Diesel hydraulic injectors

PURPOSE OF THE INJECTOR

The diesel engine compresses the intake air to such a degree that the temperature rises.
up to about 550°C when the compression ratio is 16:1.

The mixture of 20 parts by weight of air to one of fuel should be estimated as

average in a natural aspiration engine. This mixture for correct consumption
without leaving visible smoke, it must be intimately mixed, for which each particle of
The fuel will be properly atomized. The degree of fuel atomization and of
The integration or mixing with air depends on the efficiency of combustion and its speed.
The injector must perform these functions and therefore its correctness depends on it.
combustion. Excessive atomization hinders penetration and atomization
Incomplete worsens the mixture.
To achieve good combustion, the injector must have an adequate injection pressure.
A suitable number of holes, a correct diameter for each of them; a length
of the hole that relates to its diameter. Also independently there are
these other factors: compression pressure, degree of turbulence, and type of chamber. In
In summary, good combustion depends on the mixture and this on the injector. The injectors
require special care due to their high precision.

Synthesizing the work of the injector can be summarized:

Introduce a small amount of fuel into the chamber.

Spray it in small drops.

Distribute it in the air of the entire room.

Regular jets from a hole nozzle

LOCATION
The injector placed in the center of the cylinder head can project the fuel into the chamber.
of direct injection. In the indirect one, it can be located in other positions but always
about the buttstock.
CLASSIFICATION
Injectors are classified:

For its operation:

Open.
They are those in which the check valve is before a chamber that ends in the
atomization orifices (are out of use).

Closed.
They are those in which the valve seals the atomization orifices without dead space.
where the air penetrates.

By its operation

Hydraulics:

They are those in which the opening of the valve or needle occurs when the
the fuel pressure is higher than the pressure of the regulator spring that
close the valve after finishing the injection.
Operating phase of an injector.

Mechanics:
They are those in which a spring withdraws the needle like a piston allowing the
fuel enters a bowl and then a lever expels the fuel that it admitted
previously measured by the pump.

By the number of holes and by its type of needle.

Hydraulic injectors are classified into:

a. Hole injectors.

b. Multi-orifice injectors.

c. They can also be short needle or long needle.

For the class of spike.

Some injectors, instead of a needle, have a stem that controls a single hole.
also called nipple which can be cylindrical or conical.

Within the category of spike injectors, there are pintaux injectors, whose
the peculiarity is that it has a calibrated hole in addition to the axial hole and serves to
facilitate the start.

Cooling.

The normal injectors are lubricated and cooled with the fuel itself.
It is necessary to monitor the temperature of the fuel to avoid overheating.
A nozzle that burns takes on a blue color when the nozzle valve is
starts to hit by producing a lot of smoke, it is necessary to measure the temperature of the
combustible. A few injectors have passages to circulate
trio lubricant, which travels along a spiral at the tip of the nozzle.
Constitution of the hydraulic injector
The basic components of an injector can be grouped into:

Tube.
It is responsible for injecting the fuel, atomizing it, and dispersing it throughout the air,
according to the type of chamber, the number of openings, and the type of valve.

Pressure regulating mechanism.

It consists of a screw and a spring that apply pressure on the valve stem to regulate.
the value of its lift and with it the discharge pressure. In some injectors, the screw of
graduation is replaced by supplements placed at the end of the spring.

Overflow system.
Some drilled conduits in the injector body allow for the collection of fuel.
that escapes through the gap between the nozzle and its needle and that also lubricates and cools
tobera. This gap should not be greater than 0.0006mm. Otherwise, too much escapes.
combustible due to the high pressure it has.

Asbestos door.
The nozzle support with its nut is called a nozzle holder, where it is found
pressure and overflow regulation system in addition to the input connection of
combustible. It has a flange with holes to pass the screws or with a thread to
secure it to the buttstock.

Types of nozzles.

