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Diagnosis and repair



Where ideal conditions of good combustion, specified engine temperature control, and absolutely clean fuel prevail, nozzles require little attention. Nozzle trouble is usually indicated by one or more of the following symptoms:

^Smoke exhaust (black).
^Loss of power.
^Misfiring.
^Increase in fuel consumption.
^Combustion knock.
^Engine Overheating.

When faulty nozzle operation is suspected on an engine that is misfiring or puffing black smoke, a simple test can be made to determine which cylinder(s) is causing the problem.

^Run the engine at the rpm which makes the problem most pronounced.
^Momentarily loosen the high-pressure fuel inlet line connection on one nozzle assembly one-half to one turn. Then, tighten connection to 30 Nm (22 ft lb).
^Check each cylinder in the same manner.
^If one nozzle is found where loosening makes no difference in the misfiring, or the puffing black smoke stops, that nozzle should be tested. Test only the suspect nozzle(s).

Remove suspected nozzles from the engine and perform the injection nozzle test. This test will provide valuable information regarding the condition of the nozzle(s). A clean workbench, clean washing fluid containers, clean tools, and clean hands are all essential to produce satisfactory results.

{tag}582038450@

NOTE: It is advisable to test the nozzles before cleaning them. Perform this check only if engine has an obvious combustion knock or miss.

1.Prepare stand for making tests. Fill stand reservoir with clean calibration fluid. Open tester valve slightly and operate tester handle to expel air from tester and outlet pipe. Operate tester until solid fluid (without air bubbles) flows from end of outlet pipe. Close tester valve.
2.Connect injection nozzle to test stand. Care should be taken to avoid cross-threading. Tighten connector nut securely with end wrench. Nozzle adapter which is supplied with injection nozzle tester has RH thread to nozzle assembly and LH thread to tester piping.
3.Bleed air from nozzle. Open stand valve and operate tester for 8 to 10 quick strokes to expel (bleed) air from injection nozzle. Fluid should discharge from the spray hole in nozzle tip.

WARNING:
- When a nozzle is being tested or is in operation, keep hands and other parts of the body away from the nozzle. The liquid discharge leaves the nozzle tip with sufficient force to penetrate the skin and cause serious injury. The nozzle tip should be enclosed in a transparent receptacle if available.
- Always wear approved safety glasses when operating the tester. Volatile liquids can be extremely flammable when vaporized. Eliminate any ignition sources (Sparks, flames, cigarettes, etc.) when testing injection nozzles, and always have an approved fire extinguisher near-by. Only use testing fluid meeting SAE calibration no. 208629, or equivalent.

{tag}582040964@

4.Check nozzle opening pressure, close pump valve, and operate pump handle in slow even strokes to bring system up to pressure. Record highest pressure reached before nozzle opens. Repeat operation, increasing speed if necessary to establish consistant readings.

NOTE: Disregard tip leakage during the test. Spray pattern testing is not required.

{tag}582042431@

5.Check for tip leakage. Blow nozzle tip dry using filtered compressed air. Operate test pump to maintain pressure at about 1378 kPa (200 psi) below the opening pressure obtained in previous test. Wetting of the nozzle tip is acceptable as long as a drop does not fall within five seconds.

NOTE:Make sure that any accumulation at the nozzle tip is not due to test fluid leaking down the outside of the nozzle body from the return openings. If questionable, wrap a shop cloth around the nozzle body to prevent fluid leaking down the outside of the nozzle body from reaching the tip.

6.After testing is completed, make sure to open the pump valve to release the built up pressure prior to removing the nozzle from the tester. When nozzle is removed, cap the nozzle tip and inlet until installed back in engine.

NOTE: If nozzle passes the nozzle opening pressure and tip leakage tests, it is suitable for further service in the engine.


Where ideal conditions of good combustion, specified engine temperature control, and absolutely clean fuel prevail, nozzles require little attention. Nozzle trouble is usually indicated by one or more of the following symptoms:

^Smoke exhaust (black).
^Loss of power.
^Misfiring.
^Increase in fuel consumption.
^Combustion knock.
^Engine Overheating.

When faulty nozzle operation is suspected on an engine that is misfiring or puffing black smoke, a simple test can be made to determine which cylinder(s) is causing the problem.

