Information injection-pump assembly
BOSCH
9 400 613 884
9400613884
ZEXEL
101402-3990
1014023990
KOMATSU
3863765
3863765
Rating:
Service parts 101402-3990 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
9 400 613 884
9400613884
ZEXEL
101402-3990
1014023990
KOMATSU
3863765
3863765
Zexel num
Bosch num
Firm num
Name
101402-3990
9 400 613 884
3863765 KOMATSU
INJECTION-PUMP ASSEMBLY
S4D102E K 14BD INJECTION PUMP ASSY PE4AD PE
S4D102E K 14BD INJECTION PUMP ASSY PE4AD PE
101402-3990
9 400 613 884
6732711280 KOMATSU
INJECTION-PUMP ASSEMBLY
S4D102E K 14BD INJECTION PUMP ASSY PE4AD PE
S4D102E K 14BD INJECTION PUMP ASSY PE4AD 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 hydraulic cylinder 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
(1)Speed = aa (active mode)
(2)Speed = bb (normal mode)
(3)Use the center hole above R = cc
----------
aa=1200r/min bb=1100r/min cc=80mm
----------
a=18deg+-3deg b=35deg+-5deg c=5deg+-5deg
----------
aa=1200r/min bb=1100r/min cc=80mm
----------
a=18deg+-3deg b=35deg+-5deg c=5deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)No return spring
----------
----------
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:
(1) End play for shaft (new) ... 0.114 0.038 mm (.0045 .0015 in.) Maximum permissible end play (worn) ... 0.20 mm (.008 in.)(2) Tighten band clamps with procedure that follows: a. Tighten to ... 13.6 1.1 N (120 10 lb.in.)b. Tap (hit) clamp lightly all around.c. Tighten again to ... 13.6 1.1 N (120 10 lb.in.)(3) Thickness of thrust bearing ... 5.36 0.03 mm (.211 .001 in.)(4) Diameter of shaft (new) ... 14.254 to 14.262 mm (.5612 to .5615 in.) Bore in the bearing (new) ... 14.293 to 14.300 mm (.5627 to .5630 in.)Maximum permissible clearance between bearing and shaft (worn) ... 0.08 mm (.003 in.)(5) Maximum permissible gap of oil seal ring, measured in bore of housing ... 0.23 mm (.009 in.)(6) Bore in housing (new) ... 22.255 to 22.268 mm (.8762 to .8767 in.) Outside diameter of the bearing (new) ... 22.144 to 22.154 mm (.8718 to .8722 in.)Maximum permissible clearance between bearing and bore in housing (worn) ... 0.15 mm (.006 in.)(7) Turbocharger impeller installation at room temperature: a. Put 6V1541 Quick Cure Primer on the nut and the shaft threads to clean them, if necessary.b. Put a small amount of 9S3265 Retaining Compound on the nut and shaft threads.
Do not let the retaining compound get into the compressor wheel bore or on the shaft, because it can make removal of the compressor wheel difficult during future turbocharger disassembly.
c. Put a small amount of lubricant, such as Lubriplate, on the nut seat area on the compressor. Do not put lubricant on the threads.d. Tighten the compressor wheel retainer nut to a torque of ... 60 3 N m (44 2 lb.ft.)
Do not bend or add stress to the shaft when the nut is tightened.
(8) Thickness of each thrust ring ... 2.553 0.013 mm (.1005 .0005 in.)(9) Torque for four nuts (put 5P3931 Anti-Seize Compound on threads) ... 55 5 N m (40 4 lb.ft.)
Do not let the retaining compound get into the compressor wheel bore or on the shaft, because it can make removal of the compressor wheel difficult during future turbocharger disassembly.
c. Put a small amount of lubricant, such as Lubriplate, on the nut seat area on the compressor. Do not put lubricant on the threads.d. Tighten the compressor wheel retainer nut to a torque of ... 60 3 N m (44 2 lb.ft.)
Do not bend or add stress to the shaft when the nut is tightened.
(8) Thickness of each thrust ring ... 2.553 0.013 mm (.1005 .0005 in.)(9) Torque for four nuts (put 5P3931 Anti-Seize Compound on threads) ... 55 5 N m (40 4 lb.ft.)
Have questions with 101402-3990?
Group cross 101402-3990 ZEXEL
Komatsu
Komatsu
Komatsu
Komatsu
101402-3990
9 400 613 884
3863765
INJECTION-PUMP ASSEMBLY
S4D102E
S4D102E
101402-3990
9 400 613 884
6732711280
INJECTION-PUMP ASSEMBLY
S4D102E
S4D102E