3003, 3013, 3014 and 3024 Engines for Caterpillar Built Machines Caterpillar


Fuel Injection Nozzle - Test

Usage:

CB-214D 1TZ
Perform the following procedures in order to determine if a fuel injection nozzle does not work correctly.

Table 1
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     1    
6V-6068     SAE J-967 Calibration Fluid     1    



Illustration 1g00691280

(1) Fuel injection nozzle

(2) Seal

(3) Cap

(4) Spacer

(5) Gasket




Illustration 2g00749601

(1) Fuel injection nozzle

(5) Gasket

  1. Run the engine at low idle.

  1. 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.

  1. 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.

Inspection and Cleaning of the Fuel Injection Nozzles




Illustration 3g00457586

Fuel injection nozzle components

(1) Nut

(2) Body

(3) Shims

(4) Spring

(5) Rod

(6) Spacer

(7) Nozzle

(8) Nozzle nut

(9) Gasket

Before a fuel injection nozzle is tested, remove any loose carbon from the tip of nozzle (7). 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.

Perform the following procedures to inspect the fuel injection nozzle.

  1. Place nozzle nut (8) in a vise. Turn body (2) in a counterclockwise direction in order to disassemble the fuel injection nozzle.

  1. Disassemble the fuel injection nozzle. Inspect each component for the following conditions: sticking, wear, scratches and cracks. If any component is damaged, the fuel injection nozzle must be replaced.

    Note: All components of the fuel injection nozzle must be kept clean. Keep the components in clean diesel fuel.

    Note: Before a new fuel injection nozzle is installed, soak the nozzle in a light oil. Calibration fluid can be used. Heat the oil to a temperature of 50 to 60 °C (122 to 130 °F). The oil will remove anti-corrosion material from the fuel injection nozzle.

  1. Reassemble the fuel injection nozzle. Refer to the Specifications Module, "Fuel Injection Nozzle" topic for the correct torque.

Leakage Test




Illustration 4g00470020

Pressure test the fuel injection nozzle by using the 5P-4150 Nozzle Testing Group .

(1) 5P-7448 Adapter

(2) Fuel injection nozzle

(3) 5P-4721 Tube

(4) 1U-8857 Extension

(5) 8S-2270 Fuel Collector

(6) 8T-5313 Filter

This procedure tests for leakage around all components of the fuel injection nozzle.

  1. 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 (4) and 8S-2270 Fuel Collector (5) .

  1. Pump the pressure to about 1030 kPa (150 psi) below the opening pressure of fuel injection nozzle (2). 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 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) .

  1. 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.

  1. Pump the pressure of the nozzle tester to approximately 2030 kPa (300 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) .

Pressure Test

------ WARNING! ------

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 5g00470020

Pressure test the fuel injection nozzle by using 5P-4150 Nozzle Testing Group .

(1) 5P-7448 Adapter

(2) Fuel injection nozzle

(3) 5P-4721 Tube

(4) 1U-8857 Extension

(5) 8S-2270 Fuel Collector

(6) 8T-5313 Filter


NOTICE

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.

  1. Connect fuel injection nozzle (2) to the tooling that is shown in Illustration 5.

    The spray from fuel injection nozzle (2) must be directed into 1U-8857 Extension (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.

  1. 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.

  1. 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 the Specifications Module, "Fuel Injection Nozzles" topic 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 or a new shim must be installed.

  1. In order to adjust the pressure setting by the use of a new shim, disassemble the fuel injection nozzle. Refer to this Systems Operation, Testing and Adjusting Module, "Inspection and Cleaning of the Fuel Injection Nozzles" topic.

  1. Install additional shims in order to increase the pressure setting. Remove shims or replace the shim with a thinner shim in order to decrease the pressure setting.

    The pressure setting will increase 980 kPa (142 psi) for an increase of 0.10 mm (0.004 inch) in the thickness of the shim. The pressure setting will decrease 980 kPa (142 psi) for a decrease of 0.10 mm (0.004 inch) in the thickness of the shim.

Injector Spray Pattern Test

------ WARNING! ------

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 6g00470020

Pressure test the fuel injection nozzle by using the 5P-4150 Nozzle Testing Group .

(1) 5P-7448 Adapter

(2) Fuel injection nozzle

(3) 5P-4721 Tube

(4) 1U-8857 Extension

(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.

  1. Connect fuel injection nozzle (2) to the tooling that is shown in Illustration 6.

    Position fuel injection nozzle (2) so that the direction of the fuel spray is into 1U-8857 Extension (4) and 8S-2270 Fuel Collector (5) .

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



    Illustration 7g00468241

    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

  1. 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 7.

    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.

Caterpillar Information System:

3034 Engine for Caterpillar Built Machines Piston Cooling Jet
3034 Engine for Caterpillar Built Machines Flywheel Housing
2000/03/01 190-02 "Loss of Engine RPM Signal" with an ADEM II ECM {1901, 1912}
G3516B Engines Engine Misfires, Runs Rough or Is Unstable
G3516B Engines Engine Cranks but Will Not Start
3034 Engine for Caterpillar Built Machines Fuel Filter Base
3003, 3013, 3014 and 3024 Engines for Caterpillar Built Machines Flywheel Housing
3126 Truck Engine Military Housing (Front) - Remove
G3516B Engines Engine Will Not Crank
G3304 and G3306 Engines Battery
3612 and 3616 Engines Test Tools for the Electrical System
3612 and 3616 Engines Lubricator and Strainer
SR4 and SR4B Electric Power Generation Rewind Data Winding Data for <B>5N-0051</B> Generator through <B>5N-0075</B> Generator
2000/04/17 A New 169-4309 Mounting Bar Provides Easier Alignment of Heat Exchanger Plates {0708, 1379}
2000/04/01 Improved Water Connection Group {1393}
3003, 3013, 3014 and 3024 Engines for Caterpillar Built Machines Glow Plugs - Test
2000/04/01 Oil Mister Pump And Lines Groups No Longer Used {1105, 1319}
3114, 3116, and 3126 Engines Air Inlet and Exhaust System
3046 Engine for Caterpillar Built Machines Engine Oil Pressure Switch - Test
3046 Engine for Caterpillar Built Machines Coolant Temperature Switch - Test
3003, 3013, 3014 and 3024 Engines for Caterpillar Built Machines Fuel Shutoff Solenoid - Test
3064 and 3066 Engines for Caterpillar Built Machines Alternator - Test
2000/04/17 New 171-4660 Engine Stand Adapter Assembly Is Now Available {0701, 1000}
3003, 3013, 3014 and 3024 Engines for Caterpillar Built Machines Electric Starting System - Test
Back to top
The names Caterpillar, John Deere, JD, JCB, Hyundai or any other original equipment manufacturers are registered trademarks of the respective original equipment manufacturers. All names, descriptions, numbers and symbols are used for reference purposes only.
CH-Part.com is in no way associated with any of the manufacturers we have listed. All manufacturer's names and descriptions are for reference only.