^Run the engine at the rpm which makes the problem most pronounced.
^Momentarily loosen the high-pressure fuel inlet line connection on one nozzle assembly one-half to one turn. Then, tighten connection to 30 Nm (22 ft lb).
^Check each cylinder in the same manner.
^If one nozzle is found where loosening makes no difference in the misfiring, or the puffing black smoke stops, that nozzle should be tested. Test only the suspect nozzle(s).

Remove suspected nozzles from the engine and perform the injection nozzle test. This test will provide valuable information regarding the condition of the nozzle(s). A clean workbench, clean washing fluid containers, clean tools, and clean hands are all essential to produce satisfactory results.

Injection Nozzle TesterInjection Nozzle Tester


NOTE: It is advisable to test the nozzles before cleaning them. Perform this check only if engine has an obvious combustion knock or miss.

1.Prepare stand for making tests. Fill stand reservoir with clean calibration fluid. Open tester valve slightly and operate tester handle to expel air from tester and outlet pipe. Operate tester until solid fluid (without air bubbles) flows from end of outlet pipe. Close tester valve.
2.Connect injection nozzle to test stand. Care should be taken to avoid cross-threading. Tighten connector nut securely with end wrench. Nozzle adapter which is supplied with injection nozzle tester has RH thread to nozzle assembly and LH thread to tester piping.
3.Bleed air from nozzle. Open stand valve and operate tester for 8 to 10 quick strokes to expel (bleed) air from injection nozzle. Fluid should discharge from the spray hole in nozzle tip.

WARNING:
- When a nozzle is being tested or is in operation, keep hands and other parts of the body away from the nozzle. The liquid discharge leaves the nozzle tip with sufficient force to penetrate the skin and cause serious injury. The nozzle tip should be enclosed in a transparent receptacle if available.
- Always wear approved safety glasses when operating the tester. Volatile liquids can be extremely flammable when vaporized. Eliminate any ignition sources (Sparks, flames, cigarettes, etc.) when testing injection nozzles, and always have an approved fire extinguisher near-by. Only use testing fluid meeting SAE calibration no. 208629, or equivalent.

{tag}582040964@

4.Check nozzle opening pressure, close pump valve, and operate pump handle in slow even strokes to bring system up to pressure. Record highest pressure reached before nozzle opens. Repeat operation, increasing speed if necessary to establish consistant readings.

NOTE: Disregard tip leakage during the test. Spray pattern testing is not required.

{tag}582042431@

5.Check for tip leakage. Blow nozzle tip dry using filtered compressed air. Operate test pump to maintain pressure at about 1378 kPa (200 psi) below the opening pressure obtained in previous test. Wetting of the nozzle tip is acceptable as long as a drop does not fall within five seconds.

NOTE:Make sure that any accumulation at the nozzle tip is not due to test fluid leaking down the outside of the nozzle body from the return openings. If questionable, wrap a shop cloth around the nozzle body to prevent fluid leaking down the outside of the nozzle body from reaching the tip.

6.After testing is completed, make sure to open the pump valve to release the built up pressure prior to removing the nozzle from the tester. When nozzle is removed, cap the nozzle tip and inlet until installed back in engine.

NOTE: If nozzle passes the nozzle opening pressure and tip leakage tests, it is suitable for further service in the engine.


Where ideal conditions of good combustion, specified engine temperature control, and absolutely clean fuel prevail, nozzles require little attention. Nozzle trouble is usually indicated by one or more of the following symptoms:

^Smoke exhaust (black).
^Loss of power.
^Misfiring.
^Increase in fuel consumption.
^Combustion knock.
^Engine Overheating.

When faulty nozzle operation is suspected on an engine that is misfiring or puffing black smoke, a simple test can be made to determine which cylinder(s) is causing the problem.

^Run the engine at the rpm which makes the problem most pronounced.
^Momentarily loosen the high-pressure fuel inlet line connection on one nozzle assembly one-half to one turn. Then, tighten connection to 30 Nm (22 ft lb).
^Check each cylinder in the same manner.
^If one nozzle is found where loosening makes no difference in the misfiring, or the puffing black smoke stops, that nozzle should be tested. Test only the suspect nozzle(s).

Remove suspected nozzles from the engine and perform the injection nozzle test. This test will provide valuable information regarding the condition of the nozzle(s). A clean workbench, clean washing fluid containers, clean tools, and clean hands are all essential to produce satisfactory results.

