101991-1150 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1019911150 3196180031

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101991-1150 1019911150

MITSUBISHI 3196180031 3196180031

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Buy INJECTION-PUMP ASSEMBLY 101991-1150 zexel genuine, new aftermarket engine parts with delivery

Service parts 101991-1150 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101099-0061

3. GOVERNOR 105410-2120

4. SUPPLY PUMP 105210-4130

5. AUTOM. ADVANCE MECHANIS 105614-0680

6. COUPLING PLATE 105662-0570

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105151-1330

11. Nozzle and Holder 31161-18000

12. Open Pre:MPa(Kqf/cm2) 11.8{120}

13. NOZZLE-HOLDER 105081-2140

14. NOZZLE

105000-1130

15. NOZZLE SET

Include in #1:

101607-6700 as _

101991-1150 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101991-1150 1019911150

MITSUBISHI 3196180031 3196180031

Zexel num

Bosch num

Firm num

Name

101991-1150

3196180031 MITSUBISHI

INJECTION-PUMP ASSEMBLY
10DC60 * K

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113 or {SAEJ967d}

Test oil temperature degC 40 40 45

Nozzle 105780-0020

Bosch type code NP-DN4SD24T

Nozzle holder 105031-2010

Bosch type code NP-KB56SD273

Opening pressure MPa 11.8

Opening pressure kgf/cm2 120

Injection pipe
Outer diameter - inner diameter - length (mm) mm 6-1.6-550

Overflow valve 132424-0620

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 1-2-7-8- 5-6-3-4- 9-10

Pre-stroke mm 2.1 2.05 2.15

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. 72 71.5 72.5

Difference between angles 3
Cal 1-8 deg. 117 116.5 117.5

Difference between angles 4
Cal 1-5 deg. 144 143.5 144.5

Difference between angles 5
Cal 1-6 deg. 189 188.5 189.5

Difference between angles 6
Cal 1-3 deg. 216 215.5 216.5

Difference between angles 7
Cal 1-4 deg. 261 260.5 261.5

Difference between angles 8
Cal 1-9 deg. 288 287.5 288.5

Difference between angles 9
Cal 1-10 deg. 333 332.5 333.5

Injection quantity adjustment

Adjusting point A

Rack position 12.5

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 130 126.1 133.9

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 12

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 123 118 128

Max. variation between cylinders % 0 -4 4

Fixing the rack *

Injection quantity adjustment_03

Adjusting point C

Rack position 11.3

Pump speed r/min 750 750 750

Average injection quantity mm3/st. 110 105.5 114.5

Max. variation between cylinders % 0 -4 4

Fixing the rack *

Injection quantity adjustment_04

Adjusting point D

Rack position 7.2+-0.5

Pump speed r/min 250 250 250

Average injection quantity mm3/st. 20 17 23

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Timer adjustment

Pump speed r/min 250+-50

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 600

Advance angle deg. 3 2.5 3.5

Timer adjustment_03

Pump speed r/min 900

Advance angle deg. 5.5 5 6

Timer adjustment_04

Pump speed r/min 1200

Advance angle deg. 8 7.5 8.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)RACK LIMIT: RAL (3)Control lever's minimum speed setting (4)Control lever's full speed setting (5)Idle sub spring setting: L1.
----------
K=5 RAL=13.3+0.5mm L1=6.2-0.2mm
----------

Speed control lever angle

I:Idle S:Stop (1)Set the pump speed at aa (2)Set the pump speed at bb.
----------
aa=900r/min bb=750r/min
----------
a=13deg+-5deg b=32deg+-3deg c=22deg+-5deg d=5deg+-5deg

Information:

face="Courier New" size=-1>0.0% 0.0% 0.0%
This is a 5.0-hour job for Group 2
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
*******Group 3*******
0-3000 hrs,
0-24 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 5.0-hour job for Group 3
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
*******Group 4*******
0-3000 hrs,
0-24 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 5.0-hour job for Group 4
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
*******Group 5*******
0-3000 hrs,
0-24 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 5.0-hour job for Group 5
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Rework Procedure
Engine Injector Change:
First identify which level of injector you currently have in your engine and establish which is the latest injector to replace it.
To remove and replace the injectors use the following Disassembly and Assembly Instructions.
C6.6 Caterpillar Industrial Engines: Install and Remove procedure RENR9722
C6.6 Caterpillar Built Machine: Install and Remove procedure KENR6081
Engine Reflash:
To update the flash file follow the procedure below. Refer to TMI or SISWeb for the latest flash file.
Tools Required:
PC or laptop with CAT ET installed and licensed (Version 2007A minimum) Communication Adaptor with diagnostic connector.
Flash File procedure:
Process:
1. Download the correct flash file from TMI or SISWeb.
2. Save the correct flash file to your local hard drive.
3. Connect to the ECM using Service Tool (CAT ET).
4. Make sure the ECM is powered up (Check that Red light on Comm. Adaptor is illuminated).
5. Go to "Winflash" or "Flash Memory".
6. CAT ET re-connect to the ECM.
7. Using the browse function in the top right hand corner, select the new flash file previously saved to hard drive.
8. Select "Begin Flash" (bottom right hand corner).
9. Once Flashing is complete select "CAT ET".
10. The Personality Module Mismatch should appear, select the ok button.
11. The factory password screen should now appear.
12. Use https://fps.cat.com to obtain factory passwords.
13. Enter Factory Passwords.
14. CAT ET High Level Configuration screen should be displayed.
15. Re-flash complete.