1、 Collection of SANS standards in electronic format (PDF) 1. Copyright This standard is available to staff members of companies that have subscribed to the complete collection of SANS standards in accordance with a formal copyright agreement. This document may reside on a CENTRAL FILE SERVER or INTRA
2、NET SYSTEM only. Unless specific permission has been granted, this document MAY NOT be sent or given to staff members from other companies or organizations. Doing so would constitute a VIOLATION of SABS copyright rules. 2. Indemnity The South African Bureau of Standards accepts no liability for any
3、damage whatsoever than may result from the use of this material or the information contain therein, irrespective of the cause and quantum thereof. ISBN 978-0-626-22621-3 SANS 10166:2009Edition 1.2 SOUTH AFRICAN NATIONAL STANDARD The overhaul of diesel fuel injection equipment Published by SABS Stand
4、ards Division 1 Dr Lategan Road Groenkloof Private Bag X191 Pretoria 0001 Tel: +27 12 428 7911 Fax: +27 12 344 1568 www.sabs.co.za SABS SANS 10166:2009 Edition 1.2 Table of changes Change No. Date Scope Amdt 1 1991 Amended to upgrade the requirements to which diesel fuel injection equipment shall co
5、nform. Amdt 2 2009 Amended to change the designation from SABS to SANS, to move reference to South African legislation in the text to the foreword, and to change the name of the testing authority. Acknowledgement The SABS Standards Division wishes to acknowledge the valuable assistance derived from
6、publications of the International Organization for Standardization. Foreword This South African standard was approved by National Committee SABS TC 22J, Steering committee for construction of motor vehicles Automotive after market centres, in accordance with procedures of the SABS Standards Division
7、, in compliance with annex 3 of the WTO/TBT agreement. This document was published in December 2009. This document supersedes SABS 0166:1984 (edition 1). A vertical line in the margin shows where the text has been technically modified by amendment No. 2. Reference is made in 3.1 to the “relevant nat
8、ional legislation“. In South Africa this means the Skills Development Act, 1998 (Act No. 97 of 1998). Amdt 2 Reference is made in 3.1 to the “relevant national testing authority“. In South Africa this means the Institute for the National Development of Learnership Employment Skills and Labour Assess
9、ments. Amdt 2 Reference is made in 3.2.1 to the “relevant national legislation“. In South Africa this means the Occupational Health and Safety Act, 1993 (Act No. 85 of 1993). Amdt 2 SANS 10166:2009 Edition 1.2 1 Contents Page Acknowledgement Foreword 1 Scope . 3 2 Definitions. 3 3 Staff and premises
10、 3 4 Equipment 5 5 Maintenance . 7 6 Equipment operating instructions . 10 7 Fuel injection equipment overhaul procedure. 11 8 Service conformity 12 9 Methods of test . 13 10 Specific maintenance procedure for test injectors 17 10.1 Nozzle opening pressure checking and setting 17 10.2 Changing of th
11、e nozzle assembly. 17 10.3 Cleaning of the edge filter. 18 10.4 Checking of the back leakage. 18 10.5 Tester for testing of calibrating injectors. 19 Appendix A Applicable standards. 20 Appendix B Equipment data . 21 Appendix C Maintenance records. 22 SANS 10166:2009 Edition 1.2 2 This page is inten
12、tionally left blank SANS 10166:2009 Edition 1.2 3 The overhaul of diesel fuel injection equipment 1 Scope 1.1 This code of practice covers the provisions for the equipment, premises and procedures used, and for the staff engaged in the overhaul of diesel fuel injectors and diesel fuel injection equi
13、pment for engines requiring fuel delivery, at full load, of up to 300 mm3per injection per cylinder. NOTE The standards referred to in the code are listed in appendix A. 2 Definitions 2.1 For the purposes of this code the following definitions shall apply: graduate graduated measuring cylinder manuf
14、acturer unless otherwise stated, the manufacturer of the fuel pump test bench 3 Staff and premises 3.1 Staff Ensure that at least one staff member who qualifies for one or more of the following categories is available on the premises at all reasonable times: a) a journeyman who has completed an appr
15、enticeship of at least three years duration in terms of the relevant national legislation (see foreword) in the designated trade of fuel injection mechanic; Amdt 2 b) a journeyman who has completed an apprenticeship of at least three years duration in terms of the relevant national legislation (see
16、foreword) in any designated trade in the motor industry or in the iron, steel and metallurgical industries and who has received a certificate of competence from an authorized franchise holder of diesel fuel injection equipment, to the effect that he is competent to service a specific range of diesel
17、 fuel injection equipment as detailed in the certificate; Amdt 2 c) a person who, after at least five years experience in the overhaul and servicing of diesel fuel injection pumps and component parts, has passed a trade test at the relevant national testing authority (see foreword) in the trade of f
