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Copyright 1991, 2003 Caterpillar Inc. All Rights Reserved.
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9TC D8N TRACK-TYPE TRACTOR Instruccin Especial

Nmero de publicacin SEHS7292-10 Fecha de publicacin 2002/02/02 Fecha de actualizacin 2002/05/01
Using The 5P-4150 Nozzle Testing Group

0782
Introduction
The 5P-4150 Tester Group is used for testing:
Capsule-Type Fuel Valves

Pencil-Type Fuel Nozzles
Caterpillar Direct Injection Fuel Nozzles
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
file://C:\SIS\TMP\sis1A1prt.html
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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.) Drum
6V-6068 Calibration Fluid...19 L (5.0 gal U.S.) Pail
9U-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 5P8558 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.
Refer to "Calibration (Method 1 or Method 2)" in this manual.
The rate of 8T-0856 Pressure Gauge is 0-6000 kPa (0-870 psi) with minor divisions (increments) of 100
kPa (20 psi).
The range of 8T-0860 Pressure Gauge is 0-40 000 kPa (0-5800 psi) with minor divisions (increments) of
1000 kPa (100 psi).
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The accuracy for either gauge is 2.0 percent full scale across the entire readable range.
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.
When testing fuel injection nozzles, always wear eye protection.

Fuel sprays from the orifices in the nozzle tip under high
pressure. It can pierce the skin and cause serious injury to the
operator. Always keep the tip of the nozzle pointed away from
the operator and into 8S-2270 Fuel Collector Assembly and FT1384 or 1U-8857 Extension Tube.
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:
SEHS7350 "Test Sequence For Capsule-Type Fuel Nozzles"

SEHS7390 "Test Sequence For Pencil-Type Fuel Nozzles"
SEHS9083 "Test Sequence For Caterpillar 7000 Series Fuel Nozzles"
Order these publications using the normal literature ordering procedure.
Components Of 5P-4150 Tester Group
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Installation Of 5P-4150 Tester Group In Permanent Location
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It is possible to get more accurate tests and easier operation if 5P-4150 Tester Group is fastened
permanently and securely to a work bench. This can be performed with bolts or clamps, or with the use
of a bracket similar to mounting bracket (1).
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.
Service Parts for 5P-8744 Nozzle Adapter Assembly
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(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
1. Place nuts (1) and sleeves (2) on tube (3).

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.
Components Needed That Are Not Part of 5P-4150 Tester Group
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(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).
Additional Parts Needed to Test 7N-0449 Fuel Injection Nozzle Assembly And Caterpillar 7000
Series Direct Injection Fuel Nozzles
The parts shown above [6V-2170 Tube Assembly (1), 6V-2171 Tube Assembly (2) and two 5P-7448
Fuel Valve Adapters (3)] are not part of the tester group but are needed to test some 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, 5P4721 Tube, and Ft-1743 Line Assembly (none of which are shown here) to perform the test procedure.
Specific procedures are given in this manual.
NOTE: The FT-1743 Line Assembly is constructed from 1W-4660 Fuel Injector Line Assembly. See
the Tool Guide for FT print ordering information.
Optional Modification/Installation Of Quick Disconnect Couplings For Nozzle Adapters
Installation and use of the optional quick disconnect couplings on 5P-4150 Tester Group allows for
much faster and easier exchange from one nozzle adapter to another during a test procedure.
The following procedure lists all of the quick disconnect adapter that can be used.
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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.
The shortened tube shown here and new 6V-4143 Coupler Assembly (to be installed later) will provide
the correct length for this test.
2. Cut off 75 mm (3.0 in) from long end (B) of one 6V-2170 Tube Assembly (2).
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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:
5P-8744 Nozzle Adapter Assembly (7).

5P-7448 Fuel Valve Adapter (8) (at three locations).
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5P-4718 Nozzle Test Adapter Assembly (9), and

5P-4244 Nozzle Adapter (10).
NOTE: Install each 3J-1905 Fitting Sleeve so the longer part of the sleeve is toward nut (6).
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.
NOTE: DO NOT weld shut the orifice of the nozzles that are to be tested.
Former 5P-4717 Adapter Assembly.
5P-8744 Nozzle Adapter Assembly.
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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.
Install top part (A) of the capsule valve holder.
Position nozzle (1) with the welded shut orifice in bottom part (b) of the valve holder.
Install and tighten bottom part (B) to top part (A).
1. CLOSE On/Off valve (2).

