Information injection-pump assembly
BOSCH
9 400 610 341
9400610341
ZEXEL
101402-3782
1014023782
KOMATSU
6732711130
6732711130
Rating:
Service parts 101402-3782 INJECTION-PUMP ASSEMBLY:
1.
_
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
Cross reference number
BOSCH
9 400 610 341
9400610341
ZEXEL
101402-3782
1014023782
KOMATSU
6732711130
6732711130
Zexel num
Bosch num
Firm num
Name
9 400 610 341
6732711130 KOMATSU
INJECTION-PUMP ASSEMBLY
S4D102E K 14BC INJECTION PUMP ASSY PE4A,5A, PE
S4D102E K 14BC INJECTION PUMP ASSY PE4A,5A, PE
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
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
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
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
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
Drive side NO.1
Difference between angles 1
Cal 1-3 deg. 90 89.5 90.5
Cal 1-3 deg. 90 89.5 90.5
Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5
Cal 1-4 deg. 180 179.5 180.5
Difference between angles 3
Cyl.1-2 deg. 270 269.5 270.5
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.
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 the hydraulic cylinder is ON (P1)
----------
K=15 BCL=0.8+-0.1mm P1=((392)kPa{(4)kgf/cm2})
----------
----------
K=15 BCL=0.8+-0.1mm P1=((392)kPa{(4)kgf/cm2})
----------
Speed control lever angle
F:Full speed
I:Idle
S:Stop
(1)Speed = aa (active mode)
(2)-
(3)Speed = bb (normal mode)
(4)-
----------
aa=1200r/min bb=1100r/min
----------
a=18deg+-3deg b=35deg+-5deg c=32deg+-3deg d=5deg+-5deg
----------
aa=1200r/min bb=1100r/min
----------
a=18deg+-3deg b=35deg+-5deg c=32deg+-3deg d=5deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=0deg+-5deg b=53deg+-5deg
----------
----------
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.
----------
aa=16deg bb=0deg
----------
a=54deg54min+-3deg b=8deg+-30min
----------
aa=16deg bb=0deg
----------
a=54deg54min+-3deg b=8deg+-30min
Information:
Parts Needed
Group 1
6 - 1136145 Seat6 - 1136303 Seal-O-Ring1 - 1192940 Gasket6 - 1249714 Tube Assembly6 - 1265424 Clamp-InjectorGroup 2
6 - 0R4970 Injector (for 230 HP and Above)6 - 0R4972 Injector (for 210 HP and Below)6 - 1136303 Seal O-Ring (if not included in group 1)6 - 1148718 Seal O-Ring1 - 1192940 Gasket (if not included in group 1)6 - 1231199 Seal6 - 1258274 Seal O-RingAction Required
See attached rework procedure.
Service Claim Allowances
Group 1
Affected Product
* After failure repairs made prior to January 1, 1996 should claim actual reasonable time. * After failure repairs made January 1, 1996 or later should use the 3126 Time Requirement Guide to determine additional labor hours.
* Before failure repair should claim the labor hours listed below:
If Group 1 and Group 2 repairs are performed, claim Group 2 SMCS Codes ONLY.
Add an additional 1.6 Hours to both groups 1 and 2 if the procedure is done in a motor home.
Parts Stock
Submit one claim for all 1249714 Tube Assemblies removed from Parts Stock.
US and Canadian Dealers Only - When submitting a Parts Stock claim use 99Z00007 in the Product Identification Number Field.
TEPS/MEPS dealers must return the affected Parts Stock to their Caterpillar dealer for replacement.
Group 2
Add an additional 1.6 Hours to both groups 1 and 2 if the procedure is done in a motor home.
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Attach.(1-Rework Procedure)Rework Procedure
Group 1
Affected Product
Jumper Tube Removal
1. Loosen, but do not back off the jumper tube flare nut at the end nearest the high pressure oil manifold, using the 5P0144 Crow's Foot Socket.2. Remove the 8T0292 Bolt and the fuel injector hold-down clamp.3. Loosen and back out the #10 Allen head bolts at the fuel injector using the 1252584 Ball Head Hex Drive Bit (4mm). Leave the bolts in the jumper tube flange while removing the jumper tube. Retain the bolts for reassembly.4. Stabilize the top of the tube with one finger and back out the nut at the mainfold end of the tube.5. Carefully remove the jumper tube from the fuel injector and oil manifold.6. Remove the jumper tube seat and O-ring from the top of the fuel injector. A magnet is recommended for picking up the seat.