{tag}582038450@

NOTE: It is advisable to test the nozzles before cleaning them. Perform this check only if engine has an obvious combustion knock or miss.

1.Prepare stand for making tests. Fill stand reservoir with clean calibration fluid. Open tester valve slightly and operate tester handle to expel air from tester and outlet pipe. Operate tester until solid fluid (without air bubbles) flows from end of outlet pipe. Close tester valve.
2.Connect injection nozzle to test stand. Care should be taken to avoid cross-threading. Tighten connector nut securely with end wrench. Nozzle adapter which is supplied with injection nozzle tester has RH thread to nozzle assembly and LH thread to tester piping.
3.Bleed air from nozzle. Open stand valve and operate tester for 8 to 10 quick strokes to expel (bleed) air from injection nozzle. Fluid should discharge from the spray hole in nozzle tip.

WARNING:
- When a nozzle is being tested or is in operation, keep hands and other parts of the body away from the nozzle. The liquid discharge leaves the nozzle tip with sufficient force to penetrate the skin and cause serious injury. The nozzle tip should be enclosed in a transparent receptacle if available.
- Always wear approved safety glasses when operating the tester. Volatile liquids can be extremely flammable when vaporized. Eliminate any ignition sources (Sparks, flames, cigarettes, etc.) when testing injection nozzles, and always have an approved fire extinguisher near-by. Only use testing fluid meeting SAE calibration no. 208629, or equivalent.

Nozzle Opening Pressure Nozzle Opening Pressure


4.Check nozzle opening pressure, close pump valve, and operate pump handle in slow even strokes to bring system up to pressure. Record highest pressure reached before nozzle opens. Repeat operation, increasing speed if necessary to establish consistant readings.

NOTE: Disregard tip leakage during the test. Spray pattern testing is not required.

{tag}582042431@

5.Check for tip leakage. Blow nozzle tip dry using filtered compressed air. Operate test pump to maintain pressure at about 1378 kPa (200 psi) below the opening pressure obtained in previous test. Wetting of the nozzle tip is acceptable as long as a drop does not fall within five seconds.

NOTE:Make sure that any accumulation at the nozzle tip is not due to test fluid leaking down the outside of the nozzle body from the return openings. If questionable, wrap a shop cloth around the nozzle body to prevent fluid leaking down the outside of the nozzle body from reaching the tip.

6.After testing is completed, make sure to open the pump valve to release the built up pressure prior to removing the nozzle from the tester. When nozzle is removed, cap the nozzle tip and inlet until installed back in engine.

NOTE: If nozzle passes the nozzle opening pressure and tip leakage tests, it is suitable for further service in the engine.


Where ideal conditions of good combustion, specified engine temperature control, and absolutely clean fuel prevail, nozzles require little attention. Nozzle trouble is usually indicated by one or more of the following symptoms:

^Smoke exhaust (black).
^Loss of power.
^Misfiring.
^Increase in fuel consumption.
^Combustion knock.
^Engine Overheating.

When faulty nozzle operation is suspected on an engine that is misfiring or puffing black smoke, a simple test can be made to determine which cylinder(s) is causing the problem.

^Run the engine at the rpm which makes the problem most pronounced.
^Momentarily loosen the high-pressure fuel inlet line connection on one nozzle assembly one-half to one turn. Then, tighten connection to 30 Nm (22 ft lb).
^Check each cylinder in the same manner.
^If one nozzle is found where loosening makes no difference in the misfiring, or the puffing black smoke stops, that nozzle should be tested. Test only the suspect nozzle(s).

Remove suspected nozzles from the engine and perform the injection nozzle test. This test will provide valuable information regarding the condition of the nozzle(s). A clean workbench, clean washing fluid containers, clean tools, and clean hands are all essential to produce satisfactory results.

Injection Nozzle TesterInjection Nozzle Tester


NOTE: It is advisable to test the nozzles before cleaning them. Perform this check only if engine has an obvious combustion knock or miss.

1.Prepare stand for making tests. Fill stand reservoir with clean calibration fluid. Open tester valve slightly and operate tester handle to expel air from tester and outlet pipe. Operate tester until solid fluid (without air bubbles) flows from end of outlet pipe. Close tester valve.
2.Connect injection nozzle to test stand. Care should be taken to avoid cross-threading. Tighten connector nut securely with end wrench. Nozzle adapter which is supplied with injection nozzle tester has RH thread to nozzle assembly and LH thread to tester piping.
3.Bleed air from nozzle. Open stand valve and operate tester for 8 to 10 quick strokes to expel (bleed) air from injection nozzle. Fluid should discharge from the spray hole in nozzle tip.