2. OPEN pump isolator valve (3).
3. Pump the tester until a pressure of 24 000 kPa (3500 psi) is attained on the pressure gauge.
CLOSE pump isolator valve (3).
Inspect all connections for leaks. Perform repairs as necessary.
4. Open On/Off valve (2) and remove the fuel nozzle with the welded shut orifice.
Be sure to open On/Off valve (2) before removal of the welded

shut fuel nozzle. Fuel under high pressure can cause injury to
the operator of the nozzle tester if the On/Off valve is not open
when bottom part (B) is loosened.
NOTE: The top sealing surface of the welded shut test nozzle and all other nozzles that are to be tested
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MUST be free of scratches and burrs (sharp edges).

5. Repeat Step(s) 1-4:
Each time 5P-8744 Nozzle Adapter Assembly or 5P-4717 Adapter Assembly is removed and then
installed again.
Before and after a series of tests.

If there is an indication of a problem with the nozzle tester.
Test Sequence For Precombustion Chamber Fuel Nozzles
DO NOT drill or ream the orifice of a nozzle. DO NOT use a steel

brush or a wire wheel to clean the tip of the nozzle because the
orifice and valve can easily be damaged. A hand-held brass brush is
acceptable for cleaning the nozzle tip. For nozzle cleaning
procedure, refer to Special Instruction SEHS8627 "use Of 8S-2245
Nozzle Cleaning Tool Group".
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.
Bleed (Remove) Air From Tester
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1. Loosen one-half turn bottom part (A) of the adapter.

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.
3. Tighten bottom part (A) of the adapter.
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.
Pressure Loss Test
1. OPEN gauge protector valve (2) an additional one-half turn.

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.
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4. If the pressure loss is NOT within the Pressure Loss Specification, STOP the test sequence.
DO NOT use the nozzle.
Valve Opening Pressure (VOP) Test
1. OPEN pump isolator valve (3) one-half turn.

2. SLOWLY increase the pressure until the test fluid just begins to flow from the nozzle tip. This is
valve opening pressure (VOP).
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3. If VOP is NOT within the VOP Specification, STOP the test.

DO NOT use the nozzle
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.
Test Sequence For Direct Injection Fuel Nozzles
DO NOT drill or ream the orifices of a nozzle. DO NOT use a steel

brush or a wire wheel to clean the tip of the nozzle because the
orifices and valve can easily be damaged. The use of a hand-held
brass brush is acceptable for cleaning the nozzle tip. For nozzle
cleaning procedure, refer to Special Instruction SEHS8627 "Use Of
8S-2245 Nozzle Cleaning Tool Group".
Nozzle Installation
1. Position the nozzle to be tested in the nozzle holder.
Install the nozzle holder and tighten the adapter nut.
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2. CLOSE On/Off valve (1).

OPEN gauge protector valve (2) one-half turn [0-34 470 kPa (0-5000 psi) gauge].
OPEN pump isolator valve (3) one-half turn.
CLOSE gauge protector valve (4).
Bleed (Remove) Air From Tester
1. Loosen one-half turn bottom part (A) of the adapter.

2. Operate the pump until clear test fluid comes from threads (C) of adapter (B).
3. Tighten bottom part (A) of the adapter.
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.
Pressure Loss Test
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1. OPEN gauge protector valve (2) an additional one-half turn.

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.
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1. OPEN gauge protector valve (2) one-half turn.

2. SLOWLY increase the pressure until the test fluid flows from the nozzle tip.
3. If VOP is NOT within the VOP Specification, STOP the test.

Nozzle Flushing Procedure
1. CLOSE gauge protector valve (2).

2. Pump the tester three full strokes.
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3. OPEN gauge protector valve (2).

