104749-0670 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047490670 rfk413800

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 104749-0670 1047490670

MAZDA RFK413800 rfk413800

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Cross reference number

ZEXEL 104749-0670 1047490670

MAZDA RFK413800 rfk413800

Zexel num

Bosch num

Firm num

Name

104749-0670
104749-0671

RFK413800 MAZDA

INJECTION-PUMP ASSEMBLY
RFT * K 11CL COVEC 4 COVEC

Calibration Data:

Adjustment conditions

Test oil
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

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)
Right R

Injection timing adjustment

Pump speed r/min 1250 1250 1250

Boost pressure kPa 33.3 32 34.6

Boost pressure kgf/cm2 0.34 0.326 0.354

Boost pressure mmHg 250 240 260

Average injection quantity mm3/st. 43.3 42.8 43.8

Difference in delivery mm3/st. 3.5

Basic *

Oil temperature degC 50 48 52

Remarks
CBS

Injection timing adjustment_02

Pump speed r/min 1250 1250 1250

Boost pressure kPa 69.3 68 70.6

Boost pressure kgf/cm2 0.7 0.686 0.714

Boost pressure mmHg 520 510 530

Average injection quantity mm3/st. 48.6 48.1 49.1

Difference in delivery mm3/st. 4

Basic *

Oil temperature degC 50 48 52

Remarks
Full

Injection timing adjustment_03

Pump speed r/min 750 750 750

Boost pressure kPa 33.3 32 34.6

Boost pressure kgf/cm2 0.34 0.326 0.354

Boost pressure mmHg 250 240 260

Average injection quantity mm3/st. 42.8 42.8 42.8

Oil temperature degC 50 48 52

Injection timing adjustment_04

Pump speed r/min 1250 1250 1250

Boost pressure kPa 0 0 0

Boost pressure kgf/cm2 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 36.7 36.7 36.7

Oil temperature degC 50 48 52

Injection timing adjustment_05

Pump speed r/min 1250 1250 1250

Boost pressure kPa 33.3 32 34.6

Boost pressure kgf/cm2 0.34 0.326 0.354

Boost pressure mmHg 250 240 260

Average injection quantity mm3/st. 43.3 42.3 44.3

Difference in delivery mm3/st. 4

Oil temperature degC 50 48 52

Injection timing adjustment_06

Pump speed r/min 1250 1250 1250

Boost pressure kPa 69.3 68 70.6

Boost pressure kgf/cm2 0.7 0.686 0.714

Boost pressure mmHg 520 510 530

Average injection quantity mm3/st. 48.6 47.6 49.6

Difference in delivery mm3/st. 4.5

Oil temperature degC 50 48 52

Injection timing adjustment_07

Pump speed r/min 2150 2150 2150

Boost pressure kPa 69.3 68 70.6

Boost pressure kgf/cm2 0.7 0.686 0.714

Boost pressure mmHg 520 510 530

Average injection quantity mm3/st. 41.4 41.4 41.4

Oil temperature degC 52 50 54

Injection quantity adjustment

Pump speed r/min 2500 2500 2500

Boost pressure kPa 69.3 68 70.6

Boost pressure kgf/cm2 0.7 0.686 0.714

Boost pressure mmHg 520 510 530

Average injection quantity mm3/st. 21.8 19.8 23.8

Basic *

Oil temperature degC 55 52 58

Injection quantity adjustment_02

Pump speed r/min 2800 2800 2800

Boost pressure kPa 69.3 68 70.6

Boost pressure kgf/cm2 0.7 0.686 0.714

Boost pressure mmHg 520 510 530

Average injection quantity mm3/st. 5

Oil temperature degC 55 52 58

Injection quantity adjustment_03

Pump speed r/min 2500 2500 2500

Boost pressure kPa 69.3 68 70.6

Boost pressure kgf/cm2 0.7 0.686 0.714

Boost pressure mmHg 520 510 530

Average injection quantity mm3/st. 21.8 19.3 24.3

Oil temperature degC 55 52 58

Governor adjustment

Pump speed r/min 360 360 360

Boost pressure kPa 0 0 0

Boost pressure kgf/cm2 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 14.2 13.2 15.2

