Using The 5P-4150 Nozzle Testing Group{0782} Caterpillar


Using The 5P-4150 Nozzle Testing Group{0782}

Usage:

Introduction

The 5P-4150 Tester Group is used for testing:

* Capsule-Type Fuel Valves
* Pencil-Type Fuel Nozzles
* Caterpillar Direct Injection Fuel Nozzles

NOTE: The additional tools referenced in this manual are needed for testing or cleaning specific fuel valves and nozzles or are part of 8S-2245 Cleaning Tool Group. These tools are available from the Parts Department.

The 8T-0860 and 8T-0856 Pressure Gauges, 1U-9578 Repair Kit (not shown), 8T-5313 Nozzle Test Filter (1), and 6V-0183 Pump Body Gasket (2) are all available from the Parts Department.

Install a new 8T-5313 Nozzle Tester Filter (1) at least once every three months, or more often when necessary. Install a new 6V-0183 Pump Body Gasket (2) when necessary.

NOTE: For nozzle cleaning procedure, refer to Special Instruction SEHS8627 entitled "Use Of 8S2245 Nozzle Cleaning Tool Group".

Reference: Service Manual Parts Book, Special Instruction SEHS8627 "Use of 8S2245 Nozzle Cleaning Tool Group", SEHS7390 "Test Sequence For Pencil-Type Fuel Nozzles".

General Information

NOTE: When testing either new nozzles or nozzles that are not suspected of a failure, it is permissible to flush each nozzle three full strokes before the test.

It is necessary to have an accurate record of the test results for each nozzle that is tested. Record the results of each nozzle test procedure on SEHS8144 "Nozzle Test Record".

These test sheets are available through Miscellaneous Order Division. Pads containing 50 sheets may be ordered with special instruction SEHS8144. A copy of SEHS8144 is shown at the back of this manual.

NOTE: Always keep the reservoir filled with CLEAN calibration fluid. Low oil level will cause SOFT or SPONGY operation of the tester pump. Use SAE J-967 Calibration Fluid in the tester. Order calibration fluid, according to the amount needed, by the following part numbers.

6V-6067 Calibration Fluid...208 L (54.9 gal U.S.) Drum6V-6068 Calibration Fluid...19 L (5.0 gal U.S.) Pail9U-7411 Calibration Fluid...3.8 L (1.0 gal U.S.) Pail

Have the pressure gauges checked and calibrated at least once each year. Checking and calibration should be performed more often if the test results become inconsistent of inaccuracy is suspected.

NOTE: There are two methods for gauge calibration. Gauge calibration should be checked using the 5P-8558 Pressure Gauge Calibrating Group or calibrated by the gauge manufacture.

This manual contains the instructions for gauge calibration when using 5P-8558 Pressure Gauge Calibrating Group. This Manual also contains the procedures to follow if the gauges are sent to the manufacturer for calibration.

Refer to "Calibration (Method 1 or Method 2)" in this manual.

The rate of 8T-0856 Pressure Gauge is 0-6000 kPa (0-870 psi) with minor divisions (increments) of 100 kPa (20 psi).

The range of 8T-0860 Pressure Gauge is 0-40 000 kPa (0-5800 psi) with minor divisions (increments) of 1000 kPa (100 psi).

The accuracy for either gauge is ± 2.0 percent full scale across the entire readable range.

The test information in this manual has been obtained by comparison tests of fuel nozzles known to be good. These tests are not intended to be a duplication of conditions that exist during engine operation.

The tests in this manual will provide an indication of nozzle condition. A nozzle that has a defect is NOT always the only cause for a specific engine problem.

NOTE: The absence of valve chatter or spray during the test does not indicate that the nozzle has a defect. Chatter can occur on the tester but not occur when the nozzle is installed in the engine.

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

When testing fuel injection nozzles, always wear eye protection. Fuel sprays from the orifices in the nozzle tip under high pressure. It can pierce the skin and cause serious injury to the operator. Always keep the tip of the nozzle pointed away from the operator and into 8S-2270 Fuel Collector Assembly and FT-1384 or 1U-8857 Extension Tube.

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

The test procedures for Capsule-Type Fuel Nozzles, Pencil-Type Fuel Nozzles, and Caterpillar 7000 Series Fuel Nozzles are provided in hits manual. In addition, the test procedures are also available in an abbreviated, chart-type form. The form numbers for these charts are:

* SEHS7350 "Test Sequence For Capsule-Type Fuel Nozzles"
* SEHS7390 "Test Sequence For Pencil-Type Fuel Nozzles"
* SEHS9083 "Test Sequence For Caterpillar 7000 Series Fuel Nozzles"

Order these publications using the normal literature ordering procedure.

