104749-0620 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047490620 rfj113800

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 104749-0620 1047490620

MAZDA RFJ113800 rfj113800

Cross reference number

ZEXEL 104749-0620 1047490620

MAZDA RFJ113800 rfj113800

Zexel num

Bosch num

Firm num

Name

104749-0620
104749-0621

RFJ113800 MAZDA

INJECTION-PUMP ASSEMBLY
RFX * K

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113orSAEJ967d

Test oil temperature degC 45 45 50

Nozzle 105780-0060

Bosch type code NP-DN0SD1510

Nozzle holder 105780-2150

Opening pressure MPa 13 13 13.3

Opening pressure kgf/cm2 133 133 136

Injection pipe 157805-7320

Injection pipe
Inside diameter - outside diameter - length (mm) mm 2-6-450

Joint assembly 157641-4720

Tube assembly 157641-4020

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 600 600 600

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 38.2 37.7 38.7

Difference in delivery mm3/st. 3.5

Basic *

Remarks
NA

Injection timing adjustment_02

Pump speed r/min 1000 1000 1000

Boost pressure kPa 33.35 32 34.7

Boost pressure mmHg 250 240 260

Average injection quantity mm3/st. 46.1 45.6 46.6

Difference in delivery mm3/st. 3.5

Basic *

Remarks
CBS

Injection timing adjustment_03

Pump speed r/min 1000 1000 1000

Boost pressure kPa 86.65 85.3 88

Boost pressure mmHg 650 640 660

Average injection quantity mm3/st. 50.4 49.9 50.9

Difference in delivery mm3/st. 4

Basic *

Remarks
Full

Injection timing adjustment_04

Pump speed r/min 2550 2550 2550

Boost pressure kPa 86.65 85.3 88

Boost pressure mmHg 650 640 660

Average injection quantity mm3/st. 10 6 14

Injection timing adjustment_05

Pump speed r/min 2250 2250 2250

Boost pressure kPa 86.65 85.3 88

Boost pressure mmHg 650 640 660

Average injection quantity mm3/st. 37 34.5 39.5

Injection timing adjustment_06

Pump speed r/min 2150 2150 2150

Boost pressure kPa 86.65 85.3 88

Boost pressure mmHg 650 640 660

Average injection quantity mm3/st. 42.1 39.6 44.6

Injection timing adjustment_07

Pump speed r/min 1250 1250 1250

Boost pressure kPa 86.65 85.3 88

Boost pressure mmHg 650 640 660

Average injection quantity mm3/st. 50.6 49.1 52.1

Injection timing adjustment_08

Pump speed r/min 1000 1000 1000

Boost pressure kPa 86.65 85.3 88

Boost pressure mmHg 650 640 660

Average injection quantity mm3/st. 49.9 49.4 50.4

Injection timing adjustment_09

Pump speed r/min 1000 1000 1000

Boost pressure kPa 33.35 32 34.7

Boost pressure mmHg 250 240 260

Average injection quantity mm3/st. 46.1 45.1 47.1

Injection timing adjustment_10

Pump speed r/min 1000 1000 1000

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 42.5 40 45

Injection timing adjustment_11

Pump speed r/min 600 600 600

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 38.2 37.2 39.2

Injection quantity adjustment

Pump speed r/min 2250 2250 2250

Boost pressure kPa 86.65 85.3 88

Boost pressure mmHg 650 640 660

Average injection quantity mm3/st. 37 35 39

Basic *

Injection quantity adjustment_02

Pump speed r/min 2700 2700 2700

Boost pressure kPa 86.65 85.3 88

Boost pressure mmHg 650 640 660

Average injection quantity mm3/st. 3

Governor adjustment

Pump speed r/min 425 425 425

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 13.4 12.4 14.4

Difference in delivery mm3/st. 2

Basic *

Governor adjustment_02

Pump speed r/min 425 425 425

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 13.4 11.9 14.9

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. 7

Governor adjustment_04

Pump speed r/min 1000 1000 1000

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. 56 56

Basic *

Speed control lever angle

Pump speed r/min 425 425 425

