Usage:
Reference: Service Manual, Parts Book, Special Instruction Form SEHS7292
Use the 8S2245 Nozzle Cleaning Tool Group, shown above, when cleaning of fuel injection nozzles is necessary. DO NOT disassemble and clean a nozzle unless testing indicates the need to do so. Always keep the work area and tools absolutely clean.
| NOTICE |
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DO NOT use a steel wire brush or a wire wheel to clean the nozzle, nozzle tip or nozzle parts. |
NOTE: Nozzle test procedures are given in Form SEHS7292, USE OF 5P4150 NOZZLE TESTING GROUP.
Troubleshooting, Cleaning and Adjustment (Pencil-Type Nozzles Only)
A. To troubleshoot these nozzles, use the troubleshooting procedures as given in this instruction.
B. Use only the procedure as given by the nozzle part number to clean these nozzles. Refer to the index of this instruction for the correct page for the cleaning procedure needed.
C. If Valve Opening Pressure (VOP) is less than specified in the chart that follows, do not use the nozzle.
Nozzle Cleaning (9L7883, 9L9263 and 9N2366 Nozzles)
Do not disassemble and clean a nozzle unless testing indicates the need to do so. Use the 8S2245 Cleaning Kit. Keep the work area and tools absolutely clean.
1. Put the nozzle in a vise using 8S2250 Nozzle Holding Tool (1). For the 9L9263 Nozzle Assembly, loosen pressure adjusting screw locknut (2). For the 9L7883 Nozzle Assembly, loosen lift adjusting screw locknut (3) and pressure adjusting screw (4). For the 9N2366 Nozzles, loosen the locknut for the lift adjusting screw and the locknut for the pressure adjusting screw.
2. Back out pressure adjusting screw (4) or (5) and lift adjusting screw (6). Allow spring (7), the seats and ballwasher, or spring (7), the seat and shim(s) (8) to fall into the hand.
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If lift adjusting screw (6) is not backed out, valve (9) can be damaged in later steps. |
3. If valve (9) does not slide out, remove it with 8S2254 Retractor Assembly (10) for the 9L9263 Nozzle Assembly, or with the 5P0958 Retractor Assembly for a 9L7883 or 9N2366 Nozzle Assembly. Push the retractor down and turn the knurled nut counterclockwise to secure the collet and withdraw the valve.
4. Use the 8S2246 Wire Assembly followed by the larger 8S2247 Wire Assembly to clean the carbon from the spray orifices. Secure the wire in the 8S2256 Vise Assembly (11), letting the end protrude about 1.0 mm (1/32"). Use 8S2260 Honing Stone to remove burrs from the wire ends. Stone a slightly flat surface on one side of the wire to help cut carbon from the orifice. While slowly rotating the wire, insert it into each orifice until it turns freely.
| NOTICE |
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Do not use punching action to remove deposits. |
5. Flush the body with solvent and inspect the tip for orifice condition. Discard a nozzle having chipped or eroded orifices.
6. Use 8S2255 Scraper (12) to clean deposits from the tip seat area.
7. Use 8S2251 Drill (13) in 8S2256 Vise Assembly to ream deposits from the sac hole area. Repeat steps 4 and 5.
8. Clean nozzle valve (9) with 8S2258 Brass Wire Brush (14). Remove varnish with a solvent and 8S2249 Pad. Do not chuck the valve in a motor-driven lathe or use a steel wire brush on nozzle parts. Inspect and wash the nozzle parts; then wet with clean fuel.
9. Assembly of 9L9263 Nozzle
A. Hold valve (9) by the shank and slide it partially into the nozzle body.
B. Assemble ballwasher (15), upper spring seat (16), spring (7) and lower spring seat (17), to screw (5).
C. Tilt the nozzle body with lower seat (17) contacting the top of valve (9). Push the valve and spring components into the nozzle body. Do not dislodge the lower seat.
D. Thread pressure adjusting screw (5) by hand until the spring compresses to hold the parts in place.
E. Refer to "Adjustment of 9L9263 Nozzle Assembly".
10. Assembly of 9L7883 Nozzle
A. Hold valve (9) by the shank and slide it partially into the nozzle body.
B. Assemble shims (8), spring (7) and seat (18) to the pressure screw assembly; make sure the thickest shim is against the pressure screw.
