Westerbeke 12.0KW - 50Hz EDT Installation Manual download pdf (Page 34)

FUEL

INJECTORS

REMOVING

THE

INJECTORS

NOTE:

Injector

must

be

serviced

in

a

"clean

room"

environment.

1.

Disconnect

the

high pressure lines

from

the injectors and

loosen

the

lines at their attachment

to

the

injection pump

and

move

them

out of the

way

of

the

injectors.

Avoid

bending

the

lines.

2.

Using

a

17mm

long socket, remove

the

fuel

return line in

its

entirety

from

the

top

of the injectors.

Take

care

not

to

lose

the

two

sealing

washers

and

banjo

bolt

that attaches

the

fuel

return line

to

each

injector.

NOTE:

Clean

the

area

around

the

base

of

the

injector

prior

to

lifting

it

out

of

the

cylinder

head

to

help prevent

any

rust

or

debris

from falling

down

into

the

injector

hole.

If

the

injector will not lift out

easily

and is held

in

by

carbon

build

up

or

the

like,

work

the

injector

side

to

side

with

the

aid

of

the

17mm

deep

socket

wrench

to

free

it and

then

lift it

out.

3. The injector seats

in

the

cylinder

head

on

a copper seal-

ing

washer.

This washer should

be

removed

with

the

injector

and

replaced

with

a

new

washer

when

the

injec-

tor

is

reinstalled.

INJECTION

TESTING

1.

Using

the

nozzle

tester,

check

the

spray

pattern

and

injec-

tion

starting pressure of

nozzle

and,

if

it exceeds

the

limit,

adjust

or

replace

the

nozzle.

When

using

nozzle

tester,

take

the following precautions:

A

CAUTION:

The

spray

injected

from

the

nozzle

is

of

such

velocity

that

it

may

penetrate

deeply

into

the

skin

of

fingers

and

hands

j

destroying

tissue.

If

it

enters

the

bloodstream,

it

may

cause

blood

poisoning.

a. If

the

diesel

fuel

of

the

nozzle

tester

is

discolored,

replace

it. At the

same

time,

clean or replace

the

filter.

b. Set

the

nozzle tester

in

a clean place where there is

no

dust

or

dirt.

c. Mount the nozzle

and

nozzle holder

on

the nozzle

tester.

d.

Use

the

fuel

at the approximate temperature

of

68" F

(20"

C)

e.

Operate

the

hand

lever

of

nozzle

tester several times

to

bleed

the

air

in

the

nozzle

line,

then

move

the

hand

lever

at intervals

of

one stroke per second while read-

ing

the

injection starting pressure.

INJECTION

PRESSURE

1920

PSI

Inspecting

Spray

Pattern

1,

Operate

the

hand

lever

of

the

nozzle tester

at

intervals

of

one stroke per

second

to

check if the

fuel

is

injected

cor-

rectly

in

its

axial

direction. A nozzle

is

defective

if it

injects

fuel

in

an

oblique direction or

in

several

separate

strips. Also, a spray

in

the

form

of particles indicates a

defect These defects

may

sometimes

be

caused

by

clog-

ging with dust

and,

therefore,

all

parts should

be

carefully

cleaned before

reassembly.

(Care should

be

taken

not

to

expose ones

skin

to

this

spray

as

it may penetrate

the

skin

and cause infection.)

b;J

~\

NORMAL

11

m

lull'

m,;l

[d

~~i

fii

FAULTY

~X~

.\~

CHATTERING

TEST

2.

Apply the pressure of 1635

Ib/in

2

(115

kg/cm2)

to

nozzle

by

operating the

hand

lever,

and check the

drips

from

the

nozzle

tip.

If

it drips or

has

a large accumulation 'of

fuel

on the bottom, it

is

considered defective

and

should

be

repl!lced.

A very small amount

of

fuel

may

sometimes

remain

on

the

tip

of the

nozzle;

however,

this

does

not

indicate a defect

NORMAL

DRIP

TEST

The injection starting pressure for the injectors

is

adjusted

by

increasing or decreasing the thickness

of

the adjusting

shim.

The shim

has

10

different thicknesses for

every

0.0020

in

(0.05

rom):

between

O.0049in

(1.25mrn).to 0.0669in

(1.7mm)

With each

O.OO2Oin

(O.05mrn)

increase, injection pressure

is

increased approximately

71.1

Ib/in

2

(5.0

kg/cm!).

When

replacing the

shim,

grip

the

retaining nut

in

a

vise

and

remove the body

with

a

wrench.

TIghten

the retaining

nut

to

the specified

torque:

ADJUSTING

SHIM

I

SHIM

THICKNESS

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