Disassemble, clean, assemble and set nozzle holder and injection nozzle

AR07.03-B-6713A

Disassemble, clean, assemble and set nozzle holder and injection nozzle

18.02.2020

Engine

372 in model 682.118/128/191

Engine

374 in model 688.101/102/103/111/118/121/123/133/143/156/157/158/159

Engine

374 in model 688.156/174/176/177/187/270/272

Engine

374 in model 693.023

Engine

376 in model 382.004/005/010/020/022/033/058/068/069, 384.081/085/087/088/091/097/098

Engine

376 in model 384.003/004/009/014/023/024/041/045/047/114/145, 386.004/014/015/024/025/027/041/043/045/314/354/364/367/369, 682.003/023/027/028/081/102/103/107/108/118/122/123/127/128/132/133/181/183/186/191/195/308/313/318

Engine

377 in model 382.004/005/020/022/033/034/058/069, 384.072/073/081/087/088

Engine

377 in model 693.108/127/128/144/182/184/191/195, 694.004/024/041/047, 695.013/014/015/016/039/043/056/301/302

Engine

386 in model 684.200/201/262

1

Nozzle holder

2

Adjustment washer

3

Spring

4

Thrust pin

5

Positioning ring

6

Injector needle

7

Injector nozzle

8

Assembly nut

9

Fastening device

10

Special wrench

11

Test device

12

Fastening device



Disassemble

1

Remove the injector holder (1)

.

AR07.11-B-5500A

2

Secure the device (9) to a vise, place the injector holder (1) on the device and loosen the nut (8)

 Mounting fixture

*403589003100

 Open-end wrench socket

*000589011300

 Wrench socket

*403589001300

3

Disassemble the set based on the following sequence: (8), (7), (6), (5), (4), (3), (2) and (1)

 Disassemble more than one set separately. Do not mix parts, especially needles (6) and nozzles (7).

 Danger

Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel as well as risk of injury to eyes and skin caused by contactwith fuel.

No fires, sparks, open flames or smoking. Pour fuels into suitable and appropriately marked containers only.
Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

4

Clean the parts (1), (2), (3), (4), (5), (6), (7) and (8)

 Use kerosene or diesel oil. Do not carry out the cleaning of injection nozzles employing mechanical processes, such as metal needles, steel brushes, sandpaper, etc. The adoption of such procedures will damage the injection nozzles.

5

Clean the injector nozzle holes (2) with ultrasound

AR07.03-B-6833TA

 The cleaning must be carried out when the injector nozzles conditions assessment is carried out or when they present deposits, which generally occurs due to the use of inadequate fuels (not filtered).



Assemble

6

Secure the device (12) in a vise; place the injector holder (1) on the device (9) and place it on device (12)



Shim (10°) for setting microswitch at injection pump

WF58.50-B-0710-02A

 Mounting fixture

*403589003100

7

Sequentially assemble parts (2), (3), (4), (5), (6), (7) and (8) onto the injector holder (1)

8

Press the injector (7) using the device handle (12) and manually thread the nut (8) until the stop

 This procedure prevents the detachment of shavings, which, if lodged inside the injector, will cause malfunctions

9

With the injector holder (1) on the device (9), tighten the nut (8)

 .Injection nozzle to injector holder

*BA07.11-B-1001-01A

 Open-end wrench socket

*000589011300

 Wrench socket

*403589001300



Check

 Danger

Risk of explosion caused by fuel igniting. Risk of injury to skin and eyes caused by fuel spraying out at high pressure

Keep all ignition sources out of hazard area.
Do not carry out any work on system when it is pressurized.

AS07.16-Z-0001-01B

10

Install the injector holder (1) on the test equipment (11)

 Only injector testing oil or filtered diesel may be used to test the injectors (1).

