106871-2083 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1068712083 me066429

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106871-2083 1068712083

MITSUBISHI ME066429 me066429

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Cross reference number

ZEXEL 106871-2083 1068712083

MITSUBISHI ME066429 me066429

Zexel num

Bosch num

Firm num

Name

106871-2083

ME066429 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 *

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+3+2.8mm DL=6.5-0.2mm
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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=600r/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=25.5deg+-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:

PARTS NEEDED
Qty
Part Number Description
2 5P4115 WASHER-HARD
2 6S8620 CLAMP-HOSE
4 8T4121 WASHER-HARD
2 8T4171 BOLT-HEX HEAD
2 8T4195 BOLT-HEX HEAD
1 3550632 CONNECTOR-SPL
1 4609257 INJECTOR AS-DEF
1 4719926 TANK AS-ALUMINUM
1 4719927 PLATE AS
2 4719928 PLATE AS
9 4721116 HOSE-BULK (9cm)
1 5218238 SFWR GP-A1000
1 BULK_COOLANT COOLANT - See Action Required
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 7% 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
1. Replace the DEF Injector, As per the Disassembly and Assembly, "DEF Injector and Mounting - Remove and Install". Please ensure that the coolant drained from the system is stored in a suitable storage container and not refilled until the end of the following procedure.
2. Position bracket assembly 471-9927 onto the CEM. Ensure that the bracket is correctly orientated. As per Image 1
3. Position the two 471-9928 plates onto the CEM and install 8T-4195 bolts with the 8T-4121 washers. As per Image 2
4. Position coolant tank 471-9926 onto bracket. Install bolts 8T-4171 with 5P-4115 washer. Tighten to 9 Nm. As per Image 1
5. Remove coolant supply hose 349-6234 from DEF injector and connect to tank 471-9926 inlet using existing clamp. As per Image 1
6. Connect hose assembly 472-1116 (9cm) to tank 471-9926 and the DEF injector. Secure with 2 off 6S?8620 clamps, As per Image 1
7. Refill the cooling system with coolant. Refer to Operation and Maintenance Manual, ?Cooling System Coolant - Change? for the correct procedure. If required, top up the coolant system.
8. Flash the engine ECM with the software or latest available in SIS Web.
For flash programming the engine ECM, refer to Troubleshooting, "Flash Programming".
Image1
Image2
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
0-3000 hrs,
0-36 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 2.5-hour job
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.