WARNING:
- When a nozzle is being tested or is in operation, keep hands and other parts of the body away from the nozzle. The liquid discharge leaves the nozzle tip with sufficient force to penetrate the skin and cause serious injury. The nozzle tip should be enclosed in a transparent receptacle if available.
- Always wear approved safety glasses when operating the tester. Volatile liquids can be extremely flammable when vaporized. Eliminate any ignition sources (Sparks, flames, cigarettes, etc.) when testing injection nozzles, and always have an approved fire extinguisher near-by. Only use testing fluid meeting SAE calibration no. 208629, or equivalent.

Nozzle Opening Pressure Nozzle Opening Pressure


4.Check nozzle opening pressure, close pump valve, and operate pump handle in slow even strokes to bring system up to pressure. Record highest pressure reached before nozzle opens. Repeat operation, increasing speed if necessary to establish consistant readings.

NOTE: Disregard tip leakage during the test. Spray pattern testing is not required.

{tag}582042431@

5.Check for tip leakage. Blow nozzle tip dry using filtered compressed air. Operate test pump to maintain pressure at about 1378 kPa (200 psi) below the opening pressure obtained in previous test. Wetting of the nozzle tip is acceptable as long as a drop does not fall within five seconds.

NOTE:Make sure that any accumulation at the nozzle tip is not due to test fluid leaking down the outside of the nozzle body from the return openings. If questionable, wrap a shop cloth around the nozzle body to prevent fluid leaking down the outside of the nozzle body from reaching the tip.

6.After testing is completed, make sure to open the pump valve to release the built up pressure prior to removing the nozzle from the tester. When nozzle is removed, cap the nozzle tip and inlet until installed back in engine.

NOTE: If nozzle passes the nozzle opening pressure and tip leakage tests, it is suitable for further service in the engine.


Where ideal conditions of good combustion, specified engine temperature control, and absolutely clean fuel prevail, nozzles require little attention. Nozzle trouble is usually indicated by one or more of the following symptoms:

^Smoke exhaust (black).
^Loss of power.
^Misfiring.
^Increase in fuel consumption.
^Combustion knock.
^Engine Overheating.

When faulty nozzle operation is suspected on an engine that is misfiring or puffing black smoke, a simple test can be made to determine which cylinder(s) is causing the problem.

^Run the engine at the rpm which makes the problem most pronounced.
^Momentarily loosen the high-pressure fuel inlet line connection on one nozzle assembly one-half to one turn. Then, tighten connection to 30 Nm (22 ft lb).
^Check each cylinder in the same manner.
^If one nozzle is found where loosening makes no difference in the misfiring, or the puffing black smoke stops, that nozzle should be tested. Test only the suspect nozzle(s).

Remove suspected nozzles from the engine and perform the injection nozzle test. This test will provide valuable information regarding the condition of the nozzle(s). A clean workbench, clean washing fluid containers, clean tools, and clean hands are all essential to produce satisfactory results.

{tag}582038450@

NOTE: It is advisable to test the nozzles before cleaning them. Perform this check only if engine has an obvious combustion knock or miss.

1.Prepare stand for making tests. Fill stand reservoir with clean calibration fluid. Open tester valve slightly and operate tester handle to expel air from tester and outlet pipe. Operate tester until solid fluid (without air bubbles) flows from end of outlet pipe. Close tester valve.
2.Connect injection nozzle to test stand. Care should be taken to avoid cross-threading. Tighten connector nut securely with end wrench. Nozzle adapter which is supplied with injection nozzle tester has RH thread to nozzle assembly and LH thread to tester piping.
3.Bleed air from nozzle. Open stand valve and operate tester for 8 to 10 quick strokes to expel (bleed) air from injection nozzle. Fluid should discharge from the spray hole in nozzle tip.

WARNING:
- When a nozzle is being tested or is in operation, keep hands and other parts of the body away from the nozzle. The liquid discharge leaves the nozzle tip with sufficient force to penetrate the skin and cause serious injury. The nozzle tip should be enclosed in a transparent receptacle if available.
- Always wear approved safety glasses when operating the tester. Volatile liquids can be extremely flammable when vaporized. Eliminate any ignition sources (Sparks, flames, cigarettes, etc.) when testing injection nozzles, and always have an approved fire extinguisher near-by. Only use testing fluid meeting SAE calibration no. 208629, or equivalent.