18、uel injection mechanic. Amdt 2 SANS 10166:2009 Edition 1.2 4 3.2 Workroom 3.2.1 The workroom and its equipment shall comply with the relevant regulations promulgated in terms of the relevant national legislation (see foreword) and also with the relevant requirements given in 3.2.2 to 3.2.7 (inclusiv
19、e). Amdt 2 3.2.2 Size The room where diesel fuel injection equipment overhauls are carried out must be large enough to accommodate at least one set of the equipment specified in 4.1, 4.2, 4.3 and 4.5 for at least one make and type of fuel pump. 3.2.3 Activities The room must not be used for any acti
20、vity that will produce dust, metallic particles or a corrosive atmosphere, unless such products are directly extracted from the room as they are produced or unless partitions are erected to ensure that such products cannot be transferred to the fuel injection equipment assembly area. 3.2.4 Exclusion
21、 of dust The room must be so designed or located that wind-borne dust from outside the building is prevented from entering the room. 3.2.5 Cleanliness Ensure that the room is at all times kept in a clean and tidy condition and that floors, walls, ceilings and work surfaces do not have any loose fini
22、sh that could release dust or other abrasive matter. 3.2.6 Environment a) Ventilation Ventilation must be of the forced filtered type and such as to provide clean, fresh air. Ideally the system should create a small positive pressure within the workroom. b) Lighting Augment, when necessary, any natu
23、ral light by artificial lighting to a level suitable for close work. c) Heating If heating systems are installed, they must be of a design that does not permit condensation. d) Noise Provide ear protection for staff who either work immediately adjacent to or use a fuel injection pump test bench. 3.2
24、.7 Installation Ensure that the test bench(benches) and all other workshop equipment have been installed in accordance with the instructions of the relevant manufacturer. SANS 10166:2009 Edition 1.2 5 4 Equipment 4.1 General purpose equipment 4.1.1 Cleaning equipment Provide, for cleaning purposes,
25、the following equipment that is so designed or located, as relevant, as to ensure compliance with the provisions of 3.2.2: a) enough protective clothing, appropriate to the solvent, oil or grinding process, as relevant, for the number of staff engaged in that process; b) deleted by amendment No. 1;
26、c) a supply of dry air at a pressure variable in the range 0-300 kPa and located adjacent to the pressure test tank; d) a motorized wire brush and buff; e) a cleaning tank or tanks, floor mounted and fitted with a lid or lids; and f) when required, alternative means of cleaning components, for examp
27、le, by the ultrasonic method. 4.1.2 General equipment Provide the following: a) a work bench or benches with a frontal dimension of at least 1 m and a durable oil-resistant working surface of at least 0,5 m2per user; b) separate trays or containers, each designed to hold components awaiting inspecti
28、on, cleaning or assembly; c) a receptacle containing clean calibration fluid for immersion of components that require wet assembly; d) a bench for the mounting of immovable tools; e) a cupboard or racks for ancillary test equipment and special product tools not in use; f) racks that are demarcated t
29、o hold new work, work in progress and outgoing work; g) dry compressed air at each work point; Amdt 1 h) a three-phase electrical supply, sufficient to deliver the rated input power of the fuel injection pump test bench and any other equipment in the room, and with at least one mains output for port
30、able power tools; and i) facilities for the storage of technical literature and of work records, for a period of at least two years. 4.1.3 Hand tools In the fuel pump test room provide at least one of each of the following items of equipment: a) a suitable torque wrench; Amdt 1 SANS 10166:2009 Editi
31、on 1.2 6 b) a set of steel 3 mm letter and figure punches; c) a 0-150 mm vernier calliper capable of measuring internal and external diameters and depths with an accuracy of 0,05 mm; d) an engraving tool; e) a suitable tachometer accurate to within 1 % of each reading or 10 r/min, whichever is the g
32、reater tolerance; Amdt 1 f) a stop-watch graduated in steps of 0,1 s and accurate to within 2 s in 1 h; g) sets of open-ended spanners and flare nut wrenches, covering the size ranges 0,25-0,75 in. AF and 5-22 mm; h) a set of suitable socket wrenches; i) a nipple forming tool and suitable reamers (s
33、ee 5.2.4(b); j) a delivery valve spanner/socket; Amdt 1 k) sealing pliers, locking wire and seals; and l) a set of hexagon wrench keys. NOTE A viscometer of accuracy suitable for the relevant type of calibration fluid and a thermometer with a range of 0100 C are recommended additions to the above li
