101492-3811 ZEXEL 9 400 613 359 BOSCH INJECTION-PUMP ASSEMBLY 9400613359 1014923811 6205711242

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 613 359 9400613359

ZEXEL 101492-3811 1014923811

KOMATSU 6205711242 6205711242

Service parts 101492-3811 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101049-8680

3. GOVERNOR 105400-5502

4. SUPPLY PUMP 105220-5270

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-4160

11. Nozzle and Holder 6206-11-3100

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

13. NOZZLE-HOLDER 105048-3060

14. NOZZLE

105017-0140

15. NOZZLE SET

Include in #1:

101492-3811 as INJECTION-PUMP ASSEMBLY

106682-4894 as _

Cross reference number

BOSCH 9 400 613 359 9400613359

ZEXEL 101492-3811 1014923811

KOMATSU 6205711242 6205711242

Zexel num

Bosch num

Firm num

Name

101492-3811
101492-3880

9 400 613 359

6205711242 KOMATSU

INJECTION-PUMP ASSEMBLY
S4D95L 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 131424-7420

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 1-2-4-3

Pre-stroke mm 3.2 3.15 3.25

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 9.9

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 71.9 70.9 72.9

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point -

Rack position 7.7+-0.5

Pump speed r/min 450 450 450

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 CAP: R1 (3)The torque control spring must does not have a set force. (4)Rack difference from N = N1
----------
K=14 R1=15+-1mm N1=1100r/min
----------

Speed control lever angle

F:Full speed I:Idle S:Stop (1)Use the hole at R = aa
----------
aa=80mm
----------
a=34deg+-5deg b=18deg+-3deg c=32deg+-3deg

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)-
----------

----------
a=58deg+-3deg b=2deg+-30min