Service Manual

Injector Tests
There are several tests to examine the condition of the
injection nozzles. These tests require the use of a
nozzle tester and nozzle tester adapter.
The nozzle tester forces fuel from the nozzle
under extremely high pressure. Always point
the nozzle tip away from yourself and any
other personnel. Contact with the fuel stream,
even though it appears to be a mist can cause
fuel to penetrate clothing and skin. If fuel is
injected into the skin get proper medical at-
tention from a doctor immediately. A serious
infection or other reaction can develop if the
injury is not properly treated. Tighten all
adapter fittings to prevent leaks. If a leak is
suspected, use a piece of cardboard, not your
hands to search for a leak.
To prevent possible injury, wear eye protec-
tion when operating the nozzle tester.
IMPORTANT: Always use fresh filtered fuel in the
nozzle tester. Use of dirty fuel can damage the
precision parts of the injector nozzle. It is a good
practice to:
1. Bolt the tester securely to the test bench.
2. Use a drain pan to catch fuel.
3. Flush the adapter by pumping the handle of the tester
slowly several times before attaching the nozzle to be
tested.
Injection Pressure Test
The diesel engine requires that fuel be sprayed into the
combustion chamber at a precise point in the compres-
sion stroke. The point at which this fuel injection occurs
is determined by the injection timing. If the nozzle is
defective, damaged or adjusted incorrectly, starting fail-
ures, low power output, or engine knocking can occur.
1. Securely fasten the nozzle to the adapter.
2. Pump the handle several times to purge air from the
nozzle mechanism.
3. Allow pressure to dissipate before performing the test.
4. Operate the pump handle slowly and observe the
gauge to determine the pressure at which the nozzle
opens and the fuel is sprayed.
5. Verify that starting pressure is within the following
limits: 130 ± 5 bar or kg/cm
2
(1885 ± 70 psi)
6. Starting pressure can be adjusted by adding or re-
moving shims from the nozzle. A 0.10 mm shim thick-
ness will cause a 10 bar or kg/cm
2
(140 psi) starting
pressure difference.
7. Repeat the test after installing shim to verify that a
correct opening pressure has been obtained.
Chattering Test
Proper and free operation of the nozzle valve can be
determined by the chattering test.
1. Securely fasten the nozzle to be tested to the adapter.
2. Operate the pump handle slowly (1 - 2 strokes per
second). As the pump pressure reaches the starting
pressure the nozzle valve will chatter or buzz as it opens
and closes rapidly. A nozzle which does not chatter or
buzz may be the result of a binding or bent nozzle valve.
CAUTION
Engine
Reelmaster 6500-D/6700-D Page 3 - 29 Engine