Information injection-pump assembly
ZEXEL
104303-2180
1043032180
Rating:
Service parts 104303-2180 INJECTION-PUMP ASSEMBLY:
1.
_
3.
GOVERNOR
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
16600-90061
12.
Open Pre:MPa(Kqf/cm2)
9.8{100}
15.
NOZZLE SET
Include in #1:
104303-2180
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
104303-2180
1043032180
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 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
1-3-2
Pre-stroke
mm
1.75
1.7
1.8
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-3 deg. 120 119.5 120.5
Cal 1-3 deg. 120 119.5 120.5
Difference between angles 2
Cyl.1-2 deg. 240 239.5 240.5
Cyl.1-2 deg. 240 239.5 240.5
Injection quantity adjustment
Adjusting point
A
Rack position
10
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
34.1
33.1
35.1
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
C
Rack position
6.6+-0.5
Pump speed
r/min
350
350
350
Average injection quantity
mm3/st.
8
6.9
9.1
Max. variation between cylinders
%
0
-15
15
Fixing the lever
*
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
Adjust only variation between cylinders; adjust governor according to governor specifications.
Injection quantity adjustment_03
Adjusting point
B
Rack position
10
Pump speed
r/min
1550
1550
1550
Average injection quantity
mm3/st.
34.4
31.4
37.4
Max. variation between cylinders
%
0
-4
4
Fixing the lever
*
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Set the idle spring.
(2)Main spring setting
----------
----------
----------
----------
Speed control lever angle
F:Full speed
I:Idle
----------
----------
a=18deg+-3deg b=40deg+-6deg
----------
----------
a=18deg+-3deg b=40deg+-6deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=19deg+-5deg b=(38deg)
----------
----------
a=19deg+-5deg b=(38deg)
Timing setting
(1)Pump vertical direction
(2)Position of camshaft's key groove at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(50deg)
----------
----------
a=(50deg)
Information:
2. Locate wire 405-GY on the main cab harness near the connector exiting the cab wall on the right hand side, as shown by arrow.Cut this wire close to the connector. Splice it and the wire just assembled using an 8S4626 Splice. Be sure to splice to the portion of the wire that goes into the cab harness.3. Connect the 7N9738 Housing to the two pin connector on the 8X9862 Harness Assembly (housing containing 405-GY). Clip with a 3T3048 Clip Assembly.Installation of 8X8384 Ether (Chassis) Wiring Harness
The 8X7433 Chassis Harness called out in the AEIS Special Instruction, is replaced with 8X8384 Chassis Harness.Follow the installation procedure outlined in the AEIS Special Instruction for the 8X7433 Harness Assembly. Be sure to use the new 8X8382 Wire Assembly for the harness code plug.Installation of 8X8385 Ether (Engine) Wiring Harness
The 8X7107 Engine Harness on the AEIS is replaced with 8X8385 Harness Assembly.Follow the installation procedure outlined in the AEIS Special Instruction for the 8X7107 Harness Assembly. In addition, the following steps need to be performed. 1. Route the end of the harness with the 8T8732 Receptacle to the 3E3530 Electronic Control Group [oil pressure sensor] (2), installed at the right rear of the engine as shown.2. Connect the three pin receptacle to the connector on the 3E3530 Electronic Control Group (2) and clip into the 9X3495 Clip Assembly (7) installed earlier. Use 3S2093 Straps to loosely secure the harness to the top rear of the engine as shown.3. Remove the 8W3048 Harness Assembly that is connected to the remaining 6T7663 Oil Pressure Switch (9) and was connected to the 6T7663 Oil Pressure Switch that was removed.4. Connect an 8X8337 Harness Assembly to the one remaining oil pressure switch and reconnect to the engine harness. Clip with the existing clip. DO NOT tighten the straps or clips until all new wiring harnesses have been installed so any repositioning or adjustments can be made as necessary.Checking the Automatic Ether Injection System
* The system check-out will be same as for the AEIS with the following change:"A4" harness code on the 777B (indicates 3508 application) for two seconds.Retrofit to an Existing AEIS System
Necessary Parts
Installation of 3E3778 Ether Control Group
The 3E3778 Control Group is required for the MPPS System.Check the electronic control box installed with the AEIS to see if it is a 3E3778 or a 9X5303 Control Group. If a 9X5303 Control Group is installed, replace it with 3E3778 Control Group and 3E3779 Film.Follow the control box installation instructions outlined in the AEIS installation Special Instruction, SEHS9329. Be sure to install the 8X8386 Wire Assembly between the control and mounting plate. If an MPPS identification film is needed for a language other than English, refer to the following chart for the part number of the film for a specific language. Installation of 3E3530 Electronic Control Group [(PWM) Oil Pressure Sensor]
1. Remove the 6T7663 Oil Pressure Switch and adapter from the turbo oil adapter on the right rear of the engine (switch on bottom port with
The 8X7433 Chassis Harness called out in the AEIS Special Instruction, is replaced with 8X8384 Chassis Harness.Follow the installation procedure outlined in the AEIS Special Instruction for the 8X7433 Harness Assembly. Be sure to use the new 8X8382 Wire Assembly for the harness code plug.Installation of 8X8385 Ether (Engine) Wiring Harness
The 8X7107 Engine Harness on the AEIS is replaced with 8X8385 Harness Assembly.Follow the installation procedure outlined in the AEIS Special Instruction for the 8X7107 Harness Assembly. In addition, the following steps need to be performed. 1. Route the end of the harness with the 8T8732 Receptacle to the 3E3530 Electronic Control Group [oil pressure sensor] (2), installed at the right rear of the engine as shown.2. Connect the three pin receptacle to the connector on the 3E3530 Electronic Control Group (2) and clip into the 9X3495 Clip Assembly (7) installed earlier. Use 3S2093 Straps to loosely secure the harness to the top rear of the engine as shown.3. Remove the 8W3048 Harness Assembly that is connected to the remaining 6T7663 Oil Pressure Switch (9) and was connected to the 6T7663 Oil Pressure Switch that was removed.4. Connect an 8X8337 Harness Assembly to the one remaining oil pressure switch and reconnect to the engine harness. Clip with the existing clip. DO NOT tighten the straps or clips until all new wiring harnesses have been installed so any repositioning or adjustments can be made as necessary.Checking the Automatic Ether Injection System
* The system check-out will be same as for the AEIS with the following change:"A4" harness code on the 777B (indicates 3508 application) for two seconds.Retrofit to an Existing AEIS System
Necessary Parts
Installation of 3E3778 Ether Control Group
The 3E3778 Control Group is required for the MPPS System.Check the electronic control box installed with the AEIS to see if it is a 3E3778 or a 9X5303 Control Group. If a 9X5303 Control Group is installed, replace it with 3E3778 Control Group and 3E3779 Film.Follow the control box installation instructions outlined in the AEIS installation Special Instruction, SEHS9329. Be sure to install the 8X8386 Wire Assembly between the control and mounting plate. If an MPPS identification film is needed for a language other than English, refer to the following chart for the part number of the film for a specific language. Installation of 3E3530 Electronic Control Group [(PWM) Oil Pressure Sensor]
1. Remove the 6T7663 Oil Pressure Switch and adapter from the turbo oil adapter on the right rear of the engine (switch on bottom port with