101402-3980 ZEXEL 9 400 613 883 BOSCH INJECTION-PUMP ASSEMBLY 9400613883 1014023980 3863655

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 613 883 9400613883

ZEXEL 101402-3980 1014023980

KOMATSU 3863655 3863655

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Buy INJECTION-PUMP ASSEMBLY 101402-3980 zexel genuine, new aftermarket engine parts with delivery

Service parts 101402-3980 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101041-9260

3. GOVERNOR 105404-5340

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)

13. NOZZLE-HOLDER

14. NOZZLE

15. NOZZLE SET

Include in #1:

101402-3980 as INJECTION-PUMP ASSEMBLY

108622-3913 as _

Cross reference number

BOSCH 9 400 613 883 9400613883

ZEXEL 101402-3980 1014023980

KOMATSU 3863655 3863655

Zexel num

Bosch num

Firm num

Name

101402-3980

9 400 613 883

3863655 KOMATSU

INJECTION-PUMP ASSEMBLY
4D102E K

101402-3980

9 400 613 883

6731711130 KOMATSU

INJECTION-PUMP ASSEMBLY
4D102E K

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 8.3

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 70.5 69.5 71.5

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point -

Rack position 7.2+-0.5

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 10 9 11

Max. variation between cylinders % 0 -15 15

Fixing the rack *

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 *

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
----------
K=16
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting (2)Use the center hole at R = aa
----------
aa=80mm
----------
a=22deg+-3deg b=26deg+-5deg

Stop lever angle

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

----------
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=18deg bb=0deg
----------
a=54deg54min+-3deg b=9deg+-30min

Information:

(1) 4N5906 Spring for valves (new): Length under test force ... 54.99 mm (2.165 in.)Test force ... 344 34 N (77 7.6 lb.)Use again minimum load at length under test force ... 291 N (65.4 lb.)Length of spring at valve open position ... 42.93 mm (1.690 in.)Use again minimum load at valve open position ... 817 N (183.6 lb.)Free length after test ... 62.7 mm (2.47 in.)Outside diameter ... 31.75 mm (1.250 in.)Spring must not be bent more than ... 2.18 mm (.086 in.)(2) Height to top of valve guide ... 32.3 0.8 mm (1.27 .03 in.)(3) Diameter of valve stem (new) ... 9.441 0.008 mm (.3717 .0003 in.) Use again minimum diameter of intake and exhaust valve stem ... 9.408 mm (.3704 in.)7N2271 Exhaust Valve - Do not use again.Bore in valve guide with guide installed in the head (new) ... 9.487 0.025 mm (.3735 .0010 in.)(4) Diameter of valve head: Exhaust valve ... 41.81 0.13 mm (1.646 .005 in.)Intake valve ... 44.98 0.13 mm (1.771 .005 in.)(5) Angle of intake valve face ... 29 1/4 1/4°Angle of exhaust valve face ... 44 1/4 1/4° (6) Depth of bore in head for valve seat insert (new) ... 13.01 0.38 mm (.512 .015 in.)(7) Diameter of valve seat insert for exhaust valve ... 42.850 0.013 mm (1.6870 .0005 in.) Bore in head for valve seat insert for exhaust valve ... 42.774 0.025 mm (1.6840 .0010 in.)(7) Diameter of valve seat insert for intake valve ... 46.025 0.013 mm (1.8120 .0005 in.) Bore in head for valve seat insert for intake valve ... 45.949 0.025 mm (1.8090 .0010 in.)(8) Angle of face of intake valve seat insert ... 30 1/4 1/2°Angle of face of exhaust valve seat insert ... 44 3/4 1/2°(9) Dimension from end of closed valve to machined face of head. Maximum permissible dimension:Below (recessed from) machined face ... 1.22 mm (.048 in.)Above (extended from) machined face ... 0.20 mm (.008 in.)(10) Outside diameter of the face of the valve seat insert: Exhaust seat ... 40.41 0.13 mm (1.591 .005 in.)Intake seat ... 44.04 0.13 mm (1.734 .005 in.)(11) "Use again" thickness of valve lip: Exhaust valve ... 2.03 mm (.080 in.)Intake valve ... 2.51 mm (.099 in.)