Information injection-pump assembly
BOSCH
9 400 611 470
9400611470
ZEXEL
106682-9771
1066829771

Rating:
Service parts 106682-9771 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
6212-11-3202
12.
Open Pre:MPa(Kqf/cm2)
24.5{250}
15.
NOZZLE SET
Include in #1:
106682-9771
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
9 400 611 470
9400611470
ZEXEL
106682-9771
1066829771
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
3.5
3.45
3.55
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
13.4
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
315
312
318
Max. variation between cylinders
%
0
-3
3
Basic
*
Fixing the lever
*
Boost pressure
kPa
58.7
58.7
Boost pressure
mmHg
440
440
Remarks
Standard point A's rack position same as row R
Standard point A's rack position same as row R
Injection quantity adjustment_02
Adjusting point
C
Rack position
8+-0.5
Pump speed
r/min
360
360
360
Average injection quantity
mm3/st.
16
14.5
17.5
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Boost compensator adjustment
Pump speed
r/min
1000
1000
1000
Rack position
10.9
Boost pressure
kPa
4
1.3
6.7
Boost pressure
mmHg
30
10
50
Boost compensator adjustment_02
Pump speed
r/min
1000
1000
1000
Rack position
13.4
Boost pressure
kPa
45.3
38.6
52
Boost pressure
mmHg
340
290
390
Test data Ex:
Governor adjustment

N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)Tolerance for racks not indicated: +-0.05mm.
(3)RACK LIMIT for 106684-4301
(4)Set the No 1 idle sub spring.
(5)Set the 2nd idle sub spring.
(6)Boost compensator stroke: BCL
(7)Rack difference between N = N1 and N = N2
----------
K=23 BCL=2.5+-0.1mm N1=1000r/min N2=700r/min
----------
----------
K=23 BCL=2.5+-0.1mm N1=1000r/min N2=700r/min
----------
Speed control lever angle

F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=35deg+-5deg b=26deg+-5deg
----------
----------
a=35deg+-5deg b=26deg+-5deg
Stop lever angle

N:Pump normal
S:Stop the pump.
(1)Pump speed aa and rack position bb (to be sealed at delivery)
(2)Normal
----------
aa=0r/min bb=1-0.5mm
----------
a=29deg+-5deg b=(73deg)
----------
aa=0r/min bb=1-0.5mm
----------
a=29deg+-5deg b=(73deg)
Timing setting

