General Maintenance And Troubleshooting For Fuel Injection Equipment Test Stands (FIETS) And 5P-4150 Nozzle Tester{0784} Caterpillar

General Information Section

Introduction

The Fuel Injection Equipment Test Stand (FIETS) is used to efficiently and accurately test all of Caterpillar's fuel injection pumps. These include forged body fuel pumps, compact fuel injection pumps, scroll fuel injection pumps, sleeve metering injection pumps, and 3000 Series fuel pumps.

The maintenance and verification procedures in this Tool Operating Manual apply to 6V-7900, 6V-7901, 6V-7902, 6V-7903, 6V-9440, 1U-8212, and 1U-8213 Fuel Injection Equipment Test Stands.

Assuring Accuracy

Obtaining accurate and usable results from the FIETS is only possible if the test stand is properly and accurately maintained. If the test stand is not regularly calibrated to factory specifications, the data provided may not be accurate. Test stand maintenance must include testing the quality of the calibration fluid, gauges, and calibration tubes, in addition to changing filters, tightening drive belts, and replacing worn parts.

This Tool Operating Manual provides procedures to test, adjust, clean, and maintain the test stand in proper working order. The manual also contains forms to accurately record the history of the maintenance procedures.

Remember, test results are only as good as the equipment used to test the fuel injection pump.

Test Stand Repair Information

If the test stand needs more than general maintenance or adjusting, contact the original equipment manufacturer.

USA and Canada

All Other Locations

Gauge Repair Information

Liquid-filled pressure gauge repair service

Record Keeping And Data Sheets

Blank forms, referred to in this manual, are contained in the "Forms" section. These forms can be copied and used to record the test procedure and maintenance schedule.

References

It is important to have and maintain a complete library for the FIETS. This material should include the manuals listed in the "Reference Publications" chart. It is also important to update the manuals as new revisions are available. This will provide the latest and most current reference information.

Tooling And Equipment

Test Stand Service Parts

Specifications

Operation Section

Testing A Pump

Bench testing verifies the condition of the plunger and barrel as well as the cam profile. If the plunger and barrel is worn, the delivery rate will be low. Insufficient delivery rates can also be caused by worn cam lobes.

Governor settings can also be verified and adjusted using the test stand. Refer to SEHS8200, "Caterpillar Fuel Injection Equipment Test Stand" for complete instructions on testing fuel injection pumps.

TMI Data Specifications

Test specification data for newer Caterpillar fuel injection pumps can be found on the Technical Marketing Information (TMI) system. Refer to TMI Manual, LEBQ0724, for additional information on using TMI. Also refer to Tool Operating Manual, NEHS0594, "Using the TMI System to Retrieve Off Engine Injection Pump Test Specifications for the Fuel Injection Equipment Test Stand" for information on using TMI to obtain test specifications using the FIETS.

Specific lines and master nozzles must be used for for testing pumps using TMI data. Use the 9U-6705 Master Nozzle with 9U-5298, 9U-5299, or 127-4365 High Pressure Fuel Lines.

Safety Precautions

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Petroleum fluids, especially the lighter distillates in the solvent, kerosene and diesel fuel ranges, can cause skin irritation. This is true with the Test Oil used in the FIETS. Take extra precautions to remove test oil from the skin. Also use a protective hand cream to prevent irritation. When checking or calibrating the test bench, never work on or near moving parts when the drive start button is illuminated. Failure to follow this recommendation can result in bodily injury. Never make adjustments, such as drive belt tension, while the test stand is operating (rotating). Make sure all compressed air lines and high pressure fuel lines are correctly connected and tightened. Test fluid under pressure can cause injury to the operator or technician. Do not wear loose fitting clothing around test stand. Always wear ear and eye protection when test stand is operating. Keep away from fuel spray coming from high pressure fuel lines or master nozzles. Install all guards and safety equipment before operating the test stand. When performing maintenance procedures, make sure the area has good lighting and is well ventilated. Before starting any maintenance procedure around moving or potentially moving parts of the test stand, turn the power OFF and lock-out the power. Lock-out both the main electrical box and the power switch on the back of the machine. Place an SEHS7332, "Warning: Do Not Operate" tag on both the main electrical box and the main power switch.

