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3208 GENERATOR SET ENGINE 29A00225-UP(SEBP1372 - 06) - Documentación

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Producto: GEN SET ENGINE
Modelo: 3208 GEN SET ENGINE 29A
Configuración: 3208 GENERATOR SET ENGINE 29A00225-UP

Instrucción Especial
Test Sequence For Caterpillar 7000 Series Fuel Nozzles{1254}
Número de medio -SEHS9085-09

Fecha de publicación -12/04/2011

Fecha de actualización -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)

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

The following information will summarize the related documentation. refer to Tool Operating Manual. 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. • For information that relates to the setup and operation of the tools that are used to clean fuel nozzles. 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. SEHS7292. "Engine Nozzle Test Record" in order to record the results while you are testing each fuel nozzle. When fuel injection nozzles are tested.jsp?returnurl=/sisweb/sisw. Testing 7000 Series Fuel Nozzles Ensure that you wear eye protection at all times during testing. "Using the 5P-4150 Nozzle Testing Group".com/sisweb/sisweb/techdoc/techdoc_print_page. These record sheets can be used for recording and correlating the test data that is accumulated. refer to Special Instruction. • Use the Special Instruction. SEHS8144.Documentación Página 2 de 13 3304 (S/N: 13E1-UP) 3304B (S/N: 1PS1-UP. and the calibration of the test equipment. 1TS1-UP) 3412 (S/N: 3JK146-UP) 3412B (S/N: 3JK1-145) 3412C (S/N: 60M1-UP. 10/01/2013 . SEHS8627. • For information on the setup. test fluids travel through the orifices of https://sis. These record sheets are available through normal channels for literature distribution. Additionally. There is also a publication that provides record sheets. The record sheets are available in pads that contain 50 sheets. there is information on the setup and operation of the cleaning equipment that is necessary in order to clean the fuel nozzles.06) . "Using the 8S-2245 Nozzle Cleaning Tool Group". 1NS1-UP) 3306B (S/N: 1RS1-UP) 3408B (S/N: 8RG1-UP) 3408C (S/N: 99U1-UP..cat. Note: The publications that are mentioned above may contain information that must be referenced in order to test the fuel injection nozzles.3208 GENERATOR SET ENGINE 29A00225-UP(SEBP1372 .. operation.

Inspect the Fuel Nozzle for Damage Perform a visual inspection of the fuel nozzle.jsp?returnurl=/sisweb/sisw. Refer to Tool operating Manual.3208 GENERATOR SET ENGINE 29A00225-UP(SEBP1372 . Failure to do so may damage the fuel nozzles that you are testing and will reduce the life of the test equipment. NOTICE Always ensure that the test fixture is in proper working order. Under this amount of pressure.. SEHS7292. the test fluid can pierce the skin and cause serious injury to the operator. 10/01/2013 . the 5P-4150 Nozzle Testing Group must be equipped with a 8T-0860 Pressure Gauge . Install the Fuel Nozzle onto the Test Fixture Note: Be sure to check the test fixture for leaks prior to performing this test procedure.cat. If any of these forms of damage has been found. do not use the damaged fuel nozzle. Replace the original 8T-0859 Pressure Gauge with the 8T-0860 Pressure Gauge . 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. https://sis. "Using the 5P-4150 Nozzle Testing Group" for information that relates to the replacement of the pressure gauge. Check that the fluid reservoir contains clean test fluid.Documentación Página 3 de 13 the nozzle tip with high pressure. all of the fuel nozzles must be replaced. Inspect each fuel nozzle for any sign of damage that may contribute to the improper operation of the fuel nozzle.06) .com/sisweb/sisweb/techdoc/techdoc_print_page. "Using the 5P-4150 Nozzle Testing Group" for information that is related to the operation of the nozzle testing group. Refer to Tool Operating Manual.. SEHS7292. Note: Prior to starting this test procedure. Always keep the tip of the fuel injection nozzle pointed away from the operator and into the fuel collector and extension.

000 kPa (0 to 5.cat. Illustration 1 g00945947 2. Open the gauge protector valve (0 to 40. Place the 8S-2270 Fuel Collector and the 1U-8857 Extension Tube under the fuel nozzle.jsp?returnurl=/sisweb/sisw.3208 GENERATOR SET ENGINE 29A00225-UP(SEBP1372 .Documentación Página 4 de 13 1. 3.com/sisweb/sisweb/techdoc/techdoc_print_page. 7. Install tube assembly (1) and nozzle adapter (2) onto the test fixture. 5.. 6. If the fuel nozzle is equipped with a purging screw.800 psi) gauge) for one-half of a turn. 10/01/2013 . 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. 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. Close the ON/OFF valve. remove the purging screw and seal washer from the fuel nozzle.. Refer to Table 1 for the correct tube assembly and the correct fuel nozzle adapter to use for your application. Open the pump isolator valve for one-half turn.06) . Loosen the adapter fitting at the fuel nozzle. 4. Bleed the Air from the Nozzle Assembly 1. https://sis.

