104748-0225 ZEXEL test values diesel fuel-injection equipment 15/06/23 13:22:42 Page 1
ZEXEL Ass'y No. 104748-0225
Bosch Ass'y No. 9 460 610 666
Bosch Typecode
Engine Type R2
Manufacturer MAZDA
Edition date 05/02/02
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 105000-2010
Bosch type code NP-DN12SD12TT
Nozzle holder 105780-2080
P Opening pressure MPa 14.7 14.7 15.19
P Opening pressure kgf/cm2 150 150 155
P Injection pipe mm 2-6-840
Inside diameter - outside diameter - length (mm)
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) R
Right
2 Adjustment specification
2.1 Full load delivery
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1500 1500 1500
S Average injection quantity mm3/st. 37.5 37 38
S Difference in delivery mm3/st. 3 3
P Basic *
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 2400 2400 2400
C Average injection quantity mm3/st. 13.1 10.1 16.1
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 2125 2125 2125
C Average injection quantity mm3/st. 32.8 30.8 34.8
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1500 1500 1500
C Average injection quantity mm3/st. 37.5 36.5 38.5
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 500 500 500
C Average injection quantity mm3/st. 31.5 29.5 33.5
2.2 Governing
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 2400 2400 2400
S Average injection quantity mm3/st. 13.1 11.1 15.1
P Basic *
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 2550 2550 2550
C Average injection quantity mm3/st. 4 4
2.3 Idle
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 350 350 350
S Average injection quantity mm3/st. 8 6 10
S Difference in delivery mm3/st. 2 2
P Basic *
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 350 350 350
C Average injection quantity mm3/st. 8 6 10
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 450 450 450
C Average injection quantity mm3/st. 4 4
2.4 Start
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 100 100 100
S Average injection quantity mm3/st. 42 42
P Basic *
2.5 Stop
CAT Designation Unit Set value min. max. Actual values OT
S = Setting value, C = Check value)
OT = Outside Tolerance (X is set)
104748-0225 ZEXEL test values diesel fuel-injection equipment 15/06/23 13:22:42 Page 2
P Pump speed r/min 350 350 350
C Average injection quantity mm3/st. 0 0 0
Remarks
Magnet OFF
2.6 Overflow
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1500 1500 1500
C Overflow quantity cm3/min 460 330 590
2.7 Pump chamber pressure
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1500 1500 1500
S Pressure kPa 578.5 549 608
S Pressure kgf/cm2 5.9 5.6 6.2
P Basic *
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 500 500 500
C Pressure kPa 294.5 265 324
C Pressure kgf/cm2 3 2.7 3.3
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1500 1500 1500
C Pressure kPa 578.5 549 608
C Pressure kgf/cm2 5.9 5.6 6.2
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 2125 2125 2125
C Pressure kPa 745.5 716 775
C Pressure kgf/cm2 7.6 7.3 7.9
2.8 Timer
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1500 1500 1500
S Timer stroke mm 4.7 4.5 4.9
P Basic *
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1250 1250 1250
C Timer stroke mm 3.5 2.9 4.1
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1500 1500 1500
C Timer stroke mm 4.7 4.4 5
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 2125 2125 2125
C Timer stroke mm 7.6 7 8.2
2.9 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
2.10 Additional device adjustment
S = Setting value, C = Check value)
OT = Outside Tolerance (X is set)
104748-0225 ZEXEL test values diesel fuel-injection equipment 15/06/23 13:22:42 Page 3
2.10.1 Additional device 1
Name M-CSD ADJUSTMENT
L=L1=0.5+2mm
L=L2=0mm
L3=4.0mm
L4=6.2+-1mm
T1=6~9Nm(0.6~0.9kgfm)
T2=3.4~4.9Nm(0.35~0.5kgfm)
b=7deg
L1=0.5+2mm M-CSD adjustment
L2=0mm 1. Fixing the M-CSD
L3=4.0mm (1)At roller holder advance angle a adjust the lever shaft ball pin so that it contacts the roller hold
L4=6.2+-1mm er.
T1=6~9Nm(0.6~0.9kgfm) (2)At this time, adjust the position of the M-CSD lever (A) using adjusting screw (C) so that the cle
T2=3.4~4.9Nm(0.35~0.5kgfm) arance L between the M-CSD lever (A) and the stopper (B) becomes L1. Then fix using nut (D).
a=0deg T1T1
b=7deg 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 le
ver (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 [th
e clearance from screw (I) is L4]. Then fix using nut (J).
T1T1
Control lever position b, L4
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 5.8 5.7 5.9
S MS dimension mm 1.5 1.4 1.6
S Control lever angle alpha deg. 35 31 39
S Control lever angle beta deg. 45 40 50
S = Setting value, C = Check value)
OT = Outside Tolerance (X is set)
