Yanmar Mechnical Pump

EP-1

Diesel Fuel Injection Pump

A- type Fuel Injection Pump 1. Valve holder 2. Delivery valve 3. Pump barrel 4. Pump plunger 5. Control rack 6. Control sleeve 7. Plunger return spring 8. Spring seat 9. Roller tappet 10. Camshaft

RBSI/ASA Strictly confidential | Department | 04/18/2005 | Filing note | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.

EP-1

Diesel Fuel Injection Pump

Plunger Operation 1. Pump Barrel 2. Inlet Port 3. Pump plunger 4. Helix 5. Control rack Zero Delivery

Partial Delivery

Maximum Delivery

1. Plunger Helix 2. Upper and Lower Helix 3. Starting Groove 4. Leakage return slot

RBSI/ASA Strictly confidential | Department | 04/18/2005 | Filing note | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.

EP-1

Diesel Fuel Injection Pump

Plunger Phases BDC

Prestroke

Fuel Intake

Retraction Lift

Effective Stroke

Delivery Start of Delivery End of intake

End of Delivery

Residual Stroke

Fuel Discharge

RBSI/ASA Strictly confidential | Department | 04/18/2005 | Filing note | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.

Plunger Stroke

TDC

EP-1

Diesel Fuel Injection Pump

Delivery Valve

1. Delivery valve holder

1. Valve seat

2. Delivery valve spring

2. Retraction piston

3. Delivery valve 4. Valve seat

3. Ring-shaped groove 4. Valve stem

5. Valve holder

5. Vertical slot

What is the purpose of the delivery valves ? 1. To interrupt the high pressure circuit between fuel injection lines and pump plunger 2. To relieve pressure lines and nozzle space which causes the nozzle to close rapidly thus preventing undesirable fuel dribble. What is the purpose of the retraction piston ? To separate the pipe line against element chamber, maintaining certain volume depending on the length of pipe. RBSI/ASA Strictly confidential | Department | 04/18/2005 | Filing note | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.

EP-1

Diesel Fuel Injection Pump

RDV Valve

What is the purpose of the RDV valve ? 1. Faster peak pressure and filling of high pressure pipe, opened through bore. 2. Maintains feed pressure of 3-3.5 bar in the element chamber and pipes when engine is not running. RBSI/ASA Strictly confidential | Department | 04/18/2005 | Filing note | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.

EP-1

Diesel Fuel Injection Pump

GDV – Constant Pressure Valve 1. Ball 2. Spring seat 3. Compression spring 4. Filler piece 5. Valve holder 6. Valve element 7. Valve spring

When are these constant pressure valves used ?

For high pressure fuel injection pumps which develop Pressures above 800 bar and high speed DI engines.

What are the advantages for this type of valves ? It avoids cavitation in the fuel pressure lines and Improves hydraulic stability. RBSI/ASA Strictly confidential | Department | 04/18/2005 | Filing note | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.

EP-1

Diesel Fuel Injection Pump

P Type Pump How long is the plunger stroke ? 10 mm How high is the peak injection Pressure ?

Delivery valve

Approximately 800 bars

Fuel gallery Plunger barrel

How is the injection pump lubricated ?

Control rod

From the engine lubrication system

Control sleeve Plunger return spring

How far does the control rod travel ? Approximately 21 mm

Roller tappet

Where are these pumps fitted ? Camshaft Commercial vehicles, stationary engines

Cam lobe

How is the prestroke adjusted ? Prestroke discs beneath the barrel and valve assembly

RBSI/ASA Strictly confidential | Department | 04/18/2005 | Filing note | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.

EP-1

Diesel Fuel Injection Pump

MW Type Pump Delivery valve holder Filler piece Delivery valve spring Plunger flange assy Delivery valve Inlet bore Plunger helix Upper spring seat Control sleeve Plunger Plunger return spring Lower spring seat Roller tappet

Cam lobe

RBSI/ASA Strictly confidential | Department | 04/18/2005 | Filing note | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.

