Information injection-pump assembly
BOSCH
9 400 612 760
9400612760
ZEXEL
106684-4411
1066844411
Rating:
Service parts 106684-4411 INJECTION-PUMP ASSEMBLY:
1.
_
3.
GOVERNOR
5.
AUTOM. ADVANCE MECHANIS
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
6215-11-3700
12.
Open Pre:MPa(Kqf/cm2)
24.5{250}
15.
NOZZLE SET
Include in #1:
106684-4411
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
9 400 612 760
9400612760
ZEXEL
106684-4411
1066844411
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
255
255
255
Tester oil delivery pressure
kgf/cm2
2.6
2.6
2.6
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.
328
325
331
Max. variation between cylinders
%
0
-3
3
Basic
*
Fixing the rack
*
Remarks
Standard point A's rack position same as row L
Standard point A's rack position same as row L
Injection quantity adjustment_02
Adjusting point
-
Rack position
7.2+-0.5
Pump speed
r/min
400
400
400
Average injection quantity
mm3/st.
8.5
7
10
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Injection quantity adjustment_03
Remarks
Rack limit set at R = 14.1+0.2.
Rack limit set at R = 14.1+0.2.
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:
You must read and understand the warnings and instructions contained in the Safety section of this manual before performing any operation or maintenance procedures.Engine Compartment
Walk-Around Inspection
Inspect Engine for Leaks and Loose Connections
For maximum service life of your truck engine, make a thorough under the hood inspection before starting the engine. Look for such items as oil or coolant leaks, loose bolts, worn fan and accessory drive belts, loose connections and trash build-up. Remove trash build-up and have repairs made as needed. Check the fluid levels more frequently than the recommended maintenance intervals and continue to monitor fluid levels until any leak is found and fixed.* Wipe all fittings, caps and plugs before performing maintenance to reduce the chance of system contamination.* Inspect all lines, tubes and hoses carefully. Do not use your bare hands to check for leaks. Tighten all connections to the recommended torque.Inspect:* Radiator and ATAAC core for leaks and trash build-up.* Radiator and ATAAC air intake system hoses and elbows for cracks and loose clamps (especially in arctic conditions).* Fan and accessory drive belts for cracks, breaks or other damage (especially in arctic conditions). Inspect:* Water pump for coolant leaks. The water pump seal is lubricated by coolant and it is normal for a small amount of leakage to occur as the engine cools down and parts contract. If leaks are found, check the coolant level frequently and continue to monitor the level until the water pump is repaired. Excessive coolant leakage may indicate the need to replace the water pump seal. For removal and installation of water pumps and/or seals, see the Service Manual for this engine or consult Caterpillar.Inspect:* Lube system for leaks, such as front and rear crankshaft seals, oil pan, oil filters and valve covers.* Fuel system for leaks, loose fuel line fittings and loose or worn hoses.* Engine wiring and harnesses for loose connections and worn or frayed wires (especially in arctic conditions).* Engine electrical grounding system for good connections and condition. Some vehicles will use a starter to battery ground strap. If a starting motor change is made, consult Caterpillar to make sure that the proper grounding procedures are followed for that model starting motor.* All guards must be in place. Repair or replace missing or damaged guards.Engine Crankcase
Make sure you read and understand the information in the Safety and Lubricant Specifications sections of this Manual before you proceed with maintenance of the crankcase lube oil system.
Check Oil Level
The vehicle must be parked on a level surface to perform this maintenance procedure.
1. Check the oil level with the engine stopped. DO NOT check the oil level with the engine running. Refer to the Refill Capacities chart for the proper amount of oil at oil change time to determine the correct position on the dipstick for your application. If more oil than the specified Refill Capacity is required to reach the OPERATING RANGE (FULL) mark, consult Caterpillar. DO NOT OVERFILL above the OPERATING RANGE (FULL) mark on
Walk-Around Inspection
Inspect Engine for Leaks and Loose Connections
For maximum service life of your truck engine, make a thorough under the hood inspection before starting the engine. Look for such items as oil or coolant leaks, loose bolts, worn fan and accessory drive belts, loose connections and trash build-up. Remove trash build-up and have repairs made as needed. Check the fluid levels more frequently than the recommended maintenance intervals and continue to monitor fluid levels until any leak is found and fixed.* Wipe all fittings, caps and plugs before performing maintenance to reduce the chance of system contamination.* Inspect all lines, tubes and hoses carefully. Do not use your bare hands to check for leaks. Tighten all connections to the recommended torque.Inspect:* Radiator and ATAAC core for leaks and trash build-up.* Radiator and ATAAC air intake system hoses and elbows for cracks and loose clamps (especially in arctic conditions).* Fan and accessory drive belts for cracks, breaks or other damage (especially in arctic conditions). Inspect:* Water pump for coolant leaks. The water pump seal is lubricated by coolant and it is normal for a small amount of leakage to occur as the engine cools down and parts contract. If leaks are found, check the coolant level frequently and continue to monitor the level until the water pump is repaired. Excessive coolant leakage may indicate the need to replace the water pump seal. For removal and installation of water pumps and/or seals, see the Service Manual for this engine or consult Caterpillar.Inspect:* Lube system for leaks, such as front and rear crankshaft seals, oil pan, oil filters and valve covers.* Fuel system for leaks, loose fuel line fittings and loose or worn hoses.* Engine wiring and harnesses for loose connections and worn or frayed wires (especially in arctic conditions).* Engine electrical grounding system for good connections and condition. Some vehicles will use a starter to battery ground strap. If a starting motor change is made, consult Caterpillar to make sure that the proper grounding procedures are followed for that model starting motor.* All guards must be in place. Repair or replace missing or damaged guards.Engine Crankcase
Make sure you read and understand the information in the Safety and Lubricant Specifications sections of this Manual before you proceed with maintenance of the crankcase lube oil system.
Check Oil Level
The vehicle must be parked on a level surface to perform this maintenance procedure.
1. Check the oil level with the engine stopped. DO NOT check the oil level with the engine running. Refer to the Refill Capacities chart for the proper amount of oil at oil change time to determine the correct position on the dipstick for your application. If more oil than the specified Refill Capacity is required to reach the OPERATING RANGE (FULL) mark, consult Caterpillar. DO NOT OVERFILL above the OPERATING RANGE (FULL) mark on