06) .com/sisweb/sisweb/techdoc/techdoc_print_page. Record this pressure as the valve opening pressure of the fuel nozzle.Documentación Página 5 de 13 2. Table 2 Specifications for Valve Opening Pressure Fuel Nozzle 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 Valve Opening Pressure 11.. Adjust the orientation of the fuel nozzle to the vertical position and tighten the adapter fitting.100 to 16. 10/01/2013 . Valve Opening Pressure Test 1. Wrap a clean cloth around the top of the fuel nozzle in order to absorb any internal return leakage.200 kPa (1.3208 GENERATOR SET ENGINE 29A00225-UP(SEBP1372 . 3.cat..jsp?returnurl=/sisweb/sisw.300 psi) https://sis. Check the tube assembly and adapter fittings for leakage. Operate the pump handle until test fluid that is free of air bubbles flows from the threads of the adapter. 2. Refer to the information that is provided in Table 2 in order to evaluate the results of the test. Slowly increase the pressure on the fuel nozzle until fluid begins to flow from the tip of the fuel nozzle.600 to 2.

000 to 2.600 to 24.200 psi) https://sis.400 to 3.06) .500 to 22. 10/01/2013 .700 psi) 20.3208 GENERATOR SET ENGINE 29A00225-UP(SEBP1372 .700 to 26.jsp?returnurl=/sisweb/sisw.100 kPa (2.700 to 3.100 kPa (2.800 to 18...com/sisweb/sisweb/techdoc/techdoc_print_page.Documentación 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 100-7567 104-9450 (1) 104-9452 (1) 104-9453 (1) 104-9454 (1) 121-4353 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 154-3198 Página 6 de 13 13.200 kPa (2.cat.000 to 3.900 psi) 18.500 psi) 16.900 kPa (3.

.06) . 7. Check for Tip Leakage 1.000 kPa (0 to 5. 10. During the first portion of the valve movement.com/sisweb/sisweb/techdoc/techdoc_print_page.800 psi) gauge).380 kPa (200 psi) from the minimum valve opening pressure for the nozzle. All test fluid should be wiped from the nozzle assembly. If the fuel nozzle is not within specifications. the second portion of the valve movement begins the injection cycle.000 kPa (0 to 5. Refer to the information that is provided in Table 3 in order to evaluate the results of the test. Open the gauge protector valve (0 to 40. Calculate the test pressure that will be used for the tip leakage test. 10/01/2013 . Slowly apply the test pressure. 5. a. Subtract a value of 1. Use the minimum value of the fuel nozzle's valve opening pressure to calculate the test pressure for the nozzle that is being tested. Flush the fuel nozzle that is being tested by pumping the tester for 3 full strokes.3208 GENERATOR SET ENGINE 29A00225-UP(SEBP1372 .jsp?returnurl=/sisweb/sisw. Record the result of the calculation as the test pressure that will be used for the tip leakage test. Use the pump isolator valve to adjust the test pressure and close the valve in order to maintain the test pressure. to the fuel nozzle. Open the pump isolator valve in order to release the pressure on the fuel nozzle when the test is completed. Close the pump isolator valve. 4. 8. that has been calculated in Step 6. 2. an audible click can be heard and a small amount of fuel will be released.800 psi) gauge).. Count the number of drops of test fluid that drips from the nozzle during the duration of the test. 3. A clean cloth should be wrapped around the top of the fuel nozzle in order to absorb any internal return leakage. b.Documentación (1) Página 7 de 13 This fuel nozzle uses an internal valve with a two-stage relief action. 6. Use a clean cloth to dry the tip and the body of the fuel injector. 9.cat. Table 3 Specifications for Tip Leakage No more than 3 drops in 15 seconds https://sis. stop the test and do not use the nozzle. As valve opening pressure is achieved. Close the gauge protector valve (0 to 40. Hold this test pressure for 15 seconds. The cloth should cover the hole for the purging screw in order to absorb any leakage from the hole.

. (2) The spray orifice is manufactured with a 15° angle that is measured from the centerline of the fuel injector body. 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.000 kPa (0 to 5.800 psi) gauge).com/sisweb/sisweb/techdoc/techdoc_print_page. Close the gauge protector valve (0 to 40. 10/01/2013 .Documentación Página 8 de 13 If the tip leakage for the fuel nozzle is not within specifications. 1. Visually inspect the pattern of the fuel nozzle for a uniform spray. 2. stop the test and do not use the fuel nozzle.3208 GENERATOR SET ENGINE 29A00225-UP(SEBP1372 . Test the Fuel Nozzle for Plugged Orifices Illustration 2 g00453787 Types of spray pattern for the 7000 Series fuel nozzles..06) . https://sis.jsp?returnurl=/sisweb/sisw.cat.