7. Retain the removed jumper tube, seat, and O-ring until the warranty claim is processed.Jumper Tube Installation
1. Place a new 1136303 O-Ring into the channel on top of the fuel injector. Do not use STP to lube O-rings. STP traps moisture and will cause rust buildup in the O-ring groove.
2. Place a new 1136145 Jumper Tube Seat over the O-ring on top of the injector. The earlier tubes have a shiny appearance on the two bolt flange. The new tubes have a phosphate and oil coating, which is black, similar in color to an internal engine bolt.
The following guidelines should be used to identify parts in the system. The date code on the 1249714 Tube plastic wrapper is in the form 01996476. The first four numbers represent the month and year,
Group 1
6 - 1136145 Seat6 - 1136303 Seal-O-Ring1 - 1192940 Gasket6 - 1249714 Tube Assembly6 - 1265424 Clamp-InjectorGroup 2
6 - 0R4970 Injector (for 230 HP and Above)6 - 0R4972 Injector (for 210 HP and Below)6 - 1136303 Seal O-Ring (if not included in group 1)6 - 1148718 Seal O-Ring1 - 1192940 Gasket (if not included in group 1)6 - 1231199 Seal6 - 1258274 Seal O-RingAction Required
See attached rework procedure.
Service Claim Allowances
Group 1
Affected Product
* After failure repairs made prior to January 1, 1996 should claim actual reasonable time. * After failure repairs made January 1, 1996 or later should use the 3126 Time Requirement Guide to determine additional labor hours.
* Before failure repair should claim the labor hours listed below:
If Group 1 and Group 2 repairs are performed, claim Group 2 SMCS Codes ONLY.
Add an additional 1.6 Hours to both groups 1 and 2 if the procedure is done in a motor home.
Parts Stock
Submit one claim for all 1249714 Tube Assemblies removed from Parts Stock.
US and Canadian Dealers Only - When submitting a Parts Stock claim use 99Z00007 in the Product Identification Number Field.
TEPS/MEPS dealers must return the affected Parts Stock to their Caterpillar dealer for replacement.
Group 2
Add an additional 1.6 Hours to both groups 1 and 2 if the procedure is done in a motor home.
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Attach.(1-Rework Procedure)Rework Procedure
Group 1
Affected Product
Jumper Tube Removal
1. Loosen, but do not back off the jumper tube flare nut at the end nearest the high pressure oil manifold, using the 5P0144 Crow's Foot Socket.2. Remove the 8T0292 Bolt and the fuel injector hold-down clamp.3. Loosen and back out the #10 Allen head bolts at the fuel injector using the 1252584 Ball Head Hex Drive Bit (4mm). Leave the bolts in the jumper tube flange while removing the jumper tube. Retain the bolts for reassembly.4. Stabilize the top of the tube with one finger and back out the nut at the mainfold end of the tube.5. Carefully remove the jumper tube from the fuel injector and oil manifold.6. Remove the jumper tube seat and O-ring from the top of the fuel injector. A magnet is recommended for picking up the seat.
7. Retain the removed jumper tube, seat, and O-ring until the warranty claim is processed.Jumper Tube Installation
1. Place a new 1136303 O-Ring into the channel on top of the fuel injector. Do not use STP to lube O-rings. STP traps moisture and will cause rust buildup in the O-ring groove.
2. Place a new 1136145 Jumper Tube Seat over the O-ring on top of the injector. The earlier tubes have a shiny appearance on the two bolt flange. The new tubes have a phosphate and oil coating, which is black, similar in color to an internal engine bolt.
The following guidelines should be used to identify parts in the system. The date code on the 1249714 Tube plastic wrapper is in the form 01996476. The first four numbers represent the month and year,