101402-3952 ZEXEL 9 400 611 654 BOSCH INJECTION-PUMP ASSEMBLY 9400611654 1014023952 3863594

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 611 654 9400611654

ZEXEL 101402-3952 1014023952

KOMATSU 3863594 3863594

Service parts 101402-3952 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101041-9260

3. GOVERNOR 105404-5292

4. SUPPLY PUMP

105220-5960

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY

11. Nozzle and Holder

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

13. NOZZLE-HOLDER

14. NOZZLE

15. NOZZLE SET

Include in #1:

101402-3952 as INJECTION-PUMP ASSEMBLY

108622-3891 as _

Cross reference number

BOSCH 9 400 611 654 9400611654

ZEXEL 101402-3952 1014023952

KOMATSU 3863594 3863594

Zexel num

Bosch num

Firm num

Name

101402-3952

9 400 611 654

3863594 KOMATSU

INJECTION-PUMP ASSEMBLY
S4D102E K

101402-3952

9 400 611 654

6732711250 KOMATSU

INJECTION-PUMP ASSEMBLY
S4D102E 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 131424-3420

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 1-3-4-2

Pre-stroke mm 2.5 2.45 2.55

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-3 deg. 90 89.5 90.5

Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5

Difference between angles 3
Cyl.1-2 deg. 270 269.5 270.5

Injection quantity adjustment

Adjusting point A

Rack position 10

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 84 83 85

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Boost pressure kPa 46 46

Boost pressure mmHg 345 345

Hydraulic cylinder ON *

Injection quantity adjustment_02

Adjusting point C

Rack position 7.9+-0.5

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 13 12 14

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Hydraulic cylinder ON *

Injection quantity adjustment_03

Adjusting point D

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 85 85 95

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Hydraulic cylinder OFF *

Rack limit *

Boost compensator adjustment

Pump speed r/min 1200 1200 1200

Rack position R1-0.9

Boost pressure kPa 18.7 16 21.4

Boost pressure mmHg 140 120 160

Boost compensator adjustment_02

Pump speed r/min 1200 1200 1200

Rack position R1(10)

Boost pressure kPa 32.7 26 39.4

Boost pressure mmHg 245 195 295

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)RACK LIMIT (When hydraulic cylinder is OFF) (4)Main spring setting (5)Set idle sub-spring (6)The torque control spring must does not have a set force. (7)Boost compensator stroke: BCL (8)When the hydraulic cylinder is ON (P1) (9)Adjust the secondary timing before adjusting the governor.
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K=16 BCL=0.9+-0.1mm P1=(392)kPa{(4)kgf/cm2}
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Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting (2)At hole above R = aa (center)
----------
aa=80mm
----------
a=47deg+-3deg b=35deg+-5deg

Stop lever angle

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

----------
a=0deg+-5deg b=53deg+-5deg

Timing setting

(1)Pump vertical direction (2)Key groove position at No. 1 cylinder's beginning of injection position (at BTDC: aa). (3)Position of the key groove of the No. 1 cylinder at B.T.D.C. bb (fix the governor flyweight at this position for delivery). (4)B.T.D.C.: aa (5)At second timing adjustment, set the camshaft at the * position and tighten the flyweight locknut. (6)Align the flyweight's timing gear position with the lockpin groove and then fully tighten the flyweight to the camshaft. (7)Remove the lock pin and adjust the governor. Reinstall the lock pin to fix the flyweight for delivery.
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aa=16deg bb=0deg
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a=54deg54min+-3deg b=8deg+-30min