C. Tilt the nozzle body with seat (18) contacting the top of valve (9).
D. Push the valve and spring components into the nozzle body. Do not dislodge the spring seat.
E. Thread the pressure adjusting screw by hand until the spring compresses to hold the parts in place.
F. Refer to "Adjustment of 9L7883 Nozzle Assembly".
11. Assembly of 9N2366 Nozzle
A. Hold valve (9) by the shank and slide it partially into the nozzle body,.
B. Assemble shim (8), spring (7) and seat (18) to pressure screw (5).
C. Tilt the nozzle body with seat (18) contacting the top of valve (9).
D. Push the valve and spring components into the nozzle body. Do not dislodge the spring seat.
E. Thread pressure adjusting screw (5) by hand, until the spring compresses to hold the parts in place.
F. Refer to "Adjustment of 9L6969, 7N0449, 9N2366, 9N3299, 9N3700, 9N3979, 1W5829, 4W1819, 4W8483 and 7W3710 Nozzles.".
Troubleshooting - 9L7883, 9L9263 and 9N2366 Nozzles
If cleaning does not restore the nozzle to its proper operating condition, clean the valve by lapping it to the tip seat. Place a small amount of the 8S2259 Lapping Compound on the valve seat and insert the valve into the body. Grip the top of the valve with retractor (10) and rotate it 3 to 5 turns in each direction. Clean and reassemble the valve.
NOTE: Use the 8S2254 Retractor for the 9L9263 Nozzle Assembly, and the 5P0958 Retractor for the 9L7883 and 9N2366 Nozzle Assemblies. See the TROUBLESHOOTING GUIDE FOR PENCIL-TYPE NOZZLES (ONLY) in this instruction
Nozzle Cleaning (9L6969, 7N0449, 9N3299, 9N3700, 9N3979, 1W5829, 4W1819, 4W8483 and 7W3710 Nozzles)
Do not disassemble and clean a nozzle unless testing indicates the need to do so. Use the 8S2245 Cleaning Kit. Keep the work area and tools absolutely clean.
1. Put the nozzle in a vise using 8S2250 Nozzle Holding Tool (1). Remove cap (2) if it has not already been removed.
2. Loosen lift adjusting screw locknut (3) and pressure adjusting screw locknut (4).
3. Back out lift adjusting screw (5) and pressure adjusting screw (6). Tip the nozzle body and allow shim (7), spring (8) and spring seat (9) to fall into the hand.
4. If nozzle valve (10) will not slide out, remove it with 5P0958 Retractor Assembly (11). If valve (10) is stuck and cannot be removed with the retractor assembly, a new nozzle must be used.
5. For all nozzles except 7N0449, use the 8S2246 Wire Assembly followed by the larger 8S2247 Wire Assembly to clean the carbon from the spray orifices. Secure the wire in the 8S2256 Vise Assembly (12), letting the end protrude about 1.0 mm (1/32"). Use 8S2260 Honing Stone to remove burrs from the wire ends. Stone a slightly flat surface on one side of the wire to help cut carbon from the orifice. While slowly rotating the wire, insert it into each orifice until it turns freely.
| NOTICE |
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Do not use punching action to remove deposits. |
6. Flush the body with solvent and inspect the tip for orifice condition. Discard a nozzle having chipped or eroded orifices.
7. Use 8S2255 Scraper (13) to clean deposits from the tip seat area.
8. Use 8S2251 Drill (14) in 8S2256 Vise Assembly to ream deposits from the sac hole area. Repeat steps 5 and 6.
9. Clean nozzle valve (10) with 8S2258 Brass Wire Brush (15). Remove varnish with a solvent and 8S2249 Pad. Do not chuck the valve in a motor driven lathe or use a steel wire brush on nozzle parts. Inspect and wash the nozzle parts; then wet with clean fuel.
