A) Type and adjustment of bench nozzles.
- Type of control nozzles of the fuel stand - DN12SD12 (NIPPONDENSO)
- The pressure of the beginning of the lifting of the nozzle needle - 145-155 bar
b) Check the stand tachometer error.
- Maximum permissible error -±40 rpm
V) Install the injection timing sensor.
G) Mount the injection pump on the stand.
Note: Mark the coupler against the pump shaft key.
d) Install high pressure fuel lines with the following specifications:
- 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 nipple bolt of the fuel supply pipe.
and) After unscrewing the two bolts, remove the right cover of the injection advance machine.
h) Install a pressure gauge that measures the internal pressure in the injection pump housing and a device for measuring the plunger stroke.
- Tightening torque - 8 Nm
Note: bleed air using the air bleed screw.
And) Connect the wire to the supply cutoff solenoid valve terminal and apply 12V.
Note:
- - The battery should be located as far as possible from the injection pump to avoid "overshoots" sparks.
- - Connect the wire to the solenoid valve terminal first.
To) The pressure in the fuel supply pipe must 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 injection pump control lever.
n) Lock the top of the control lever to the maximum feed position.
O) Check cam washer installation.
(1) Disconnect the high pressure fuel pipe from the injection fitting marked "WITH", applied on the distribution head of the injection pump.
(2) Using a special tool, unscrew the case (union) discharge valve.
(3) Check that fuel flows out of the distributor head opening at the position of the mark on the adapter, in accordance with the figure.
(4) If fuel does not come out, disassemble the relevant parts and turn the cam 180°.
Note: Disconnect the fuel cut solenoid valve terminal when performing this operation.
(5) Using a special tool, screw the case (union) discharge valve.
- Tightening torque - 59 Nm
(6) Install the high pressure fuel lines.
- Tightening torque - 22 Nm
P) Bleed the air from the high pressure fuel pipes.
R) Let the injection pump run for 5 minutes at 2000 rpm.
Note: Check for fuel leaks and strange noises.
Table 1
table 2
Table 3
Note:
- - Determine the volume of fuel in volumetric flasks (beakers).
- - Before the next measurement, drain the fuel from the beaker for at least 30 seconds.
2. Preliminary adjustment of nominal fuel supply.
A) Set the top of the injection pump control lever to the maximum feed position.
b) Measure the amount of fuel supply. (see table 1).
V) If there is an O-ring seal, while holding the rated feed adjusting screw, release the sealing collar from the weld by turning the lock nut counterclockwise 90°or more.
Use a screwdriver to remove the sealing collar.
G) If there is a wire seal, cut the wire.
d) Adjust the fuel supply by turning the fuel supply adjustment screw.
Note: Turning the nominal flow adjusting screw ½ turn changes the fuel supply by approximately 3 cm3.
3. Preliminary adjustment of the position of the regulator shaft.
Using a special tool and an Allen key, adjust the protrusion of the governor shaft.
- Shaft protrusion - 0.5-2.0 mm
4. Preliminary adjustment of the maximum speed.
A) Set the injection pump control lever to the maximum feed position.
b) Measure the amount of fuel supply (see table 2).
V) Remove the seal from the maximum speed screw.
G) Adjust the feed rate with the maximum speed adjusting screw.
Adjust the fuel pressure inside the injection pump housing.
A) Set the injection pump control lever to the maximum feed position.
b) Measure the fuel pressure inside the injection pump housing at the speeds indicated in table 3.
V) If the pressure is less than the specified values, then adjust it with a metal rod with light blows on the stop of the pressure reducing valve spring, while simultaneously observing the readings of the pressure gauge measuring the pressure inside the injection pump housing.
If the pressure exceeds the specified values or if the pressure reducing valve is ignited, then it must be replaced.
6. Check fuel volume.
a) Set the injection pump control lever to the maximum feed position.
b) Measure the volume of fuel supplied through the fuel return hose from the injection pump housing at the indicated speeds.
- High-pressure fuel pump drive shaft speed - 2100 rpm
- The amount of fuel removed - 167-364 cm33
Note: Always install the fuel return pipe bolt that was installed with the injection pump.
7. For the following adjustments, turn off the engine warm-up control.
A) Turn the heat control lever 20°counterclockwise.
6) Place a 8.5-10 mm metal plate between the lever and the heat control actuator.
Note: Keep the overspeed warm-up system disabled until all measurements and adjustments have been made.
8. Measure and adjust the injection advance plunger stroke.
A) Set the plunger stroke scale to zero.
b) Measure the injection advance plunger stroke at the given speeds.
Table 4
V) Use a 5mm Allen key to adjust the advance plunger stroke.
Note: Plunger travel 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) plus 13-23°, (B - minimum idle) minus 24-34°.
b) Measure cyclic flow at full load (see above table 1).
V) Adjust the fuel supply at full load with the rated supply adjusting screw.
Note: The feed amount changes by approx. 3 cm3 for every half turn of the screw.
