101606-9400 ZEXEL 9 400 619 523 BOSCH INJECTION-PUMP ASSEMBLY 9400619523 1016069400


 

Information injection-pump assembly

BOSCH 9 400 619 523 9400619523
ZEXEL 101606-9400 1016069400
101606-9400 INJECTION-PUMP ASSEMBLY
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Service parts 101606-9400 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101060-3290
3. GOVERNOR 105492-0330
4. SUPPLY PUMP 105220-5200
5. AUTOM. ADVANCE MECHANIS 105643-0250
6. COUPLING PLATE 105661-0350
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105101-5440
11. Nozzle and Holder
12. Open Pre:MPa(Kqf/cm2) 21.6{220}
13. NOZZLE-HOLDER 105031-3522
14. NOZZLE 105015-7100
15. NOZZLE SET

Include in #1:

101606-9400 as INJECTION-PUMP ASSEMBLY

Include in #2:

Cross reference number

BOSCH 9 400 619 523 9400619523
ZEXEL 101606-9400 1016069400


Zexel num
Bosch num
Firm num
Name
101606-9400 
9 400 619 523 
   
INJECTION-PUMP ASSEMBLY
K 14BE INJECTION PUMP ASSY 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   131424-1520
Overflow valve opening pressure kPa   157 123 191
Overflow valve opening pressure kgf/cm2   1.6 1.25 1.95
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
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left
  L
Injection order   1-5-3-6- 2-4
Pre-stroke mm   3.3 3.25 3.35
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   12.2
Pump speed r/min   1450 1450 1450
Average injection quantity mm3/st.   80 78 82
Max. variation between cylinders %   0 -3 3
Basic   *
Fixing the lever   *
Injection quantity adjustment_02
Adjusting point   C
Rack position   9.9+-0.5
Pump speed r/min   250 250 250
Average injection quantity mm3/st.   10.1 8.6 11.6
Max. variation between cylinders %   0 -15 15
Fixing the rack   *
Injection quantity adjustment_03
Adjusting point   D
Rack position   -
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   74.5 74.5
Fixing the lever   *
Remarks
After startup boost setting
 
Timer adjustment
Pump speed r/min   550--
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   500
Advance angle deg.   0.5
Timer adjustment_03
Pump speed r/min   1000
Advance angle deg.   3.2 2.7 3.7
Timer adjustment_04
Pump speed r/min   1500
Advance angle deg.   6.5 6 7
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101606-9400
N:Pump speed R:Rack position (mm) (1)Tolerance for racks not indicated: +-0.05mm. (2)Excess fuel setting for starting: SXL (N = N1) (3)Damper spring setting (4)Rack difference between N = N2 and N = N3
----------
SXL=12.6+0.2mm N1=450r/min N2=1450r/min N3=900r/min
----------

Speed control lever angle

Test data 101606-9400
F:Full speed
----------

----------
a=10deg+-5deg

0000000901

Test data 101606-9400
F:Full load I:Idle (1)Use the hole at R = aa (2)Stopper bolt setting
----------
aa=55mm
----------
a=5.5deg+-5deg b=22deg+-3deg

Stop lever angle

Test data 101606-9400
N:Pump normal S:Stop the pump. (1)Use the pin at R = aa
----------
aa=30mm
----------
a=35deg+-5deg b=71deg+-5deg

Timing setting

Test data 101606-9400
(1)Pump vertical direction (2)Coupling's key groove position for the No. 6 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(30deg)




Information:

A "single" winding (single output) magnetic pickup sensor is recommended for use as a vehicle speed sensor for the 3406B (PEEC III) System. Experience has shown that use of a "dual" winding (dual output) vehicle speed sensor can contribute to electrical noise problems. Vehicle speed buffer negative battery pin must be connected to engine ground, not to cab ground. The vehicle speed circuit consists of the Vehicle Speed Sensor, the Vehicle Speed Buffer and associated wiring. The sensor is a standard magnetic pickup and is supplied by the truck manufacturer. It senses the movement of teeth on the output shaft of the transmission. The buffer (Caterpillar supplied) takes the signal from the sensor, conditions it and sends it to both the ECM and the vehicle speedometer.There are three acceptable options for wiring of the vehicle speed circuit: For all three options, the Vehicle Speed Buffer should be grounded to the same ground point as the ECM. On 3406B (PEEC III) Engines, the ECM ground point is the cylinder head ground stud.Option 1. Use separate sensors for the Vehicle Speed Buffer and the speedometer, with the second sensor supplying the signal to the speedometer. This option completely isolates the two circuits and is preferred by Caterpillar. See Illustration 1.
Illustration 1
Recommended vehicle speed circuit wiring when using two separate sensors.Option 2. Use a single sensor, with the Vehicle Speed Buffer supplying the signal to the speedometer. This option provides good results when correctly wired. Note that this illustration is electrically identical to the schematic in the 3406B (PEEC III) Diesel Truck Engine Electrical Schematic, Form No SENR5152, which is in the complete Service Manual, 3406B (PEEC III) Diesel Truck Engine, Form No. SENR5150, but shows the required grounding for the speedometer more clearly.The 3E0020 buffer provides a second output line for speedometer requiring two signal lines.
Illustration 2
Recommended vehicle speed circuit wiring using a single sensor.Option 3. Use a dual winding sensor, with the second winding supplying the signal to the speedometer. This option is not preferred by Caterpillar, but can provide acceptable results if the sensor is installed correctly.Dual winding sensors may be used in some new OEM installations which have been specifically reviewed by Caterpillar.
Illustration 3
Recommended vehicle speed circuit wiring when using a dual-winding sensor.The Vehicle Speed Buffer has a five-pin connector (J14/P14) with pins to battery negative, battery positive, the ECM and two for the vehicle speedometer.+ Battery (Pin A) supplies battery power to the buffer.- Battery (Pin B) provides battery ground through the cylinder head ground stud.Buffer Output to the ECM (Pin D) supplies a series of 5 volt DC pulses to the ECM. The frequency of the pulses varies directly with the speed of the vehicle.When a single Vehicle Speed Sensor is used, as in Illustration 2, the vehicle speed signal to the speedometer is provided by the buffer.The 3E0020 buffer has two speedometer outputs, one at P14, Pin C and one at P14, Pin E. Output at each one is a series of -8 volt

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