Components Of 5P-4150 Tester Group

Installation Of 5P-4150 Tester Group In Permanent Location

It is possible to get more accurate tests and easier operation if 5P-4150 Tester Group is fastened permanently and securely to a work bench. This can be performed with bolts or clamps, or with the use of a bracket similar to mounting bracket (1).

There are four holes in the bottom of tester reservoir (2). These holes have 1/4 inch - 20 threads. Use the dimensions shown to locate and then to drill four holes (A) 7.5 mm (.30 in) at the specific location where the tester will be fastened.

Holes (A) can be drilled in a workbench, a fabricated bracket (1), or any other desired location that is to serve as the permanent location for the tester. Use the necessary bolts and washers in order to fasten the tester in position.

Service Parts for 5P-8744 Nozzle Adapter Assembly


(1) 5P-4720 Fitting.(2) 5P-8741 Adapter.(3) 5P-8740 Retainer.(4) 5P-8742 Piston.(5) 2S-4663 O-ring Seal.

Use rod (6) or a screwdriver, as shown, to push 5P-8742 Piston (4) out of 5P-8741 Adapter (2).

Replacement Of 5P-4721 Tube

1. Place nuts (1) and sleeves (2) on tube (3).

NOTE: Install each sleeve (2) so longer part (A) of each sleeve is toward each nut (1).

2. Install elbow (4) and fitting (5). Tighten nuts (1) until the threads on elbow (4) and fitting (5) are covered by the nut.

Components Needed That Are Not Part of 5P-4150 Tester Group


(1) FT-1384 or 1U-8857 Extension Tube.(2) 5P-7448 Fuel Valve Adapter (for testing flat seat fuel nozzles).(3) 8S-2270 Fuel Collector Assembly.(4) 5P-4718 Nozzle Test Adapter Assembly (for testing Perkins fuel nozzles).

Additional Parts Needed to Test 7N-0449 Fuel Injection Nozzle Assembly And Caterpillar 7000 Series Direct Injection Fuel Nozzles

The parts shown above [6V-2170 Tube Assembly (1), 6V-2171 Tube Assembly (2) and two 5P-7448 Fuel Valve Adapters (3)] are not part of the tester group but are needed to test some nozzles.

One 6V-2171 Tube Assembly (2) and one 5P-7448 Fuel Valve Adapter (3) are needed to test 7N-0449 Fuel Injection Nozzle Assembly.

One 6V-2170 Tube Assembly (1) and one 5P-7448 Fuel Valve Adapter (3) are needed to test certain Caterpillar 7000 Series Nozzles.

For some other Caterpillar 7000 Series Nozzles, it will be necessary to use 5P-4244 Nozzle Adapter, 5P-4721 Tube, and Ft-1743 Line Assembly (none of which are shown here) to perform the test procedure. Specific procedures are given in this manual.

NOTE: The FT-1743 Line Assembly is constructed from 1W-4660 Fuel Injector Line Assembly. See the Tool Guide for FT print ordering information.

Optional Modification/Installation Of Quick Disconnect Couplings For Nozzle Adapters

Installation and use of the optional quick disconnect couplings on 5P-4150 Tester Group allows for much faster and easier exchange from one nozzle adapter to another during a test procedure.

The following procedure lists all of the quick disconnect adapter that can be used.

1. Cut off exactly 59 mm (2.3 in) from short end (A) of one 5P-4721 Tube (1). Temporarily place this tube aside. (The 5P-8744 Nozzle Adapter Assembly will be installed on this tube later in the procedure.)

NOTE: The Pressure Loss Specifications for capsule-type fuel nozzles, as shown in this manual, were developed with the use of a standard (unmodified) 5P-4150 Tester Group.

The shortened tube shown here and new 6V-4143 Coupler Assembly (to be installed later) will provide the correct length for this test.

2. Cut off 75 mm (3.0 in) from long end (B) of one 6V-2170 Tube Assembly (2).

3. Cut off 75 mm (3.0 in) from short end (A) of three additional 5P-4721 Tubes (1) and one 6V-2171 Tube Assembly (3).

4. Remove the burrs from the cut ends. Thoroughly clean the tubes.

5. Install, as shown, 5P-4719 Fitting (4) and 6V-3989 Unvalved Nipple (5) at the cut end of each tube (1), (2), and (3).

6. Use 3J-1906 Nuts (6) with 3J-1905 Fitting Sleeves to install:

* 5P-8744 Nozzle Adapter Assembly (7).
* 5P-7448 Fuel Valve Adapter (8) (at three locations).
* 5P-4718 Nozzle Test Adapter Assembly (9), and
* 5P-4244 Nozzle Adapter (10).