Difference in delivery mm3/st. 2

Basic *

Oil temperature degC 48 46 50

Governor adjustment_02

Pump speed r/min 360 360 360

Boost pressure kPa 0 0 0

Boost pressure kgf/cm2 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 14.2 12.7 15.7

Difference in delivery mm3/st. 2.5

Oil temperature degC 48 46 50

Timer adjustment

Pump speed r/min 100 100 100

Boost pressure kPa 0 0 0

Boost pressure kgf/cm2 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 58 58

Basic *

Oil temperature degC 48 46 50

Timer adjustment_02

Pump speed r/min 100 100 100

Boost pressure kPa 0 0 0

Boost pressure kgf/cm2 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 58 58

Oil temperature degC 48 46 50

Speed control lever angle

Pump speed r/min 360 360 360

Boost pressure kPa 0 0 0

Boost pressure kgf/cm2 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 0 0 0

Oil temperature degC 48 46 50

Remarks
Magnet OFF

0000000901

Pump speed r/min 1000 1000 1000

Boost pressure kPa 69.3 68 70.6

Boost pressure kgf/cm2 0.7 0.686 0.714

Boost pressure mmHg 520 510 530

Overflow quantity cm3/min 600 470 730

Oil temperature degC 50 48 52

Stop lever angle

Pump speed r/min 1000 1000 1000

Boost pressure kPa 69.3 68 70.6

Boost pressure kgf/cm2 0.7 0.686 0.714

Boost pressure mmHg 520 510 530

Pressure kPa 618 589 647

Pressure kgf/cm2 6.3 6 6.6

Basic *

Oil temperature degC 50 48 52

Stop lever angle_02

Pump speed r/min 1000 1000 1000

Boost pressure kPa 69.3 68 70.6

Boost pressure kgf/cm2 0.7 0.686 0.714

Boost pressure mmHg 520 510 530

Pressure kPa 618 579 657

Pressure kgf/cm2 6.3 5.9 6.7

Oil temperature degC 50 48 52

0000001101

Pump speed r/min 1000 1000 1000

Boost pressure kPa 69.3 68 70.6

Boost pressure kgf/cm2 0.7 0.686 0.714

Boost pressure mmHg 520 510 530

TCV duty (%) F TCV 60Hz % 100 100 100

Timer stroke mm 10.6 10.4 10.8

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 100 100 100

Boost pressure kPa 69.3 68 70.6

Boost pressure kgf/cm2 0.7 0.686 0.714

Boost pressure mmHg 520 510 530

TCV duty (%) F TCV 60Hz % 100 100 100

Timer stroke mm 3.5 3.5 3.5

Oil temperature degC 48 46 50

_03

Pump speed r/min 1000 1000 1000

Boost pressure kPa 69.3 68 70.6

Boost pressure kgf/cm2 0.7 0.686 0.714

Boost pressure mmHg 520 510 530

TCV duty (%) F TCV 60Hz % 100 100 100

Timer stroke mm 10.6 10.6 10.6

Oil temperature degC 50 48 52

_04

Pump speed r/min 2150 2150 2150

Boost pressure kPa 69.3 68 70.6

Boost pressure kgf/cm2 0.7 0.686 0.714

Boost pressure mmHg 520 510 530

TCV duty (%) F TCV 60Hz % 100 100 100

Timer stroke mm 11.4 11.4 11.4

Oil temperature degC 52 50 54

0000001301

Max. applied voltage V 8 8 8

Test voltage V 13 12 14

0000002701

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

Control lever angle alpha deg. 0 -4 4

Control lever angle beta deg. 35 32 38

Test data Ex:

