Northern Lights M864W Operator's Manual - page 19
OM864W 09/07
19
Servicing
SP12. INJECTOR SERVICE
1. Injectors should be checked every 750 hours. This
check should be made by a Northern Lights dealer or
local injection repair station.
To insure that your engine stays in compliance with
applicable EPA and CARB emission standards, the
following maintenance procedures and intervals
must be maintained.
1500 Hours: Fuel injectors are to be removed and
injector tips cleaned.
3000 Hours: Fuel injectors removed for adjustment,
cleaning, and repaired.
CAUTION: Escaping diesel fuel under pressure
can have suffi cient force to penetrate the skin
causing serious personal injury. If injured by
escaping fuel, see a doctor at once.
2. Injector
Removal:
a. Clean loose dirt from around the injectors and
the fuel lines.
b. Relieve high pressure in the fuel lines by
loosening the delivery line fl are nuts at each
injector.
Figure 11: Injectors
c. Remove delivery lines (
Figure 12-B
) by
disconnecting from injectors and injection pump.
Remove all lines as an assembly; do not remove
the spacers. Cover the ends of the lines, the injector
inlets and injection pump outlets to keep dirt out.
d. Remove the return line retaining nuts, washers,
and return line.
e. Loosen the injector (
Figure 12-I
). Remove the
injector.
f. Remove the injector seat. Cover the holes to
prevent debris from entering the cylinders.
NOTE: Do not use pry bars to remove injectors
from the cylinder head.
3. Injector Repair and Cleaning
a. Take injectors to your Northern Lights dealer
or local injection repair station for testing and
service.
4. Injector
Installation:
a. Install new injector seal washer seat and
injector. Tighten the injector (
Figure 11-1
)
to 42 - 50 ft/lbs. (5.8 - 6.9 k/gm). Do not
overtighten.
b. Reinstall the return line (
Figure 11-4
) using
new sealing washers (
Figure 11-2
).
Tighten bolts (
Figure 11-3
) to 18 - 25 ft/lbs
(2.5 - 3.5 k/gm).
NOTE: Overtightening can damage injectors.
c. Reinstall injection lines (
Figure 12-B
). Tighten
fl are nuts (
Figure 12-K
) at injection pump to
18.2 - 25.3 ft/lbs (2.5 - 3.5 k/gm). Leave the lines
loose at injectors for bleeding.
d. Bleed the injection lines (
Figure 12-B
). Crank the
engine
to
fi ll the lines. Tighten fl are nuts at
injectors to 18.2 - 25.3 ft/lbs (2.5 - 3.5 k/gm).
e. Start the engine and check for leaks using a piece
of paper or cardboard. Do not use your hand to
check for leaks.