Diesel Injector repairs + pressure setting, Perkins 4.203 engine (CAV injectors)

These are the injectors of my Perkins 4.203 forklift engine with CAV injectors, the engine was smoking badly and misfiring sometimes, too.
Time for the 500 hour maintenance as i think that no one looked at these for a long time.
It turned out that 2 were leaking badly and nozzles were stuck, the #3 pintle was a real challenge to get out, so we applied some rather unusual method to get it out. Another one was a different type and all were low on opening pressure. one as low as 95 bar,
Standard setting for this engine should be 120bar.
All 4 now performing reasonably ok and the engine runs much better.
Episode #3 of the forklift story (coming soon) will show dismantling the first injector, this video shows cleaning, re-assembly and pressure setting.
The engine is not the best anymore, producing a lot of blowby, so every little helps, but sooner or later, i will need to rebuild it anyway.
Therefore i am happy with the result, even the injectors would need new nozzle kits to make them perfect.
The Lansing Playlist is here:
• Lansing Bagnall Forklift
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www.dynoguy.co.uk

[@rasoul786]

Interesting. loved that oil can! Dad had one just like it, and the hand rolled smokes! in one hand while working. perfect

[@pearcemachineshop5200]

Good luck Mike I hope works well enough for the time being.
Al.

[@dynoguy]

Thanks Al,...they already back in and it smokes a lot less now, ...hope you well

[@HolzMichel]

as bad as the resolution of your camera is, the scoring on that pin is baaaaad...you definitely nailed it when you said "chisel mechanic"...

[@dynoguy]

Well, being 40 something years old, it looks like there was more than one expert applying different levels of destructive skills .... this thing gives me new surprises every day ...

[@johnstrange6799]

Thanks :)

[@dynoguy]

Wow, that was quick......i was still in the middle of finishing the description .....thanks for watching

[@johnstrange6799]

@@dynoguy Slow night here. :)

[@sadiqmirza3055]

Nozzle DL 110 S 6133/ 6267

[@dynoguy]

Thank you

[@milk6355]

Next time you spin the nozzle in the lathe add a bit of toothpaste with the the oil

[@dynoguy]

Well, i'd rather use lapping paste, but in this case i deliberately did not use any abrasive (not even toothpaste ...:), because it certainly would increase the clearance and these nozzles are worn already. Still works fine the way i did it.