2) 3.) 4) Ajax Jet Cell Operation and Maintenance-ESS-L-921 Supplement Assembly Procedure ESS-L-923 and ESS-T-911 Operation and Maintenance Outline-ESS-L-922 Low Emissions Conversion Kit BrochureENGINEER TNG ~ SALES ~ SERVECE DATA AJAX-SUPERIOR ENGINES-PUMPS SPRINGFIELD, OHIO 45505 ‘COMPRESSORS: ESS-L-921 AJAX LOW EMISSIONS ENGINES AJAX JET CELL OPERATION AND MAINTENANCE ABSTRACT The jet cell concept is required for low emission or emission reduction engines. The high energy torch issuing from the pre-chamber allows the main chamber to be operated with a leaner mixture and consistantly ignited as compared to a conventional spark plug ignition of a lean misture. Also, the jet cell is applied to units to improve combustion stability and improve fuel consumption when operating at variable speeds and reduced torque. This paper describes the jet cell operation and general maintenance procedures relating to AJAX Low Emissions Two Cycle Engines. JET CELL OPERATION The jet cell or pre-combustion chamber is a unit which is installed in the cylinder head. The nozzle end is designed with a specified volume and has a communicating angled exit orifice hole. A spark plug for ignition and fuel admission check valve completes the necessary operational components. Pilot fuel headers supply fuel to each admission check valve. The supply to the header is taken prior to the governor regulated fuel valve, filtered, and the pressure regulated with an additional regulator. The ignitor fuel pressure is thus regulated manually according to site conditions. For one cycle of operation, as the piston comes up on compression, the pressure within the cylinder is lower than the pilot gas pressure and fuel is admitted into the cell. When the pressure within the cylinder becomes greater than the fuel pressure, then the pilot check valves close. The main fuel valve admits fuel into the cylinder per the designed timing. Ignition occurs within the jet cell and the rich fuel mixture ignites. The pressure rise of this energy release forces the burning mixture to exit through the nozzle orifice across the top of the piston in the main combustion chamber. igniting the main combustible charge. Updated 12/92ESS-L-921 ‘AJAX LOW EMISSIONS ENGINES IGNITION TIMING In standard spark ignited engines, the spark plugs ignite the charge and a progressive flame front occurs within the combustion chamber. Due to the tine required for this flame propagation, the ignition timing is approximately 9*-12* before top dead center. With the jet cell, a torch of fire emitting from the orificed exit hole penetrates into the fuel air mixture within the main combustion chamber. The mixture is ignited uniformly with a higher energy source which promotes faster burning. For this reason, the ignition timing is 3° before top dead center. For an engine operating at 400 rpm, this sequence of fuel admission, ignition, etc., occurs 6.6 times per second, 400 times per minute, 24,000 times per hour, 576,000 times per day (24 hrs) and 30 days of operation would equal 17,280,000. MAINTENANCE The cell, when installed into the cylinder head, has a round Armco iron gasket which acts as a fire seal; a graphoil seal employed as a bottom water seal, and an "o" ring as the top water seal. The unit is held in place with a two-bolt flange and torqued to 70 ft. Ibs. If a cell is removed from the head, it is important that the access hole for the cell is clean and free of any scale build-up. New gaskets and seals should be installed and the unit properly torqued. A locating dowel is used to assure proper orientation of the exit orifice hole of the cell in relation to the main combustion chamber. ‘SPARK PLUGS Cooling of the plug is accomplished primarily through the spark plug gasket seating surface and the threads. These areas within the cell have thin metal sections and are surrounded with engine coolant. In service, the center and ground electrodes will deteriorate which increases the spark plug gap. Erratic firing will occur once the gap increases .005" - .010" from original setting and the plugs should be replaced. Where an A-4502-M head and YK-8209-C ignitor are being used, a Champion RW77N (BM-1022-2) spark plug is used with an initial gap of 0.015" to 0.018". Where an A-4502-N head and YK-8209-C-1 ignitor are being utilized, a Champion W-18 (BH- 1022) spark plug is used with an initial gap of 0.30". The secondary ignition wiring and associated components should always be in good condition. Updated 12/92ESS-L-921 AJAX LOW EMISSIONS ENGINES FUEL ADMISSION CHECK VALVE This component is most important in the operation of the jet cell. As noted previously, the number of cyclic operations relates to the unit’s speed with fuel being admitted when the cylinder pressure is less than the pilot fuel pressure and closes as the cylinder pressure increases. It also withstands