104749-0441 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047490441 rfc413800

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 104749-0441 1047490441

MAZDA RFC413800 rfc413800

Cross reference number

ZEXEL 104749-0441 1047490441

MAZDA RFC413800 rfc413800

Zexel num

Bosch num

Firm num

Name

104749-0441
104749-0447

RFC413800 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. 12.5 11.5 13.5

Difference in delivery mm3/st. 2

Basic *

Governor adjustment_02

Pump speed r/min 750 750 750

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 3

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

Governor adjustment_04

Pump speed r/min 360 360 360

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 12.5 11.5 13.5

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 608 579 637

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 2.85 2.6 3.1

_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 Potentiometer confirmation (input voltage: V3) Control lever: (1) idle position : V1 (adjusting point) (2)Full position: V2 (check point) Wire length confirmation (1)Accelerator wire : idle~full stroke: L1 (2)A/T wire: idle~full stroke: L2
----------
V1=1.6+-0.03V V2=7.44+-0.7V V3=10.00V L1=33.5+-3.5mm L2=30.0+-2mm
----------

0000001901 M-CSD ADJUSTMENT

M-CSD adjustment 1. Fixing the M-CSD (1)At roller holder advance angle a 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 S between the M-CSD lever (A) and the stopper (B) becomes L1. Then fix using nut (D). 2. Fixing the M-CSD lever plate E Adjust using the adjusting screw (E) so that the control lever 7's position is b (distance from idle screw is L2) when the CSD lever (A) is moved through the full stroke [until it contacts the other end of the stopper (B)]. Then, fix using the nut (F). H = (from idle)
----------
L1=0.5+2mm L2=3+-1mm a=0deg b=4.5deg
----------
S=L1=0.5+2mm L2=3+-1mm b=4.5deg T=6~9N-m(0.6~0.9kgf-m)