104740-0151 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047400151 482713800a

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 104740-0151 1047400151

MAZDA 482713800A 482713800a

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Cross reference number

ZEXEL 104740-0151 1047400151

MAZDA 482713800A 482713800a

Zexel num

Bosch num

Firm num

Name

104740-0151
104740-0156

482713800A MAZDA

INJECTION-PUMP ASSEMBLY
XA *

Calibration Data:

Adjustment conditions

(Note)
For Japan: year/month/day (change sequence) 1988/08/05 (1)

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 1000 1000 1000

Average injection quantity mm3/st. 45.9 45.4 46.4

Difference in delivery mm3/st. 3

Basic *

Injection timing adjustment_02

Pump speed r/min 1380 1380 1380

Average injection quantity mm3/st. 15.5 12.5 18.5

Injection timing adjustment_03

Pump speed r/min 1300 1300 1300

Average injection quantity mm3/st. 47.8 45.8 49.8

Injection timing adjustment_04

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 45.9 44.9 46.9

Injection timing adjustment_05

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 40.5 38.5 42.5

Injection timing adjustment_06

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 44.8 44.3 45.3

Difference in delivery mm3/st. 3

Basic *

Remarks
For Japan

Injection timing adjustment_07

Pump speed r/min 1380 1380 1380

Average injection quantity mm3/st. 15.1 12.1 18.1

Remarks
For Japan

Injection timing adjustment_08

Pump speed r/min 1300 1300 1300

Average injection quantity mm3/st. 46.7 44.7 48.7

Remarks
For Japan

Injection timing adjustment_09

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 44.8 43.8 45.8

Remarks
For Japan

Injection timing adjustment_10

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 39.5 37.5 41.5

Remarks
For Japan

Injection quantity adjustment

Pump speed r/min 1380 1380 1380

Average injection quantity mm3/st. 15.5 13.5 17.5

Basic *

Injection quantity adjustment_02

Pump speed r/min 1440 1440 1440

Average injection quantity mm3/st. 4

Injection quantity adjustment_03

Pump speed r/min 1380 1380 1380

Average injection quantity mm3/st. 15.1 12.1 18.1

Basic *

Remarks
For Japan

Injection quantity adjustment_04

Pump speed r/min 1440 1440 1440

Average injection quantity mm3/st. 4

Remarks
For Japan

Governor adjustment

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 6.4 4.4 8.4

Difference in delivery mm3/st. 2

Basic *

Governor adjustment_02

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 6.4 4.4 8.4

Governor adjustment_03

Pump speed r/min 500

Average injection quantity mm3/st. 0 0 0

Governor adjustment_04

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 6.2 4.2 8.2

Difference in delivery mm3/st. 2

Basic *

Remarks
For Japan

Governor adjustment_05

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 6.2 4.2 8.2

Remarks
For Japan

Governor adjustment_06

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 0 0 0

Remarks
For Japan

Timer adjustment

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 80.4 80.4

Basic *

Timer adjustment_02

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 78 78

Basic *

Remarks
For Japan

Speed control lever angle

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 0 0 0

Remarks
Magnet OFF

Speed control lever angle_02

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 0 0 0

Remarks
For Japan: Magnet OFF

0000000901

Pump speed r/min 1000 1000 1000

Overflow quantity cm3/min 460 328 592

_02

Pump speed r/min 1000 1000 1000

Overflow quantity cm3/min 456 324 588

Remarks
For Japan