{tag}582040964@

4.Check nozzle opening pressure, close pump valve, and operate pump handle in slow even strokes to bring system up to pressure. Record highest pressure reached before nozzle opens. Repeat operation, increasing speed if necessary to establish consistant readings.

NOTE: Disregard tip leakage during the test. Spray pattern testing is not required.

Nozzle Leakage PatternsNozzle Leakage Patterns


5.Check for tip leakage. Blow nozzle tip dry using filtered compressed air. Operate test pump to maintain pressure at about 1378 kPa (200 psi) below the opening pressure obtained in previous test. Wetting of the nozzle tip is acceptable as long as a drop does not fall within five seconds.

NOTE:Make sure that any accumulation at the nozzle tip is not due to test fluid leaking down the outside of the nozzle body from the return openings. If questionable, wrap a shop cloth around the nozzle body to prevent fluid leaking down the outside of the nozzle body from reaching the tip.

6.After testing is completed, make sure to open the pump valve to release the built up pressure prior to removing the nozzle from the tester. When nozzle is removed, cap the nozzle tip and inlet until installed back in engine.

NOTE: If nozzle passes the nozzle opening pressure and tip leakage tests, it is suitable for further service in the engine.


Where ideal conditions of good combustion, specified engine temperature control, and absolutely clean fuel prevail, nozzles require little attention. Nozzle trouble is usually indicated by one or more of the following symptoms:

^Smoke exhaust (black).
^Loss of power.
^Misfiring.
^Increase in fuel consumption.
^Combustion knock.
^Engine Overheating.

When faulty nozzle operation is suspected on an engine that is misfiring or puffing black smoke, a simple test can be made to determine which cylinder(s) is causing the problem.

^Run the engine at the rpm which makes the problem most pronounced.
^Momentarily loosen the high-pressure fuel inlet line connection on one nozzle assembly one-half to one turn. Then, tighten connection to 30 Nm (22 ft lb).
^Check each cylinder in the same manner.
^If one nozzle is found where loosening makes no difference in the misfiring, or the puffing black smoke stops, that nozzle should be tested. Test only the suspect nozzle(s).

Remove suspected nozzles from the engine and perform the injection nozzle test. This test will provide valuable information regarding the condition of the nozzle(s). A clean workbench, clean washing fluid containers, clean tools, and clean hands are all essential to produce satisfactory results.

Injection Nozzle TesterInjection Nozzle Tester


NOTE: It is advisable to test the nozzles before cleaning them. Perform this check only if engine has an obvious combustion knock or miss.

1.Prepare stand for making tests. Fill stand reservoir with clean calibration fluid. Open tester valve slightly and operate tester handle to expel air from tester and outlet pipe. Operate tester until solid fluid (without air bubbles) flows from end of outlet pipe. Close tester valve.
2.Connect injection nozzle to test stand. Care should be taken to avoid cross-threading. Tighten connector nut securely with end wrench. Nozzle adapter which is supplied with injection nozzle tester has RH thread to nozzle assembly and LH thread to tester piping.
3.Bleed air from nozzle. Open stand valve and operate tester for 8 to 10 quick strokes to expel (bleed) air from injection nozzle. Fluid should discharge from the spray hole in nozzle tip.

WARNING:
- When a nozzle is being tested or is in operation, keep hands and other parts of the body away from the nozzle. The liquid discharge leaves the nozzle tip with sufficient force to penetrate the skin and cause serious injury. The nozzle tip should be enclosed in a transparent receptacle if available.
- Always wear approved safety glasses when operating the tester. Volatile liquids can be extremely flammable when vaporized. Eliminate any ignition sources (Sparks, flames, cigarettes, etc.) when testing injection nozzles, and always have an approved fire extinguisher near-by. Only use testing fluid meeting SAE calibration no. 208629, or equivalent.

{tag}582040964@

4.Check nozzle opening pressure, close pump valve, and operate pump handle in slow even strokes to bring system up to pressure. Record highest pressure reached before nozzle opens. Repeat operation, increasing speed if necessary to establish consistant readings.

NOTE: Disregard tip leakage during the test. Spray pattern testing is not required.

