104749-0431 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047490431 rfc313800

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 104749-0431 1047490431

MAZDA RFC313800 rfc313800

Cross reference number

ZEXEL 104749-0431 1047490431

MAZDA RFC313800 rfc313800

Zexel num

Bosch num

Firm num

Name

104749-0431
104749-0437

RFC313800 MAZDA

INJECTION-PUMP ASSEMBLY
RFT *

Calibration Data:

Adjustment conditions

Test oil
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

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

Injection timing adjustment

Pump speed r/min 1250 1250 1250

Boost pressure kPa 69.3 68 70.6

Boost pressure mmHg 520 510 530

Average injection quantity mm3/st. 48.3 47.8 48.8

Difference in delivery mm3/st. 4

Basic *

Remarks
Full

Injection timing adjustment_02

Pump speed r/min 1250 1250 1250

Boost pressure kPa 33.35 32 34.7

Boost pressure mmHg 250 240 260

Average injection quantity mm3/st. 44 43.5 44.5

Difference in delivery mm3/st. 3.5

Basic *

Remarks
CBS

Injection timing adjustment_03

Pump speed r/min 2500 2500 2500

Boost pressure kPa 69.3 68 70.6

Boost pressure mmHg 520 510 530

Average injection quantity mm3/st. 19.5 17 22

Injection timing adjustment_04

Pump speed r/min 2150 2150 2150

Boost pressure kPa 69.3 68 70.6

Boost pressure mmHg 520 510 530

Average injection quantity mm3/st. 38.4 35.9 40.9

Injection timing adjustment_05

Pump speed r/min 1250 1250 1250

Boost pressure kPa 69.3 68 70.6

Boost pressure mmHg 520 510 530

Average injection quantity mm3/st. 48.3 47.3 49.3

Remarks
Full

Injection timing adjustment_06

Pump speed r/min 1250 1250 1250

Boost pressure kPa 33.35 32 34.7

Boost pressure mmHg 250 240 260

Average injection quantity mm3/st. 44 43 45

Remarks
CBS

Injection timing adjustment_07

Pump speed r/min 1250 1250 1250

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 38.9 36.9 40.9

Injection timing adjustment_08

Pump speed r/min 750 750 750

Boost pressure kPa 33.35 32 34.7

Boost pressure mmHg 250 240 260

Average injection quantity mm3/st. 42.3 39.8 44.8

Injection quantity adjustment

Pump speed r/min 2500 2500 2500

Boost pressure kPa 69.3 68 70.6

Boost pressure mmHg 520 510 530

Average injection quantity mm3/st. 19.5 17.5 21.5

Basic *

Injection quantity adjustment_02

Pump speed r/min 2850 2850 2850

Boost pressure kPa 69.3 68 70.6

Boost pressure mmHg 520 510 530

Average injection quantity mm3/st. 5

Governor adjustment

Pump speed r/min 360 360 360

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 9 8 10

Difference in delivery mm3/st. 2

Basic *

Governor adjustment_02

Pump speed r/min 360 360 360

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 9 8 10

Governor adjustment_03

Pump speed r/min 500 500 500

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 3

Timer adjustment

Pump speed r/min 100 100 100

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 55 55

Basic *

Speed control lever angle

Pump speed r/min 360 360 360

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 0 0 0

Remarks
Magnet OFF

0000000901

Pump speed r/min 1000 1000 1000

Boost pressure kPa 69.3 68 70.6

Boost pressure mmHg 520 510 530

Overflow quantity cm3/min 378 246 510

Stop lever angle

Pump speed r/min 1250 1250 1250

Boost pressure kPa 69.3 68 70.6

Boost pressure mmHg 520 510 530

Pressure kPa 470.5 451 490

Pressure kgf/cm2 4.8 4.6 5

Basic *

Stop lever angle_02

Pump speed r/min 1250 1250 1250

Boost pressure kPa 69.3 68 70.6

Boost pressure mmHg 520 510 530

Pressure kPa 470.5 451 490

Pressure kgf/cm2 4.8 4.6 5

Stop lever angle_03

Pump speed r/min 1750 1750 1750

Boost pressure kPa 69.3 68 70.6

Boost pressure mmHg 520 510 530

Pressure kPa 593 549 637

Pressure kgf/cm2 6.2 5.9 6.5

Stop lever angle_04

Pump speed r/min 2150 2150 2150