Front Side Of SEHS7332 Warning Tag

Rear Side Of SEHS7332 Warning Tag

Reference Iron

To verify the calibration of the test stand, a reference fuel injection pump, new high pressure fuel injection lines, and a set of master nozzles should be obtained. These parts are known as "Reference Iron". The reference pump should be a pump that is known to be of good quality. It should be tested and all the data (specifications) recorded. Refer to SEHS9847 for additional information.

Using Reference Iron

Reference iron can be quickly installed onto the test stand and actual test readings can be compared to the historical reference iron data. If the current readings do not correspond to the historical data, the test stand is probably out of calibration. Further testing of the test stand would then be required to determine and correct the problem. Refer to the "Troubleshooting Test Stand Problems Using Reference Pump" section for additional information.

If a just tested fuel injection pump has a higher or lower than expected delivery rate, the reference iron should be installed and tested. If the reference iron performance is within specifications, the test stand calibration will be confirmed and the pump in question will be out of specification. If the reference pump is out of tolerance the test stand calibration is in question and should be investigated.

A set of high pressure fuel lines and master nozzles should be obtained and used only when testing the reference iron. Each line should be specified and tagged to operate only on one certain master nozzle, but at two locations on the test stand.

For example:

Reference Pump Plunger and Barrel 1-2-3-4-5-6

Line number 1-2-3-4-5-6

Nozzle number 1-2-3-4-5-6

Test stand number 1-2-3-4-5-6 and 7-8-9-10-11-12

Refer to the "Test Stand Service Parts" chart for a list of applicable high pressure lines.

Test Specification Data

Refer to TMI or SEHS8200 for specific information on installing, connecting the pump, and test data for the test stand.

Reference Iron Storage

Whenever the reference pump is stored, all openings should be plugged or capped. Use either a 5F-2807 Cap or 2F-2990 Plug.

Documenting Test Equipment Service Or Maintenance

An up-to-date log book documenting all the maintenance procedures, testing, and calibrating of test equipment is essential. This log book will also help to maintain a regular maintenance program. Below is a sample log sheet. A blank form is located in the "Forms" section.

Maintenance Section

Maintenance Schedule

NOTE: Blank data sheets are located in the "Forms" section. Many of these checks can be performed concurrently. For example, reference iron performance, graduate drain, shot count and tachometer checks, can be done with two or three runs.

Daily Maintenance

Check Oil Level In Lube And Test Oil Sumps

Check the sight tubes for the test and lube oil sumps. Make sure the supply tanks are at the correct level by removing the tank access panel from each side of the test stand.

Check The Lube and Test Oil Sump Sight Tubes For Correct Oil Level

Check For Oil Leaks

Visually checks for oil leaks on or around the test stand.

Weekly Maintenance

Magnetic Filter

Clean the magnetic filter in the test oil sump each week using the following procedure.

Clean Magnetic Filter In Test Oil Sump
(1) Filter panel. (2) Magnetic filter. (A) Filter tab. (B) Slot for filter tab.

1. Remove the drain return pipes from the lid of the tank marked "TEST OIL".

2. Remove both lids.

3. Slide filter panel (1) from the sludge trap as shown.

4. Wipe magnetic filter (2) clean with a soft cloth.

5. Reinstall the filter panel. Be sure that tab (A) slides into slot (B) in the sides of the sludge trap.

Monthly Maintenance (100 Hours Of Service) Main Drive Belt Tension

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Before starting the belt tensioning procedure, turn the power OFF and lock-out the electrical box and/or switch. Place an SEHS7332, "Warning: Do Not Operate" tag on the electrical box and the main power switch of the test bench.

Check and adjust the tension on the main drive belt. Drive belt tension is measured at mid-span (A) on the long side of the drive belt. Use a spring scale to apply a 2 kg (4.5 lb) force at mid-span (A). There should be a 10.0 mm (.40 in) deflection at location (B).

