Information injection-pump assembly
ZEXEL
101607-6952
1016076952
Rating:
Service parts 101607-6952 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
ME070516
12.
Open Pre:MPa(Kqf/cm2)
17.7{180}
15.
NOZZLE SET
Cross reference number
ZEXEL
101607-6952
1016076952
Zexel num
Bosch num
Firm num
Name
101607-6952
INJECTION-PUMP ASSEMBLY
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
131424-5520
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
2.95
3.05
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
A
Rack position
9.5
Pump speed
r/min
1400
1400
1400
Average injection quantity
mm3/st.
83.5
82.5
84.5
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
8.2+-0.5
Pump speed
r/min
325
325
325
Average injection quantity
mm3/st.
17.2
14.6
19.8
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
Adjust only variation between cylinders; adjust governor according to governor specifications.
Timer adjustment
Pump speed
r/min
1050--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1000
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
1400
Advance angle
deg.
2
1.5
2.5
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Notch fixed: K
(2)Tolerance for racks not indicated: +-0.05mm.
(3)Torque spring does not operate.
(4)Set idle sub-spring
(5)Main spring setting
(6)Set at delivery
----------
K=12
----------
----------
K=12
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
(2)At delivery
----------
----------
a=(34deg)+-5deg b=(2deg) c=(23deg)+-5deg
----------
----------
a=(34deg)+-5deg b=(2deg) c=(23deg)+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=26deg+-5deg b=53deg+-5deg
----------
----------
a=26deg+-5deg b=53deg+-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=14deg
----------
a=(1deg)
----------
aa=14deg
----------
a=(1deg)
Information:
Mast Cab Side Bank-Lube Points and Locations
Illustration 14 g06355954
Mast cab side bank-lube points
(A) Right Mast Pivot Pin
(B) Right Mast Raise Cylinder Upper Pin
(C) Gear Box Air Seal (Top side)
(D) Gear Box Top Lip Seal Top Air Seal (Bottom Side)
(E) Pipe Rack Upper Swing Cylinder Head End
(F) Pipe Rack Carousel Support Bearing
(G) Pipe Rack Journal Bearing
(H) Pipe Rack Journal Bearing
(J) Left Side Top Sheave Pin
(K) Right Side Top Sheave Pin
(L) Left Side Bottom Sheave Pin
(M) Right Side Bottom Sheave Pin
(N) Right Side Pipe Positioner Roller Pin
(P) Right Side Pipe Positioner Swing Pin
(R) Left Side Pipe Positioner Swing Pin
(S) Left Side Pipe Positioner Roller Pin
Table 12
Mast Cab Side Bank
Item Description Sleeve color
A Right Mast Pivot Pin Red
B Right Mast Raise Cylinder Upper Pin Red
C Gear Box Air Seal (Top side) Nut
D Gear Box Top Lip Seal Top Air Seal (Bottom Side) Red
E Pipe Rack Upper Swing Cylinder Head End Red
F Pipe Rack Carousel Support Bearing Red
G Pipe Rack Journal Bearing Red
H Pipe Rack Journal Bearing Red
J Left Side Top Sheave Pin Red
K Right Side Top Sheave Pin Red
L Left Side Bottom Sheave Pin Red
M Right Side Bottom Sheave Pin Red
N Right Side Pipe Positioner Roller Pin Red
P Right Side Pipe Positioner Swing Pin Nut
R Left Side Pipe Positioner Swing Pin Nut
S Right Side Pipe Positioner Roller Pin Red Hydraulic Break Out Wrenches (Hobo)-Lube Points
Illustration 15 g06355971
Hobo-lube points
(A) HOBO Rotate Cylinder Head End
(B) HOBO Swing Pivot Pin Top
(C) HOBO Swing Pivot Pin Bottom
(D) HOBO Swing Cylinder Rod End
(E) HOBO Clamp Slide
(F) HOBO Rotate Cylinder Rod End
(G) HOBO Clamp Cylinder Rod End
(H) HOBO Clamp Pin
Table 13
Hydraulic Break Out Wrenches (HOBO)
Item Description Sleeve color
A HOBO Rotate Cylinder Head End Nut
B HOBO Swing Pivot Pin Top Red
C HOBO Swing Pivot Pin Bottom Red
D HOBO Swing Cylinder Rod End Red
E HOBO Clamp Slide Red
F HOBO Rotate Cylinder Rod End Nut
G HOBO Clamp Cylinder Rod End Nut
H HOBO Clamp Pin Red
Illustration 14 g06355954
Mast cab side bank-lube points
(A) Right Mast Pivot Pin
(B) Right Mast Raise Cylinder Upper Pin
(C) Gear Box Air Seal (Top side)
(D) Gear Box Top Lip Seal Top Air Seal (Bottom Side)
(E) Pipe Rack Upper Swing Cylinder Head End
(F) Pipe Rack Carousel Support Bearing
(G) Pipe Rack Journal Bearing
(H) Pipe Rack Journal Bearing
(J) Left Side Top Sheave Pin
(K) Right Side Top Sheave Pin
(L) Left Side Bottom Sheave Pin
(M) Right Side Bottom Sheave Pin
(N) Right Side Pipe Positioner Roller Pin
(P) Right Side Pipe Positioner Swing Pin
(R) Left Side Pipe Positioner Swing Pin
(S) Left Side Pipe Positioner Roller Pin
Table 12
Mast Cab Side Bank
Item Description Sleeve color
A Right Mast Pivot Pin Red
B Right Mast Raise Cylinder Upper Pin Red
C Gear Box Air Seal (Top side) Nut
D Gear Box Top Lip Seal Top Air Seal (Bottom Side) Red
E Pipe Rack Upper Swing Cylinder Head End Red
F Pipe Rack Carousel Support Bearing Red
G Pipe Rack Journal Bearing Red
H Pipe Rack Journal Bearing Red
J Left Side Top Sheave Pin Red
K Right Side Top Sheave Pin Red
L Left Side Bottom Sheave Pin Red
M Right Side Bottom Sheave Pin Red
N Right Side Pipe Positioner Roller Pin Red
P Right Side Pipe Positioner Swing Pin Nut
R Left Side Pipe Positioner Swing Pin Nut
S Right Side Pipe Positioner Roller Pin Red Hydraulic Break Out Wrenches (Hobo)-Lube Points
Illustration 15 g06355971
Hobo-lube points
(A) HOBO Rotate Cylinder Head End
(B) HOBO Swing Pivot Pin Top
(C) HOBO Swing Pivot Pin Bottom
(D) HOBO Swing Cylinder Rod End
(E) HOBO Clamp Slide
(F) HOBO Rotate Cylinder Rod End
(G) HOBO Clamp Cylinder Rod End
(H) HOBO Clamp Pin
Table 13
Hydraulic Break Out Wrenches (HOBO)
Item Description Sleeve color
A HOBO Rotate Cylinder Head End Nut
B HOBO Swing Pivot Pin Top Red
C HOBO Swing Pivot Pin Bottom Red
D HOBO Swing Cylinder Rod End Red
E HOBO Clamp Slide Red
F HOBO Rotate Cylinder Rod End Nut
G HOBO Clamp Cylinder Rod End Nut
H HOBO Clamp Pin Red
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101607-6952
INJECTION-PUMP ASSEMBLY