104748-0330 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047480330

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Information injection-pump assembly

ZEXEL 104748-0330 1047480330

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Components :

0.	INJECTION-PUMP ASSEMBLY	104748-0330
1.	_
2.	FUEL INJECTION PUMP
3.	NUMBER PLATE	146900-0700
4.	_	146672-0920
5.	CAPSULE
6.	ADJUSTING DEVICE	593175-3522
7.	NOZZLE AND HOLDER ASSY	105141-2240
8.	Nozzle and Holder	S210 13 640
9.	Open Pre:MPa(Kqf/cm2)	13.2{135}
10.	NOZZLE-HOLDER	105071-1530
11.	NOZZLE	105000-1740

Scheme ###:

1/6.	[1]	146601-0100	PACKING RING
6.	[1]	146100-0120	SUPPLY PUMP D20
9.	[1]	146103-0000	COVER
10.	[2]	139104-0000	FLAT-HEAD SCREW
12/1.	[1]	146200-0300	DRIVE SHAFT
12/2.	[1]	146201-0000	WOODRUFF KEY
12/3.	[2]	146202-0001	DAMPER
12/4.	[1]	146203-0000	TOOTHED GEAR
17.	[1]	146204-0000	PLAIN WASHER
20.	[1]	146210-1120	ROLLER SET
24.	[1]	146303-0100	BEARING PIN
25.	[1]	146304-0000	BEARING PIN
26.	[1]	146305-0000	CLAMPING BAND
27.	[1]	146205-0000	SLOTTED WASHER
29.	[1]	146220-0220	CAM PLATE '02'SK3074
30.	[1]	146600-0800	O-RING
31.	[1]	146300-0700	PUMP PLUNGER ' 7' 5-11.
32.	[1]	146301-0000	SLIDING PIECE
33.	[1]	146603-0700	SHIM
34.	[1]	146302-3400	COMPRESSION SPRING K=2.25
34B.	[1]	146302-3300	COMPRESSION SPRING K=2.05
35/1.	[1]	146603-0700	SHIM
35/1.	[1]	146603-0800	SHIM
35/1.	[1]	146603-0900	SHIM
35/1.	[1]	146603-1000	SHIM
35/1.	[1]	146603-1100	SHIM
35/1.	[1]	146603-3600	SHIM
36.	[1]	146600-0800	O-RING
37.	[1]	146310-0700	COVER
38.	[2]	139106-0000	FLAT-HEAD SCREW
39.	[1]	146310-0100	COVER
40.	[2]	139106-0000	FLAT-HEAD SCREW
43.	[1]	146230-0000	SHIM
44.	[1]	146230-0100	PLAIN WASHER
45.	[1]	146231-0000	SLOTTED WASHER
47.	[2]	146233-0000	SLOTTED WASHER
48/1.	[1]	146603-0000	SHIM
48/1.	[1]	146603-0100	SHIM
48/1.	[1]	146603-0200	SHIM
48/1.	[1]	146603-0300	SHIM
48/1.	[1]	146603-0400	SHIM
48/1.	[1]	146603-0500	SHIM
48/1.	[1]	146603-0600	SHIM
48/1.	[1]	146690-1400	SHIM
48/1.	[1]	146690-1500	SHIM
48/1.	[1]	146690-1600	SHIM
48/1.	[1]	146690-1700	SHIM
48/1.	[1]	146690-1800	SHIM
48/1.	[1]	146690-1900	SHIM
49.	[2]	146234-0020	GUIDE PIN
50.	[1]	146400-4820	HYDRAULIC HEAD
50.	[1]	146400-4820	HYDRAULIC HEAD
50.	[1]	146400-4820	HYDRAULIC HEAD
51.	[1]	146600-0000	O-RING
52/1.	[1]	146420-0000	SHIM
52/1.	[1]	146420-0100	SHIM
52/1.	[1]	146420-0200	SHIM
52/1.	[1]	146420-0300	SHIM
52/1.	[1]	146420-0400	SHIM
52/1.	[1]	146420-0500	SHIM
52/1.	[1]	146420-0600	SHIM
52/1.	[1]	146420-0700	SHIM
52/1.	[1]	146420-0800	SHIM
52/1.	[1]	146420-0900	SHIM
52/1.	[1]	146420-1000	SHIM
52/1.	[1]	146420-1100	SHIM
52/1.	[1]	146420-1200	SHIM
52/1.	[1]	146420-1300	SHIM
52/1.	[1]	146420-1400	SHIM
52/1.	[1]	146420-1500	SHIM
