Prueba de Inyectores de La Serie 7000

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Producto: GEN SET ENGINE

Modelo: 3208 GEN SET ENGINE 29A

Configuracin: 3208 GENERATOR SET ENGINE 29A00225-UP

Instruccin Especial Test Sequence For Caterpillar 7000 Series Fuel Nozzles{1254}

Nmero de medio -SEHS9085-09 Fecha de publicacin -12/04/2011 Fecha de actualizacin -12/04/2011

i04359490

Test Sequence For Caterpillar 7000 Series Fuel Nozzles{1254}SMCS - 1254-081

Machine Engines: 3204 3208 3304 3306 3406 3408 3412 Industrial Engines:

3204 (S/N: 3PC1-UP) 3306 (S/N: 64Z1-UP) 3306B (S/N: 7JB1-UP; 5GZ1-UP) 3408 (S/N: 67U1-UP) 3412 (S/N: 9XF1-UP) 3412C (S/N: 38S1-UP)

Generator Engines:3208 (S/N: 29A1-UP; 30A1-UP) 3304B (S/N: 9HK1-UP) 3306 (S/N: 85Z1-UP) 3306B (S/N: 2AJ1-UP; 8JJ1-UP; 9NR1-UP; 9DS1-UP) 3406B (S/N: 2WB1-UP) 3406C (S/N: 4RG1502-UP; 4JK99-UP; 4ZR1-UP; 1SS1-UP; 8FS1-UP) 3408C (S/N: 78Z4867-UP) 3408B (S/N: 78Z1-4866) 3412C (S/N: BAK1-UP; BAX1-UP; 81Z1-UP) 3304 (S/N: 83Z1-UP) 3412 (S/N: 2WJ1-UP) 3406 (S/N: 4RG1-1501; 4JK1-98)

Truck Engines:3208 (S/N: 02Z1-UP; 51Z1-UP) 3306B (S/N: 63Z1-UP; 5KD1-UP) 3306C (S/N: 7RJ1-UP; 3KS1-UP; 9TL1-UP) 3406B (S/N: 8TC1-UP; 7FB1-UP; 5YG1-UP; 4MG1-3599) 3406C (S/N: 3ZJ16182-UP; 5KJ7800-UP; 8PN1-UP) 3406 (S/N: 3ZJ1-16181; 5KJ1-7799; 4CK1-845) 3408 (S/N: 28V1-UP)

Marine Engines:3208 (S/N: 75V1-UP; 01Z1-UP)

Pgina 1 de 133208 GENERATOR SET ENGINE 29A00225-UP(SEBP1372 - 06) - Documentacin

10/01/2013https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw...

3304 (S/N: 13E1-UP) 3304B (S/N: 1PS1-UP; 1NS1-UP) 3306B (S/N: 1RS1-UP) 3408B (S/N: 8RG1-UP) 3408C (S/N: 99U1-UP; 1TS1-UP) 3412 (S/N: 3JK146-UP) 3412B (S/N: 3JK1-145) 3412C (S/N: 60M1-UP; 9BR1-UP) 3412D (S/N: REA1-UP) 3306 (S/N: 84Z1-UP) 3406 (S/N: 4TB1-UP)

IntroductionThis Special Instruction has been written in order to provide procedural information for testing 7000 Series fuel nozzles.

There is an extensive amount of information that relates to the setup and the calibration of the tools that will be used to test the fuel nozzles.

Additionally, there is information on the setup and operation of the cleaning equipment that is necessary in order to clean the fuel nozzles.

There is also a publication that provides record sheets. These record sheets can be used for recording and correlating the test data that is accumulated. The following information will summarize the related documentation.

For information on the setup, operation, and the calibration of the test equipment, refer to Tool Operating Manual, SEHS7292, "Using the 5P-4150 Nozzle Testing Group".

For information that relates to the setup and operation of the tools that are used to clean fuel nozzles, refer to Special Instruction, SEHS8627, "Using the 8S-2245 Nozzle Cleaning Tool Group".

Use the Special Instruction, SEHS8144, "Engine Nozzle Test Record" in order to record the results while you are testing each fuel nozzle. These record sheets are available through normal channels for literature distribution. The record sheets are available in pads that contain 50 sheets.

