Installation manual
ENGINE
ADJUSTMENTS
REMOVING
THE
INJECTORS
NOTE:
Injector
must
be
selViced
in
a
"clean
room"
enviromnent
C
Disconnect
the
high
pressure
lines
from
Ille
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.
Thke
care
not
to
lose
the
two
sealing
washers
and
banjo
bolt that
attaches
lbe
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 deb/is
from
falling
down
into
the
inj~ctor
hole.
If
the
injecto.r
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
wrellch
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
~tarting
pre~sure
of
nozzle
and,
if it
exceeds
the
limit,
adjust
or
replace
the
nozzle.
When
usIng
nozzle
tester,
take.
tile
following
precautions:
a.
,If
the
diesel
fuel
of
the
nozzle
tester
is
discolored,
replace
it.
At
the
same
fune,
clean
or replace
the
filter.
b.
Set
the
nozzle
tester
in
a
clean
place
where
there
is
no
dust
or
dirt.
e.
Mount
the
nozzle
and
nozzle
holder
on
the
nozzle
tester.
d.
Use·the
fueIat
the
approximate
temperature
of 68' F (20· C)
e.
Operate
the
Iland
lever
of
nozzle
tester several
funes
to
bleed
the air in.the
hOzzle
lIne,
then
move
Ille
hand
lever
at
intervals
of
one
strokC
per
second
while
read-
ing
the
injection
starting
pressure.
,
A
CAUTION:
The
spray
injected
from
the
nozzle
is
sf
such
velocity
that
it
may
penetrate
deeply
into
the
skin
of
fingers
and
hands,
destt-oying
tissue.
If
it
enters
the
bloodstream,
it
may
cause
blood
pOisoning.
FUE{
INJECTION
PRESSURE
FACTORY
SPECIFICATIONS
·13.73
-14.71MPA
,140 -150
kgf/cm'
1991
-
2134
psi
/.INOZZLE
INJECTION.
Inspecting
Spray,Pattern
1.
Operate
the
hand
lever
of
the
nozzle
tesler
at
intervals
of.
on.e
stroke
per
second
to
check
if
tlle
fuel
is
injected
Cor-
rectly
in
its
axial
directiori.
A
nozzle
is
defective
ifit
injects
fuel
in
an
oblique
direction
or
in
several
separate
strips.
Also,
a
spray
in
tile
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
tile
skin
and
cause
infection.)
..
~
..
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1J
.....
~
I~
II,
p}
FAULTY
-~I,
;FAULTY
~!l'\'
h
""'.
~I
1'1'1.
'II
CHATTERING
TEST
';0,
2.
Apply
the
pressure
of
1991
kg/em'
(140
Ib/in')
to
iJ(izzle
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
replaced.
A
very
small
amount
of
fuel
may
sometimes
remaIn
on
the
tip
of
the
nozzle;
however,
this
does
not
indicate
a
defect.
DRIP
TEST
The
injection
starting
pressure
for
the
injectors
is
adjusted
by
increasing
or
decreasing
the
thickness
of
the
adjusting
shim.
Pressure variation with
O.01mm
(O.004In)
difference of
adjustIng
",asher thickness.
235
kPa
(2.4
kgflcm', 4 psi) .
ADJUSTING
!
SHIM
THICKNESS
~
. i
TYPICAL
INJECTOR
VALVE
TIGHTNESS
1.
Set
the
injector
nozzle'to a
nozzle
tester.
2.
Raise
the
fuel
pressure
and
keep
it
at
12.75
MPa
(130kgf/cm',
1849
psi)
for
10
seconds.
3.
If
a
fuel
leak is
found,
replace
.the
nozzle
piece
.
.
"·FACTORY
SPECIFICATIONS
'""'" WESTERBEKE
ND
fuel
leak
at:
12:75MPA
.
130
kgf/cm"
.1849
psi
. _ .E'lglnes
Qt
__
QEmerator~
23