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)
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)

Introduction

This 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.

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

------ 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.

----------------------

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:

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.

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


    Illustration 1 g00945947

  1. 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.

    Table 1
    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)    
    ( 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 .

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

  1. Close the ON/OFF valve.

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

  1. Open the gauge protector valve (0 to 40,000 kPa (0 to 5,800 psi) gauge) for one-half of a turn.

  1. Place the 8S-2270 Fuel Collector and the 1U-8857 Extension Tube under the fuel nozzle.

Bleed the Air from the Nozzle Assembly

  1. 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.

  1. 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.

Valve Opening Pressure Test

  1. 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.

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

Table 2
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)    
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

  1. 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.

  1. Open the gauge protector valve (0 to 40,000 kPa (0 to 5,800 psi) gauge).

  1. 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.

  1. 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.

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

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

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

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

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

  1. 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.

  1. Hold this test pressure for 15 seconds.

  1. 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.

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

    Table 3
    Specifications for Tip Leakage    
    No more than 3 drops in 15 seconds    

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



Illustration 2 g00453787

Types of spray pattern for the 7000 Series fuel nozzles.

Table 4
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    
( 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.

  1. 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.

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

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

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

  1. Check the individual spray orifices for partial plugging.

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

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

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.



Illustration 3 g00453789

Typical example of a 7000 Series fuel nozzle

  1. 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.


    Illustration 4 g00453809

  1. Tighten purging screw (D) or purging screw (E) to a torque of 2.2 ± 0.8 N·m (20 ± 7 lb in).

    Note: Use a 6V-4980 Torque Screwdriver Tool Group in order to torque the purging screw.

  1. Apply a test pressure of 13,800 kPa (2,000 psi) to the fuel nozzle.

    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



Illustration 5 g00453817

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.

Table 5
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)    
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
131-1242
131-1243
131-7937
134-0944
171-4093    		 7W-4487 (Black)    
1.27 mm (0.050 inch)    
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)