hl MEMORANDUM FOR FSIT Trade: Earthmoving Equipment Description: Diesel Fuel Injector Test Code: FSIT TEST ELEMENTS IMPORTANT: Assessor to be familiar with the test task instructions, mark sheet criteria and the memorandum before the candidate attempts this sheet. A.THEORY SECTION The candidate will be assessed on the points accumulated in the theory section as a whole. Total points possible 44. Candidate must have at least 36 points correct to receive an acceptable grade for the theory section. 1. PARTS IDENTIFICATION (18) Nozzle holder Nozzle nut Spindle Spring Upper spring plate ‘Spring cap nut Cap nut Cap nut joint washer 9. Inlet adaptor joint washer 10. Leak-off connection joint washers 11, Inlet adaptor 12. Leak-off connection 13. Banjo screw 14, Dowel 16. Nozzle 16 Needle valve PN OBRONH 2. Write down the function of a fuel injector. 3) The function of a fuel injector is to inject diesel fuel at the right pressure and angle and into the combustion chamber in an atomised state Revision August 2007 Page 1 of 6MEMORANDUM FOR FSIT 3. Operation of the injector from where the fuel enters the injector body (25) a The nozzle is operated by fuel pressure generated by the fuel Injector pump. . The pressure acts on the exposed annular area of the nozzle valve. 2) . As soon as the pressure acting on the annular area exceeds the counter acting force of the pressure spring. The nozzle valve lifts from its seat ) |. The fuel is then injected through the nozzle orifices into the combustion chamber. (4) . A measured amount of fuel is delivered by the injector pump. (2) . After injection, the pressure spring again forces the valve back onto its seat via the spindle and the valve stem . The injector is then closed for the next pressure stroke from the injector pump. (3) Total Points 44 B. PRACTICAL SECTION . DISMANTLE AND ASSEMBLE 1.1 - 1.4 Candidate to record on test task the specifications he / she needs during the test task. Assessor to write on candidate's task instruction the specification requested “1.5 To pressure test an injector, expel the air from the injector tester, fir the injector to the adaptor provided for the purpose, depress the lever very slowly and observe the highest pressure reading obtained before the pressure gauge needle flicks 1.6 The atomisation and spry pattern test is a visual check in most instances. The usual procedure is to fit the injector to an injector tester. Isolate the pressure gauge and pump the handle about sixty strokes per minute. The spray should be without distortion and without visible streaks of un-vaporized fuel. A multi-hole injector should produce sprays of equal length. Revision August 2007 Page 2 of 6CLAUSE: MEMORANDUM FOR FSIT 1.7 Pressure gauge must be isolated during the spray pattern test 1.8 Injector manufacturers recommendations regarding the dribble test (seat tightness test) vary, but the basic test may be performed as follows. Fit the injector to the injector test, wipe the nozzle dry, raise the pressure to test specifications. Maintain the pressure and after a specified time the nozzle time should remain dry. 1.9 Generally accepted procedure when testing an injector for back- leakage is to pump the injector test to near opening pressure then isolate the pump if possible. The pressure shown will slowly fall, due to fuel leakage past the needle valve. The rate at which the pressure falls indicates the clearance between the needle valve and the nozzle body 1.10 During the back-leakage test the pump must be isolated where possible. “1.14 Adhere to all safety requirements during the injector pre-check e.g. wear eye protection during testing procedures and do not put hands in front of the injector when injector discharges high pressure fuel NOTE: Assessor to use own discretion on what safety is appropriate and required Apply safe practices during test. If candidate does not apply safe working practices during the test, he / she will receive and unacceptable grade and the Assessor will record the incident in the remark section, whereupon, the candidate will sign indication his / her knowledge of the malpractice. Severity of malpractice is left to the discretion of the Assessor who will decide upon an immediate unacceptable grade or reprimand at first and an unacceptable grade on a repetition of malpractice after reprimand. Evaluation of candidate’s performance on the test will be done up until he / she was stopped. Revision August 2007 Page 3 of 6MEMORANDUM FOR FSIT é este] 1 TYPICAL SPRAY FROM MULTI HOLE NOZZLE “ |b) Reject — Poor atomieatian, ©) Reject - blocked spray hole. 2. STRIPPING AND CLEANING 2.1 All parts to be placed in clean diesoline or appropriate solvent 2.2 Removed all traced of carbon from the exterior of the nozzle with the brass wire brush (Refer picture 1) Picture 1 2.3 The correct sequence to dismantle the injector to prevent damage to the needle and seat is to release the pressure spring tension before dismantling the injector nozzle. 