Service Manual

Injector Service
NOTE: If injectors need to be inspected or repaired it is
recommended that it be done by an authorized CAV
Lucas ROTO DIESEL service dealer - especially during
the warranty period. Repairs by non-authorized dealers
WILL void the warranty on the injectors.
Removal
1. Clean top of cylinder head and injection pipes.
2. Remove injection pipes (Fig. 57, Item 12).
3. Disconnect injector leakage pipe.
4. Remove the injectors (Fig. 58, Item 19) and retrieve
t
he copper washer (Item 20) and flame trap washer
(Item 21).
NOTE: Never disassemble injector before checking its
oper
ation.
Disassembly and Cleaning
1. Secure the injector body in a “V” type injector holder.
2. Remove the injector holder nut.
3. Remove the injector, spacer, push rod, pressure
s
etting spring, adjusting shims and body.
4. Dip all parts in clean diesel fuel.
5. Clean nozzle and needle in clean diesel fuel.
6. De-carbon injector nozzle using a wooden spatula.
Never use metallic objects, emery cloth or rags. Do not
attempt to grind the needle on its seat. Clean each
injector separately to matched parts are not mixed up.
The needle should slide freely and fall in the nozzle by
its own weight.
1
8
2
3
4
9
5
10
6
7
Figure 40
1. Body
2. Adjusting shim
3. Pressure setting spring
4. Push rod
5. 2-sealing face spacer
6. Injector
7. Injector nut
8. Leak return connectors
9. Injector holder nut
10. Thread
Engine Page 3 - 34
Rev. B
Reelmaster 335-D/3500-D