Information injection-pump assembly
BOSCH
9 400 611 015
9400611015
ZEXEL
106871-3700
1068713700
Rating:
Service parts 106871-3700 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
23600-1530
12.
Open Pre:MPa(Kqf/cm2)
18.1{185}
15.
NOZZLE SET
Include in #1:
106871-3700
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
9 400 611 015
9400611015
ZEXEL
106871-3700
1068713700
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
105780-8140
Bosch type code
EF8511/9A
Nozzle
105780-0000
Bosch type code
DN12SD12T
Nozzle holder
105780-2080
Bosch type code
EF8511/9
Opening pressure
MPa
17.2
Opening pressure
kgf/cm2
175
Injection pipe
Outer diameter - inner diameter - length (mm) mm 8-3-600
Outer diameter - inner diameter - length (mm) mm 8-3-600
Overflow valve
134424-1020
Overflow valve opening pressure
kPa
127
107
147
Overflow valve opening pressure
kgf/cm2
1.3
1.1
1.5
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
1-8-6-2-
7-5-4-3
Pre-stroke
mm
4.4
4.34
4.4
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-8 deg. 45 44.75 45.25
Cal 1-8 deg. 45 44.75 45.25
Difference between angles 2
Cal 1-6 deg. 90 89.75 90.25
Cal 1-6 deg. 90 89.75 90.25
Difference between angles 3
Cyl.1-2 deg. 135 134.75 135.25
Cyl.1-2 deg. 135 134.75 135.25
Difference between angles 4
Cal 1-7 deg. 180 179.75 180.25
Cal 1-7 deg. 180 179.75 180.25
Difference between angles 5
Cal 1-5 deg. 225 224.75 225.25
Cal 1-5 deg. 225 224.75 225.25
Difference between angles 6
Cal 1-4 deg. 270 269.75 270.25
Cal 1-4 deg. 270 269.75 270.25
Difference between angles 7
Cal 1-3 deg. 315 314.75 315.25
Cal 1-3 deg. 315 314.75 315.25
Injection quantity adjustment
Adjusting point
B
Rack position
10.2
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
132.5
130.5
134.5
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
C
Rack position
5.6+-0.5
Pump speed
r/min
360
360
360
Average injection quantity
mm3/st.
8
5
11
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Injection quantity adjustment_03
Adjusting point
D
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
110
110
130
Fixing the lever
*
Timer adjustment
Pump speed
r/min
900--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
850
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
1000
Advance angle
deg.
1.7
1.2
2.2
Timer adjustment_04
Pump speed
r/min
-
Advance angle
deg.
3.5
3.5
3.5
Remarks
Measure the actual speed, stop
Measure the actual speed, stop
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
----------
K=7
----------
----------
K=7
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=3deg+-5deg b=28deg+-5deg
----------
----------
a=3deg+-5deg b=28deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Rack position aa or less, pump speed bb
----------
aa=5.1mm bb=0r/min
----------
a=26.5deg+-5deg b=53deg+-5deg
----------
aa=5.1mm bb=0r/min
----------
a=26.5deg+-5deg b=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=(80deg)
----------
----------
a=(80deg)
Information:
Safety Section
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products.Dispose of all fluids according to local regulations and mandates.
Illustration 1 g00104545Prevent the machine from movement. Park the machine on a level surface.Attach a "Do Not Operate" warning tag or a similar warning tag to the start switch or to the controls before you service the equipment. These warning tags (Special Instruction, SEHS7332) are available from your Caterpillar dealer.Required Parts
Table 1 contains the parts needed to complete the installation of the new DEF filter.Note: Only one DEF filter group is required per engine. Use Table 2 to determine which filter is the appropriate filter for each DEF header. Illustration 2 shows the location of the DEF header part number.
