106871-2082 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1068712082 me066126

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106871-2082 1068712082

MITSUBISHI ME066126 me066126

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Service parts 106871-2082 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106087-5191

3. GOVERNOR 105487-0960

4. SUPPLY PUMP 105207-1050

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:

106871-2082 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106871-2082 1068712082

MITSUBISHI ME066126 me066126

Zexel num

Bosch num

Firm num

Name

106871-2082
106871-2083

ME066126 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 A

Rack position R1(9.7+- 0.5)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 105 104 106

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1(9.7+- 0.5)

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_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 (5)When air cylinder is operating.
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SXL=R1+0.2mm DL=5-0.2mm
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Speed control lever angle

(1)Pump speed = aa (2)Pump speed = bb (3)Pump speed cc
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aa=1150r/min bb=250r/min cc=610r/min
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a=6deg+-5deg b=8deg+-5deg c=2deg+-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
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N1=325+-5r/min Ra=6.3mm
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Information:

ACTION REQUIRED
Refer to the attached Rework Procedure.
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
0-2000 hrs,
0-24 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 2.0-hour job
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Rework Procedure
Use the procedures on the following pages in order to apply the updates to your machine.
- Park the machine on a firm, level surface.
- Fully retract and lower the boom.
- Place the travel select lever in the (N) NEUTRAL position.
- Apply Park Brake.
- Shut the engine off and remove the key from the MAIN switch located inside the engine compartment.
- Properly disconnect the battery.
- Place a Do Not Operate Tag on both the ignition key-switch and the steering wheel, stating that the machine should not be operated.
- Allow the engine area and antifreeze to cool down.
- Remove the cab rear cover.
- Use all applicable safety precautions while working on, around or under any machinery.
1. Locate DEF coolant supply hose (1) and DEF coolant return hose (2) on the engine. Refer to Image1.2.1.
Image1.2.1
2. Trace the routing of DEF coolant supply hose (1) on the engine to DEF coolant control valve (3) located in the middle of the frame. Refer to Image1.2.1 and 1.3.1.
Image1.3.1
3. Trace the routing of DEF coolant return hose (2) from the engine to DEF tank (4) located behind rear of the cab. Refer to Image1.2.1 and 1.4.1.
Image1.4.1
4. If the routing of DEF coolant supply hose (1) and DEF coolant return hose (2) are found to be correct, remount the cab rear cover and place the unit back in service.
5. If the routing of DEF coolant line (1) and DEF coolant return hose (2) are found to be incorrect, please continue the next steps to correct the DEF coolant line installation.
6. Remove all the cable straps that securing the two DEF coolant lines together or to other hoses. Refer to Image1.6.1. Some of the parts have been removed for clarity. Cut the 610cm of 5P-0767 Hose into two pieces: 330cm and 280cm.
Image1.6.1
7. Taking all precautions to minimize and contain any antifreeze spillage, disconnect DEF coolant supply hose (1) from DEF coolant control valve (3) and from the engine side DEF coolant supply port. The hose will not be reused. Retain the hose clamps for reuse. Refer to Image1.2.1 and 1.4.1.
8. Disconnect DEF coolant return hose (2) from DEF coolant tank (4) and from the engine side DEF coolant return port. The hose will not be reused. Retain the hose clamps for reuse. Refer to Image1.2.1 and 1.6.1.
9. Identify the new DEF coolant supply hose. It is the shorter