Information injection-pump assembly
BOSCH
9 400 614 451
9400614451
ZEXEL
101492-3732
1014923732
KOMATSU
6204731211
6204731211
Rating:
Service parts 101492-3732 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
9 400 614 451
9400614451
ZEXEL
101492-3732
1014923732
KOMATSU
6204731211
6204731211
Zexel num
Bosch num
Firm num
Name
101492-3732
9 400 614 451
6204731211 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
10.7
Pump speed
r/min
1050
1050
1050
Average injection quantity
mm3/st.
38
37
39
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
9.2+-0.5
Pump speed
r/min
495
495
495
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.
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 LIMIT: RAL
(3)Rack difference between N = N1 and N = N2
(4)Rack difference between N = N3 and N = N4
----------
K=16 RAL=15+0.2mm N1=1050r/min N2=750r/min N3=1050r/min N4=350r/min
----------
----------
K=16 RAL=15+0.2mm N1=1050r/min N2=750r/min N3=1050r/min N4=350r/min
----------
Speed control lever angle
F:Full speed
I:Idle
S:Stop
----------
----------
a=9deg+-5deg b=32deg+-3deg c=25deg+-5deg
----------
----------
a=9deg+-5deg b=32deg+-3deg c=25deg+-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:
TERMINATION DATE
30Sep2014
PROBLEM
The existing fuel injector has a 150 degree spray pattern. During the combustion stroke (process), the current end of injection timing maps can allow the 150 degree spray pattern to temporarily impinge upon the exposed wall of the cylinder liner as the piston moves downward in the bore.
Depending on engine speed and load factors, the fuel making contact with the liner can dilute the oil film or cause excessive soot. The excessive soot can build up to form carbon deposits at the piston lands and grooves, resulting in uneven top ring and groove wear, which may cause ring breakage. This situation is aggravated by contamination within the air and lubrication systems.
AFFECTED PRODUCT
Model Identification Number
793D FDB01439, 1442-1443, 1450-1451, 1561-1562, 1566-1567, 1576, 1620-1622, 1627, 1629
PARTS NEEDED
Qty
Part Number Description
16 4237547 INJECTOR GP-FUEL
1 4264383 SOFTWARE GP-ELEK
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 32% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.
ACTION REQUIRED
Refer to the service manual if/as necessary.
Install a full set of sixteen 145 degree fuel injectors along with
the software.
NOTE 1: Do not mix the 145 degree fuel injectors with the former 150 degree fuel injectors in the same engine.
NOTE 2: Do not install the software that is listed in the Parts Needed unless all sixteen fuel injectors have been replaced by the 145 degree spray pattern fuel injectors that is listed in the Parts Needed.
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
0-20000 hrs,
0-72 mo 100.0% 50.0% 0.0% 0.0% 0.0% 50.0%
This is a 8.0-hour job
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Have questions with 101492-3732?
Group cross 101492-3732 ZEXEL
Komatsu
Komatsu
101492-3732
9 400 614 451
6204731211
INJECTION-PUMP ASSEMBLY
4D95L
4D95L