NOTE: Install each 3J-1905 Fitting Sleeve so the longer part of the sleeve is toward nut (6).

7. Remove the original tube assembly and fitting from the tester. Then, install 6V-4143 Coupler Assembly (11) with 5P-3238 Hex Pipe Reducing Nipple as a replacement.

Testing Capsule-Type Fuel Nozzles For Precombustion Chamber Engines and Direct Injection Engines

Weld shut the orifice of an old capsule-type fuel nozzle. Keep the fuel nozzle with the tester group for future use.

NOTE: DO NOT weld shut the orifice of the nozzles that are to be tested.


Former 5P-4717 Adapter Assembly.


5P-8744 Nozzle Adapter Assembly.

The procedure to use for either of the adapters is the same except where indicated.

NOTE: The 5P-4717 Adapter Assembly is cancelled and has been replaced by 5P-8744 Nozzle Adapter Assembly.

The 5P-4717 Adapter Assembly is shown to illustrate the difference between the two adapters.

NOTE: The 5P-8744 Nozzle Adapter Assembly is the preferred adapter because it permits better test results on capsule-type nozzles.

Install top part (A) of the capsule valve holder.

Position nozzle (1) with the welded shut orifice in bottom part (b) of the valve holder.

Install and tighten bottom part (B) to top part (A).

1. CLOSE On/Off valve (2).

2. OPEN pump isolator valve (3).

3. Pump the tester until a pressure of 24 000 kPa (3500 psi) is attained on the pressure gauge.

CLOSE pump isolator valve (3).

Inspect all connections for leaks. Perform repairs as necessary.

4. Open On/Off valve (2) and remove the fuel nozzle with the welded shut orifice.

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

Be sure to open On/Off valve (2) before removal of the welded shut fuel nozzle. Fuel under high pressure can cause injury to the operator of the nozzle tester if the On/Off valve is not open when bottom part (B) is loosened.

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

NOTE: The top sealing surface of the welded shut test nozzle and all other nozzles that are to be tested MUST be free of scratches and burrs (sharp edges).

5. Repeat Step(s) 1-4:

* Each time 5P-8744 Nozzle Adapter Assembly or 5P-4717 Adapter Assembly is removed and then installed again.
* Before and after a series of tests.
* If there is an indication of a problem with the nozzle tester.

Test Sequence For Precombustion Chamber Fuel Nozzles


NOTICE

DO NOT drill or ream the orifice of a nozzle. DO NOT use a steel brush or a wire wheel to clean the tip of the nozzle because the orifice and valve can easily be damaged. A hand-held brass brush is acceptable for cleaning the nozzle tip. For nozzle cleaning procedure, refer to Special Instruction SEHS8627 "use Of 8S-2245 Nozzle Cleaning Tool Group".


Nozzle Installation

1. Place one of the nozzles to be tested in the nozzle holder. Install the nozzle holder and tighten the adapter nut.

2. Close On/Off valve (1).

OPEN gauge protector valve (2) [0-6900 kPa (0-1000 psi) gauge]. Pump isolator valve (3) one-half turn.

Bleed (Remove) Air From Tester

1. Loosen one-half turn bottom part (A) of the adapter.

2. Operate the pump until clear test fluid flows from threads (C) of adapter (B).

NOTE: With 5P-8744 Nozzle Adapter Assembly, pressure may begin to build before clear test fluid appears. If this condition exists, proceed to Step 3.

3. Tighten bottom part (A) of the adapter.

NOTE: The 5P-8744 Nozzle Adapter Assembly is self-sealing and normally very little turning force is required on bottom part (A) of the adapter.

Pressure Loss Test

1. OPEN gauge protector valve (2) an additional one-half turn.

2. SLOWLY increase the pressure to 2070 kPa (300 psi). CLOSE pump isolator valve (3).

Again adjust the pressure to 2070 kPa (300 psi) with gauge protector valve (2).

3. After thirty seconds, record the pressure loss.

4. If the pressure loss is NOT within the Pressure Loss Specification, STOP the test sequence.

DO NOT use the nozzle.

Valve Opening Pressure (VOP) Test

1. OPEN pump isolator valve (3) one-half turn.

2. SLOWLY increase the pressure until the test fluid just begins to flow from the nozzle tip. This is valve opening pressure (VOP).

3. If VOP is NOT within the VOP Specification, STOP the test.

DO NOT use the nozzle

NOTE: Spray pattern or atomization tests are not specified for precombustion chamber type fuel nozzles. Such tests do not provide an accurate indication of a good or defective nozzle.