There are two types:

Nozzles with various openings, DL - DLL. They are used in direct injection engines and for
distribute the injection in the chamber the axes of the holes form a wide angle up to
at 1800C. The injection pressure is high, around 300 Kg/cm2 to achieve a good
atomization without losing the proper penetration. The holes are 0.05 mm.
the greater the number of openings, the smaller its diameter. The short nozzles are designated
by DL and the longer ones by DLL. These dimensions are only useful for locating more accurately
ease the injector in the cylinder head. Whatever its size, the clearance between the body
the nozzle and its needle is 0.0006 mm as the fuel escapes when there is,
wear
Reading plates and nozzles. Manufacturing houses use a coding system for the purpose of
to identify the different types of fuel injectors. A code is used to
the nozzles and another for the nozzle holder, being stamped on the flat surface
of the injector.

Current injectors are classified under the following coding:

To respond to the different sizes of injectors, there are five classes and they can
identify yourself using table II
The nozzles have the explanatory nomenclature of their characteristics printed as follows:

1° D = nozzle

2° N = Espiga L = Aguja corta LL = Aguja larga

3° N2 = Figure of the angular value of the jet.

4° R= 16mm S1l7 mm T 22 mm U 3º mm V 42mm

5° D = Strangulated effect

6 Factory reference

Examples:

1. DL 120 S = D - Nozzle L - short needle 120 - jet angle S - 17 mm O

2. DLL 160 T = D - Long needle nozzle LL - 160 - jet angle T - 22 - mm of O

3. DN45R=D-Nozzle N-detected 4s-jet angle R-16 mm of O

The nozzle tips are designated with the acronym DN used in injection engines.
indirect. Pre-combustion chamber, pre-chamber or energy cells. They use pressures of
discharge of 100 to 150 Kg./cm2 The body of the nozzle has its discharge opening in
central position, where the tip of the valve protrudes in a conical or cylindrical shape. The
pintaux has another lateral opening that starts in the annular chamber. When the injection is
very small there will only be fuel to lift the valve very little but enough
to make a good side injection for the energy cells.
Single hole nozzles
A few needle valve nozzles are single hole, therefore they can be
used in cameras in a special way by placing them off-center. When mounting a nozzle
From this class in your portable device, a mounting guide is used in order to locate it.
correctly making it fire its injection in the intended direction, that is to say without
crash against any unwanted surface.

Operation of the injector.

The fuel comes from the injection pump through the high-pressure line to the fitting of
entry. Follow through the body duct to the nozzle chamber, around its
needle. The push of the fuel against the valve overcomes the spring, lifting it from its
seat, allowing the fuel to flow through the holes where it is atomized. The cone
the atomized fuel formed depends on the axis of the holes, referred to as
injection angle.
Fixing of the injectors
The fixing of the injectors to the cylinder head is generally done with a flange that
It supports the body of the injector and is held in place with screws or bolts. There is another one, of
flange fixation in which it is an integral part of the injector body. The fastening system
by nut consists of a hexagonal nut that freely rotates around the body of the
injector that screws into the cylinder head for fastening.

Fuel atomization
Spraying is defined as the division of fuel into small droplets. This is
important because a drop inflates superficially and its total combustion depends
of its size and speed as it moves through the air, it brings oxygen while it
Remove the inflamed gases. Otherwise, it will show a great delay in the inflammation.

Droplet of fuel moving inside the chamber.

Damage to the hydraulic injector.

Nozzle with blocked holes

Carbon deposits or solid particles suspended in the fuel can
cover the openings of the nozzles, especially the smallest ones. When a nozzle gets blocked
this can totally explode or the Teflon seal breaks, nullifying the operation
from this cylinder. If the obstruction is partial, that is to say one or two openings, the fuel
it is not distributed throughout the chamber, degrading the mixture, due to excessive atomization
proceed to uncover the holes.

2. Miscalibrated hydraulic injector

If an injector has its spring very compressed, the fuel discharge will occur at a
excessive pressure, which leads to a lot of atomization and poor penetration.

If on the contrary, it discharges at low pressure, then the spraying is very thick and its
penetration is high. In both cases, problems arise as poor penetration
it implies a very pronounced poor mixture if the engine is of low turbulence. When the
penetration is excessive, the mixture loses fuel and additionally, it washes the lubricant
from the cylinder, causes lubrication problems. It is of special concern to calibrate to the pressure
just a recommendation from the engine manufacturer.