Adjust Main Drive Belt Tension
(1) Bolt. (2) Pulley. (3) Tension adjustment bolt. (A) Apply force using spring scale at this location. (B) Deflection measurement of 10.0 mm (.40 in).

Follow this procedure to adjust the belt tension.

1. Loosen bolt (2) which holds pulley (3) in place.

2. Adjust bolt (4) to obtain the correct belt tension.

3. After the correct belt tension is obtained, tighten bolt (2).

3 Month Maintenance (300 Hours Of Service)

Test Oil (Calibration Fluid)

The oil used in the test oil sump is SAE J967 or ISO 4113 Calibration Fluid. This oil is designed to have the same viscosity as diesel fuel. The quality and condition of the calibration fluid will affect the test results of a given fuel injection pump.

It must be remembered that clean test fluid, and test fluid of the correct viscosity, are an absolute necessity to accurately test a fuel system.

This fluid may be referred to as Test Oil, Test Fluid, Calibration Oil, Calibration Fluid, Fuel, or Lube in the various reference manuals.

The oil is available by ordering 6V-6067 Calibration Fluid [208 L (55 gal)], 6V-6068 Calibration Fluid [19 L (5 gal)], or 9U-7411 Calibration Fluid 4 L (1 gal).

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Never use diesel fuel in the test stand. Use of diesel fuel can cause damage to the bench and possibly cause personal injury.

It is critical to maintain the calibration fluid's cleanliness, viscosity, and specific gravity. In order to maintain quality oil, it must be regularly tested. Refer to the Tool Operating Manual NEHS0607, "9U-7840 Fuel Injection Equipment Calibration Fluid Test Kit" for additional information on testing of calibration fluid.

Other conditions that require replacement of the test oil are: visible contamination of the test fluid; increase in test fluid foam, or color change of the calibration oil.

NOTE: It's recommended that if approximately 300 fuel injection pump groups have been tested before three months or 300 hours of service that the test fluid and the test fluid filter element be changed.

Checking Viscosity

One method to determine when to change the test oil, is to check the viscosity using the 9U-7840 Test Kit.

9U-7840 Test Kit

1. Take a sample of the test oil.

2. Use the viscosity test kit and check the oil viscosity. Follow the directions in Tool Operating Manual NEHS0607, "9U-7840 Fuel Injection Equipment Calibration Fluid Test Kit" for the correct procedure.

3. Fill out the "Viscosity Data Sheet" and mark the date on the "Viscosity Inspection Record" and place these data sheets into the log book.

Make Sure Date Of Viscosity Check Is Recorded

4. If the test oil meets required specifications, fill out the NEEG2656 Tag and attach it to the oil sump.

Fill Out Tag With Calibration Fluid Test Date

5. If the oil does not meet specifications, change it. Refer to "Changing Test Oil" in this manual.

Changing Test Oil

The test oil should be changed whenever it does not meet viscosity or specific gravity requirements, has a foamy appearance, or is discolored/contaminated.

Change the oil after:

* testing approximately 300 fuel injection pumps

* three months

* 300 hours of service

1. Remove access cover to access the test oil sump.

2. Pull sight tube (1) out of bracket (2) and drain the oil into a shallow pan.

Changing Test Oil
(1) Sight tube. (2) Bracket. (3) Sump cover.

3. Remove lid (3) to clean the bottom of the test oil supply tank.

(1) Lube filter. (2) Fuel (calibration fluid) filter.

4. Install a new 1R-0712 Fuel Filter and refill the tank with approximately 45 L (12 gal) of calibration fluid.

5. After the oil is changed, fill out the NEEG2656 Tag and attach it to the oil sump.

Fill Out Tag With Calibration Fluid Change Date

Lube Oil

It is necessary to check the condition of the test stand lube oil and filter at specific intervals. Change the test stand lubrication oil and oil filter every three months. Use of the 8C-3694 10W Engine Oil is recommended in the lube oil sump, however, a 10W30 Engine Oil may also be used. The 10W30 is available by ordering 3E-9709 Engine Oil [19 L (5 gals)] or 3E-9708 Engine Oil [208 L (5 gals). Even though use of 10W30 oil is acceptable, it can cause the drain pan to drain slowly.