Nozzle Leakage PatternsNozzle Leakage Patterns


5.Check for tip leakage. Blow nozzle tip dry using filtered compressed air. Operate test pump to maintain pressure at about 1378 kPa (200 psi) below the opening pressure obtained in previous test. Wetting of the nozzle tip is acceptable as long as a drop does not fall within five seconds.

NOTE:Make sure that any accumulation at the nozzle tip is not due to test fluid leaking down the outside of the nozzle body from the return openings. If questionable, wrap a shop cloth around the nozzle body to prevent fluid leaking down the outside of the nozzle body from reaching the tip.

6.After testing is completed, make sure to open the pump valve to release the built up pressure prior to removing the nozzle from the tester. When nozzle is removed, cap the nozzle tip and inlet until installed back in engine.

NOTE: If nozzle passes the nozzle opening pressure and tip leakage tests, it is suitable for further service in the engine.


Where ideal conditions of good combustion, specified engine temperature control, and absolutely clean fuel prevail, nozzles require little attention. Nozzle trouble is usually indicated by one or more of the following symptoms:

^Smoke exhaust (black).
^Loss of power.
^Misfiring.
^Increase in fuel consumption.
^Combustion knock.
^Engine Overheating.

When faulty nozzle operation is suspected on an engine that is misfiring or puffing black smoke, a simple test can be made to determine which cylinder(s) is causing the problem.

^Run the engine at the rpm which makes the problem most pronounced.
^Momentarily loosen the high-pressure fuel inlet line connection on one nozzle assembly one-half to one turn. Then, tighten connection to 30 Nm (22 ft lb).
^Check each cylinder in the same manner.
^If one nozzle is found where loosening makes no difference in the misfiring, or the puffing black smoke stops, that nozzle should be tested. Test only the suspect nozzle(s).

Remove suspected nozzles from the engine and perform the injection nozzle test. This test will provide valuable information regarding the condition of the nozzle(s). A clean workbench, clean washing fluid containers, clean tools, and clean hands are all essential to produce satisfactory results.

{tag}582038450@

NOTE: It is advisable to test the nozzles before cleaning them. Perform this check only if engine has an obvious combustion knock or miss.

1.Prepare stand for making tests. Fill stand reservoir with clean calibration fluid. Open tester valve slightly and operate tester handle to expel air from tester and outlet pipe. Operate tester until solid fluid (without air bubbles) flows from end of outlet pipe. Close tester valve.
2.Connect injection nozzle to test stand. Care should be taken to avoid cross-threading. Tighten connector nut securely with end wrench. Nozzle adapter which is supplied with injection nozzle tester has RH thread to nozzle assembly and LH thread to tester piping.
3.Bleed air from nozzle. Open stand valve and operate tester for 8 to 10 quick strokes to expel (bleed) air from injection nozzle. Fluid should discharge from the spray hole in nozzle tip.

WARNING:
- When a nozzle is being tested or is in operation, keep hands and other parts of the body away from the nozzle. The liquid discharge leaves the nozzle tip with sufficient force to penetrate the skin and cause serious injury. The nozzle tip should be enclosed in a transparent receptacle if available.
- Always wear approved safety glasses when operating the tester. Volatile liquids can be extremely flammable when vaporized. Eliminate any ignition sources (Sparks, flames, cigarettes, etc.) when testing injection nozzles, and always have an approved fire extinguisher near-by. Only use testing fluid meeting SAE calibration no. 208629, or equivalent.

Nozzle Opening Pressure Nozzle Opening Pressure


4.Check nozzle opening pressure, close pump valve, and operate pump handle in slow even strokes to bring system up to pressure. Record highest pressure reached before nozzle opens. Repeat operation, increasing speed if necessary to establish consistant readings.

NOTE: Disregard tip leakage during the test. Spray pattern testing is not required.

Nozzle Leakage PatternsNozzle Leakage Patterns


5.Check for tip leakage. Blow nozzle tip dry using filtered compressed air. Operate test pump to maintain pressure at about 1378 kPa (200 psi) below the opening pressure obtained in previous test. Wetting of the nozzle tip is acceptable as long as a drop does not fall within five seconds.

NOTE:Make sure that any accumulation at the nozzle tip is not due to test fluid leaking down the outside of the nozzle body from the return openings. If questionable, wrap a shop cloth around the nozzle body to prevent fluid leaking down the outside of the nozzle body from reaching the tip.