3. Seals and gaskets

When hermeticity cannot be achieved based on a good fullness, one resorts to
a leak-proof seal, pressing two surfaces, one of which is
malleable in order to achieve deformation and adapt to the other surface
eliminating the pores or scratches that would otherwise present escape routes.
Very malleable copper washers are used to seal parts that cannot be sealed.
seal yourself in another way.

PLANITUD

The cartridge holders and the nozzles

They present a perfect flatness or smooth surface without roughness, which are polished with
mirror finish with the help of polishing paste or water sandpaper, supported on a
planimeter. The abrasive must be fine to achieve a scratch-free surface.
appreciable.

Hermeticity
When flatness is good, between two surfaces, they provide adequate contact for
prevent the escape of low viscosity fuel despite the high pressures that
support
GATE OF THE NOZZLE VALVE
The defective valve seal causes leaks before and after injection, leaks
that are not atomized. This dripping will quickly form soot in the chamber, plus
meaning higher fuel consumption.

The defect may be due to wear on the seats or simply due to lacquers or any
dirty that remains stuck in its seat. The settlement with ointment is sufficient
to avoid the problem unless a nozzle change is required.

EXCESSIVE RETURN OR FUEL OVERFLOW

When a nozzle has worked many hours or with low-quality fuel, it...
there may be wear between the needle and its housing in the nozzle that
It is normally 0.0006 mm. As you will understand, the increase in this
Huelgo presents an easy way for the fuel to leak back to the return.
decreasing the injected amount. If the overflow is very varied from one nozzle to another, it
You will understand that some cylinders will exert more effort than others. In the case of excessive
The rebose must be replaced with a new nozzle.
NOZZLE WITH THE NEEDLE STUCK
In low-quality or contaminated fuels, heat produces transformations of
its components in: soot, lacquers, and oxides. The lacquers adhere to the needles of the
nozzles, canceling their movement just like oxidation or corrosion does.
In addition, the deformations in the nozzles, caused by re-heating or by
excessive adjustment of your nut or the injector against the cylinder head. An extended time of
motor not working, is another cause of the nozzles getting stuck.

PIPES WITH DEFORMED HOLES

Oxidation or corrosion can abrade the holes of the nozzles, but it is more
common the damage caused when trying to open them, we use a larger wire
diameter than that of the hole whose value is from 0.05 mm to 0.55 mm. Its largest diameter or
its deformation allows the jet to spread unevenly, which harms the mixing,
causes washing of the lubricant or forms carbon deposits. It goes without saying that it needs to be changed.
INCORRECT NOZZLE HEIGHT
To create a seal between the nozzle and the cylinder head, a metal washer is used. When assembling the
Injector we may forget the washer or that we placed two at a time,
we must also remove the dirt or any foreign body inside the hole of the
culata. Como es natural, la punta de la tobera no quedará a la altura conveniente y sus
jets. They will strike against the butt or against the head of the piston, forming deposits of
soot and hindering the good mixture, take greater care as it can also
hit the nozzle with the piston.

I screw by the nozzle nut

A cracked or loose nut presents a poor seal between the nozzle and its body, so
The fuel will escape so much, leading to increased costs and unattractive leaks.
Any scratch or foreign body on the settling face will present the same.
escape, making this more frequent. To avoid the escape, level the surfaces of
contact.

CLEANING OF THE INJECTORS

Disassembly:

[Link] the injection pipe fittings.

b. Disconnect and remove the fuel return tubes.
Injection tube nut

SPILL TUBE = Tubo de retorno.

c. Loosen the injection support nuts or brackets and remove it

UNARMED

a. Mount the injector on the tool to disassemble it if available, otherwise mount it on a

bank press without subjecting it to much adjustment, with the end of the nozzle facing up.

b. Loosen the nozzle nut and remove it.

c. Remove the nozzle.

d. Remove the spacer if present, the spring seat, shims

of adjustment if any.

e. Be careful with the position of the elements during disassembly.

