Information injection-pump assembly
ZEXEL
101607-6480
1016076480

Rating:
Service parts 101607-6480 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
ME076952
12.
Open Pre:MPa(Kqf/cm2)
15.7{160}/21.6{220}
14.
NOZZLE
Include in #1:
101607-6480
as INJECTION-PUMP ASSEMBLY
Include in #2:
104746-6990
as _
Cross reference number
ZEXEL
101607-6480
1016076480
Zexel num
Bosch num
Firm num
Name
101607-6480
INJECTION-PUMP ASSEMBLY
14BF PE6AD PE
14BF PE6AD PE
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 6-2-600
Outer diameter - inner diameter - length (mm) mm 6-2-600
Overflow valve
131424-8420
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)
Left L
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
Left L
Injection order
1-5-3-6-
2-4
Pre-stroke
mm
3.2
3.15
3.25
Beginning of injection position
Governor side NO.1
Governor side NO.1
Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5
Cal 1-5 deg. 60 59.5 60.5
Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5
Cal 1-3 deg. 120 119.5 120.5
Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5
Cal 1-6 deg. 180 179.5 180.5
Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5
Cyl.1-2 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5
Cal 1-4 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
-
Rack position
11.7
Pump speed
r/min
850
850
850
Each cylinder's injection qty
mm3/st.
77.4
75.1
79.7
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
Z
Rack position
9.5+-0.5
Pump speed
r/min
800
800
800
Each cylinder's injection qty
mm3/st.
10.8
9.2
12.4
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(11.7)
Pump speed
r/min
850
850
850
Average injection quantity
mm3/st.
77.4
76.4
78.4
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+0.55
Pump speed
r/min
1450
1450
1450
Average injection quantity
mm3/st.
87.7
83.7
91.7
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
C
Rack position
R1-0.4
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
56
52
60
Fixing the lever
*
Injection quantity adjustment_06
Adjusting point
E
Rack position
(R1+0.5)
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
87.6
83.6
91.6
Fixing the lever
*
Injection quantity adjustment_07
Adjusting point
I
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
91
81
101
Fixing the lever
*
Rack limit
*
Timer adjustment
Pump speed
r/min
1150--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1100
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
1450
Advance angle
deg.
6
5.5
6.5
Remarks
Finish
Finish
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)RACK LIMIT
----------
T1=H50
----------
----------
T1=H50
----------
Speed control lever angle

F:Full speed
I:Idle
(1)Stopper bolt set position 'H'
----------
----------
a=18.5deg+-5deg b=(42deg)+-3deg
----------
----------
a=18.5deg+-5deg b=(42deg)+-3deg
Stop lever angle

N:Engine manufacturer's normal use
S:Stop the pump.
(1)Set the stopper bolt at pump speed = aa and rack position = bb (non-injection rack position). Confirm non-injection.
(2)After setting the stopper bolt, confirm non-injection at speed cc. Rack position = dd (non-injection rack position).
(3)Rack position = approximately ee.
(4)Free (at delivery)
----------
aa=1450r/min bb=7.2-0.5mm cc=275r/min dd=(8.8)mm ee=15mm
----------
a=36.5deg+-5deg b=(25deg) c=13deg+-5deg
----------
aa=1450r/min bb=7.2-0.5mm cc=275r/min dd=(8.8)mm ee=15mm
----------
a=36.5deg+-5deg b=(25deg) c=13deg+-5deg
0000001501 LEVER

(A) Idle
(B) Full speed
(C) Base lever
(D) Accelerator lever
(E) Accelerator lever delivery position
1. Measure speed lever angle
(1)Measure the angle when the accelerator lever (D) contacted the base lever (C) at a.
----------
----------
b=(42deg)+-3deg c=18.5deg+-5deg
----------
----------
b=(42deg)+-3deg c=18.5deg+-5deg
Timing setting

