101495-3420 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014953420

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101495-3420 1014953420

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Cross reference number

ZEXEL 101495-3420 1014953420

Zexel num

Bosch num

Firm num

Name

101495-3420

INJECTION-PUMP ASSEMBLY

Calibration Data:

Adjustment conditions

Test oil
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

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

Injection timing adjustment

Direction of rotation (viewed from drive side)
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

Difference between angles 1
Cyl.1-2 deg. 90 89.5 90.5

Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5

Difference between angles 3
Cal 1-3 deg. 270 269.5 270.5

Injection quantity adjustment

Adjusting point A

Rack position 10.6

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 63.5 62.5 64.5

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the rack *

Injection quantity adjustment_02

Adjusting point -

Rack position 8.4+-0.5

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 8 7 9

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Remarks
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)Tolerance for racks not indicated: +-0.05mm. (3)RACK CAP: R1 (4)Idle sub spring setting: L1.
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K=15 R1=(17.5)mm L1=5.9-0.5mm
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Speed control lever angle

F:Full speed I:Idle (1)Set the pump speed at aa. ( At delivery ) (2)Set the pump speed at bb. (3)Stopper bolt setting
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aa=900r/min bb=750r/min
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a=49deg+-5deg b=24deg+-5deg c=7deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Rack position = aa, speed = bb (stamp at delivery) (2)No return spring
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aa=1-0.5mm bb=0r/min
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a=27.5deg+-5deg b=(55deg)

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)- (5)-
----------

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a=58deg+-3deg b=2deg+-30min

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.