5 Do a leakage test as follows:
5.1 Increase the pressure of the test fluid to approximately 600 bar (or more if
possible).
5.2 Make sure that there is no leakage on the injection valve and no test fluid comes
out from the nozzle holes.
5.3 If there is leakage, find the cause and repair the fault.
6 Do a functional test at 600 bar as follows:
6.1 Set the pressure of the test fluid to 600 bar.
6.2 Start a test injection on the test bench.
6.3 Make sure that a spray comes out from the injection nozzle.
6.4 Make sure that after the spray no leakage or only some droplets come out from
the injection nozzle.
6.5 If no spray comes out from the injection nozzle or if there is leakage after the
spray, find the cause and repair the fault.
6.6 Do Step 6.2 to Step 6.5 again a few times.
6.7 Wait approximately 60 seconds and make sure that no injection takes place.
7 Do a check of the seating surface between the needle seat and the nozzle as follows:
7.1 Set the pressure of the test fluid to 400 bar.
7.2 Make sure that for 30 seconds there is no leakage on the injection valve.
7.3 If leakage comes out from the injection nozzle, find the cause and repair the
fault.
8 Find the Lowest Possible Opening/Operation Pressure (LPOP) as follows:
8.1 Set the pressure of the test fluid to 300 bar.
8.2 Start a test injection on the test bench.
8.3 If no spray comes out from the injection nozzle, do as follows:
8.3.1 Increase the pressure a small step (for example 20 bar).
8.3.2 Do Step 8.2 again.
8.4 If a spray comes out from the injection nozzle, the related pressure is thus the
LPOP.
NOTE: The LPOP should be between 350 and 500 bar.
9 If there is a malfunction that you cannot repair, speak to or send a message to WinGD.
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X72DF
AA00-2722-00AAA-340A-A
Maintenance Manual Direct controlled injection valve - do a functional test
Winterthur Gas & Diesel Ltd.
- 262 - Issue 002 2020-10
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