8/16/2019 C7.

1 DE200E0/DE220E0 Generator Set GTY00001-UP(SEBP7395 - 11) - Documentation

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Product: GENER ATO R SET

Mode l: C 7.1DE200E GENER ATO R SET GTY
C onfiguration: C 7.1 DE200E0/DE220E0 Ge ne rator Se t GTY00001-UP

Testing and Adjusting

C7.1 Generator Set Engines
Media Number -M0071960-00 Publication Date -01/04/2016 Date Updated -27/04/2016

i05182682

Fuel Injection Nozzle - Test

SMCS - 1254-081

Specifications
Table 1
Specifications for Testing the Fuel Injection Nozzles

Bench Test Temperature 18° to 20 °C (64° to 70 °F)

Nozzle Cap Nut Torque 34 ± 3 N·m (25 ± 2 lb ft)

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

Required Tools
Table 2
Required Tools

Part Number Part Description Qty

5P-4150 Nozzle Testing Group 1

5P-4718 Adapter 1

6V-2170 Tube Assembly 1

8S-2270 Fuel Collector 1

1U-8857 Extension 1

6V-6068 SAE J-967 Calibration Fluid 1

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Test Procedure
Bench test the fuel injection nozzles at a temperature of 18° to 20 °C (64° to 70 °F)

Test the Fuel Injection Nozzles

Bench test the fuel injection nozzles at a temperature of 18° to 20 °C (64° to 70 °F)

Illustration 1 g01141683
Fuel injection nozzles and lines
(1) Nut for the fuel supply line

1. Run the engine at low idle.

2. Loosen the nut for the fuel supply line (1) at the fuel injection nozzle on cylinder number 1. Do not loosen the nut
more than half of a turn. Listen for the low idle to decrease or become rough. Tighten the nut for the fuel supply
line on cylinder number 1. Perform this test on each cylinder.

3. The fuel injection nozzle is faulty when the nut for the fuel supply line is loosened and the following events occur:

The engine rpm does not decrease.

The engine does not idle roughly.

4. Remove the faulty fuel injection nozzle for additional testing.

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

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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 or spray distortion. Dirt in the orifices of the nozzle tip can damage engine
components. Dirt can also distort the spray pattern of the nozzle.

Test the Spray Pattern

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 2 g00322083
Correct spray pattern for a fuel injection nozzle

1. Connect fuel injection nozzle (3) to the tooling that is shown in Illustration 3.

Position the fuel injection nozzle so that the fuel spray is directed into the 1U-8857 Extension (4) and the 8S-2270
Fuel Collector (6).

2. Close the gauge protector valve and the shutoff valve. Open the pump isolator valve.

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3. Pump the nozzle tester at approximately 60 strokes per minute 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. The fuel injection nozzle is faulty if
there is a difference in the vertical patterns or a difference in the horizontal patterns. Refer to the correct spray
pattern in Illustration 2.

Note: If the nozzle tester is pumped too slowly, the fuel injection nozzle can develop a hydraulic lock. If this
situation occurs, release the nozzle cap nut in order to release the pressure and then tighten the nozzle cap nut to a
torque of 34 ± 3 N·m (25 ± 2 lb ft). Test the spray pattern again.

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.

Pressure Test

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.

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Illustration 3 g01141684
5P-4150 Nozzle Testing Group
(1) 5P-4718 Adapter
(2) 6V-2170 Tube assembly
(3) Fuel injection nozzle
(4) 1U-8857 Extension
(5) 8T-5313 Filter
(6) 8S-2270 Fuel collector

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 fuel injection nozzle (3) to the tooling that is shown in Illustration 3.

Position the fuel injection nozzle so that the fuel spray is directed into the 1U-8857 Extension (4) and the 8S-2270
Fuel Collector (6).

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.

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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. Move the pump lever quickly downward 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.

4. Refer to the table in Specifications, "Fuel Injection Nozzles" for the correct pressure settings.

If the opening pressure is not within the range of the setting that is given in the table, the fuel injection nozzle must
be replaced.

Fuel Injection Nozzle and Seat Test

1. Connect fuel injection nozzle (3) to the tooling that is shown in Illustration 3.

Position the fuel injection nozzle so that the fuel spray is directed into the 1U-8857 Extension (4) and the 8S-2270
Fuel Collector (6).

2. Pump the pressure of the nozzle tester at 60 strokes per minute 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
for at least ten seconds. A light dampness is acceptable. If the results of the tests are not acceptable, clean the fuel
injection nozzle. After you clean the fuel injection nozzle and the fuel leakage still occurs, the nozzle must be
replaced.

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Fri Aug 16 2019 07:10:46 GMT+0400 (Gulf Standard Tim e )
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