:MPa(Kqf/cm2)
24.5{250}
15.
NOZZLE SET
Include in #1:
106682-9593
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
9 400 611 282
9400611282
ZEXEL
106682-9593
1066829593
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
105780-8130
Bosch type code
EFEP215A
Nozzle
105780-0050
Bosch type code
DN6TD119NP1T
Nozzle holder
105780-2090
Bosch type code
EFEP215
Opening pressure
MPa
17.2
Opening pressure
kgf/cm2
175
Injection pipe
Outer diameter - inner diameter - length (mm) mm 8-4-1000
Outer diameter - inner diameter - length (mm) mm 8-4-1000
Overflow valve
131425-1620
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)
Right R
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
Right R
Injection order
1-5-3-6-
2-4
Pre-stroke
mm
3.3
3.25
3.35
Beginning of injection position
Drive side NO.1
Drive 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
A
Rack position
12.7
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
348
343
353
Max. variation between cylinders
%
0
-3
3
Basic
*
Fixing the rack
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
12.2
Pump speed
r/min
750
750
750
Average injection quantity
mm3/st.
304
298
310
Fixing the rack
*
Injection quantity adjustment_03
Adjusting point
C
Rack position
6.8+-0.5
Pump speed
r/min
405
405
405
Average injection quantity
mm3/st.
8.5
7
10
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Injection quantity adjustment_04
Adjusting point
E
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
405
395
415
Fixing the lever
*
Rack limit
*
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Minimum - maximum speed specification
(2)Target notch: K
(3)Tolerance for racks not indicated: +-0.05mm.
(4)RACK LIMIT
(5)Load lever stop (with the speed lever at full)
(6)Variable speed specification: idling adjustment
(7)Set idle sub-spring
(8)Main spring setting
----------
K=18
----------
----------
K=18
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Set the pump speed at aa
(2)Set the pump speed at bb.
(3)Stopper bolt setting
----------
aa=750r/min bb=900r/min
----------
a=10deg+-5deg b=14deg+-5deg c=28deg+-5deg
----------
aa=750r/min bb=900r/min
----------
a=10deg+-5deg b=14deg+-5deg c=28deg+-5deg
0000000901
F:Full load
I:Idle
S:Stop
(1)Use the hole at R = aa
----------
aa=27mm
----------
a=26.5deg+-5deg b=29deg+-5deg c=53deg+-5deg
----------
aa=27mm
----------
a=26.5deg+-5deg b=29deg+-5deg c=53deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(10deg)
----------
----------
a=(10deg)
Information:
Caterpillar Diesel Engines can operate effectively in cold weather. However, engine starting and operation in cold weather is dependent on the type of fuel used (and how well the fuel moves through fuel related components), oil viscosity and other optional starting aids. The purpose of this section is to explain potential problems and steps which can be taken to minimize starting and operation problems when the ambient air temperature is colder than 5°C (40°F).Fuel and the Effect from Cold Weather
The two types of diesel fuel recommended for your engine are grades No. 1 and No. 2. Although No. 2 diesel fuel is the most commonly used fuel, No. 1 diesel fuel or a blend of No. 1 and No. 2, is the fuel that is best suited for cold weather operation.During cold weather operation, it may be necessary for you to use No. 2 diesel fuel since quantities of No. 1 diesel fuel are limited and generally are only available in certain areas.There are three major differences between No. 1 and No. 2 diesel fuel.* No. 1 diesel fuel has a lower cloud point. The cloud point is the temperature at which a cloud or haze of wax crystals will begin to form in the fuel and cause fuel filters to plug.* No. 1 diesel fuel has a lower pour point. The pour point is the temperature which diesel fuel will begin to thicken and be more resistant to flow through fuel pumps and lines.* No. 1 diesel fuel has a lower BTU (kJ) (heat content) rating per unit volume of fuel than the average No. 2 diesel fuel. When using No. 1 diesel fuel, you may notice a drop in power and fuel efficiency, but should not experience any other operating effects. Before troubleshooting for low power or poor performance in winter months, check the type of fuel being used.Be aware of these fuel values when purchasing your diesel fuel and anticipate the average outside (ambient) temperature for the area your engine will be operating. Engines fueled in one climate may not operate satisfactorily if moved to another because of problems that result from cold weather.Attachments are available from your Caterpillar dealer to minimize cold weather starting and operation problems. The use of starting aids, engine oil pan heaters, engine coolant heaters, fuel heaters and fuel line insulation also provide a means of minimizing starting and fuel problems in cold weather when No. 2 diesel fuel is used.For further information on cylinder block (coolant) heaters, contact your Caterpillar dealer. The average No. 1 diesel fuel has a lower kJ (BTU) (heat content) rating per unit volume of fuel than the average No. 2 diesel fuel. When using No. 1 diesel fuel, you may notice a drop in power and fuel efficiency, but should not experience any other operating effects.Fuel Related Components in Cold Weather
Fuel Tanks
Store the fuel outside to allow water (condensation) to freeze after separation from the fuel and to indicate any immediate temperature affect on
The two types of diesel fuel recommended for your engine are grades No. 1 and No. 2. Although No. 2 diesel fuel is the most commonly used fuel, No. 1 diesel fuel or a blend of No. 1 and No. 2, is the fuel that is best suited for cold weather operation.During cold weather operation, it may be necessary for you to use No. 2 diesel fuel since quantities of No. 1 diesel fuel are limited and generally are only available in certain areas.There are three major differences between No. 1 and No. 2 diesel fuel.* No. 1 diesel fuel has a lower cloud point. The cloud point is the temperature at which a cloud or haze of wax crystals will begin to form in the fuel and cause fuel filters to plug.* No. 1 diesel fuel has a lower pour point. The pour point is the temperature which diesel fuel will begin to thicken and be more resistant to flow through fuel pumps and lines.* No. 1 diesel fuel has a lower BTU (kJ) (heat content) rating per unit volume of fuel than the average No. 2 diesel fuel. When using No. 1 diesel fuel, you may notice a drop in power and fuel efficiency, but should not experience any other operating effects. Before troubleshooting for low power or poor performance in winter months, check the type of fuel being used.Be aware of these fuel values when purchasing your diesel fuel and anticipate the average outside (ambient) temperature for the area your engine will be operating. Engines fueled in one climate may not operate satisfactorily if moved to another because of problems that result from cold weather.Attachments are available from your Caterpillar dealer to minimize cold weather starting and operation problems. The use of starting aids, engine oil pan heaters, engine coolant heaters, fuel heaters and fuel line insulation also provide a means of minimizing starting and fuel problems in cold weather when No. 2 diesel fuel is used.For further information on cylinder block (coolant) heaters, contact your Caterpillar dealer. The average No. 1 diesel fuel has a lower kJ (BTU) (heat content) rating per unit volume of fuel than the average No. 2 diesel fuel. When using No. 1 diesel fuel, you may notice a drop in power and fuel efficiency, but should not experience any other operating effects.Fuel Related Components in Cold Weather
Fuel Tanks
Store the fuel outside to allow water (condensation) to freeze after separation from the fuel and to indicate any immediate temperature affect on