Test Sequence For Direct Injection Fuel Nozzles


NOTICE

DO NOT drill or ream the orifices of a nozzle. DO NOT use a steel brush or a wire wheel to clean the tip of the nozzle because the orifices and valve can easily be damaged. The use of a hand-held brass brush is acceptable for cleaning the nozzle tip. For nozzle cleaning procedure, refer to Special Instruction SEHS8627 "Use Of 8S-2245 Nozzle Cleaning Tool Group".


Nozzle Installation

1. Position the nozzle to be tested in the nozzle holder.

Install the nozzle holder and tighten the adapter nut.

2. CLOSE On/Off valve (1).

OPEN gauge protector valve (2) one-half turn [0-34 470 kPa (0-5000 psi) gauge].

OPEN pump isolator valve (3) one-half turn.

CLOSE gauge protector valve (4).

Bleed (Remove) Air From Tester

1. Loosen one-half turn bottom part (A) of the adapter.

2. Operate the pump until clear test fluid comes from threads (C) of adapter (B).

3. Tighten bottom part (A) of the adapter.

NOTE: The 5P-8744 Nozzle Adapter Assembly is self-sealing and normally very little turning force is required on bottom part (A) of the adapter.

It may be necessary to use 1P-2853 Spanner Wrench and a 1 1/8 inch open-end wrench to tighten the adapter. This will prevent excessive leakage from some direct injection fuel nozzles for the 3400 Engines.

Pressure Loss Test

1. OPEN gauge protector valve (2) an additional one-half turn.

2. SLOWLY increase the pressure to 15 170 kPa (2200 psi) and CLOSE pump isolator valve (3).

A loss of pressure to zero (0) AFTER five seconds is acceptable.

NOTE: To assure consistent tests, verify that the tester does not internally leak. Refer to Testing Capsule-Type Fuel Nozzles For Precombustion Chamber Engines and Direct Injection Engines in this manual.

3. If pressure loss is NOT within the Pressure Loss Specification, STOP the test.

DO NOT use the nozzle.

Valve Opening Pressure (VOP) Test

1. OPEN gauge protector valve (2) one-half turn.

2. SLOWLY increase the pressure until the test fluid flows from the nozzle tip.

3. If VOP is NOT within the VOP Specification, STOP the test.

DO NOT use the nozzle.

Nozzle Flushing Procedure

1. CLOSE gauge protector valve (2).

2. Pump the tester three full strokes.

3. OPEN gauge protector valve (2).

Tip Leakage Test

1. Wipe dry the nozzle tip and adapter. Wrap a clean shop towel around the lower part of the adapter. The towel prevents return leakage down the outside of the adapter which may give a false tip leakage indication.

2. Increase the pressure to between 3450 kPa (500 psi) and 6900 kPa (1000 psi). Hold this pressure for thirty seconds.

3. If the tip leakage is NOT within the Tip Leakage Specification, STOP the test.

DO NOT use the nozzle.

Spray Pattern Test

1. Rapidly increase the pressure until the nozzle valve opens and the test fluid sprays from the tip.

NOTE: "RAPIDLY increase the pressure" is defined as:

* Each full pump stroke is performed in LESS than one second.


Direct injection capsule nozzles must give an appearance as shown above.

The test fluid must flow from all orifices.

2. Use the 8S-2258 Cleaning Nozzle Brush from the 8S-2245 Cleaning Tool Group in order to remove any loose carbon from the nozzle tip.

Refer to Special Instruction, SEHS8627 "Use Of 8S-2245 Nozzle Cleaning Tool Group" for tool usage and cleaning procedure.


NOTICE

DO NOT use a steel brush or a wire wheel to clean the nozzle tip. These tools can cause a reduction of orifice size as shown at location (Y). This type nozzle damage can cause a large change in engine horsepower. The illustration shows a normal orifice at location (X) and an orifice at location (Y) that has been damaged by an incorrect cleaning procedure.


Pencil-Type Fuel Nozzle Part Number Reference Chart


NOTICE

DO NOT use a steel brush or a wire wheel to clean the nozzle body or the nozzle tip. Use of these tools can cause a reduction of orifice size as shown at location (Y) and cause a large reduction of engine horsepower. The illustration shows a normal orifice at location (X) and an orifice at location (Y) that has been damaged by wire brushing. Excessive brushing will also remove the coating. Stain on the nozzle coating is normal.


Use needle nose pliers to remove and discard compression seal (1) and carbon dam (2). Use care to avoid damaging the nozzle.

Caterpillar And Supplier Pencil-Type Fuel Nozzle Part Number Cross-Reference Chart

The only identification given on some pencil-type nozzles is the supplier part number. Use the following chart to cross-reference specific nozzles between the supplier part number and the Caterpillar part number.

