Professional Documents
Culture Documents
Pgina 1 de 15
Previous Screen
Welcome: r40bvjn
i05436568
Introduction
Important Safety Information
Illustration 1 g02139237
Think Safety
https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/siswe... 5/31/2016
Media Search - NEHS0607 - 9U-7840 Fuel Injection Equipment Calibration Fluid Test ... Pgina 2 de 15
Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic
safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations
before an accident occurs. A person must be alert to potential hazards. This person should also have the
necessary training, skills, and tools to perform these functions properly.
Improper operation, lubrication, maintenance, or repair of this product can be dangerous and could
result in injury or death.
Do not operate or perform any lubrication, maintenance, or repair on this product until you have read
and understood the Tool Operating Manual.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings
are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the "Safety Alert Symbol" and followed by a "Signal Word" such as
"DANGER","WARNING", or "CAUTION". The Safety Alert "WARNING" label is shown below.
A non-exhaustive list of operations that may cause product damage are identified by "NOTICE" labels on
the product and in this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The
warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure,
work method, or operating technique that is not recommended by Caterpillar is used, the operator
must be sure that the procedures are safe. The operator must also be sure that the product will not be
damaged or made unsafe by any unspecified procedures.
The information, specifications, and illustrations in this publication are based on information that was
available at the time that the publication was written. The specifications, torques, pressures, measurements,
adjustments, illustrations, and other items can change at any time. These changes can affect the service that
is given to the product. Obtain the complete and most current information before you start any job.
When replacement parts are required for this product Caterpillar recommends using Caterpillar
replacement parts or parts with equivalent specifications including, but not limited to, physical
dimensions, type, strength, and material.
Literature Information
This manual contains safety information, operation instructions and maintenance information and should be
stored with the tool group
Some photographs or illustrations in this publication may show details that can be different from your
service tool. Guards and covers might have been removed for illustrative purposes.
Continuing improvement and advancement of product design might have caused changes to your service
tool, which are not included in this publication.
Whenever a question arises regarding your service tool or this publication, consult Dealer Service Tools
(DST) for the latest available information.
Safety Section
https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/siswe... 5/31/2016
Media Search - NEHS0607 - 9U-7840 Fuel Injection Equipment Calibration Fluid Test ... Pgina 3 de 15
Read and understand the basic precautions listed in the Safety section before operating or performing
maintenance and repair on this service tool.
The General Information section describes tooling functions and features. The section provides useful
information on individual parts, additional tooling, and resources.
Operation Section
The Operation section is a reference for the new operator and a refresher for the experienced operator.
Photographs and illustrations guide the operator through correct procedures for using the tool group.
Operating techniques outlined in this publication are basic. Skill and techniques develop as the operator
gains knowledge of the service tool and the tools capabilities.
Maintenance Section
The Maintenance section is a guide to tool inspection, cleaning, storage, and tool disposal
The Service Parts section is a reference for parts identification and available part numbers.
For additional product support questions concerning this tool, contact the Dealer Service Tools Hotline at:
International: 1-309-578-7372
Note: Continuing improvement and advancement of product design can mean some photographs or
illustrations in this publication will show details that are different from your service tool.
Controlling viscosity is critical because internal leakage in pumps or nozzles will cause changes in delivery
if the fluid is out of specification. In time the fluid will become diluted with diesel fuel and lube oil.
The 9U-7841 Viscosity Cup is calibrated to measure the viscosity of J967D Calibration Fluid between the
temperatures of 16 67C (60 120F). Testing may be done on the fluid in the test stand reservoir before
start up, when the fluid is at room temperature; or on a beaker of fluid left standing at room temperature for a
minimum of one hour. A constant thermometer reading is an indicator to proceed with the test.
https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/siswe... 5/31/2016
Media Search - NEHS0607 - 9U-7840 Fuel Injection Equipment Calibration Fluid Test ... Pgina 4 de 15
Many factors affect the maintenance intervals. These include testing of used injection pumps, heat, or oil
dilution. Other conditions that will require the replacement of the test fluid include visible contamination,
color change, and increased foaming tendency.
Illustration 2 g02444856
3. 1 P7438 Beaker
https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/siswe... 5/31/2016
Media Search - NEHS0607 - 9U-7840 Fuel Injection Equipment Calibration Fluid Test ... Pgina 5 de 15
6. 9U7839 Stopwatch
8. 9U7842 Beaker
Note: Before testing, wipe all instruments clean of any residue (packing foam, lint, etc.) that could restrict
the cup orifice. Blowout the cup orifice with compressed air if required.
Note: Make and use copies of the Maintenance Record and Data Sheet contained in this book for your
records.
