101606-0200 ZEXEL 9 400 615 409 BOSCH INJECTION-PUMP ASSEMBLY 9400615409 1016060200 8976004970


 

Information injection-pump assembly

BOSCH 9 400 615 409 9400615409
ZEXEL 101606-0200 1016060200
ISUZU 8976004970 8976004970
101606-0200 INJECTION-PUMP ASSEMBLY
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Cross reference number

BOSCH 9 400 615 409 9400615409
ZEXEL 101606-0200 1016060200
ISUZU 8976004970 8976004970


Zexel num
Bosch num
Firm num
Name
101606-0200 
9 400 615 409 
8976004970  ISUZU
INJECTION-PUMP ASSEMBLY
6HH1-S K 14BF INJECTION PUMP ASSY PE6AD 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   131424-4920
Overflow valve opening pressure kPa   127 107 147
Overflow valve opening pressure kgf/cm2   1.3 1.1 1.5
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
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left
  L
Injection order   1-5-3-6- 2-4
Pre-stroke mm   4.7 4.65 4.75
Rack position
After adjusting injection quantity.
  R=A
Beginning of injection position
Governor 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   -
Rack position   13
Pump speed r/min   850 850 850
Average injection quantity mm3/st.   86.5 84.9 88.1
Max. variation between cylinders %   0 -2.5 2.5
Basic   *
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_02
Adjusting point   -
Rack position   9.6+-0.5
Pump speed r/min   275 275 275
Average injection quantity mm3/st.   9.4 8.1 10.7
Max. variation between cylinders %   0 -14 14
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
 
Injection quantity adjustment_03
Adjusting point   A
Rack position   R1(13)
Pump speed r/min   850 850 850
Average injection quantity mm3/st.   86.5 85.5 87.5
Basic   *
Fixing the lever   *
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1+0.15
Pump speed r/min   1450 1450 1450
Average injection quantity mm3/st.   95.5 92.3 98.7
Fixing the lever   *
Injection quantity adjustment_05
Adjusting point   C
Rack position   R1-0.25
Pump speed r/min   600 600 600
Average injection quantity mm3/st.   77.5 74.3 80.7
Fixing the lever   *
Timer adjustment
Pump speed r/min   905--
Advance angle deg.   0 0 0
Load   3/5
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   855
Advance angle deg.   0.3
Load   3/5
Timer adjustment_03
Pump speed r/min   -
Advance angle deg.   1.5 1 2
Load   5/5
Remarks
Measure the actual speed.
 
Timer adjustment_04
Pump speed r/min   1110
Advance angle deg.   1.5 1 2
Load   3/5
Timer adjustment_05
Pump speed r/min   1450
Advance angle deg.   7 6.5 7.5
Load   5/5
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101606-0200
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm.
----------
T1=K09
----------

Speed control lever angle

Test data 101606-0200
F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=60mm
----------
a=28.5deg+-5deg b=40deg+-3deg

Stop lever angle

Test data 101606-0200
N:Pump normal S:Stop the pump. (1)Use the pin at R = aa
----------
aa=46.5mm
----------
a=34.5deg+-5deg b=40deg+-5deg

0000001501 I/P WITH LOAD PLUNGER ADJ

Plunger assembly number: PL (stamping: ST) 1. Adjustment procedures (1)Insert the pre-stroke adjusting shims L1 for each cylinder. (2)Adjust injection quantity.(max. var. bet. cyl. idling a1, full a2) (3)At basic point A, adjust so that the pre-stroke is L2. (4)Reconfirm the injection quantity.
----------
PL=131153-9020 ST=A769 L1=1mm L2=4.7+-0.05mm a1=+-14% a2=+-2.5%
----------

0000001601 AIR CYLINDER

Test data 101606-0200
1. (1) Set the speed lever to idle. (2)Screw in air cylinder (A) (3)Set the clearance from the speed lever (B) at approximately L.
----------
L=1mm
----------

Timing setting

Test data 101606-0200
(1)Pump vertical direction (2)Position of timer's threaded hole at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)At rack position = bb
----------
aa=6deg bb=R1(13)mm
----------
a=(150deg)




Information:

3406 Electronic Truck Engine
Oil Filter (1), Oil Level Gage (2), Water Pump (3), Alternator Bracket (4), Turbocharger (5), Crankcase Breather (6), Damper (7), Water Temperature Sensor (8) and Thermostat Housing (9).
Fuel Filter and Priming Pump (10), Electronic Governor (11), Electronic ECM (12), Oil Filler (13), Compressor (14), Grounding Stud (15) and Lift Eye (16).Engine Information
The Caterpillar 3406 Diesel Truck engine is direct fuel injected, turbocharged and an air-to-air aftercooler arrangement (ATAAC). The cooling system consists of a gear driven centrifugal pump, with one thermostat which regulates the engine coolant water temperature, an oil cooler and an OEM radiator incorporating a shunt system.The engine lubricating oil, which is both cooled and filtered, is supplied by a gear-type pump. Bypass valves provide unrestricted flow of lubrication oil to the engine parts when oil viscosity is high, or if either the oil cooler or the oil filter elements should become plugged.Engine efficiency, efficiency of emission controls and engine performance depend on adherence to proper operation and maintenance recommendations, and the use of recommended fuels and lubrication oils.Electronic Engine Control (if equipped)
The programmable electronic engine control is designed to provide electronic governing, automatic air-fuel ratio control, torque rise shaping, injection timing control and system diagnostics with the capability for future expansion.Other benefits such as improved cold starting capability, tamper diagnostics, cruise control, vehicle speed limiting, low and high gears engine rpm limiting (progressive shift engine speed control), PTO governor, ATA data link (SAE J1587) and an Engine Monitoring Package.The fuel system is mechanically actuated and electronically controlled combining the pumping, electronic fuel metering and injecting elements to produce higher injection pressures.High injection pressures help to reduce fuel consumption and particulate emissions.Individual injection pumps, one for each cylinder, meter and pump fuel under high pressure to an injection valve for each cylinder.A full range electronic governor controls the fuel injection pump output to maintain desired engine rpm. The governor functions like the Caterpillar mechanical governor in the mid-range, but includes additional features. These include programmable isochronous low idle and 20 to 200 rpm governor overrun.Automatic timing advance provides the best fuel injection timing over the full range of engine speed. The injection timing is varied as a function of engine operating conditions.This optimizes the engine's performance for starting, emissions, noise, fuel consumption and driveability.The Electronic Engine Control has built-in diagnostics to assure that all components are functioning and operating properly.In the event of a system component deviation from programmed limits, the operator will be alerted to the condition by a dashboard mounted CHECK ENGINE/DIAGNOSTIC lamp.A Caterpillar service tool or cruise control switches (if equipped) are needed to read the numerical code of the diagnostic flash code. There are three types of diagnostic codes; active (fault), logged and event. These codes are logged and stored in the system memory.Multi-Torque Rating (if equipped)
Multi-torque ratings provide for additional torque as engine load increases. This feature provides higher torque levels and better driveability while in the top gears ONLY. The engine electronics are able to determine when

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