Test Sequence for Pencil-Type Fuel Nozzles

NOTE: The cap on these nozzles must be removed to prevent hydraulic lock or incorrect VOP measurement during testing.

1. Position 8S-2250 Nozzle Holding Tool (1) in a vise.

2. Position the nozzle in the holding tool. Remove cap (2).

Return Leakage Test (Except Type A Nozzles)


Position of nozzle for return leakage test

1. Position the top of the nozzle slightly below the horizontal.

Wrap a clean shop towel around the nozzle tip, as shown, in order to absorb any test fluid that may flow out of a defective nozzle.

2. OPEN gauge protector valve (4) and pump isolator valve (5) one-half turn.

CLOSE On/Off valve (6).

3. Apply and hold a pressure of 9650 kPa (1400 psi) to 11 030 kPa (1600 psi).

4. Count the leakage for fifteen seconds after the first drop falls.

5. If leakage is NOT within Return Leakage Specifications, STOP the test. DO NOT use the nozzle.

Nozzle Installation For Pencil-Type (A, B And C) Fuel Injection Nozzles

Install 6V-2171 Tube Assembly (1) and 5P-4244 Direct Injection Nozzle Adapter (2) on the tester, for all 3208-type pencil-type fuel nozzles except 7N-0449 Fuel Injection Nozzle Assembly. The 3300-type 7N-0449 Fuel Injection Nozzle Assembly requires 5P-7448 Flat Seat Fuel Valve Adapter.


Illustration of 1H-1023 O-ring Seal (1) on typical nozzle assembly.

Inspect 1H-1023 O-ring Seal (1) for damage on all nozzles except 7N-0499.

Install nozzle (3) on adapter (2) so the tip is approximately 15 degrees from vertical [dimension (A)] toward the rear of the tester as shown and inside 8S-2270 Fuel Collector Assembly and FT-1384 or 1U-8857 Extension Tube.

Turn On/Off valve (4) to the CLOSED position. OPEN pump isolator valve (5) and 0-25 000 kPa (0-3625 psi) gauge protector valve (6) one-half turn.

Valve Opening Pressure (VOP) Test

1. Change the position of the nozzle so the nozzle tip is inside FT-1384 or 1U-8857 Extension Tube and 8S-2270 Fuel Collector Assembly.

2. As shown, place a clean shop towel around the top of the nozzle in order to absorb any return leakage.

3. OPEN gauge protector valve (4) one-half turn.

4. SLOWLY increase the pressure until test fluid flows from the nozzle orifices.

5. If the VOP is NOT within VOP Specifications, STOP the test.

DO NOT use the nozzle.

Nozzle Flushing Procedure

NOTE: The nozzle must be flushed clean before the Tip Leakage Test:

1. CLOSE gauge protector valve (4).

2. Pump the tester three rapid FULL strokes.

3. OPEN gauge protector valve (4).

Tip Leakage Test

1. Wipe dry the nozzle tip and body.

Wrap a clean, lint-free cloth around the top of the nozzle (pressure screw end) in order to prevent bleed-back fluid from draining down and dripping off the nozzle tip.

2. Apply a pressure of 1380 kPa (200 psi) below the minimum VOP.

Hold this pressure fifteen seconds.

3. If the tip leakage is NOT within the Tip Leakage Specifications, STOP the test.

DO NOT use the nozzle.

Refer to the "Troubleshooting Guide" in this manual.

Spray Pattern Test

NOTE: Use 8S-2257 Loupe from 8S-2245 Cleaning Tool Group or 6V-2196 Inspection Microscope in order to visually inspect the nozzle orifices and in order to inspect for any indication of orifice plugging or damage.

1. RAPIDLY increase the pressure (full stroke in less than one second) until the nozzle valve opens and test fluid flows from the tip. The test fluid spray is similar to Illustration A shown as SATISFACTORY. The fluid must spray from all orifices.

NOTE: "RAPIDLY increase the pressure" is defined as:

* Each full pump stroke is performed in LESS than one second.
* The nozzle must produce a pattern as shown in the Illustration A.
* The test fluid must flow evenly from all orifices.


Illustration A. SATISFACTORY fluid spray.

2. DO NOT use a nozzle that has an unsatisfactory fluid flow, such as that in Illustration B shown as UNSATISFACTORY: PLUGGED ORIFICE and Illustration C shown as UNSATISFACTORY: HORIZONTAL DEFECTION.


Illustration B. UNSATISFACTORY fluid spray: PLUGGED ORIFICE


Illustration C. UNSATISFACTORY fluid spray: HORIZONTAL DEFLECTION.

