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Using The 5P-4150 Nozzle Testing Group (0782) #SEHS72920001 Caterpillar
Using The 5P-4150 Nozzle Testing Group (0782) #SEHS72920001 Caterpillar
Introduction
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.
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.
Show/hide table
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:
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.
(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
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.
(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).
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.
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.
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:
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.
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.
3. Pump the tester until a pressure of 24 000 kPa (3500 psi) is attained on the pressure gauge.
4. Open On/Off valve (2) and remove the fuel nozzle with the welded shut
orifice
.
Show/hide table
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).
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.
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.
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.
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.
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.
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.
Nozzle Installation
1. Position the nozzle to be tested in the nozzle holder.
OPEN gauge protector valve (2) one-half turn [0-34 470 kPa (0-5000 psi) gauge].
2. Operate the pump until clear test fluid comes from threads (C) of adapter (B).
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.
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.
2. SLOWLY increase the pressure until the test fluid flows from the nozzle tip.
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.
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.
Show/hide table
Use needle nose pliers to remove and discard compression seal (1) and carbon dam (2). Use
care to avoid damaging the nozzle.
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.
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.
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.
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.
4. SLOWLY increase the pressure until test fluid flows from the nozzle
orifice
s.
NOTE: The nozzle must be flushed clean before the Tip Leakage Test:
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.
3. If the tip leakage is NOT within the Tip Leakage Specifications, STOP the test.
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
orifice
s.
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.
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).
NOTE: Engine overheating can cause carbon dam seal material to melt and thinly adhere up
the side of the nozzle body.
NOTE: Use 8S-2257 Loupe, from 8S-2245 Nozzle Cleaning Tool Group or 6V-2196 Inspection
Microscope, to visually inspect nozzle
orifice
s and to visually inspect for indication of
orifice
plugging or damage.
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.
Install nozzle (2) on adapter (4) so the hole for bleed screw (1) is toward nozzle tester (5).
OPEN pump isolator valve (7) and 0-40,000 kPa (0-5800 psi) gauge protector valve (8) one-half
turn.
Install 8S-2270 Fuel Collector Assembly and FT-1384 or 1U-8857 Extension Tube in the
position as shown.
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.
3. If the tip leakage is NOT within the Tip Leakage Specification, STOP the test.
Plugged Orifice
Test
RAPIDLY increase the pressure until the nozzle valve opens and the test fluid sprays from the
tip.
DO NOT use a nozzle that has a spray pattern that is different from what is shown in the
illustration.
Use a moderate pump stroke to open the nozzle. View the individual spray plumes for partial
orifice
plugging.
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.
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).
* 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.
Use 6V-4979 Carbon Stop Seal Tool (4) to install new carbon dam (5) on nozzle (2).
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.
U.S. Mail:
OTC Division
SPX Corporation
655 Eisenhower Drive
Owatonna, Minnesota 55060, U.S.A.
Telephone:
Fax:
(800) 955-8329
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:
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:
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:
(708) 339-8200
Fax:
(708) 339-9830
The 5P-8558 Pressure Gauge Calibrating Group consists of three gauges, each with 0.5
percent accuracy:
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.
(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.
The 5P-8558 Pressure Gauge Calibrating Group can be used in you own shop to calibrate and
check the accuracy of the test gauges.
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:
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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