Nozzle holder = cuerpo. Adjusting shim = Suplementos de ajuste. Nozzle spring =Resorte
del inyector. Spring seat = Asiento del resorte. Spacer = [Link] = [Link]
needle = Aguja [Link] assembly = Tobera. Retaining nut = Tuerca de la
tobera.

Inspection

Completely clean all elements with A.C.P.M.

b. If the spray needle is damaged or blunt, replace the nozzle.

If the spray needle is excessively blue, replace the nozzle.

d. Observe the seating area of the nozzle nut, if it is corroded or damaged

replace it.

e. Observe the spring and check its length, if it is bent, if so, change it.

Cleaning

Clean the injector components with an injector cleaning kit.

b. The parts that must be clear are indicated in the Figure.

Nozzle holder = Cuerpo del inyector. Adjusting shim = Suplementos de ajuste. Nozzle
spring = Resorte del inyector. Spring seat = Asiento de resorte Spacer = Espaciador. Nozzle
needle = Aguja Pulverizadora. Nozzle assembly = Tobera. Retaining nut = Fuera de la
faucet

Clean the injector seat with the appropriate tool.

Clean the spray holes of the nozzle by selecting the appropriate diameter.
of the wire.

f. De-carbon the tip of the spray nozzle. Using the appropriate tool
(fine-grained stone).

g. Check the needle in the nozzle hole. Place the needle in the nozzle hole and
this should fall gently into the body by its own weight.
For the navy.
Repeat the steps observed during the disassembly in reverse order. Tighten the nut of
the nozzle to the troque, specified by the manufacturer in the service manual.

Caution:
When using the injector tester, be careful that the high-pressure fuel does not...
make contact with your hand or body and be sure to protect your eyes with glasses.

Injector calibration.
1. To perform the injector calibration, it can be done using two methods.

a. With a adjusting screw: It consists of a screw that, when tightened, makes contact with the
spring, pressing it against the stem that pushes the needle against its seat, which
it increases the fuel pressure when it exits through the openings. By loosening them, the force
from the spring against the rod, gives way, decreasing the fuel pressure upon exit, and a
nut responsible for fixing the screw so that the injector does not get misaligned.

Injector with screw regulation

b. With calibrated washers. To carry out the calibration with calibrated washers. It should be
to have a good assortment of these in different thicknesses. Generally
they come in hundredths of a millimeter and thousandths of an inch. With this method it is a
not very costly the gauge as washers must be placed in the injector and checked
Every time they are changed. Placing washers increases the pressure, removing them decreases it.

Injector calibration

1. Install the injector on the injector tester and remove the air by loosening the tube nut.
high pressure.

2. Pump slowly (once per second) and observe the manometer.

3. Read the pressure on the manometer just when the injector sprays and adjust it if necessary.
necessary to the injection pressure recommended by the manufacturer in the manual of
service.

Drip test
Maintain the pressure (between 120 and 250 psi) below the injection pressure.

2. Check for any dripping at the nozzle tip or around the body.

If there is dripping, clean it and give it a settlement, if the dripping continues replace the nozzle.
SPRAY TEST
Move the pumping lever 4 to 6 times per second or more.

2. Observe the spraying.

3. If the spraying is not correct, clean the nozzle. If it doesn't improve, change the nozzle.

Pressure measurements

Injection pressure is important as it requires a value that raises the

valve overcoming a spring. When injection begins, the fuel must
encontrar oposición en los orificios para mantener abierta la válvula y lograr la
atomization.

When the engine speed is low, the fuel also has a low speed.
which causes the pressure to tend to drop so that the valve descends blocking the
output and raising the pressure. This way, a needle oscillation can be repeated with its
characteristic click. (Sound). The pressure should not exceed normal.
present excessive atomization degrading the mixture and penetration.

Let's see some equivalences of the problems' manometers:

1 K/cm2 = 14.2 lb. /puIg2= 1,033 Kg./cm2

1 KPa = 10 Newton/m2
1 ATM = 760 mm of mercury column.
1 SAR = 100 KPa.
1 ATM = 14.7 lb./in²
1 BAR = 1Q Pa.
1 ATM = 10,033 m. water column.

1 BAR = 0.98 ATM.