Information injection-pump assembly
BOSCH
9 400 611 471
9400611471
ZEXEL
106684-4301
1066844301

Rating:
Service parts 106684-4301 INJECTION-PUMP ASSEMBLY:
1.
_
3.
GOVERNOR
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:
106684-4301
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
9 400 611 471
9400611471
ZEXEL
106684-4301
1066844301
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 rack
*
Remarks
Rack position for N = 1000 is same as standard point A for row L 106682-9771.
Rack position for N = 1000 is same as standard point A for row L 106682-9771.
Injection quantity adjustment_02
Adjusting point
-
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
*
Test data Ex:
Timing setting

(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(150deg)
----------
----------
a=(150deg)
Information:
Burn Prevention
Do not touch any part of an operating engine. Allow the engine to cool before any repair or maintenance is performed on the engine.Relieve all pressure in air, oil, fuel or cooling systems before any lines, fittings or related items are disconnected or removed.Coolant
To prevent personal injury, do not step up on engine to remove the filler cap, if applicable. Use an adequate ladder.At operating temperature, the engine coolant is hot and under pressure. The radiator and all lines to heaters or the engine contain hot water. When pressure is relieved rapidly, this hot water can turn into steam.Allow cooling system components to cool before draining. Any contact with hot water or steam can cause severe burns.Check the coolant level only after the engine has been stopped and the filler cap is cool enough to remove with your bare hand. Remove the cooling system filler cap slowly to relieve pressure.Cooling system supplemental additive contains alkali. To prevent personal injury, avoid contact with the skin and eyes and do not drink.Oils
Hot oil and components can cause personal injury. Do not allow hot oil or components to contact the skin.Batteries
Battery electrolyte contains acid and can cause injury. Avoid contact with the skin and eyes. Wash hands after touching batteries and connectors. Use of gloves is recommended. Always wear protective glasses when working with batteries.Batteries give off flammable fumes which can explode. Always thaw a frozen battery before jump starting. Frozen batteries can explode. Do not smoke when observing the battery electrolyte levels.Fire or Explosion Prevention
Determine whether the engine will be operated in an environment in which combustible gases could be drawn through the air inlet system. These gases could cause the engine to overspeed, which in turn could seriously damage the engine and result in bodily injury or property damage.If your application involves the presence of combustible gases, consult your Caterpillar dealer to obtain additional information concerning protection devices suitable for the application involved.Inhaling freon gas through a lit cigarette or other smoking method, or inhaling fumes released from a flame contacting freon could cause bodily harm or death. Do not smoke when servicing, charging or working around air conditioners or where freon gas may be present.All fuels, most lubricants and some coolant mixtures are flammable. Diesel fuel is flammable. Gasoline is flammable. The mixture of diesel and gasoline fumes are extremely explosive.Do not smoke while refueling or in a refueling area.Do not smoke in areas where batteries are charged, or where flammable materials are stored.Keep all fuels and lubricants stored in properly marked containers and away from all unauthorized persons.Store all oily rags or other flammable material in a protective container, in a safe place.Do not weld or flame cut on pipes or tubes that contain flammable fluids. Clean them thoroughly with nonflammable solvent before welding or flame cutting on them.Remove all flammable materials such as fuel, oil and other debris before they accumulate on the truck engine.Do not expose the engine to flames, burning brush, etc., if
Do not touch any part of an operating engine. Allow the engine to cool before any repair or maintenance is performed on the engine.Relieve all pressure in air, oil, fuel or cooling systems before any lines, fittings or related items are disconnected or removed.Coolant
To prevent personal injury, do not step up on engine to remove the filler cap, if applicable. Use an adequate ladder.At operating temperature, the engine coolant is hot and under pressure. The radiator and all lines to heaters or the engine contain hot water. When pressure is relieved rapidly, this hot water can turn into steam.Allow cooling system components to cool before draining. Any contact with hot water or steam can cause severe burns.Check the coolant level only after the engine has been stopped and the filler cap is cool enough to remove with your bare hand. Remove the cooling system filler cap slowly to relieve pressure.Cooling system supplemental additive contains alkali. To prevent personal injury, avoid contact with the skin and eyes and do not drink.Oils
Hot oil and components can cause personal injury. Do not allow hot oil or components to contact the skin.Batteries
Battery electrolyte contains acid and can cause injury. Avoid contact with the skin and eyes. Wash hands after touching batteries and connectors. Use of gloves is recommended. Always wear protective glasses when working with batteries.Batteries give off flammable fumes which can explode. Always thaw a frozen battery before jump starting. Frozen batteries can explode. Do not smoke when observing the battery electrolyte levels.Fire or Explosion Prevention
Determine whether the engine will be operated in an environment in which combustible gases could be drawn through the air inlet system. These gases could cause the engine to overspeed, which in turn could seriously damage the engine and result in bodily injury or property damage.If your application involves the presence of combustible gases, consult your Caterpillar dealer to obtain additional information concerning protection devices suitable for the application involved.Inhaling freon gas through a lit cigarette or other smoking method, or inhaling fumes released from a flame contacting freon could cause bodily harm or death. Do not smoke when servicing, charging or working around air conditioners or where freon gas may be present.All fuels, most lubricants and some coolant mixtures are flammable. Diesel fuel is flammable. Gasoline is flammable. The mixture of diesel and gasoline fumes are extremely explosive.Do not smoke while refueling or in a refueling area.Do not smoke in areas where batteries are charged, or where flammable materials are stored.Keep all fuels and lubricants stored in properly marked containers and away from all unauthorized persons.Store all oily rags or other flammable material in a protective container, in a safe place.Do not weld or flame cut on pipes or tubes that contain flammable fluids. Clean them thoroughly with nonflammable solvent before welding or flame cutting on them.Remove all flammable materials such as fuel, oil and other debris before they accumulate on the truck engine.Do not expose the engine to flames, burning brush, etc., if