52/1.	[1]	146420-1600	SHIM
52/1.	[1]	146420-1700	SHIM
52/1.	[1]	146420-1800	SHIM
52/1.	[1]	146420-1900	SHIM
52/1.	[1]	146420-2000	SHIM
52/1.	[1]	146420-2100	SHIM
52/1.	[1]	146420-2200	SHIM
52/1.	[1]	146420-2300	SHIM
52/1.	[1]	146420-2400	SHIM
52/1.	[1]	146420-2500	SHIM
52/1.	[1]	146420-2600	SHIM
52/1.	[1]	146420-2700	SHIM
52/1.	[1]	146420-2800	SHIM
52/1.	[1]	146420-2900	SHIM
52/1.	[1]	146420-3000	SHIM
52/1.	[1]	146420-3100	SHIM
52/1.	[1]	146420-3200	SHIM
52/1.	[1]	146420-3300	SHIM
52/1.	[1]	146420-3400	SHIM
52/1.	[1]	146420-3500	SHIM
52/1.	[1]	146420-3600	SHIM
52/1.	[1]	146420-3700	SHIM
52/1.	[1]	146420-3800	SHIM
52/1.	[1]	146420-3900	SHIM
52/1.	[1]	146420-4000	SHIM
52/1.	[1]	146420-4100	SHIM
52/1.	[1]	146420-4200	SHIM
52/1.	[1]	146420-4300	SHIM
52/1.	[1]	146420-4400	SHIM
52/1.	[1]	146420-4500	SHIM
52/1.	[1]	146420-4600	SHIM
52/1.	[1]	146420-4700	SHIM
52/1.	[1]	146420-4800	SHIM
52/1.	[1]	146420-4900	SHIM
52/1.	[1]	146420-5000	SHIM
52/1.	[1]	146420-5100	SHIM
52/1.	[1]	146420-5200	SHIM
52/1.	[1]	146420-5300	SHIM
52/1.	[1]	146420-5400	SHIM
52/1.	[1]	146420-5500	SHIM
52/1.	[1]	146420-5600	SHIM
52/1.	[1]	146420-5700	SHIM
52/1.	[1]	146420-5800	SHIM
54.	[4]	146433-0100	GASKET
55.	[4]	146430-0020	DELIVERY-VALVE ASSEMBLY 'VE1' VR35
56.	[4]	146432-0000	COMPRESSION SPRING K=0.48
58.	[4]	146440-0220	FITTING D0.45 L=50
60.	[3]	139106-0100	FLAT-HEAD SCREW
66.	[1]	146600-0100	O-RING
67.	[1]	146502-4221	GOVERNOR COVER
67/1.	[1]	146605-8121	GOVERNOR COVER NMC VC INLET
67/13.	[1]	146621-1700	UNION NUT
67/14.	[1]	146621-1800	UNION NUT
67/15.	[1]	146526-3400	BLEEDER SCREW
67/16.	[1]	146526-2900	BLEEDER SCREW
67/78.	[1]	146600-1000	SEAL RING
67/200.	[1]	139308-0300	PLAIN WASHER
67/201.	[1]	146545-0300	THREADED PIN
67/201B.	[1]	146545-0400	THREADED PIN
67/201C.	[1]	146545-0500	THREADED PIN
67/202.	[1]	139208-0100	UNION NUT
67/203.	[1]	146600-1200	O-RING
68.	[1]	146510-5820	CONTROL SHAFT R=10 W R
69.	[1]	139310-0200	PLAIN WASHER
72.	[1]	146537-1620	CONTROL LEVER '716'
73.	[1]	014110-6440	LOCKING WASHER
75.	[1]	146541-3600	LEVER SHAFT
95.	[1]	146551-7020	FULCRUM LEVER I=2.2 SKH51
104.	[2]	146568-0000	SLOTTED SPRING PIN
105.	[2]	026508-1140	GASKET
106.	[2]	146588-0500	COILED SPRING
107.	[1]	146569-0000	UNION NUT
108.	[1]	146570-0420	GOVERNOR SHAFT R-L/T
109.	[1]	146600-0400	O-RING
110/1.	[1]	146571-0000	SHIM
110/1.	[1]	146571-0100	SHIM
110/1.	[1]	146571-0200	SHIM
110/1.	[1]	146571-0300	SHIM
110/1.	[1]	146571-0400	SHIM
110/1.	[1]	146571-0500	SHIM
110/1.	[1]	146571-0600	SHIM
110/1.	[1]	146571-0700	SHIM
110/1.	[1]	146571-0800	SHIM
111.	[1]	146602-0600	PLAIN WASHER
112.	[1]	146572-0020	FLYWEIGHT ASSEMBLY
114.	[1]	146602-0500	PLAIN WASHER
115.	[1]	146575-4500	SLIDING SLEEVE '45' D0.5G2-0.5
