Information injection-pump assembly
BOSCH
9 400 614 056
9400614056
ZEXEL
101405-3150
1014053150
KOMATSU
3863885
3863885
Rating:
Service parts 101405-3150 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
9 400 614 056
9400614056
ZEXEL
101405-3150
1014053150
KOMATSU
3863885
3863885
Zexel num
Bosch num
Firm num
Name
101405-3150
9 400 614 056
3863885 KOMATSU
INJECTION-PUMP ASSEMBLY
4D102E K
4D102E K
101405-3150
9 400 614 056
6731711390 KOMATSU
INJECTION-PUMP ASSEMBLY
4D102E K
4D102E K
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
10.1
Pump speed
r/min
875
875
875
Average injection quantity
mm3/st.
74.5
73.5
75.5
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
8.2+-0.5
Pump speed
r/min
510
510
510
Average injection quantity
mm3/st.
15
14
16
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)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)Set idle sub-spring
(7)Main spring setting
(8)Rack difference between N = N1 and N = N2
----------
K=6 N1=875r/min N2=600r/min
----------
----------
K=6 N1=875r/min N2=600r/min
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=5deg+-5deg b=18deg+-5deg
----------
----------
a=5deg+-5deg b=18deg+-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=15deg bb=0deg
----------
a=54deg54min+-3deg b=7deg30min+-30min
----------
aa=15deg bb=0deg
----------
a=54deg54min+-3deg b=7deg30min+-30min
Information:
Bridge Adjustment
Intake and Exhaust Valve Mechanism
(1) Adjustment locknut, (2) Exhaust bridge, (3) Adjustment locknut, (4) Intake bridgeThe valve bridge should be checked and/or adjusted each time valve clearance is checked and/or adjusted. Valve and valve mechanism components do not always wear evenly which can allow the bridge to be out of adjustment.It is not necessary to remove the rocker arm shaft to adjust the valve bridges, but there must be clearance. Use the procedure that follows to make an adjustment to the bridge. Valves must be fully closed.1. Remove the valve covers from the engine.2. Lubricate the bridge dowel, bridge bore and the top pad of the bridge assembly with engine oil.3. While firmly pressing straight down on the bridge pad with a force of 1 to 10 lb (0.5 to 4.5 kg), turn the adjusting screw clockwise (CW) until contact is made with the valve stem.4. Turn the adjusting screw clockwise (CW) an additional 45° (1/8 turn) to straighten the dowel in the guide and compensate for slack in the threads.5. Hold the adjusting screw in this position and tighten the adjustment locknut to a torque of 18 5 lb ft (25 7 N m).6. Put engine oil at the point where the rocker arms make contact with the bridges.Valve Lash (Clearance) and Unit Injector Preload Adjustment
Valve clearance is measured between the rocker arm and the bridge for the valves.
Measure the valve lash with the engine stopped. To obtain an accurate measurement, allow at least 20 minutes for the valves to cool to engine cylinder head and block temperature.
When the valve lash (clearance) is checked, an adjustment is NOT necessary if the measurement is within the range given in the "Valve Clearance Check" chart shown. If the measurement is outside of the valve clearance check range shown, an adjustment is necessary. See the "Valve Clearance Setting" chart shown and make the setting to the nominal (desired) specifications in this chart. Adjust the valve clearance to within .003 in ( 0.08 mm) of the value given in the chart above.Rotate the engine crankshaft 360° in the normal crankshaft rotation direction before any adjustments are made. Operation of Caterpillar engines with improper valve adjustments will reduce engine efficiency. This reduced efficiency could result in excessive fuel usage and/or shortened engine component life.
Cylinder and Valve LocationTo make an adjustment to the valve clearance, turn the adjustment screw in the rocker arm. Valve clearance adjustments can be made by using the following procedure. The No. 1 piston must be at top center (TC) on the compression stroke. Follow the first three steps to find top center position for piston No. 1.
Locating Top Center for Piston No. 1
(1) Bolts (two - 6V5219), (2) Cover, (3) Flywheel Housing1. Remove two bolts (1) and remove cover (2) from the flywheel housing (3) to open the turning hole.2. Put one of the 6V5219 bolts in the timing hole located approximately 5 to 6 inches (127 to 152 mm) above the turning hole in
Intake and Exhaust Valve Mechanism
(1) Adjustment locknut, (2) Exhaust bridge, (3) Adjustment locknut, (4) Intake bridgeThe valve bridge should be checked and/or adjusted each time valve clearance is checked and/or adjusted. Valve and valve mechanism components do not always wear evenly which can allow the bridge to be out of adjustment.It is not necessary to remove the rocker arm shaft to adjust the valve bridges, but there must be clearance. Use the procedure that follows to make an adjustment to the bridge. Valves must be fully closed.1. Remove the valve covers from the engine.2. Lubricate the bridge dowel, bridge bore and the top pad of the bridge assembly with engine oil.3. While firmly pressing straight down on the bridge pad with a force of 1 to 10 lb (0.5 to 4.5 kg), turn the adjusting screw clockwise (CW) until contact is made with the valve stem.4. Turn the adjusting screw clockwise (CW) an additional 45° (1/8 turn) to straighten the dowel in the guide and compensate for slack in the threads.5. Hold the adjusting screw in this position and tighten the adjustment locknut to a torque of 18 5 lb ft (25 7 N m).6. Put engine oil at the point where the rocker arms make contact with the bridges.Valve Lash (Clearance) and Unit Injector Preload Adjustment
Valve clearance is measured between the rocker arm and the bridge for the valves.
Measure the valve lash with the engine stopped. To obtain an accurate measurement, allow at least 20 minutes for the valves to cool to engine cylinder head and block temperature.
When the valve lash (clearance) is checked, an adjustment is NOT necessary if the measurement is within the range given in the "Valve Clearance Check" chart shown. If the measurement is outside of the valve clearance check range shown, an adjustment is necessary. See the "Valve Clearance Setting" chart shown and make the setting to the nominal (desired) specifications in this chart. Adjust the valve clearance to within .003 in ( 0.08 mm) of the value given in the chart above.Rotate the engine crankshaft 360° in the normal crankshaft rotation direction before any adjustments are made. Operation of Caterpillar engines with improper valve adjustments will reduce engine efficiency. This reduced efficiency could result in excessive fuel usage and/or shortened engine component life.
Cylinder and Valve LocationTo make an adjustment to the valve clearance, turn the adjustment screw in the rocker arm. Valve clearance adjustments can be made by using the following procedure. The No. 1 piston must be at top center (TC) on the compression stroke. Follow the first three steps to find top center position for piston No. 1.
Locating Top Center for Piston No. 1
(1) Bolts (two - 6V5219), (2) Cover, (3) Flywheel Housing1. Remove two bolts (1) and remove cover (2) from the flywheel housing (3) to open the turning hole.2. Put one of the 6V5219 bolts in the timing hole located approximately 5 to 6 inches (127 to 152 mm) above the turning hole in
Have questions with 101405-3150?
Group cross 101405-3150 ZEXEL
Komatsu
Komatsu
101405-3150
9 400 614 056
3863885
INJECTION-PUMP ASSEMBLY
4D102E
4D102E
101405-3150
9 400 614 056
6731711390
INJECTION-PUMP ASSEMBLY
4D102E
4D102E