Tip Leakage Test
1. Wipe dry the nozzle tip and adapter. Wrap a clean shop towel around the lower part of the adapter.
The towel prevents return leakage down the outside of the adapter which may give a false tip leakage
indication.
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.
Spray Pattern Test
1. Rapidly increase the pressure until the nozzle valve opens and the test fluid sprays from the tip.
NOTE: "RAPIDLY increase the pressure" is defined as:
Each full pump stroke is performed in LESS than one second.
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Direct injection capsule nozzles must give an appearance as shown above.

The test fluid must flow from all orifices.
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.
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DO NOT use a steel brush or a wire wheel to clean the nozzle tip.
These tools can cause a reduction of orifice size as shown at location
(Y). This type nozzle damage can cause a large change in engine
horsepower. The illustration shows a normal orifice at location (X)
and an orifice at location (Y) that has been damaged by an
incorrect cleaning procedure.
Pencil-Type Fuel Nozzle Part Number Reference Chart
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DO NOT use a steel brush or a wire wheel to clean the nozzle body
or the nozzle tip. Use of these tools can cause a reduction of orifice
size as shown at location (Y) and cause a large reduction of engine
horsepower. The illustration shows a normal orifice at location (X)
and an orifice at location (Y) that has been damaged by wire
brushing. Excessive brushing will also remove the coating. Stain on
the nozzle coating is normal.
Use needle nose pliers to remove and discard compression seal (1) and carbon dam (2). Use care to
avoid damaging the nozzle.
Caterpillar And Supplier Pencil-Type Fuel Nozzle Part Number Cross-Reference Chart
The only identification given on some pencil-type nozzles is the supplier part number. Use the following
chart to cross-reference specific nozzles between the supplier part number and the Caterpillar part
number.
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Test Sequence for Pencil-Type Fuel Nozzles

NOTE: The cap on these nozzles must be removed to prevent hydraulic lock or incorrect VOP
measurement during testing.
1. Position 8S-2250 Nozzle Holding Tool (1) in a vise.

2. Position the nozzle in the holding tool. Remove cap (2).
Return Leakage Test (Except Type A Nozzles)
Position of nozzle for return leakage test

1. Position the top of the nozzle slightly below the horizontal.
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.
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CLOSE On/Off valve (6).

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.
Nozzle Installation For Pencil-Type (A, B And C) Fuel Injection Nozzles
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Install 6V-2171 Tube Assembly (1) and 5P-4244 Direct Injection Nozzle Adapter (2) on the tester, for
all 3208-type pencil-type fuel nozzles except 7N-0449 Fuel Injection Nozzle Assembly. The 3300-type
7N-0449 Fuel Injection Nozzle Assembly requires 5P-7448 Flat Seat Fuel Valve Adapter.
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 1U8857 Extension Tube.
Turn On/Off valve (4) to the CLOSED position. OPEN pump isolator valve (5) and 0-25 000 kPa (03625 psi) gauge protector valve (6) one-half turn.
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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.
3. OPEN gauge protector valve (4) one-half turn.
4. SLOWLY increase the pressure until test fluid flows from the nozzle orifices.
5. If the VOP is NOT within VOP Specifications, STOP the test.
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NOTE: The nozzle must be flushed clean before the Tip Leakage Test:
2. Pump the tester three rapid FULL strokes.
Tip Leakage Test
1. Wipe dry the nozzle tip and body.
Wrap a clean, lint-free cloth around the top of the nozzle (pressure screw end) in order to prevent bleedback fluid from draining down and dripping off the nozzle tip.
2. Apply a pressure of 1380 kPa (200 psi) below the minimum VOP.
Hold this pressure fifteen seconds.
3. If the tip leakage is NOT within the Tip Leakage Specifications, STOP the test.
Refer to the "Troubleshooting Guide" in this manual.
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Spray Pattern Test

NOTE: Use 8S-2257 Loupe from 8S-2245 Cleaning Tool Group or 6V-2196 Inspection Microscope in
order to visually inspect the nozzle orifices and in order to inspect for any indication of orifice plugging
or damage.
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 orifices.
NOTE: "RAPIDLY increase the pressure" is defined as:
Each full pump stroke is performed in LESS than one second.

The nozzle must produce a pattern as shown in the Illustration A.
The test fluid must flow evenly from all orifices.
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Illustration A. SATISFACTORY fluid spray.