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 86.65 85.3 88

Boost pressure mmHg 650 640 660

Overflow quantity cm3/min 600 468 732

Stop lever angle

Pump speed r/min 1500 1500 1500

Boost pressure kPa 86.65 85.3 88

Boost pressure mmHg 650 640 660

Pressure kPa 539.5 510 569

Pressure kgf/cm2 5.5 5.2 5.8

Basic *

Stop lever angle_02

Pump speed r/min 1500 1500 1500

Boost pressure kPa 86.65 85.3 88

Boost pressure mmHg 650 640 660

Pressure kPa 539.5 510 569

Pressure kgf/cm2 5.5 5.2 5.8

Stop lever angle_03

Pump speed r/min 2150 2150 2150

Boost pressure kPa 86.65 85.3 88

Boost pressure mmHg 650 640 660

Pressure kPa 696.5 667 726

Pressure kgf/cm2 7.1 6.8 7.4

0000001101

Pump speed r/min 1500 1500 1500

Boost pressure kPa 86.65 85.3 88

Boost pressure mmHg 650 640 660

Timer stroke mm 4.6 4.4 4.8

Basic *

_02

Pump speed r/min 1250 1250 1250

Boost pressure kPa 86.65 85.3 88

Boost pressure mmHg 650 640 660

Timer stroke mm 3.3 2.7 3.9

_03

Pump speed r/min 1500 1500 1500

Boost pressure kPa 86.65 85.3 88

Boost pressure mmHg 650 640 660

Timer stroke mm 4.6 4.3 4.9

_04

Pump speed r/min 2150 2150 2150

Boost pressure kPa 86.65 85.3 88

Boost pressure mmHg 650 640 660

Timer stroke mm 8.15 7.7 8.6

0000001201

Max. applied voltage V 8 8 8

Test voltage V 13 12 14

0000001401

Pump speed r/min 1500 1500 1500

Boost pressure kPa 86.65 85.3 88

Boost pressure mmHg 650 640 660

Average injection quantity mm3/st. 32.3 31.8 32.8

Timer stroke variation dT mm 0.4 0.2 0.6

Basic *

_02

Pump speed r/min 1500 1500 1500

Boost pressure kPa 86.65 85.3 88

Boost pressure mmHg 650 640 660

Average injection quantity mm3/st. 32.3 31.3 33.3

Timer stroke variation dT mm 0.4 0.1 0.7

_03

Pump speed r/min 1500 1500 1500

Boost pressure kPa 86.65 85.3 88

Boost pressure mmHg 650 640 660

Average injection quantity mm3/st. 27.3 25.8 28.8

Timer stroke variation dT mm 0.8 0.4 1.2

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 2.9 2.7 3.1

Pre-stroke mm 0.3 0.28 0.32

Control lever angle alpha deg. 25 21 29

Control lever angle beta deg. 41 38 44

Test data Ex:

0000001801 CONTROL LEVER ANGLE

Control lever angle measurement position
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Ya=8.8~14.1mm Yb=12.0~13.9mm Alpha=21~29deg Beta=38~44deg

0000001901 SIDE LINK LEVER ADJUSTMENT

Side link lever adjustment 1. Fixing the side link lever (1)Hold the control lever in the position a. (2)Adjust the length of the connecting rod D so that a pin L1 can pass between the side link B and the actuator bracket C at A. Then fix. 2. Idle switch confirmation Confirm that the switch is ON at the idle lever position. 3. Potentiometer confirmation (input voltage: V1) Control lever: (1)Idle position: V2 (checking point) (2)Full position: V3 (adjusting point) 4. Confirming wire length Accelerator wire (1)Idle position: L2 (2)Idle~full stroke: L3 A/T wire: (1)Idle position: L4 (2)Idle~full stroke: L5
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L1=Dia.5.8-0.2mm L2=161+-3mm L3=32.5+-3mm L4=108+-3mm L5=32.5+-3mm V1=10.00V V2=2.26+-0.7V V3=9.1+-0.03V a=0deg
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0000002001 W-CSD ADJUSTMENT

Adjustment of the W-CSD 1. Adjustment of the advance angle of the timer (1)Determine the timer advance angle from the graph in Fig. 2 (D). (2)Adjust screw A so that the timer advance angle determined in item (1) is obtained. 2. Adjust dimension L. Adjust using turnbuckle B so that the dimension L is as described on the figure 2 D. (C): figure 1 (G) : Timer stroke: TA = -0.04t+1.6t (t>=0 deg C) Control lever gap: L = -0.072t + 3.6 (t >= 0 deg C) X = temperature t Y1 = timer stroke TA Y2 = control lever gap L
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