Table 1
Part Number Part Description Qty
378-3187 Diesel Exhaust Fluid Filter Gp 1
423-3251 Connector 1
391-5262 Gasket 1
425-0385 Filter As 1
452-6055 Filter Base As 1
453-1604(1) Diesel Exhaust Fluid Filter Gp 1
453-1605(1) Diesel Exhaust Fluid Filter Gp 1
453-1606(1) Diesel Exhaust Fluid Filter Gp 1
(1) Use Table 2 to choose the correct part that corresponds to the DEF header
Illustration 2 g03745839
(1) Location of DEF heater part number
Table 2
DEF Heater Part Number Required DEF Filter
434-3241 453-1604
434-3242 453-1605
434-3243 453-1606 Installation Procedure
Ensure that the area around the DEF heater is clean and free from debris.
Remove manifold DEF heater from DEF tank. Refer to Disassembly and Assembly, Manifold (DEF Heater) - Remove and Install for the correct procedure.
Illustration 3 g06013988
Typical example
Position filter base assembly (3) to DEF heater (2). Install screws (1) to filter base assembly (3). Tighten the self-tapping screws (1) securely.Note: Each half of the adapter has two small locking tabs that secure to the bottom side of the DEF heater.
Remove existing filter from the pickup pipe on manifold DEF heater. Refer to Disassembly and Assembly, Manifold (DEF Heater) - Remove and Install for the correct procedure.
Install a new filter to the pickup pipe on manifold DEF heater. Refer to Disassembly and Assembly, Manifold (DEF Heater) - Remove and Install for the correct procedure.
Illustration 4 g06013992
Typical example
Position the correct DEF filter (5) to the filter base assembly (3). Install band clamp (4). Tighten the band clamp to a torque
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products.Dispose of all fluids according to local regulations and mandates.
Illustration 1 g00104545Prevent the machine from movement. Park the machine on a level surface.Attach a "Do Not Operate" warning tag or a similar warning tag to the start switch or to the controls before you service the equipment. These warning tags (Special Instruction, SEHS7332) are available from your Caterpillar dealer.Required Parts
Table 1 contains the parts needed to complete the installation of the new DEF filter.Note: Only one DEF filter group is required per engine. Use Table 2 to determine which filter is the appropriate filter for each DEF header. Illustration 2 shows the location of the DEF header part number.
Table 1
Part Number Part Description Qty
378-3187 Diesel Exhaust Fluid Filter Gp 1
423-3251 Connector 1
391-5262 Gasket 1
425-0385 Filter As 1
452-6055 Filter Base As 1
453-1604(1) Diesel Exhaust Fluid Filter Gp 1
453-1605(1) Diesel Exhaust Fluid Filter Gp 1
453-1606(1) Diesel Exhaust Fluid Filter Gp 1
(1) Use Table 2 to choose the correct part that corresponds to the DEF header
Illustration 2 g03745839
(1) Location of DEF heater part number
Table 2
DEF Heater Part Number Required DEF Filter
434-3241 453-1604
434-3242 453-1605
434-3243 453-1606 Installation Procedure
Ensure that the area around the DEF heater is clean and free from debris.
Remove manifold DEF heater from DEF tank. Refer to Disassembly and Assembly, Manifold (DEF Heater) - Remove and Install for the correct procedure.
Illustration 3 g06013988
Typical example
Position filter base assembly (3) to DEF heater (2). Install screws (1) to filter base assembly (3). Tighten the self-tapping screws (1) securely.Note: Each half of the adapter has two small locking tabs that secure to the bottom side of the DEF heater.
Remove existing filter from the pickup pipe on manifold DEF heater. Refer to Disassembly and Assembly, Manifold (DEF Heater) - Remove and Install for the correct procedure.
Install a new filter to the pickup pipe on manifold DEF heater. Refer to Disassembly and Assembly, Manifold (DEF Heater) - Remove and Install for the correct procedure.
Illustration 4 g06013992
Typical example
Position the correct DEF filter (5) to the filter base assembly (3). Install band clamp (4). Tighten the band clamp to a torque