106961-1509 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1069611509 1156032111


 

Information injection-pump assembly

ZEXEL 106961-1509 1069611509
ISUZU 1156032111 1156032111
106961-1509 INJECTION-PUMP ASSEMBLY
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Service parts 106961-1509 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 106096-9302
3. GOVERNOR 105488-0452
4. SUPPLY PUMP 105237-1940
5. AUTOM. ADVANCE MECHANIS 105687-0631
6. COUPLING PLATE
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105100-7192
11. Nozzle and Holder
12. Open Pre:MPa(Kqf/cm2) 15.7(160)/22.1(225)
13. NOZZLE-HOLDER 105031-4831
14. NOZZLE 105015-6651
15. NOZZLE SET

Include in #1:

106961-1509 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106961-1509 1069611509
ISUZU 1156032111 1156032111


Zexel num
Bosch num
Firm num
Name
106961-1509 
106961-6220 
 
1156032111  ISUZU
INJECTION-PUMP ASSEMBLY
10PC1 * K 14CE PE10P PE

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 (drive side)   134424-3520
Overflow valve opening pressure (drive side) kPa   255 255 255
Overflow valve opening pressure (drive side) kgf/cm2   2.6 2.6 2.6
Overflow valve (governor side)   134424-2720
Overflow valve opening pressure (governor side) kPa   255 255 255
Overflow valve opening pressure (governor side) kgf/cm2   2.6 2.6 2.6
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   1-8-7-6- 5-4-3-10 -9-2
Pre-stroke mm   4 3.97 4.03
Beginning of injection position
Governor side
  NO.1
Difference between angles 1
Cal 1-8
deg.   27 26.75 27.25
Difference between angles 2
Cal 1-7
deg.   72 71.75 72.25
Difference between angles 3
Cal 1-6
deg.   99 98.75 99.25
Difference between angles 4
Cal 1-5
deg.   144 143.75 144.25
Difference between angles 5
Cal 1-4
deg.   171 170.75 171.25
Difference between angles 6
Cal 1-3
deg.   216 215.75 216.25
Difference between angles 7
Cal 1-10
deg.   243 242.75 243.25
Difference between angles 8
Cal 1-9
deg.   288 287.75 288.25
Difference between angles 9
Cyl.1-2
deg.   315 314.75 315.25
Injection quantity adjustment
Adjusting point   A
Rack position   8.1
Pump speed r/min   700 700 700
Average injection quantity mm3/st.   85.6 84.1 87.1
Max. variation between cylinders %   0 -2 2
Basic   *
Fixing the lever   *
Injection quantity adjustment_02
Adjusting point   B
Rack position   7.9+-0.5
Pump speed r/min   1250 1250 1250
Average injection quantity mm3/st.   95.9 91.9 99.9
Max. variation between cylinders %   0 -3 3
Fixing the lever   *
Injection quantity adjustment_03
Adjusting point   C
Rack position   5.4+-0.5
Pump speed r/min   225 225 225
Average injection quantity mm3/st.   8 6.6 9.4
Max. variation between cylinders %   0 -13 13
Fixing the rack   *
Injection quantity adjustment_04
Adjusting point   E
Rack position   -
Pump speed r/min   150 150 150
Average injection quantity mm3/st.   137 137
Fixing the lever   *
Remarks
When manual lever is on the boost side
 
Timer adjustment
Pump speed r/min   750+50
Advance angle deg.   0 0 0
Load   1/4
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   1000+50
Advance angle deg.   1 0.5 1
Load   3/4
Timer adjustment_03
Pump speed r/min   (1075)
Advance angle deg.   1 0.5 1
Load   4/4
Timer adjustment_04
Pump speed r/min   1150
Advance angle deg.   3 2.7 3.3
Load   4/4
Timer adjustment_05
Pump speed r/min   1250
Advance angle deg.   6 5.5 6.5
Load   4/4
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 106961-1509
N:Pump speed R:Rack position (mm) (1)Lever ratio: RT (2)Target shim dimension: TH (3)Tolerance for racks not indicated: +-0.05mm. (4)Deliver with damper spring not operating. (5)At excess fuel lever operation: not exceeding EXL (6)Excess fuel setting for starting: SXL (N = N1) (7)Supply solenoid operating voltage DC24V and move the solenoid body so that the excess lever reaches the excess position at the solenoid's maximum stroke.
----------
RT=0.8 TH=2.4mm EXL=2mm SXL=9.2+-0.1mm N1=320r/min
----------

Speed control lever angle

Test data 106961-1509
F:Full speed
----------

----------
a=9deg+-5deg

0000000901

Test data 106961-1509
F:Full load I:Idle (1)Stopper bolt setting (2)Use the hole at R = aa
----------
aa=35mm
----------
a=10deg+-5deg b=33deg+-3deg

Stop lever angle

Test data 106961-1509
N:Pump normal S:Stop the pump.
----------

----------
a=60deg+-5deg b=73deg+-5deg

0000001101

Test data 106961-1509
N:Normal B:When boosted
----------

----------
a=(5deg) b=(24deg)

Timing setting

Test data 106961-1509
(1)Pump vertical direction (2)Position of "Z" mark at the No 1 cylinder's beginning of injection (governor side) (3)B.T.D.C.: aa (4)-
----------
aa=12deg
----------
a=(170deg)




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.

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Group cross 106961-1509 ZEXEL

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