10. Adjustment at maximum speed.
A) Measure the volume of injected fuel at maximum speeds.
Table 5
- Number of cycles - 200
- Angle of rotation of the injection pump control lever - plus 13-23°
V) Adjust the amount of injected fuel with the maximum speed adjusting screw.
11. Check the volume of injected fuel.
A) Measure the volume of injected fuel at the speed indicated in table 6.
- Number of cycles - 200
- Angle of rotation of the injection pump control lever - plus 13-23°
b) If the starting feed value (at 100 rpm) does not correspond to the table value, then replace the plug of the regulator sleeve: press the plug out of the regulator sleeve.
V) Remove the parts shown in the figure.
1 - retaining ring,
2 - thrust ring,
3 - thrust bearing,
4 - cork.
G) Measure the thickness of the bushing plug head, select a new bushing plug.
Note: lengthening the plug by 0.1 mm increases the starting feed by 0.6 cm3/200 cycles. If the supply unevenness exceeds the specified value, then replace the discharge valve.
Stoppers are available with different head thicknesses from 2.2 to 3.4 mm (in steps of 0.1 mm).
d) Assemble the regulator bushing in the reverse order of disassembly, press the plug into the bushing.
12. Adjust the position of the governor shaft according to the load.
A) Adjustment is carried out by turning the shaft of the regulator sleeve. Adjust the start and end points of the speed control clutch travel.
b) Set the injection pump control lever to the maximum feed position.
Table 6
Table 7
Note: where A is the value measured in subparagraph, d) paragraph 15.
Table 8
Table 9
V) Measure the fuel supply.
- Number of cycles - 200
- Speed - 1500 rpm
d) Slowly move the lever towards the minimum idle stop and secure the lever at the point where the pressure in the pump housing begins to drop.
e) Measure the flow at the point where the pressure drop begins. Calculate the difference in feeds and compare with the data.
- Speed - 1500 rpm
- Feed difference - 1.0±0.3 cm3
- Number of cycles - 200
and) Adjust the feed difference by turning the governor shaft.
Note: Half a turn of the governor shaft changes the feed rate by 3 cm.
h) Slowly move the lever towards the minimum idle stop and secure the lever at the point where pressure in the pump housing stops dropping.
Compare the amount of fuel supply with the data in table 7.
And) Check the difference in the stroke of the plunger of the injection advance machine according to the load when the injection pump control lever is moved from the position of the maximum speed to the position of idling (see table 8.)
To) Measure the protrusion of the governor shaft.
- Shaft protrusion - 0.5-2.0 mm
16. Idling feed adjustment.
A) Measure the flow rate at different speeds of the injection pump drive shaft (see table 9).
- Angle of rotation of the injection pump control lever - minus 24-34°
- Number of cycles - 200
- Permissible unevenness - 0.34 cm
b) Adjust the injection fuel supply at the minimum idle speed mode with the adjusting screw of the minimum idle speed.
17. Adjust the heating control system.
A) Remove the fuel return pipe mounting bolt and measure the fuel temperature inside the injection pump housing.
- Fuel temperature - 15-35°С
b) Install the injection pump drive shaft so that the segment key is in a vertical or horizontal position.
V) Set the scale of the injection advance plunger stroke gauge to zero.
G) Check the initial angle by adjusting the injection pump heating control lever, which we will consider as zero.
d) Remove the metal plate that was installed between the adjusting lever and the heat control actuator.
e) Turn the automatic control lever of the warm-up control clockwise with a force of approximately 4.9 Nm and hold it in this position with a torque wrench at the specified gain for 10 seconds, then remove the force.
and) Measure the advance-injection plunger stroke at a temperature of 25°C and the high-pressure fuel pump drive shaft speed of 400 rpm.
Plunger stroke:
- with manual transmission - 0.74-1.14 mm
- with automatic transmission - 0.55-0.95 mm
If it is out of specification, adjust it with 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 adjusting screw.
20. Check after adjustment.
A) Check that the flow stops when the fuel cut off solenoid valve is disconnected.
- High-pressure fuel pump shaft speed - 100 rpm
b) Check the movement of the control lever.
- Adjustment angle of the position of the control lever - 42-52°
V) Remove the metal plate between the lever and the heat control actuator.
21. Adjust the control lever position sensor.
A) Set the control lever to the position corresponding to the amount of fuel injected in the data.
- Fuel delivery - 5.6 cm3
- Number of cycles - 200
- High-pressure fuel pump drive shaft speed - 700 rpm
b) Loosen the two screws securing the control lever position sensor to the bracket.
V) Apply 5V between pins "VC" And "E2".
G) Connect a voltmeter to the terminals "VTA" And "E2" control lever position sensor.
d) Slowly turn the control lever position sensor until the output voltage becomes:
- Voltage - 2.74±0.025 V
22. Remove the injection pump from the stand.
23. Install seals.
Seal the adjusting screws for maximum speed and nominal feed (full load) new wire seals.