NOTE: If it is difficult to view all orifices at one time, it is permissible to use a slow stroke to verify that all orifices are open.

A RAPID stroke must be used, however, for the final test.

NOTE: This completes the test sequence for Type B 9L-9263, 9L-7883, and 9N-2366 Nozzle Assemblies.

Installation Of Cap (Type A And C Nozzles Only)

1. Remove the nozzle from the tester and install it in 8S-2250 Nozzle Holding Tool. Position the tool, with nozzle, in a vise.

2. Install new 1H-1023 O-ring Seal (1) and cap (2). Tighten cap (2) to a torque of 12.0 N·m (106 lb in) to 14.0 N·m (124 lb in).

NOTE: Do not over-tighten cap (2).

Cap Leakage Test

1. Install the nozzle on 5P-4150 Tester Group.

Position the nozzle so its spray is directed into 8S-2270 Fuel Collector Assembly and FT-1384 or 1U-8857 Extension Tube.

2. Pump the tester until cap (1) is completely full of fuel and the pressure on the gauge is 20 700 kPa (3000 psi).

NOTE: It may take 15-20 strokes to reach 20 700 kPa (3000 psi).

NOTE: A hydraulic lock can prevent the nozzle 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.

OPEN the nozzle tester On/Off valve to release trapped pressure. Remove the nozzle from the tester.

3. Install new compression seal (3). Use 6V-4979 Carbon Stop Seal Tool to install new carbon dam (2).

Inspect For Damage

Inspect for damage caused by:

* Steel wire brushing.
* Partially melted carbon dam seal.

NOTE: Engine overheating can cause carbon dam seal material to melt and thinly adhere up the side of the nozzle body.

If this condition is found, replace the entire set of fuel nozzles.

NOTE: Use 8S-2257 Loupe, from 8S-2245 Nozzle Cleaning Tool Group or 6V-2196 Inspection Microscope, to visually inspect nozzle orifices and to visually inspect for indication of orifice plugging or damage.

Inspect for any other obvious damage.

DO NOT use damaged fuel nozzles.

Nozzle Installation For Caterpillar 7000 Series Direct Injection Nozzles

Remove bleed screw (1) and seal from nozzle (2).

NOTE: On Caterpillar 7000 Series Nozzles with a date code of H7 and newer, it will be necessary to also use 1U-5895 Insert Bit to remove the Type B bleed screw that is shown in the illustration.

NOTE: 104-9450 thru 104-9455 Nozzle Assemblies DO NOT have bleed screws.

Installation Of 3300 Engine Nozzles.

Install 6V-2170 Tube Assembly (3) and 5P-7448 Fuel Valve Adapter (4) on nozzle tester (5).

Install nozzle (2) on adapter (4) so the hole for bleed screw (1) is toward nozzle tester (5).

Installation Of 3400 Engine Nozzles.

Install 5P-4721 Tube (10), 5P-4244 Nozzle Adapter (11), and FT-1743 Line Assembly (12) [fabricate from 1W-4660 Fuel Injector Line Assembly] on nozzle tester (5).

Install nozzle (9) on FT-1741 Line Assembly (12).

Installation Of 3200 Engine Nozzles.

Install 5P-4721 Tube (10) and 5P-4244 Nozzle Adapter (11) on nozzle tester (5).

Install nozzle (2) on adapter (11).

Turn On/Off valve (6) to the CLOSED position.

OPEN pump isolator valve (7) and 0-40,000 kPa (0-5800 psi) gauge protector valve (8) one-half turn.

Wrap a clean shop towel around the nozzle body.

Install 8S-2270 Fuel Collector Assembly and FT-1384 or 1U-8857 Extension Tube in the position as shown.

VALVE OPENING PRESSURE (VOP) TEST

1. SLOWLY increase the pressure until the test fluid just begins to flow from the nozzle tip.

NOTE: An audible click may be heard and a small spurt of fuel may be seen before the VOP is reached. This is a proper function of 104-9450 through 104-9455 Nozzle Assemblies.

2. If VOP is NOT within VOP Specifications, STOP the test.

DO NOT use the nozzle.

Nozzle Flushing Procedure

1. CLOSE gauge protector valve (8).

2. Pump the tester three full strokes.

3. OPEN gauge protector valve (8).

Tip Leakage Test

1. Wipe dry the nozzle tip and body. Wrap a clean, lint-free cloth around the top of the nozzle (covering the bleed screw hole) in order to prevent bleed-back fluid from draining down and dripping off the nozzle tip.

2. Apply a pressure of 1380 kPa (200 psi) below the valve opening pressure (VOP) )(as measured in Step 2).

Maintain this pressure for fifteen seconds.

