Measuring Fuel Spill Rate

Pressure Limiter
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In the high pressure line, there are three elements for fuel spill. First one is plunger and barrel of high pressure pump. Second
is injector two way valve. And third is pressure limiter.
It is impossible to measure fuel spill rate on high pressure pump, however, we can measure fuel spill on both injector and
pressure limiter.
Drain pipe arrangement is little bit different for 125 and 140, and some models. We will look at drain pipe arrangement for
WA480-5 as example.
 Drain line block

Remove the pipe between pressure limiter and drain line block.
 Pressure limiter

Eye-pipe Plastic tube

Install eye-pipe to pressure limiter using existing eye bolt and seal, then install plastic tube to the eye-pipe.
Install spacer the place where the removed pipe has been existed so that pressure limiter drain line and injector drain line are
separated.
!! CAUTION
After machine is operated, fuel becomes very hot, so to be careful for scald by fuel spatter.

Set plastic tube end to container and start engine, then set engine speed to 1600 rpm with no load. If failure is existing, engine
speed can not reach 1600 rpm, but only around 1200 rpm. In those case, depress the accelerator pedal fully and record engine
speed as reference.
Timekeeper sends signal to measure man and starts stopwatch at one time to begin the measurement. Measure man shifts the
plastic tube end from container to measuring cylinder. Timekeeper sends signal to the measure man for the end of
measurement. Measuring time is one minute.
After measurement, judge the pressure limiter condition with standard of fuel spill rate. Spill rate unit is cc/minute.
 Drain hose Measuring hose
To measure injector fuel spill rate, remove drain hose existing and install measuring hose.
While measuring injector fuel spill rate, leave the plastic tube end for pressure limiter measuring to container.
!! CAUTION
After machine is operated, fuel becomes very hot, so to be careful for scald by fuel spatter.

Set measuring hose end to container and start engine, then set engine speed to 1600 rpm with no load. If failure is existing,
engine speed can not reach 1600 rpm, but only around 1200 rpm. In those case, depress the accelerator pedal fully and record
engine speed as reference.
Timekeeper sends signal to measure man and starts stopwatch at one time to begin the measurement. Measure man shifts the
measuring hose end from container to measuring cylinder. Timekeeper sends signal to the measure man for the end of
measurement. Measuring time is one minute.
If injector spill rate is too big, measuring time can be shorten then reading can be converted to one minute rate.
After measurement, judge the injector condition with standard of fuel spill rate. Spill rate unit is cc/minute.