Note: The charts included with this booklet are calibrated for a specific cup. The serial number of your cup
must match that noted on your charts for proper test results. The charts in this booklet are for reference
only.
2. Slowly submerge the 9U-7841 Cup into the fluid sample. The cup portion should be completely
submerged. Place one of the hydrometers in the fluid sample next to the cup. This will be used as a
thermometer only. Let these soak for at least 10 minutes so all pieces stabilize at the same
temperature.
3. When all temperatures have stabilized, remove the hydrometer and record the temperature.
4. Holding the stop watch in one hand and the top of the handle in the other, raise the cup completely out
of the fluid in a smooth rapid vertical motion. Keep the cup as level as possible.
Start the stop watch as soon as the top of the cup breaks the surface of the fluid. Hold the cup very
steady for the first 10 seconds until the fluid level drops below the cup lip.
Stop the watch as soon as the last drop of fluid completely drains through the hole on the inside of the
cup.
6. Repeat steps 4 and 5 three times averaging the readings which should fall within one second of each
other. Record the average elapsed time in seconds with temperature.
7. Locate on the vertical axis of Chart I the average elapsed time obtained from step 6. Follow the value
to the diagonal line. From this point drop down vertically to read the viscosity in Centistokes
{mm2/sec}. Record this viscosity.
https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/siswe... 5/31/2016
Media Search - NEHS0607 - 9U-7840 Fuel Injection Equipment Calibration Fluid Test ... Pgina 6 de 15
8. Locate the viscosity on the vertical axis of Chart II. Locate the measured temperature of the test fluid
on the horizontal axis. If the point of intersection of these two values is between the upper and lower
limit lines the fluid is satisfactory for continued use.
The fluid can be tested at the sump if desired. All required test equipment must be submerged in the sump
until all temperatures are stabilized.
Illustration 3 g02444876
Fill a 1P-7438 Beaker (1) about two-thirds full of the calibration fluid to be tested. Carefully lower the
thermo-hydrometer (2) into the fluid. Push the thermo-hydrometer to below its float level, then allow it to
float freely. Wait two or three minutes until the thermo-hydrometer is stationary so there are no air bubbles
in the fluid, and the thermometer reading stabilizes.
Read the measured API gravity directly from the thermo-hydrometer. Use the scale on the narrow upper
portion (A). To read the hydrometer scale, look at the fuel surface from slightly below the surface as shown
in the left illustration. Then raise the eye slowly until this surface, which is first seen as an ellipse, becomes a
straight line as shown in the right illustration. Read the API gravity number at the point this line cuts the
hydrometer scale.
Record the observed API gravity. Record fluid temperature in degrees F, from the lower portion (B) of the
thermo-hydrometer.
Note: If the fluid is not clear, read from above the surface and estimate as accurately as possible the point to
which the fuel rises on the hydrometer scale.
https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/siswe... 5/31/2016
Media Search - NEHS0607 - 9U-7840 Fuel Injection Equipment Calibration Fluid Test ... Pgina 7 de 15
Locate the intersection of the measured temperature and the measured specific gravity on Chart III. If the
intersection is within the upper and lower limit, the fluid is okay. If the fluid is outside the limits it should be
discarded.
https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/siswe... 5/31/2016
Media Search - NEHS0607 - 9U-7840 Fuel Injection Equipment Calibration Fluid Test ... Pgina 8 de 15
Illustration 4 g02444881
https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/siswe... 5/31/2016
Media Search - NEHS0607 - 9U-7840 Fuel Injection Equipment Calibration Fluid Test ... Pgina 9 de 15
Illustration 5 g02444882
https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/siswe... 5/31/2016
Media Search - NEHS0607 - 9U-7840 Fuel Injection Equipment Calibration Fluid T... Pgina 10 de 15
Illustration 6 g02444883
Year ______
Table 1
INSPECTION RECORD
(Circle when OK - Note Changes) g
Illustration 7 g02444884
https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/siswe... 5/31/2016
Media Search - NEHS0607 - 9U-7840 Fuel Injection Equipment Calibration Fluid T... Pgina 11 de 15
Illustration 8 g02444896
https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/siswe... 5/31/2016
Media Search - NEHS0607 - 9U-7840 Fuel Injection Equipment Calibration Fluid T... Pgina 12 de 15
Many complaints of lack of power from diesel engines can be traced to a light grade of diesel fuel. Power
obtained from diesel fuel is determined by its BTU content, which is in direct relation to its weight per
gallon. By simply measuring the API (American Petroleum Institute) gravity of the fuel, the performance of
the engine can be compared with the factory horsepower ratings. The horsepower ratings of diesel engines as
listed in the Caterpillar Rack Setting Information were obtained with fuel having an API gravity of 35 at
60 F. If a fuel with a high API gravity is used (lighter in pounds per gallon), the power output from the
engine will be lower than listed because there is less heat value per unit volume of fuel.