EP-1

Diesel Fuel Injection Pump

A Type Pump 1.

Delivery Valve

2.

Pump barrel

8 mm

3.

Pump Plunger

How high is the peak injection pressure ? Approximately 440 bar

4.

Control rack

5.

Control sleeve

6.

Plunger return spring

How long is the plunger stroke ?

How is the injection pump lubricated ? From the engine lubrication system How far does the control rack travel ? Approximately 21 mm

7.

Adjusting screw

8.

Roller tappet

9.

Camshaft

10.

Cam lobe

Where are these pumps fitted ? Commercial vehicles and stationary engines How is the prestroke adjusted ? At the tappet screw

RBSI/ASA Strictly confidential | Department | 04/18/2005 | Filing note | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.

SHIN DAE-A ENGINEERING

SHIN DAE-A ENGINEERING

SHIN DAE-A ENGINEERING

SHIN DAE-A ENGINEERING

SHIN DAE-A ENGINEERING

SHIN DAE-A ENGINEERING

SHIN DAE-A ENGINEERING 뿑 INJECTION PUMP의 탈, 부착 뿑 집합 식 -

PUMP

** 엔진 종류에 따라 다른 유형의 장착 과정이 있다. 일반적으로 YANMAR 6RAL, NIIGATA 6L16XC등은 커플링(Coupling)타입으로서 분사시기 조정을 아주 간단하면서 쉽게 조정하게 구성되어 있음. - 기본 과정은 어느 엔진에 한하여 동일함. - ENGINE은 2CYCLE, 4CYCLE이 있는데, 보통 4CYCLE ENGINE에 INJECTION PUMP가 주로 많이 장착되어 있다. 펌프 장착에 있어 먼저 알아야 할게 분사 순서 또는 폭발 순서이다. 분사(폭발) 순서는 PUMP TEST과정에 알 수가 있다. 이는 커플링에서든, 아님 가바나 에서든 상관이 없다. (주의! 엔진에 장착 시 TEST 과정의 시작 시점을 알아야 함.) ENGINE에서는 폭발 순서인데, 예를 들어 6 기, 8기 엔진을 보면 (직렬PUMP일 때) 1 - 5 - 3 - 6 - 2 - 4 또는 1 - 4 - 2 - 6 - 3 - 5, 1 - 3 - 5 - 6 - 4 - 2, 1 - 2 - 7 - 3 - 4 - 5 - 6 - 8

또는 1 - 8 - 4 - 3 - 6 - 5 - 7 - 2 ~ .

이때 엔진에서 1번 또는 6, 8번인데 주로 앞 쪽(FLYWHEEL 반대쪽)이 1번이다 펌프장착은 엔진폭발 순서와 펌프분사 순서가 맞아야 하는데 그 기준이 1번이다 예를 들어 엔진의 앞쪽이 1번일 경우, (4CYCLE 엔진은 폭발순서의 절반을 나누면 된다 -

1 - 5 - 3 - 6 - 2 - 4 일 경우, 1, 5, 3

/ 6, 2, 4로 나누면 1번과 6번이 시작

인데, 여기서 6번 실린더(CYLINDER) 로커 암(ROCKER ARM)의 배기가 닫히고 흡기가 열리는 시점) INJECTION 펌프 1번과 맞추면 된다.(주로 펌프장착에 있어 기준은 엔진이 기준임.) 하지만 여기서도 미세 조정이 있다. 타이밍(FUEL TIMING). 어느 엔진이든 다가지고 있는데, 메인 플레이트(Main plate), 지침서, 매뉴얼에 있다. 예) YANMAR 6RAL -18° ~ 20°,

NIIGATA 6L16XC -19° ~ 21° 등.

미세 조정은 FLYWHEEL에 주로 표시되어 있는데, 상사 점(펌프에서 보면 PLUNGER가 연료를 분사하는 시점이다.) 전에 이루어진다. 미세 조정은 타이밍을 맞추고도 연소상태, 배기 온도이상 등의 문제 발생 시 조정하게 제작되어 있다.