Fuel Injectors; Injection Testing - Westerbeke 22.0 EDE 60Hz Operator's Manual

FUEL INJECTORS
REMOVING THE INJECTORS
NOTE:
h'ljector must be serviced
in
a "clean room" enviro1mzent.
1. Disconnect 1he high pressure lines from the injectors and
loosen the lines at their attachment to the injection pump
and move 1hem out of the way of the injectors. Avoid
bending 1he lines.
2. Using a 17mm long socket, remove the fuel return line in
its entirety from 1he top of the injectors. Take care not to
Jose 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 1he 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 pf]netrate deeply into the
skin of fingers and hands; 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 tl1e hand
lever at intervals of one stroke per second while read-
ing the injection starting pressw-e.
INJECTOR
START TO INJECTION PRESSURE
1
1991 - 2134 psi (13.73 -14.71 MPa)
INJECTION
PRESSURE TEST . ·
Inspecting Spray Pattern
1. Operate 1he hand lever of the nozzle tester at intervals of
one stroke per second to check if the. fuel
i~
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 1he form of particles indicates
a
defect. These defects may sometimes be caused by clog-
ging with dust and, therefore, ali 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.)
bl
l.
~~~
1 ,
1
,t
1 NORMAL
f/j
FAULTY
illi\1
~~~
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CHATTERING TEST
2.
Apply 1he pressure of 1635 lb/in
2
(115 kg/cm
2 )
to nozzle
by operating the hand lever, and check the drips from the
nozzle tip. Hit drips or has a large accumulation ·of fuel
on the bottom, it is considered defective and should be
repl!J.ced. A very small amount of fuel may sometimes
remain on the tip of the nozzle; however, this does not
indicate a defect.
DEl
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 mm): between 0.0049in (1.25mm).to 0.0669in (l.7mm)
With each 0.0020in (0.05mm) increase, injection pressure is
increased approximately 71.1lb/in
2
(5.0 kg/cm
2 ).
When
replacing the shim, grip the retaining nut in a vise and
remove tl1e body with a wrench. Tighten the retaining nut to
tl1e specified torque;
INJECTOR TO CYliNDER HEAD TIGHTENING TORQUE
36.2- 50.6 (49- 68.6 Nm)
TYPICAL INJECTOR •
ADJUSTING
SHIM
!
SHIM THICKNESS
PRESSURE VARIATION
WITH 0.01 mm (0.004 in)
ADJUSTING WASHER IS
34 PSI (235 KPa)
Engines
&
Generators
28