101602-1530 ZEXEL 9 400 610 571 BOSCH INJECTION-PUMP ASSEMBLY 9400610571 1016021530

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 610 571 9400610571

ZEXEL 101602-1530 1016021530

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Buy INJECTION-PUMP ASSEMBLY 101602-1530 zexel genuine, new aftermarket engine parts with delivery

Service parts 101602-1530 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101061-9900

3. GOVERNOR 105402-2700

4. SUPPLY PUMP

105210-5250

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE 156639-1020

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-5031

11. Nozzle and Holder ME016655

12. Open Pre:MPa(Kqf/cm2) 21.6{220}

13. NOZZLE-HOLDER 105048-3590

14. NOZZLE

105017-1040

15. NOZZLE SET

Include in #1:

101602-1530 as INJECTION-PUMP ASSEMBLY

103672-0391 as _

Cross reference number

BOSCH 9 400 610 571 9400610571

ZEXEL 101602-1530 1016021530

Zexel num

Bosch num

Firm num

Name

101602-1530
101602-1531

9 400 610 571

INJECTION-PUMP ASSEMBLY
* K 14BE PE6A 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 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)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-5-3-6- 2-4

Pre-stroke mm 3.5 3.45 3.55

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5

Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5

Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5

Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5

Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5

Injection quantity adjustment

Adjusting point A

Rack position 9.8

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 71.5 70.5 72.5

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point -

Rack position 7.4+-0.5

Pump speed r/min 450 450 450

Average injection quantity mm3/st. 8 6.7 9.3

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Injection quantity adjustment_03

Adjusting point D

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 65 65 70

Fixing the lever *

Rack limit *

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Tolerance for racks not indicated: +-0.05mm. (3)Supplied with torque spring not set. (4)RACK LIMIT (5)Set idle sub-spring (6)Main spring setting
----------
K=9
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=5deg+-5deg b=24deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=26.5deg+-5deg b=53deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of gear mark '3' at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=12.5deg
----------
a=(130deg)

Information:

Problem
Some remanufactured fuel injection pumps have been built with the control solenoid in the wrong position. If the solenoid is in the wrong position, the wiring harness may be impossible to connect to the solenoid due to interference of other components.The affected fuel pump part numbers are:
10R-7659 Unit Injection Hydraulic Pump and Mounting Gp
10R-7660 Unit Injection Hydraulic Pump and Mounting Gp
10R-7661 Unit Injection Hydraulic Pump and Mounting Gp
10R-7662 Fuel Pump Gp
20R-3815 Fuel Injection Pump GpSolution
Illustration 1 g06120812
View of the top of the 10R-7661 Unit Injection Hydraulic Pump and Mounting Gp and 10R-7662 Fuel Pump Gp.
(X) Pump center line
(Y) Acceptable solenoid connector orientation (—30 degrees to 30 degrees from pump center line)
Illustration 2 g06120817
View of the top of the 10R-7659 Unit Injection Hydraulic Pump and Mounting Gp, 10R-7660 Unit Injection Hydraulic Pump and Mounting Gp, and 20R-3815 Fuel Injection Pump Gp.
(X) Pump center line
(Z) Acceptable solenoid connector orientation (15 degrees to 45 degrees from pump center line)Check the fuel injection pump solenoid position before attempting to install the pump. Refer to Illustration 1 and Illustration 2. If the orientation of the connector on the solenoid is not within the acceptable range, return the faulty pump and replace the pump with the same part number.Note: Do not attempt to disassemble the fuel injection pump to reposition the solenoid.