HYUNDAI AERO TOWN D6DA 2010 hệ THỐNG NHIÊN LIỆU KIM PHUN NHIÊN LIỆU disassembly

Check out the nozzle operation pressure and then adjust it.1 Set assembled nozzle holder on the nozzle tester, and operate the lever 50 to 60... Attach nozzle holder to nozzle tester, an

1

Clean the surroundings of nozzle and fuel line connector.

Letting the alien substance into combustion chamber may bring problems to the engine

2

Take fuel-spraying pipe out.

Cover the ends of pipe and fuel-spraying pump, to prevent alien material from penetrating in

3

Remove nozzle holder.

After removing the nozzle holder, cover it with cloth Also, cover the cylinder head

to prevent dust from going through the head

4

Check out the nozzle operation pressure and then adjust it.(1 Set assembled nozzle holder on the nozzle tester, and operate the lever 50 to 60

) times per minute.

• Diesel oil is flammable Adjusting the nozzle must be done in a

well-ventilated place without any source of flame and electric spark

• Pay special attention to keep the fuel spray off the eyes or skin

(2

) At the same time, see if the nozzle pressure is in the prescribed range If not, adjustthe pressure to prescribed figure, using adjusting screw

Replace gasket with a new one

Altered Pressure

Engine

D6DA 1st opening Pressure (nominal) 160 kgf.cm²

1st Regulated Pressure 165~173 kgf.cm² 2nd opening Pressure (nominal) 220 kgf.cm² 2nd Regulated Pressure 235~245 kgf.cm²

(nozzle cover typestroke 0.11mm) (2nd Opening Pressure : 225~235kgf.cm²) Test of Injection Form:

In case of a new nozzle, operate the lever at the rate of 30~60 strokes a minute And in case of a used nozzle, operate the lever 15~60 strokes a minute

5

Test of oil leakageWhen checking the oil leaks from the nozzle, apply the pressure which is

0.98~1.96MPa(10~20kgf/cm²) lower than the nozzle controlling pressure(N.C.P)

Inspection

Examining the Finished Device

1

Attach nozzle holder to nozzle tester, and check the 1st altered pressure, injection, sealing around sheet, and oil leakage from each part

2 When the nozzle needs to be replaced, use "nozzle service kit," which has the

assembly of nozzle, lift piece and spacer.

If only the nozzle is replaced, free lift will range beyond the specification

Torque-nozzle

Adjustment of KBL2.3-S type 2nd spring nozzle holder

In the event of adjusting, follow the procedures below, assembling parts Also, as this 2nd spring nozzle holder is adjusted in 1/100mm, the foreign matters like dust must be

thoroughly cleared, using clean oil (e.g diesel fuel, etc.) The number in the ( ) following the nomenclature of each part signifies the number in the pictures of KK 200 001 series Operation Procedures

Adjustment of 1st opening pressure

1

Attach the plate of the plate assembly on vice.

Plate assembly is used to fix nozzle holder with flange Set directly on vice the nozzle holder without flange

2

Fix 2 pins on plate with nuts.

Put the nozzle holder body(1) on plate, with the cap nut downward.

4

Assemble adjusting seam(10) and 2nd spring sheet(12) (in this order) into the nozzle holder body

2nd spring is the same one as 1st spring

5

Put together pin(14), lift piece(13) and spacer(15) into the nozzle holder.

Assemble pin(16) and nozzle(A) into spacer.

7

After capping gasket on the head of nozzle, fit the nozzle in nozzle holder body with retaining nut for adjustment

1 Tighten retaining nut after seeing if lock pin falls fully into the nozzle

2 After tightening the retaining nut using fingers, tighten it again with torque wrench to the specified torque level

8

You need to follow the specified torque when tightening the retaining nut for adjustment

Specified torque: 59~78N·m(6.0~8.0kgf·m)

9

Attach the nozzle holder on the plate, with cap nut upward.

10

Insert push road(2), 1st spring(3) and adjusting screw(4) (in this order) into the nozzle holder 11

Attach gasket(6) and cap nut(7) to adjusting screw(4).

12

Attach nozzle and nozzle holder to nozzle tester.