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.
Illustration B. UNSATISFACTORY fluid spray: PLUGGED ORIFICE
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Illustration C. UNSATISFACTORY fluid spray: HORIZONTAL DEFLECTION.

NOTE: If it is difficult to view all orifices at one time, it is permissible to use a slow stroke to verify
that all orifices are open.
A RAPID stroke must be used, however, for the final test.
NOTE: This completes the test sequence for Type B 9L-9263, 9L-7883, and 9N-2366 Nozzle
Assemblies.
Installation Of Cap (Type A And C Nozzles Only)
1. Remove the nozzle from the tester and install it in 8S-2250 Nozzle Holding Tool. Position the tool,
with nozzle, in a vise.
2. Install new 1H-1023 O-ring Seal (1) and cap (2). Tighten cap (2) to a torque of 12.0 Nm (106 lb in)
to 14.0 Nm (124 lb in).
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NOTE: Do not over-tighten cap (2).

Cap Leakage Test
1. Install the nozzle on 5P-4150 Tester Group.
Position the nozzle so its spray is directed into 8S-2270 Fuel Collector Assembly and FT-1384 or 1U8857 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.
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3. Install new compression seal (3). Use 6V-4979 Carbon Stop Seal Tool to install new carbon dam (2).
Inspect For Damage
Inspect for damage caused by:
Steel wire brushing.

Partially melted carbon dam seal.
NOTE: Engine overheating can cause carbon dam seal material to melt and thinly adhere up the side of
the nozzle body.
If this condition is found, replace the entire set of fuel nozzles.
NOTE: Use 8S-2257 Loupe, from 8S-2245 Nozzle Cleaning Tool Group or 6V-2196 Inspection
Microscope, to visually inspect nozzle orifices and to visually inspect for indication of orifice plugging
or damage.
Inspect for any other obvious damage.
DO NOT use damaged fuel nozzles.
Nozzle Installation For Caterpillar 7000 Series Direct Injection Nozzles
Remove bleed screw (1) and seal from nozzle (2).

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.
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NOTE: 104-9450 thru 104-9455 Nozzle Assemblies DO NOT have bleed screws.
Installation Of 3300 Engine Nozzles.
Install 6V-2170 Tube Assembly (3) and 5P-7448 Fuel Valve Adapter (4) on nozzle tester (5).
Install nozzle (2) on adapter (4) so the hole for bleed screw (1) is toward nozzle tester (5).
Install 5P-4721 Tube (10), 5P-4244 Nozzle Adapter (11), and FT-1743 Line Assembly (12) [fabricate
from 1W-4660 Fuel Injector Line Assembly] on nozzle tester (5).
Install nozzle (9) on FT-1741 Line Assembly (12).
Install 5P-4721 Tube (10) and 5P-4244 Nozzle Adapter (11) on nozzle tester (5).
Install nozzle (2) on adapter (11).
Turn On/Off valve (6) to the CLOSED position.
OPEN pump isolator valve (7) and 0-40,000 kPa (0-5800 psi) gauge protector valve (8) one-half turn.
Wrap a clean shop towel around the nozzle body.
Install 8S-2270 Fuel Collector Assembly and FT-1384 or 1U-8857 Extension Tube in the position as
shown.
VALVE OPENING PRESSURE (VOP) TEST
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1. SLOWLY increase the pressure until the test fluid just begins to flow from the nozzle tip.
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.
2. If VOP is NOT within VOP Specifications, STOP the test.

2. Pump the tester three full strokes.
Tip Leakage Test
1. Wipe dry the nozzle tip and body. Wrap a clean, lint-free cloth around the top of the nozzle (covering
the bleed screw hole) in order to prevent bleed-back fluid from draining down and dripping off the
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nozzle tip.
2. Apply a pressure of 1380 kPa (200 psi) below the valve opening pressure (VOP) )(as measured in
Step 2).
Maintain this pressure for fifteen seconds.
3. If the tip leakage is NOT within the Tip Leakage Specification, STOP the test.
Spray Pattern Test
Copyright 1991, 2003 Caterpillar Inc.

All Rights Reserved.
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Copyright 1991, 2003 Caterpillar Inc. All Rights Reserved.

