101495-3021 ZEXEL 9 400 614 509 BOSCH INJECTION-PUMP ASSEMBLY 9400614509 1014953021 6204711411

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 614 509 9400614509

ZEXEL 101495-3021 1014953021

KOMATSU 6204711411 6204711411

Service parts 101495-3021 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101049-8820

3. GOVERNOR 105400-3521

4. SUPPLY PUMP 105220-5610

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:

101495-3021 as INJECTION-PUMP ASSEMBLY

101495-3360 as _

Cross reference number

BOSCH 9 400 614 509 9400614509

ZEXEL 101495-3021 1014953021

KOMATSU 6204711411 6204711411

Zexel num

Bosch num

Firm num

Name

101495-3021

9 400 614 509

6204711411 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

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 10.9

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 53.3 52.3 54.3

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point -

Rack position 9+-0.5

Pump speed r/min 420 420 420

Average injection quantity mm3/st. 8 7 9

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)Tolerance for racks not indicated: +-0.05mm. (3)The torque control spring must does not have a set force. (4)RACK CAP: R1 (5)Rack difference between N = N1 and N = N2 (6)Idle sub spring setting: L1.
----------
K=17 R1=(17.5)mm N1=850r/min N2=400r/min L1=7.8-0.5mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Set the pump speed at aa. ( At delivery ) (2)Set the pump speed at bb. (3)Stopper bolt setting
----------
aa=953r/min bb=750r/min
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a=(57deg)+-5deg b=(23deg)+-5deg c=(7deg)+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)No return spring
----------

----------
a=47deg+-5deg b=53deg+-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)-
----------

----------
a=59deg36min+-3deg b=0deg24min+-30min