Stop lever angle

Pump speed r/min 1000 1000 1000

Pressure kPa 431.5 402 461

Pressure kgf/cm2 4.4 4.1 4.7

Basic *

Stop lever angle_02

Pump speed r/min 500 500 500

Pressure kPa 255 226 284

Pressure kgf/cm2 2.6 2.3 2.9

Stop lever angle_03

Pump speed r/min 1000 1000 1000

Pressure kPa 431.5 402 461

Pressure kgf/cm2 4.4 4.1 4.7

Stop lever angle_04

Pump speed r/min 1300 1300 1300

Pressure kPa 539.5 510 569

Pressure kgf/cm2 5.5 5.2 5.8

Stop lever angle_05

Pump speed r/min 1000 1000 1000

Pressure kPa 421.5 392 451

Pressure kgf/cm2 4.3 4 4.6

Basic *

Remarks
For Japan

Stop lever angle_06

Pump speed r/min 500 500 500

Pressure kPa 245.5 216 275

Pressure kgf/cm2 2.5 2.2 2.8

Remarks
For Japan

Stop lever angle_07

Pump speed r/min 1000 1000 1000

Pressure kPa 421.5 392 451

Pressure kgf/cm2 4.3 4 4.6

Remarks
For Japan

Stop lever angle_08

Pump speed r/min 1300 1300 1300

Pressure kPa 529.5 500 559

Pressure kgf/cm2 5.4 5.1 5.7

Remarks
For Japan

0000001101

Pump speed r/min 1000 1000 1000

Timer stroke mm 2.6 2.4 2.8

Basic *

_02

Pump speed r/min 1000 1000 1000

Timer stroke mm 2.6 2.3 2.9

_03

Pump speed r/min 1300 1300 1300

Timer stroke mm 4.4 3.8 5

_04

Pump speed r/min 1000 1000 1000

Timer stroke mm 2.5 2.3 2.7

Basic *

Remarks
For Japan

_05

Pump speed r/min 1000 1000 1000

Timer stroke mm 2.5 2.2 2.8

Remarks
For Japan

_06

Pump speed r/min 1300 1300 1300

Timer stroke mm 4.3 3.7 4.9

Remarks
For Japan

0000001201

Max. applied voltage V 8 8 8

Test voltage V 13 12 14

Timing setting

K dimension mm 3.3 3.2 3.4

KF dimension mm 5.8 5.7 5.9

MS dimension mm 1.6 1.5 1.7

Control lever angle alpha deg. 13 9 17

Control lever angle beta deg. 41 36 46

Information:

Image1.1.1
4) Remove the 90 degree pressure line fitting under the sensor box.
5) Remove the 90 degree pressure line fitting from the DPF center section that is closest to the outlet side.
6) The new pressure line that will fit into the DPF center section will need to be installed into the port in which the thermocouple was fitted. The existing thermocouple will need to be fitted into the port in which the old pressure line was fitted.
Swapping of the ports is only necessary on the outlet side of the center section.
Image1.2.1
Image1.2.2
7) Install the 7W-3556 washer on the 304-8042 straight fitting. Install the straight fitting into the DPF pressure port (towards the outlet side) in which the thermocouple was previously installed, tighten to a torque of 24 +/- 4 Nm (212 +/- 35 lb-in). Screw the 2N-8142 tee fitting onto that straight fitting and tighten to a torque of 24 +/- 4 Nm (212 +/- 35 lb-in).
Image1.3.1
8) Replace the O-ring on the sensor box where the old 90 degree pressure line fitting was located. Install the 4S-4857 tee fitting in the sensor box to a torque of 11 +/- 1 Nm (97 +/- 9 lb-in).
Image1.4.1
9) Where applicable, perform Service Letter REBE3391 at this time.
10) Install sensor box bracket and existing heat shield. Tighten all six bolts to a torque of 12 +/- 3 Nm (106 +/- 27 lb-in).
11) Install sensor box, new pressure lines (tube assemblies), thermocouples onto DPF, and cable straps.
Reference appropriate Disassembly and Assembly manual for proper torque and use of anti-seize.
Image1.5.1
12) Start the engine and use CAT ET to ensure that the status parameter Diesel Particulate Trap #1 Differential Pressure has a value greater than zero. Also, ensure status parameters Diesel Particulate Trap #1 Intake Temperature, and Diesel Particulate Trap #1 Outlet Temperature show reasonable values and increase with the rising exhaust temperatures.