104749-0760 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047490760 rfr313800

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Information injection-pump assembly

ZEXEL 104749-0760 1047490760

MAZDA RFR313800 rfr313800

Cross reference number

ZEXEL 104749-0760 1047490760

MAZDA RFR313800 rfr313800

Zexel num

Bosch num

Firm num

Name

104749-0760
104749-0761

RFR313800 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 kgf/cm2 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 38.8 38.3 39.3

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 kgf/cm2 0.34 0.326 0.354

Boost pressure mmHg 250 240 260

Average injection quantity mm3/st. 47.2 46.7 47.7

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 kgf/cm2 0.88 0.866 0.894

Boost pressure mmHg 650 640 660

Average injection quantity mm3/st. 52.6 52.1 53.1

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 kgf/cm2 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 38.8 37.8 39.8

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 kgf/cm2 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 42.1 39.6 44.6

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 kgf/cm2 0.34 0.326 0.354

Boost pressure mmHg 250 240 260

Average injection quantity mm3/st. 47.2 46.2 48.2

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 kgf/cm2 0.88 0.866 0.894

Boost pressure mmHg 650 640 660

Average injection quantity mm3/st. 52.6 51.6 53.6

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 kgf/cm2 0.88 0.866 0.894

Boost pressure mmHg 650 640 660

Average injection quantity mm3/st. 43.3 40.8 45.8

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 kgf/cm2 0.88 0.866 0.894

Boost pressure mmHg 650 640 660

Average injection quantity mm3/st. 37 35 39

Difference in delivery mm3/st. 11

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 kgf/cm2 0.88 0.866 0.894

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 kgf/cm2 0.88 0.866 0.894

Boost pressure mmHg 650 640 660

Average injection quantity mm3/st. 37 34.5 39.5

Difference in delivery mm3/st. 11.5

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 kgf/cm2 0.88 0.866 0.894

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 kgf/cm2 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 kgf/cm2 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 kgf/cm2 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 kgf/cm2 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 kgf/cm2 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 kgf/cm2 0.88 0.866 0.894

