101492-3880 ZEXEL 9 400 611 423 BOSCH INJECTION-PUMP ASSEMBLY 9400611423 1014923880 6205711243

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 611 423 9400611423

ZEXEL 101492-3880 1014923880

KOMATSU 6205711243 6205711243

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Service parts 101492-3880 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101049-8780

3. GOVERNOR 105400-6341

4. SUPPLY PUMP

105220-5960

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-4710

11. Nozzle and Holder 6202-13-3300

12. Open Pre:MPa(Kqf/cm2) 22.1{225}

13. NOZZLE-HOLDER 105048-3300

14. NOZZLE

105017-0630

15. NOZZLE SET

Include in #1:

101492-3880 as INJECTION-PUMP ASSEMBLY

106682-4380 as _

Cross reference number

BOSCH 9 400 611 423 9400611423

ZEXEL 101492-3880 1014923880

KOMATSU 6205711243 6205711243

Zexel num

Bosch num

Firm num

Name

101492-3880

9 400 611 423

6205711243 KOMATSU

INJECTION-PUMP ASSEMBLY
S4D95L 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 131424-7420

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 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

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 73.5 72.5 74.5

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point -

Rack position 7.8+-0.5

Pump speed r/min 450 450 450

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.

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)RACK LIMIT: RAL (3)Rack difference from N = N1 (4)Rack difference between N = N2 and N = N3
----------
K=14 RAL=12.5+0.2mm N1=1100r/min N2=1100r/min N3=500r/min
----------

Speed control lever angle

F:Full speed I:Idle S:Stop (1)Use the hole at R = aa
----------
aa=80mm
----------
a=34deg+-5deg b=17deg+-3deg c=32deg+-3deg

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

Information:

If there has been a previous repair, part age/hours will apply. Retain a copy of the previous repair invoice in the dealer's records for audit purposes, and specify repair date and machine hours in the "Additional Comments" section of the warranty claim.
PARTS DISPOSITION
****Parts Stock****
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
****Affected Product****
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Rework Procedure
Note: Ensure that all safety information, warnings, and instructions are read and understood before any operation or any maintenance procedures are performed. Refer to the Operation and Maintenance Manual "Safety Section".
C175 Injector Sleeve Re-Seal Process:
This Rework Procedure outlines how to correctly remove, inspect, and install a C175 injector sleeve into a cylinder head, with a new process designed to stop coolant leaks caused by injector sleeve seal failure.
Parts and Materials Needed:
8T-2223 Quill Tube Bolts/Cylinder - Qty 4
8T-0106 injector Hold Down Bolt/Cylinder - Qty 1
298-5347 Injector Sleeve/Cylinder - Qty 1
247-1074 Injector Sleeve O-Rings/Cylinder - Qty 2
8C-3132 Injector Tip O-Ring/Cylinder - Qty 1
339-9352 Injector System Cap Kit/Engine - Qty 1
- Battery powered screwdriver/impact
- Soft bristled brush (nylon or other non-metallic material), Cat part number 6V-7096 is an example. Refer to Image1.2.1.
- Injector sleeve torque tool (333-0759, or new tool provided by Lafayette)
- Vacuum attachment, for removing debris from inside cylinder
- Deep well socket, inverted
- Wrap a lint free shop towel around the socket, secure to the socket with an O-ring
- Brake clean or similar solvent
- Torque wrench capable of reaching 200 N.m
- Anti-seize (C5-A Loctite 51007)
- Clean engine oil
Image1.2.1
Removal of Valve Covers:
1. Remove four quill tube bolts and slide quill out of head. Refer to Image1.3.1.
2. Place quill tube into sealed plastic bag.
3. Place plugs into the quill tube hole and over fuel limiter in the fuel rail.
4. Remove the injectors.
5. Place injectors in plastic bag.
Image1.3.1
Removal of the Injector Sleeves:
1. Remove the injector sleeves. Refer to Image 1.4.1.
2. Vacuum out any loose debris.
3. Clean remaining Loctite debris from the injector sleeve seat using brake-clean or a similar solvent, a nylon bristled brush (Cat part number 6V-7096), and an inverted socket with a lint free rag or towel wrapped around it).
4. Use an O-ring to keep the rag around the socket.
5. Clean the threads in the head with the soft bristled brush. Refer to Image1.4.2.
6. Clean the seat surface with the inverted socket and a new rag until the rag no longer picks up debris or dirt from the seat. Refer to Image1.4.3 and 1.4.4.
Image1.4.1
Image1.4.2
Image1.4.3
Image1.4.4
Inspection of the Injector Sleeve Seat:
1. The seat and threads must be free of any debris.
2. The seat must not have any visible guttering around the surface.
3. There should be a continuous shiny band