Information injection-pump assembly
ZEXEL
101492-3770
1014923770
KOMATSU
6202731140
6202731140
Rating:
Cross reference number
ZEXEL
101492-3770
1014923770
KOMATSU
6202731140
6202731140
Zexel num
Bosch num
Firm num
Name
101492-3770
6202731140 KOMATSU
INJECTION-PUMP ASSEMBLY
4D95S * K
4D95S * K
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
Rack position
Point A R=A
Point A R=A
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
Pump speed
r/min
1225
1225
1225
Average injection quantity
mm3/st.
36.4
35.4
37.4
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
350
350
350
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 CAP: R1
----------
K=19 R1=(13)mm
----------
----------
K=19 R1=(13)mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=18deg+-5deg b=30deg+-5deg
----------
----------
a=18deg+-5deg b=30deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=26.5deg+-5deg b=53deg+-5deg
----------
----------
a=26.5deg+-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)-
(5)-
----------
----------
a=59deg36min+-3deg b=0deg24min+-30min
----------
----------
a=59deg36min+-3deg b=0deg24min+-30min
Information:
TERMINATION DATE
30Apr2017
PROBLEM
The existing diesel exhaust fluid filter can become plugged due to debris on certain 725C, and 730C Articulated Trucks. If the existing filter plugs it will cause E931 low DEF pressure fault codes and E1389 inducements. There is new engine and aftertreatment software available that should also be installed as part of this letter.
AFFECTED PRODUCT
Model Identification Number
725C TFB00111-00329
730C TFF00121-00537
730C EJ TFH00131-00146
PARTS NEEDED
Qty
Part Number Description
1 3783187 FILTER-DEF
1 3915262 GASKET
1 4233251 CONNECTOR AS
1 4250385 FILTER AS-DEF
1 4526055 BASE AS-FILTER
1 4531604 FILTER-DEF
1 4653400 SFWR GP-Engine
1 4653401 SFWR GP-Aftertreatment
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 20% 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
To install the new filter. Refer to Special Instruction, REHS9664, "Installation of the New Diesel Exhaust Fluid Filter On Certain Tier 4 Final Applications".
Flash the 465-3400 Engine Software and the 465-3401 Aftertreatment Software or latest available on SIS Web.
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
0-3000 hrs,
0-72 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 2.0-hour job
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Have questions with 101492-3770?
Group cross 101492-3770 ZEXEL
Komatsu
Komatsu
101492-3770
6202731140
INJECTION-PUMP ASSEMBLY
4D95S
4D95S