101495-3435 ZEXEL 9 400 612 655 BOSCH INJECTION-PUMP ASSEMBLY 9400612655 1014953435 6204711150

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 612 655 9400612655

ZEXEL 101495-3435 1014953435

KOMATSU 6204711150 6204711150

Service parts 101495-3435 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101049-8800

3. GOVERNOR 105400-9151

4. SUPPLY PUMP

105220-5960

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-6700

11. Nozzle and Holder 6204-11-3100

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

13. NOZZLE-HOLDER 105048-3300

14. NOZZLE

105017-2670

15. NOZZLE SET

Include in #1:

101492-3930 as _

101495-3435 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 612 655 9400612655

ZEXEL 101495-3435 1014953435

KOMATSU 6204711150 6204711150

Zexel num

Bosch num

Firm num

Name

101495-3435
101495-3471

9 400 612 655

6204711150 KOMATSU

INJECTION-PUMP ASSEMBLY
4D95L * K 14BC PE4A,5A, PE

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 3.2 3.15 3.25

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 900 900 900

Average injection quantity mm3/st. 67.5 66.5 68.5

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point -

Rack position 8.5+-0.5

Pump speed r/min 400 400 400

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)RACK CAP: R1 (4)Set idle sub-spring
----------
K=12 R1=(17.5)mm
----------

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=920r/min bb=755r/min
----------
a=4deg+-5deg b=25deg+-5deg c=6deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Rack position = aa, speed = bb (stamp at delivery) (2)No return spring
----------
aa=1-0.5mm bb=0r/min
----------
a=27.5deg+-5deg b=(55deg)

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)- (5)-
----------

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