3054 Engine Caterpillar


Fuel Injection Nozzle - Test

Usage:

554 1AM

Fuel Injection Nozzle Tests On Type 1 Engines and 9RM Engines

Note: For a complete description of Type 1 and Type 2 engines, refer to the Systems Operation, Testing and Adjusting Module, "Engine Design" for more information.

Table 1
Tools Needed 
Part Number  Part Name  Quantity 
5P-4150  Nozzle Testing Group 
5P-4718  Adapter 
6V-2170  Tube 
8S-2245  Injector Cleaning Tool Group 
8S-2270  Fuel Collector 
1U-8857  Extension Tube 
6V-6068  Calibration Fluid 

Perform the following procedure in order to identify the fuel injection nozzles which do not operate correctly.



    Illustration 1g00804139
    Fuel injection nozzles and lines
    (1) Nuts for the fuel injection lines

  1. Run the engine at low idle.

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

  3. The fuel injection nozzle has a defect when the nut of the fuel injection line (1) is loosened and the following items do not occur: idle decreases and rough idle. Remove the fuel injection nozzle for additional testing.

    Note: If leakage at the nut of the fuel line occurs, make sure that the fuel line and the nut are correctly aligned with the inlet connection of the fuel injection nozzle. Do not tighten the nuts on the high pressure fuel lines more than the recommended torque. If the nut is tightened more, the fuel line may be restricted or the threads of the fuel injection nozzle and the nut may be damaged.

Pressure Test And Adjustment

------ 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 2g00804566
5P-4150 Nozzle Testing Group
(1) 5P-7448 Adapter
(2) Fuel injection nozzle
(3) 6V-2170 Tube
(4) 1U-8857 Extension Tube
(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.


  1. Refer to Illustration 2 in order to connect the fuel injection nozzle (2) to the tooling.

    The spray from the fuel injection nozzle must be directed into the 1U-8857 Extension Tube (4) and the 8S-2270 Fuel Collector (5).

    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 by using 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 gauge before the pointer decreases 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 valve needle 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 which is listed in the table, the opening pressure of the fuel injection nozzle must be adjusted.

  4. Loosen the cap nut (8). Turn the pressure adjuster (10) clockwise in order to increase the pressure. Turn the pressure adjuster counterclockwise in order to decrease the pressure.

  5. Tighten the cap nut (8). Check the opening pressure again on the nozzle tester. If the pressure is correct, remove the fuel injection nozzle from the nozzle tester.

    Note: Before the fuel injection nozzle is removed from the tester, be sure that the gauge protector valve is closed in order to prevent damage to the pressure gauge.

Cleaning The Fuel Injection Nozzles

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

  1. Fasten the fuel injection nozzle in a holder or a vise with brass jaws. Release the pressure on the nozzle holder spring by loosening the adjuster. Remove the nozzle cap nut and the nozzle with the correct size of wrench.


    Illustration 3g00804568
    (7) Fuel inlet
    (8) Cap nut
    (9) Fuel return
    (10) Pressure adjuster
    (11) Spring for pressure adjuster
    (12) Body
    (13) Spindle for spring
    (14) Retaining nut for fuel injection nozzle
    (15) Valve needle
    (16) Nozzle
    (17) Seat washer
    (18) Orifices

  2. Remove the valve needle (15) from the nozzle body. Use the Brass Wire Brush in the 8S-2245 Injector Cleaning Tool Group in order to remove any carbon that may be on the body (12).

  3. Clean the seat of the valve needle (15) and the fuel reservoir with a Scraper. The Scraper is in the 8S-2245 Injector Cleaning Tool Group.

    Note: Use extra care not to break a wire of the brass wire brush in an orifice (18) or passage in the fuel injection nozzle. Removal of a broken wire is very difficult. Removal of a broken wire may damage the fuel injection nozzle.

  4. Clean the orifices (18) in the nozzle tip with a cleaning wire. If the size is not known, carefully try different sizes of wires in order to find the correct wire. Insert the wire into the orifice. Slowly rotate the wire in order to clean the orifice.

    Note: Extra care must be used in handling the valve needle (15) in order to prevent scratches or burrs on the needle. Scratches and burrs could cause leakage through the valve and spray distortion.

Back Leakage Test

  1. Refer to Illustration 2 in order to connect the fuel injection nozzle (2) to the tooling.

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

  2. Pump the pressure to about 1030 kPa (150 psi) less than the opening pressure of the fuel injection nozzle. Refer to the Specifications Module, "Fuel Injection Nozzles" for the correct setting of the opening pressure. Release the handle. 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.

  3. When the test in Step 2 is done, look for any leakage from the pressure faces of the holder and the retaining nut of the fuel injection nozzle. If leaks are 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 threaded surfaces are clean and the threaded surfaces are undamaged, test the fuel injection nozzle again by using Steps 1 and 2.

