101402-3941 ZEXEL 9 400 610 452 BOSCH INJECTION-PUMP ASSEMBLY 9400610452 1014023941 3863530

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 610 452 9400610452

ZEXEL 101402-3941 1014023941

KOMATSU 3863530 3863530

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Buy INJECTION-PUMP ASSEMBLY 101402-3941 zexel genuine, new aftermarket engine parts with delivery

Service parts 101402-3941 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101041-9270

3. GOVERNOR 105404-5270

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:

101402-3941 as INJECTION-PUMP ASSEMBLY

108622-3881 as _

Cross reference number

BOSCH 9 400 610 452 9400610452

ZEXEL 101402-3941 1014023941

KOMATSU 3863530 3863530

Zexel num

Bosch num

Firm num

Name

101402-3941

9 400 610 452

3863530 KOMATSU

INJECTION-PUMP ASSEMBLY
S4D102E K 14BC INJECTION PUMP ASSY PE4A,5A, PE

101402-3941

9 400 610 452

6732711240 KOMATSU

INJECTION-PUMP ASSEMBLY
S4D102E K 14BC INJECTION PUMP ASSY PE4A,5A, 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 10.2

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 82 81 83

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=13 N1=1250r/min N2=400r/min N3=1250r/min N4=700r/min
----------

Speed control lever angle

F:Full speed I:Idle S:Stop (1)-
----------

----------
a=14deg+-5deg b=32deg+-3deg c=32deg+-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

Information:

Model IdentificationNumber
3412C DJN758-762,790, 796-797, 802-805, 807, 809-811, 813, 815, 820-821TFT441PARTS NEEDED
Qty
Part Number Description
* 6I-2358 Injection Pump* Order only if needed after the inspectionhas been completed.ACTION REQUIRED
See the attached Rework Procedure.OWNER NOTIFICATION
U.S. and Canadian owners will receive the attachedOwner Notification.SERVICE CLAIM ALLOWANCES
Caterpillar Dealer Suggested Customer Suggested
Parts Labor Hrs. Parts Labor Hrs. Parts Labor Hrs.
100% 6.5 0 0 0 0
Thisis a 5.0 hr job for the pump relplacement. An additonal 1 hr segment willalso be added to the labor hours to account for dyno testing an enginethat has had the fuel injection pump replaced.* An additional 0.5 hrs will beallowed for inspection per engine. PARTS DISPOSITION
All dealers are to make sure the outsideof the shipping container is marked with the service letter number.***** All Dealers *****Return all defective 6I-2358 injection pumpsremoved from engines. Also send in a copy of the claim to:Caterpillar Inc.
Attn: Supplier Recovery
Service Claims Room
8201 N. University
Peoria, IL 61615MAKE EVERY EFFORT TO COMPLETE THIS PROGRAMAS SOON AS POSSIBLE.Attach. (1-Owner Notification)
(2-Rework Procedure)COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS
XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999PRIORITY - PRODUCT IMPROVEMENT PROGRAM FORREPLACING THE INJECTION PUMPMODELS INVOLVED - CERTAIN 3412C GENERATOR SETSDear Caterpillar Product Owner:The injection pump needs to be inspected andpossibly replaced on the products listed below. You will not be chargedfor 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 April 3, 2006 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 April 3, 2006 Service LetterRework ProcedureInspection: Illustration 1Suspect serial number range is from 14415965to 14446549.
Illustration 2 Illustration 3 Illustration 4 Illustration 5 Illustration 6 Illustration 7 Illustration 8 Illustration 9 Illustration 10 Illustration 11 Illustration 12 Illustration 13 Illustration 14 Illustration 15 Illustration 16Fuel Injection Pump replacement:Follow the removal procedure within publication"Remove Fuel Injection Pumps", SENR4628 to remove the injection pump fromthe engine.After the injection pump is removed, replacethe injection pump using publication "Install Fuel Injection Pumps", SENR4628.
If the fuel injection pump is replacedon an engine it must be dynometer tested to ensure proper functionality.