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101491-9530

ZEXEL Ass'y No.


Bosch Ass'y No.
Bosch Typecode
Engine Type
Manufacturer
Edition date

P
P

P
P
P
P

Page 1

101491-9530

SL-T/C
MAZDA
21.12.04 (3)

1 Adjustment conditions
CAT Designation
Test oil

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ZEXEL test values diesel fuel-injection equipment

Test oil temperature


Nozzle and nozzle holder
Bosch type code
Nozzle
Bosch type code
Nozzle holder
Bosch type code
Opening pressure
Opening pressure
Injection pipe
Overflow valve
Overflow valve opening pressure
Overflow valve opening pressure
Tester oil delivery pressure
Tester oil delivery pressure
Direction of rotation (viewed from drive side)

Unit

Set value
min.
ISO4113 or {SAEJ96
7d}

1404 Test oil


degC

max.

40
40
105780-8140
EF8511/9A
105780-0000
DN12SD12T
105780-2080
EF8511/9
MPa
17.2
kgf/cm2
175
mm
6-2-600
Outer diameter - inner diameter - length (mm)
131424-3420
kPa
255
221
kgf/cm2
2.6
2.25
kPa
157
157
kgf/cm2
1.6
1.6
R
Right

45

Unit

min.

max.

1-3-4-2
3.2
NO.1

3.15

3.25

90

89.5

90.5

180

179.5

180.5

270

269.5

270.5

Set value
-

min.

max.

Actual values

OT

Actual values

OT

Actual values

OT

289
2.95
157
1.6

2 Adjustment specification
2.1 Injection timing adjustment
CAT Designation
P
Direction of rotation (viewed from drive side)

Set value
R

Right
P
S
P

Injection order
Pre-stroke
Beginning of injection position

Difference between angles 1

Difference between angles 2

Difference between angles 3

2.2 Injection quantity adjustment


CAT Designation
P
Adjusting point
S = Setting value, C = Check value)
OT = Outside Tolerance (X is set)

mm
Drive side
deg.
Cal 1-3
deg.
Cal 1-4
deg.
Cyl.1-2
Unit

101491-9530
P
P
S
S
P
P
P
CAT
P
P
P
S
S
P
P

31.07.14 18:50:13

ZEXEL test values diesel fuel-injection equipment

Rack position
Pump speed
r/min
Average injection quantity
mm3/st.
Max. variation between cylinders
%
Basic
Fixing the rack
Standard for adjustment of the maximum vari
ation between cylinders

12.77+-0.02
1000
73.2
0
*
*
*

Designation
Adjusting point
Rack position
Pump speed
Average injection quantity
Max. variation between cylinders
Fixing the rack
Standard for adjustment of the maximum vari
ation between cylinders
Remarks

Set value
10.1+-0.5
340
10
0
*
*

Unit

r/min
mm3/st.
%

1000
72.7
-2.5

1000
73.7
2.5

min.

max.

340
8
-14

340
12
14

Page 2

Actual values

OT

Adjust only variation between cylinders; adjust governor according to governor specifications.
CAT
P
P
P
S
P
P
P
P

Designation
Adjusting point
Rack position
Pump speed
Average injection quantity
Basic
Fixing the lever
Boost pressure
Boost pressure

Unit

CAT
P
P
P
S
P
P
P

Designation
Adjusting point
Rack position
Pump speed
Average injection quantity
Fixing the lever
Boost pressure
Boost pressure

Unit

CAT
P
P
P
S
P
P
P

Designation
Adjusting point
Rack position
Pump speed
Average injection quantity
Fixing the lever
Boost pressure
Boost pressure

Unit

CAT
P
P
P
S

Designation
Adjusting point
Rack position
Pump speed
Average injection quantity

Unit

S = Setting value, C = Check value)


OT = Outside Tolerance (X is set)

r/min
mm3/st.

kPa
mmHg

r/min
mm3/st.
kPa
mmHg

r/min
mm3/st.
kPa
mmHg

r/min
mm3/st.

Set value
A
12.77+-0.5
1000
73.2
*
*
21.3
160

min.

max.

1000
72.7

1000
73.7

Set value
B
12.91+-0.5
1600
83.7
*
21.3
160

min.

max.

1600
81.7

1600
85.7

Set value
C
11.97+-0.5
750
49.3
*
21.3
160

min.

max.

750
47.3

750
51.3

Set value
I
100
75

min.

max.

