104749-0680 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047490680 rfl313800

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 104749-0680 1047490680

MAZDA RFL313800 rfl313800

Cross reference number

ZEXEL 104749-0680 1047490680

MAZDA RFL313800 rfl313800

Zexel num

Bosch num

Firm num

Name

104749-0680
104749-0681

RFL313800 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 *

Oil temperature degC 50 48 52

Remarks
NA

Injection timing adjustment_02

Pump speed r/min 1000 1000 1000

Boost pressure kPa 33.3 32 34.6

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 *

Oil temperature degC 50 48 52

Remarks
CBS

Injection timing adjustment_03

Pump speed r/min 1000 1000 1000

Boost pressure kPa 86.6 85.3 87.9

Boost pressure mmHg 650 640 660

Average injection quantity mm3/st. 50.4 49.9 50.9

Difference in delivery mm3/st. 4

Basic *

Oil temperature degC 50 48 52

Remarks
Full

Injection timing adjustment_04

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

Difference in delivery mm3/st. 4

Oil temperature degC 50 48 52

Injection timing adjustment_05

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

Oil temperature degC 50 48 52

Injection timing adjustment_06

Pump speed r/min 1000 1000 1000

Boost pressure kPa 33.3 32 34.6

Boost pressure mmHg 250 240 260

Average injection quantity mm3/st. 46.1 45.1 47.1

Difference in delivery mm3/st. 4

Oil temperature degC 50 48 52

Injection timing adjustment_07

Pump speed r/min 1000 1000 1000

Boost pressure kPa 86.6 85.3 87.9

Boost pressure mmHg 650 640 660

Average injection quantity mm3/st. 50.4 49.4 51.4

Difference in delivery mm3/st. 4.5

Oil temperature degC 50 48 52

Injection timing adjustment_08

Pump speed r/min 2150 2150 2150

Boost pressure kPa 86.6 85.3 87.9

Boost pressure mmHg 650 640 660

Average injection quantity mm3/st. 42.1 39.6 44.6

Oil temperature degC 52 50 54

Injection quantity adjustment

Pump speed r/min 2250 2250 2250

Boost pressure kPa 86.6 85.3 87.9

Boost pressure mmHg 650 640 660

Average injection quantity mm3/st. 37 35 39

Basic *

Oil temperature degC 52 50 54

Injection quantity adjustment_02

Pump speed r/min 2700 2700 2700

Boost pressure kPa 86.6 85.3 87.9

Boost pressure mmHg 650 640 660

Average injection quantity mm3/st. 3

Oil temperature degC 55 52 58

Injection quantity adjustment_03

Pump speed r/min 2250 2250 2250

Boost pressure kPa 86.6 85.3 87.9

Boost pressure mmHg 650 640 660

Average injection quantity mm3/st. 37 34.5 39.5

Oil temperature degC 52 50 54

Injection quantity adjustment_04

Pump speed r/min 2550 2550 2550

Boost pressure kPa 86.6 85.3 87.9

Boost pressure mmHg 650 640 660

Average injection quantity mm3/st. 10 6 14

Oil temperature degC 55 52 58

Governor adjustment

Pump speed r/min 435 435 435

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 10 9 11

Difference in delivery mm3/st. 2

Basic *

Oil temperature degC 48 46 50

Governor adjustment_02

Pump speed r/min 435 435 435

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 10 8.5 11.5

Difference in delivery mm3/st. 2.5

Oil temperature degC 48 46 50

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 *

Oil temperature degC 48 46 50

Remarks
Full

Timer adjustment_02

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

Oil temperature degC 48 46 50

Speed control lever angle

Pump speed r/min 435 435 435

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 0 0 0

Oil temperature degC 48 46 50

Remarks
Magnet OFF at idling position

0000000901

Pump speed r/min 1000 1000 1000

