3054B Engine for Caterpillar Built Machines Caterpillar

Illustration 1	g00293085
(1) Connection for the nut (not shown) of the fuel supply line (2) Threaded hole for the banjo bolt of the fuel return line (3) Nut of the fuel injection nozzle (4) Wire clip (5) Seat washer

Illustration 2	g00313043
Fuel injection nozzles and lines (1) Nut for the fuel supply line (2) Banjo bolt (6) Fuel supply line (7) Fuel return line

1. Run the engine at low idle.

2. Loosen the nut for fuel supply line (1) at each fuel injection nozzle. Listen for the low idle to decrease or listen for the low idle to become rough at each engine cylinder.

3. The fuel injection nozzle is faulty when fuel supply line (1) is loosened and the following events occur:

   • The engine rpm does not decrease.

   • The engine does not idle roughly.

   If a faulty fuel injection nozzle is suspected, remove the fuel injection nozzle for additional testing.

   Note: If leakage occurs at the connection for the nut of the fuel supply line (1), make sure that fuel supply line (6) and the connection are correctly aligned. Do not tighten the nut for fuel supply line (6) 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.

Inspection and Cleaning of the Fuel Injection Nozzles

Before a fuel injection nozzle is tested, remove any loose carbon from the tip of the fuel injection nozzle. Do not use abrasive material or a wire brush in order to clean the nozzle.

The fuel injection nozzle is not a serviceable part. Disassembling or adjusting the nozzle will violate the standards for emissions.

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. A scratch or a burr can also cause spray distortion. Keep the nozzle tip clean. Dirt in the orifices can damage engine components. Dirt in the orifices can also cause spray distortion.

Perform the following procedures in order to determine if a fuel injection nozzle does not work correctly.

Pressure Test

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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.

Illustration 3	g00322849
5P-4150 Nozzle Testing Group (8) 5P-7448 Adapter (9) Fuel injection nozzle (10) 6V-2170 Tube (11) 1U-8857 Extension Tube (12) 8S-2270 Fuel Collector (13) 8T-5313 Filter

1. Connect fuel injection nozzle (9) to the fuel injection nozzle testing group. Refer to Illustration 3 in order to set up the fuel injection nozzle testing group.

   The spray from the fuel injection nozzle must be directed into the 1U-8857 Extension Tube (11) and the 8S-2270 Fuel Collector (12).

   Refer to the table in the Specifications Module, "Fuel Injection Nozzles" topic for the correct pressure settings. If the opening pressure is not within the range of the setting that is specified in the table, the fuel injection nozzle must be replaced.

   Use clean 6V-6068 Calibration Fluid when the fuel injection nozzles are tested. The calibration fluid is equivalent to SAE J-967 (ISO 4113) oil.

2. Close the gauge protector valve. Close the shutoff valve. Open the pump isolator valve. In order to flush the fuel injection nozzle, operate the nozzle tester for 10 to 15 strokes at a rate of approximately 60 strokes per minute.

3. Open the gauge protector valve. Slowly increase the pressure until the valve in the fuel injection nozzle 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 the fuel injection nozzle. The opening pressure is defined when the needle valve is lifted from the valve seat.

   Refer to the table in the Specifications Module, "Fuel Injection Nozzles" for correct pressure settings. If the opening pressure is not within the range of the setting that is specified in the table, the fuel injection nozzle must be replaced.

Back Leakage Test

1. Connect fuel injection nozzle (9) to the fuel injection nozzle testing group. Refer to Illustration 3 in order to set up the fuel injection nozzle testing group.

   Position the fuel injection nozzle so that the direction of the fuel spray is into the 1U-8857 Extension Tube (11) and the 8S-2270 Fuel Collector (12).

2. Pump the pressure to about 1030 kPa (150 psi) below the opening pressure of the fuel injection nozzle. Refer to the Specifications Module, "Fuel Injection Nozzles" topic for the correct setting of the opening pressure. Release the handle. When the pressure begins to decrease, note the time that is required for the pressure to decrease to approximately 0 kPa (0 psi). If the fuel injection nozzle 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 the fuel injection nozzle.

3. Look for any leakage from the pressure faces of the holder and the retaining nut of the fuel injection nozzle. If leakage is visible, make sure that the components are tightened to the correct torque.

   If leakage continues to occur, unscrew the retaining nut from the body. Inspect the threaded surfaces for foreign particles and damage. If the faces are clean and undamaged, test the fuel injection nozzle. Repeat Steps 1 and 2.

Fuel Injection Nozzle and Seat Test

1. Connect fuel injection nozzle (9) to the fuel injection nozzle testing group. Refer to Illustration 3 in order to set up the fuel injection nozzle testing group.

   Position the fuel injection nozzle so that the direction of the fuel spray is into the 1U-8857 Extension Tube (11) and the 8S-2270 Fuel Collector (12).

2. Pump the pressure of the nozzle tester to approximately 1030 kPa (150 psi) below the opening pressure of the fuel injection nozzle. Fuel should not collect on the tip of the fuel injection nozzle 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 the fuel injection nozzle.

Test 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.

The pressure adjustment must be correct before the spray pattern is tested.

Illustration 4	g00322083
Correct nozzle spray pattern

1. Connect fuel injection nozzle (9) to the fuel injection nozzle testing group. Refer to Illustration 3 in order to set up the fuel injection nozzle testing group.

   Position the fuel injection nozzle so that the direction of the fuel spray is into the 1U-8857 Extension Tube (11) and 8S-2270 Fuel Collector (12).

2. Close the gauge protector valve and the shutoff valve. Open the pump isolator valve.

3. Quickly pump the nozzle tester and look at the spray pattern when the fluid begins to flow through the orifices of the fuel injection nozzle.

   The spray, which flows from all of the orifices, must have the same pattern. Refer to the correct spray pattern in Illustration 4. Any vertical change or any horizontal change from the correct spray pattern indicates a faulty fuel injection nozzle.

   Note: Be sure that the gauge protector valve is closed before the fuel injection nozzle is removed from the nozzle tester. Closing the valve will prevent damage to the pressure gauge.

Installation of the Fuel Injection Nozzles

1. When a fuel injection nozzle is removed from the cylinder head, replace seat washer (5). Refer to Illustration 1 for more information.

   Note: If a seat washer remains in the recess of the cylinder head for the fuel injection nozzle, the protrusion of the fuel injection nozzle into the engine cylinder will be incorrect. Also, if the seat washer is damaged, the protrusion of the fuel injection nozzle into the engine cylinder will be incorrect.

2. Place a 2 mm (0.1 inch) bead of 4C-5591 Anti-Seize Compound on the first two threads of the fuel injection nozzle below nut (3). Refer to Illustration 1 for more information.

   Note: Do not rotate the fuel injection nozzle after the fuel injection nozzle has been tightened to the specified torque. Rotating the fuel injection nozzle will cause a broken seal of the anti-seize compound between the threads. A seal which is broken may allow leakage of combustion gas through the threads.