| NOTICE |
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Never use a steel wire brush for nozzle orifice cleaning. |
Assembly of 9L6969, 7N449, 9N3299, 9N3700, 9N3979, 1W5829, 4W1819, 4W8483 and 7W3710 Nozzles
A. Hold valve (10) by the shank and slide it partially into the nozzle body.
B. Assemble spring seat (9), spring (8), shim (7) and pressure adjusting screw (6) on lift adjusting screw (5).
C. Install locknuts (3) and (4).
D. Tilt the nozzle body with spring seat (9) touching valve (10).
E. Assemble the components into the nozzle body.
F. Refer to "Adjustment of 9L6969, 7N0449, 9N2366, 9N3299, 9N3700, 9N3979, 1W5829, 4W1819, 4W8483 and 7W3710 Nozzles."
Troubleshooting - 9L6969, 7N0449, 9N3299, 9N3700, 9N3979, 1W5829, 4W1819, 4W8483 and 7W3710 Nozzles
If cleaning does not restore the nozzle to its proper operating condition, clean the valve by lapping it to the tip seat. Place a small amount of 8S2259 Lapping Compound on the valve seat and insert the valve into the body. Grip the top of the valve with 5P0958 Retractor (11) and rotate it 3 to 5 turns in each direction. Clean and reassemble the valve. See the TROUBLESHOOTING GUIDE FOR PENCIL-TYPE NOZZLES (ONLY) in this instruction.
Adjustment of 9L9263 Nozzles
1. Put the nozzle in a vise with 8S2250 Nozzle Holding Tool (1). Loosen adjusting screw locknut (2). Install the nozzle on the tester.
2. Turn lift adjusting screw (3) two full turns counterclockwise (CCW).
| NOTICE |
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If lift adjusting screw (3) is not loosened, the valve can be damaged in later steps. |
3. Pressurize the nozzle and turn pressure adjusting screw (4) (counterclockwise to decrease and clockwise to increase) to obtain the opening pressure given in the chart. Do not tighten locknut (5).
4. Valve Lift Adjustment-9L9263 Nozzle
A. When the correct opening pressure is set, and while pumping test fluid through the nozzle, hold the pressure adjusting screw locknut and slowly turn the lift adjusting screw clockwise until pressure rises 1380-3450 kPa (200-500 psi) above the nozzle opening pressure. Some test fluid may collect on the nozzle tip, but there must not be a rapid dribble.
| NOTICE |
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Do not bend the valve by bottoming with too much force. |
B. Back out (loosen) the lift adjustment screw 3/4 ± 1/8of a turn.
C. Put the nozzle in a vise with 8S2250 Holding Tool (1). Hold pressure adjusting screw (4) and tighten the locknut to a torque of 8.0-8.5 N·m (70-75 lb in) using the 2P5487 Adapter (A). Recheck the opening pressure.
Adjustment of 9L7883 Nozzles
1. Remove the nozzle from the tester and place in a vise using 8S2250 Nozzle Holding Tool (1). Loosen lift adjusting screw locknut (2). Loosen lift adjusting screw (3) two full turns counterclockwise.
| NOTICE |
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If lift adjusting screw (3) is not loosened, the valve can be damaged in later steps. |
2. Loosen pressure adjusting screw (4) and remove the nozzle from the nozzle holding tool.
3. Tilt the nozzle slightly down from the vertical position and remove pressure screw (4) and shims (5).
NOTE: If the shims do not come out of the nozzle, invert the nozzle and let the shims, spring and spring seat fall into the hand. If the valve comes out of its own weight, handle it carefully by its stem.
4. To increase the opening pressure, add a 4N5730 Shim. The 4N5730 Shim is 0.13 mm (.005") thick and will increase the opening pressure approximately 1725 kPa (250 psi). A maximum of two shims can be added; if two shims do not increase opening pressure to specification given, discard the nozzle.
5. Assemble the nozzle, making sure the thickest shim (C) is against pressure screw (4). Put the nozzle in a vise using 8S2250 Nozzle Holding Tool (1). Tighten the pressure adjusting screw to 8.0-9.1 N·m (70-80 lb in) torque.
6. Remove the nozzle from the holding tool. Connect the nozzle, with the tip facing downward, to the tester. Point the nozzle tip into the 8S2270 Fuel Collector and the FT1384 Extension. Check the opening pressure and if it is not within specifications, repeat steps 4 and 5.
Valve Lift Adjustment-9L7883 Nozzles
A. When the correct opening pressure is set, and while pumping test fluid through the nozzle, hold the lift adjusting screw locknut and slowly turn the lift adjusting screw clockwise (CW) until valve pressure rises 1380-3450 kPa (200-500 psi) above the nozzle opening pressure. Some test fluid may collect on the tip, but it must not flow at a rapid dribble.
| NOTICE |
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Do not bend the valve by bottoming with too much force. |
B. Back out the lift screw 3/4 ± 1/8 turn, hold the lift adjusting screw, and tighten the locknut just enough so the screw will not turn; the lift is now set.
