a) Type and adjustment of bench injectors.
- Fuel test bench control nozzle type — DN12SD12 (NIPPONDENSO)
- The pressure at which the injector needle begins to rise is 145-155 bar
b) Check the error of the stand tachometer.
- Maximum permissible error - ±40 rpm
c) Install the injection advance angle sensor.
d) Secure the fuel injection pump to the stand.
Note: Place a mark on the coupling opposite the pump shaft key.
d) Install high pressure fuel pipes with the following characteristics:
- Outer diameter - 6.0 mm
- Inner diameter - 2.0 mm
- Length - 840 mm
- The minimum allowable bending radius is more than 25 mm
- Tightening torque - 22 Nm
e) Unscrew the fuel supply pipe union bolt.
g) After unscrewing two bolts, remove the right cover of the injection advance unit.
c) Install a pressure gauge that measures the internal pressure in the fuel injection pump body and a device for measuring the plunger stroke.
- Tightening torque - 8 Nm
Note: Remove air using the air bleed screw.
i) Connect the wire to the terminal of the solenoid valve of the supply cut-off and apply 12 V voltage.
Note:
- - The battery should be located as far as possible from the fuel injection pump to avoid sparks.
- - First connect the wire to the solenoid valve terminal.
k) The pressure in the fuel supply pipe should be 0.2 kg/cm². The fuel temperature should be 40-45°C.
m) Install the protractor on the fuel stand and connect it to the fuel injection pump control lever.
n) Secure the upper part of the control lever to the maximum feed position.
o) Check the installation of the cam washer.
(1) Disconnect the high-pressure fuel pipe from the delivery fitting marked "C" on the injection pump distributor head.
(2) Using a special tool, unscrew the body (nipple) of the discharge valve.
(3) Check that fuel flows out of the distributor head hole when the mark on the adapter is positioned as shown in the figure.
(4) If fuel does not flow out, disassemble the relevant parts and turn the cam washer 180°.
Note: When performing this operation, disconnect the fuel shut-off solenoid valve terminal.
(5) Using a special tool, tighten the body (nipple) of the discharge valve.
- Tightening torque - 59 Nm
(6) Install the high pressure fuel pipes.
- Tightening torque - 22 Nm
p) Remove air from the high pressure fuel lines.
p) Let the fuel injection pump run for 5 minutes at 2000 rpm.
Note: Check for fuel leaks and abnormal noise.
Table 1
Table 2
Table 3
Note:
- - Determine the volume of fuel in measuring flasks (beakers).
- - Before the next measurement, drain the fuel from the measuring cylinder for at least 30 seconds.
2. Preliminary adjustment of the nominal fuel supply.
a) Set the upper part of the fuel injection pump control lever to the maximum feed position.
b) Measure the amount of fuel supplied. (see table 1).
c) If there is a ring seal, hold the nominal feed adjusting screw and release the sealing cuff from the weld by turning the lock nut counterclockwise 90° or more.
Use a screwdriver to remove the sealing cuff.
d) If there is a wire seal, cut the wire.
d) Adjust the fuel supply by turning the fuel supply adjustment screw.
Note: When the nominal flow adjustment screw is turned by ½ turn, the fuel flow changes by approximately 3 cm³.
3. Preliminary adjustment of the regulator shaft position.
Using a special tool and an Allen key, adjust the amount of protrusion of the regulator shaft.
- The shaft protrusion is 0.5-2.0 mm
4. Preliminary adjustment of maximum rotation speed.
a) Set the fuel injection pump control lever to the maximum feed position.
b) Measure the amount of fuel supplied (see table 2).
c) Remove the seal from the maximum speed screw.
d) Adjust the feed rate with the maximum speed adjusting screw.
Adjust the fuel pressure inside the injection pump housing.
a) Set the fuel injection pump control lever to the maximum feed position.
b) Measure the fuel pressure inside the fuel injection pump housing at the rotation speeds specified in Table 3.
c) If the pressure is less than the specified values, then adjust it using a metal rod by lightly tapping the stop of the pressure reducing valve spring, while simultaneously observing the readings of the pressure gauge measuring the pressure inside the fuel injection pump housing.
If the pressure exceeds the specified values or if the pressure reducing valve is stuck, it must be replaced.
6. Check the fuel volume.
a) Set the fuel injection pump control lever to the maximum supply position.
b) Measure the volume of fuel supplied through the fuel return hose from the fuel injection pump housing at the specified rotation speeds.
- The rotation frequency of the injection pump drive shaft is 2100 rpm
- Volume of fuel removed - 167-364 cm³
Note: Always install the fuel return pipe mounting bolt that was installed with the injection pump.
7. For the following adjustments, turn off the engine warm-up control device.
a) Turn the heating control lever 20° counterclockwise.
6) Place a 8.5-10mm metal plate between the lever and the heating control actuator.
Note: Keep the warm-up overspeed system disabled until all measurements and adjustments have been made.
8. Measure and adjust the stroke of the injection advance plunger.
a) Set the plunger stroke measurement scale to zero.
b) Measure the stroke of the injection advance plunger at the specified rotation speeds.
Table 4
c) Using a 5 mm Allen key, adjust the stroke of the advance mechanism plunger.
Note: The plunger stroke decreases when the screw is turned clockwise and increases when the screw is turned counterclockwise.
9. Adjustment of cyclic feed at full load.
a) Angle of rotation of the regulator lever: (A - maximum idle speed) plus 13-23°, (B - minimum idle speed) minus 24-34°.
b) Measure the cyclic flow at full load (see table 1 above).
c) Adjust the fuel supply at full load with the nominal supply adjusting screw.