 Tester

*000589142700

11

Check the tightness of the injector

 Close the test device valve (11) and perform a few injection cycles by operating the hand lever several times. Next, open the valve and slowly operate the lever until the manometer reads 20 bar below the opening pressure indicated for the injector. Keep the desired pressure for ten seconds checking whether the injector nozzle is correctly tight.

 The leaking or up to 2 drops during ten seconds is admissible.

 If due tightness is not assessed after a thorough cleaning of the seating surfaces of the body and of the needle, the injector nozzle (7) and the needle (6) must be replaced.

Nozzle opening pressure.



On engine 377.987Injection pressure of nozzle

*BE07.03-B-1004-01D

Engine 372.9, 374.9, 376.9, 377.9, 386.9 except 377.987Injection pressure of nozzle

*BE07.03-B-1004-01C

12

Check the injector nozzle opening pressure

 Open the device valve (11). Actuate slowly the lever and check the pressure indicated in the manometer, at the moment in which the injector nozzle opens. If the pressure differs from the prescribed values, it must be corrected by replacing the adjustment washers (2).

 Do not use more than two pressure adjustment washers (2) on each injector. The need for more than two washers or washers greater than 3 mm indicates that the spring (3) is weak and must be replaced.

 The injector nozzle must not be re-manufactured. Nozzles beyond specifications must be replaced.

Engine 372.9, 374.9, 376.9, 377.9, 386.9 except 377.987Shim thickness to adjust the opening pressure

*BE07.03-B-1003-01C

Engine 372.9, 374.9, 376.9, 377.9, 386.9 except 377.987Injection pressure of nozzle

*BE07.03-B-1004-01C

On engine 377.987Shim thickness to adjust the opening pressure

*BE07.03-B-1003-01D

On engine 377.987Injection pressure of nozzle

*BE07.03-B-1004-01D

13

Install the injector holder (9)

.

AR07.11-B-5500A

Injection nozzles

Number

Designation

Engine 372.961; 374.905/950/980, 374.984; 376.951/952/956, 376.930/984; 377.943/945/962; 377.964/980/981, 377.983/985; 386.951

BE07.03-B-1003-01C

Shim thickness to adjust the opening pressure

P type nozzle, 0.02 increments

mm

1,00...1,98

S type nozzle, 0.05 increments

mm

1,00...1,95

Injection nozzles

Number

Designation

Engine 377.987

BE07.03-B-1003-01D

Shim thickness to adjust the opening pressure

Nozzle, 0.02 increments

mm

1,00...1,98

Injection nozzles

Number

Designation

Engine 372.961; 374.905/950/980, 374.984; 376.951/952/956, 376.930/984; 377.943/945/962; 377.964/980/981, 377.983/985; 386.951

BE07.03-B-1004-01C

Injection pressure of nozzle

Normal, with engraving 791/92, 926, 1013/96, 1103/57, 1264/66, 6882/94

bar

200...208

Minimum,, with engraving 791/92, 926, 1013/96, 1103/57, 1264/66, 6882/94

bar

180

Normal, with engraving 422/30 L066B

bar

260...270

Minimum, with engraving 422/30, L066BPA

bar

235

Normal, with engraving 1286

bar

230 ... 238

Minimum, with engraving 1286

bar

205

Normal, with engraving 371/72

bar

250...258

Minimum, with engraving 371/72

bar

225

Normal, with engraving 296, 301

bar

280...288

Minimum, with engraving 296, 301

bar

250

Normal, with engraving 1314

bar

330...340

Minimum, with engraving 1314

bar

300

Normal, with engraving 1560

bar

300...310

Minimum, with engraving 1560

bar

270

Injection nozzles

Number

Designation

Engine 377.987

BE07.03-B-1004-01D

Injection pressure of nozzle

Normal, with engraving 5161

bar

300...310

Minimum, with engraving 5161

bar

270

 Diesel injection system

Number

Designation

Engine 372, 374, 376, 377

BA07.11-B-1001-01A

Injection nozzle to injector holder

Nm

80