103862-0140 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1038620140 0429110920


 

Information injection-pump assembly

ZEXEL 103862-0140 1038620140
  0429110920
103862-0140 INJECTION-PUMP ASSEMBLY
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Cross reference number

ZEXEL 103862-0140 1038620140
  0429110920


Zexel num
Bosch num
Firm num
Name
103862-0140 
103862-0212 
 
0429110920   
INJECTION-PUMP ASSEMBLY
S16N *

Calibration Data:

Adjustment conditions
Test oil
1404 Test oil
  ISO4113 or {SAEJ967d}
Test oil temperature degC   40 40 45
Nozzle   105011-9210
Bosch type code   DL155T406NP1
Nozzle holder   105043-3010
Opening pressure MPa   34.4
Opening pressure kgf/cm2   350
Injection pipe
Outer diameter - inner diameter - length (mm)
mm   6-2.4-1124
Overflow valve   131424-1420
Overflow valve opening pressure kPa   157 123 191
Overflow valve opening pressure kgf/cm2   1.6 1.25 1.95
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)
Left
  L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left
  L
Injection order   1-6-2-4- 8-3-7-5
Pre-stroke mm   2.05 2 2.1
Rack position
Point A
  R=A
Beginning of injection position
Governor side
  NO.1
Difference between angles 1
Cal 1-6
deg.   45 44.5 45.5
Difference between angles 2
Cyl.1-2
deg.   90 89.5 90.5
Difference between angles 3
Cal 1-4
deg.   135 134.5 135.5
Difference between angles 4
Cal 1-8
deg.   180 179.5 180.5
Difference between angles 5
Cal 1-3
deg.   225 224.5 225.5
Difference between angles 6
Cal 1-7
deg.   270 269.5 270.5
Difference between angles 7
Cal 1-5
deg.   315 314.5 315.5
Injection quantity adjustment
Adjusting point   A
Rack position   14
Pump speed r/min   450 450 450
Average injection quantity mm3/st.   400 390 410
Max. variation between cylinders %   0 -3 3
Basic   *
Fixing the rack   *
Remarks
Standard point A's rack position same as 103864-0090 in row R
 
Injection quantity adjustment_02
Adjusting point   B
Rack position   10
Pump speed r/min   450 450 450
Average injection quantity mm3/st.   240 228 252
Max. variation between cylinders %   0 -5 5
Fixing the rack   *
Injection quantity adjustment_03
Adjusting point   C
Rack position   7.5+-0.5
Pump speed r/min   250 250 250
Average injection quantity mm3/st.   68 61.2 74.8
Max. variation between cylinders %   0 -10 10
Fixing the rack   *

Test data Ex:

Governor adjustment

Test data 103862-0140
N:Pump speed R:Rack position (mm) (1)Idle sub spring setting: L1.
----------
L1=4.5-0.5mm
----------

Speed control lever angle

Test data 103862-0140
F:Full speed S:Stop
----------

----------
a=10deg+-5deg b=30deg+-5deg

Stop lever angle

Test data 103862-0140
N:Pump normal S:Stop the pump. I:Idle (1)Clearance between stopper bolt and lever must be aa.
----------
aa=(0.8)mm
----------
a=4.5deg+-5deg b=30deg+-5deg c=10deg+-5deg




Information:

Introduction
The problem that is identified below does not have a known permanent solution. Until a permanent solution is known, use the solution that is identified below.Problem
Diesel exhaust fluid may begin to leak from the 421-6842 Control Valve As due to breakage of the valve stem.
Illustration 1 g03774942
Location of valve assemblySolution
In order to fix the valve assembly leakage, rework the hose installation and replace the valve if the valve stem has broken. Refer to the following ""Rework Procedure"".Required Parts
Table 1
Required Parts    
Item    Qty    Part Number    Description    
1     1     421-6842     Control Valve As (1)    
2     2     132-5789     Clip    
3     2     3S-2093     Cable Strap    
( 1 ) If neededRework Procedure
Check the diesel exhaust fluid leakage from valve assembly (1). If there is no leakage, skip Steps 2 and 3. If there is leakage present, perform the following Steps 1 through 6.
Illustration 2 g03774935
(1) 421-6842 Control Valve As (4) 8M-2773 Clip or 067-2551 Clip (depending on sales model) (5) 8T-4137 Bolt (6) 8T-4121 Hard Washer (7) 6S-8620 Hose Clamp
Remove two clips (4), two bolts (5), and two washers (6) .Note: Retain the bolts and washers for reuse when installing the new clips.
Remove valve assembly (1) and two clamps (7) .
Attach the two hoses to new valve assembly (1). Secure by tightening the clamps to a torque of 1.4 0.3 N m (12.4 2.7 lb in).Note: Insert the hose up to the root of the valve tube.Note: Place the clamp on the straight portion of the hose by the bead of the valve tube.
Illustration 3 g03774975
(1) 421-6842 Control Valve As (3) 3S-2093 Cable Strap (5) 8T-4137 Bolt (6) 8T-4121 Hard Washer (A) 90 degree angle
Install two new clips (2) and secure with bolts (5) and washers (6) on the mounting boss.
Tighten bolts (5) to a torque of 55 10 N m (40.6 7.8 lb ft).
Secure both hoses to clips (2) using straps (3). Ensure that both hoses are straight against valve assembly (1) .Note: The clips must be attached at a 90 degree angle to the valve assembly. Refer to Illustration 3.Note: Do not apply a twisting force on the valve assembly when securing the hoses.Note: Do not deform the hoses when tightening the straps.

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