ENGINE
ADJUSTMENTS
TORQUING
CYLINDER
HEAD
BOLTS
Tighten the cylinder head bolts according
to
the sequence
shown
in
the illustration below. Make sure the engine is cold
when this is done, and loosen one head bolt one-half tum and
then tighten it between 85 to
90 lb-ft. (11.8
to
12.5 kg/m) for
the BED
20KW and 25KW. The. 32 KW head bolts do NOT
require retorquing.
CYLINDER
HEAD
BOLT
PATTERN
2 3
11
20
19
18
16
13 9 5 4 8 12
ENGINE
COMPRESSION
Check the compression pressure. To do this, warm the
engine, remove all
fuel
injectors, or glow plugs, disconnect
the fuel shut-off solenoid wire, and install a compression
adapter in the injector hole or glow plug hole. Connect a
compression tester on the adapter and crank the engine with
the starter motor until the pressure reaches a maximum value.
Repeat this process for each cylinder. Look for cylinders with
dramatically (at least
20%) lower compression than the aver-
age of the others. Compression pressure should not differ by
more than 42.7 psi
(3.0 kg/cm2) at 200 rpm.
COMPRESSION
TESTER
If
a
-:veak
cylinder
is
flanked by healthy cylinders, the prob-
lem
IS either valve-or piston related. Check the valve clear-
ances for the weak cylinder, adjust as needed and test again.
If
the cylinder
is
still low apply a small amount
of
oil into the
cylinder to seal the rings and repeat the test.
If
compression
comes up
- the rings are faulty.
Abnormally high readings on all cylinders indicate heavy
c~rbon
ac~umulations,
a condition that
might
be accompa-
med by
htgh pressures and noise.
NOTE:
In
case
of
severe vibrations and detonation noise, have
the injectors checked and overhauled
by
an authorized fuel
injection service center.
Poor
fuel quality, contaminates and
loss
of
positive fuel pressure to the injection
pump
will result
in injector faults.
TESTING
FUEL
INJECTORS
Remove the injectors and check injector spray
pressure and spray pattern. Correct as needed.
TESTER
INJECTION
PRESSURE
TEST
1.
Using the nozzle tester, check the spray pattern and
injection starting pressure
of
nozzle and,
if
it exceeds the
limit, adjust or replace the nozzle. When using nozzle
tester, take thefollowing precautions:
A
CAUTION:
The
spray
injected
from
the
nozzle
is
of
such
velocity
that
it
may
penetrate
deeply
into
the
skin
of
fingers
and
hands,
destroying
tissue.
If it
enters
the
bloodstream,
it
may
cause
blood
poisoning.
a.
!f
the diesel fuel
of
the nozzle tester is stained,
repl~~e
tt.
At the same time, clean or replace the fuel filter.
b. Set the nozzle tester in a clean place where there is
no
dust or dirt.
c.
Mount the nozzle and nozzle holder on the nozzle
tester.
d.
Operate the hand lever
of
nozzle tester several times
to
bleed the
air
in the nozzle line, then move the hand lever
~~
_int~rvals
of_
one stroke per second while reading the
InJection startmg pressure. Refer to the models
Specification page for Injector Spray Pressure.
ADJUSTING
!
ISHIM'THICKNESS
INJECTOR
U.1mm
D.2mm
D.3mm
D.5mm
Engines
&
Generators
29
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