Note: The publications that are mentioned above may contain information that must be referenced in order to test the fuel injection nozzles.

Testing 7000 Series Fuel Nozzles

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.

NOTICE

Always ensure that the test fixture is in proper working order. Check that the fluid reservoir contains clean test fluid. Failure to do so may damage the fuel nozzles that you are testing and will reduce the life of

the test equipment.

Note: Prior to starting this test procedure, the 5P-4150 Nozzle Testing Group must be equipped with a 8T-0860 Pressure Gauge . Replace the original 8T-0859 Pressure Gauge with the 8T-0860 Pressure Gauge . Refer to Tool Operating Manual, SEHS7292, "Using the 5P-4150 Nozzle Testing Group" for information that relates to the replacement of the pressure gauge.

Inspect the Fuel Nozzle for Damage

Perform a visual inspection of the fuel nozzle. Inspect each fuel nozzle for any sign of damage that may contribute to the improper operation of the fuel nozzle. Check for signs of damage that may have been caused by any of the following conditions:

Engine overheating (discolored fuel nozzles)Improper cleaning (use of a wire brush for cleaning)Partially melted carbon dam seal

Fuel nozzles that are deformed or bent

Cracking or splitting of the nozzle tip

Other obvious damage

Note: If there are signs of engine overheating, all of the fuel nozzles must be replaced.

If any of these forms of damage has been found, do not use the damaged fuel nozzle.

Install the Fuel Nozzle onto the Test Fixture

Note: Be sure to check the test fixture for leaks prior to performing this test procedure. Refer to Tool operating Manual, SEHS7292, "Using the 5P-4150 Nozzle Testing Group" for information that is related to the operation of the nozzle testing group.



If the fuel nozzle is equipped with a purging screw, remove the purging screw and seal washer from the fuel nozzle.

1.

Illustration 1 g00945947

Install tube assembly (1) and nozzle adapter (2) onto the test fixture. Refer to Table 1 for the correct tube assembly and the correct fuel nozzle adapter to use for your application.

2.

Tool Requirements for 7000 Series Fuel Nozzles

Engine Family Tube Assembly Fuel Nozzle Adapter

3200 5P-4721 5P-4244

3300 6V-2170 5P-7448

3400 5P-4721 5P-4244 (1)

Table 1

( 1 ) You must use the FT-1743 Fuel Test Line in order to properly attach the fuel nozzle to the fuel nozzle adapter. This test line may be fabricated from the 1W-4660 Fuel Injection Line As .

Position the fuel nozzle onto the tube assembly and hand tighten the nozzle to the adapter fitting.

3.

Close the ON/OFF valve.4.

Open the pump isolator valve for one-half turn.5.

Open the gauge protector valve (0 to 40,000 kPa (0 to 5,800 psi) gauge) for one-half of a turn.6.Place the 8S-2270 Fuel Collector and the 1U-8857 Extension Tube under the fuel nozzle.7.

Bleed the Air from the Nozzle Assembly

Loosen the adapter fitting at the fuel nozzle.1.



Operate the pump handle until test fluid that is free of air bubbles flows from the threads of the adapter.

2.

Adjust the orientation of the fuel nozzle to the vertical position and tighten the adapter fitting. Check the tube assembly and adapter fittings for leakage.

3.

Valve Opening Pressure Test

Wrap a clean cloth around the top of the fuel nozzle in order to absorb any internal return leakage.

1.

Slowly increase the pressure on the fuel nozzle until fluid begins to flow from the tip of the fuel nozzle. Record this pressure as the valve opening pressure of the fuel nozzle.

2.

Refer to the information that is provided in Table 2 in order to evaluate the results of the test.

