Information injection-pump assembly
BOSCH
9 400 619 315
9400619315
ZEXEL
108822-2662
1088222662
MITSUBISHI
ME094938
me094938
Rating:
Cross reference number
BOSCH
9 400 619 315
9400619315
ZEXEL
108822-2662
1088222662
MITSUBISHI
ME094938
me094938
Zexel num
Bosch num
Firm num
Name
108822-2662
9 400 619 315
ME094938 MITSUBISHI
INJECTION-PUMP ASSEMBLY
8DC11 K 14CK INJECTION PUMP ASSY TICS HD-TI8M TICS
8DC11 K 14CK INJECTION PUMP ASSY TICS HD-TI8M TICS
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
105780-8250
Bosch type code
1 688 901 101
Nozzle
105780-0120
Bosch type code
1 688 901 990
Nozzle holder
105780-2190
Opening pressure
MPa
20.7
Opening pressure
kgf/cm2
211
Injection pipe
Outer diameter - inner diameter - length (mm) mm 8-3-600
Outer diameter - inner diameter - length (mm) mm 8-3-600
Overflow valve
131425-0220
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
255
255
255
Tester oil delivery pressure
kgf/cm2
2.6
2.6
2.6
PS/ACT control unit part no.
407980-2
24*
Digi switch no.
42
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
8.5
8.47
8.53
Beginning of injection position
Governor side NO.1
Governor side NO.1
Difference between angles 1
Cyl.1-2 deg. 45 44.75 45.25
Cyl.1-2 deg. 45 44.75 45.25
Difference between angles 2
Cal 1-7 deg. 90 89.75 90.25
Cal 1-7 deg. 90 89.75 90.25
Difference between angles 3
Cal 1-3 deg. 135 134.75 135.25
Cal 1-3 deg. 135 134.75 135.25
Difference between angles 4
Cal 1-4 deg. 180 179.75 180.25
Cal 1-4 deg. 180 179.75 180.25
Difference between angles 5
Cal 1-5 deg. 225 224.75 225.25
Cal 1-5 deg. 225 224.75 225.25
Difference between angles 6
Cal 1-6 deg. 270 269.75 270.25
Cal 1-6 deg. 270 269.75 270.25
Difference between angles 7
Cal 1-8 deg. 315 314.75 315.25
Cal 1-8 deg. 315 314.75 315.25
Injection quantity adjustment
Adjusting point
-
Rack position
13.3
Pump speed
r/min
650
650
650
Average injection quantity
mm3/st.
136.5
134.9
138.1
Max. variation between cylinders
%
0
-3
3
Basic
*
Fixing the rack
*
PS407980-224*
V
2.45+-0.
01
PS407980-224*
mm
6.1+-0.0
5
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
Z
Rack position
8.7+-0.5
Pump speed
r/min
345
345
345
Average injection quantity
mm3/st.
23.5
20.9
26.1
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
PS407980-224*
V
V1+0.05+
-0.01
PS407980-224*
mm
8.4+-0.0
3
Standard for adjustment of the maximum variation between cylinders
*
Remarks
Refer to items regarding the pre-stroke actuator
Refer to items regarding the pre-stroke actuator
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(13.3)
Pump speed
r/min
650
650
650
Average injection quantity
mm3/st.
136.5
135.5
137.5
Basic
*
Fixing the lever
*
PS407980-224*
V
2.45+-0.
01
PS407980-224*
mm
6.1+-0.0
5
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+1.35
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
135.5
131.5
139.5
Fixing the lever
*
PS407980-224*
V
2.45+-0.
01
PS407980-224*
mm
6.1+-0.0
5
Injection quantity adjustment_05
Adjusting point
C
Rack position
(R1-0.7)
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
132.5
128.5
136.5
Fixing the lever
*
PS407980-224*
V
2.45+-0.
01
PS407980-224*
mm
6.1+-0.0
5
0000001601
Pre-stroke
mm
8.5
8.47
8.53
Remarks
When the timing sleeve is pushed up
When the timing sleeve is pushed up
_02
Connector angle
deg.
8.5
8
9
Remarks
When the eccentric pin is tightened
When the eccentric pin is tightened
_03
Supply voltage
V
24
23.5
24.5
Ambient temperature
degC
23
18
28
Pre-stroke
mm
6.1
6.05
6.15
Output voltage
V
2.45
2.44
2.46
Adjustment
*
_04
Supply voltage
V
24
23.5
24.5
Ambient temperature
degC
23
18
28
Pre-stroke
mm
8.5
8.47
8.53
Output voltage
V
1.2
1
1.4
Confirmation
*
Remarks
Output voltage V1
Output voltage V1
_05
Supply voltage
V
24
23.5
24.5
Ambient temperature
degC
23
18
28
Pre-stroke
mm
5.5
Output voltage
V
3
2.98
3
Confirmation
*
_06
Supply voltage
V
24
23.5
24.5
Ambient temperature
degC
23
18
28
Output voltage
V
3.05
3.05
Confirmation of operating range
*
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
(2)Tolerance for racks not indicated: +-0.05mm.
(3)Damper spring setting
----------
T1=AD92
----------
----------
T1=AD92
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt set position 'H'
(3)Viewed from feed pump side.
----------
aa=37.5mm
----------
a=34deg+-5deg b=31.5deg+-3deg
----------
aa=37.5mm
----------
a=34deg+-5deg b=31.5deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Use the hole at R = aa
(2)Set the stopper bolt so that speed = bb and rack position = cc. (Confirm non-injection.)