Adjust the assembly with adjusting screw(4) until 1st opening pressure reaches the specified level

14

Fix the nozzle holder body with spanner, and tighten cap nut(SW19mm) to the level of specified torque Torque for tightening cap nut: 29~39N·m(3.0~4.0kg·m)

Checking the maximum lift of needle valve

1

Attach gasket and plug to the retaining nut for adjustment.

Attach nozzle holder on plate, with cap nut upward.

3

Attach the holder(SW12mm) to cap nut.

4

Fit a nut(17mm) in the holder.

5

Insert pin haul into the dial gauge.

Below is the length excluding the screw part

6

Insert dial gauge into nozzle holder assembly with the pin contacting the top of push road(2), and fix it with a nut

1 Fix the dial gauge within the range of 2mm

2 If the nut is tightened too hard, shift of the dial gauge may get stuck

7

Attach the nozzle and nozzle holder assembly to nozzle tester, and set the gauge to "0" 8

Check fuel leakage, turning the nozzle tester on and bleeding air inside of the retainingnut

When the pipe pressure is lifted up to 34.3~44.1MPa (350~450kgf/cm²) after the operation of the nozzle tester, needle valve will reach the maximum Maximum lift records "L" at this time

This test is conducted in order to determine whether the nozzle sheet is irregularly frayed and/or whether nozzle assembly is the specified part

Checking pre-lift

1

Keep the handle of nozzle tester still with the needle valve lifted to the max, and the pressure inside the cylinder will be lowered and the lift of the needle valve (numerical indication of the dial gauge) will also be lowered

By reading the numerical indication after the operation of the 2nd spring and of the needle valve is finished (the point of needle valve lift in the pictures KK200 022 and

KK 200 023), you can see if the indication stays within the specified range

Gauging point of pre-lift

Read the indicator of the dial gauge as when 1st opening pressure +1MPa is applied Find the point of 1st opening pressure+1MPa(10kg/cm²), lowering pressure

3

In case that pre-lift stays beyond the specified range, replace pin(14,16) lift piece(13), spacer(15) and nozzle assembly(A) with nozzle service kit

Checking the 2nd opening pressure

1

Check the pre-lift and get the nozzle tester to function After that, increase the chamberpressure up to 34.2~44.1MPa (350~450kgf/cm²), which will cause needle valve to be lifted to the maximum point

2

At the time the pipe pressure goes down by leaving the handle as it moves, check the movement of the dial gauge pointer

3

Reading needle valve lift and checking 2nd opening pressure.Read the indication of the pressure gauge at the moment dial gauge pointer indicates the specified lift (usually, pre-lift "i"+0.05mm) Read needle valve lift and check out the 2nd opening pressure

Adjustment of 2nd opening pressure

1

When the indication goes beyond the specified range, and it makes little difference, re-adjust the 1st opening pressure (within the specified range of 1st opening pressure)

A In case of low 2nd opening pressure below the specification: Elevate the 1st

opening pressure over the specification and check the 2nd opening pressure

B In case of higher 2nd opening pressure: Decrease 1st opening pressure below the specification

2

In case that the 2nd opening pressure does not fit within the specified range despite there-adjustment of the 1st opening pressure, disassemble the nozzle from the nozzle holder and take out the adjusting seam(10)

In case that 2nd opening pressure goes over the specification, replace the adjusting seam with the thinner one 4

After replacing the adjusting seam, check again the 2nd opening pressure and adjust the indication until it meets the specification

Replacement

1

Pull out dial gauge, nut, holder, and gasket from the cap nut(7).

2

Disassemble retaining nut for adjustment and gasket, and put the approved retaining nut(17:SW19mm) in Torque for retaining nuts : 59~78N·m(6.0~8.0kgf·m)

Installation

Install the assembled nozzle holder

Screw the right nozzle holder bolt and left one in turn, and evenly screw the bolt until

it reaches the specified torque.

Torque : 150~180 kgf.cm²

If one bolt is already screwed until the specification, actual torque will be excessive upon screwing the other one and also it might cause damage to nozzle holder or bolt

On the other hand, if bolts are not completely tightened, it will cause gas leaks and soot in the nozzle