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


101402-3990 INJECTION-PUMP ASSEMBLY
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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

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

Test data 101402-3990
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)
----------

Speed control lever angle

Test data 101402-3990
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

Test data 101402-3990
N:Pump normal S:Stop the pump. (1)No return spring
----------

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

Timing setting

Test data 101402-3990
(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.
----------
aa=16deg bb=0deg
----------
a=54deg54min+-3deg b=8deg+-30min




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Group cross 101402-3990 ZEXEL

Komatsu 

9 400 610 448 
3863466 
INJECTION-PUMP ASSEMBLY
S4D102E
9 400 610 448 
6732711191 
INJECTION-PUMP ASSEMBLY
S4D102E
9 400 610 449 
3863479 
INJECTION-PUMP ASSEMBLY
S4D102E
9 400 610 449 
6732711210 
INJECTION-PUMP ASSEMBLY
S4D102E
9 400 610 450 
3863496 
INJECTION-PUMP ASSEMBLY
S4D102E
9 400 610 450 
6732711220 
INJECTION-PUMP ASSEMBLY
S4D102E
9 400 610 451 
3863529 
INJECTION-PUMP ASSEMBLY
S4D102E
9 400 610 451 
6732711230 
INJECTION-PUMP ASSEMBLY
S4D102E
 
 
INJECTION-PUMP ASSEMBLY

Komatsu 

9 400 610 452 
3863530 
INJECTION-PUMP ASSEMBLY
S4D102E
9 400 610 452 
6732711240 
INJECTION-PUMP ASSEMBLY
S4D102E
 
 
INJECTION-PUMP ASSEMBLY
 
 
INJECTION-PUMP ASSEMBLY

Komatsu 

9 400 611 654 
3863594 
INJECTION-PUMP ASSEMBLY
S4D102E
9 400 611 654 
6732711250 
INJECTION-PUMP ASSEMBLY
S4D102E
 
 
INJECTION-PUMP ASSEMBLY

Komatsu 

9 400 611 495 
3863644 
INJECTION-PUMP ASSEMBLY
S4D102E
9 400 611 495 
6732711270 
INJECTION-PUMP ASSEMBLY
S4D102E
9 400 612 647 
3863639 
INJECTION-PUMP ASSEMBLY
S4D102E
9 400 612 647 
6732711260 
INJECTION-PUMP ASSEMBLY
S4D102E
9 400 613 883 
3863655 
INJECTION-PUMP ASSEMBLY
4D102E
9 400 613 883 
6731711130 
INJECTION-PUMP ASSEMBLY
4D102E
101402-3990  
9 400 613 884 
3863765 
INJECTION-PUMP ASSEMBLY
S4D102E
101402-3990  
9 400 613 884 
6732711280 
INJECTION-PUMP ASSEMBLY
S4D102E
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