Information injection-pump assembly
BOSCH
9 400 614 051
9400614051
ZEXEL
101405-3081
1014053081
KOMATSU
3863855
3863855

Rating:
Service parts 101405-3081 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
9 400 614 051
9400614051
ZEXEL
101405-3081
1014053081
KOMATSU
3863855
3863855
Zexel num
Bosch num
Firm num
Name
101405-3081
9 400 614 051
3863855 KOMATSU
INJECTION-PUMP ASSEMBLY
4D102E K 14BC INJECTION PUMP ASSY PE4A,5A, PE
4D102E K 14BC INJECTION PUMP ASSY PE4A,5A, PE
101405-3081
9 400 614 051
6731711360 KOMATSU
INJECTION-PUMP ASSEMBLY
4D102E K 14BC INJECTION PUMP ASSY PE4A,5A, PE
4D102E 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
9.9
Pump speed
r/min
1075
1075
1075
Average injection quantity
mm3/st.
71.5
70.5
72.5
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
8.4+-0.5
Pump speed
r/min
440
440
440
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.
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.
85
85
95
Fixing the lever
*
Rack limit
*
Test data Ex:
Governor adjustment

N:Pump speed
R:Rack position (mm)
(1)Notch fixed: 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
----------
K=8
----------
----------
K=8
----------
Speed control lever angle