Note: The feed rate changes by approximately 3 cm³ for every half turn of the screw.
10. Adjustment at maximum speed.
a) Measure the volume of injected fuel at maximum engine speed values.
Table 5
- Number of cycles - 200
- The angle of rotation of the fuel injection pump control lever is plus 13-23°
c) Adjust the volume of fuel injected using the maximum speed adjusting screw.
11. Check the volume of injected fuel.
a) Measure the volume of fuel injected at the speed specified in Table 6.
- Number of cycles - 200
- The angle of rotation of the fuel injection pump control lever is plus 13-23°
b) If the starting feed rate (at a speed of 100 rpm) does not correspond to the table value, then replace the regulator sleeve plug: press the plug out of the regulator sleeve.
c) Remove the parts shown in the figure.
1 - retaining ring,
2 - thrust ring,
3 - thrust bearing,
4 - cork.
d) Measure the thickness of the bushing plug head, select a new bushing plug.
Note: 0.1 mm plug extension increases the starting flow by 0.6 cm³/200 cycles. If the flow irregularity exceeds the specified value, replace the delivery valve.
The plugs are available with different head thicknesses from 2.2 to 3.4 mm (with a step of 0.1 mm).
d) Assemble the regulator sleeve in the reverse order of disassembly, press the plug into the sleeve.
12. Adjust the position of the regulator shaft according to the load.
a) Adjustment is made by turning the shaft of the regulator sleeve. Adjust the starting and ending points of the speed regulator clutch stroke.
b) Set the fuel injection pump control lever to the maximum feed position.
Table 6
Table 7
Note: where A is the value measured in subparagraph c) of paragraph 15.
Table 8
Table 9
c) Measure the fuel supply.
- Number of cycles - 200
- Rotation speed - 1500 rpm
d) Slowly move the lever to the minimum idle stop and secure the lever at the point where the pressure in the pump body begins to drop.
e) Measure the flow rate at the point where the pressure starts to drop. Calculate the difference in flow rates and compare with the data.
- Rotation speed - 1500 rpm
- Feed difference is 1.0±0.3 cm³
- Number of cycles - 200
g) Adjust the feed difference by turning the regulator shaft.
Note: Half a turn of the regulator shaft changes the feed by 3 cm.
h) Slowly move the lever to the minimum idle stop and secure the lever at the point where the pressure in the pump body stops dropping.
Compare the fuel supply value with the data in Table 7.
i) Check the difference in the plunger stroke of the injection advance machine by load when moving the fuel injection pump control lever from the maximum speed position to the idle position (see table 8.)
k) Measure the governor shaft protrusion.
- Shaft protrusion - 0.5-2.0 mm
16. Adjusting the idle speed.
a) Measure the feed at different speeds of the injection pump drive shaft (see table 9).
- The angle of rotation of the fuel injection pump control lever is minus 24-34°
- Number of cycles - 200
- Permissible unevenness - 0.34 cm
b) Adjust the fuel injection rate at minimum idle speed using the minimum idle speed adjusting screw.
17. Adjust the heating control system.
a) Unscrew the fuel return pipe mounting bolt and measure the fuel temperature inside the high-pressure fuel pump housing.
- Fuel temperature - 15-35°C
b) Install the fuel injection pump drive shaft so that the woodruff key is in a vertical or horizontal position.
c) Set the scale of the device for measuring the stroke of the injection advance plunger to zero.
d) Check the initial angular position of the fuel injection pump heating control adjustment lever, which we will consider as zero.
d) Remove the metal plate that was installed between the adjusting lever and the heating control drive.
e) Turn the automatic heating control lever clockwise with a force of approximately 4.9 Nm and hold it in this position with a torque wrench at the specified force for 10 seconds, then release the force.
g) Measure the stroke of the injection advance plunger at a temperature of 25°C and the rotation speed of the injection pump drive shaft of 400 rpm.
Plunger stroke:
- with manual transmission - 0.74-1.14 mm
- with automatic transmission - 0.55-0.95 mm
If it is not within specification, adjust it using the adjusting screw.
19. Adjust the high idle speed.
a) Measure the clearance between the control lever and the idle speed adjusting screw.
Clearance at fuel temperature:
- 25°C — 1.4 mm
- 50°C — 0 mm
b) Adjust the clearance by turning the high idle speed adjusting screw.
20. Checking after adjustment.
a) Check that the supply stops when the fuel shut-off solenoid valve is disconnected.
- The rotation frequency of the injection pump shaft is 100 rpm
b) Check the movement of the control lever.
- The adjustment angle of the control lever position is 42-52°
c) Remove the metal plate between the lever and the heating control drive.
21. Adjust the control lever position sensor.
a) Set the control lever to the position corresponding to the fuel injection volume specified in the data.
- Fuel supply - 5.6 cm³
- Number of cycles - 200
- The rotation frequency of the injection pump drive shaft is 700 rpm
b) Loosen the two screws securing the control lever position sensor to the bracket.
c) Apply 5V voltage between terminals "VC" and "E2".
d) Connect the voltmeter to the "VTA" and "E2" terminals of the control lever position sensor.
d) Smoothly turn the control lever position sensor so that the output voltage becomes:
- Voltage - 2.74 ±0.025 V
22. Remove the fuel injection pump from the stand.
23. Install seals.
Seal the maximum speed and nominal feed adjustment screws (full load) with new wire seals.
