Information injection-pump assembly
ZEXEL
106876-2020
1068762020
Rating:
Cross reference number
ZEXEL
106876-2020
1068762020
Zexel num
Bosch num
Firm num
Name
106876-2020
INJECTION-PUMP ASSEMBLY
8DC9TC
8DC9TC
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
131424-4620
Overflow valve opening pressure
kPa
255
221
289
Overflow valve opening pressure
kgf/cm2
2.6
2.25
2.95
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
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
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
Governor side NO.1
Difference between angles 1
Cyl.1-2 deg. 45 44.5 45.5
Cyl.1-2 deg. 45 44.5 45.5
Difference between angles 2
Cal 1-7 deg. 90 89.5 90.5
Cal 1-7 deg. 90 89.5 90.5
Difference between angles 3
Cal 1-3 deg. 135 134.5 135.5
Cal 1-3 deg. 135 134.5 135.5
Difference between angles 4
Cal 1-4 deg. 180 179.5 180.5
Cal 1-4 deg. 180 179.5 180.5
Difference between angles 5
Cal 1-5 deg. 225 224.5 225.5
Cal 1-5 deg. 225 224.5 225.5
Difference between angles 6
Cal 1-6 deg. 270 269.5 270.5
Cal 1-6 deg. 270 269.5 270.5
Difference between angles 7
Cal 1-8 deg. 315 314.5 315.5
Cal 1-8 deg. 315 314.5 315.5
Injection quantity adjustment
Adjusting point
A
Rack position
11.3
Pump speed
r/min
800
800
800
Average injection quantity
mm3/st.
161
158
164
Max. variation between cylinders
%
0
-3
3
Basic
*
Fixing the lever
*
Boost pressure
kPa
61.3
61.3
Boost pressure
mmHg
460
460
Injection quantity adjustment_02
Adjusting point
B
Rack position
5.6+-0.5
Pump speed
r/min
275
275
275
Average injection quantity
mm3/st.
15.5
12.9
18.1
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Boost compensator adjustment
Pump speed
r/min
500
500
500
Rack position
R1-1.3
Boost pressure
kPa
21.3
20
22.6
Boost pressure
mmHg
160
150
170
Boost compensator adjustment_02
Pump speed
r/min
500
500
500
Rack position
R1(11.3)
Boost pressure
kPa
48
41.3
54.7
Boost pressure
mmHg
360
310
410
Timer adjustment
Pump speed
r/min
950--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
900
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
1100
Advance angle
deg.
0.5
0
1
Timer adjustment_04
Pump speed
r/min
-
Advance angle
deg.
1
1
1
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)Supplied with torque spring not set.
(3)Excess fuel lever setting: EXL (at boost pressure 0)
(4)Main spring setting
(5)Set idle sub-spring
(6)Boost compensator stroke: BCL
(7)At delivery
----------
K=10 EXL=13++mm BCL=1.3+-0.1mm
----------
----------
K=10 EXL=13++mm BCL=1.3+-0.1mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
(2)At delivery
----------
----------
a=6deg+-5deg b=28deg+-5deg c=(2deg)
----------
----------
a=6deg+-5deg b=28deg+-5deg c=(2deg)
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Normal
----------
----------
a=19deg+-5deg b=46deg+-5deg
----------
----------
a=19deg+-5deg b=46deg+-5deg
0000001101
N:Normal
B:When boosted
(1)Rack position = at least aa (speed = bb; at boost pressure 0)
----------
aa=13mm bb=0r/min
----------
a=(10deg) b=(15deg)
----------
aa=13mm bb=0r/min
----------
a=(10deg) b=(15deg)
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=14deg
----------
a=(40deg)
----------
aa=14deg
----------
a=(40deg)
Information:
Engine Parameters
Rating Number:
Number of rating within the horsepower family. The personality module defines the horsepower family (such as 325 hp). This number defines which rating is used (such as 325 hp at 1900 rpm or 325 hp at 2100 rpm) within the family.Top Engine Limit (TEL):
Maximum engine rpm when the engine is under load. The engine will still achieve rated rpm under no load.Minimum ... Map (Rating) DependentMaximum ... Rated rpm + 20 rpmDefault ... Rated rpm + 20 rpmLow Idle RPM:
Minimum engine rpm.Minimum ... 600 rpmMaximum ... 750 rpmDefault ... 700 rpmIdle Shutdown Time:
Time (in minutes) that engine will idle before shutting down (between 3 and 60 minutes). Engine will only shut down if the ECM sees no engine load, no vehicle speed, the parking brake is set and there has been no change in the status of the service brakes and clutch. If this parameter is programmed to 0, the feature is disabled. Refer to P-230: Idle Shutdown Timer Test for more detail on operation of the idle shutdown timer.Minimum ... 3 min.Maximum ... 60 min.Default ... 0 min.Vehicle ID:
Identification of vehicle assigned by customer. Used only for customer reference; not used by the ECM.Factory Passwords