  4. If the pressure decreases to 0 kPa (0 psi) in less than 5 seconds, too much fuel leaks around the valve needle. The valve needle or the fuel injection nozzle must be replaced in order to correct the problem.

Fuel Injection Nozzle And Seat Test

  1. Refer to Illustration 2 in order to connect the fuel injection nozzle (2) to the tooling.

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

  2. Pump the pressure of the nozzle tester to approximately 1030 kPa (150 psi) below the opening pressure of the fuel injection nozzle. A drop of fuel should not form on the tip of the fuel injection nozzle in order for a sufficient quantity to drip from the tip for at least ten seconds. A light dampness is acceptable. If the results of the tests are not acceptable, clean the fuel injection nozzle. If the fuel injection nozzle has been cleaned and fuel leakage is present then replace the fuel injection nozzle.

Test The Spray Pattern

------ 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.


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



Illustration 4g00322083
Correct spray pattern for a fuel injection nozzle

  1. Refer to Illustration 2 in order to connect the fuel injection nozzle (2) to the tooling.

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

  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 (18) 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 A Fuel Injector Nozzle



Illustration 5g00804690
Components for installation of a fuel injector nozzle
(19) Clamp
(20) Spacer
(21) Dust seal
(22) Body
(23) Seat washer

  1. When a fuel injection nozzle is removed from the cylinder head, replace the seat washer (23) and the dust seal (21).

    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 cylinder will be incorrect.

  2. The dust seal (21) is positioned under the spacer (20) and the clamp (19). The dust seal is positioned on the face of the cylinder head.

Fuel Injection Nozzle Tests On Type 2 Engines and 7BJ Engines

Note: For a complete description of Type 1 and Type 2 engines, refer to the Systems Operation, Testing and Adjusting Module, "Engine Design" for more information.

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

Table 2
Tools Needed 
Part Number  Part Name  Quantity 
5P-4150  Nozzle Testing Group 
5P-7448  Adapter 
6V-2170  Tube 
8S-2270  Fuel Collector 
1U-8857  Extension Tube 
6V-6068  Calibration Fluid 


Illustration 6g00293085
(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 7g00804871
Fuel injection nozzles and lines
(6) Nut for the fuel supply line
(7) Fuel supply line
(8) Fuel return line
(9) Banjo bolt

  1. Run the engine at low idle.

  2. Loosen the nut for the fuel supply line (6) at each fuel injection nozzle. Listen for the low idle to decrease or become rough at each engine cylinder.

  3. The fuel injection nozzle is faulty when the fuel supply line (6) is loosened and the following events occur:

    • The engine rpm does not decrease.

    • The engine does not idle roughly.

    Remove the fuel injection nozzle for additional testing.

    Note: If leakage occurs at the nut for the fuel supply line (6), make sure that the fuel supply line (7) and the nut for the fuel supply line (6) are correctly aligned with the inlet connection of the fuel injection nozzle (6). Do not tighten the nut for the 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.

Cleaning Of 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.

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 8g00804876
5P-4150 Nozzle Testing Group
(10) 5P-7448 Adapter
(11) Fuel injection nozzle
(12) 6V-2170 Tube
(13) 1U-8857 Extension Tube
(14) 8S-2270 Fuel Collector
(15) 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.


  1. Connect the fuel injection nozzle (11) to the tooling that is shown in Illustration 8.

    The spray from the fuel injection nozzle must be directed into the 1U-8857 Extension Tube (13) and the 8S-2270 Fuel Collector (14).

    Refer to the table in the Specifications Module, "Fuel Injection Nozzles" for the correct pressure settings. If the opening pressure is not within the range of the setting which 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 valve needle 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 the fuel injection nozzle (9) to the tooling. Refer to Illustration 8 for more information.

    Position the fuel injection nozzle so that the direction of the fuel spray is into the 1U-8857 Extension Tube (13) and the 8S-2270 Fuel Collector (14).

  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" 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 the fuel injection nozzle (11) to the tooling. Refer to Illustration 8 for more information.

    Position the fuel injection nozzle so that the direction of the fuel spray is into the 1U-8857 Extension Tube (13) and the 8S-2270 Fuel Collector (14).

  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 Spray Pattern

------ 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.


The pressure adjustment must be correct before testing the spray pattern.



Illustration 9g00322083
Correct spray pattern for fuel injection nozzles

  1. Connect the fuel injection nozzle (11) to the tooling. Refer to Illustration 8 for more information.

    Position the fuel injection nozzle so that direction of the fuel spray is into the 1U-8857 Extension Tube (13) and 8S-2270 Fuel Collector (14).

  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 9. 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 Fuel Injection Nozzles

  1. When a fuel injection nozzle is removed from the cylinder head, replace the seat washer (5). Refer to Illustration 6 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 the nut (3). Refer to Illustration 6 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.

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