| Required Tools | ||
|---|---|---|
| Part Number | Part Name | Qty |
| 5P-4150 | Tester Group | 1 |
| 5P-7448 | Adapter | 1 |
| 6V-2170 | Tube Assembly | 1 |
| 8S-2270 | Fuel Collector | 1 |
| 1U-8857 | Extension Tube | 1 |
| 6V-6068 | Calibration Fluid | 1 |
- Run the engine at low idle.
- Loosen the nut for the fuel supply line at each fuel injection nozzle (1). Listen for the low idle to decrease or become rough when the nuts are loosened at each cylinder.
The fuel injection nozzle may be faulty if the following items occur during the test:
- Engine rpm does not decrease.
- The engine continues to run properly.
- If the fuel injection nozzle is worn or damaged, remove the fuel injection nozzle for additional testing.
Note: If leakage at the nut for the fuel supply line occurs, make sure that the fuel supply line and the nut for the fuel supply line are correctly aligned with the inlet connection of the fuel injection nozzle. Do not tighten the nut for the fuel supply line on the high pressure fuel line more than the recommended torque. If the nut is tightened more, the fuel line may become restricted or the threads of the fuel injection nozzle and the nut may be damaged.
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| Illustration 1 | g00846800 |
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(1) Fuel injection nozzle
(2) Gasket | |
Inspection and Cleaning of the Fuel Injection Nozzles
Before a fuel injection nozzle is tested, remove any loose carbon from the tip of nozzle. Do not use abrasive material or a wire brush in order to clean the nozzle.
Note: Extra care should be used in handling the fuel injection nozzle in order to prevent damage to the nozzle tip. A scratch or a burr could cause needle leakage or spray distortion. Dirt in the orifices of the nozzle tip can damage engine components. The dirt can also distort the spray pattern of the nozzle.
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| Illustration 2 | g00470020 |
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5P-4150 Nozzle Testing Group (1) 5P-7448 Adapter (2) Fuel injection nozzle (3) 6V-2170 Tube Assembly (4) 1U-8857 Extension Tube (5) 8S-2270 Fuel Collector (6) 8T-5313 Filter | |
This procedure tests for leakage around all components of the fuel injection nozzle.
- Connect fuel injection nozzle (2) to the tooling that is shown in Illustration 2.
Position fuel injection nozzle (2) so that the direction of the fuel spray is into 1U-8857 Extension Tube (4) and 8S-2270 Fuel Collector (5).
- Pump the pressure to about
2030 kPa (294 psi) below the opening pressure of fuel injection nozzle (2). Release the handle. When the pressure begins to decrease, note the time that is required for the pressure to decrease to approximately0 kPa (0 psi) . If fuel injection nozzle (2) is not faulty, the time will not be less than 5 seconds or more than 45 seconds.If the time that is required for the pressure to decrease to
0 kPa (0 psi) is less than 5 seconds, too much fuel is leaking around the valve needle. Replace fuel injection nozzle (2). - Look for any leakage in the connection from the adapter to fuel injection nozzle (2). If leakage is visible, make sure that the components are tightened to the correct torque.
If leakage continues to occur, unscrew the body of fuel injection nozzle (2) from the nozzle nut. Inspect the threaded surfaces for foreign particles and damage.
If the faces are damaged, replace fuel injection nozzle (2).
If the faces are undamaged, clean the faces. Repeat Steps 1 and 2. If leakage continues to occur, replace the fuel injection nozzle.
- Pump the pressure of the nozzle tester to approximately
2030 kPa (294 psi) below the opening pressure of fuel injection nozzle (2). Fuel should not collect on the tip of fuel injection nozzle (2) in a sufficient quantity in order to drip from the tip for at least ten seconds. A light dampness is acceptable.If the results of the tests are not acceptable, replace fuel injection nozzle (2).