Boost pressure mmHg 650 640 660

Oil temperature degC 50 48 52

Remarks
MEASURE

Stop lever angle

Pump speed r/min 1000 1000 1000

Boost pressure kPa 86.6 85.3 87.9

Boost pressure kgf/cm2 0.88 0.866 0.894

Boost pressure mmHg 650 640 660

Pressure with S/T ON kPa 432 412 452

Pressure with S/T ON kgf/cm2 4.4 4.2 4.6

Pressure with S/T OFF kPa 314 275 353

Pressure with S/T OFF kgf/cm2 3.2 2.8 3.6

Basic *

Oil temperature degC 50 48 52

Remarks
ON

Stop lever angle_02

Pump speed r/min 500 500 500

Boost pressure kPa 86.6 85.3 87.9

Boost pressure kgf/cm2 0.88 0.866 0.894

Boost pressure mmHg 650 640 660

Pressure with S/T ON kPa 284 235 333

Pressure with S/T ON kgf/cm2 2.9 2.4 3.4

Oil temperature degC 48 46 50

Stop lever angle_03

Pump speed r/min 1000 1000 1000

Boost pressure kPa 86.6 85.3 87.9

Boost pressure kgf/cm2 0.88 0.866 0.894

Boost pressure mmHg 650 640 660

Pressure with S/T ON kPa 432 403 461

Pressure with S/T ON kgf/cm2 4.4 4.1 4.7

Pressure with S/T OFF kPa 314 265 363

Pressure with S/T OFF kgf/cm2 3.2 2.7 3.7

Basic *

Oil temperature degC 50 48 52

Remarks
ON

Stop lever angle_04

Pump speed r/min 1500 1500 1500

Boost pressure kPa 86.6 85.3 87.9

Boost pressure kgf/cm2 0.88 0.866 0.894

Boost pressure mmHg 650 640 660

Pressure with S/T ON kPa 559 510 608

Pressure with S/T ON kgf/cm2 5.7 5.2 6.2

Pressure with S/T OFF kPa 432 383 481

Pressure with S/T OFF kgf/cm2 4.4 3.9 4.9

Oil temperature degC 50 48 52

Stop lever angle_05

Pump speed r/min 2150 2150 2150

Boost pressure kPa 86.6 85.3 87.9

Boost pressure kgf/cm2 0.88 0.866 0.894

Boost pressure mmHg 650 640 660

Pressure with S/T ON kPa 716 667 765

Pressure with S/T ON kgf/cm2 7.3 6.8 7.8

Pressure with S/T OFF kPa 579 530 628

Pressure with S/T OFF kgf/cm2 5.9 5.4 6.4

Oil temperature degC 52 50 54

0000001101

Pump speed r/min 1000 1000 1000

Boost pressure kPa 86.6 85.3 87.9

Boost pressure kgf/cm2 0.88 0.866 0.894

Boost pressure mmHg 650 640 660

Timer stroke with S/T ON mm 3.6 3.4 3.8

Timer stroke with S/T OFF mm 1.6 1.1 2.1

Basic *

Oil temperature degC 50 48 52

Remarks
ON

_02

Pump speed r/min 500 500 500

Boost pressure kPa 86.6 85.3 87.9

Boost pressure kgf/cm2 0.88 0.866 0.894

Boost pressure mmHg 650 640 660

Timer stroke with S/T ON mm 1.2 0.6 1.8

Oil temperature degC 50 48 52

_03

Pump speed r/min 1000 1000 1000

Boost pressure kPa 86.6 85.3 87.9

Boost pressure kgf/cm2 0.88 0.866 0.894

Boost pressure mmHg 650 640 660

Timer stroke with S/T ON mm 3.6 3.2 4

Timer stroke with S/T OFF mm 1.6 0.9 2.3

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 kgf/cm2 0.88 0.866 0.894

Boost pressure mmHg 650 640 660

Timer stroke with S/T ON mm 9 8.3 9.6

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 1000 1000 1000

Boost pressure kPa 86.6 85.3 87.9

Boost pressure kgf/cm2 0.88 0.866 0.894

Boost pressure mmHg 650 640 660

Average injection quantity mm3/st. 44 43.5 44.5

Timer stroke TA mm 2.8 2.6 3

Timer stroke variation dT mm 0.8 0.8 0.8

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 1000 1000 1000

Boost pressure kPa 86.6 85.3 87.9

Boost pressure kgf/cm2 0.88 0.866 0.894

Boost pressure mmHg 650 640 660

Average injection quantity mm3/st. 44 43 45

Timer stroke TA mm 2.8 2.4 3.2

Oil temperature degC 50 48 52

_03

Pump speed r/min 1000 1000 1000

Boost pressure kPa 86.6 85.3 87.9

Boost pressure kgf/cm2 0.88 0.866 0.894

Boost pressure mmHg 650 640 660

Average injection quantity mm3/st. 30 28.5 31.5

Timer stroke TA mm 1.9 1.3 2.5

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 3.6 3.4 3.8

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:

0000001601 BOOST COMPENSATOR ADJUSTMENT

BCS adjustment procedure 1. At full boost pressure, set so that the full injection quantity is within the specifications (adjusting point). 2. Perform boost compensator intermediate operation point adjustment (pump speed N1, boost pressure P1). 3. When injection quantity at boost pressure P2 and pump speed N2 is not as specified, loosen nut (A) and adjust position of screw (B) so that injection quantity is as specified. The screw position should be within +-1 turn of initial position. 4. The nut tightening torque is T.
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N1=1000r/min N2=600r/min P1=33.3kPa(250mmHg) P2=0kPa(0mmHg) T=6~9N-m(0.6~0.9kgf-m)
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SW=10mm T=6~9N-m(0.6~0.9kgf-m)

0000001801 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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0000001901 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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