(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(30deg)
----------
----------
a=(30deg)
Information:
Commercial Oils
If oils other than Caterpillar oils are used, the following oil specifications provide guidelines for the selection of commercial products.* API specifications CF-4, CF-4/SF, or CF-4/SG
Failure to follow the commercial oil recommendation for API CF-4 performance oils can cause shortened engine life due to piston carbon deposits, liner bore polish and/or abnormally higher increasing oil consumption.API CC and CD oils are unacceptable in this Caterpillar diesel engine.
Lubricant Viscosity Recommendations
The proper SAE grade of oil to select is determined by the minimum outside temperature at which the engine will be started and the maximum outside temperature in which the engine will be operating. This recommendation is to ensure the correct viscosity is used until the next oil change.The recommendation would be to use the highest viscosity oil possible. Even though the ambient temperature may be low, operating engines can still be subjected to normal oil temperatures because of regulated temperature components. The higher viscosity oils will provide better protection to all components which it contacts during the full operating cycle.The use of API CF-4 multi-viscosity oils is recommended because of full protection through a wider temperature range. See chart for recommended viscosity and temperature range.To determine if the oil in the crankcase will flow in cold weather, remove the oil dipstick before starting. If the oil will flow off, the oil is fluid enough to circulate properly. Air Starting Motor Oiler
A lubricator should be used with the starting system.* Use 10 weight non-detergent engine oil above 0°C (32°F) or* diesel fuel or kerosene at temperatures below 0°C (32°F).Lubricant Total Base Number (TBN)
New engine oil must have a TBN of 10 times (for direct injection engines) the percent fuel sulfur as measured by ASTM (American Society of Testing Materials) D2896 method. Refer to the Fuel Specifications in this manual for additional information. Additional Notes
The percentage of sulfur in the fuel will affect the engine oil recommendations. For fuel sulfur effects, the Infrared Analysis or the ASTM D2896 procedure can be used to evaluate the residual neutralization properties of an engine oil. The sulfur products formation depends on the fuel sulfur content, oil formulation, crankcase blowby, engine operating conditions and ambient temperature.The fuel sulfur neutralization of today's new oil formulations along with direct injection (DI) system engines are more effective. Field results indicate that direct injection combustion (DI) systems and the oils now recommended for these engines will operate at an oil TBN equal to 10 times the fuel sulfur. Therefore, the Caterpillar requirements reflect this value of 10 times instead of the previous 20 times for oil TBN when related to fuel sulfur for Cat DI engines and API CF-4 oils. Used oil analysis should be a part of the overall program to provide the assurance that a particular engine installation with all its parameters (engine, oil, operation, maintenance and fuel) are under control. Consult with your Caterpillar dealer for the latest lubrication recommendations.Synthetic Base Stock Oils (SPC)
The performance characteristics of the oil depends on the base oil and
If oils other than Caterpillar oils are used, the following oil specifications provide guidelines for the selection of commercial products.* API specifications CF-4, CF-4/SF, or CF-4/SG
Failure to follow the commercial oil recommendation for API CF-4 performance oils can cause shortened engine life due to piston carbon deposits, liner bore polish and/or abnormally higher increasing oil consumption.API CC and CD oils are unacceptable in this Caterpillar diesel engine.
Lubricant Viscosity Recommendations
The proper SAE grade of oil to select is determined by the minimum outside temperature at which the engine will be started and the maximum outside temperature in which the engine will be operating. This recommendation is to ensure the correct viscosity is used until the next oil change.The recommendation would be to use the highest viscosity oil possible. Even though the ambient temperature may be low, operating engines can still be subjected to normal oil temperatures because of regulated temperature components. The higher viscosity oils will provide better protection to all components which it contacts during the full operating cycle.The use of API CF-4 multi-viscosity oils is recommended because of full protection through a wider temperature range. See chart for recommended viscosity and temperature range.To determine if the oil in the crankcase will flow in cold weather, remove the oil dipstick before starting. If the oil will flow off, the oil is fluid enough to circulate properly. Air Starting Motor Oiler
A lubricator should be used with the starting system.* Use 10 weight non-detergent engine oil above 0°C (32°F) or* diesel fuel or kerosene at temperatures below 0°C (32°F).Lubricant Total Base Number (TBN)
New engine oil must have a TBN of 10 times (for direct injection engines) the percent fuel sulfur as measured by ASTM (American Society of Testing Materials) D2896 method. Refer to the Fuel Specifications in this manual for additional information. Additional Notes
The percentage of sulfur in the fuel will affect the engine oil recommendations. For fuel sulfur effects, the Infrared Analysis or the ASTM D2896 procedure can be used to evaluate the residual neutralization properties of an engine oil. The sulfur products formation depends on the fuel sulfur content, oil formulation, crankcase blowby, engine operating conditions and ambient temperature.The fuel sulfur neutralization of today's new oil formulations along with direct injection (DI) system engines are more effective. Field results indicate that direct injection combustion (DI) systems and the oils now recommended for these engines will operate at an oil TBN equal to 10 times the fuel sulfur. Therefore, the Caterpillar requirements reflect this value of 10 times instead of the previous 20 times for oil TBN when related to fuel sulfur for Cat DI engines and API CF-4 oils. Used oil analysis should be a part of the overall program to provide the assurance that a particular engine installation with all its parameters (engine, oil, operation, maintenance and fuel) are under control. Consult with your Caterpillar dealer for the latest lubrication recommendations.Synthetic Base Stock Oils (SPC)
The performance characteristics of the oil depends on the base oil and