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Ensure that you wear eye protection at all times during testing. When fuel injection nozzles are tested, test fluids travel through the orifices of the nozzle tip with high pressure. Under this amount of pressure, the test fluid can pierce the skin and cause serious injury to the operator. Always keep the tip of the fuel injection nozzle pointed away from the operator and into the fuel collector and extension. |
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| Illustration 3 | g00470020 |
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5P-4150 Nozzle Testing Group (1) 5P-7448 Adapter (2) Fuel injection nozzle (3) 6V-2170 Tube Assembly (4) 1U-8857 Extension Tube (5) 8S-2270 Fuel Collector (6) 8T-5313 Filter | |
| NOTICE |
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Do not use dirty test fluids when you test fuel injection nozzles. Also, do not test fuel injection nozzles unless you have the correct service tools.The use of dirty test fluids and the use of incorrect service tools will result in damage to fuel injection nozzles. |
Note: This procedure is a test of the opening pressure of the fuel injection nozzle.
- Connect fuel injection nozzle (2) to the tooling that is shown in Illustration 3.
The spray from fuel injection nozzle (2) must be directed into 1U-8857 Extension Tube (4) and 8S-2270 Fuel Collector (5).
Use clean 6V-6068 Calibration Fluid when the fuel injection nozzles are tested. The calibration fluid is similar to SAE J-967 (ISO 4113) oil.
- Close the gauge protector valve. Close the shutoff valve. Open the pump isolator valve. Flush fuel injection nozzle (2) by operating the nozzle tester. Operate the nozzle tester for 10 to 15 strokes at a rate of approximately sixty strokes per minute.
- Open the gauge protector valve. Slowly increase the pressure until the valve in fuel injection nozzle (2) opens. Note the highest pressure indication on the dial indicator before the pointer moves to
0 kPa (0 psi) . This highest pressure indication is the opening pressure of fuel injection nozzle (2). The opening pressure occurs when the valve needle is lifted from the nozzle seat.Refer to Specifications, "Fuel Injection Nozzles" for the correct pressure settings. If the opening pressure is not within the range of the setting which is given in the table, fuel injection nozzle (2) must be replaced.
Test for the Nozzle Spray Pattern
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Ensure that you wear eye protection at all times during testing. When fuel injection nozzles are tested, test fluids travel through the orifices of the nozzle tip with high pressure. Under this amount of pressure, the test fluid can pierce the skin and cause serious injury to the operator. Always keep the tip of the fuel injection nozzle pointed away from the operator and into the fuel collector and extension. |
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| Illustration 4 | g00470020 |
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5P-4150 Nozzle Testing Group (1) 5P-7448 Adapter (2) Fuel injection nozzle (3) 6V-2170 Tube Assembly (4) 1U-8857 Extension Tube (5) 8S-2270 Fuel Collector (6) 8T-5313 Filter | |
The pressure adjustment must be correct before you test the spray pattern.
This procedure tests for the correct spray pattern for fuel injection nozzles.
- Connect fuel injection nozzle (2) to the tooling that is shown in Illustration 4.
Position fuel injection nozzle (2) so that the direction of the fuel spray is into 1U-8857 Extension Tube (4) and 8S-2270 Fuel Collector (5).
- Close the gauge protector valve and the shutoff valve. Open the pump isolator valve.
Show/hide table
Illustration 5 g00468241 Phases of operation and spray pattern of the fuel injection nozzle
The spray angle is 4 degrees from the vertical when the nozzle is fully open.
(A) Closed nozzle
(B) Open nozzle
(C) Fully open nozzle - Quickly pump the nozzle tester and look at the spray pattern when the fluid begins to flow through the orifices of fuel injection nozzle (2) .
The spray flows around the tip of the nozzle. A difference in the nozzle spray patterns indicates that fuel injection nozzle (2) is faulty. Refer to the correct spray pattern in Illustration 5.
Observe the following characteristics of the spray:
- Drops of fuel should not be in the spray.
- Fuel should be sprayed in the shape of a cone around the nozzle.
- Fuel should be sprayed evenly in a 360 degree pattern around the nozzle.
Note: Be sure that the gauge protector valve is closed before fuel injection nozzle (2) is removed from the nozzle tester. Closing the valve will prevent damage to the pressure gauge.
