Fuel Injectors; Injector Testing; Spray Pattern - Westerbeke 8.0KW - 60Hz EDT Operator's 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.
Using a 17mm long socket, remove the fuel retum 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 J7mm 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 ppnetrate 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 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.)
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CHATTERING TEST
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2. Apply the pressure of 1635 lb/in' (115 kg/em') 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~ced. A very small amount of fuel may sometimes
remain on the tip of the nozzle; however, this does not
indicate a defect.
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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 (1.7mm)
With each 0.0020in (0.05mm) increase, injection pressure is
increased approximately 71.1lb/in' (5.0 kg/em'). When
replacing the shim, grip the retaining nut in a vise and
remove the body with a wrench. Tighten the retruning nut to
the specified torque:
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SHIM THICKNESS
~
ADJUSTING
SHIM
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WESTERBEKE
Engines &
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