F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=(6deg)+-5deg b=(22deg)+-5deg
----------
----------
a=(6deg)+-5deg b=(22deg)+-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:
Antifreeze
Caterpillar recommends that the coolant mix contain a minimum of 30% Caterpillar Antifreeze, or equivalent and acceptable water to maintain an adequate water pump cavitation temperature for efficient water pump performance.Premix coolant solution to provide protection to the lowest expected outside (ambient) temperature. Pure undiluted antifreeze will freeze at -10°F (-23°C).Only use a greater concentration (above 30%) of Caterpillar Antifreeze as needed for anticipated outside (ambient) temperatures. Do not exceed a coolant mixture of 60% antifreeze to water since a concentration above 60% antifreeze will reduce the engine's freeze protection and increase the possibility of deposit formation in the cooling system.
Use Caterpillar Antifreeze or ASTM D4985-89 (GM Specification 6038-M) Antifreeze. However, supplemental coolant conditioner must be added to these coolants. See topic "Supplemental CoolantAdditive (Conditioner)" in this manual for further information.Caterpillar Antifreeze is available through your Caterpillar dealer in quantities that follow. Most commercial antifreezes are formulated for gasoline engine applications and will, therefore, have high silicate content. Caterpillar Antifreeze is formulated with a low silicate content and the proper coolant additives for heavy duty diesel engines. Caterpillar does not recommend use of high silicate antifreeze in the 3176 engine.ASTM D4985-89 (GM Specification 6038-M) is a low silicate antifreeze, but supplemental coolant additive must be added.The major advantages of Caterpillar Antifreeze are:* Significantly reduces water pump seal leakage problems caused by excessive concentration of chemical additives.* There is no need to add supplemental coolant additive (conditioner) on initial fill, which must be done with current commercially available antifreezes.* High silicate antifreezes used with a supplemental coolant additive can cause a build-up of solids over a period of time which can cause plugging, loss of heat transfer, and water pump seal damage.Make proper antifreeze additions.
Adding pure antifreezes as a makeup solution for cooling system top-off is an unacceptable practice. It increase the concentration of antifreeze in the cooling system which increases the concentration of dissolved solids and undissolved chemical inhibitors in the cooling system. Add antifreeze mixed with acceptable water to the same freeze protection as your cooling system. Pure, undiluted antifreeze will freeze at -10°F (-23°C).Use the chart below to assist in determining the concentration of Caterpillar Antifreeze to use.
5P0957 Coolant Tester (°F) or 5P3514 Coolant Tester (°C)Both are available at your Caterpillar dealer.Check the coolant solution frequently in cold weather for glycol concentration with the 5P0957 or 5P3514 Coolant Tester to ensure adequate protection. Both testers are identical except temperature scale. They give immediate, accurate readings and can be used for antifreeze/coolants that contain ethylene or propylene glycol.If propylene glycol based antifreeze is used, DO NOT allow concentration greater than a 50/50 antifreeze to water mixture. The measurement of freeze protection must be made with a refractive-type tester (Cat 5P0957 or 5P3514) rather than a hydrometer-type, which can be used to test ethylene glycol based antifreeze.Supplemental Coolant Additive (Conditioner)
Supplemental coolant additive (conditioner) is necessary to prevent rust, scale, pitting and/or corrosion of engine parts that coolant comes in contact with. Most antifreeze solutions DO NOT contain sufficient
Caterpillar recommends that the coolant mix contain a minimum of 30% Caterpillar Antifreeze, or equivalent and acceptable water to maintain an adequate water pump cavitation temperature for efficient water pump performance.Premix coolant solution to provide protection to the lowest expected outside (ambient) temperature. Pure undiluted antifreeze will freeze at -10°F (-23°C).Only use a greater concentration (above 30%) of Caterpillar Antifreeze as needed for anticipated outside (ambient) temperatures. Do not exceed a coolant mixture of 60% antifreeze to water since a concentration above 60% antifreeze will reduce the engine's freeze protection and increase the possibility of deposit formation in the cooling system.
Use Caterpillar Antifreeze or ASTM D4985-89 (GM Specification 6038-M) Antifreeze. However, supplemental coolant conditioner must be added to these coolants. See topic "Supplemental CoolantAdditive (Conditioner)" in this manual for further information.Caterpillar Antifreeze is available through your Caterpillar dealer in quantities that follow. Most commercial antifreezes are formulated for gasoline engine applications and will, therefore, have high silicate content. Caterpillar Antifreeze is formulated with a low silicate content and the proper coolant additives for heavy duty diesel engines. Caterpillar does not recommend use of high silicate antifreeze in the 3176 engine.ASTM D4985-89 (GM Specification 6038-M) is a low silicate antifreeze, but supplemental coolant additive must be added.The major advantages of Caterpillar Antifreeze are:* Significantly reduces water pump seal leakage problems caused by excessive concentration of chemical additives.* There is no need to add supplemental coolant additive (conditioner) on initial fill, which must be done with current commercially available antifreezes.* High silicate antifreezes used with a supplemental coolant additive can cause a build-up of solids over a period of time which can cause plugging, loss of heat transfer, and water pump seal damage.Make proper antifreeze additions.
Adding pure antifreezes as a makeup solution for cooling system top-off is an unacceptable practice. It increase the concentration of antifreeze in the cooling system which increases the concentration of dissolved solids and undissolved chemical inhibitors in the cooling system. Add antifreeze mixed with acceptable water to the same freeze protection as your cooling system. Pure, undiluted antifreeze will freeze at -10°F (-23°C).Use the chart below to assist in determining the concentration of Caterpillar Antifreeze to use.
5P0957 Coolant Tester (°F) or 5P3514 Coolant Tester (°C)Both are available at your Caterpillar dealer.Check the coolant solution frequently in cold weather for glycol concentration with the 5P0957 or 5P3514 Coolant Tester to ensure adequate protection. Both testers are identical except temperature scale. They give immediate, accurate readings and can be used for antifreeze/coolants that contain ethylene or propylene glycol.If propylene glycol based antifreeze is used, DO NOT allow concentration greater than a 50/50 antifreeze to water mixture. The measurement of freeze protection must be made with a refractive-type tester (Cat 5P0957 or 5P3514) rather than a hydrometer-type, which can be used to test ethylene glycol based antifreeze.Supplemental Coolant Additive (Conditioner)
Supplemental coolant additive (conditioner) is necessary to prevent rust, scale, pitting and/or corrosion of engine parts that coolant comes in contact with. Most antifreeze solutions DO NOT contain sufficient
Have questions with 101405-3081?
Group cross 101405-3081 ZEXEL
Komatsu
Komatsu
Komatsu
Komatsu
Komatsu
Komatsu
101405-3081
9 400 614 051
3863855
INJECTION-PUMP ASSEMBLY
4D102E
4D102E
101405-3081
9 400 614 051
6731711360
INJECTION-PUMP ASSEMBLY
4D102E
4D102E