the high pressure within the cell at time of ignition. Present production valves use a ceramic ball with tool steel enclosure and seats. AJAX is continuing to improve the life and operation of the valves with on-going research and development programs. From the check valve proper, the fuel gas enters the ignitor nozzle area through drilled communication holes. Due to fuel entrapment, incomplete combustion can occur in these passages which tends to produce a soot-carbon residue. In some cases, this build-up is not detrimental to the valves’ operation and in other cases, it can be severe. If this build-up becomes heavy, erratic operation of the valves will occur and they should be removed, cleaned, and tested. Whenever the spark plugs are replaced, it would be appropriate to remove and clean the valves. Some customers have a spare set of valves which are installed at this time, and the removed set is cleaned for reinstallation at a later date. A jet cell equipped unit does require some additional maintenance procedures over the standard unit. These procedures are offset with the gains in combustion stability and improved fuel economy associated with this style of engine. Updated 12/92lof 4 ENGINEERING - SALES-~SERVICE DATA AJAX-SUPERIOR ENGINES - PUMPS SPRINGFIELD, OHIO 45505 COMPRESSORS ——— ESS-L-923 AJAX LOW EMISSIONS RETROFIT CONVERSIONS 1 AND_15" BORES SUPPLEMENT ASSEMBLY PROCEDURE The new AJAX Low Emissions Engine utilizes a squish design combustion chamber that includes an ignitor cell. The assembly procedure is basically the same as a standard engine with the following additions and changes in gas valve timing, ignition timing and piston position. 1. PISTON & HEAD INSTALLATION: A) The piston used on the low emissions unit does not incorporate notches or tapped holes in the crown for installation or removal. It is reconmended that a rod wrench (or strap wrench) be used to install or remove piston. 8) Screw piston into crosshead until approximately three (3) threads are left showing on the rod. Do not tighten rod nut at this time. C) Install cylinder head (with gasket) and torque to 600 ft. Ibs. Use D) Using solder, set piston to head striking clearance at 7680" (+ .010",- -000"). This is measured at the 6:00 position by inserting solder through gas injection hole down towards bottom of head. Roll piston forward past TOC, thus crushing solder. Using a micrometer, measure thickness of crushed solder. Refer to FIG 1. £) Once clearance is set, torque rod nut and check clearance again. Piston has a tendency to turn slightly when tightening rod nut. 2. GAS CAM TIMING Refer to ESS-T-911 as a basis for fuel injection cam timing. The following changes must be made when converting an engine to low emissons application. Updated 12/922 of 4 ESS-L-923 ‘AJAX SUPPLEMENT ASSEMBLY PROCEDURE A) The flywheel and gear shield must be removed in order to remove layshaft gear and reset cam timing. 8) Cam timing is retarded from the standard 13* ABDC beginning of injectfon to 37° ABDC. DO NOT GO BEYOND 37° ABDC! _ If gears do not line up with cams at 37°, go back towards BDC (ie: 35° ABDC). Beginning of injection is 37° ABDC for all jet cell units, but the method of setting the timing is different on the DPC-800. C) On DPC-800’s, the control box utilizes one (1) cam for two (2) cylinders. #1 and #3 cylinders run off cam closest to the power cylinders. #2 and #4 cylinders run off the other (See FIG 2). #1 power cylinder gas cam timing is referenced off the #3 bank on the control box. The crankshaft should be rotated to 26° ABDC #1 power cylinder. D0 NOT GO_ BEYOND 26° ABD‘ If gears do not line up with cams at 26", go back towards 80C 24° ABDC). The crankshaft _is positioned at 26° ABDC for setting cam timing on the DPC-800 only. The reason for this is due to the way the cam is installed on the layshaft. The result will give you a beginning of injection at 37° ABDC (See FIG 3). The cam can now be set using the method illustrated on ESS-T-911. D) Once the preceding is complete, the layshaft gear should be installed and re- indexed. IGNITION TIMING Ignition timing is changed on all low emissions engines to 3° BTDC. New mag pick-up brackets are furnished for all conversions through the DPC-600 to accommodate the timing change. On the DPC-800 where the ALTRONIC III ignition system is used, the alternator must be removed and re-indexed to 3° BTOC (refer to the standard DPC-800 Operations and Maintenance Manual for procedure) . IGNITOR ASSEMBLY INSTALLATION (Refer to FIG 4 for the following) A) Ignitor assembly is indexed with a roll pin that lines up with a slot machined in power head. This insures proper direction of ignitor. It is very important that they are lined up. Misalignment will result in severe piston crown damage. It should be noted that when ignitor is torqued into head, the Updated 12/92