101602-2401 ZEXEL 9 400 619 654 BOSCH INJECTION-PUMP ASSEMBLY 9400619654 1016022401

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 619 654 9400619654

ZEXEL 101602-2401 1016022401

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Buy INJECTION-PUMP ASSEMBLY 101602-2401 zexel genuine, new aftermarket engine parts with delivery

Service parts 101602-2401 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-3461

3. GOVERNOR 105400-5580

4. SUPPLY PUMP 105210-4351

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE 105661-0410

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-5490

11. Nozzle and Holder 236001830A

12. Open Pre:MPa(Kqf/cm2) 19.6{200}

13. NOZZLE-HOLDER 105030-4060

14. NOZZLE 105015-7180

15. NOZZLE SET

Include in #1:

101602-2401 as INJECTION-PUMP ASSEMBLY

106671-4960 as _

Cross reference number

BOSCH 9 400 619 654 9400619654

ZEXEL 101602-2401 1016022401

Zexel num

Bosch num

Firm num

Name

101602-2401
101602-2402

9 400 619 654

INJECTION-PUMP ASSEMBLY
* K

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 134424-0920

Overflow valve opening pressure kPa 162 147 177

Overflow valve opening pressure kgf/cm2 1.65 1.5 1.8

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 1-4-2-6- 3-5

Pre-stroke mm 4.8 4.77 4.83

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-4 deg. 60 59.75 60.25

Difference between angles 2
Cyl.1-2 deg. 120 119.75 120.25

Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25

Difference between angles 4
Cal 1-3 deg. 240 239.75 240.25

Difference between angles 5
Cal 1-5 deg. 300 299.75 300.25

Injection quantity adjustment

Adjusting point A

Rack position 9.7

Pump speed r/min 750 750 750

Average injection quantity mm3/st. 103.3 101.3 105.3

Max. variation between cylinders % 0 -3.5 3.5

Basic *

Fixing the rack *

Injection quantity adjustment_02

Adjusting point B

Rack position 10.2

Pump speed r/min 750 750 750

Average injection quantity mm3/st. 117.3 115.3 119.3

Fixing the rack *

Injection quantity adjustment_03

Adjusting point -

Rack position 6+-0.5

Pump speed r/min 360 360 360

Average injection quantity mm3/st. 10 9 11

Max. variation between cylinders % 0 -10 10

Fixing the rack *

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

Injection quantity adjustment_04

Adjusting point D

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 133 133 143

Fixing the lever *

Rack limit *

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)RACK LIMIT (3)Set idle sub-spring (4)Main spring setting
----------
K=13
----------

Speed control lever angle

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

----------
a=(9deg)+-5deg b=(17deg)+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)At shipping
----------

----------
a=27deg+-5deg b=53deg+-5deg

Timing setting

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(50deg)

Information:

Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.
New DEF sensor kits are available. The new sensor kit allows the DEF sensor to be repaired on DEF manifold assemblies.Note: If troubleshooting procedures indicate a replacement of the DEF manifold, do not replace the DEF Manifold. Repair the DEF Manifold using the DEF manifold sensor kit.Refer to Table 1 for the appropriate DEF sensor kit for the DEF manifold installed.
Table 1
DEF manifold Part Number Part Description Repair with DEF Sensor Kit
462-3219 11 inch (279mm) Manifold 593-0641
462-3610 13 inch (330mm) Manifold 593-0642
462-3232 18 inch (457mm) Manifold 593-0643
Illustration 1 g06508474New disassembly and assembly instructions are available. Refer to Disassembly and Assembly, Manifold (DEF Heater) - Disassemble and Disassembly and Assembly, Manifold (DEF Heater) - Assemble for the correct procedures.