Information injection-pump assembly
BOSCH
9 400 610 191
9400610191
ZEXEL
101492-3540
1014923540
KOMATSU
6204711440
6204711440
Rating:
Service parts 101492-3540 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
6207-11-3102
12.
Open Pre:MPa(Kqf/cm2)
19.6{200}
15.
NOZZLE SET
Cross reference number
BOSCH
9 400 610 191
9400610191
ZEXEL
101492-3540
1014923540
KOMATSU
6204711440
6204711440
Zexel num
Bosch num
Firm num
Name
9 400 610 191
6204711440 KOMATSU
INJECTION-PUMP ASSEMBLY
4D95L K 14BC INJECTION PUMP ASSY PE4A,5A, PE
4D95L K 14BC INJECTION PUMP ASSY PE4A,5A, PE
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
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
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
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
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
Drive side NO.1
Difference between angles 1
Cyl.1-2 deg. 90 89.5 90.5
Cyl.1-2 deg. 90 89.5 90.5
Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5
Cal 1-4 deg. 180 179.5 180.5
Difference between angles 3
Cal 1-3 deg. 270 269.5 270.5
Cal 1-3 deg. 270 269.5 270.5
Injection quantity adjustment
Adjusting point
A
Rack position
9.6
Pump speed
r/min
850
850
850
Average injection quantity
mm3/st.
36.5
35.5
37.5
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
8.2+-0.5
Pump speed
r/min
375
375
375
Average injection quantity
mm3/st.
6.2
5.2
7.2
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
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)The torque control spring must does not have a set force.
(3)RACK CAP: R1
(4)Rack difference between N = N1 and N = N2
(5)Idle sub spring setting: L1.
----------
K=12++ R1=(17.5)mm N1=850r/min N2=400r/min L1=7.5-0.5mm
----------
----------
K=12++ R1=(17.5)mm N1=850r/min N2=400r/min L1=7.5-0.5mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Speed set at aa (setting at shipping)
(2)Stopper bolt setting
(3)Set the pump speed at bb.
----------
aa=900r/min bb=750r/min
----------
a=(9deg)+-5deg b=(22deg)+-5deg c=(6deg)+-5deg
----------
aa=900r/min bb=750r/min
----------
a=(9deg)+-5deg b=(22deg)+-5deg c=(6deg)+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)No return spring
----------
----------
a=47deg+-5deg b=53deg+-5deg
----------
----------
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
----------
----------
a=59deg36min+-3deg b=0deg24min+-30min
Information:
3. Remove turbo supply and drain lines (1). 4. Remove bolts (3) that holds bonnet (2) to engine block and torque converter oil cooler.5. Remove bolts (5), (6) and (7) (not shown) and remove cooler. Install in the reverse order. Fill cooling system with coolant. See the Operation & Maintenance Manual for the proper procedure and levels. Check the engine oil level. See the Operation & Maintenance Manual for the proper procedure and levels.End By:a. install oil filters and baseDisassemble Engine Oil Cooler & Bypass Valves
Start By:a. remove engine oil cooler and bypass valves 1. Remove bolts (1) to remove bypass valve assembly (3) from oil cooler (2). 2. Remove adapter (6) from the engine oil cooler. Remove O-ring seals (5) from the adapter.3. Remove bolts (4) to remove cover (7). Remove valves (9) and springs (8) from water line.4. Remove tube (10) from water lines. Remove O-ring seals (11) from the tube. 5. Clean the engine oil cooler tubes with a 3.2 mm (.125 in) diameter rod as shown.Assemble Engine Oil Cooler & Bypass Valves
1. Install new O-ring seals (1) on adapter (2). Install adapter (2) in the engine oil cooler.2. Install new O-ring seals (7) on tube (6). Install tube in water lines.3. Install valves (5) and springs (4) in the water line. Install cover (3) with the bolts (9) that hold it. 4. Install the bypass valve assembly on the engine oil cooler with the bolts (8) that hold it. Install the cover and bolts (9).End By:a. install engine oil cooler and bypass valves
Start By:a. remove engine oil cooler and bypass valves 1. Remove bolts (1) to remove bypass valve assembly (3) from oil cooler (2). 2. Remove adapter (6) from the engine oil cooler. Remove O-ring seals (5) from the adapter.3. Remove bolts (4) to remove cover (7). Remove valves (9) and springs (8) from water line.4. Remove tube (10) from water lines. Remove O-ring seals (11) from the tube. 5. Clean the engine oil cooler tubes with a 3.2 mm (.125 in) diameter rod as shown.Assemble Engine Oil Cooler & Bypass Valves
1. Install new O-ring seals (1) on adapter (2). Install adapter (2) in the engine oil cooler.2. Install new O-ring seals (7) on tube (6). Install tube in water lines.3. Install valves (5) and springs (4) in the water line. Install cover (3) with the bolts (9) that hold it. 4. Install the bypass valve assembly on the engine oil cooler with the bolts (8) that hold it. Install the cover and bolts (9).End By:a. install engine oil cooler and bypass valves