104740-0976 ZEXEL test values diesel fuel-injection equipment 23.01.

10 11:55:26 Page 1

ZEXEL Ass'y No. 104740-0976

Bosch Ass'y No. 9 460 614 208
Bosch Typecode
Engine Type WLT
Manufacturer MAZDA
Edition date 25.04.08 (8)

1 Adjustment conditions
CAT Designation Unit Set value min. max. Actual values OT
Test oil ISO4113orSAEJ967
d
1404 Test oil
P Test oil temperature degC 45 45 50
Nozzle 105780-0060
Bosch type code NP-DN0SD1510
Nozzle holder 105780-2150
P Opening pressure MPa 13 13 13.3
P Opening pressure kgf/cm2 133 133 136
Injection pipe 157805-7320
P Injection pipe mm 2-6-450
Inside diameter - outside diameter - length (mm)
Joint assembly 157641-4720
Tube assembly 157641-4020
P Transfer pump pressure kPa 20 20 20
P Transfer pump pressure kgf/cm2 0.2 0.2 0.2
Direction of rotation (viewed from drive side) L
Left

2 Adjustment specification
2.1 Full load delivery
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 750 750 750
P Boost pressure kPa 0 0 0
P Boost pressure mmHg 0 0 0
S Average injection quantity mm3/st. 47.9 47.4 48.4
S Difference in delivery mm3/st. 4 4
P Basic *
P Oil temperature degC 50 48 52
Remarks
NA
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 750 750 750
P Boost pressure kPa 43.3 42 44.6
P Boost pressure mmHg 325 315 335
S Average injection quantity mm3/st. 64.1 63.6 64.6
S Difference in delivery mm3/st. 5.5 5.5
P Basic *
P Oil temperature degC 50 48 52
Remarks
CBS
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1000 1000 1000
P Boost pressure kPa 80 78.7 81.3
P Boost pressure mmHg 600 590 610
S Average injection quantity mm3/st. 76.3 75.8 76.8
S Difference in delivery mm3/st. 6.5 6.5
P Basic *
P Oil temperature degC 50 48 52
Remarks
Full
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 750 750 750
P Boost pressure kPa 0 0 0
P Boost pressure mmHg 0 0 0
C Average injection quantity mm3/st. 47.9 46.9 48.9
C Difference in delivery mm3/st. 4.5 4.5
P Basic *
P Oil temperature degC 50 48 52
Remarks
NA
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 750 750 750
P Boost pressure kPa 43.3 42 44.6

S = Setting value, C = Check value)

OT = Outside Tolerance (X is set)
104740-0976 ZEXEL test values diesel fuel-injection equipment 23.01.10 11:55:26 Page 2

P Boost pressure mmHg 325 315 335

C Average injection quantity mm3/st. 64.1 63.1 65.1
C Difference in delivery mm3/st. 6 6
P Basic *
P Oil temperature degC 50 48 52
Remarks
CBS
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1000 1000 1000
P Boost pressure kPa 80 78.7 81.3
P Boost pressure mmHg 600 590 610
C Average injection quantity mm3/st. 76.3 75.3 77.3
C Difference in delivery mm3/st. 7 7
P Basic *
P Oil temperature degC 50 48 52
Remarks
Full
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 2000 2000 2000
P Boost pressure kPa 80 78.7 81.3
P Boost pressure mmHg 600 590 610
C Average injection quantity mm3/st. 67.8 64.3 71.3
About
P Oil temperature degC 50 48 52
2.2 Governing
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 2450 2450 2450
P Boost pressure kPa 80 78.7 81.3
P Boost pressure mmHg 600 590 610
S Average injection quantity mm3/st. 23.5 20.5 26.5
S Difference in delivery mm3/st. 7 7
P Basic *
P Oil temperature degC 55 52 58
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 2450 2450 2450
P Boost pressure kPa 80 78.7 81.3
P Boost pressure mmHg 600 590 610
C Average injection quantity mm3/st. 23.5 13.5 33.5
C Difference in delivery mm3/st. 7.5 7.5
P Basic *
P Oil temperature degC 55 52 58
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 2800 2800 2800
P Boost pressure kPa 80 78.7 81.3
P Boost pressure mmHg 600 590 610
C Average injection quantity mm3/st. 6 6
P Oil temperature degC 55 52 58
2.3 Idle
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 390 390 390
P Boost pressure kPa 0 0 0
P Boost pressure mmHg 0 0 0
S Average injection quantity mm3/st. 11.4 10.4 12.4
S Difference in delivery mm3/st. 1.7 1.7
P Basic *
P Oil temperature degC 48 46 50
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 390 390 390
P Boost pressure kPa 0 0 0
P Boost pressure mmHg 0 0 0
C Average injection quantity mm3/st. 11.4 9.9 12.9
C Difference in delivery mm3/st. 2.2 2.2
P Basic *
P Oil temperature degC 48 46 50
2.4 Partial injection quantity
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 400 400 400
P Boost pressure kPa 0 0 0
P Boost pressure mmHg 0 0 0
C Average injection quantity mm3/st. 17 15 19
C Difference in delivery mm3/st. 3 3
About
P Oil temperature degC 48 46 50

S = Setting value, C = Check value)