116.	[1]	146576-0200	CAP
117/1.	[1]	146577-1800	PLUG
117/1.	[1]	146577-1900	PLUG
117/1.	[1]	146577-2000	PLUG
117/1.	[1]	146577-2100	PLUG
117/1.	[1]	146577-2200	PLUG
117/1.	[1]	146577-2300	PLUG
117/1.	[1]	146577-2400	PLUG
117/1.	[1]	146577-2500	PLUG
117/1.	[1]	146577-2600	PLUG
117/1.	[1]	146577-2700	PLUG
117/1.	[1]	146577-2800	PLUG
117/1.	[1]	146577-2900	PLUG
117/1.	[1]	146577-3000	PLUG
117/1.	[1]	146577-3100	PLUG
117/1.	[1]	146577-3200	PLUG
117/1.	[1]	146577-3300	PLUG
117/1.	[1]	146577-6700	PLUG
117/1.	[1]	146577-6800	PLUG
117/1.	[1]	146577-6900	PLUG
117/1.	[1]	146577-7000	PLUG
117/1.	[1]	146577-7100	PLUG
117/1.	[1]	146577-7200	PLUG
117/1.	[1]	146577-7300	PLUG
117/1.	[1]	146577-7400	PLUG
117/1.	[1]	146577-7500	PLUG
117/1.	[1]	146577-7600	PLUG
117/1.	[1]	146577-7700	PLUG
117/1.	[1]	146577-7800	PLUG
117/1.	[1]	146577-7900	PLUG
117/1.	[1]	146577-8000	PLUG
117/1.	[1]	146577-8100	PLUG
123.	[4]	139106-0200	FLAT-HEAD SCREW
130.	[1]	146421-0020	CAPSULE D14
130/2.	[1]	026508-1140	GASKET
130/3.	[1]	146422-0000	BLEEDER SCREW
130/4.	[1]	146600-0500	O-RING
133.	[1]	146600-0600	O-RING
134.	[1]	146600-0700	O-RING
135.	[1]	146110-0920	CONTROL VALVE '09'4XD1.6K=2.0
135/5.	[1]	146114-0000	SPRING WASHER
136.	[1]	146120-0020	OVER FLOW VALVE
137.	[2]	026512-1540	GASKET
138.	[1]	146609-8320	INLET UNION B2
200.	[1]	146206-0100	COILED SPRING
205.	[1]	029470-4030	WOODRUFF KEY
221.	[1]	146625-2520	BRACKET
222.	[1]	139106-0400	FLAT-HEAD SCREW
232.	[1]	146659-0800	CLAMPING BAND
235.	[1]	146629-5220	BRACKET
236.	[1]	020106-2540	BLEEDER SCREW
237.	[1]	146620-0200	HEX-SOCKET-HEAD CAP SCREW
240.	[1]	146650-0720	PULLING ELECTROMAGNET
240/8.	[1]	146600-1700	O-RING
242.	[1]	146658-0720	WIRE ' 7' 12V
243.	[1]	146621-1000	UNION NUT
245.	[3]	026512-1540	GASKET
246.	[1]	139812-0500	EYE BOLT
247.	[1]	146609-9920	INLET UNION IN B3
248.	[1]	146614-0200	SPACER BUSHING
275.	[1]	146612-2700	BRACKET
276.	[2]	010010-1640	BLEEDER SCREW
280.	[1]	146360-5520	COVER
281.	[1]	146600-0800	O-RING
282.	[2]	020106-1640	BLEEDER SCREW
329.	[1]	146541-4900	PLAIN WASHER CD17 AUTO
484.	[1]	146537-2220	PLATE TKC P322
800S.	[1]	146019-0620	PUMP HOUSING
800S/1/6.	[1]	146601-0100	PACKING RING
800S/1/6.	[1]	146601-0100	PACKING RING
804S.	[1]	146232-0320	COMPRESSION SPRING
805S.	[1]	146574-0120	PARTS SET
810S.	[1]	146600-2420	REPAIR SET
902.	[1]	146670-3821	MICROSWITCH
902/1.	[1]	146670-2510	MICROSWITCH
902/2.	[1]	146626-4420	BRACKET TKC P322 RF
902/3.	[1]	146541-5120	CONTROL LEVER TKC P322 RF
902/4.	[1]	139106-0400	FLAT-HEAD SCREW
902/5.	[2]	010206-2040	HEX-SOCKET-HEAD CAP SCREW
903.	[1]	146672-0920	PULSE GENERATOR
903/2.	[1]	146600-1300	O-RING
905.	[1]	593175-3522	ADJUSTING DEVICE
906.	[1]	146900-0700	NAMEPLATE