The oil filter and supply tank are located behind the lower panels on the right side of the test stand.

1. Remove the necessary side panels to access the lube oil supply tank.

2. Pull sight tube (1) from bracket (2) and drain the lube oil from the tank into a shallow pan.

Changing Lube Oil
(1) Sight tube. (2) Bracket. (3) Sump cover.

3. Remove lid (3) to clean the bottom of the lubrication oil supply tank.

4. Install a new 2P-4005 Lube Oil Filter (4) at the location shown.

(4) Lube filter. (5) Fuel filter.

5. Install drain/sight tube (1) in bracket (2).

6. Fill the lubrication oil supply tank with approximately 26 L (8 gal) of clean lubrication oil. Install lid (3) and fill out the NEEG2656 Tag and attach it to the oil sump.

Check High Pressure Fuel Line For Closure

Repeated assembly of the high pressure fuel lines can cause the tubing's inside diameter to collapse or "close-in", resulting in low delivery volume. Testing fuel injection pumps using worn or partially closed high pressure fuel lines will cause inaccurate test results. All high pressure fuel lines used on the test stand should be checked every three months.

Check Fuel Line For "Close-In"

NOTE: Do not use fuel lines with an inside diameter of 1.191 mm (.0469 in) or less. Replace the lines if erosion is present.

1. Remove each master fuel line from the test stand and visually inspect both ends. Use a 1U-8122 Drill (1.20 mm) or 1U-5588 Drill (.0469 in) and check the fuel line opening for minimum size.

2. If the drill used in Step 1 does not fit into the opening, replace the fuel line or enlarge the hole.

3. Use a 1U-8126 Drill (1.8 mm) or 1U-5590 Drill (.078 in) to open the hole in the tip to the correct size. Do not drill deeper than 3.0 mm (.12 in).

4. After the hole has been drilled to the correct size, clean the line with solvent and remove any metal particles. Blow compressed air through the lines, after cleaning, to remove any solvent.

Inspect Master Nozzle Tip Shields

Remove tip shields and inspect for excessive erosion from nozzle spray. Replace the tip shield, if required.

Inspect Tip Shields For Excessive Wear

Deburr Mounting Rails

Remove any nicks or burrs from the rails and mounting fixtures with a fine file. Then use a 6V-2010 Stone to polish all the rails surfaces.

Deburr Surfaces Of Mounting Rails

6 Month Maintenance (600 Hours Of Service)

Cleaning Graduate Tubes

The graduate tubes should be regularly cleaned. Also, check the seals and valve assembly. This can be done in place, however in some cases, the graduates should be removed.

1. Remove two socket head screws (3) and shutter control lever (4) from the top of the calibrator.

2. Pivot the graduate assembly away from the shutter mechanism.

3. Gently lift each graduate (5), as shown, away from the dump valve, until free enough to be moved sideways and pulled downward.

4. Clean each graduate carefully with a wad of cotton soaked in calibration fluid or commercial solvent.

5. Rinse and dry each graduate tube.

6. Carefully replace each graduate, and secure the graduate assembly back into the calibrator.

7. Replace shutter control lever (4) and reposition stream deflector at top of graduate as required.

12 Month Maintenance (1200 Hours Of Service)

Main Motor Brushes

Every twelve months, or more often for those test stands that are in constant use, inspect the brushes of the main drive motor. Install new brushes, and any other parts that are needed, in the drive motor, as necessary.

Replacement Procedure

1. Remove the side panels from each side of the test stand to access the drive motor.

2. Remove air duct (1).

3. Loosen screws (2) that fasten split ring cover (3) in position. Part of cover (3) forms a support for cooling fan motor (4).

4. Slide the split ring with fan motor assembly toward the front of the test stand.

Brushes (5) are 40.0 mm (1.50 in) long when they are new. If the brushes are worn more than 20.0 mm (.75 in) in one year, it is recommended that the brushes be removed and new brushes be installed.

If there is a very small amount of wear to the brushes, or if the brushes will last another year without being worn to less than the 20.0 mm (.75 in) dimension, it is not necessary to install new brushes.