(1)Pump vertical direction
(2)Position of timer's tooth at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=10deg
----------
a=(2deg)
----------
aa=10deg
----------
a=(2deg)
Information:
Recommendations
Cat does not recommend the use of multigrade oils in the 3116 and 3126 Marine Diesel Engines that use mechanical unit injection (MUI).Multigrade oils use high molecular weight polymers as viscosity index improvers. When the crankcase blowby flows through the turbocharger and the aftercooler, the viscosity index improvers can adhere to the turbocharger compressor and aftercooler core.The fouling of the turbocharger and aftercooler can cause reduced air flow, loss of power, and increased black smoke. The emission of black smoke results in buildup of soot on the transom of the boat.Note: Cat recommends the use of single grade oils that pass all API CF-4 category requirements unless crankcase blowby has been routed away from the air cleaner inlet.Cat SAEO (Special Application Engine Oil)
Note: Cat SAEO is recommended for use in Cat 3116 and 3126 Marine Diesel Engines with mechanical unit injection. 3116 and 3126 Marine Diesel Engines that begin with the following serial number prefixes are included:
(S/N: 6SR)
(S/N: 8NM)
(S/N: 4KG)
(S/N: 1SK)
(S/N: 1ZJ)
(S/N: 6MK)
(S/N: 4EZ)The factory-fill for 3116 and 3126 Marine Engines is Cat SAEO with the following properties:
Meets all requirements of API CF-4 category
Viscosity grade of SAE 30For maximum performance in 3116 and 3126 Marine Diesel Engines with mechanical unit injection, Cat recommends the following engine oil:
Cat SAEO (SAE 30)
Cat SAEO (SAE 40)Commercial Oils (3116 and 3126 Marine Engines)
Cat does not warrant the quality or performance of non-Cat fluids.
When Cat SAEO is not used, use the following commercial oils:
Single grade oil with a viscosity of SAE 30 or SAE 40 that meets all API CF category requirements is preferred.
Single grade oil with a viscosity of SAE 30 or SAE 40 with an API CF additive package and no viscosity improvers is acceptable oil.API oil category CF is obsolete. The API (American Petroleum Institute) does not license this category effective end of 2010. API does not validate the quality of API CF oils and does not allow the display of API symbol (also called API doughnut) with CF as highest claim on the oil container.Oil products that used to be licensed as API CF oil performance category and have not changed formulation are acceptable for use in Cat 3116 and 3126 marine engines.For an acceptable commercial single grade oil, consult your Cat dealer.Some commercial oils that meet the requirements API CF-4 category may require reduced oil change intervals. To determine the oil change interval, closely monitor the condition of the oil and perform a wear metal analysis. Cat S O S Services oil analysis program is the preferred method.
Failure to follow these oil recommendations can cause shortened engine service life due to deposits and/or excessive wear.
Fuel Sulfur Impact on Engine Oil
Follow the recommendations given in the "Fuel Sulfur Impact on Engine Oil" section given earlier in this Special Publication in the Engine Oil chapter.Use the single grade oils recommended for the 3116 and 3126 marine engines in order to ensure the protection of the engines and follow the recommendations in your Operation and Maintenance Manual for oil drain intervals.
Cat does not recommend the use of multigrade oils in the 3116 and 3126 Marine Diesel Engines that use mechanical unit injection (MUI).Multigrade oils use high molecular weight polymers as viscosity index improvers. When the crankcase blowby flows through the turbocharger and the aftercooler, the viscosity index improvers can adhere to the turbocharger compressor and aftercooler core.The fouling of the turbocharger and aftercooler can cause reduced air flow, loss of power, and increased black smoke. The emission of black smoke results in buildup of soot on the transom of the boat.Note: Cat recommends the use of single grade oils that pass all API CF-4 category requirements unless crankcase blowby has been routed away from the air cleaner inlet.Cat SAEO (Special Application Engine Oil)
Note: Cat SAEO is recommended for use in Cat 3116 and 3126 Marine Diesel Engines with mechanical unit injection. 3116 and 3126 Marine Diesel Engines that begin with the following serial number prefixes are included:
(S/N: 6SR)
(S/N: 8NM)
(S/N: 4KG)
(S/N: 1SK)
(S/N: 1ZJ)
(S/N: 6MK)
(S/N: 4EZ)The factory-fill for 3116 and 3126 Marine Engines is Cat SAEO with the following properties:
Meets all requirements of API CF-4 category
Viscosity grade of SAE 30For maximum performance in 3116 and 3126 Marine Diesel Engines with mechanical unit injection, Cat recommends the following engine oil:
Cat SAEO (SAE 30)
Cat SAEO (SAE 40)Commercial Oils (3116 and 3126 Marine Engines)
Cat does not warrant the quality or performance of non-Cat fluids.
When Cat SAEO is not used, use the following commercial oils:
Single grade oil with a viscosity of SAE 30 or SAE 40 that meets all API CF category requirements is preferred.
Single grade oil with a viscosity of SAE 30 or SAE 40 with an API CF additive package and no viscosity improvers is acceptable oil.API oil category CF is obsolete. The API (American Petroleum Institute) does not license this category effective end of 2010. API does not validate the quality of API CF oils and does not allow the display of API symbol (also called API doughnut) with CF as highest claim on the oil container.Oil products that used to be licensed as API CF oil performance category and have not changed formulation are acceptable for use in Cat 3116 and 3126 marine engines.For an acceptable commercial single grade oil, consult your Cat dealer.Some commercial oils that meet the requirements API CF-4 category may require reduced oil change intervals. To determine the oil change interval, closely monitor the condition of the oil and perform a wear metal analysis. Cat S O S Services oil analysis program is the preferred method.
Failure to follow these oil recommendations can cause shortened engine service life due to deposits and/or excessive wear.
Fuel Sulfur Impact on Engine Oil
Follow the recommendations given in the "Fuel Sulfur Impact on Engine Oil" section given earlier in this Special Publication in the Engine Oil chapter.Use the single grade oils recommended for the 3116 and 3126 marine engines in order to ensure the protection of the engines and follow the recommendations in your Operation and Maintenance Manual for oil drain intervals.
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Mitsubishi
Mitsubishi
Mitsubishi
101607-6480
INJECTION-PUMP ASSEMBLY