9TC D8N TRACK-TYPE TRACTOR Instruccin Especial

Using The 5P-4150 Nozzle Testing Group

The 5P-4150 Tester Group is used for testing:

Capsule-Type Fuel Valves

Copyright 1991, 2003 Caterpillar Inc. All Rights Reserved.

Copyright 1991, 2003 Caterpillar Inc. All Rights Reserved.

When testing fuel injection nozzles, always wear eye protection.

SEHS7350 "Test Sequence For Capsule-Type Fuel Nozzles"

Components Of 5P-4150 Tester Group

Copyright 1991, 2003 Caterpillar Inc. All Rights Reserved.

Copyright 1991, 2003 Caterpillar Inc. All Rights Reserved.

Copyright 1991, 2003 Caterpillar Inc. All Rights Reserved.

Copyright 1991, 2003 Caterpillar Inc. All Rights Reserved.

Copyright 1991, 2003 Caterpillar Inc. All Rights Reserved.

Installation Of 5P-4150 Tester Group In Permanent Location

Copyright 1991, 2003 Caterpillar Inc. All Rights Reserved.

Copyright 1991, 2003 Caterpillar Inc. All Rights Reserved.

1. Place nuts (1) and sleeves (2) on tube (3).

Copyright 1991, 2003 Caterpillar Inc. All Rights Reserved.

Copyright 1991, 2003 Caterpillar Inc. All Rights Reserved.

Copyright 1991, 2003 Caterpillar Inc. All Rights Reserved.

5P-8744 Nozzle Adapter Assembly (7).

Copyright 1991, 2003 Caterpillar Inc. All Rights Reserved.

5P-4718 Nozzle Test Adapter Assembly (9), and

Former 5P-4717 Adapter Assembly.

5P-8744 Nozzle Adapter Assembly.

Copyright 1991, 2003 Caterpillar Inc. All Rights Reserved.

1. CLOSE On/Off valve (2).

Be sure to open On/Off valve (2) before removal of the welded

Copyright 1991, 2003 Caterpillar Inc. All Rights Reserved.

MUST be free of scratches and burrs (sharp edges).

Before and after a series of tests.

DO NOT drill or ream the orifice of a nozzle. DO NOT use a steel

2. Close On/Off valve (1).

Copyright 1991, 2003 Caterpillar Inc. All Rights Reserved.

1. Loosen one-half turn bottom part (A) of the adapter.

1. OPEN gauge protector valve (2) an additional one-half turn.

Copyright 1991, 2003 Caterpillar Inc. All Rights Reserved.

1. OPEN pump isolator valve (3) one-half turn.

Copyright 1991, 2003 Caterpillar Inc. All Rights Reserved.

3. If VOP is NOT within the VOP Specification, STOP the test.

DO NOT drill or ream the orifices of a nozzle. DO NOT use a steel

Copyright 1991, 2003 Caterpillar Inc. All Rights Reserved.

2. CLOSE On/Off valve (1).

1. Loosen one-half turn bottom part (A) of the adapter.

Copyright 1991, 2003 Caterpillar Inc. All Rights Reserved.

1. OPEN gauge protector valve (2) an additional one-half turn.

A loss of pressure to zero (0) AFTER five seconds is acceptable.

Copyright 1991, 2003 Caterpillar Inc. All Rights Reserved.

Valve Opening Pressure (VOP) Test

1. OPEN gauge protector valve (2) one-half turn.

3. If VOP is NOT within the VOP Specification, STOP the test.

1. CLOSE gauge protector valve (2).

Copyright 1991, 2003 Caterpillar Inc. All Rights Reserved.

3. OPEN gauge protector valve (2).

Each full pump stroke is performed in LESS than one second.

Copyright 1991, 2003 Caterpillar Inc. All Rights Reserved.

Direct injection capsule nozzles must give an appearance as shown above.

Copyright 1991, 2003 Caterpillar Inc. All Rights Reserved.

Pencil-Type Fuel Nozzle Part Number Reference Chart

Copyright 1991, 2003 Caterpillar Inc. All Rights Reserved.

Copyright 1991, 2003 Caterpillar Inc. All Rights Reserved.

Copyright 1991, 2003 Caterpillar Inc. All Rights Reserved.