5. Remove the brushes, following these steps.

a. Push up on spring clip (6), then pull outward on the brush.

b. Loosen nut (7) to release spade terminal (8) and remove the brush from the brush holder. If new brushes are installed, be sure to check for freedom of brush movement.

6. Be sure there is no loose fabric on the sides of brushes (5). Loose threads of fabric can cause the brushes to stick.

7. Install split ring cover (3) in its original location, then install and tighten bolts (2).

8. Clean fan screen and install air duct (1).

Drive Coupling Torque

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Before starting the drive coupling procedure, turn the power OFF and lock-out the electrical boxes and/or switches. Place an SEHS7332, "Warning: Do Not Operate" tag on the electrical box and the main power switch of the test bench.

1. Remove the coupling guard.

2. Remove the flexible coupling.

3. Install two bolts, used to attach the flexible coupling, into adjacent holes in the drive hub.

4. Place a 9S-1309 Pry Bar between the bolts and against a stationary surface.

5. Use a 4C-5491 Torque Wrench and 2P-8268 Socket (3/8 inch Allen) to check the torque on the bolt that fastens the nose cone mounting flange in position. The correct minimum torque for this bolt is 80 N·m (60 lb ft).

NOTE: The nose cone is held in place with anti-backlash drive coupling bolts.

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Do not operate the test bench without the coupling guard in place. Failure to follow this precaution can result in personal injury.

6. Reinstall the flexible element coupling and coupling guard.

7. Remove the locks and tags from the electrical boxes.

Check Drive Hub Runout

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Before starting the drive hub runout procedure, turn the power OFF and lock-out the electrical boxes and/or switches. Place an SEHS7332, "Warning: Do Not Operate" tag on the electrical box and the main power switch of the test bench.

1. Turn the test bench OFF and lock-out the electrical boxes and/or switches.

2. Remove the coupling guard and flexible coupling.

3. Reinstall two of the coupling bolts to secure the nose cone to the drive shaft. The bolts must be placed opposite of each other.

4. Place a dial indicator and an indicator base (part of 8T-5096 Indicator Group) onto the rails of the test bench.

5. Zero the indicator on the outside of the nose cone pilot.

6. Rotate the nose cone two complete revolutions and check the runout of the spindle. The runout should not exceed 0.064 mm (.0025 in) Total Indicator Runout (TIR).

7. If the runout exceeds the maximum tolerance, consult the bench manufacturer.

NOTE: If the runout tolerance has been exceeded, first check for dirt, nicks, or other foreign material between the nose cone and spindle.

8. Reinstall the flexible coupling and coupling guard. Remove Locks and tags from electrical boxes and switches.

9. Record the information on the "Drive System Evaluation" data sheet in the "Static Maintenance Procedures" section and place it in the log book.

Test Stand Pressure Gauges

The Fuel Injection Equipment Test Stand uses high quality, liquid-filled pressure gauges. These gauges are extremely accurate and durable.

NOTE: Do not replace the Caterpillar high quality pressure gauge with another type, or less expensive substitute. Other gauges may not give the accurate test result required when testing fuel pumps and can cause a high rate of failed pumps that are actually good.

The gauges should be removed from the test bench and tested every 12 months. The test can be done by using the 5P-8558 Pressure Gauge Calibrating Group.

The gauge calibration should also be checked if:

* Fuel pump test result appear to be inconsistent

* Gauge needle does not return to zero when pressure is released

* Gauge is damaged

NOTE: Pressure gauges should be replaced if they have leaked glycerin, or if the glycerin has been contaminated.

Gauge Removal Procedure

Remove and check one gauge at a time. When the gauge is removed make sure to keep the gauge port and tubing clean and free of any foreign material or debris.

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Before starting any maintenance procedure on the test bench, turn the power OFF and lock-out the electrical boxes and/or switches. Place an SEHS7332, "Warning: Do Not Operate" tag on the electrical box and the main power switch of the test bench.

1. Turn power OFF at main electrical box and at rear of test bench. Lock-out and tag both power switches using an SEHS7332 "Warning Tag".

