101402-3961 ZEXEL 9 400 611 495 BOSCH INJECTION-PUMP ASSEMBLY 9400611495 1014023961 3863644

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 611 495 9400611495

ZEXEL 101402-3961 1014023961

KOMATSU 3863644 3863644

Service parts 101402-3961 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101041-9340

3. GOVERNOR 105404-5360

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:

101402-3961 as INJECTION-PUMP ASSEMBLY

108622-3903 as _

Cross reference number

BOSCH 9 400 611 495 9400611495

ZEXEL 101402-3961 1014023961

KOMATSU 3863644 3863644

Zexel num

Bosch num

Firm num

Name

101402-3961

9 400 611 495

3863644 KOMATSU

INJECTION-PUMP ASSEMBLY
S4D102E K 14BC INJECTION PUMP ASSY PE4A,5A, PE

101402-3961

9 400 611 495

6732711270 KOMATSU

INJECTION-PUMP ASSEMBLY
S4D102E K 14BC INJECTION PUMP ASSY PE4A,5A, 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 131424-3420

Overflow valve opening pressure kPa 255 255 255

Overflow valve opening pressure kgf/cm2 2.6 2.6 2.6

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 11.1

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 82.5 81.5 83.5

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Boost pressure kPa 40 40

Boost pressure mmHg 300 300

Hydraulic cylinder ON *

Injection quantity adjustment_02

Adjusting point C

Rack position 9.1+-0.5

Pump speed r/min 335 335 335

Average injection quantity mm3/st. 10.5 9.5 11.5

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. 75 75 85

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 750 750 750

Rack position 10.1

Boost pressure kPa 10.7 9.4 12

Boost pressure mmHg 80 70 90

Boost compensator adjustment_02

Pump speed r/min 750 750 750

Rack position 11.5

Boost pressure kPa 26.7 26.7 26.7

Boost pressure mmHg 200 200 200

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)RACK LIMIT (When hydraulic cylinder is OFF) (3)Boost compensator stroke: BCL (4)When hydraulic cylinder ON: P1 (5)Rack difference between N = N1 and N = N2 (6)Adjust the secondary timing before adjusting the governor.
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K=10 BCL=1.4+-0.1mm P1=((392)kPa{(4)kgf/cm2}) N1=1250r/min N2=750r/min
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Speed control lever angle

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

----------
a=18deg+-5deg b=28deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)No return spring
----------

----------
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