Specifications for Valve Opening Pressure

Fuel Nozzle Valve Opening Pressure

4W-7011 4W-7012 4W-7013 4W-7014 4W-7015 4W-7016 4W-7017 4W-7018 4W-7019 4W-7020 4W-7021 4W-7022 7W-7023 7W-7024 7W-7026 7W-7030 7W-7031 7W-7032 7W-7033 7W-7035 7W-7037 7W-7038 8N-7001 8N-7002 8N-7003 8N-7004 8N-7005 8N-7006 8N-7007

170-5187

11,100 to 16,200 kPa (1,600 to 2,300 psi)

Table 2



7W-7040 7W-7041 7W-7042 7W-7043 7W-7044 7W-7045 100-7550 100-7551 100-7552 100-7556 100-7557 100-7558 100-7559 100-7560 100-7561 100-7562 100-7563 100-7564 100-7565 100-7600 104-3377 129-1351 167-7489 170-5181 170-5183 171-4093

131-3190

13,800 to 18,200 kPa (2,000 to 2,700 psi)

100-7567 104-9450 (1) 104-9452 (1) 104-9453 (1) 104-9454 (1) 121-4353

20,700 to 26,900 kPa (3,000 to 3,900 psi)

127-9792 127-9793 130-1804 130-1806 130-5187 130-5190 131-0811 131-0812 131-1242 131-1243 131-7937 133-3896

134-0944

18,600 to 24,100 kPa (2,700 to 3,500 psi)

154-3198 16,500 to 22,100 kPa (2,400 to 3,200 psi)



( 1 ) This fuel nozzle uses an internal valve with a two-stage relief action. During the first portion of the valve movement, an audible click can be heard and a small amount of fuel will be released. As valve opening pressure is achieved, the second portion of the valve movement begins the injection cycle.

If the fuel nozzle is not within specifications, stop the test and do not use the nozzle.

Check for Tip Leakage

Close the gauge protector valve (0 to 40,000 kPa (0 to 5,800 psi) gauge).1.Flush the fuel nozzle that is being tested by pumping the tester for 3 full strokes.2.

Open the gauge protector valve (0 to 40,000 kPa (0 to 5,800 psi) gauge).3.Use a clean cloth to dry the tip and the body of the fuel injector. All test fluid should be wiped from the nozzle assembly.

4.

A clean cloth should be wrapped around the top of the fuel nozzle in order to absorb any internal return leakage. The cloth should cover the hole for the purging screw in order to absorb any leakage from the hole.

5.

Calculate the test pressure that will be used for the tip leakage test.6.

Use the minimum value of the fuel nozzle's valve opening pressure to calculate the test pressure for the nozzle that is being tested.

Subtract a value of 1,380 kPa (200 psi) from the minimum valve opening pressure for the nozzle.

a.

Record the result of the calculation as the test pressure that will be used for the tip leakage test.

b.

Slowly apply the test pressure, that has been calculated in Step 6, to the fuel nozzle.7.

Close the pump isolator valve. Use the pump isolator valve to adjust the test pressure and close the valve in order to maintain the test pressure.

8.

Hold this test pressure for 15 seconds.9.

Count the number of drops of test fluid that drips from the nozzle during the duration of the test. Open the pump isolator valve in order to release the pressure on the fuel nozzle when the test is completed.

10.

Refer to the information that is provided in Table 3 in order to evaluate the results of the test.

Specifications for Tip Leakage

No more than 3 drops in 15 seconds

Table 3



If the tip leakage for the fuel nozzle is not within specifications, stop the test and do not use the fuel nozzle.

Test the Fuel Nozzle for Plugged Orifices


Types of spray pattern for the 7000 Series fuel nozzles.

Identification of Spray Patterns

Spray Pattern (1) Engine Family Number Of Orifices

"1" 3200 Four

"2" 3300 Six (2)

"3" 3300 Nine (2)

"4" 3400 Six

"5" 3400 Seven

Table 4

( 1 ) Refer to Illustration 2 for identification of the spray pattern.( 2 ) The spray orifice is manufactured with a 15 angle that is measured from the centerline of the fuel injector body.

Close the gauge protector valve (0 to 40,000 kPa (0 to 5,800 psi) gauge).1.Visually inspect the pattern of the fuel nozzle for a uniform spray.2.



Note: For this test, each full stroke of the pump should be performed in less than one second.

Rapidly increase the pressure on the fuel nozzle until fluid sprays from the tip of the fuel nozzle.

a.

Test fluid should spray from the tip of the nozzle in a pattern that is uniform. Refer to Illustration 2.

b.