Include in #2:

104748-0330 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 104748-0330 1047480330

Zexel num

Bosch num

Firm num

Name

104748-0330
104748-0335

MAZDA

INJECTION-PUMP ASSEMBLY
R2 *

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 1500 1500 1500

Average injection quantity mm3/st. 38.7 38.2 39.2

Difference in delivery mm3/st. 2.5

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. 34 32 36

Injection timing adjustment_04

Pump speed r/min 1500 1500 1500

Average injection quantity mm3/st. 38.7 37.7 39.7

Injection timing adjustment_05

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 32.7 30.7 34.7

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 365 365 365

Average injection quantity mm3/st. 8 6 10

Difference in delivery mm3/st. 2

Basic *

Governor adjustment_02

Pump speed r/min 365 365 365

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 365 365 365

Average injection quantity mm3/st. 0 0 0

Remarks
Magnet OFF

0000000901

Pump speed r/min 1250 1250 1250

Overflow quantity cm3/min 430 298 562

Stop lever angle

Pump speed r/min 1500 1500 1500

Pressure kPa 441.5 412 471

Pressure kgf/cm2 4.5 4.2 4.8

Basic *

Stop lever angle_02

Pump speed r/min 500 500 500

Pressure kPa 186.5 157 216

Pressure kgf/cm2 1.9 1.6 2.2

Stop lever angle_03

Pump speed r/min 1500 1500 1500

Pressure kPa 441.5 412 471

Pressure kgf/cm2 4.5 4.2 4.8

Stop lever angle_04

Pump speed r/min 2125 2125 2125

Pressure kPa 588.5 559 618

Pressure kgf/cm2 6 5.7 6.3

0000001101

Pump speed r/min 1500 1500 1500

Timer stroke mm 4.8 4.6 5

Basic *

_02

Pump speed r/min 1250 1250 1250

Timer stroke mm 3.3 2.7 3.9

_03

Pump speed r/min 1500 1500 1500

Timer stroke mm 4.8 4.5 5.1

_04

Pump speed r/min 2125 2125 2125

Timer stroke mm 8.4 7.8 9

0000001201

Max. applied voltage V 8 8 8

Test voltage V 13 12 14

0000001401

Pump speed r/min 1500 1500 1500

Average injection quantity mm3/st. 32.7 32.2 33.2

Timer stroke TA mm 4 3.8 4.2

Basic *

_02

Pump speed r/min 1500 1500 1500

Average injection quantity mm3/st. 32.7 31.2 34.2

Timer stroke TA mm 4 3.7 4.3

_03

Pump speed r/min 1500 1500 1500

Average injection quantity mm3/st. 21.1 19.6 22.6

Timer stroke TA mm 1.6 0.9 2.3

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. 30 28 32

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 between the M-CSD lever (A) and the stopper (B) becomes L1. Then fix using nut (D). TT 2. M-FICD adjustment (1)Move the CSD lever (A) through its full stroke. (2)Adjust screw (E) so that the control lever (G)'s position is b (the clearance between the control lever and the idling set screw is L2). Then fix using the nut (F). TT Pump speed NE H = from idle to position b
----------
L1=0.5+1mm L2=5.5+-1mm a=0deg b=8deg NE=-r/min T=4.9~7N-m(0.5~0.7kgf-m)
----------
L1=0.5+1mm L2=5.5+-1mm T=4.9~7N-m(0.5~0.7kgf-m)