Boost pressure kPa 69.3 68 70.6

Boost pressure mmHg 520 510 530

Pressure kPa 715.5 686 745

Pressure kgf/cm2 7.3 7 7.6

Stop lever angle_05

Pump speed r/min 2250 2250 2250

Boost pressure kPa 69.3 68 70.6

Boost pressure mmHg 520 510 530

Pressure kPa 755 716 794

Pressure kgf/cm2 7.7 7.3 8.1

0000001101

Pump speed r/min 1250 1250 1250

Boost pressure kPa 69.3 68 70.6

Boost pressure mmHg 520 510 530

Timer stroke mm 2.9 2.7 3.1

Basic *

_02

Pump speed r/min 1000 1000 1000

Boost pressure kPa 69.3 68 70.6

Boost pressure mmHg 520 510 530

Timer stroke mm 1.2 0.8 1.6

_03

Pump speed r/min 1250 1250 1250

Boost pressure kPa 69.3 68 70.6

Boost pressure mmHg 520 510 530

Timer stroke mm 2.9 2.6 3.2

_04

Pump speed r/min 1750 1750 1750

Boost pressure kPa 69.3 68 70.6

Boost pressure mmHg 520 510 530

Timer stroke mm 6.5 5.9 7.1

_05

Pump speed r/min 2150 2150 2150

Boost pressure kPa 69.3 68 70.6

Boost pressure mmHg 520 510 530

Timer stroke mm 8.1 7.6 8.6

0000001201

Max. applied voltage V 8 8 8

Test voltage V 13 12 14

0000001401

Pump speed r/min 1250 1250 1250

Boost pressure kPa 69.3 68 70.6

Boost pressure mmHg 520 510 530

Average injection quantity mm3/st. 35.5 35 36

Timer stroke variation dT mm 0.7 0.5 0.9

Basic *

_02

Pump speed r/min 1250 1250 1250

Boost pressure kPa 69.3 68 70.6

Boost pressure mmHg 520 510 530

Average injection quantity mm3/st. 35.5 34.5 36.5

Timer stroke variation dT mm 0.7 0.4 1

_03

Pump speed r/min 1250 1250 1250

Boost pressure kPa 69.3 68 70.6

Boost pressure mmHg 520 510 530

Average injection quantity mm3/st. 28.5 27 30

Timer stroke variation dT mm 1.7 1.2 2.2

Timing setting

K dimension mm 3.3 3.2 3.4

KF dimension mm 5.8 5.7 5.9

MS dimension mm 1.7 1.6 1.8

BCS stroke mm 3.6 3.5 3.7

Control lever angle alpha deg. 0 -4 4

Control lever angle beta deg. 35 32 38

Test data Ex:

0000001801 POTENTIOMETER ADJUSTMENT

Adjustment of the idle SW Confirm that the switch is ON at the idle lever position. Potentiometer confirmation (input voltage: V3) Control lever (1) Full position: V1 (Adjusting point) (2)Idle position: V2 (checking point) Wire length confirmation (a = a1) Accelerator wire: (1) idle position : L1 (2)Idle~full stroke: L2
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V1=1.6+-0.03V V2=7.44+-0.7V V3=10.00V L1=33.5+-3.5mm L2=-mm
----------

0000001901 M-CSD ADJUSTMENT

M-CSD adjustment 1. Fixing the M-CSD (1)At roller holder advance angle d, adjust the lever shaft ball pin so that it contacts the roller holder. (2)At this time, adjust the position of the M-CSD lever (A) using adjusting screw (C) so that the clearance a between the M-CSD lever (A) and the stopper (B) becomes L1. Then fix using nut (D). Tightening torque T1. 2. Fixing CSD lever plate (E) (1)Make the clearance between the CSD lever (A) and the stopper (B) L2. (2)Fix the CSD lever plate (E) using the bolt (F) so that the clearance b between the intermediate lever (G)'s roller (H) and the CSD lever plate is L3. Tightening torque T2. 3. Fixing the FICD screw (I) (1)Move the CSD lever (A) through its full stroke. (2)Adjust the intermediate lever G's FICD lever screw I so that the control lever K's position is e (the gap c between the control lever and the screw M is L4). Then fix using the nut J. Tightening torque T1. 4. V-FICD adjustment (1)Move the actuator O through its full stroke. (2)Adjust the position of the actuator (O) so that the control lever (K)'s position is f [the clearance between the control lever (K) and the screw (M) is c = L5]. Then, fix using the bolt (P). Tightening torque T1.
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L1=0.5+2mm L2=0mm L3=4mm L4=4.2+-0.5mm L5=3.6+-0.5mm d=0deg e=7deg f=6deg T1=6~9N-m(0.6~0.9kg-fm) T2=3.4~4.9N-m(0.35~0.5kgf-m)
----------
a=L1=0.5+2mm a=L2=0mm b=L3=4mm c=L4=4.2+-0.5mm c=L5=3.6+-0.5mm