Information injection-pump assembly
BOSCH
9 400 614 459
9400614459
ZEXEL
101492-3960
1014923960
KOMATSU
6204711231
6204711231
Rating:
Service parts 101492-3960 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
9 400 614 459
9400614459
ZEXEL
101492-3960
1014923960
KOMATSU
6204711231
6204711231
Zexel num
Bosch num
Firm num
Name
101492-3960
9 400 614 459
6204711231 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
10.5
Pump speed
r/min
1250
1250
1250
Average injection quantity
mm3/st.
37.5
36.5
38.5
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
10.5+-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.
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=17 RAL=15+0.2mm N1=1250r/min N2=800r/min N3=1250r/min N4=500r/min
----------
----------
K=17 RAL=15+0.2mm N1=1250r/min N2=800r/min N3=1250r/min N4=500r/min
----------
Speed control lever angle
F:Full speed
I:Idle
S:Stop
----------
----------
a=15deg+-5deg b=32deg+-3deg c=35deg+-5deg
----------
----------
a=15deg+-5deg b=32deg+-3deg c=35deg+-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:
PARTS NEEDED
Qty
Part Number Description
1 7K1181 STRAP-CABLE
1 1325789 CLIP-LADDER
1 4182073 GASKET AS
1 4609257 INJECTOR AS-DEF
1 5407232 SFWR GP-A1000
1 BULK_COOLANT COOLANT See OMM (After Failure Only)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 2% 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 attached Rework Procedure.
Reflash the engine controller (ECM) with the software listed in the Parts Needed 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,
0-36 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
3001-5000 hrs,
37-60 mo 100.0% 0.0% 0.0% 0.0% 0.0% 100.0%
This is a 2.0-hour job
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Rework Procedure
Diesel Exhaust Fluid Pressure Line Rerouting:
1. Unbolt strap (1) from current position.
Loosen clip-loop (2) and reorient the clip on the hose.
Bolt strap to new location (3) and tighten clip-loop to hold the hose in position.
2. Loosen upper clip-loop (4) to allow hose to be pulled through.
3. Add the following parts in the position shown (5);
Clip-ladder, 132-5789
Strap-cable, 7K-1181
4. Tighten upper clip-loop (4) to retain hose in position.
Image1.1.1
DEF Injector Replacement ? Remove and Install:
1. Remove DEF injector and replace. Follow Disassembly and Assembly, UENR6559, for DEF Injector and Mounting - Remove and Install.
Update Engine Software:
Reflash the engine controller (ECM) with the software listed in the Parts Needed or latest available on SIS Web.
Have questions with 101492-3960?
Group cross 101492-3960 ZEXEL
Komatsu
101492-3960
9 400 614 459
6204711231
INJECTION-PUMP ASSEMBLY
4D95L
4D95L