101492-3940 ZEXEL 9 400 614 457 BOSCH INJECTION-PUMP ASSEMBLY 9400614457 1014923940 6204711211

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 614 457 9400614457

ZEXEL 101492-3940 1014923940

KOMATSU 6204711211 6204711211

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Buy INJECTION-PUMP ASSEMBLY 101492-3940 zexel genuine, new aftermarket engine parts with delivery

Service parts 101492-3940 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP

101049-8760

3. GOVERNOR 105400-6350

4. SUPPLY PUMP 105220-5610

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-4110

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2) 19.6{200}

13. NOZZLE-HOLDER 105048-3060

14. NOZZLE

105017-0090

15. NOZZLE SET

Include in #1:

101492-3940 as INJECTION-PUMP ASSEMBLY

106682-4421 as _

106682-4422

Cross reference number

BOSCH 9 400 614 457 9400614457

ZEXEL 101492-3940 1014923940

KOMATSU 6204711211 6204711211

Zexel num

Bosch num

Firm num

Name

101492-3940

9 400 614 457

6204711211 KOMATSU

INJECTION-PUMP ASSEMBLY
4D95L 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

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 3.6 3.55 3.65

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 10.3

Pump speed r/min 1200 1200 1200

Average injection quantity mm3/st. 34.2 33.2 35.2

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point -

Rack position 9.5+-0.5

Pump speed r/min 425 425 425

Average injection quantity mm3/st. 8 7 9

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)The torque control spring must does not have a set force. (3)RACK LIMIT: RAL (4)Rack difference between N = N1 and N = N2
----------
K=9 RAL=15+0.2mm N1=1200r/min N2=750r/min
----------

Speed control lever angle

F:Full speed I:Idle S:Stop
----------

----------
a=6deg+-5deg b=21deg+-5deg 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=59deg36min+-3deg b=0deg24min+-30min

Information:

(1) Remove the plug in the dash and install 3T306 Starting Aid Switch (1). Connect two purple wires (2), from the wiring harness, to switch (1).(2) On machines with a bulldozer, remove two nuts (3), washers and bolts. Remove two bolts (4) and washers. Remove bracket (5) from bracket (6). (3) Put 7G6359 Box Assembly (7) in position and install two 5F4899 Bolts (8) and 5M2894 Washers. Install two S1594 Bolts (9), 5P1075 Washers and 1D4717 Nuts to hold box assembly (7) to bracket (6). Install 4M7470 Grommet in hole (A).(4) Put the wires of 6N7674 Valve Assembly (10) through hole (A) and install valve assembly (10) on box assembly (7) with two S1617 Bolts (11), 5P4116 Washers and 1D4716 Nuts. Install 7N2059 Clamp Assembly (12) with two S1617 Bolts, 5P4116 Washers and 1D4716 Nuts. Install 63801 Washer (13) on 6D1746 Bolt (14). Put bolt (14) in position in cover (15) and install L1365 Washer (16) on bolt (14). Install 3B4610 Cotter Pin (17) in bolt (14). (5) Remove the plug from the manifold and install 6N9995 Atomizer Assembly (18) as shown. The orifices of the atomizer must be toward each end of the manifold. Install 5P7907 Connector (19) in valve assembly (10). Connect 9G941 Tube (20) to atomizer assembly (18). Use 5P6314 Sleeve (21) and 5P6313 Nut (22) to connect tube (20) to connector (19). Remove the plug from the bypass elbow of the water lines group and install 6N5899 Switch (23). Connect 9G6560 Wire Assembly (24) to switch (23) and to valve assembly (10). Connect 9G6561 Wire Assembly (25) to valve assembly (10) and to the purple wire, from the starting aid switch, at the rear of the engine. Use former clips (26) to hold wire assemblies (24) and (25) in position.(6) Remove cap (27) from valve assembly (10) and install a 7N296 Cylinder Assembly. (7) For machines without bulldozer lines, remove the two bolts from the cylinder head and put 7G6359 Box Assembly (7) in position. Install two 5F4899 Bolts (8) and 5M2894 Washers. Remove the bolt from the exhaust manifold and put 3T1685 Bracket (27) in position. Install L2070 Bolt (28), 5M2894 Washer and 1D4717 Nut. Install two S1594 Bolts (9), 5P1075 Washers and 1D4717 Nuts. Install the 4M7470 Grommet in hole (A), see Step 3. Follow Steps 1, 4, 5 and 6 for installation of the group.