Information injection-pump assembly
ZEXEL
104748-0221
1047480221
MAZDA
R23013800A
r23013800a
Rating:
Cross reference number
ZEXEL
104748-0221
1047480221
MAZDA
R23013800A
r23013800a
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
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
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
Right R
Injection timing adjustment
Pump speed
r/min
1500
1500
1500
Average injection quantity
mm3/st.
37.5
37
38
Difference in delivery
mm3/st.
3
Basic
*
Injection timing adjustment_02
Pump speed
r/min
2400
2400
2400
Average injection quantity
mm3/st.
13.1
10.1
16.1
Injection timing adjustment_03
Pump speed
r/min
2125
2125
2125
Average injection quantity
mm3/st.
32.8
30.8
34.8
Injection timing adjustment_04
Pump speed
r/min
1500
1500
1500
Average injection quantity
mm3/st.
37.5
36.5
38.5
Injection timing adjustment_05
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
31.5
29.5
33.5
Injection quantity adjustment
Pump speed
r/min
2400
2400
2400
Average injection quantity
mm3/st.
13.1
11.1
15.1
Basic
*
Injection quantity adjustment_02
Pump speed
r/min
2550
2550
2550
Average injection quantity
mm3/st.
4
Governor adjustment
Pump speed
r/min
350
350
350
Average injection quantity
mm3/st.
8
6
10
Difference in delivery
mm3/st.
2
Basic
*
Governor adjustment_02
Pump speed
r/min
350
350
350
Average injection quantity
mm3/st.
8
6
10
Governor adjustment_03
Pump speed
r/min
450
450
450
Average injection quantity
mm3/st.
4
Timer adjustment
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
42
42
Basic
*
Speed control lever angle
Pump speed
r/min
350
350
350
Average injection quantity
mm3/st.
0
0
0
Remarks
Magnet OFF
Magnet OFF
0000000901
Pump speed
r/min
1500
1500
1500
Overflow quantity
cm3/min
460
330
590
Stop lever angle
Pump speed
r/min
1500
1500
1500
Pressure
kPa
578.5
549
608
Pressure
kgf/cm2
5.9
5.6
6.2
Basic
*
Stop lever angle_02
Pump speed
r/min
500
500
500
Pressure
kPa
294.5
265
324
Pressure
kgf/cm2
3
2.7
3.3
Stop lever angle_03
Pump speed
r/min
1500
1500
1500
Pressure
kPa
578.5
549
608
Pressure
kgf/cm2
5.9
5.6
6.2
Stop lever angle_04
Pump speed
r/min
2125
2125
2125
Pressure
kPa
745.5
716
775
Pressure
kgf/cm2
7.6
7.3
7.9
0000001101
Pump speed
r/min
1500
1500
1500
Timer stroke
mm
4.7
4.5
4.9
Basic
*
_02
Pump speed
r/min
1250
1250
1250
Timer stroke
mm
3.5
2.9
4.1
_03
Pump speed
r/min
1500
1500
1500
Timer stroke
mm
4.7
4.4
5
_04
Pump speed
r/min
2125
2125
2125
Timer stroke
mm
7.6
7
8.2
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
1.5
1.4
1.6
Control lever angle alpha
deg.
35
31
39
Control lever angle beta
deg.
45
40
50
Test data Ex:
0000001801 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 L between the M-CSD lever (A) and the stopper (B) becomes L1. Then fix using nut (D).
T1T1
2. Fixing CSD lever plate (E)
(1)Make the clearance between the CSD lever (A) and the stopper (B) L2.
(2)Fix the CSD lever plate (E) using the bolt (F) so that the clearance between the intermediate lever (G)'s roller (H) and the CSD lever plate is L3.
T2T2
3. Fixing the FICD screw (I)
(1)Move the CSD lever (A) through its full stroke.
(2)Adjust the intermediate lever (G)'s FICD screw (I) so that the control lever (K)'s position is a [the clearance from screw (I) is L4]. Then fix using nut (J).
T1T1
Control lever position b, L4
----------
L1=0.5+2mm L2=0mm L3=4.0mm L4=6.2+-1mm T1=6~9N-m(0.6~0.9kgf-m) T2=3.4~4.9N-m(0.35~0.5kgf-m) a=0deg b=7deg
----------
L=L1=0.5+2mm L=L2=0mm L3=4.0mm L4=6.2+-1mm T1=6~9N-m(0.6~0.9kgf-m) T2=3.4~4.9N-m(0.35~0.5kgf-m) b=7deg
----------
L1=0.5+2mm L2=0mm L3=4.0mm L4=6.2+-1mm T1=6~9N-m(0.6~0.9kgf-m) T2=3.4~4.9N-m(0.35~0.5kgf-m) a=0deg b=7deg
----------
L=L1=0.5+2mm L=L2=0mm L3=4.0mm L4=6.2+-1mm T1=6~9N-m(0.6~0.9kgf-m) T2=3.4~4.9N-m(0.35~0.5kgf-m) b=7deg
Information:
Inspect/Replace
Alternator and Fan Drive Belts
Inspect the condition and adjustment of alternator and accessory drive belts. Examine all drive belts for wear and replace if they show any signs of wear. Loose or worn pulley grooves cause belt slippage and low accessory drive speed. If belts are too loose, they vibrate enough to cause unnecessary wear on the belts and pulleys and possibly slip enough to cause overheating.If belts are too tight, unnecessary stresses are placed upon the pulley bearings and belts which might shorten the life of both.If one belt in a set requires replacement, always install a new matched set of belts. Never replace just the worn belt. If only the worn belt is replaced, the new belt will carry all the load, as it will not be stretched as much as the older belts. All the belts will fail in rapid succession.Adjust
1. Remove belt guard. Inspect the condition and adjustment of alternator belts and accessory drive belts, if equipped.2. To check the belt tension, apply 110 Newton (25 lb) force, perpendicular to the belt, midway between the driving and driven pulley. Measure the belt deflection. Correctly adjusted belts will deflect 15 to 20 mm (9/16 to 7/8 inch).If the belt does not require replacement or adjustment, install the belt guard. If the belt requires adjustment or replacement, do not install the belt guard. Perform the following procedure to adjust the belt tension.