100
70

100
85

Actual values

OT

Actual values

OT

Actual values

OT

Actual values

OT

21.3
160

21.3
160

21.3
160

101491-9530
P
P

31.07.14 18:50:13

ZEXEL test values diesel fuel-injection equipment

Fixing the lever


Rack limit

S = Setting value, C = Check value)


OT = Outside Tolerance (X is set)

*
*

Page 3

101491-9530

ZEXEL test values diesel fuel-injection equipment

2.3 Governor adjustment


Name

S = Setting value, C = Check value)


OT = Outside Tolerance (X is set)

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Page 4

101491-9530

ZEXEL test values diesel fuel-injection equipment

S = Setting value, C = Check value)


OT = Outside Tolerance (X is set)

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Page 5

101491-9530

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ZEXEL test values diesel fuel-injection equipment

T1=C60
R1=+-0.02mm
N1=+-3r/min
BCL=1.2+-0.1mm

2.4 Boost compensator adjustment


CAT Designation
P
Pump speed
P
Rack position
S
Boost pressure
S
Boost pressure
CAT Designation
P
Pump speed
P
Rack position
S
Boost pressure
S
Boost pressure
2.5 Timer adjustment
CAT Designation
P
Pump speed
S
Advance angle
Remarks

Page 6

N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
(2)Tolerance for racks not indicated: R1, speed N1
(3)RACK LIMIT
(4)Boost compensator stroke: BCL
Unit
r/min

Set value
600
10.49+-0.05
2
15

min.
600

max.
600

2
15

4.7
35

min.
600

max.
600

kPa
mmHg

Set value
600
11.69+-0.02
12
90

9.3
70

14.7
110

Unit
r/min
deg.

Set value
1500+-25
0

min.

max.

Set value
1750
3

min.

max.

2.7

3.3

kPa
mmHg
Unit
r/min

Actual values

OT

Actual values

OT

Actual values

OT

Actual values

OT

Start
CAT Designation
P
Pump speed
S
Advance angle
Remarks

Unit
r/min
deg.
Finish

S = Setting value, C = Check value)


OT = Outside Tolerance (X is set)

101491-9530

ZEXEL test values diesel fuel-injection equipment

2.6 Speed control lever angle


Name
a=20deg+-5deg
b=43deg+-3deg

aa=36mm

F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt set position 'H'

2.7 Stop lever angle


Name
a=14deg+-5deg
b=(29deg)+-5deg

aa=39mm

2.8 Additional device adjustment


S = Setting value, C = Check value)
OT = Outside Tolerance (X is set)

N:Pump normal
S:Engine stop
(1)Use the hole at R = aa
(2)Set the stop adjuster screw

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Page 7

101491-9530

ZEXEL test values diesel fuel-injection equipment

2.8.1 Additional device 1


Name
GOV RACK POSITION CONFIRM
Na=1000r/min
Nb=625r/min
Nc=1700r/min
Nd=1500r/min
Ne=1250r/min
Nf=400r/min
Ra=12.77+-0.02mm
Rb=11.69+-0.02mm
Rc=12.84+-0.05mm
Rd=13.04+-0.05mm
Re=13.23+-0.05mm
Rf=12.15+-0.05mm

Confirm the governor adjustment rack position.


(N): Speed of the pump
(R) Rack position (mm)
Standard point A
(B) Confirmation
Remarks C

S = Setting value, C = Check value)


OT = Outside Tolerance (X is set)

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Page 8

101491-9530

ZEXEL test values diesel fuel-injection equipment

31.07.14 18:50:13

Page 9

2.8.2 Additional device 2


Name
LEVER

Na=1825r/min
Nb=340r/min
Ra=5.3-0.5mm

S = Setting value, C = Check value)


OT = Outside Tolerance (X is set)

CL:Center line of camshaft


ST:Stop adjuster screw
f1:Direction for pulling the speed lever
f2:Direction for pulling the stop lever
1. Stop lever adjustment outline
(1)After completing all adjustments, confirm that the lever angle is within the specifications in the
normal position.
(2)Set the speed lever in the full speed position.
(3)At pump speed Na, position the rack at non-injection position Ra.
(4)Set the stop adjusting screw to fix the speed lever in the idling position.
(5)Confirm that there is no injection at pump speed Nb.

101491-9530

ZEXEL test values diesel fuel-injection equipment

31.07.14 18:50:13

2.9 Timing setting


Name
a=(130deg)

(1)Pump vertical direction


(2)Position of gear mark 'CC' at No 1 cylinder's beginning of injection
(3)(4)-

S = Setting value, C = Check value)


OT = Outside Tolerance (X is set)

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