Information injection-pump assembly
BOSCH
9 400 614 521
9400614521
ZEXEL
101495-3241
1014953241
KOMATSU
6204731230
6204731230
Rating:
Service parts 101495-3241 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
9 400 614 521
9400614521
ZEXEL
101495-3241
1014953241
KOMATSU
6204731230
6204731230
Zexel num
Bosch num
Firm num
Name
101495-3241
9 400 614 521
6204731230 KOMATSU
INJECTION-PUMP ASSEMBLY
4D95L K
4D95L 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
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
10.8
Pump speed
r/min
1150
1150
1150
Average injection quantity
mm3/st.
40.2
39.2
41.2
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
9.8+-0.5
Pump speed
r/min
475
475
475
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)The torque control spring must does not have a set force.
(4)Rack difference between N = N1 and N = N2
(5)Damper spring setting: DL
----------
K=11 RAL=15+0.2mm N1=1150r/min N2=750r/min DL=7.3+-0.1mm
----------
----------
K=11 RAL=15+0.2mm N1=1150r/min N2=750r/min DL=7.3+-0.1mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=11deg+-5deg b=26deg+-5deg
----------
----------
a=11deg+-5deg b=26deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=1deg+-5deg b=53deg+-5deg
----------
----------
a=1deg+-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=59deg36min+-3deg b=0deg24min+-30min
----------
----------
a=59deg36min+-3deg b=0deg24min+-30min
Information:
Remove the single tie bolt (6) that is located in the top left corner of the pump by using Tooling (B). Refer to Illustration 7. Only remove the single tie bolt (6). Removing more bolts will result in damage to the pump.
Illustration 2 g01132938
(1) HEUI pump (2) Fuel transfer pump (4) Drive gear (5) 227-5904 O-Ring Seal (6) Tie Bolt (7) Bolts for the fuel transfer pump (8) Tie Bolts (9) Location for service bolt (12) 185-3241 O-Ring Seal
Replace tie bolt (6) with the temporary service bolt (9) that is provided in the service kit.Note: The service bolt that is provided in the kit has an undersized bolt head. The service bolt prevents the body of the HEUI pump from separating during service. Do not remove the service bolt until the fuel transfer pump has been completely reinstalled.
Tighten the service bolt (9) to 10 N m (7.4 lb ft) by using Tooling (C) .Note: Do not place an excessive torque on the service bolt. The aluminum housing of the pump could be damaged.
After installing the service bolt (9) in the top left location, remove the three bolts (7) that fasten the fuel transfer pump to the HEUI pump by using Tooling (A) .
Proceed by removing the remaining three tie bolts (8) by using Tooling (B) .
Separate the fuel transfer pump from the HEUI pump. Refer to Illustration 3.
Illustration 3 g01132944
(1) HEUI pump (2) Fuel transfer pump (9) Service bolt (10) Seals (11) SealInstalling the Fuel Transfer Pump onto the HEUI Pump
Install the two new 239-2402 Seals (10) on the back face of the HEUI pump (1). Refer to Illustration 4.
Illustration 4 g01077898
(1) HEUI pump (10) 239-2402 Seals
Install a new 179-8128 Seal (11) on the fuel transfer pump (2). Refer to Illustration 5. Use 1U-6396 O-Ring Assembly Compound in order to hold the seal in place during assembly. Ensure that the seal is completely seated.
Illustration 5 g01132957
(2) Fuel transfer pump (11) 179-8128 Seal
Do not remove the service bolt. Position the fuel transfer pump on the HEUI pump. Be sure to properly align the drive tang on the fuel transfer pump with the drive slot on the HEUI pump.Note: Align the drive tang of the fuel transfer pump so that the flat end is vertical. Refer to Illustration 5. Align the drive slot in the HEUI pump to a similar vertical orientation by using a flat head screwdriver. Refer to Illustration 6.
Illustration 6 g01132969
Note: Once the fuel transfer pump has been placed onto the HEUI pump, ensure that the face of the fuel transfer pump is flush with the face of the HEUI pump. If the pump faces are not flush, verify the alignment of the drive tang.
Install the three mounting bolts (7) for the fuel transfer pump (2). Tighten
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Group cross 101495-3241 ZEXEL
Komatsu
Komatsu
Komatsu
101495-3241
9 400 614 521
6204731230
INJECTION-PUMP ASSEMBLY
4D95L
4D95L