2. Remove five screws and remove top cover.

3. Remove fluid line (1) connected to gauge.

4. Remove two wing nuts (2) and bracket (3) retaining gauge.

5. Remove gauge from front of panel.

Remove Gauge From Test Stand
(1) Fluid line. (2) Wing nut. (3) Bracket.

Gauge Testing Procedure

The 5P-8558 Pressure Gauge Calibrating Group is self-contained in a metal case. It requires a 1U-5230 Hand Pump, fittings, and hose (part of 5P-8558) to apply pressure to the gauge.

5P-8558 Pressure Gauge Calibrating Group and 1U-5230 Hand Pump

1. Connect the hose from 1U-5230 Hand Pump to pressure port of tester.

2. Install pressure gauge adapter from 5P-8558 Pressure Gauge Calibrating Group onto the pressure gauge.

3. Install gauge onto test gauge port.

Install Gauge

4. Use the hand pump to apply pressure to the gauge. Increase the pressure to 25% of the pressure gauges capacity.

5. Check and record the actual gauge pressure with the tester's gauge reading. The two pressures should be within two percent of each other.

6. Repeat Step 5 at 50, 75 and 100 percent increments and record each reading on the "Pressure Gauge Accuracy" data sheet in the "Forms, Static Maintenance Procedures" section. Each increment should be within two percent of the tester gauge reading.

7. If the pressure is not within two percent, the pressure gauge should be replaced.

8. The gauge needle must return to zero range after the pressure is released.

9. Remove the gauge from the tester and install in test bench. Check all five gauges using this procedure.

Gauge Replacement

If gauges do not meet testing specifications, replace or repair the gauge. If new gauges are required, refer to the "Test Stand Service Parts" chart for the correct part number. If gauges can be repaired, they can be sent to a repair facility such as listed below.

Liquid-filled pressure gauge repair service

Test Stand Performance Section

General Method Of Taking And Recording Test Data

It is critical to be consistent in measuring fuel flow using open top graduates. Pump speed and rack should be set precisely and the operating temperatures must be allowed to stabilize. One sample should be collected and drained before the first test sample is recorded. This allows "wetting" of the graduate for run-to-run consistency. Always allow 60 seconds of drain time between runs and a minimum of 60 seconds of settle time after the shot count ends, before taking a reading.

Data can be recorded on blank sheet contained in the "Forms" section. This sheet provides space for all test variables. Two sheets must be used for 8 and 12 cylinder pumps. The following sheet is a sample of a reference pump test.

This section is designed to verify the operation and accuracy of the tachometer, temperature read-out, shot counter, and graduates. To perform these tests, the test stand must be running with the reference pump installed.

Following the test in the order it is presented will help make the test more efficient. For example, while waiting for the graduate leak test, which takes 10 minutes to perform, the accuracy of the temperature read-out can be verified at the same time.

Run Reference Pump

Setup and run the reference pump. Record all the data on the "Fuel Injection Pump Test Data Sheet". Refer to SEHS9847 for a complete verification procedure.

Verify Tachometer Accuracy

The tachometer of the test stand read-out must be periodically checked. Use a 9U-7401 Multitach II to verify the tachometer accuracy.

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Be sure the safety shield is in place over the coupling before operating the test bench.

1. Place a piece of reflective tape on the test bench spindle.

2. Install the safety shield.

3. Make sure the test stand is at operating temperature, 40°C (104°F).

4. Start the bench and run it up to the correct rpm for the reference pump.

5. Take an rpm reading using the Multitach.

6. Compare the reading of the Multitach to the reading on the bench display. The two readings must be within 4 rpm of each other. If the reading is not within the tolerance, contact the bench manufacturer.

Verify Shot Counter Accuracy

If the shot count is not accurate, the test results of the fuel injection pump will also not be accurate. For this reason, is it critical to verify that the number of shots per minute is accurate. To verify the shot count, use a 9U-7839 Stop Watch (part of 9U-7840 Fuel Injection Equipment Calibration Fluid Test Kit).

1. Make sure the test bench is at operating temperature, 40°C (104°F).

2. Start the test bench and run it at the rpm specified on the "Verifying Shot Count Accuracy" data sheet in the "Forms, Running Maintenance Procedures" section.

