Information injection-pump assembly
BOSCH
9 400 610 449
9400610449
ZEXEL
101402-3910
1014023910
KOMATSU
3863479
3863479
Rating:
Service parts 101402-3910 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
9 400 610 449
9400610449
ZEXEL
101402-3910
1014023910
KOMATSU
3863479
3863479
Zexel num
Bosch num
Firm num
Name
101402-3910
9 400 610 449
3863479 KOMATSU
INJECTION-PUMP ASSEMBLY
S4D102E K 14BC INJECTION PUMP ASSY PE4A,5A, PE
S4D102E K 14BC INJECTION PUMP ASSY PE4A,5A, PE
101402-3910
9 400 610 449
6732711210 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
9.4
Pump speed
r/min
950
950
950
Average injection quantity
mm3/st.
89
88
90
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
7.1+-0.5
Pump speed
r/min
465
465
465
Average injection quantity
mm3/st.
12.5
11.5
13.5
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
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
*
Rack limit
*
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)RACK LIMIT
(5)Adjust the secondary timing before adjusting the governor.
----------
K=12
----------
----------
K=12
----------
Speed control lever angle
F:Full speed
I:Idle
S:Stop
(1)At hole above R = aa (center)
----------
aa=80mm
----------
a=8deg+-3deg b=32deg+-3deg c=26deg+-5deg
----------
aa=80mm
----------
a=8deg+-3deg b=32deg+-3deg c=26deg+-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=15deg bb=0deg
----------
a=54deg54min+-3deg b=7deg30min+-30min
----------
aa=15deg bb=0deg
----------
a=54deg54min+-3deg b=7deg30min+-30min
Information:
August 31, 2004
O-219
Priority PRODUCT IMPROVEMENT PROGRAM FOR REPLACINGTHE INJECTION ACTUATION PRESSURE SENSOR ON CERTAIN 3126E ENGINES
7755,1925 PI30676
This Program must be administered assoon as possible. When reporting the repair, use "PI30676" as the Partnumber and "7751" as the Group Number, "56" as the Warranty Claim DescriptionCode and "T" as the SIMS Description Code. Exception: If the repair isdone after failure, use "PI30676" as the Part Number, "7751" as the GroupNumber, "96" as the Warranty Claim Description Code, and "Z" as the SIMSDescription Code. The information supplied in this serviceletter may not be valid after the termination date of this program. Donot perform the work outlined in this Service Letter after the terminationdate without first contacting your Caterpillar product analyst.
COMPLETION DATE
TERMINATION DATE
February 28, 2005 August 31, 2005PROBLEM
Replace the injection actuation pressure sensorcertain 3126E engines. The old sensor may leak oil.AFFECTED PRODUCT
Model IdentificationNumber
3126E G3E230-497PARTS NEEDED
Qty
Part Number Description
1 2244536 SENSOR GP-PRACTION REQUIRED
Remove the 194-6726 Pressure Sensor and replaceit with part number 224-4536 Pressure Sensor.OWNER NOTIFICATION
U.S. and Canadian owners will receive the attachedOwner Notification.SERVICE CLAIM ALLOWANCES
Caterpillar Dealer Suggested Customer Suggested
Parts Labor Hrs Parts LaborHrs Parts LaborHrs
100% 1.0 0 0 0 0
This is a 1.0-hour job. U.S. and Canadian Dealers Only - Eligibledealers may enter a Type 2 SIMS ReportPARTS DISPOSITION
Handle the parts in accordance with your WarrantyBulletin on warranty parts handling.MAKE EVERY EFFORT TO COMPLETE THIS PROGRAMAS SOON AS POSSIBLE.Attach. (Owner Notification)COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS
XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999PRIORITY - THE INJECTION ACTUATION PRESSURESENSOR NEEDS TO BE REPLACED.MODELS INVOLVED - CERTAIN 3126E ENGINESDear Caterpillar Product Owner:A new injection actuation pressure sensor needsto be installed on the products listed below. The current sensor may leakoil. You will not be charged for the service performed.Contact your local Caterpillar dealer immediatelyto schedule this service. The dealer will advise you of the time requiredto complete this service. Please refer the dealer to their Service Letterdated August 31, 2004 when scheduling this service.We regret the inconvenience this may causeyou, but urge you to have this service performed as soon as possible toprevent unscheduled downtime.Caterpillar Inc.
Identification #(s)Attached to August 31, 2004 Service Letter
O-219
Priority PRODUCT IMPROVEMENT PROGRAM FOR REPLACINGTHE INJECTION ACTUATION PRESSURE SENSOR ON CERTAIN 3126E ENGINES
7755,1925 PI30676
This Program must be administered assoon as possible. When reporting the repair, use "PI30676" as the Partnumber and "7751" as the Group Number, "56" as the Warranty Claim DescriptionCode and "T" as the SIMS Description Code. Exception: If the repair isdone after failure, use "PI30676" as the Part Number, "7751" as the GroupNumber, "96" as the Warranty Claim Description Code, and "Z" as the SIMSDescription Code. The information supplied in this serviceletter may not be valid after the termination date of this program. Donot perform the work outlined in this Service Letter after the terminationdate without first contacting your Caterpillar product analyst.
COMPLETION DATE
TERMINATION DATE
February 28, 2005 August 31, 2005PROBLEM
Replace the injection actuation pressure sensorcertain 3126E engines. The old sensor may leak oil.AFFECTED PRODUCT
Model IdentificationNumber
3126E G3E230-497PARTS NEEDED
Qty
Part Number Description
1 2244536 SENSOR GP-PRACTION REQUIRED
Remove the 194-6726 Pressure Sensor and replaceit with part number 224-4536 Pressure Sensor.OWNER NOTIFICATION
U.S. and Canadian owners will receive the attachedOwner Notification.SERVICE CLAIM ALLOWANCES
Caterpillar Dealer Suggested Customer Suggested
Parts Labor Hrs Parts LaborHrs Parts LaborHrs
100% 1.0 0 0 0 0
This is a 1.0-hour job. U.S. and Canadian Dealers Only - Eligibledealers may enter a Type 2 SIMS ReportPARTS DISPOSITION
Handle the parts in accordance with your WarrantyBulletin on warranty parts handling.MAKE EVERY EFFORT TO COMPLETE THIS PROGRAMAS SOON AS POSSIBLE.Attach. (Owner Notification)COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS
XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999PRIORITY - THE INJECTION ACTUATION PRESSURESENSOR NEEDS TO BE REPLACED.MODELS INVOLVED - CERTAIN 3126E ENGINESDear Caterpillar Product Owner:A new injection actuation pressure sensor needsto be installed on the products listed below. The current sensor may leakoil. You will not be charged for the service performed.Contact your local Caterpillar dealer immediatelyto schedule this service. The dealer will advise you of the time requiredto complete this service. Please refer the dealer to their Service Letterdated August 31, 2004 when scheduling this service.We regret the inconvenience this may causeyou, but urge you to have this service performed as soon as possible toprevent unscheduled downtime.Caterpillar Inc.
Identification #(s)Attached to August 31, 2004 Service Letter
Have questions with 101402-3910?
Group cross 101402-3910 ZEXEL
Komatsu
101402-3910
9 400 610 449
3863479
INJECTION-PUMP ASSEMBLY
S4D102E
S4D102E
101402-3910
9 400 610 449
6732711210
INJECTION-PUMP ASSEMBLY
S4D102E
S4D102E