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fkpqor`qflk=
Engine type Ref. Date Document No. DLC Issue Page

Wrtsil Italy, Service Subject

Fuel Injection valve adjustment

ALL

WIT-S

09.01.07

I-ALL.0002.GB

161

00

1/4

Fuel Injection valve adjustment

1 Application
ALL Wrtsil diesel engines excluding solenoid controlled injectors

General

There are different practices on evaluating the injection nozzles. In order to unify the rules and practices how the nozzles should be tested and evaluated this Operating Instruction bulleting is giving general instructions.

IMPORTANT! Please always refer to the engine instruction manual for operational maintenance. This service instruction doesnt want to replace or supersede any specific bulletin.

Cleaning procedure and proper test fluid choice

When using new nozzle, it needs to be washed with clean fuel oil or similar in order to remove preservation oil. Before using a new injection valve use it is not required to dismantle the nozzle. The injector needs to be flushed and tested and, if needed, readjusted to the stated needle opening pressure mentioned in the engine manual or according to specific engine instructions. It is recommended to perform the test with clean calibration oil. NOTE! Very good cleanliness is required when working with injection components! Wrtsil recommends the following fluids: - Molyguard Calibration A - Shell Calibration fluid S9365 Or similar fluid with the following characteristics: Viscosity, cSt/20C Viscosity, cSt/40C Flammability, C Density, kg/l /15C 3,8 2,6 > 99 0,827

Wrtsil Italia SpA Service

Bagnoli della Rosandra, 334 34018 San Dorligo Della Valle (TS) ITALY

Telephone : Fax :

+39 040 319 5000 +39 040 319 5647

fkpqor`qflk=
Engine type Ref. Date Document No. DLC Issue Page

Wrtsil Italy, Service Subject

Fuel Injection valve adjustment

ALL

WIT-S

09.01.07

I-ALL.0002.GB

161

00

2/4

4
4.1

Testing of the new injector valve

Checking NOP and tightness of the nozzle seat

After assembling the injector to testing pump, the NOP (Needle Opening Pressure) has to be adjusted according to instruction manual. The nozzle should be completely tightened at opening pressure: NOP-20/50 bars. No drops are allowed for at least 5 s. Check and readjust the opening pressure if needed

4.2

Atomization test

The nozzle atomization test is to verify that the nozzle spray holes are open. Check the flow-through pattern of the nozzle with a few test pump strokes with released spring tension. All the holes must be clear and produce an even distributed discharge. Test to be carried out with no spring load on the nozzle needle. If test is performed with spring load, its recommended to use pneumatic or hydraulic pumps. If performed with manual hand pump, the results can be sometimes unsatisfactory because its delivery is too low and is not describing the situation in the engine. NOTE: The nozzles are not needed to chatter when tested.

4.3

Back flow test

The test is not needed with new valve, but this value is a reference value in order to evaluate the nozzle after use. Different test devices can give different back flow values.

4.4

Handling

Be aware of hitting on the nozzle tip. Never lay the injector so that the nozzle tip is against the hard surface. The tip is very sensitive and can break easily. Always store the injectors covered and protected in clean place before assembling.

5
5.1

Testing and inspection of used injector valve

Visual inspection

Clean the nozzle tip from carbon deposit. If possible, use a chemical carbon dissolving solution. If such solution is not available, immerse the components in clean fuel oil or similar to soak carbon, and then clean the parts carefully. Do not use steel wire brushes or hard abrasive tools. Brass brush is allowed. Check the condition of the nozzle tip for wear of nozzle holes and possible corrosion of the nozzle.

5.2

Checking of opening pressure

After cleaned, increase NOP pressure and record it

Wrtsil Italia SpA Service

Bagnoli della Rosandra, 334 34018 San Dorligo Della Valle (TS) ITALY

Telephone : Fax :

+39 040 319 5000 +39 040 319 5647

fkpqor`qflk=
Engine type Ref. Date Document No. DLC Issue Page

Wrtsil Italy, Service Subject

Fuel Injection valve adjustment

ALL

WIT-S

09.01.07

I-ALL.0002.GB

161

00

3/4

After reassembled, flush the injector properly several times, Increase the opening pressure gradually up to the stated opening pressure and record it. In case the nozzle seat tightness test fails, skip to chapter Dismantle of the nozzle in the instruction manual.

5.3

Checking of tightness of the nozzle seat

Check the nozzle seat tightness with reduced opening pressure in order to use the whole needle lift. The nozzle should not leak. Anyway the nozzle should be completely tight at opening pressure: NOP-20/50 bars. No drops are allowed for at least 5 s. In case the nozzle seat tightness test fails, skip to chapter Dismantle of the nozzle in the instruction manual.

5.4

Atomization test

The nozzle atomization check consists in verify that the nozzle spray holes are open. Check the flow-through pattern of the nozzle with a few test pump strokes with released spring tension. All the holes must be clear and produce an even distributed discharge. Test to be carried out with no spring load on the nozzle needle. If test is performed with spring load, its recommended to use pneumatic or hydraulic pumps. If performed with manual hand pump, the results can be sometimes unsatisfactory because its delivery is too low and is not describing the situation in the engine. If some spray holes are clogged they can be opened, but if not possible the nozzle needs to be rejected. Open the spray holes with the required tools.

5.5

Readjusting the opening pressure

Readjust the nozzle opening pressure to the value according to the engine instruction manual.

5.6

Back flow test

It is not compulsory to do the back flow test. It gives some idea of guidance clearance, if done with the same test device as new.

5.7

Notes

- Never recondition or repair the nozzle by lapping it into its needle seat - Some spill fuel may appear from the nozzle holder due to leak along side the needle. Small amount is considered to be normal, check that connecting piece is tightened. If suspected leakage from nozzle top surface, recondition is not allowed as the surface is lapped.

6 Distribution
Wrtsil Service Network Owners of engines concerned

Wrtsil Italia SpA Service

Bagnoli della Rosandra, 334 34018 San Dorligo Della Valle (TS) ITALY

Telephone : Fax :

+39 040 319 5000 +39 040 319 5647

fkpqor`qflk=
Engine type Ref. Date Document No. DLC Issue Page

Wrtsil Italy, Service Subject

Fuel Injection valve adjustment

ALL

WIT-S

09.01.07

I-ALL.0002.GB

161

00

4/4

7 Liability
NO LIABILITY WHETHER DIRECT, INDIRECT, SPECIAL INCIDENTAL OR CONSEQUENTIAL, IS ASSUMED WITH RESPECT TO THE INFORMATION CONTAINED HEREIN. THIS PUBLICATION IS CONFIDENTIAL AND INTENDED FOR INFORMATION PURPOSES ONLY.

8 Validity
This general instruction is valid until further notice.

Wrtsil Italia SpA Service

Bagnoli della Rosandra, 334 34018 San Dorligo Della Valle (TS) ITALY

Telephone : Fax :

+39 040 319 5000 +39 040 319 5647