3. Set the shot counter at the indicated shots per minute.

4. Press the shot count button. Start timing when the graduates begin to fill (deflector solenoid energized).

NOTE: There is a slight delay between the time the shot count button is pushed and the filling of the graduate tubes begin.

5. Stop timing when the shot count ends (deflector solenoid de-energized).

6. Record the stop watch reading.

7. Run the test three times and take an average of the readings.

8. The average of the stop watch readings should be within two seconds of the calculated time. If the counter is out of specification, contact the test stand manufacturer.

Graduate Leak Test

Consistency is essential when taking readings on the test bench. This test will help determine if the graduate seals are leaking. The following procedure will make sure the measurement graduates provide consistent readings.

Before conducting the test, visually inspect the graduates for obvious signs of dirt or debris and clean as necessary. Also check the flow deflector in the top of the graduate tube. If it is not properly located, use a 5P-1720 Seal Pick to reposition the deflector.

NOTE: The graduates should be wet (filled with oil and then drained), before conducting this test.

1. Make sure test stand is at operating temperature, 40°C (104°F).

2. Close the graduate drains.

3. Adjust the flow deflector and fill the six larger center graduates approximately one-half full. To do this:

a. Set the shot counter to infinite.

b. When the graduate tube is approximately one-half full, set the shot counter to zero.

c. Move the flow deflector to the small graduates and repeat.

4. Fill the remaining six large and six small graduates, when reference hardware is moved to remaining graduates.

NOTE: If using a six-cylinder reference fuel injection pump, the fuel lines must be changed to fill all the graduate tubes. If using a twelve-cylinder pump, all graduates can be filled at the same time.

5. Allow test fluid to settle for at least 60 seconds after the last shot.

6. Record the volume level in each graduate. Refer to the "Graduate Leak Test" data sheet in the "Forms, Running Maintenance Procedures" section

7. Allow the test fluid to stand in the graduate tubes for approximately ten minutes.

8. Check the actual volume level against the recorded volume level. If the levels are not identical, the seals and/or the drain must be replaced.

9. If the drain valve or seals are replaced, repeat the entire procedure again.

Verify Test Oil And Lube Oil Temperature Read-Out And Control

1. Stabilize test stand calibrating fluid operating temperature at 40°C (104°F), using the bench control and read out.

2. Remove the test bench side panels to access the test oil and lube oil sump.

3. Use a 4C-6501 Digital Thermometer or equivalent to verify sump temperatures.

Compare Test Stand Temperature Read-Out for Test and Lube Oil Sumps to Digital Thermometer Reading

4. Run the the test stand. Check and record the temperature on the bench read-out on the data sheet.

5. Submerse the temperature probe into the test oil sump. Leave the thermometer in until the reading stabilizes.

6. Compare the thermometer reading to the temperature on the read-out. The two readings should be within 2°C (3.6°F). If the readings are not within the tolerance, contact the bench manufacturer.

7. Repeat Steps 4 through 6 on the lube oil sump.

Troubleshooting Test Stand Problems Using Reference Pump

When questionable readings are obtained, check for the following possible causes.

Maintenance And Functional Tests For 5P-4150 Nozzle Testing Group

If the nozzle tester is not maintained it will not provide accurate and consistent test results of the nozzles. A preventive maintenance schedule is critical in order to obtain accurate test results.

Refer to SEHS7292, "Use of the 5P-4150 Nozzle Testing Group" for additional information. To clean nozzles before testing, refer to SEHS8627, "Use of 8S-2245 Nozzle Cleaning Tool Group".

Changing Filter Element

A 1U-9578 Repair Kit (Nozzle Tester) is available to maintain the tester. The repair kit contains a new filter along with seals, gaskets, and instructions on how to use the kit. Do not reuse seals and gaskets when changing the filter. Always use new seals and gaskets.

Calibration Fluid

The calibration fluid should be changed every three months or after testing 50 nozzles. The fluid should also be changed whenever inaccurate test results are suspected.

