106871-2022 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1068712022 me066127

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106871-2022 1068712022

MITSUBISHI ME066127 me066127

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Service parts 106871-2022 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106087-5192

3. GOVERNOR 105487-0470

4. SUPPLY PUMP 105207-1051

5. AUTOM. ADVANCE MECHANIS 105636-0460

6. COUPLING PLATE 105663-0260

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-4761

11. Nozzle and Holder 31261-30020

12. Open Pre:MPa(Kqf/cm2) 21.6{220}

13. NOZZLE-HOLDER 105031-3522

14. NOZZLE

105015-4370

15. NOZZLE SET

Include in #1:

106871-2022 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106871-2022 1068712022

MITSUBISHI ME066127 me066127

Zexel num

Bosch num

Firm num

Name

106871-2022

ME066127 MITSUBISHI

INJECTION-PUMP ASSEMBLY
8DC9 *

Calibration Data:

Adjustment conditions

Test oil
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

Overflow valve 134424-1320

Overflow valve opening pressure kPa 157 123 191

Overflow valve opening pressure kgf/cm2 1.6 1.25 1.95

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

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-2-7-3- 4-5-6-8

Pre-stroke mm 4.8 4.75 4.85

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cyl.1-2 deg. 45 44.5 45.5

Difference between angles 2
Cal 1-7 deg. 90 89.5 90.5

Difference between angles 3
Cal 1-3 deg. 135 134.5 135.5

Difference between angles 4
Cal 1-4 deg. 180 179.5 180.5

Difference between angles 5
Cal 1-5 deg. 225 224.5 225.5

Difference between angles 6
Cal 1-6 deg. 270 269.5 270.5

Difference between angles 7
Cal 1-8 deg. 315 314.5 315.5

Injection quantity adjustment

Adjusting point -

Rack position 9.7

Pump speed r/min 700 700 700

Each cylinder's injection qty mm3/st. 105 102 108

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point C

Rack position 6.7+-0.5

Pump speed r/min 200 200 200

Each cylinder's injection qty mm3/st. 18.5 15.7 21.3

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point B

Rack position R1(9.7)

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 116 111.4 120.6

Difference in delivery mm3/st. 9.2 9.2 9.2

Fixing the lever *

Injection quantity adjustment_04

Adjusting point A

Rack position R1(9.7)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 105 104 106

Fixing the lever *

Injection quantity adjustment_05

Adjusting point E

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 135 115 155

Fixing the lever *

Remarks
After startup boost setting

Timer adjustment

Pump speed r/min 600+-50

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 700

Advance angle deg. 0.7 0.2 1.2

Timer adjustment_03

Pump speed r/min 850

Advance angle deg. 2 1.5 2.5

Timer adjustment_04

Pump speed r/min 1000

Advance angle deg. 3.6 3.1 4.1

Timer adjustment_05

Pump speed r/min 1150

Advance angle deg. 5.5 5 6

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Adjust with speed control lever at full position (minimum-maximum speed specification) (2)Adjust with the load control lever in the full position (variable speed specification). (3)Excess fuel setting for starting: SXL (4)Beginning of damper spring operation: DL
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SXL=R1+0.2mm DL=5-0.2mm
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Speed control lever angle

(1)Set the pump speed at aa (2)Set the pump speed at bb.
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aa=1150r/min bb=690r/min
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a=21deg+-5deg b=15deg+-5deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting
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a=10deg+-5deg b=27deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump.
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a=10deg+-5deg b=64deg+-5deg

