101402-3990 ZEXEL 9 400 613 884 BOSCH INJECTION-PUMP ASSEMBLY 9400613884 1014023990 3863765

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 613 884 9400613884

ZEXEL 101402-3990 1014023990

KOMATSU 3863765 3863765

Service parts 101402-3990 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101041-9260

3. GOVERNOR 105404-5041

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:

101402-3990 as INJECTION-PUMP ASSEMBLY

107691-3441 as _

Cross reference number

BOSCH 9 400 613 884 9400613884

ZEXEL 101402-3990 1014023990

KOMATSU 3863765 3863765

Zexel num

Bosch num

Firm num

Name

101402-3990

9 400 613 884

3863765 KOMATSU

INJECTION-PUMP ASSEMBLY
S4D102E K 14BD INJECTION PUMP ASSY PE4AD PE

101402-3990

9 400 613 884

6732711280 KOMATSU

INJECTION-PUMP ASSEMBLY
S4D102E K 14BD INJECTION PUMP ASSY PE4AD 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 255 221 289

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 9.7

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 93.5 92.5 94.5

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Boost pressure kPa 53.3 53.3

Boost pressure mmHg 400 400

Hydraulic cylinder ON *

Injection quantity adjustment_02

Adjusting point -

Rack position 7.1+-0.5

Pump speed r/min 450 450 450

Average injection quantity mm3/st. 10 9 11

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 *

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Injection quantity adjustment_03

Adjusting point D

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 90 90 100

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 650 650 650

Rack position R1-0.8

Boost pressure kPa 26 23.3 28.7

Boost pressure mmHg 195 175 215

Boost compensator adjustment_02

Pump speed r/min 650 650 650

Rack position R1(9.7)

Boost pressure kPa 40 33.3 46.7

Boost pressure mmHg 300 250 350

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)The torque control spring does not operate. (4)Adjust the secondary timing before adjusting the governor. (5)RACK LIMIT (When hydraulic cylinder is OFF) (6)Boost compensator stroke: BCL (7)When hydraulic cylinder ON: P1
----------
K=15 BCL=0.8+-0.1mm P1=(392)kPa((4)kgf/cm2)
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Speed control lever angle

F:Full speed I:Idle (1)Speed = aa (active mode) (2)Speed = bb (normal mode) (3)Use the center hole above R = cc
----------
aa=1200r/min bb=1100r/min cc=80mm
----------
a=18deg+-3deg b=35deg+-5deg c=5deg+-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