Information injection-pump assembly
ZEXEL
103862-0140
1038620140
0429110920

Rating:
Cross reference number
ZEXEL
103862-0140
1038620140
0429110920
Zexel num
Bosch num
Firm num
Name
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
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
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
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
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
Point A R=A
Beginning of injection position
Governor side NO.1
Governor side NO.1
Difference between angles 1
Cal 1-6 deg. 45 44.5 45.5
Cal 1-6 deg. 45 44.5 45.5
Difference between angles 2
Cyl.1-2 deg. 90 89.5 90.5
Cyl.1-2 deg. 90 89.5 90.5
Difference between angles 3
Cal 1-4 deg. 135 134.5 135.5
Cal 1-4 deg. 135 134.5 135.5
Difference between angles 4
Cal 1-8 deg. 180 179.5 180.5
Cal 1-8 deg. 180 179.5 180.5
Difference between angles 5
Cal 1-3 deg. 225 224.5 225.5
Cal 1-3 deg. 225 224.5 225.5
Difference between angles 6
Cal 1-7 deg. 270 269.5 270.5
Cal 1-7 deg. 270 269.5 270.5
Difference between angles 7
Cal 1-5 deg. 315 314.5 315.5
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
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

N:Pump speed
R:Rack position (mm)
(1)Idle sub spring setting: L1.
----------
L1=4.5-0.5mm
----------
----------
L1=4.5-0.5mm
----------
Speed control lever angle

F:Full speed
S:Stop
----------
----------
a=10deg+-5deg b=30deg+-5deg
----------
----------
a=10deg+-5deg b=30deg+-5deg
Stop lever angle

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
----------
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.
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.