C. Put the nozzle in a vise using 8S2250 Holding Tool (1). Tighten the locknut to 4.0-4.5 N·m (35-40 lb in). Recheck valve opening pressure.
Adjustment of 9L6969, 7N0449, 9N3299, 9N3700, 9N3979, 1W5829, 4W1819, 4W8483 and 7W3710 Nozzles
1. Put the nozzle in a vise using the 8S2250 Holding Tool (1). Loosen lift adjusting screw locknut (2). Turn lift adjusting screw (3) two full turns counterclockwise (CCW).
2. Hold lift adjusting screw (3) with a .08 mm (5/64") hex wrench (4) and remove locknut (2). Loosen locknut (5) that holds pressure adjusting screw (6).
3. Adjust VOP as follows:
A. Install the nozzle on the 5P4150 Tester.
B. Pressurize the nozzle.
C. Turn pressure adjusting screw (6) clockwise (CW) to raise the VOP and counterclockwise (CCW) to lower the VOP.
NOTE: Each one-fourth of a turn will change the VOP approximately 1720 kPa (250 psi).
4. Hold pressure adjusting screw (6) and tighten locknut (5) just enough to keep pressure adjusting screw (6) from turning.
5. Install locknut (2), but do not tighten at this time.
6. Valve Lift Adjustment
A. With valve opening pressure set correctly, pump test fluid through the fuel injection nozzle and hold locknut (2).
B. Slowly turn lift adjusting screw (3) clockwise (CW) until the pressure starts to increase above the valve opening pressure.
C. Make the pressure go 1380-3450 kPa (200-500 psi) above the valve opening pressure, to be sure the valve is on its seat.
| NOTICE |
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Do not bend the valve or damage the seat by turning lift adjusting screw (3) with too much force. |
NOTE: It is permissible to have some test fluid at the tip of the nozzle, but there must not be a steady flow.
D. Turn lift adjusting screw (3) counterclockwise (CCW) 3/4 ± 1/8 turn.
E. Hold adjusting screw (3) with a .08 mm (5/64") hex wrench and tighten locknut (2) just enough so adjusting screw (3) will not turn.
7. Tightening Locknuts (and Cap)
A. Remove the nozzle from the tester and put it in a vise with the 8S2250 Holding Tool.
B. Tighten locknut (5), that holds the pressure adjusting screw, to a torque of 7.9-9.0 N·m (70-80 lb in).
C. Tighten locknut (2), that holds lift adjusting screw (3), to 4.0-5.0 N·m (35-45 lb in).
NOTE: The information given in steps (D) and (E) that follow, does not apply to 9N2366 Nozzles because they do not have the cap that is shown below.
D. Install a new 1H1023 O-ring Seal (7) and cap (8).
E. Tighten cap (8) to a torque of 12.0-14.0 N·m (110-120 lb in).
| NOTICE |
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Do not overtighten cap (8). |
8. Cap Leakage Test
NOTE: After the tests and adjustments are complete, check for leakage between cap (8) and the nozzle body.
A. Install the nozzle on the 5P4150 Nozzle Tester with the tip in the 8S2270 Fuel Collector and FT1384 Extension.
B. With the gauge protector valve open, pump the tester until cap (8) is completely full of test fluid and the pressure on the gauge is 20700 kPa (3000 psi).
NOTE: It may take 15-20 strokes to reach the 20700 kPa (3000 psi) pressure.
NOTE: A hydraulic lock can prevent the nozzle valve from opening, when the cap is completely full of test fluid. This can happen when the nozzle is on the nozzle tester, because of the large volume of test fluid delivered by the nozzle tester pump, and the pressure held in the line at the end of each pump stroke. A fuel system that operates correctly on-engine, will not permit a hydraulic lock to occur in the nozzle.
C. There must not be any leakage between cap (8) and the nozzle body. If there is leakage, install a new 1H1023 O-ring Seal (7), and inspect cap (8) for cracks.
D. Test the nozzle again. If there is still leakage, do not use the fuel nozzle.