34、st. 4.2 Fuel pump test bench 4.2.1 Performance and design data a) New fuel pump test benches Ensure that each new fuel injection pump test bench installed after the date of adoption of this code is supplied with the manufacturers performance and design data in accordance with ISO 4008-1. b) Existing
35、 fuel pump test benches In the case of a fuel pump test bench that was installed before the date of adoption of this code, ensure that, in the absence of the data required in terms of (a) above, corresponding data covering instructions and estimated maximum performances and prepared by the supplier
36、of the test bench, are kept in a file in the workroom. 4.2.2 Test injectors Test injectors must be of the type and have the performance detailed by the fuel injection pump manufacturer in his test schedule. Injectors and nozzles must bear the name of the manufacturer of the test injector and, where
37、applicable, comply with a relevant standard (for example ISO 4010). 4.2.3 High pressure pipes High pressure pipes must comply with the specification detailed by the fuel injection pump manufacturer in his test schedule. Pipes must be so marked as to be identifiable in relation to the type of pump. A
38、mdt 1 SANS 10166:2009 Edition 1.2 7 4.2.4 Pump mountings and other accessories These mountings and accessories must comply with the standard specified in the instructions given by the fuel injection pump manufacturer or by the test bench manufacturer, as relevant. 4.2.5 Deleted by amendment No. 1. 4
39、.2.6 Calibration fluid Ensure that the correct calibration fluid (see 4.4) is present in the test bench. 4.3 Injector test equipment 4.3.1 Injector tester Provide an injector tester (see 10.5) that is of a type a) suitable for the testing of fuel injectors fitted to engines requiring fuel delivery,
40、at full load, of up to 300 mm3per injection per cylinder, b) suitable for use with the calibration fluid given in 4.2.6. If not already incorporated, provide also a spray extraction system. 4.3.2 Needle lift gauge If needle overhauls are undertaken, a needle lift gauge is required. The gauge shall h
41、ave graduations preferably at 0,01 mm intervals, and the stroke length shall be at least 8 mm. (For imperial sizes these values are 0,000 5 in. and 0,3 in. respectively.) Amdt 1 4.4 Calibration fluid Provide only calibration fluid that complies with the specification required in the fuel injection p
42、ump manufacturers test schedules. 4.5 Special tools and equipment Provide, in the workroom, all of the special tools and equipment recommended by the manufacturer of the fuel pump test bench, or alternatively, the engine or the vehicle or the fuel injection equipment relevant to the overhaul of the
43、particular fuel injection equipment to be carried out in that workroom. 5 Maintenance 5.1 Workroom Maintain the workroom in a clean, dust-free and well-ordered condition, to minimize defects in fuel injection equipment overhaul that could arise from the presence of contaminants or the mixing of comp
44、onents. Maintain the test injector in accordance with table 1 (see also 5.2.3(b). SANS 10166:2009 Edition 1.2 8 Table 1 Test injector maintenance schedule 1 2 3 Number of pumps tested by the new test injector or after the fitting of a new nozzle assembly Action Detailed procedure, subsection After 1
45、0 Check opening pressure and reset if necessary 10.1 Every 50 Check opening pressure and reset if necessary 10.1 After 200 Clean edge filter. Check back leakage 10.3 10.4 Every 50 Check opening pressure and reset if necessary 10.1 After 400 Clean edge filter. Check back leakage 10.3 10.4 Every 50 Ch
46、eck opening pressure and reset if necessary 10.1 After 600 Fit new nozzle assembly, and clean edge filter 10.2 10.3 601 3 000 Repeat above schedule At 3 000 Fit new edge filter 10.3 3 001 6 000 Repeat above schedule At 6 000 Fit a new complete test injector 5.2 Test bench and accessories 5.2.1 Gener
47、al Maintain all equipment required in terms of this code in a clean condition, in good working order, and so as to comply with all the relevant recommendations for equipment laid down in this code. 5.2.2 Test benches a) Ensure that the test bench manufacturer has provided adequate operation, install
48、ation and maintenance instructions, including details of any special adjustments or settings which could affect fluid measurement accuracy, and follow such instructions carefully. b) When replacing critical parts, fit only spare parts that are authenticated for the particular test bench, by the test
49、 bench manufacturer. 5.2.3 Test injectors a) Keep a record of the number of pumps tested by test injectors. b) Unless otherwise stated by the manufacturer, follow, according to the specific procedures given in section 10, the test injector maintenance schedule shown in table 1. c) Every 12 months check, in accordance with 9.1, those test benches that comply with ISO 4008-1 and ensure that the percentage zero error EZdoes not exceed 0,5 % and that the count error Ectdoes not exceed 1 % of Noor 0,5 revolutions, whichever is the lesser. Repair or replace as necessary to ensure
