Information injection-pump assembly
ZEXEL
104761-4132
1047614132
Rating:
Cross reference number
ZEXEL
104761-4132
1047614132
Zexel num
Bosch num
Firm num
Name
104761-4132
INJECTION-PUMP ASSEMBLY
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113orSAEJ967d
1404 Test oil ISO4113orSAEJ967d
Test oil temperature
degC
45
45
50
Nozzle
105000-2010
Bosch type code
NP-DN12SD12TT
Nozzle holder
105780-2080
Opening pressure
MPa
14.7
14.7
15.19
Opening pressure
kgf/cm2
150
150
155
Injection pipe
Inside diameter - outside diameter - length (mm) mm 2-6-840
Inside diameter - outside diameter - length (mm) mm 2-6-840
Transfer pump pressure
kPa
20
20
20
Transfer pump pressure
kgf/cm2
0.2
0.2
0.2
Direction of rotation (viewed from drive side)
Right R
Right R
Injection timing adjustment
Pump speed
r/min
750
750
750
Average injection quantity
mm3/st.
58.6
58.1
59.1
Difference in delivery
mm3/st.
3
Basic
*
Oil temperature
degC
50
48
52
Injection timing adjustment_02
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
56.7
54.2
59.2
Oil temperature
degC
50
48
52
Injection timing adjustment_03
Pump speed
r/min
750
750
750
Average injection quantity
mm3/st.
58.6
57.6
59.6
Difference in delivery
mm3/st.
3
Basic
*
Oil temperature
degC
50
48
52
Injection timing adjustment_04
Pump speed
r/min
1125
1125
1125
Average injection quantity
mm3/st.
53
50.5
55.5
Difference in delivery
mm3/st.
5
Oil temperature
degC
50
48
52
Injection quantity adjustment
Pump speed
r/min
1225
1225
1225
Average injection quantity
mm3/st.
13.7
10.7
16.7
Difference in delivery
mm3/st.
4.5
Basic
*
Oil temperature
degC
50
48
52
Injection quantity adjustment_02
Pump speed
r/min
1300
1300
1300
Average injection quantity
mm3/st.
3
Oil temperature
degC
50
48
52
Injection quantity adjustment_03
Pump speed
r/min
1225
1225
1225
Average injection quantity
mm3/st.
13.7
10.2
17.2
Difference in delivery
mm3/st.
4.5
Basic
*
Oil temperature
degC
50
48
52
Governor adjustment
Pump speed
r/min
350
350
350
Average injection quantity
mm3/st.
16.6
14.6
18.6
Difference in delivery
mm3/st.
2
Basic
*
Oil temperature
degC
48
46
50
Governor adjustment_02
Pump speed
r/min
350
350
350
Average injection quantity
mm3/st.
16.6
14.1
19.1
Difference in delivery
mm3/st.
2
Basic
*
Oil temperature
degC
48
46
50
Timer adjustment
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
70
55
85
Basic
*
Oil temperature
degC
48
46
50
Remarks
Full
Full
Timer adjustment_02
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
70
55
85
Oil temperature
degC
48
46
50
Speed control lever angle
Pump speed
r/min
150
150
150
Average injection quantity
mm3/st.
20
Remarks
Magnet OFF at idling position
Magnet OFF at idling position
Speed control lever angle_02
Pump speed
r/min
200
200
200
Average injection quantity
mm3/st.
15
Remarks
Magnet OFF at idling position
Magnet OFF at idling position
0000000901
Pump speed
r/min
750
750
750
Overflow quantity
cm3/min
330
150
510
Oil temperature
degC
50
48
52
Stop lever angle
Pump speed
r/min
250
250
250
Pressure
kPa
127
107
147
Pressure
kgf/cm2
1.3
1.1
1.5
Basic
*
Oil temperature
degC
48
46
50
Stop lever angle_02
Pump speed
r/min
250
250
250
Pressure
kPa
127
98
156
Pressure
kgf/cm2
1.3
1
1.6
Basic
*
Oil temperature
degC
48
46
50
Stop lever angle_03
Pump speed
r/min
750
750
750
Oil temperature
degC
50
48
52
Remarks
MEASURE
MEASURE
0000001101
Pump speed
r/min
750
750
750
Timer stroke
mm
0.8
0.6
1
Basic
*
Oil temperature
degC
50
48
52
_02
Pump speed
r/min
750
750
750
Timer stroke
mm
0.8
0.5
1.1
Basic
*
Oil temperature
degC
50
48
52
_03
Pump speed
r/min
950
950
950
Timer stroke
mm
1.6
1.2
2.1
Oil temperature
degC
50
48
52
0000001201
Max. applied voltage
V
16
16
16
Test voltage
V
25
24
26
Timing setting
K dimension
mm
3
2.9
3.1
KF dimension
mm
5.2
5.1
5.3
MS dimension
mm
0.7
0.6
0.8
Pre-stroke
mm
25
21
29
Control lever angle alpha
deg.
40
35
45
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 Ether (Chassis) Wiring Harness
The ether chassis harness for MPPS is different than the one called out in the AEIS Special Instruction.* Substitute 8X8468 Harness Assembly for 8X7653 Harness Assembly on the 785 Trucks.* Substitute 8X8467 Harness Assembly for 8X7652 Harness Assembly on the 789 Trucks.Follow the installation procedure outlined in the AEIS Special Instruction for the Ether Chassis Harness Assembly. Be sure to use the 8X8466 Wire Assembly for the 785 Trucks or the 8X8429 Wire Assembly for the 789 Trucks. This is the new harness code plug required with MPPS.Installation of 8X8469 Ether (Engine) Wiring Harness
The 8X7106 Engine Harness on the AEIS is replaced with 8X8469 Harness Assembly.Follow the installation procedure outlined in the AEIS Special Instruction for the 8X7106 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) 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 (8) 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 (9) that was removed.4. Connect an 8X8337 Harness Assembly (10) 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: "A5" harness code on the 785 (indicates 3512 application) or "A6" harness code on the 789 (indicates 3516 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 "Installation of 9X5303 Ether Control Group" instructions outlined in the AEIS installation Special Instruction, SEHS9293. Be sure to install the 8X8398 Wire Assembly between the control and mounting plate. If an MPPS identification film is
The ether chassis harness for MPPS is different than the one called out in the AEIS Special Instruction.* Substitute 8X8468 Harness Assembly for 8X7653 Harness Assembly on the 785 Trucks.* Substitute 8X8467 Harness Assembly for 8X7652 Harness Assembly on the 789 Trucks.Follow the installation procedure outlined in the AEIS Special Instruction for the Ether Chassis Harness Assembly. Be sure to use the 8X8466 Wire Assembly for the 785 Trucks or the 8X8429 Wire Assembly for the 789 Trucks. This is the new harness code plug required with MPPS.Installation of 8X8469 Ether (Engine) Wiring Harness
The 8X7106 Engine Harness on the AEIS is replaced with 8X8469 Harness Assembly.Follow the installation procedure outlined in the AEIS Special Instruction for the 8X7106 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) 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 (8) 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 (9) that was removed.4. Connect an 8X8337 Harness Assembly (10) 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: "A5" harness code on the 785 (indicates 3512 application) or "A6" harness code on the 789 (indicates 3516 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 "Installation of 9X5303 Ether Control Group" instructions outlined in the AEIS installation Special Instruction, SEHS9293. Be sure to install the 8X8398 Wire Assembly between the control and mounting plate. If an MPPS identification film is
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Komatsu
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104761-4132
INJECTION-PUMP ASSEMBLY