E5 Fuel Injectors

1-) Sketch and describe a fuel injector for a modern marine diesel engine.
Oil flows through the center bore of the non-return valve and out through the
circulation bore. Oil flows through inside of the valve housing to the outlet pipe
and back to fuel oil return line. The valve is kept warm by circulating fuel oil.

Load on the spring holding the slide valve is overcome by the rapid pressure
rise. Slide valve is lifted and circulation bore is closed. And than, fuel flows to the
spindle guide.

The pressure raised overcomes the forced exerted on the non-return valve by the
heavy valve spring.When the opening pressure is reached; spindle is lifted and
fuel is injected.

After the injection sequence, pressure will decreases, heavy spring reseats the
spindle, light spring reseats the slide valve and circulation bore will open. Fuel is
recirculate back to the fuel oil return line.

2-) Detail what faults are likely to be experienced with the injector.

Oil must not flow from the nozzle holes.

The pressure drops relatively slowly to about 15 bar, after which it drops
quickly to 0,
the slide is pressed against the conical seat and opens for circulation oil.
Oil flows out of the leak oil outlet when the fuel valve is full of oil.

Cause of fault :

If oil flows out of nozzle holes, the cause is either

1. Defective spindle guide at needle seat or a sticking spindle.
2. Too quick pressure drop – The clearance of the movable parts both
of spindle and of thrust piece / valve slide in the non return valve are too
large.
If the opening pressure is higher than specified, the cause
may be that wrong type of spring is used. Replace the
spring on the thrust spindle, if necessary, replace the
complete thrust spindle.
If the opening pressure is lower than specified, the cause
may be that the spring has sagged. Replace the spring or
add a special thin disc.
If a spring or a disc has been changed, the pressure testing
procedure of the fuel valve must repeated .
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3. The seats between the thrust piece / spindle in the spindle guide or
thrust piece / valve slide in the non return valve are damaged.
4. Sliding function.
If a quick pressure drop from 15 bar to 0 can not be registered , the valve
slide is
sticking or the vent hole in the thrust piece is blocked.

And also wearing and tearing of all running surfaces (sealing and sliding) - at
both needle valves. Sometimes spring requires additional washers installation
and change the spring.

The fuel nozzle holes may be clogged and the nozzle may need to be replaced.

3-) Explain the procedure for accurately setting the injector lifting pressure

If the opening pressure is higher than specified, the cause

may be that wrong type of spring is used. Replace the
spring on the thrust spindle, if necessary, replace the
complete thrust spindle.

If the opening pressure is lower than specified, the cause

may be that the spring has sagged. Replace the spring or
add a special thin disc.

If a spring or a disc has been changed, the pressure testing

procedure of the fuel valve must repeated .