0000001901 TIMER PISTON SEVSOR ADJ

TPS (timer piston sensor) adjustment Use the special circuit (corresponding to H) to measure TPS output voltage. (1)Measure the TPS output voltage for zero compensation (no resistance). (A): timer stroke TA (V): compensation zero TPS output voltage (VTPS) (2)Compensation resistor installation: From the table, select and install a compensation resistor so that the compensation output voltage value is zero. (R): selected compensation resistance
----------
H=479040-5600
----------
A1=0mm V0=0.510+-0.128V V1=0.382~0.401V V2=0.402~0.421V V3=0.422~0.440V V4=0.441~0.460V V5=0.461~0.479V V6=0.480~0.499V V7=0.500~0.519V V8=0.520~0.539V V9=0.540~0.558V V10=0.559~0.578V V11=0.579~0.597V V12=0.598~0.617V V13=0.618~0.637V R1=No.1,0.18kohm R2=No.2,0.30kohm R3=No.3,0.43kohm R4=No.4,0.62kohm R5=No.5,0.82kohm R6=No.6,1.10kohm R7=No.7,1.50kohm R8=No.8,2.00kohm R9=No.9,2.70kohm R10=No.10,3.90kohm R11=No.11,5.60kohm R12=No.12,8.20kohm R13=No.13,15.00kohm

0000002001 POTENTIOMETER ADJUSTMENT

Adjustment of the potentiometer (1)Potentiometer setting: (A): Adjusting point (B): Checking point (C): Control lever opening (V): P/N output voltage (2)Dummy bolt setting: Fix the control lever with the dummy bolt so that the injection quantity is as shown in the following table at the pump speed = N1. (N): Speed of the pump (Q): Injection quantity (D): Targeted lever angle C1:Full speed position C2:Idling position (3)Read the output voltage (V) of the potentiometer in the state indicated in (2) above. Then, select the compensation resistor from the following table and replace. (R): Compensation resistance Note After replacing the compensation resistor, the output voltage is the potentiometer value when the special compensation circuit (control unit) is used. Caution: The potentiometer output voltage is the voltage at the applied voltage Vi, and the control unit output voltage is the voltage at the applied voltage ViC.
----------
N1=1000r/min Vi=10V Vic=5V
----------
V1=8.4+-0.03V V2=2.56+-0.7V N1=1000r/min Q1=31.9+-1.0cm3/1000st D1=16deg V3=4.42~4.53V V4=4.54~4.65V V5=4.66~4.77V V6=4.78~4.89V V7=4.90~5.01V V8=5.02~5.13V V9=5.14~5.25V V10=5.26~5.37V V11=5.38~5.49V V12=5.50~5.61V V13=5.62~5.73V V14=5.74~5.85V V15=5.86~5.97V R1=No.1,0.18kohm R2=No.2,0.30kohm R3=No.3,0.43kohm R4=No.4,0.62kohm R5=No.5,0.82kohm R6=No.6,1.10kohm R7=No.7,1.50kohm R8=No.8,2.00kohm R9=No.9,2.70kohm R10=No.10,3.90kohm R11=No.11,5.60kohm R12=No.12,8.20kohm R13=No.13,15.00kohm

0000002101 WIRE

Confirmation of the wire length: Accelerator wire: (1) idle~full stroke: L1 Confirmation on the idle SW Confirm that the switch is ON in the idle lever position. Adjustment of the double stage actuator: (1)Apply negative pressure P = P1 {P2} to the actuator through the negative pressure inlet port 1. (2)In status (1) above, adjust the screw C so that the control lever B position is a (ie, the distance between the control lever and the idle switch E is L2). Fix using nut D. TT Reference = actuator stroke; (a) step 1: L3
----------
L1=33.5+-3.5mm L2=3.0+-0.5mm L3=6+-0.5mm L4=(4.5)mm P1=-66.6kPa P2=-500mmHg a=5deg T=6~9N-m(0.6~0.9Kgf-m)
----------
L=L2=3.0+-0.5 mm a=5deg

Information:

Installation Instructions
Using the PC, copy the file called amupdate.img to the USB stick. Make sure that the file is located directly on the USB stick and not saved in any directory on the USB stick.
Take note of the current Kernel version of the unit (if possible).
Disconnect the supply power to the unit to be upgraded.
Insert the USB stick at the back of the unit.
Reconnect the supply power to the unit and observe brief block of text message on the display, as the new kernel is being uploaded and installed. (This message is only shown for a few seconds.)
Wait for the unit to start up fully. Dismiss the USB Storage form, if shown, and remove the USB stick from the unit.
Check the Kernel version and verify that Kernel version is "180820".