3. CONDITION REPORT 3.1-3.11 Candidate to correctly identify and record serviceability of injector parts. 3.12 Candidate's comment on unserviceable parts must be correct Revision August 2007 Page 4 of 6MEMORANDUM FOR FSIT 3.13 Assessor can ask candidate to orally explain or demonstrate the needle — sliding test. There are two methods: i. When clean, without any traces of oil on the needle stem or in the nozzle bore, the needle should drop freely onto the nozzle seat ii, Another check for binding, the needle should be pressed by hand against the nozzle seat, nozzle in normal vertical position. The needle should fall freely when the nozzle is. inverted and the hand is removed. 4. ASSEMBLY AND ADJUSTMENTS 4.1 Correct assembly procedure is to assemble the injector nozzle before assembling the pressure spring 4.2 To pressure test an injector, expel the air from the injector tester, fit the injector to the adaptor provided for the purpose, depress the lever very slowly and observe the highest pressure reading obtained before the pressure gauge needle flicks. Adjust pressure within manufacturers specifications 4.3 The atomisation and spray pattern test is a visual check in most instances. The usual procedure is to fit the injector to an injector tester. Isolate the pressure gauge and pump the handle about sixty strokes per minute. The spray should be without distortion and without visible streaks on un-vaporized fuel. A multi-hole injector should produce sprays of equal length 4.4 Injection tester gauge to be isolated during the spray pattern test 4.5 Injector manufacturers recommendations regarding the dribble test (seat tightness test) vary, but the basic test may be performed as follows. Fit the injector to the injector tester, wipe the nozzle dry, raise the pressure to test specifications. Maintain the pressure and after a specified time the nozzle time should remain dry 4.6 Generally accepted procedure when test an injector for back- leakage is to pump the injector tester to near opening pressure then isolate the pump if possible. The pressure shown will slowly fall, due to fuel leakage past the needle valve. The rate at which the pressure falls indicates the clearance between the needle valve and the nozzle body 4.7 Injection tester to be isolated during the back-leakage test 4.8 Adhere to all safety requirements during the injector pre-checks Revision August 2007 Page 5 of 6MEMORANDUM FOR FSIT 4,9 Injector correctly assembled, no leaks and parts left out When a candidate exceeds the maximum time allowed for this task, he/ she will receive an unacceptable grade, although extra time may be allowed at the discretion of the Assessor IMPORTANT: Should a candidate indicate / request that he / she does want to attempt / complete a test, Assessor must note reason / request in remark section on the mark sheet and candidate must sign statement. All candidates must be given the opportunity to complete the entire test. The Assessor cannot stop the candidate during a test solely on the grounds that the candidate already failed the test. Exception will be when the Assessor feels that the candidate will damage equipment / tools or is a potential safety hazard. The above memorandum was accepted by the Earthmoving Equipment Trade Assessment committee on (date to be advised). It is the sole property of the committee any copy or misuse of it will be against the law. Any person or organisation using it without prior arrangements will be guilty of copyright. This Earthmoving Equipment Committee has been established by industries involved with earthmoving equipment in RSA and has been facilitated by INDLELA and MERSETA. The following companies were involved in the drawing up of the papers . Anglo Gold Ashanti Training & Development Services . Bell Equipment Co. (Pty) Ltd CTC Colliery Training Centre (Witbank) . Grinaker-LTA Technical Training Centre Indlela (Department of Manpower) . Komatsu S.A. OOaYNS Revision August 2007 Page 6 of 6