Check the individual spray orifices for partial plugging.3.

Use a moderate pump stroke in order to open the valve of the fuel nozzle.a.

During the pump stroke, view the individual spray orifices for partial plugging.b.

The test fluid should spray uniformly from all of the orifices.

If an orifice is plugged or the pattern is distorted, clean the fuel nozzle's orifice(s) and repeat this test. Refer to Special Instruction, SEHS8627, "Use of 8S-2245 Nozzle Cleaning Tool Group" for instructions on tool usage and cleaning procedures.

Test the Fuel Nozzle for Seal Leakage

Note: Testing for seal leakage is not a requirement for the 104-9450 Fuel Nozzle , 104-9452 Fuel Nozzle , 104-9453 Fuel Nozzle , or the 104-9454 Fuel Nozzle . Do not perform this test on these fuel nozzles.


Typical example of a 7000 Series fuel nozzle

Remove the cloth from the top of the nozzle.1.

Prior to performing this test, install a new seal washer on purging screw (A) and reinstall the purging screw into the fuel nozzle.

2.




Tighten purging screw (D) or purging screw (E) to a torque of 2.2 0.8 Nm (20 7 lb in). 3.Note: Use a 6V-4980 Torque Screwdriver Tool Group in order to torque the purging screw.

Apply a test pressure of 13,800 kPa (2,000 psi) to the fuel nozzle.4.Note: Due to the large amount of test fluid that is delivered to the fuel nozzle, hydraulic lock may prevent the nozzle from opening during this test. If a hydraulic lock occurs, slowly loosen the adapter fitting in order to relieve the pressure on the fuel nozzle's valve assembly.

If there is leakage at the purging screw, install a new 8C-3234 Screw and a 114-3364 Washer as replacement parts. Retest the fuel nozzle for leaks.

Do not use the nozzle if there is leakage that cannot be repaired at purging screw (A), upper seal joint (B), or lower seal joint (C) .

Returning Fuel Nozzles to Service




Prior to returning fuel nozzles to service, install a new seal washer (3) and install a new carbon dam (4) on the fuel nozzle (1) .Use 6V-4979 Carbon Seal Installation Tool (2) in order to install a new carbon dam (4) .Table 5 contains part numbers for the replacement of the fuel nozzle's seal washers.

Seal Washers

Fuel Nozzle Washer (Color) Washer Thickness

8N-7004 4W-3914 (Gray) 1.27 mm (0.050 inch) 4W-7012 4W-7013 4W-7014

4W-7015 4W-6060 (Blue) 3.18 mm (0.125 inch)

4W-7018 4W-7019 4W-7020 4W-7021 4W-7022 7W-7045 100-7552 100-7562 100-7563 104-3377 167-7489 170-5181

170-5183

7W-4482 (Green) 3.18 mm (0.125 inch)

133-3896 7W-4483 (Red) 2.54 mm (0.100 inch)

Table 5



4W-7011 4W-7016

7W-7024 7W-4485 (Copper) 1.27 mm (0.050 inch)

8N-7003 7W-7038 8N-7005 100-7559 100-7561 100-7564 104-9450 104-9452 104-9453 104-9454 131-3190 154-3198

170-5187

7W-4486 (Violet) 1.84 mm (0.072 inch)

4W-7017 7W-7026 7W-7030 7W-7031 7W-7032 7W-7033 7W-7035 7W-7037 7W-7040 7W-7041 7W-7042 7W-7043 7W-7044 8N-7007 100-7550 100-7551 100-7556 100-7557 100-7558 100-7560 100-7565 100-7567 100-7600 121-4353 127-9792 127-9793 129-1351 130-1804 130-1806 130-5187 130-5190 131-0811 131-0812

7W-4487 (Black) 1.27 mm (0.050 inch)



131-1242 131-1243 131-7937 134-0944

171-4093

7W-7023 7W-8119 (Yellow) 1.84 mm (0.072 inch) 8N-7001 8N-7002

8N-7006 8N-4183 (Nylon material) 1.27 mm (0.050 inch)

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Thu Jan 10 16:24:37 EST 2013



Prueba de Inyectores de La Serie 7000

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