Information injection-pump assembly
BOSCH
9 400 610 451
9400610451
ZEXEL
101402-3930
1014023930
KOMATSU
3863529
3863529
Rating:
Service parts 101402-3930 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
9 400 610 451
9400610451
ZEXEL
101402-3930
1014023930
KOMATSU
3863529
3863529
Zexel num
Bosch num
Firm num
Name
101402-3930
9 400 610 451
3863529 KOMATSU
INJECTION-PUMP ASSEMBLY
S4D102E K 14BC INJECTION PUMP ASSY PE4A,5A, PE
S4D102E K 14BC INJECTION PUMP ASSY PE4A,5A, PE
101402-3930
9 400 610 451
6732711230 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
10
Pump speed
r/min
1175
1175
1175
Average injection quantity
mm3/st.
76
75
77
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
C
Rack position
8.7+-0.5
Pump speed
r/min
400
400
400
Average injection quantity
mm3/st.
13.5
12.5
14.5
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Injection quantity adjustment_03
Adjusting point
D
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
85
85
95
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)Adjust the secondary timing before adjusting the governor.
(4)RACK LIMIT
(5)The torque control spring must does not have a set force.
(6)Rack difference between N = N1 and N = N2
(7)Rack difference between N = N3 and N = N4
----------
K=11 N1=1175r/min N2=400r/min N3=1175r/min N4=700r/min
----------
----------
K=11 N1=1175r/min N2=400r/min N3=1175r/min N4=700r/min
----------
Speed control lever angle
F:Full speed
I:Idle
S:Stop
(1)-
----------
----------
a=12deg+-5deg b=32deg+-3deg c=28deg+-5deg
----------
----------
a=12deg+-5deg b=32deg+-3deg c=28deg+-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=16.5deg bb=0deg
----------
a=54deg54min+-3deg b=8deg15min+-30min
----------
aa=16.5deg bb=0deg
----------
a=54deg54min+-3deg b=8deg15min+-30min
Information:
March 8, 2005
(Revised July 2005)
U-76
A-57
O-65
TT-3
Afterfailure only PRODUCT SUPPORT PROGRAM FOR INSTALLINGINJECTOR SLEEVE KITS IN CERTAIN C11 AND C13 TRUCK ENGINES
1713 PS50933
This Program can only be administeredafter a failure occurs. The decision whether to apply the Program is madeby the dealer. When reporting the repair, use "PS50933" as the Part numberand "7755" as the Group Number. Use "96" as the Warranty Claim DescriptionCode and use "Z" as the SIMS Description 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. This Revised Service Letter replacesthe March 8, 2005 Service Letter. Changes have been made to the ServiceClaim Allowance.TERMINATION DATE
March 31, 2007PROBLEM
This letter will address the repair proceduresand inspection guidelines for fuel in coolant failures in certain C11 andC13 ACERT engines.AFFECTED PRODUCT
Model Identification Number
C11 KCA1-2365
C13 KCB1-14118PARTS NEEDED
Qty
Part Number
Description
1 2638162 INJECTOR KITACTION REQUIRED
If a failure of an injector sleeve isdiscovered replace all 6 injector sleeves. Follow special instruction REHS2410,field installation of the 263-8162 injector sleeve kit. After the repairof the injector sleeves is completed, inspect the following components:pre-cooler hoses, coolant diverter valve, and thermostat(s). Replace anycomponents that show signs of deformity or swelling due to exposure tofuel.SERVICE CLAIM ALLOWANCES
SMCS Code Description SC MC CV CO
1240-030 Test 0.5 0.5 0.5 0.5
1240-074 Wash 0.3 0.3 0.3 0.3
1100-035 Troubleshoot 1.0 1.0 1.0 1.0
1290-010-S Remove and Install Unit Injector,Set (all) 5.2 5.0 5.0 5.1
1713-010-S Remove and Install Unit InjectorSleeve, Set (all) 2.0 2.0 2.0 2.0
1350-046-ES Flush Engine Cooling System 1.3 1.3 1.3 1.3
Note: If equippedwith a head-mounted radiator bracket, claim code (1353-010-BK).
Note: If R&I ofair cleaner housing is required, claim code (1051-010).PARTS DISPOSITION
Handle the parts in accordance with your WarrantyBulletin on warranty parts handling.
(Revised July 2005)
U-76
A-57
O-65
TT-3
Afterfailure only PRODUCT SUPPORT PROGRAM FOR INSTALLINGINJECTOR SLEEVE KITS IN CERTAIN C11 AND C13 TRUCK ENGINES
1713 PS50933
This Program can only be administeredafter a failure occurs. The decision whether to apply the Program is madeby the dealer. When reporting the repair, use "PS50933" as the Part numberand "7755" as the Group Number. Use "96" as the Warranty Claim DescriptionCode and use "Z" as the SIMS Description 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. This Revised Service Letter replacesthe March 8, 2005 Service Letter. Changes have been made to the ServiceClaim Allowance.TERMINATION DATE
March 31, 2007PROBLEM
This letter will address the repair proceduresand inspection guidelines for fuel in coolant failures in certain C11 andC13 ACERT engines.AFFECTED PRODUCT
Model Identification Number
C11 KCA1-2365
C13 KCB1-14118PARTS NEEDED
Qty
Part Number
Description
1 2638162 INJECTOR KITACTION REQUIRED
If a failure of an injector sleeve isdiscovered replace all 6 injector sleeves. Follow special instruction REHS2410,field installation of the 263-8162 injector sleeve kit. After the repairof the injector sleeves is completed, inspect the following components:pre-cooler hoses, coolant diverter valve, and thermostat(s). Replace anycomponents that show signs of deformity or swelling due to exposure tofuel.SERVICE CLAIM ALLOWANCES
SMCS Code Description SC MC CV CO
1240-030 Test 0.5 0.5 0.5 0.5
1240-074 Wash 0.3 0.3 0.3 0.3
1100-035 Troubleshoot 1.0 1.0 1.0 1.0
1290-010-S Remove and Install Unit Injector,Set (all) 5.2 5.0 5.0 5.1
1713-010-S Remove and Install Unit InjectorSleeve, Set (all) 2.0 2.0 2.0 2.0
1350-046-ES Flush Engine Cooling System 1.3 1.3 1.3 1.3
Note: If equippedwith a head-mounted radiator bracket, claim code (1353-010-BK).
Note: If R&I ofair cleaner housing is required, claim code (1051-010).PARTS DISPOSITION
Handle the parts in accordance with your WarrantyBulletin on warranty parts handling.
Have questions with 101402-3930?
Group cross 101402-3930 ZEXEL
Komatsu
101402-3930
9 400 610 451
3863529
INJECTION-PUMP ASSEMBLY
S4D102E
S4D102E
101402-3930
9 400 610 451
6732711230
INJECTION-PUMP ASSEMBLY
S4D102E
S4D102E