106873-7470 ZEXEL 9 400 618 493 BOSCH INJECTION-PUMP ASSEMBLY 9400618493 1068737470 me094475

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 618 493 9400618493

ZEXEL 106873-7470 1068737470

MITSUBISHI ME094475 me094475

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Cross reference number

BOSCH 9 400 618 493 9400618493

ZEXEL 106873-7470 1068737470

MITSUBISHI ME094475 me094475

Zexel num

Bosch num

Firm num

Name

106873-7470

9 400 618 493

ME094475 MITSUBISHI

INJECTION-PUMP ASSEMBLY
8DC9 K

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 9.3

Pump speed r/min 700 700 700

Each cylinder's injection qty mm3/st. 112.5 109.1 115.9

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point C

Rack position 6.1+-0.5

Pump speed r/min 225 225 225

Each cylinder's injection qty mm3/st. 20 17 23

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(9.3)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 112.5 111.5 113.5

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1(9.3)

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 118.5 113.3 123.7

Difference in delivery mm3/st. 10.4 10.4 10.4

Fixing the lever *

Injection quantity adjustment_05

Adjusting point E

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 140 100 180

Fixing the lever *

Remarks
After startup boost setting

Timer adjustment

Pump speed r/min 550--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 500

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1100

Advance angle deg. 5 4.5 5.5

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)Tolerance for racks not indicated: +-0.05mm. (4)Excess fuel setting for starting: SXL (5)Damper spring setting (6)When air cylinder is operating.
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SXL=12+-0.1mm
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Speed control lever angle

F:Full speed I:Idle (1)Pump speed = aa (2)Pump speed = bb
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aa=1275r/min bb=275r/min
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a=(5deg)+-5deg b=(14.5deg)+-5deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting
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a=10deg+-5deg b=23deg+-3deg

Stop lever angle

S:Stop the pump. (1)Rack position = aa (2)Stopper bolt setting (3)Free (at delivery)
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aa=4-0.5mm
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a=10.5deg+-5deg b=56deg+7deg-5deg

0000001501 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=325r/min Ra=5.6+-0.1mm
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0000001601 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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Timing setting

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
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a=(40deg)

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.Cooling System
Do not perform this maintenance until you read and understand the material in the Safety and Cooling System Specifications sections of this publication.
Drain/Flush/Replace Coolant (Long Life Coolant/Antifreeze Only)
Caterpillar Long Life Coolant/Antifreeze should be replaced every 6,000 Service Hours or 4 Years, whichever comes first. Only clean water is needed to clean and flush the cooling system when LLCA is drained and replaced.Drain
1. Stop the engine and allow the engine to cool. Loosen the coolant filler cap slowly to relieve any pressure, and remove the cap.2. Remove the radiator drain plug, or open the radiator drain valve (if equipped). Remove the block and oil cooler drain plugs. Remove the drain plug from the bottom of the water pump housing. Allow the coolant to drain.
Dispose of used engine coolant properly or recycle. Various methods have been proposed to reclaim used coolant for reuse in engine cooling systems. The full distillation procedure is the only method acceptable by Caterpillar to reclaim the used coolant. Contact your Caterpillar for information regarding disposal and recycling of used coolant.
For information regarding disposal and recycling of used coolant:Contact Caterpillar Service Technology Group:Outside Illinois: 1-800-542-TOOLInside Illinois: 1-800-541-TOOLCanada: 1-800-523-TOOLFlush
4. Flush the cooling system with clean water to remove any debris.5. Clean and install all drain plugs and/or close the drain valve(s).6. Fill the cooling system with clean water. Install the filler cap. Operate the engine until warm 49 to 66°C (150 to 120°F).7. Stop the engine and allow the engine to cool. Loosen the coolant filler cap slowly to relieve any pressure, and remove the cap. Remove the cooling system drain plug(s) or open the drain valve. Allow the water to drain. Flush the cooling system with clean water.8. Repeat steps 6 and 7.Fill
9. Fill the cooling system with LLCA. Refer to the refill capacities chart in this manual for the amount of LLCA needed to refill your system.10. Start and run the engine with the filler cap removed. Allow the LLCA to warm, the thermostat to open, and the coolant level to stabilize. Add LLCA if necessary to bring the coolant to the proper level.11. Check the condition of the filler cap gasket. If the gasket is damaged, discard the old filler cap and install a new filler cap. If the gasket is not damaged, use a 9S8140 Service Tool (available from your Caterpillar dealer) to pressure test the filler cap. The correct filler cap pressure is stamped on the face of the filler cap. If the filler cap does not hold the correct pressure, install a new filler cap.12. Start the engine and inspect for coolant leaks and proper operating temperature.