Check the individual spray orifices for partial plugging. Test fluid should spray from the tip of the nozzle in a pattern that is uniform. Illustration 3 g00453789 Typical example of a 7000 Series fuel nozzle 1. The test fluid should spray uniformly from all of the orifices. 104-9452 Fuel Nozzle . 2. If an orifice is plugged or the pattern is distorted. Remove the cloth from the top of the nozzle.Documentación Página 9 de 13 Note: For this test. Use a moderate pump stroke in order to open the valve of the fuel nozzle. clean the fuel nozzle's orifice(s) and repeat this test. a. During the pump stroke. https://sis. Refer to Special Instruction. 3. Do not perform this test on these fuel nozzles. or the 104-9454 Fuel Nozzle . Refer to Illustration 2.com/sisweb/sisweb/techdoc/techdoc_print_page.3208 GENERATOR SET ENGINE 29A00225-UP(SEBP1372 . 104-9453 Fuel Nozzle .jsp?returnurl=/sisweb/sisw. 10/01/2013 .06) . Rapidly increase the pressure on the fuel nozzle until fluid sprays from the tip of the fuel nozzle.. view the individual spray orifices for partial plugging. b.cat. Test the Fuel Nozzle for Seal Leakage Note: Testing for seal leakage is not a requirement for the 104-9450 Fuel Nozzle . a.. Prior to performing this test. b. install a new seal washer on purging screw (A) and reinstall the purging screw into the fuel nozzle. "Use of 8S-2245 Nozzle Cleaning Tool Group" for instructions on tool usage and cleaning procedures. SEHS8627. each full stroke of the pump should be performed in less than one second.

hydraulic lock may prevent the nozzle from opening during this test. slowly loosen the adapter fitting in order to relieve the pressure on the fuel nozzle's valve assembly.. Do not use the nozzle if there is leakage that cannot be repaired at purging screw (A). Apply a test pressure of 13. or lower seal joint (C) . 10/01/2013 .cat.3208 GENERATOR SET ENGINE 29A00225-UP(SEBP1372 .Documentación Illustration 4 Página 10 de 13 g00453809 3.800 kPa (2. upper seal joint (B). Note: Due to the large amount of test fluid that is delivered to the fuel nozzle. 4. Tighten purging screw (D) or purging screw (E) to a torque of 2. Retest the fuel nozzle for leaks.com/sisweb/sisweb/techdoc/techdoc_print_page.8 N·m (20 ± 7 lb in).000 psi) to the fuel nozzle.2 ± 0.06) . If a hydraulic lock occurs.. If there is leakage at the purging screw.jsp?returnurl=/sisweb/sisw. Note: Use a 6V-4980 Torque Screwdriver Tool Group in order to torque the purging screw. install a new 8C-3234 Screw and a 114-3364 Washer as replacement parts. Returning Fuel Nozzles to Service https://sis.

Table 5 contains part numbers for the replacement of the fuel nozzle's seal washers.18 mm (0.18 mm (0.125 inch) 2.. Table 5 Seal Washers Fuel Nozzle Washer (Color) 8N-7004 4W-3914 (Gray) 4W-7012 4W-7013 4W-7014 4W-7015 4W-6060 (Blue) 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) 133-3896 7W-4483 (Red) Washer Thickness 1.3208 GENERATOR SET ENGINE 29A00225-UP(SEBP1372 .com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw.54 mm (0..100 inch) https://sis. 10/01/2013 .125 inch) 3.Documentación Illustration 5 Página 11 de 13 g00453817 Prior to returning fuel nozzles to service.06) .27 mm (0.cat. Use 6V-4979 Carbon Seal Installation Tool (2) in order to install a new carbon dam (4) .050 inch) 3. install a new seal washer (3) and install a new carbon dam (4) on the fuel nozzle (1) .

10/01/2013 .06) .jsp?returnurl=/sisweb/sisw.050 inch) 1.27 mm (0.050 inch) https://sis.cat.3208 GENERATOR SET ENGINE 29A00225-UP(SEBP1372 .Documentación 4W-7011 4W-7016 7W-7024 7W-4485 (Copper) 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) 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) Página 12 de 13 1..com/sisweb/sisweb/techdoc/techdoc_print_page.072 inch) 1.27 mm (0..84 mm (0.

2013 Caterpillar Inc..cat.jsp?returnurl=/sisweb/sisw.84 mm (0. 1. 10/01/2013 .3208 GENERATOR SET ENGINE 29A00225-UP(SEBP1372 .072 inch) 1.com/sisweb/sisweb/techdoc/techdoc_print_page.050 inch) Thu Jan 10 16:24:37 EST 2013 Todos los derechos reservados.Documentación Página 13 de 13 131-1242 131-1243 131-7937 134-0944 171-4093 7W-7023 7W-8119 (Yellow) 8N-7001 8N-7002 8N-7006 8N-4183 (Nylon material) Copyright 1993 . Red privada para licenciados del SIS.06) .27 mm (0.. https://sis.