3. If the tip leakage is NOT within the Tip Leakage Specification, STOP the test.

DO NOT use the nozzle.

Spray Pattern Test

Plugged Orifice Test

RAPIDLY increase the pressure until the nozzle valve opens and the test fluid sprays from the tip.

NOTE: "RAPIDLY increase the pressure" is defined as:

* Each full pump stroke is performed in LESS than one second.

The test fluid must flow evenly from all orifices in a pattern as shown in the illustration.

DO NOT use a nozzle that has a spray pattern that is different from what is shown in the illustration.

NOTE: If it is difficult to view all orifices at one time, it is permissible to use a slow stroke to verify that all orifices are open.

A RAPID stroke must be used, however, for the final test.

Partial Plugged Orifice Test

Use a moderate pump stroke to open the nozzle. View the individual spray plumes for partial orifice plugging.

* Test fluid must spray uniformly from all orifices.

DO NOT use a nozzle that has a plugged or partially plugged orifice. DO NOT use a nozzle that has a spray pattern that is different from what is shown to be the proper spray pattern.

Seal Leakage Test

1. Remove shop towel (1). With nozzle (2) on the tester, install bleed screw (3), with the seal (washer), in nozzle (2).

Tighten a Type A or Type B bleed screw to 2.2 ± 0.8 N·m (20 ± 7 lb in). Use 6V-4980 Tool Group in order to correctly tighten the bleed screw.

NOTE: On Caterpillar 7000 Series Nozzles with a date code of H7 and new, it will be necessary to also use 1U-5895 Insert Bit to tighten the Type B bleed screw that is shown in the illustration.

2. Increase the pressure to 13 800 kPa (2000 psi). Check for leakage.

NOTE: This step is not required for 104-9450 thru 104-9455 Nozzle Assemblies.

There must be no leakage at bleed screw (3), upper joint location (D), or lower joint location (E).

NOTE: It may take 10-15 strokes to reach 13 800 kPa (2000 psi).

3. If there is leakage at the bleed screw:

* For a nozzle with a Type A or Type B bleed screw and seal (washer), install 8C-3234 Screw and 8T-0659 Sealing Washer as service replacement parts.

NOTE: A hydraulic lock can prevent the nozzle valve from opening when the upper part of the nozzle is completely full of test fluid.

This can happen when the nozzle is on the tester because of the large volume of test fluid delivered by the nozzle tester pump. It can also happen because of 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.

4. Install a new seal washer (6).

Use 6V-4979 Carbon Stop Seal Tool (4) to install new carbon dam (5) on nozzle (2).

7000 Series Nozzles


NOTICE

The part number for compression seal (3) is not the same for all nozzles. If the correct seal is not installed, the result will be high emissions. This is NOT acceptable.


Troubleshooting (Pencil-Type Fuel Nozzles Only)

A. To troubleshoot these nozzles, refer to the Troubleshooting Guide For Pencil-Type Fuel Nozzles located in this manual.

B. Refer to Special Instruction SEHS8627 "Use of 8S-2245 Nozzle Cleaning Tool Group" for the correct procedure (according to the part number of the nozzle) in order to clean these nozzles.

C. If VO is LESS than the specified value for a specific part number, DO NOT use the nozzle.

Troubleshooting Guide For Pencil-Type Fuel Nozzles

Troubleshooting Guide For Caterpillar 7000 Series Direct Injection Fuel Nozzles

Engine Nozzle Test Record Form (Sample Copy)

Repair/Calibration Information For 5P-4150 Tester Group

For the repair and/or calibration of the 5P-4150 Tester Group, contact the manufacturer:

U.S. Mail:

OTC Division
SPX Corporation
655 Eisenhower Drive
Owatonna, Minnesota 55060, U.S.A.

Telephone:

(507) 455-7000(800) 533-6127

Fax:

(800) 955-8329

Test Equipment Calibration

Caterpillar fuel nozzle and unit injector testers feature premium quality, liquid filled gauges for high accuracy and durability.

Pressure gauges, in this application must be of high quality in order to provide accurate and consistent test results.

To maintain this high degree of accuracy, gauge calibration should be checked at a MINIMUM of once a year. Additional information can be found in NEHS0631 "General Maintenance And Troubleshooting For Fuel Injection Equipment Test Stands (FIETS) And 5P-4150 Nozzle Tester".

NOTE: However, calibration should be checked at any time when the test results have become INCONSISTENT or if the gauge needle does NOT return to the 0 (zero) range when the test pressure is relieved.

