Fuel Injectors - Westerbeke 8.0KW-60Hz Service Manual

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. Remove the fuel return line in its entirety from the top of
the injectors. Take care not to lose the sea1ing washers
and banjo bolt that attaches the fuel return line to each
injector.
3. Unscrew the injector from the cylinder head using a
suitable deep socket.
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 liuild up or the like, work the injector side to
side with the aid of the socket wrench to free it and then
lift it out.
4. The injector seats in the cylinder head on a copper
sealing washer. This washer should be removed with the
injector and replaced with a new washer when the
injector is reinstalled.
NOTE: Greatest possible care should be taken in handling
the nozzles as they are precisely machined. The nozzle
and the .needle valve are matched parts. Do not mix their
original combinations. Disassemble and wash each noz-
zle assembly separately.
Carbon deposits on the nozzle body must be removed
with a piece of hard wood. However, it would be advis-
able not to clean the surrounding area of the nozzle ori-
fice to avoid possible domage to the orifice.
INJECTION TESTING/ADJUSTMENT
1. Using the nozzle tester, check the spray pattern and
injection 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, destroying
tissue. If it enters the bloodstream, it may cause
blood poisoning.
~~
!
.iT
......... Y. . .... _
RECONDITION (REPLACE
V
I '
'a.
If the diesel fuel of the nozzle tester is discolored,
replace it. At the same time, clean or replace the fuel
filter.
h. Mount the nozzle and nozzle holder on the nozzle tester.
c. 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 reading the
injection starting pressure. .
INJECfOR STARTING PRESSURE 1991 '" psi (140· kgl-cm)
d. If the fuel injection starting pressure is not within the
specification, it can be adjusted by removing or adding
shims in the injector body to achieve proper pressure ..
NOTE: An increase or decrease of shim thickness by
0.004 in (O.lmm) will vary the injection
pr~ssure
by 142
. psi (10 kgf-cm). Ten shims are available in thickness
from
1.25
mm to 170 mm (0.0492 in to 0.0669 in) in
increments of 0.0020 in (0.05 min).
e. 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. .
NOZZLE BODY TORQUE 27 ±
1.8Ib-ft(3.7~
± 0.25kgl-m)
INJECTOR
TEST SPRING FOR
TENSION ANO SDII,4REnIF88
CHECK FOR WEAR.
AND DAMAGE .
TOIIQUE: 40 ± 4 lb'- II
(5.5 K 5Kg! - m)
54Nm
6
@'·...,.---INSPECTFOR WEAR
1-+'-'----
5
CHECK FOR .cAjl'BOAI _ _ +.,~
IN OR AROUND
'H(~---_J~
NOZZLE ORIFACE
~_<----TORQlIE:27
± 1.81b - H
(3.75 K 0.25Kgf - m)
37Nm
~·-+----.:1
DISASSEMBLY AND INSPECTION
1. Clamp. the nozzle holder in a vise; ·remove the nozzle nut
and disassemble the nozzle body, spring,and needle.
2. Clean the disassembled parts with clean diesel fuel.
INSTALLING
L Install in the reverse order of removal.
NOTE: The copper washers sliould not be reused. 'Replace
with
new
washers.
2. TIghten the nozzle on the cylinder head to the specified
torque. .
NOZZLE TORQUE 40 ± 4lb-ft (5.5 ± 0.5 kgl·m)
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