(1) Typical belt assembly mounting bolt(2) adjusting nut3. Loosen the mounting bolt (1).4. Loosen the bracket adjusting nut(s) (2).5. Tighten or loosen the bracket adjusting nut(s) to obtain the correct adjustment.6. Tighten nuts (1) and (2).7. Check the belt tension. If the belt tension requires further adjustment, repeat steps 3 through 6.8. Install the belt guard.If new belts are installed, check the belt adjustment again after 30 minutes of engine operation.Hoses and Clamps
* Inspect all hoses for leaks due to cracking, softness and loose clamps. Replace hoses that are cracked or soft and tighten loose clamps.
Do not bend or strike high pressure lines. Do not install bent or damaged lines, tubes or hoses. Repair any loose or damaged fuel and oil lines, tubes and hoses. Leaks can cause fires. Inspect all lines, tubes and hoses carefully. Tighten all connections to the recommended torque.
Check for the following:* End fittings damaged, leaking or displaced.* Outer covering chafed or cut and wire reinforcing exposed.* Outer covering ballooning locally.* Evidence of kinking or crushing of the flexible part of the hose.* Armoring embedded in the outer cover.A constant torque hose clamp can be used in place of any standard hose clamp. Make sure the constant torque hose clamp is the same size as the standard clamp. Due to extreme temperature changes, hose will heat set. Heat setting causes hose clamps to loosen. Loose hose clamps can result in leaks. There have been reports of component failures caused by hose clamps loosening. The new, constant torque hose clamp will help prevent these failures.Each installation application can be different depending on
Alternator and Fan Drive Belts
Inspect the condition and adjustment of alternator and accessory drive belts. Examine all drive belts for wear and replace if they show any signs of wear. Loose or worn pulley grooves cause belt slippage and low accessory drive speed. If belts are too loose, they vibrate enough to cause unnecessary wear on the belts and pulleys and possibly slip enough to cause overheating.If belts are too tight, unnecessary stresses are placed upon the pulley bearings and belts which might shorten the life of both.If one belt in a set requires replacement, always install a new matched set of belts. Never replace just the worn belt. If only the worn belt is replaced, the new belt will carry all the load, as it will not be stretched as much as the older belts. All the belts will fail in rapid succession.Adjust
1. Remove belt guard. Inspect the condition and adjustment of alternator belts and accessory drive belts, if equipped.2. To check the belt tension, apply 110 Newton (25 lb) force, perpendicular to the belt, midway between the driving and driven pulley. Measure the belt deflection. Correctly adjusted belts will deflect 15 to 20 mm (9/16 to 7/8 inch).If the belt does not require replacement or adjustment, install the belt guard. If the belt requires adjustment or replacement, do not install the belt guard. Perform the following procedure to adjust the belt tension.
(1) Typical belt assembly mounting bolt(2) adjusting nut3. Loosen the mounting bolt (1).4. Loosen the bracket adjusting nut(s) (2).5. Tighten or loosen the bracket adjusting nut(s) to obtain the correct adjustment.6. Tighten nuts (1) and (2).7. Check the belt tension. If the belt tension requires further adjustment, repeat steps 3 through 6.8. Install the belt guard.If new belts are installed, check the belt adjustment again after 30 minutes of engine operation.Hoses and Clamps
* Inspect all hoses for leaks due to cracking, softness and loose clamps. Replace hoses that are cracked or soft and tighten loose clamps.
Do not bend or strike high pressure lines. Do not install bent or damaged lines, tubes or hoses. Repair any loose or damaged fuel and oil lines, tubes and hoses. Leaks can cause fires. Inspect all lines, tubes and hoses carefully. Tighten all connections to the recommended torque.
Check for the following:* End fittings damaged, leaking or displaced.* Outer covering chafed or cut and wire reinforcing exposed.* Outer covering ballooning locally.* Evidence of kinking or crushing of the flexible part of the hose.* Armoring embedded in the outer cover.A constant torque hose clamp can be used in place of any standard hose clamp. Make sure the constant torque hose clamp is the same size as the standard clamp. Due to extreme temperature changes, hose will heat set. Heat setting causes hose clamps to loosen. Loose hose clamps can result in leaks. There have been reports of component failures caused by hose clamps loosening. The new, constant torque hose clamp will help prevent these failures.Each installation application can be different depending on