Calibration

Two methods are available for gauge calibration:

* Method 1: Calibration by gauge manufacturer.
* Method 2: 5P-8558 Pressure Gauge Calibrating Group. Additional information can be found in NEHS0631 "General Maintenance And Troubleshooting For Fuel Injection Equipment Test Stands (FIETS) And 5P-4150 Nozzle Tester".

Calibration By Gauge Manufacturer (Method 1)

Certified calibration services are offered by Carrier - Oehler Company, a Caterpillar certified supplier of premium quality gauges.

The Carrier - Oehler Company can promptly check and recalibrate gauges at a low cost.

The Carrier - Oehler Company will also repair and recalibrate damaged gauges at a fraction of the cost of a new gauge.

When sending gauges to Carrier - Oehler Company, include the following information:

* Person or department that gauges and/or correspondence is to be directed to.
* List the quantity and a brief description of the gauge(s) problem or the service requested.
* Dealer name and address.
* Telephone number.
* Fax number.

NOTE: The Carrier - Oehler Company will advise you if repair costs exceed 50 percent of a new gauge.

NOTE: Questions on costs, service, and repair time should be directed to the Caterpillar Repair Desk:

(800) 321-3241

Shipping:

Carrier - Oehler Company
16965 Vincennes Avenue
South Holland, Illinois 60473

U.S. Mail:

Carrier - Oehler Company
Post Office Box 40
16965 Vincennes Avenue
South Holland, Illinois 60473

Telephone:

(708) 339-8200

Fax:

(708) 339-9830

5P-8558 Pressure Gauge Calibrating Group (Method 2)


(1) 5P-0946 Box Assembly.(2) 1P-2375 Quick Connective Coupler Assembly.(3) 8S-4600 Quick Disconnect Nipple (two each)(4) 8S-4599 Quick Disconnect Coupling Assembly.

NOTE: Other nipples for gauge attachment: 2S-5244 Quick Disconnect Nipple, 1/4inch NPT External Thread.

The 5P-8558 Pressure Gauge Calibrating Group consists of three gauges, each with 0.5 percent accuracy:

Each gauge has a defined pressure range:

* Gauge one...1100 kPa (160 psi)
* Gauge two...4150 kPa (600 psi)
* Gauge three...34,500 kPa (5000 psi)

The two lower pressure gauges (gauge one and two) are protected from excessive pressure by two sensor valves. The sensor valves shut OFF the pressure signal to the gauges at a preset value.

A separate source of pressure, such as the recommended 1U-5230 Pump Group or 4C-4865 Hand Pump, is required to actuate the calibrating group.

Components Used For Testing With 5P-8558 Pressure Gauge Calibrating Group


(1) 1U-5230 Pump Group.(2) 1P-2375 Quick Connective Coupler Assembly.(3) 1P-2376 Quick Connective Coupler Assembly (two each).(4) 8F-0024 Hose Assembly.(5) 1S-8937 Needle Valve.(6) 5P-8998 Pipe Nipple.

Using 5P-8558 Pressure Gauge Calibrating Group

Gauge calibration can be checked using 5P-8558 Pressure Gauge Calibrating Group.

The 5P-8558 Pressure Gauge Calibrating Group can be used in you own shop to calibrate and check the accuracy of the test gauges.

NOTE: Additional information can be found in NEHS0631 "General Maintenance And Troubleshooting For Fuel Injection Equipment Test Stands (FIETS) And 5P-4150 Nozzle Tester".

Calibration

1. Install the gauge into the calibrator.

Use the necessary adapters and fittings as shown in "Components Used For Testing With 5P-8558 Pressure Gauge Calibrating Group".

2. Pressurize the calibrator using the recommended 1U-5230 Pump Group or 4C-4865 Hand Pump.

Maintain (hold) the pressure to the gauges until the gauge needle remains steady.

NOTE: DO NOT check the calibration unit the needle remains STEADY.

3. Compare the pressure reading of the calibration gauges to the gauge being tested:

Check each pressure gauge at three scale positions (pressures).

The checking positions (pressures) for all three gauges are at a percentage of full scale:

* 25 percent,
* 50 percent,
* 75 percent, and
* 100 percent.

Also, the gauge being checked MUST compare within ± 2.0 percent of the calibrator gauge readings at all four scale positions (pressures).

The 2.0 percent value is calculated by multiplying the MAXIMUM pressure capacity of the gauge being tested times 0.02.

Example

A 0 - 6890 kPa (0 - 1000 psi) gauge MUST calibrate at all four scale positions (25%, 50%, 75%, and 100%) to ± 137.8 kPa (20.0 psi).

NOTE: Any gauge that does NOT compare WITHIN ± 2.0 percent of the calibrator MUST be replaced or repaired and then recalibrated.

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