101606-0390 ZEXEL 9 400 612 788 BOSCH INJECTION-PUMP ASSEMBLY 9400612788 1016060390 8976021370

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 612 788 9400612788

ZEXEL 101606-0390 1016060390

ISUZU 8976021370 8976021370

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Service parts 101606-0390 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-6571

3. GOVERNOR 105932-3650

4. SUPPLY PUMP 105230-1090

5. AUTOM. ADVANCE MECHANIS 105690-0270

6. COUPLING PLATE 105661-1170

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105110-7743

11. Nozzle and Holder 8-94391-291-4

12. Open Pre:MPa(Kqf/cm2) 16.5{165}/19.6{200}

13. NOZZLE-HOLDER 105041-2082

14. NOZZLE

15. NOZZLE SET 105019-2190

Include in #1:

101402-4252 as _

101606-0390 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 612 788 9400612788

ZEXEL 101606-0390 1016060390

ISUZU 8976021370 8976021370

Zexel num

Bosch num

Firm num

Name

101606-0390

9 400 612 788

8976021370 ISUZU

INJECTION-PUMP ASSEMBLY
6HL1-N K 14BN INJECTION PUMP ASSY PE

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113 or {SAEJ967d}

Test oil temperature degC 40 40 45

Nozzle and nozzle holder 105780-8310

Nozzle 105780-0120

Bosch type code 1 688 901 101

Nozzle holder 105780-2240

Opening pressure MPa 18

Opening pressure kgf/cm2 184

Injection pipe
Outer diameter - inner diameter - length (mm) mm 6-2-600

Overflow valve 131424-8620

Overflow valve opening pressure kPa 206 206 206

Overflow valve opening pressure kgf/cm2 2.1 2.1 2.1

Tester oil delivery pressure kPa 255 255 255

Tester oil delivery pressure kgf/cm2 2.6 2.6 2.6

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 3.8 3.75 3.85

Rack position
Point A 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 14.2

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 65 63.4 66.6

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 Z

Rack position 9.7+-0.5

Pump speed r/min 295 295 295

Average injection quantity mm3/st. 13 11.7 14.3

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(14.2)

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 65 64 66

Basic *

Fixing the lever *

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm.
----------
T1=P02
----------

Timer adjustment

(1)Adjusting range (2)Step response time (N): Speed of the pump (L): Load (theta) Advance angle (Srd1) Step response time 1 (Srd2) Step response time 2 1. Adjusting conditions for the variable timer (1)Adjust the clearance between the pickup and the protrusion to L.
----------
L=1.5+-0.2mm N2=800r/min C2=(8)deg t1=2--sec. t2=2--sec.
----------
N1=1300++r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=8+-0.3deg R01=0/4load R02=4/4load

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting (2)Use the pin at R = aa (3)Viewed from feed pump side.
----------
aa=35mm
----------
a=11deg+-5deg b=40deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the pin at R = aa
----------
aa=45mm
----------
a=12.5deg+-5deg b=40deg+-5deg

0000001501 RACK SENSOR

Rack sensor adjustment 1. Flange type rack sensor (rack sensor adjustment -5*20) (1)These types of rack sensors do not need adjustment. Confirm the performance with the following procedures. (2)Mount the rack sensor main body to the pump main body. (3)Fix the pump lever at full. (4)At supply voltage V1, pump speed N1 and rack position Ra, confirm that the amp's output voltage is Vist. (5)Move the pump lever two or three times. (6)Set again to full. (7)Confirm that the amplifier output voltage is Vist. (8)Fix the caution plate to the upper part of the rack sensor. (For those without the caution plate instructions, make sure the nameplate of the rack sensor carries the "Don't hold here" caution.) (9)Apply red paint to the rack sensor mounting bolts (2 places).
----------
V1=5+-0.01V N1=850r/min Ra=R1(14.2)mm Vist=3.49+-0.28V
----------

Timing setting

(1)Pump vertical direction (2)Positions of coupling's threaded installation holes at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=6deg
----------
a=(160deg)

Information:

