Information injection-pump assembly
ZEXEL
104740-0942
1047400942
MAZDA
WL8113800A
wl8113800a
Rating:
Cross reference number
ZEXEL
104740-0942
1047400942
MAZDA
WL8113800A
wl8113800a
Zexel num
Bosch num
Firm num
Name
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113orSAEJ967d
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
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)
Left L
Left L
Injection timing adjustment
Pump speed
r/min
1250
1250
1250
Average injection quantity
mm3/st.
48.7
48.2
49.2
Difference in delivery
mm3/st.
4
Basic
*
Oil temperature
degC
50
48
52
Injection timing adjustment_02
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
44.8
41.8
47.8
Oil temperature
degC
48
46
50
Injection timing adjustment_03
Pump speed
r/min
1250
1250
1250
Average injection quantity
mm3/st.
48.7
47.7
49.7
Difference in delivery
mm3/st.
4.5
Basic
*
Oil temperature
degC
50
48
52
Injection timing adjustment_04
Pump speed
r/min
2100
2100
2100
Average injection quantity
mm3/st.
44.3
40.8
47.8
Oil temperature
degC
52
50
54
Injection quantity adjustment
Pump speed
r/min
2450
2450
2450
Average injection quantity
mm3/st.
15.7
12.7
18.7
Difference in delivery
mm3/st.
5
Oil temperature
degC
55
52
58
Injection quantity adjustment_02
Pump speed
r/min
2800
2800
2800
Average injection quantity
mm3/st.
5
Oil temperature
degC
55
52
58
Injection quantity adjustment_03
Pump speed
r/min
2450
2450
2450
Average injection quantity
mm3/st.
15.7
5.7
25.7
Difference in delivery
mm3/st.
5.5
Oil temperature
degC
55
52
58
Governor adjustment
Pump speed
r/min
360
360
360
Average injection quantity
mm3/st.
9
8
10
Difference in delivery
mm3/st.
1.7
Basic
*
Oil temperature
degC
48
46
50
Governor adjustment_02
Pump speed
r/min
360
360
360
Average injection quantity
mm3/st.
9
7.5
10.5
Difference in delivery
mm3/st.
2.2
Basic
*
Oil temperature
degC
48
46
50
Boost compensator adjustment
Pump speed
r/min
400
400
400
Average injection quantity
mm3/st.
17
15.5
18.5
Difference in delivery
mm3/st.
2.5
Oil temperature
degC
48
46
50
Boost compensator adjustment_02
Pump speed
r/min
400
400
400
Average injection quantity
mm3/st.
17
15
19
Difference in delivery
mm3/st.
2.5
Oil temperature
degC
48
46
50
Timer adjustment
Pump speed
r/min
150
150
150
Average injection quantity
mm3/st.
70
55
90
Oil temperature
degC
48
46
50
Timer adjustment_02
Pump speed
r/min
150
150
150
Average injection quantity
mm3/st.
70
50
90
Oil temperature
degC
48
46
50
Speed control lever angle
Pump speed
r/min
360
360
360
Average injection quantity
mm3/st.
0
0
0
Oil temperature
degC
48
46
50
Remarks
Magnet OFF
Magnet OFF
0000000901
Pump speed
r/min
1250
1250
1250
Overflow quantity
cm3/min
420
290
550
Oil temperature
degC
50
48
52
Stop lever angle
Pump speed
r/min
250
250
250
Pressure
kPa
569
540
598
Pressure
kgf/cm2
5.8
5.5
6.1
Basic
*
Oil temperature
degC
50
48
52
Stop lever angle_02
Pump speed
r/min
1250
1250
1250
Pressure
kPa
569
530
608
Pressure
kgf/cm2
5.8
5.4
6.2
Basic
*
Oil temperature
degC
50
48
52
0000001101
Pump speed
r/min
1250
1250
1250
Timer stroke
mm
5.7
5.5
5.9
Basic
*
Oil temperature
degC
50
48
52
_02
Pump speed
r/min
500
500
500
Timer stroke
mm
1.8
1
2.6
Oil temperature
degC
48
46
50
_03
Pump speed
r/min
1250
1250
1250
Timer stroke
mm
5.7
5.3
6.1
Basic
*
Oil temperature
degC
50
48
52
_04
Pump speed
r/min
2000
2000
2000
Timer stroke
mm
9.2
8.4
10
Oil temperature
degC
50
48
52
0000001201
Max. applied voltage
V
8
8
8
Test voltage
V
13
12
14
0000001401
Pump speed
r/min
1250
1250
1250
Average injection quantity
mm3/st.
33.6
33.1
34.1
Timer stroke TA
mm
5.2
5
5.4
Timer stroke variation dT
mm
0.5
0.5
0.5
Basic
*
Oil temperature
degC
50
48
52
_02
Pump speed
r/min
1250
1250
1250
Average injection quantity
mm3/st.
33.6
32.6
34.6
Timer stroke TA
mm
5.2
4.8
5.6
Timer stroke variation dT
mm
0.5
0.5
0.5
Basic
*
Oil temperature
degC
50
48
52
_03
Pump speed
r/min
1250
1250
1250
Average injection quantity
mm3/st.
25
23.5
26.5
Timer stroke TA
mm
4.1
3.5
4.7
Timer stroke variation dT
mm
1.6
1.6
1.6
Oil temperature
degC
50
48
52
Timing setting
K dimension
mm
3.3
3.2
3.4
KF dimension
mm
6
5.9
6.1
MS dimension
mm
0.9
0.8
1
Pre-stroke
mm
0.03
0.01
0.05
Control lever angle alpha
deg.
12.5
8.5
16.5
Control lever angle beta
deg.