6.After testing is completed, make sure to open the pump valve to release the built up pressure prior to removing the nozzle from the tester. When nozzle is removed, cap the nozzle tip and inlet until installed back in engine.

NOTE: If nozzle passes the nozzle opening pressure and tip leakage tests, it is suitable for further service in the engine.


Where ideal conditions of good combustion, specified engine temperature control, and absolutely clean fuel prevail, nozzles require little attention. Nozzle trouble is usually indicated by one or more of the following symptoms:

^Smoke exhaust (black).
^Loss of power.
^Misfiring.
^Increase in fuel consumption.
^Combustion knock.
^Engine Overheating.

When faulty nozzle operation is suspected on an engine that is misfiring or puffing black smoke, a simple test can be made to determine which cylinder(s) is causing the problem.

^Run the engine at the rpm which makes the problem most pronounced.
^Momentarily loosen the high-pressure fuel inlet line connection on one nozzle assembly one-half to one turn. Then, tighten connection to 30 Nm (22 ft lb).
^Check each cylinder in the same manner.
^If one nozzle is found where loosening makes no difference in the misfiring, or the puffing black smoke stops, that nozzle should be tested. Test only the suspect nozzle(s).

Remove suspected nozzles from the engine and perform the injection nozzle test. This test will provide valuable information regarding the condition of the nozzle(s). A clean workbench, clean washing fluid containers, clean tools, and clean hands are all essential to produce satisfactory results.

Injection Nozzle TesterInjection Nozzle Tester


NOTE: It is advisable to test the nozzles before cleaning them. Perform this check only if engine has an obvious combustion knock or miss.

1.Prepare stand for making tests. Fill stand reservoir with clean calibration fluid. Open tester valve slightly and operate tester handle to expel air from tester and outlet pipe. Operate tester until solid fluid (without air bubbles) flows from end of outlet pipe. Close tester valve.
2.Connect injection nozzle to test stand. Care should be taken to avoid cross-threading. Tighten connector nut securely with end wrench. Nozzle adapter which is supplied with injection nozzle tester has RH thread to nozzle assembly and LH thread to tester piping.
3.Bleed air from nozzle. Open stand valve and operate tester for 8 to 10 quick strokes to expel (bleed) air from injection nozzle. Fluid should discharge from the spray hole in nozzle tip.

WARNING:
- When a nozzle is being tested or is in operation, keep hands and other parts of the body away from the nozzle. The liquid discharge leaves the nozzle tip with sufficient force to penetrate the skin and cause serious injury. The nozzle tip should be enclosed in a transparent receptacle if available.
- Always wear approved safety glasses when operating the tester. Volatile liquids can be extremely flammable when vaporized. Eliminate any ignition sources (Sparks, flames, cigarettes, etc.) when testing injection nozzles, and always have an approved fire extinguisher near-by. Only use testing fluid meeting SAE calibration no. 208629, or equivalent.

Nozzle Opening Pressure Nozzle Opening Pressure


4.Check nozzle opening pressure, close pump valve, and operate pump handle in slow even strokes to bring system up to pressure. Record highest pressure reached before nozzle opens. Repeat operation, increasing speed if necessary to establish consistant readings.

NOTE: Disregard tip leakage during the test. Spray pattern testing is not required.

Nozzle Leakage PatternsNozzle Leakage Patterns


5.Check for tip leakage. Blow nozzle tip dry using filtered compressed air. Operate test pump to maintain pressure at about 1378 kPa (200 psi) below the opening pressure obtained in previous test. Wetting of the nozzle tip is acceptable as long as a drop does not fall within five seconds.

NOTE:Make sure that any accumulation at the nozzle tip is not due to test fluid leaking down the outside of the nozzle body from the return openings. If questionable, wrap a shop cloth around the nozzle body to prevent fluid leaking down the outside of the nozzle body from reaching the tip.

6.After testing is completed, make sure to open the pump valve to release the built up pressure prior to removing the nozzle from the tester. When nozzle is removed, cap the nozzle tip and inlet until installed back in engine.

NOTE: If nozzle passes the nozzle opening pressure and tip leakage tests, it is suitable for further service in the engine.





This project exists mainly due to the display of advertising.

Due to the international situation, making a profit from advertising has become impossible.

If this continues, then the project will either close completely, or become closed and paid.

To support the project, you can Buy a paid subscription


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