16. Injection System 16.1 Injection pump 16.1.1 General description Date end cimersions ited with one injection pump per eylinder. The Mutrousng located in a“multihousing” The functions of the Meets specttcastten } woot 25tg ‘of mono element type, is spray lubricated. The ‘integrated pipe system with atmospheric ‘tw the low pressure side of the injection pump. groove (lead) on its side. When the plunger is at dead entre, fue flow: plunger moves up further, and the helix ofthe plungermeets with the ports, the high pressure fuel flows through the lead tothe ports and the pressure feed of fuel is completed. 4 WARTSILA 20_— = ; ‘The plunger stroke during which the fuel is fed under pressure is called the effective stroke. ‘According to the engine load, the amount of fuel injected is ‘to pop up. Once the effective stroke of the delivery valve is brought back to its original ‘position bythe spring and blocks the fuel path, thereby preventing nw ofthe ful. ‘effective stroke, the fuel is drawn back through the ‘The multihousing is provided with two erosion plugs, which ean easily be replaced when necessary. Maintenance of injection pump 16.2.1 Removal of injection pump element Hy sruton uot suppty othe engine and tp de prt pomp. Ey Remove necessary pipes, 5nd lube oi pipe. Disconnect the | fuel pipes.<= & mo) |.Toppet pin 2 loppet 3. Guiding screw “4 Rearing ring 5. Sieve a 9 Foaloce KD raercetven vavey 11. Pum element 12. Screw 13. Erosion plug 14. Plunger 16. Controiseeve 16 Spring 17.Pha 18. tappet rotor Mw Ze El cover immediately all openings with tape or pigs to Prevent drt fom entering the spate section pump tappet is ing on the base circle of, é Remove the plunger (14), by turning it about 90° using 3 tool 846017. IB, covertne opening in the mulinosing media with clean eat.20-9601 16.2.2 Mounting of injection pump element J check and clean he element. Ey Fitnew O-rings and lubricate e complete housing onto the engine and ‘ghten the m if the complete fuel pipes. Use the housing. Pay speci surfaces, rention to the O-ring a plunger and control 1 check tho! he control sleeve tnd the rack moves freely. ‘Assemble the element info the housing. Be careful ‘When connecting the plunger into the element EE Tighten the fastening screws dingo ated torque, see chapter O7 DD check thot chy the tol 861012, correct postion ly in steps to the see chapter 22 EB Remove the protecting tapes or plugs and connect the Difes and the injection pipe: Tighten the nuts ta torque BB open tuet the engine and vent the fil aystem Sontag toe tnntractions in chapar 7 ponents have been changed, ‘or one or more camshaft pieces Hl Remove the camshatt cover at the el Tur he cronkahat wl he pany appt e camshaft intermediate gear the hase eirele ofthe eamshat Ey Mount the checking too! 869001 and adjust the gauge 4) tovzero, soe Pig 162. J tum the ttywnoat in the rotating arection until the tap- pot (2) its up to Tm.TB Reassembie the camshaft cover Note! Changing ofthe Intermediate gear postion wil affect Yo al 5 d t Checking of injection timinNote! The element cylinder, plunger and delivery vaive assembly ie maiched and they mist be kept Together during the convenient forthe d Ey Remove the element as described above Ey tum the pump up side dow ‘Support the roller tappet with the tool 46016 and open the guiding serew (3). EF Relecse the spring tension and remove the too i The rolertoppet and the spring can now be removed Renew the seating ring and insert the spring plate into the housing. Lubricate the tappet is recommendable to put the pump in a screw vice, inhoe TH scrow in ond tighten the guiding screw to stated feryue, os section OF Turn the pump snd assemble the element. loss he pump is Immediately mounted on the en- ust he wel oiled and protected by aplastic ever or "The fuel ports and injection line connection must always be protected by plugs or tape 16.3 Injection line a ‘The injection line consists of two parts, the connection piece, serewed sideways into the nozzle holder, and the injec "The connection picee seals with plain metallic surfaces ahd ‘these surfaces are to be checked before mounting. Always tighten the connection piece to correct torque before mounting the injec- tion pipe; also in ease only the injection pipe has been removed, ‘because there is a risk of the eonnection piece coming loose when removing the pipe. "The injection pipe is covered by a shielding to protect the engine ‘environment from fuel leakages. The injection pipes are delivered ‘complete with conneetion nuts assembled. Alveays tighten the ‘connections to correct torque, ‘When removed, the injection line details have to be protected ‘against dirt and rust. => 16.4 Injection valve 16.4.1 Description located in the cylinder head and the nozzle (1), soe Fig 16-3. The rays through a connection piece spray. The pressure at which the nozzle operate can be corrected by turning the adjusting bridge (7) in the injection valve. Since the pressure will drop in operation, the next higher pressure step value should be used. WARTSILA 20a oO 16.4.2 Removing of injection valve J Remove the cylinder head cover. By Remove the injection pipe. EF Unscrew the connection piece and loosen the protect- Ing sleeve if neceseary Protect the fuel inlet hole of the re in the cylinder head. Injection valve 5. Spring 6 Injection valve housing n 7. Adjusting screw 8 Pug 9.04ing 10,Proteciing sleeve Fig 16-3, te 16.4.3 Overhauling of injection valve _ fe opening pressure and spraynozae, Check the nozzle needle movement which may varyas ‘+ needle completely free ‘+ needle free to move within the normal lifting range «+ needle is sticking ‘The needle must not be removed by force because this often results in complete jamming. Unless it can be eas wed, immerse the nozzle in lubricating ol and heat oll to 150 -200°C. Normally, the needle can be removed from a hot nozzle. Maximum i of nozzle, removing of nozzle ftom holdering faces of the nozzle ieand the bottom of the fuel EB Check the opening pressure: * open manometer valve, ly and watch manometer to note the opening. —~ to the stated pressure the maximum position, ‘The opening pressure can normally be adjusted by tuning the during ew Oh Gockran, see fg 168. The prosane e in average 10 bar per one step.aD ‘Adjusting of opening pressure Fig 16-5 sn BD check ne needle sea! ighines: * increase pressure toa value 20 bar below the stated opening pressure, 1 keep presure constant for 10 seconds and check that nfl Ps occur on the nozzle tip. A slight dampness may be - acceptable, TE check the needle spindle tightness: ‘* pump until pressure is 20 bar below the stated opening sare drop of 50 bar. Ifthe time is16.5 leakage occurs on the high pressure sealing surfaces damaged detail should be replaced by a new one or recon- nozzles oF injection valves are to be stored they be treated with corrosion protecting oil, 16.4.4 Mounting of injection valve fine lapping com- pound is used. T the bottom of the eylinder head bore i Put new O-rings on the connection piece and on the protecting sleeve if it has been removed. 1 Mount the protecting sieeve on the connection piece: Bi Mount the injection pipe and ti torque Hd Tighten he fastening nuts of then fergoe xe onc Ota sop of EI Mount me covers. Pneumatic overspeed trip device ‘The pneumatic overspeed trip device is mounted on the multi- stronger than the torsion spring in the regulating mechanism. For maintenance of pneumatic overspeed trip device see chapter 2