101495-3542 ZEXEL F 01G 09U 0J6 BOSCH INJECTION-PUMP ASSEMBLY f01g09u0j6 1014953542 6208711220


101495-3542 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

BOSCH F 01G 09U 0J6 f01g09u0j6
ZEXEL 101495-3542 1014953542
KOMATSU 6208711220 6208711220

Service parts 101495-3542 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101049-4120
3. GOVERNOR 105401-1421
4. SUPPLY PUMP 105220-5960
5. AUTOM. ADVANCE MECHANIS
6. COUPLING PLATE
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105119-4160
11. Nozzle and Holder
12. Open Pre:MPa(Kqf/cm2) 19.6(200)
13. NOZZLE-HOLDER 105048-4450
14. NOZZLE 105017-3630
15. NOZZLE SET

Include in #1:

101495-3542 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH F 01G 09U 0J6 f01g09u0j6
ZEXEL 101495-3542 1014953542
KOMATSU 6208711220 6208711220


Zexel num
Bosch num
Firm num
Name
101495-3542 
F 01G 09U 0J6 
6208711220  KOMATSU
INJECTION-PUMP ASSEMBLY
SAA4D95LE K 14BC INJECTION PUMP ASSY 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
Overflow valve   131425-1420
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   255 255 255
Tester oil delivery pressure kgf/cm2   2.6 2.6 2.6
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
After adjusting injection quantity.
  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   10.1
Pump speed r/min   1100 1100 1100
Average injection quantity mm3/st.   80.5 79.5 81.5
Max. variation between cylinders %   0 -2.5 2.5
Basic   *
Fixing the lever   *
Boost pressure kPa   45.3 45.3
Boost pressure mmHg   340 340
Injection quantity adjustment_02
Adjusting point   -
Rack position   7.3+-0.5
Pump speed r/min   550 550 550
Average injection quantity mm3/st.   13 12 14
Max. variation between cylinders %   0 -15 15
Fixing the rack   *
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
 
Injection quantity adjustment_03
Adjusting point   E
Rack position   10.6++
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   61 56 66
Fixing the lever   *
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Rack limit   *
Boost compensator adjustment
Pump speed r/min   750 750 750
Rack position   R2-1.55
Boost pressure kPa   6.7 5.4 8
Boost pressure mmHg   50 40 60
Boost compensator adjustment_02
Pump speed r/min   750 750 750
Rack position   R2-1.15
Boost pressure kPa   13.3 12 14.6
Boost pressure mmHg   100 90 110
Boost compensator adjustment_03
Pump speed r/min   750 750 750
Rack position   R2(10.4)
Boost pressure kPa   32 32 32
Boost pressure mmHg   240 240 240

Test data Ex:

Governor adjustment

Test data 101495-3542
N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT (4)Set idle sub-spring (5)Boost compensator stroke: BCL (6)Rack difference between N = N1 and N = N2
----------
K=10 BCL=1.55+-0.1mm N1=1100r/min N2=750r/min
----------

Speed control lever angle

Test data 101495-3542
F:Full speed I:Idle (1)Stopper bolt setting (2)Use the hole at R = aa
----------
aa=74mm
----------
a=3deg+-5deg b=27deg+-5deg

Stop lever angle

Test data 101495-3542
N:Pump normal S:Stop the pump. (1)Pump speed aa and rack position bb (to be sealed at delivery) (2)No return spring
----------
aa=0r/min bb=3-0.5mm
----------
a=0deg+-5deg b=(50deg)

0000001501 TAMPER PROOF

Test data 101495-3542
Tamperproofing-equipped boost compensator cover installation procedure (A): After adjusting the boost compensator, assemble then tighten the bolts to remove the heads. (B): Specified torque (1)Before adjusting the governor and the boost compensator, tighten the screw to the specified torque. (Tightening torque T = T1 maximum) (2)After adjusting the governor and the boost compensator, tighten to the specified torque to break off the bolt heads. (Tightening torque T = T2)
----------
T1=2.5N-m(0.25kgf-m) T2=2.9~4.4N-m(0.3~0.45kgf-m)
----------

0000001601 I/P WITH LOAD PLUNGER ADJ

Load plunger-equipped pump adjustment 1. Adjust the variation between cylinders and the injection quantity. 2. At Full point A, adjust the pre-stroke to the specified value. 3. After pre-stroke adjustment, reconfirm that the fuel injection quantity and the variation between cylinders is as specified.
----------

----------

Timing setting

Test data 101495-3542
(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)B.T.D.C.: aa (5)After adjusting the injection quantity, adjust at rack position bb.
----------
aa=7.4deg bb=10.1mm
----------
a=58deg+-3deg b=2deg+-30min




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