OT = Outside Tolerance (X is set)
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2.5 Start
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 150 150 150
P Boost pressure kPa 0 0 0
P Boost pressure mmHg 0 0 0
S Average injection quantity mm3/st. 70 55 90
P Basic *
P Oil temperature degC 48 46 50
Remarks
Full
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 150 150 150
P Boost pressure kPa 0 0 0
P Boost pressure mmHg 0 0 0
C Average injection quantity mm3/st. 70 50 90
About
P Oil temperature degC 48 46 50
Remarks
Full
2.6 Stop
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 370 370 370
P Boost pressure kPa 0 0 0
P Boost pressure mmHg 0 0 0
C Average injection quantity mm3/st. 0 0 0
P Oil temperature degC 48 46 50
Remarks
Magnet OFF
2.7 Overflow
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1000 1000 1000
P Boost pressure kPa 80 78.7 81.3
P Boost pressure mmHg 600 590 610
C Overflow quantity cm3/min 400 270 530
P Oil temperature degC 50 48 52
2.8 Pump chamber pressure
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1000 1000 1000
P Boost pressure kPa 80 78.7 81.3
P Boost pressure mmHg 600 590 610
S Pressure kPa 510 481 539
S Pressure kgf/cm2 5.2 4.9 5.5
P Basic *
P Oil temperature degC 50 48 52
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1000 1000 1000
P Boost pressure kPa 80 78.7 81.3
P Boost pressure mmHg 600 590 610
C Pressure kPa 510 471 549
C Pressure kgf/cm2 5.2 4.8 5.6
P Basic *
P Oil temperature degC 50 48 52
2.9 Timer
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1000 1000 1000
P Boost pressure kPa 80 78.7 81.3
P Boost pressure mmHg 600 590 610
S Timer stroke mm 4.8 4.6 5
P Basic *
P Oil temperature degC 50 48 52
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 500 500 500
P Boost pressure kPa 80 78.7 81.3
P Boost pressure mmHg 600 590 610
C Timer stroke mm 2.2 1.4 3
P Oil temperature degC 48 46 50
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1000 1000 1000
P Boost pressure kPa 80 78.7 81.3
P Boost pressure mmHg 600 590 610
C Timer stroke mm 4.8 4.4 5.2
P Basic *
P Oil temperature degC 50 48 52

S = Setting value, C = Check value)

OT = Outside Tolerance (X is set)
104740-0976 ZEXEL test values diesel fuel-injection equipment 23.01.10 11:55:26 Page 4

CAT Designation Unit Set value min. max. Actual values OT

P Pump speed r/min 2000 2000 2000
P Boost pressure kPa 80 78.7 81.3
P Boost pressure mmHg 600 590 610
C Timer stroke mm 9.4 8.6 10.2
P Oil temperature degC 50 48 52
2.10 Magnet
CAT Designation Unit Set value min. max. Actual values OT
C Max. applied voltage V 8 8 8
P Test voltage V 13 12 14
2.11 Compensator
2.11.1 Load-timer adjustment
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 750 750 750
P Boost pressure kPa 80 78.7 81.3
P Boost pressure mmHg 600 590 610
S Average injection quantity mm3/st. 49 48.5 49.5
S Timer stroke TA mm 2.9 2.7 3.1
S Timer stroke variation dT mm 0.7 0.7 0.7
About
P Basic *
P Oil temperature degC 50 48 52
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 750 750 750
P Boost pressure kPa 80 78.7 81.3
P Boost pressure mmHg 600 590 610
C Average injection quantity mm3/st. 49 48 50
C Timer stroke TA mm 2.9 2.5 3.3
P Basic *
P Oil temperature degC 50 48 52
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 750 750 750
P Boost pressure kPa 80 78.7 81.3
P Boost pressure mmHg 600 590 610
C Average injection quantity mm3/st. 30 28.5 31.5
C Timer stroke TA mm 1.9 1.1 2.7
P Oil temperature degC 50 48 52
2.12 Additional device adjustment

S = Setting value, C = Check value)

OT = Outside Tolerance (X is set)
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2.12.1 Additional device 1

Name 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

S = Setting value, C = Check value)

OT = Outside Tolerance (X is set)
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2.12.2 Additional device 2

Name DASHPOT ADJUSTMENT
L=8.1+-0.05(mm)
a=14.1(deg)
b=12.5+-4(deg)

L=8.1+-0.05(mm) Adjustment of the dash pot

T=T=6~9(Nm)(0.6~0.9(kgfm)) 1. Hold the control lever (A) at position a (clearance L).
a=14.1(deg) 2. In the above condition, adjust the position of the dash pot so that the end of the dash pot (B) co
b=12.5+-4(deg) ntacts the control lever (A) and fix using the nut (C). (Tightening torque T)
D:Dash pot contact position
b:Angle alpha
2.12.3 Additional device 3
Name WIRE
L2=3.4+-0.5(mm)
a=8(deg)
b=12.5+-4(deg)
c=5.9(deg)

L1=34.1+3.5-5.5(mm) Confirmation of the wire length:

L2=3.4+-0.5(mm) Accelerator wire: Idle-full stroke: L1
P1=-66.6(kPa) Adjustment of the double stage actuator:
P2=-500(mmHg) (1)Apply negative pressure P1 {P2} to the actuator through the negative pressure inlet port (A).
T=6~9(Nm)(0.6~0.9(kgfm)) (2)In status (1) above, adjust the screw C so that the control lever B positioned so that the distanc
b=12.5+-4(deg) e between the control lever and the idle screw E is L2. Fix using nut D to torque T.
b:Alpha = 12.5+-4 deg

3 Assembly dimension
CAT Designation Unit Set value min. max. Actual values OT
S K dimension mm 3.3 3.2 3.4
S KF dimension mm 6.01 5.91 6.11
S MS dimension mm 0.9 0.8 1
S BCS stroke mm 6.8 6.6 7
S Pre-stroke mm 0.03 0.01 0.05
S Control lever angle alpha deg. 12.5 8.5 16.5
S Control lever angle beta deg. 39 36 42

S = Setting value, C = Check value)

OT = Outside Tolerance (X is set)