0000001901 MICROSWITCH ADJUSTMENT

Microswitch adjustment 1. Set the control lever position at a (distance from the idling setscrew is L1). 2. Adjust the lever screw so that the microswitch turns ON and fix using the nut. Adjustment of the V-FICD 1. V-FICD installation position adjustment (1)Maintain the control lever position b. (2)Adjust the position of the bracket so that the clearance between the control lever's roller and the actuator's hook at initial installation is L2. Then, fix using the nut. 2. V-FICD stroke adjustment (1)Move the actuator through its full stroke. (2)Adjust the adjusting screw so that the control lever clearance is c (the clearance between the control lever and the idling set screw is L3), then fix using the nut. (3)Confirm full stroke at P1 {P2}. A = from idle B = adjusting screw C = gap at installation D = microswitch
----------
a=12.5deg b=0deg c=5deg L1=8.5+-1mm L2=2+2-1mm L3=3.4+-1mm
----------
a=12.5deg c=5deg L1=8.5+-1mm L2=2+2-1mm L3=3.4+-1mm

0000002001 FICD BRACKET&CONTROL LEVER

FICD bracket and control lever assembly L = ensure at least L
----------

----------
L=3 or more mm

Information:

Introduction
The following special instructions must be used to test for a crack in the Diesel Particulate Filter (DPF). Do not perform any procedure that is outlined in this Special Instruction until you have read and understand the information that is contained in this document.Required Tools
Table 1
Required Tools
Part Number Part Name Quantity
380-5200 Tool Kit 1 Testing Procedure
Perform a “Manual Diesel Particulate Filter Regeneration” using Caterpillar Electronic Technician (Cat ® ET).
After the manual DPF regeneration is complete, run the engine at 1800 rpm for a MINIMUM of 20 minutes to stabilize the DPF temperatures.Note: Manually set the engine speed to 1800 rpm, the engine must maintain a steady speed for the entire duration of the test.
Illustration 1 g02597531
(1) DPF Outlet Cap
(2) Filter Paper
(3) Hose Assembly
(4) Air Pump
Illustration 2 g02599276
(5) DPF Outlet Port
Hot parts or hot components can cause burns or personal injury. Do not allow hot parts or components to contact your skin. Use protective clothing or protective equipment to protect your skin.
Shut down the engine and remove the Delta P line from the DPF outlet port. Refer to Illustrations 1 and 2.
Illustration 3 g02599418
(6) Filter Paper
Install the filter in the fitting, Refer to Illustration 3. Install the fitting in the DPF outlet port. The filter must be installed in less than 10 minutes after the engine has shut down.
Turn the vacuum pump ON.
Disable automatic regeneration in Cat ET.
Illustration 4 g02597737
Select "Service" - "Configuration" - "Emissions Parameters" and "ARD Manual Disable Status". Select "Disabled". The check engine light and a 3714-31 active code will be present.
Override the "DPF Differential Pressure Line Override" to "Disconnected", using Cat ET. Refer to Illustration 4.
Start the engine. Run the engine at 1800 rpm for 15 minutes.Note: Manually set the engine speed to 1800 rpm, the engine must maintain a steady speed for the entire duration of the test.
Hot parts or hot components can cause burns or personal injury. Do not allow hot parts or components to contact your skin. Use protective clothing or protective equipment to protect your skin.
Shut the engine down and remove the filter holder within 25 minutes. Use proper personal protective equipment to remove the filter holder.
Allow the filter holder time to cool down before disassembly.
Carefully disassemble the filter holder to prevent contamination. Tip the fitting down on a clean surface to remove the filter paper. Handle the filter paper with clean hands and only by the edges.
Illustration 5 g02597796
Compare the stained area in the center of the filter paper to the color coded sheet provided. Refer to Illustration 5.
If the shade is equal to or darker than the "Color Code Sheet", the DPF has a crack or leak. Replace the DPF. Refer to Special Instruction, "Diesel Particulate Filter (DPF) Maintenance on Tier 4 Products Equipped with a Diesel Particulate Filter".
If the shade is lighter than the "Color Code Sheet", then return the unit to service.
Enable the Automatic regeneration in Cat ET.
Select "Service" - "Configuration" - "Emissions Parameters" and "ARD Manual Disable Status". Select "Not - Disabled". The check engine light will go off unless