(3)Normal engine position (Rack position corresponding to dd)
----------
aa=54mm bb=1100r/min cc=3.5+-0.3mm dd=18mm
----------
a=41deg+-5deg b=5.5deg+-5deg c=(31deg)
----------
aa=54mm bb=1100r/min cc=3.5+-0.3mm dd=18mm
----------
a=41deg+-5deg b=5.5deg+-5deg c=(31deg)
0000001301
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)At the No 1 cylinder's beginning of injection position, stamp an aligning mark on the damper to align with the pointer's groove.
(4)Damper
(5)Pointer
(6)B.T.D.C.: aa
(7)Pre-stroke: bb
----------
aa=4deg bb=8.5+-0.03mm
----------
a=(45deg) b=(44deg)
----------
aa=4deg bb=8.5+-0.03mm
----------
a=(45deg) b=(44deg)
0000001901
A:Sealing position
B:Pre-stroke actuator
1. When installing the pre-stroke actuator on the pump, first tighten the installation bolts loosely, then move the actuator fully counterclockwise (viewed from the drive side).
Temporary tightening torque: 1 - 1.5 N.m (0.1 - 0.15 kgf.m)
2. Move the actuator in the clockwise direction when viewed from the drive side, and adjust so that it becomes the adjustment point of the adjustment value. Then tighten it.
Tightening torque: 7^9 N.m (0.7^0.9 kgf.m)
3. After prestroke actuator installation adjustment, simultaneously stamp both the actuator side and housing side.
----------
----------
----------
----------
0000002201 RACK SENSOR
(VR) measurement voltage
(I) Part number of the control unit
(G) Apply red paint.
(H): End surface of the pump
1. Rack sensor adjustment (-0620)
(1)Fix the speed control lever at the full position
(2)Set the speed to N1 r/min.
(If the boost compensator is provided, apply boost pressure.)
(3)Adjust the bobbin (A) so that the rack sensor's output voltage is VR+-0.01.
(4)At that time, rack position must be Ra.
(5)Apply G at two places.
Connecting part between the joint (B) and the nut (F)
Connecting part between the joint (B) and the end surface of the pump (H)
----------
N1=1100r/min Ra=R1(13.3)+1.35mm
----------
----------
N1=1100r/min Ra=R1(13.3)+1.35mm
----------
Information:
03May2017
U-247
A-163
D-194
O-200
TM-3
Parts stock action only
PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY REWORKING CERTAIN REMAN FUEL INJECTORS IN DEALER PARTS STOCK
7750 PI70664
Caterpillar’s obligations under this Service Letter are subject to, and shall not apply in contravention of, the laws, rules, regulations, directives, ordinances, orders, or statutes of the United States, or of any other applicable jurisdiction, without recourse or liability with respect to Caterpillar.
When submitting claim for Parts Stock Action, Use the appropriate 99Z as the s/n, the appropriate Service Letter Program Number as the Part number in the Part Causing Failure field, "7751" as the Group Number, "56" as the Description Code.
The information supplied in this service letter may not be valid after the termination date of this program.Do not perform the work outlined in this Service Letter after the termination date without first contacting your Caterpillar product analyst.
TERMINATION DATE
31Aug2017
PROBLEM
Certain Reman fuel injectors were labeled with the same "2755" trim code from January 9, 2017 through April 18, 2017. The injector serial numbers of suspect injectors are 1825569 through 1880788. The trim code may or may not be correct. Image 1 shows a suspect trim code.
Parts from part distribution centers have been inspected and the boxes have been marked with a large green dot to indicate the injector has been inspected, marked correctly, or the trim code is correct. Refer to Image 2.
ACTION REQUIRED
Inspect the following Reman injectors in dealer parts stock:
20R0848
20R0849
20R0850
20R0863
20R0864
20R1264
20R1265
20R1266
20R1268
20R1269
20R1270
20R1271
20R1272
20R1273
20R1274
20R1275
20R1276
20R1277
20R1278
20R1279
20R1280
20R1281
20R1282
20R1283
20R2296
20R3247
20R3477
20R3479
20R3480
20R3483
Inspect the date code on the box.
If the date code on the box is not January 9, 2017 through April 18, 2017, then mark the box as inspected per this program and place the part back in dealer parts stock.
If the date code on the box is January 9, 2017 through April 18, 2017, then inspect the injector trim code.
If the trim code is not "2755", then mark the box as inspected per this program and place the part back in dealer parts stock.
If the trim code is "2755", then inspect the injector serial number using the following inspection and rework the procedure:
Use the following web address and download the spreadsheet file:
https://cat.box.com/s/4fwh9nz0lwguh8vomifxj2rapqjc27e9
Use the downloaded file. Type in the injector serial number to check the trim code. The spreadsheet will return whether the trim code is OK to use, or rework and mark the injector with the correct trim code.
Note: Some injector serial numbers will show "2755" as the correct trim code.
If the trim code is correct (acceptable trim code), record the injector serial number, then mark the box as inspected per this program and place the part back in dealer parts stock.
If the trim code is not correct (rework), the injector must be relabeled. Use an engraving tool to cross out the original trim code and write the correct trim code as shown in Image 3. Record the injector serial number and the updated/corrected trim code, then mark the box as reworked per this program and place the part back in dealer parts stock.
Image1
Image2
Image3
SERVICE CLAIM ALLOWANCES
Submit one claim for all parts inspected and reworked from dealer parts stock.
Have questions with 108822-2662?
Group cross 108822-2662 ZEXEL
Mitsubishi
Mitsubishi
Mitsubishi
Mitsubishi
Mitsubishi
Mitsubishi
Mitsubishi
108822-2662
9 400 619 315
ME094938
INJECTION-PUMP ASSEMBLY
8DC11
8DC11