Boost pressure kPa 86.6 85.3 87.9

Boost pressure mmHg 650 640 660

Overflow quantity cm3/min 600 470 730

Oil temperature degC 50 48 52

Stop lever angle

Pump speed r/min 1500 1500 1500

Boost pressure kPa 86.6 85.3 87.9

Boost pressure mmHg 650 640 660

Pressure kPa 539 510 568

Pressure kgf/cm2 5.5 5.2 5.8

Basic *

Oil temperature degC 50 48 52

Stop lever angle_02

Pump speed r/min 750 750 750

Boost pressure kPa 86.6 85.3 87.9

Boost pressure mmHg 650 640 660

Pressure kPa 324 285 363

Pressure kgf/cm2 3.3 2.9 3.7

Oil temperature degC 50 48 52

Stop lever angle_03

Pump speed r/min 1500 1500 1500

Boost pressure kPa 86.6 85.3 87.9

Boost pressure mmHg 650 640 660

Pressure kPa 539 500 578

Pressure kgf/cm2 5.5 5.1 5.9

Oil temperature degC 50 48 52

Stop lever angle_04

Pump speed r/min 2150 2150 2150

Boost pressure kPa 86.6 85.3 87.9

Boost pressure mmHg 650 640 660

Pressure kPa 696 657 735

Pressure kgf/cm2 7.1 6.7 7.5

Oil temperature degC 52 50 54

0000001101

Pump speed r/min 1500 1500 1500

Boost pressure kPa 86.6 85.3 87.9

Boost pressure mmHg 650 640 660

Timer stroke mm 4.6 4.4 4.8

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 750 750 750

Boost pressure kPa 86.6 85.3 87.9

Boost pressure mmHg 650 640 660

Timer stroke mm 0.5 0.1 1.3

Oil temperature degC 50 48 52

_03

Pump speed r/min 1500 1500 1500

Boost pressure kPa 86.6 85.3 87.9

Boost pressure mmHg 650 640 660

Timer stroke mm 4.6 4.2 5

Oil temperature degC 50 48 52

_04

Pump speed r/min 2150 2150 2150

Boost pressure kPa 86.6 85.3 87.9

Boost pressure mmHg 650 640 660

Timer stroke mm 8.2 7.6 8.8

Oil temperature degC 52 50 54

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 86.6 85.3 87.9

Boost pressure mmHg 650 640 660

Average injection quantity mm3/st. 32.3 31.8 32.8

Timer stroke TA mm 4.2 4.2 4.2

Timer stroke variation dT mm 0.4 0.2 0.6

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 1500 1500 1500

Boost pressure kPa 86.6 85.3 87.9

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 0.8

Oil temperature degC 50 48 52

_03

Pump speed r/min 1500 1500 1500

Boost pressure kPa 86.6 85.3 87.9

Boost pressure mmHg 650 640 660

Average injection quantity mm3/st. 27.3 25.8 28.8

Timer stroke variation dT mm 0.8 0.3 1.3

Oil temperature degC 50 48 52

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 IDLING SWITCH ADJUSTMENT

Idle switch confirmation Confirm that the switch is ON at the idle lever position. Potentiometer confirmation (input voltage: V1) Control lever: (1)Full position: V2 (adjusting point) (2)Idle position: V3 (check point) Wire harness length confirmation (value when wire stroke is a) Accelerator wire (1): idle position: L1 (2): idle to full: L2
----------
V1=10.00V V2=9.1+-0.03V V3=2.26+-0.7V L1=161+-3mm L2=32.0+-3mm a=Bata=41+-3deg
----------

0000001901 W-CSD ADJUSTMENT

Adjustment of the W-CSD 1. Adjustment of the advance angle of the timer (1) Find the timer advance from the graph G. Adjust screw A so that the timer advance angle determined in item (2) (1) is obtained. 2. Adjustment of the W-FICD (1) Insert a block gauge thickness L calculated from graph G between the control lever (D) and the idle switch (E). (2) Move the FICD lever C so that the distance between the control lever D and the FICD lever C pin is L0. Then, fix using bolt B. Tightening torque: T F:Fig. 1 G:Fig. 2 H:Timer stroke TA (mm) I:Control lever gap L1 (mm) J:Timer stroke (TA) K:Control lever gap (L) P:Temperature t (deg C)
----------
L=L+-0.2mm L0=3.8mm T=3.4~4.9N-m{0.35~0.5kg-m}
----------
L0=3.8mm L=L+-0.2mm