Inaccurate test results can be caused by fluid with improper specific gravity, viscosity, visible contamination, fluid that foams, or discolored fluid.

The fluid should also be checked for the correct viscosity. It is a good practice to test new calibration fluid for the correct viscosity and specific gravity. Use a 9U-7840 Test Kit to check calibration fluid.

9U-7840 Test Kit For Checking Fluid Viscosity

NOTE: Calibration fluid will last longer if the nozzles are cleaned prior to testing. As the fluid in the tester becomes contaminated, the accuracy of the test results are decreased.

Changing Calibration Fluid

1. Completely drain the reservoir and any fluid contained in the pump mechanism.

NOTE: Special care must be taken for the disposal of the calibration fluid. Recent regulations prohibit the dumping of oil; all oil must be properly disposed.

2. Thoroughly clean the reservoir using an 8T-9011 Component Cleaner or equivalent and clean towels.

3. Install a new 8T-5313 Filter Element (10 micron). A new filter element should be installed whenever the calibration fluid is changed (even if less than 3 months).

4. Fill the reservoir with clean calibration fluid (refer to the chart for part numbers).

Nozzle Tester Pressure Gauges

Pressure gauges in the nozzle tester should be checked for accuracy every 12 months or whenever inaccurate test results are suspected. Gauges should also be checked whenever a gauge is damaged or the needle does not return to zero. Record all data on the data sheets in the "Forms" section.

1. Remove pressure gauge from the nozzle tester.

2. Install gauge adapter from 5P-8558 Calibrating Group Pressure Gauge onto pressure gauge.

3. Connect pressure to tester port.

4. Use a 1U-5230 Hand Pump to apply pressure to the gauge. Increase the pressure to 25% of the pressure gauges capacity.

5. Check the actual gauge pressure with the tester gauge reading. The two pressures should be within two percent of each other.

6. Repeat Step 5 at 50, 75 and 100 percent increments. Each increment should be within two percent of the tester gauge reading.

7. If the pressure is not within two percent, the pressure gauge should be replaced.

Check Tester For Leakage

Before testing any nozzle, check the tester for obvious external leakage. Leakage in the tester will give inaccurate test results, causing good nozzles to be rejected.

Always check the tester for leakage after replacing the holding block or other maintenance procedures.

If leaks are discovered, the tester must be repaired before testing any more nozzles. Refer to Special Instruction SEHS7292 for checking the tester for leakage.

Forms

This section contains blank forms which can be copied and then kept in the test stand log book. The first part of this section contains the data sheets used to record data from the test stand while it is running. The first form is used to record maintenance and service data as the test stand is maintained.

The second part of the section contains forms to record test and maintenance data when the test stand is not running.

The last part of the section contains data sheets for recording data from the 5P-4150 Nozzle Testing Group.

The following "Fuel Injection Pump Test Data Sheet 1" is a sample to help the test stand operator in filling out this form.

Fuel Injection Pump Test Data Sheet 1

Fuel Injection Pump Test Data Sheet 1

Fuel Injection Pump Test Data Sheet 2

Viscosity Inspection Record

Viscosity Data Sheet

Static Maintenance Procedures

The following maintenance procedures should be completed with the test stand OFF.

As each test is completed, check the box and fill out the date and other applicable testing information.

Show/hide table

Before starting any of these maintenance procedures, turn the power OFF and lock-out the electrical boxes and/or switches. Place an SEHS7332, "Warning: Do Not Operate" tag on the electrical box and the main power switch of the test bench.

To calculate percent of error, subtract the reference pressure from the indicated pressure and multiply by 100. Take this number and divide it by the reference pressure. The result is the percent of error.

Running Maintenance Procedures

The following maintenance procedures should be completed with the test stand ON and the reference pump installed.

As each test is completed, check the box and fill out the date and other applicable testing information.

Verify Tachometer Accuracy

Verify Shot Count Accuracy

Run Reference Pump

Test Data Sheet For 5P-4150 Nozzle Testing Group

The following maintenance procedures should be completed with the tes t stand ON and the reference pump installed.

As each test is completed, check the box and fill out the date and other applicable testing information.