Video Tutorials
Video Tutorials:
These videos are in QuickTime format. You can download QuickTime for free from the Apple site if you don't already have it installed on your computer. The movies have been highly compressed to cut down on file size and download time. You may decide to double the screen size during playback to help make things a bit easier to see. Sound quality varies in each video depending on how many machines were running in the background during filming.
Demo 1
"Kugelfischer Injection Pump"
Gus demonstrates the interaction between throttle position and RPM on the three- dimensional control cam (also known as the "irregular cone" in the shop manual).
Throttle position causes the cam to move forward and back along its shaft. The taper of the cam, while moving, causes the stroke plate to ride up or down. This motion of the plate effects the stroke of the 4 individual plungers (you can see them clearly moving up and down in the video). As the cam moves back (throttle on) the stroke becomes deeper and more fuel is delivered. As the cam moves forward (throttle off) the stroke decreases, and less fuel is delivered.
Changes in rpm cause the 3D cam to rotate on its axis (laterally/side to side). The surface of the cam has an irregular surface, also called the fuel-map, while moving in this direction. This irregular surface also causes the stroke plate to move either up or down. The height of the stroke plate has the same effect on fuel delivery as above.
Demo 2
"Flow Bench"
Once the pump has been rebuilt, it is mounted and tested on a flow bench. The flow bench measures fuel delivery for each of the individual cylinders in the pump (a special test oil is used, not gasoline). The factory provides three test specifications that the pump must meet at: 500, 1400, and 2800 rpm. It's worth mentioning here that the pump turns at half the speed of the engine (500 rpm of the pump = 1000 rpm of the motor). There is an adjustable screw on the pump that enables you to increases or decreases the amount of fuel over the entire rpm range.
The first test is at 500 rpm, which is also idle speed of the motor (1000 rpm). Gus inserts the test-pin in the "idle position" of the throttle lever. He then increases the speed of the flow bench up to500 rpm and allows the pump to run for a specified amount of pump strokes (in this case 1000). The monitor then displays the fuel flow of each of the cylinders in real time. You can see the specification range depicted as a set of broken horizontal lines across the screen. You are able to measure the volume at different load conditions and different rpm's‹ checking that they are within specification between each cylinder and making adjustments accordingly.
The next setting to check during each test is found at the rear of the pump. In the video you can see a set of gears that rotate as the rpm's increase (which in turn effects how much the 3D cam rotates laterally on its axis). The inner most reduction gear has three markings on its face (yellow paint was added to the marks in the video to try and make it a bit more clearer. Look close and you'll see them). Once the pump reaches its intended speed the gears comes to a resting position. The 500-rpm marking on the inner gear must align with the fixed marking on the body of the pump. If it doesn't align, then it is adjusted.
The next two rpm-tests are carried out in the same fashion. There are two other slots in the throttle arm that the test-pin is inserted into: "Mid throttle" position which corresponds to the 1400 RPM test, and "full throttle" corresponding to the 2800 RPM test. The amount of fuel delivery for each cylinder must meet specifications, and the markings on the gears must align accordingly also.
Demo 3
"Test Results"
Gus goes over the test results from the flow bench printout. This may or may not be of interest to you, however I feel it does help to illustrate the test procedures and what they mean.
Demo 4
"Injector Testing"
Gus tests the condition of the injectors to make sure they are performing well enough to re-use. No point in getting your pump rebuilt and then using defective injectors!
Injectors are individually threaded onto the testing machine. Three tests are then carried out for each injector: visual check of spray pattern, opening pressure and leakage test.
A good spray pattern means you have good atomization: a fine mist of fuel, not a stream of fuel. The better the atomization the better the combustion in your engine. The video shows examples of both "good" and "bad" atomization.
Test two is opening pressure of the injectors. New injectors pop a bit higher, but Gus considers an opening pressure of at least 20 bars as acceptable and 25 - 30 bars as performing well. You can see this reading on the left-hand gage in the video.
Test three is to watch for any leakage of the injectors. The injector is left to rest while under full pressure. If the injector starts to lose pressure, visible on the pressure gage, then there is a problem.
Demo 5
"Kugelfischer Pieces"
This is for all you kids that like to take things apart and see what makes 'em tick! This is a quick video showing all of the pieces inside the Kugelfischer pump and the empty pump housing.
Demo 6
"The Rebuilt Pump"
Gus puts the final touches on this rebuilt pump, and then hands it over for its own photo shoot. Truly a thing of beauty!
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