0000001501 2-STAGE CHANGEOVER DEVICE

RFD governor 2 stage changeover mechanism adjustment outline (A) Bolt (B) bolt (c) Nut (D) Return spring (E) Bolt (F) Bolt (G) Screw (H) Bolt (I) Load lever (J) Speed lever (K) Air cylinder (M Air inlet Figure 1 is only for reference. Lever shape, etc, may vary. 1. Minimum-maximum speed specification adjustment (when running) (a) Without applying air to the air cylinder, loosen bolts (A) and (B). (1)High speed return L setting (a) In the speed range Nf~Nf - 300r/min, adjust using the speed adjusting bolt to determine the temporary beginning of high speed control speed. (b) Determine the rack position in the vicinity of Rf using the full load lever. (c) Increase speed and confirm return distance L. (d) Adjust using the tension lever bolt to obtain L. (2)Setting full load rack position Rf (a) Move the load control lever to the full side. (b) Adjust the full load adjusting bolt so that Rf can be obtained, then fix. (3)Setting the beginning of high speed operation Nf (a) Adjust using bolt (E) so that Nf can be obtained, and then fix. (4)Idle control setting (Re, Ni, Rc) (a) Set the speed at Ns + 200r/min and move the load control lever to the idle side. (b) Fix the lever in the position where Re can be obtained. (c) Next, decrease speed to Ni and screw in the idle spring. (d) Adjust to obtain rack position Ri. (e) Increase the speed and after confirming that the rack position is Re at Ns, set the speed at 0. (f) Confirm protrusion position Rc at idle. (5)Damper spring adjustment (a) Increase speed and set the speed at the rack position Rd - 0.1 mm (b) Set using the damper spring so that the rack position Rd can be obtained. (c) When Rd is not specified, Rd = Ri - 0.5 mm. (6)High speed droop confirmation (a) Return the load control lever to the full load lever position. (b) Increase the speed and confirm that Rf can be obtained at Nf r/min. (c) Confirm that speed is Nh at rack position Rh. 2. Variable speed specification adjustment (at operation) (a) Remove return spring (D). (b) Apply air pressure of 245~294 kPa {2.5~3 kg/cm2} to the air cylinder. (c) Perform the following adjustment in this condition. (1)Setting full load rack position Rf' (a) Pull the load lever to the idle side. (b) Obtain rack position Rf' using the nut (C). (Pump speed is Nf'-50 r/min.) (2)Setting full speed Nf' (a) Adjust using bolt (B) so that Nf can be obtained, and then fix. (3)Low speed side setting (a) At 350r/min, set bolt (F) at beginning of governor operation position, then fix. 3. Bolt (A) adjustment (1)Install return spring (D) and perform the adjustments below at air pressure 0. (a) Set at speed Nf using bolt (E). (b) Screw in bolt (A). (c) Screw in 1 more turn from the speed lever contact position (d) Fix bolt (A). (e) At this time confirm that the air cylinder's shaft moves approximately 1 mm towards the governor. 4. Lever operation confirmation using the air cylinder (1)Apply 588 kPa {6 kg/cm2} air pressure to the air cylinder. (2)Confirm that the cylinder piston is moved 50 mm by the spring (D).
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0000001601 MICRO SWITCH

Adjustment of the micro-switch Adjust the bolt to obtain the following lever position when the micro-switch is ON. (1)Speed N1 (2)Rack position Ra
----------
N1=325+-5r/min Ra=6.3mm
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Information:

TERMINATION DATE
31Dec2020
PROBLEM
Certain CB64B, CB13, CB66B, CB15, CB68B, CB16 Asphalt Compactors may have a problem with the DEF injector 459-7216. The internal seals within the DEF Injector may fail and allow DEF to leak into the injectors electrical connector housing. Once DEF enters the electrical housing and contacts the electrical pins a DEF Dosing current fault is triggered. This is usually accompanied by an external DEF leak being seen in and around the injectors electrical connector. DEF Dosing Unit/Actuator Diagnostic Trouble Codes (3361/3821) can be triggered which can lead to a system inducement.
AFFECTED PRODUCT
Model Identification Number
CB13 PWP00113-00218
CB15 M9400110-00144
CB16 HP500101-00105
CB64B C5600120, 122, 124, 126, 128, 133, 140, 143-144, 147-149, 151-152, 157, 159-161, 164, 166, 168-172, 175-177, 180-181, 192-193, 195, 199-201, 205, 208, 214-215, 222, 224, 233-234, 244, 247, 249, 254-255, 260, 268, 272, 275, 279, 283, 286, 289, 292-293, 297-299, 303, 307, 309, 312, 319, 321, 329-334, 337-338, 342-343, 348, 355-357, 360, 367, 370, 375-376, 378, 381, 386, 390, 394, 398-399, 401, 406, 408, 410, 412-414, 416, 419-420, 425-426, 429, 431, 433, 437-438
CB66B B6600101, 104, 106-108, 114, 116, 119-120, 124, 126-127, 129, 132, 135, 137-138, 141-144, 146-148, 150-151, 155, 157-158, 170-171, 179-180, 185-186, 189, 192-193, 203-204, 206-208, 211-212, 216, 229-232, 235-236, 238-240, 243-244, 246, 256, 261-263, 268, 271, 275, 278-279, 282, 284, 289-290, 292, 297-298, 305-306, 308-309, 313, 315-317
CB68B C6800101-00102, 105, 108-110, 114, 117-123, 126, 129, 131, 141, 146, 148
PARTS NEEDED
Qty
Part Number Description
1 4716029 MTG GP-INJECTOR
1 ENGSOFTWARE ENGINE SOFTWARE
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 1% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.
ACTION REQUIRED
If the engine software is not the latest version, update the Engine Software first.
If needed, update the engine software with the latest available in SIS Web.
For flash programming of the ECM software, refer to Troubleshooting "ECM Software - Install".
Ensure the appropriate steps have been followed when diagnosing a DEF injector failure. Refer to UENR0662.
If it is determined that replacement of DEF injector is required, refer to Disassembly and Assembly Manual - Diesel Exhaust Fluid Injector - Remove and Install.
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
0-5000 hrs,
0-60 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 3.0-hour job
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.