Caterpillar Reference Material
Oil
SEBD0640 Oil and Your EngineSEBU6310 EMA Engine Oil Data BookPEDP7105 Scheduled Oil SamplingPEDP7122 Question & Answer BookletPEHP0002 Cat Molybdenum Grease (MPGM)PEHP0003 Cat Lithium Grease (MPGL)PEHP0017 Cat Special Purpose Grease (SPG)PEHP1020 Cat Diesel Engine Oil (CF-4) Data Sheet (North America)PEHP1026 Cat Diesel Engine Oil (CF-4) Data Sheet (International)PEHP6001 How to Take a Good Oil SamplePEWP9733 Cat Fluids SelectorFuel
SEBD0717 Diesel Fuels and Your EngineSEHS7067 Fuels for Caterpillar Diesel EnginesLEKQ3363 Caterpillar Engine Data Sheet 60.1 (Fuels Recommended For Use In Caterpillar Truck Engines)Coolant
SEBD0518 Know Your Cooling SystemSEBD0970 Coolant and Your EngineService Manuals
SEBR0514 Low Emission SystemSEBR0560 3406C (Mechanical) Service Manual (3ZJ16182 and Up, 5KJ07800 and Up)SENR5505 3406C (Electronic) Service Manual (4CK00846 and Up)Special Instructions
The following Special Instructions pertain to the operation, maintenance, diagnostic tooling and programming of the PEEC system. Some of these publications will be included in the tool kits, the others will be available thru your Caterpillar dealer.SEHS7808 Using the 6V3060 Low Emission System TesterSEHS8622 Using the FT1984 Air-To-Air Aftercooler Leak Test GroupSEHS8627 and SEHS9083 Using the 1U5540 Tool GroupSEHS8741 Using the 8C5919 Service Program ModuleSEHS8742 Using the 8T8697 Electronic Control Analyzer Programmer (ECAP)SEHS8743 Using the 8C4629 Digital Diagnostic Tool (DDT) with Programmable Electronic Engine Control ModuleSEHS8746 Using the 1U5540 Tool GroupSEHS8807 Programmable Electronic Engine Control Screen Map(s)SEHS9031 Storage Procedure for Caterpillar ProductsSEHS9349 Using the 8C5919 Service Program ModuleMiscellaneous
LEBT8121 Truck Engine Application and Installation Guide (4-88)LEDT4211 PAR DirectoryLEDT5092 Driving Techniques For Maximum Fuel EconomyLEGT5087 Truck Engine Application and Installation GuideLEHQ6101 General Instructions and Application GuideLEKT8467 Specing for Peak PerformanceLEXT7056 Performance Analysis Report (PAR) Testing for 3406 Electronic Truck EnginesPEDP0026 Power Analysis ReportSEBD0794 3400 Engine-Major Component Performance GuideSEBF8029 Index to Guidelines for Reusable Parts and Salvage OperationsSEBF8062 Guideline for Reusable Parts (Cleaning and Inspection of Air Filters)SELF5052 Emission Related Components WarrantyAdditional Reference Material
ASTM D217-68 - Worked PenetrationASTM D2896 - TBN MeasurementsASTM D2982BASTM D3828AASTM D445ASTM D893ASTM 4985-89 - GM-6038M SpecificationASTM Specs can normally be obtained from your local technological society, library or college.SAE J313 - Diesel FuelsSAE J754 - NomenclatureSAE J183 - ClassificationSAE Specs can be found in your SAE handbook or can be obtained from your local library, college or technological society.* SAE handbooks can be obtained directly from:SAE International
400 Commonwealth Drive
Warrendale, PA USA 15096-0001
All of the above publications are available through your Caterpillar dealer.Customer Specified Reference Numbers
Below is space for information on the programmed specifications to be filled in by the owner. ENGINE: 3406 Electronic* VEHICLE IDENTIFICATION NO. (VIN)____________________* RATING SELECTION NUMBER____________________* CUSTOMER PASSWORDS: Password No. 1 ____________________Password No. 2 ____________________* VEHICLE SPEED PARAMETERS: Vehicle Speed Calibration____________________ppmTachometer Calibration____________________pprVehicle Speed Limit (VSL)____________________mph (km/h)5 mph Vehicle Speed Droop ____________________Engine RPM @ VSL____________________rpm* CRUISE CONTROL (CC) PARAMETERS: Low Cruise Control Speed Set Limit (LCC)____________________mph (km/h)High Cruise Control Speed Set Limit (HCC)____________________mph (km/h)Engine Retarder Mode ____________________Cruise Switch Configuration ____________________* PTO GOVERNOR PARAMETERS: PTO Mode Speed Limit____________________mph (km/h)PTO Mode Engine Speed (rpm) Limit____________________rpmPTO Engine Speed Ramp Rate____________________rpm/sec.* PROGRESSIVE SHIFTING PARAMETERS: Low Gears #1 (LoGr#1) Engine RPM Limit____________________rpmLow Gears #1 (LoGr#1)