Information injection-pump assembly
BOSCH
9 400 614 520
9400614520
ZEXEL
101495-3230
1014953230
KOMATSU
6205711310
6205711310
Rating:
Service parts 101495-3230 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
6202-13-3300
12.
Open Pre:MPa(Kqf/cm2)
22.1{225}
15.
NOZZLE SET
Cross reference number
BOSCH
9 400 614 520
9400614520
ZEXEL
101495-3230
1014953230
KOMATSU
6205711310
6205711310
Zexel num
Bosch num
Firm num
Name
101495-3230
9 400 614 520
6205711310 KOMATSU
INJECTION-PUMP ASSEMBLY
S4D95L K
S4D95L 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
3.2
3.15
3.25
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
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
72.6
71.6
73.6
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
7.6+-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 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
----------
----------
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
(1)Use the hole at R = aa
(2)Stopper bolt setting
----------
aa=60mm
----------
a=17deg+-5deg b=34deg+-5deg
----------
aa=60mm
----------
a=17deg+-5deg b=34deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)No return spring
----------
----------
a=37deg+-5deg b=53deg+-5deg
----------
----------
a=37deg+-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)-
----------
----------
a=58deg+-3deg b=2deg+-30min
----------
----------
a=58deg+-3deg b=2deg+-30min
Information:
Introduction
The following special instructions must be used to test for a crack in the Diesel Particulate Filter (DPF). Do not perform any procedure that is outlined in this Special Instruction until you have read and understand the information that is contained in this document.Required Tools
Table 1
Required Tools
Part Number Part Name Quantity
380-5200 Tool Kit 1 Testing Procedure
Perform a “Manual Diesel Particulate Filter Regeneration” using Caterpillar Electronic Technician (Cat ® ET).
After the manual DPF regeneration is complete, run the engine at 1800 rpm for a MINIMUM of 20 minutes to stabilize the DPF temperatures.Note: Manually set the engine speed to 1800 rpm, the engine must maintain a steady speed for the entire duration of the test.
Illustration 1 g02597531
(1) DPF Outlet Cap
(2) Filter Paper
(3) Hose Assembly
(4) Air Pump
Illustration 2 g02599276
(5) DPF Outlet Port
Hot parts or hot components can cause burns or personal injury. Do not allow hot parts or components to contact your skin. Use protective clothing or protective equipment to protect your skin.
Shut down the engine and remove the Delta P line from the DPF outlet port. Refer to Illustrations 1 and 2.
Illustration 3 g02599418
(6) Filter Paper
Install the filter in the fitting, Refer to Illustration 3. Install the fitting in the DPF outlet port. The filter must be installed in less than 10 minutes after the engine has shut down.
Turn the vacuum pump ON.
Disable automatic regeneration in Cat ET.
Illustration 4 g02597737
Select "Service" - "Configuration" - "Emissions Parameters" and "ARD Manual Disable Status". Select "Disabled". The check engine light and a 3714-31 active code will be present.
Override the "DPF Differential Pressure Line Override" to "Disconnected", using Cat ET. Refer to Illustration 4.
Start the engine. Run the engine at 1800 rpm for 15 minutes.Note: Manually set the engine speed to 1800 rpm, the engine must maintain a steady speed for the entire duration of the test.
Hot parts or hot components can cause burns or personal injury. Do not allow hot parts or components to contact your skin. Use protective clothing or protective equipment to protect your skin.
Shut the engine down and remove the filter holder within 25 minutes. Use proper personal protective equipment to remove the filter holder.
Allow the filter holder time to cool down before disassembly.
Carefully disassemble the filter holder to prevent contamination. Tip the fitting down on a clean surface to remove the filter paper. Handle the filter paper with clean hands and only by the edges.
Illustration 5 g02597796
Compare the stained area in the center of the filter paper to the color coded sheet provided. Refer to Illustration 5.
If the shade is equal to or darker than the "Color Code Sheet", the DPF has a crack or leak. Replace the DPF. Refer to Special Instruction, "Diesel Particulate Filter (DPF) Maintenance on Tier 4 Products Equipped with a Diesel Particulate Filter".
If the shade is lighter than the "Color Code Sheet", then return the unit to service.
Enable the Automatic regeneration in Cat ET.
Select "Service" - "Configuration" - "Emissions Parameters" and "ARD Manual Disable Status". Select "Not - Disabled". The check engine light will go off unless
The following special instructions must be used to test for a crack in the Diesel Particulate Filter (DPF). Do not perform any procedure that is outlined in this Special Instruction until you have read and understand the information that is contained in this document.Required Tools
Table 1
Required Tools
Part Number Part Name Quantity
380-5200 Tool Kit 1 Testing Procedure
Perform a “Manual Diesel Particulate Filter Regeneration” using Caterpillar Electronic Technician (Cat ® ET).
After the manual DPF regeneration is complete, run the engine at 1800 rpm for a MINIMUM of 20 minutes to stabilize the DPF temperatures.Note: Manually set the engine speed to 1800 rpm, the engine must maintain a steady speed for the entire duration of the test.
Illustration 1 g02597531
(1) DPF Outlet Cap
(2) Filter Paper
(3) Hose Assembly
(4) Air Pump
Illustration 2 g02599276
(5) DPF Outlet Port
Hot parts or hot components can cause burns or personal injury. Do not allow hot parts or components to contact your skin. Use protective clothing or protective equipment to protect your skin.
Shut down the engine and remove the Delta P line from the DPF outlet port. Refer to Illustrations 1 and 2.
Illustration 3 g02599418
(6) Filter Paper
Install the filter in the fitting, Refer to Illustration 3. Install the fitting in the DPF outlet port. The filter must be installed in less than 10 minutes after the engine has shut down.
Turn the vacuum pump ON.
Disable automatic regeneration in Cat ET.
Illustration 4 g02597737
Select "Service" - "Configuration" - "Emissions Parameters" and "ARD Manual Disable Status". Select "Disabled". The check engine light and a 3714-31 active code will be present.
Override the "DPF Differential Pressure Line Override" to "Disconnected", using Cat ET. Refer to Illustration 4.
Start the engine. Run the engine at 1800 rpm for 15 minutes.Note: Manually set the engine speed to 1800 rpm, the engine must maintain a steady speed for the entire duration of the test.
Hot parts or hot components can cause burns or personal injury. Do not allow hot parts or components to contact your skin. Use protective clothing or protective equipment to protect your skin.
Shut the engine down and remove the filter holder within 25 minutes. Use proper personal protective equipment to remove the filter holder.
Allow the filter holder time to cool down before disassembly.
Carefully disassemble the filter holder to prevent contamination. Tip the fitting down on a clean surface to remove the filter paper. Handle the filter paper with clean hands and only by the edges.
Illustration 5 g02597796
Compare the stained area in the center of the filter paper to the color coded sheet provided. Refer to Illustration 5.
If the shade is equal to or darker than the "Color Code Sheet", the DPF has a crack or leak. Replace the DPF. Refer to Special Instruction, "Diesel Particulate Filter (DPF) Maintenance on Tier 4 Products Equipped with a Diesel Particulate Filter".
If the shade is lighter than the "Color Code Sheet", then return the unit to service.
Enable the Automatic regeneration in Cat ET.
Select "Service" - "Configuration" - "Emissions Parameters" and "ARD Manual Disable Status". Select "Not - Disabled". The check engine light will go off unless
Have questions with 101495-3230?
Group cross 101495-3230 ZEXEL
Komatsu
Komatsu
101495-3230
9 400 614 520
6205711310
INJECTION-PUMP ASSEMBLY
S4D95L
S4D95L