Factory Passwords are required to perform any one of these four functions:1. Program a new ECM.When an ECM is replaced, the System Configuration Parameters must be programmed into the new ECM. These parameters are protected by Factory Passwords.2. Rerate the engine to another engine family.This requires changing the Personality Module Code, which is protected by Factory Passwords.3. Read Customer Passwords.If the owner forgets his Customer Passwords, he will not be able to program Customer Specified Parameters. Using factory passwords, one can read Customer Passwords, then use those Customer Passwords to program Customer Specified Parameters.4. Clear certain diagnostic codes.Only Diagnostic Code 35 (Engine Overspeed) requires Factory Passwords to clear once it is LOGGED. Clearing certain other codes requires Customer Passwords. The majority of LOGGED diagnostic codes require no passwords to clear.Factory Passwords are controlled by Caterpillar and may only be obtained by authorized Caterpillar Dealers. Since factory passwords contain alphabetic characters, only the ECAP may perform these functionsTo obtain factory passwords, proceed as if you already had the password. At some point, if factory passwords are truly needed, the ECAP will request factory passwords and will provide most of the information required to obtain the password on the ECAP screen.Customer Passwords
Customer Passwords are required to change ANY Customer Parameter. Customer Specified Parameters are those that affect cruise control, vehicle speed limits, progressive shifting, horsepower rating within a family and PTO operation. See the previous section on "Customer Specified Parameters" for more detail on which parameters are customer programmable.Either the ECAP or DDT can be used to change Customer Parameters. However, if a customer uses alphabetic characters in his password, only the ECAP can enter the Customer Passwords to change Customer Specified Parameters.To obtain Customer Passwords, contact the owner of the vehicle. If the owner has forgotten his passwords, customer passwords may be
Rating Number:
Number of rating within the horsepower family. The personality module defines the horsepower family (such as 325 hp). This number defines which rating is used (such as 325 hp at 1900 rpm or 325 hp at 2100 rpm) within the family.Top Engine Limit (TEL):
Maximum engine rpm when the engine is under load. The engine will still achieve rated rpm under no load.Minimum ... Map (Rating) DependentMaximum ... Rated rpm + 20 rpmDefault ... Rated rpm + 20 rpmLow Idle RPM:
Minimum engine rpm.Minimum ... 600 rpmMaximum ... 750 rpmDefault ... 700 rpmIdle Shutdown Time:
Time (in minutes) that engine will idle before shutting down (between 3 and 60 minutes). Engine will only shut down if the ECM sees no engine load, no vehicle speed, the parking brake is set and there has been no change in the status of the service brakes and clutch. If this parameter is programmed to 0, the feature is disabled. Refer to P-230: Idle Shutdown Timer Test for more detail on operation of the idle shutdown timer.Minimum ... 3 min.Maximum ... 60 min.Default ... 0 min.Vehicle ID:
Identification of vehicle assigned by customer. Used only for customer reference; not used by the ECM.Factory Passwords
Factory Passwords are required to perform any one of these four functions:1. Program a new ECM.When an ECM is replaced, the System Configuration Parameters must be programmed into the new ECM. These parameters are protected by Factory Passwords.2. Rerate the engine to another engine family.This requires changing the Personality Module Code, which is protected by Factory Passwords.3. Read Customer Passwords.If the owner forgets his Customer Passwords, he will not be able to program Customer Specified Parameters. Using factory passwords, one can read Customer Passwords, then use those Customer Passwords to program Customer Specified Parameters.4. Clear certain diagnostic codes.Only Diagnostic Code 35 (Engine Overspeed) requires Factory Passwords to clear once it is LOGGED. Clearing certain other codes requires Customer Passwords. The majority of LOGGED diagnostic codes require no passwords to clear.Factory Passwords are controlled by Caterpillar and may only be obtained by authorized Caterpillar Dealers. Since factory passwords contain alphabetic characters, only the ECAP may perform these functionsTo obtain factory passwords, proceed as if you already had the password. At some point, if factory passwords are truly needed, the ECAP will request factory passwords and will provide most of the information required to obtain the password on the ECAP screen.Customer Passwords
Customer Passwords are required to change ANY Customer Parameter. Customer Specified Parameters are those that affect cruise control, vehicle speed limits, progressive shifting, horsepower rating within a family and PTO operation. See the previous section on "Customer Specified Parameters" for more detail on which parameters are customer programmable.Either the ECAP or DDT can be used to change Customer Parameters. However, if a customer uses alphabetic characters in his password, only the ECAP can enter the Customer Passwords to change Customer Specified Parameters.To obtain Customer Passwords, contact the owner of the vehicle. If the owner has forgotten his passwords, customer passwords may be
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Group cross 106876-2020 ZEXEL
Mitsubishi
106876-2020
INJECTION-PUMP ASSEMBLY
8DC9TC
8DC9TC