40
37
43
Test data Ex:
0000001801 CONTROL STANDARD AT IDLING
Standards for idle difference in delivery control
After idle adjustment, measure the idle injection quantities of (A) to (D).
Install the colored rings to the delivery valve holders (A) to (D) in accordance with the table.
(A): A cylinder (B) :B cylinder (C) : C cylinder (D): D cylinder
(E): Collar ring
(F): (A) >= (C)
(G): (C) > (A)
(H): (A) - (C) or (C) - (A)
(I): 0.2, 0.1(mm3/st)
(J): (B) - (D) or (D) - (B)
(K): Ring color
(L): At least 0.6 mm3/st
(M): 0.3, 0.4, 0.5 (mm3/st)
(N): 0.2, 0.1, 0.0 (mm3/st)
(O): (B) >= (D)
(P): (D) > (B)
(T): Yellow
(U): White
(V): Red
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0000001901 WIRE
Confirmation of the wire length:
Accelerator wire: Idle-full stroke: L1
Adjustment of the double stage actuator:
(1)Apply negative pressure P1 {P2} to the actuator through the negative pressure inlet port (A).
(2)In status (1) above, adjust screw (C) so that the control lever (B) position is a [ie, the gap between the control lever and the idle switch (E) is (L2)]. Fix by tightening the nut (D).
TT
----------
L1=34.1+-3.5mm L2=4.0+-0.5mm a=7deg P1=-66.6kPa P2=-500mmHg T=6~9Nm(0.6~0.9kgfm)
----------
L2=4.0+-0.5mm a=7deg Alpha=12.5deg
----------
L1=34.1+-3.5mm L2=4.0+-0.5mm a=7deg P1=-66.6kPa P2=-500mmHg T=6~9Nm(0.6~0.9kgfm)
----------
L2=4.0+-0.5mm a=7deg Alpha=12.5deg
Information:
start by:a) remove air compressor 1. Remove elbow (1) and adapter. Remove the gasket, screen and gasket from behind the flange.2. Remove air compressor governor (2).3. Put a mark on the head assembly and block for correct assembly. 4. Remove six bolts (3). Remove head assembly (4). 5. Remove inlet valve springs (5) from the head assembly.6. Remove discharge valve seats (6). 7. Remove discharge valves (7). Remove springs from behind the valves. Check the discharge valve stops for wear or damage. If the discharge valve travel exceeds .057 in. (1.45 mm), make a replacement of the head assembly. 8. Remove inlet valves (8) from guides. Remove guides (9) from around the inlet valve seats. 9. Remove unloader spring (10), spring seat and spring saddle (12).10. Remove unloader plungers (11) and guides. 11. To remove unloader pistons (13) from the bore, put a cover over the inlet port, then blow air pressure in the governor mounting pad unloader port (14). 12. Check inlet valve seats (15) and unloader bore bushings (16) for damage or wear. If necessary, make a replacement. 13. Remove bolts (17). Remove cover (18) and gasket from the crankcase assembly.14. Put marks on the rod bearing caps and rods for correct assembly. 15. Remove bolts (19) and locks. Remove rod bearing caps (20). Push the pistons and rods through the top of the crankcase assembly. 16. Remove rod pin (21) from the piston. Remove rod (23).17. Remove bearings (22) from the rods and caps. 18. Use tooling (A) to remove bushing (24) from the rod. 19. Remove buttons (25) from each end of the rod pins. 20. Remove piston rings (26) from piston (27) with an approved ring expander. 21. Remove O-ring seal (29) from the crankshaft.22. Remove bolts (28). Remove adapter (30) from the crankcase assembly. 23. Remove three O-ring seals (32) from the adapter.24. Remove thrust bearing (31). 25. Use tooling (A) and a press to remove the bearing from the adapter.
Do not cause damage to the bearing surfaces of the crankshaft when it is removed from the crankcase assembly.
26. Remove crankshaft (33) from the crankcase assembly. 27. Remove bolts (34). Remove cover (35). Remove two O-ring seals from the crankcase assembly. 28. Remove O-ring seal (37) from the cover.29. Remove thrust bearing (36). 30. Remove bearing (38) from the cover.Assemble Air Compressor
1. Check all parts for damage or wear. If necessary, make a replacement with a new part.2. Make sure all parts are clean and free of dirt and foreign material. 3. Use tool (A) and a press to install the bearing in cover (1). 4. Install O-ring seal (3) on the cover.5. Install thrust bearing (2). 6. Install O-ring seals (4) in the crankcase assembly.7. Put a small amount of SAE 30 oil on the O-ring seal and install the cover on crankcase assembly (5). Tighten the bolts to a torque of 25 to 35 lb.ft. (35 to 45 N m). 8. Put crankshaft (6) in position in the crankcase assembly.
Do not cause damage to the bearing surfaces of the crankshaft when it is removed from the crankcase assembly.
26. Remove crankshaft (33) from the crankcase assembly. 27. Remove bolts (34). Remove cover (35). Remove two O-ring seals from the crankcase assembly. 28. Remove O-ring seal (37) from the cover.29. Remove thrust bearing (36). 30. Remove bearing (38) from the cover.Assemble Air Compressor
1. Check all parts for damage or wear. If necessary, make a replacement with a new part.2. Make sure all parts are clean and free of dirt and foreign material. 3. Use tool (A) and a press to install the bearing in cover (1). 4. Install O-ring seal (3) on the cover.5. Install thrust bearing (2). 6. Install O-ring seals (4) in the crankcase assembly.7. Put a small amount of SAE 30 oil on the O-ring seal and install the cover on crankcase assembly (5). Tighten the bolts to a torque of 25 to 35 lb.ft. (35 to 45 N m). 8. Put crankshaft (6) in position in the crankcase assembly.