Illustration 9 g02444916
Fill a 1P-7438 Beaker (1) about two-thirds full of the diesel fuel to be tested. Carefully lower the thermo-
hydrometer (2) into the fuel. Push the thermo-hydrometer to below its float level, then allow it to float freely.
Wait two or three minutes until the thermohydrometer is stationary so there are no air bubbles in the fuel,
and the thermometer reading stabilizes.
Read the measured API gravity directly from the thermo-hydrometer. Use the scale on the narrow upper
portion (A). To read the hydrometer scale, look at the fuel surface from slightly below the surface as shown
in the left illustration. Then raise the eye slowly until this surface, which is first seen as an ellipse, becomes a
straight line as shown in the right illustration. Read the API gravity number at the point this line cuts the
hydrometer scale.
Record the observed API gravity to the nearest full degree of API. For example, read 40.4 as 40 API.
Record fuel temperature in degrees F, from the lower portion (B) of the thermo-hydrometer. Do not use the
right scale of the thermometer.
Note: If the fuel is not clear, read from above the surface and estimate as accurately as possible the point to
which the fuel rises on the hydrometer scale.
https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/siswe... 5/31/2016
Media Search - NEHS0607 - 9U-7840 Fuel Injection Equipment Calibration Fluid T... Pgina 13 de 15
Table 2
Corrected Direct Injection Engines (Use the correct full load RPM)
Precombustion
API
Chamber
Gravity at 2000 2200 2400 2600 2800 3000 3200
Engines
60 F 1800
.986 .986 .986 .986 .986 .986 .986 .986
32.0 .984
.988 .988 .988 .988 .988 .988 .988 .988
32.5 .987
.990 .990 .990 .990 .990 .990 .990 .990
33.0 .990
.992 .992 .992 .992 .992 .992 .992 .992
33.5 .992
.995 .995 .995 .995 .995 .995 .995 .995
34.0 .995
1. Determine the rated full load horsepower from the Rack Setting Information Book.
2. Divide the rated horsepower by the horsepower correction factor for fuel density; the result is the
corrected horsepower.
https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/siswe... 5/31/2016
Media Search - NEHS0607 - 9U-7840 Fuel Injection Equipment Calibration Fluid T... Pgina 14 de 15
Example:
Calculations:
Table 3
1. Measured API gravity: 40.4' API at 50' (round to 40' API)
2. Corrected API gravity (see chart): 41' API at 60'F
3. Hpr correction factor (see chart): 1.038
Rated Hpr 270 260 Hp
4. Corrected Hp = = =
Correction Factor 1.038 (or 3.75% hp loss)
When engines are tested on a dynamometer which measures actual flywheel or drive train output, the
observed horsepower is dependent on the fuel used. If the fuel being used is not 35 API at 60F, then any
dynamometer readings must be corrected to determine the output if 35 API fuel had been used. The same
horsepower correction factor is used, but the formula is different:
Example:
Calculations:
(Although the dynamometer indicated low horsepower, if the proper fuel had been used, the engine would be
operating at rated output. The factory tolerance on rated engine output is 3%.)
REFERENCE: For more information on dynamometer testing diesel engines, see Special Instruction Form
GEG01024 .
https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/siswe... 5/31/2016
Media Search - NEHS0607 - 9U-7840 Fuel Injection Equipment Calibration Fluid T... Pgina 15 de 15
The following chart may be used to convert the fuel API gravity to Ibs./U.S. gallon or kg/liter. These
weights are for reference and are to be used when evaluating engine performance. Measurement of fuel flow
rates can be converted to horsepower (using full load brake specific fuel consumption, BSFC, values).
Table 4
Specific Weight
Fuel API Gravity
Ibs./U.S. Gallon kg/liter
32 7.026 0.8654
33 7.163 0.8602
34 7.119 0.8550
35 7.076 0.8498
36 7.034 0.8448
37 6.993 0.8398
38 6.951 0.8348
39 6.910 0.8299
40 6.870 0.8251
41 6.830 0.8203
42 6.790 0.8155
43 6.752 0.8109
44 6.713 0.8063
Copyright 1993 - 2016 Caterpillar Inc. Tue May 31 08:57:54 UTC-0400 2016
All Rights Reserved. r40bvjn
Private Network For SIS Licensees.
https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/siswe... 5/31/2016