101492-3742 ZEXEL 9 400 614 452 BOSCH INJECTION-PUMP ASSEMBLY 9400614452 1014923742 6204731220

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 614 452 9400614452

ZEXEL 101492-3742 1014923742

KOMATSU 6204731220 6204731220

Service parts 101492-3742 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101049-8280

3. GOVERNOR 105400-5601

4. SUPPLY PUMP 105220-5700

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-5631

11. Nozzle and Holder 6207-11-3102

12. Open Pre:MPa(Kqf/cm2) 19.6{200}

13. NOZZLE-HOLDER 105048-3300

14. NOZZLE 105017-1450

15. NOZZLE SET

Include in #1:

101492-3742 as INJECTION-PUMP ASSEMBLY

103662-3271 as _

Cross reference number

BOSCH 9 400 614 452 9400614452

ZEXEL 101492-3742 1014923742

KOMATSU 6204731220 6204731220

Zexel num

Bosch num

Firm num

Name

101492-3742
101492-3990

9 400 614 452

6204731220 KOMATSU

INJECTION-PUMP ASSEMBLY
4D95L 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

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 1-2-4-3

Pre-stroke mm 3.6 3.55 3.65

Rack position
Point A R=A

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cyl.1-2 deg. 90 89.5 90.5

Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5

Difference between angles 3
Cal 1-3 deg. 270 269.5 270.5

Injection quantity adjustment

Adjusting point A

Rack position 10.8

Pump speed r/min 1150 1150 1150

Average injection quantity mm3/st. 40.2 39.2 41.2

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point -

Rack position 9.8+-0.5

Pump speed r/min 475 475 475

Average injection quantity mm3/st. 10.5 9.5 11.5

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)RACK LIMIT: RAL (3)Rack difference between N = N1 and N = N2 (4)Damper spring setting: DL
----------
K=11 RAL=17.5+-0.2mm N1=1150r/min N2=750r/min DL=7.3+-0.1mm
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Speed control lever angle

F:Full speed I:Idle S:Stop
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a=11deg+-5deg b=32deg+-3deg c=26deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of key groove at No 1 cylinder's beginning of injection (3)Stamp aligning marks on the pump housing flange. (4)-
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----------
a=59deg36min+-3deg b=0deg24min+-30min