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Producto: NO SE HA ESCOGIDO NINGUN EQUIPO Modelo: NO SE HA ESCOGIDO NINGUN EQUIPO Configuración: NO SE HA ESCOGIDO NINGUN EQUIPO

Instrucción Especial

Bienvenido: r080cp9

High Leakoff of the Electronic Unit Injector on C6.6 and C4.4 Engines{1251, 1290}

Número de medio -KENR6938-07

Fecha de publicación -04/10/2012

Fecha de actualización -04/10/2012

i05117850

High Leakoff of the Electronic Unit Injector on C6.6 and C4.4 Engines{1251, 1290}

SMCS - 1251; 1290

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CB54 (S/N: JLM1-UP) CB64 (S/N: DJM1-UP) Asphalt Paver:

AP1000E (S/N: DKH1-UP) AP1055E (S/N: TRS1-UP) AP500E (S/N: JWK1-UP) AP555E (S/N: A5D1-UP) AP600D (S/N: TFM1-UP; TFZ1-UP)

AP655D (S/N: GNN1-UP; MAN1-UP; MAT1-UP; GNZ1-UP) BG555E (S/N: B5P1-UP) BG600D (S/N: B6K1-UP) BG655D (S/N: BPA1-UP; B5D1-UP) Backhoe Loader:

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430E (S/N: SCD1-UP; RLN1-UP) 450E (S/N: EBL1-UP) Industrial Engine:

C4.4 (S/N: 4441-UP) C6.6 (S/N: 6661-UP) Generator Set:

C6.6 (S/N: SDA1-UP; N6D1-UP; MRW1-UP) Excavator:

M313D (S/N: J3A1-UP; W3H1-UP) M315D (S/N: J5B1-UP; W5M1-UP) M316D (S/N: W6A1-UP; D6W1-UP) M318D (S/N: W8P1-UP; W8R1-UP; D8W1-UP; D9X1-UP)

M322D (S/N: W2S1-UP; W2T1-UP; D2W1-UP; D3X1-UP) Integrated Toolcarrier:

IT38H (S/N: JNJ1-UP) Load Haul Dump:

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M316D MHPU (S/N: KMA1-UP) Paving Compactor:

CS-533F (S/N: C5X1-UP) Pipelayer:

PL61 (S/N: WGS1-UP) Vibratory Soil Compactor:

CP44 (S/N: MPC1-UP; M4P1-UP) CP54 (S/N: C5Y1-UP) CP56 (S/N: C5P1-UP; FCP1-UP) CP64 (S/N: P7F1-UP; C6P1-UP) CP74 (S/N: P8F1-UP; C8P1-UP) CP76 (S/N: C7L1-UP; JCP1-UP) CS44 (S/N: M4C1-UP; M4S1-UP) CS54 (S/N: C5R1-UP; C5W1-UP) CS56 (S/N: C5S1-UP) CS64 (S/N: C7F1-UP; C6S1-UP; WSW1-UP) CS74 (S/N: C8F1-UP; C8S1-UP) CS76 (S/N: JCS1-UP; CYX1-UP) Track-Type Loader:

953D (S/N: LBP1-UP) 963D (S/N: LCS1-UP) Track-Type Tractor:

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IT14G2 (S/N: ERP1-UP) Wheel Loader:

910H (S/N: SAT1-UP) 924H (S/N: HXC1-UP; JTM1-UP; KLN1-UP) 924HZ (S/N: WLB1-UP; PED1-UP; JZZ1-UP) 928H (S/N: RSB1-UP) 928HZ (S/N: BYD1-UP; CXK1-UP) 930H (S/N: DHC1-UP; FTD1-UP) 938H (S/N: MJC1-UP; JKM1-UP; LKM1-UP) Wheel Tractor-Scraper:

613G (S/N: ESB1-UP)

Introduction

There have been isolated occurrences of excessive fuel leakage past the electronic unit injectors on some engines.

Accelerated wear on the delivery valve results in an increased leak rate.

For six cylinder engines, the fuel injection pump cannot generate enough fuel flow or volume in order to compensate for the leakoff rates above a critical value of 38 mL (1.3 oz) per 30 seconds of cranking at a speed of 150 rpm.

For four cylinder engines, the critical value is 25 mL (0.85 oz) per 30 seconds of cranking at a speed of 150 rpm.

If the engine turns over but the engine does not start, refer to Troubleshooting, "Engine Cranks but Will Not Start". Perform the following procedure when directed by Troubleshooting, "Engine Cranks but Will Not Start". The procedure will help to assess the amount of fuel pressure leakoff within the high-pressure fuel system.

Note: The engine may start, but you may still have high leakoff within the high-pressure fuel system.

NOTICE

Do not perform any procedure in this Special Instruction until you read this information and you understand this information.

Note: If the electronic unit injectors are replaced, ensure that the valve bridge is seated in the correct position. Failure to carry out this procedure correctly may result in engine failure. For further information, refer to Engine News, SEBD9574, "Improved Valve Bridges" and Service Magazine, SEPD0975, "Improved Valve Bridges".

Note: If applicable, a completed service report (form number 089479-00) must be included with the returned parts. ECM warranty report downloads, datalogs, and any special test results as directed by repair procedures are to be uploaded to SIMS. Checklists that are packaged with replacement parts are to be completed and packaged with parts being returned.

Refer to Special Instruction, REHS7790, "Improved Fuel System Diagnostic Test Documentation for Certain C4.4 and C6.6 Engines" for additional diagnostic test documentation.

Test Procedure for Measuring High Leakoff for the Electronic Unit Injectors

NOTICE

Before beginning any work on the fuel system, refer to Operation and Maintenance Manual, "General Hazard Information and High Pressure Fuel Lines" for safety information.

Refer to Systems Operation, Testing and Adjusting, "Cleanliness of Fuel System Components" for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.

NOTICE

After 30 seconds of cranking the engine, release the starter switch or button and wait 2 minutes to allow the starting motor to cool before attempting to start the engine again.

Note: Caterpillar recommends that the procedure should be carried out without starting the engine.

Table 1

 

Required Tools

 

Tool

Part Number

Part Description

Qty

A

300-4988

Fuel Leakoff Kit

1

  • 1. Ensure that the engine is shut down. Remove the banjo bolt that is located on the bottom of the fuel transfer pump. Retain the sealing washers for use in step 10.b.

Illustration 1 g01402111 Typical example
Illustration 1
g01402111
Typical example

2. Install Tooling (A) to the fuel transfer pump.

Note: Tooling (A) will replace the banjo bolt that was removed in step 1. Do not substitute Tooling (A). Tooling (A) is specially designed for the test.

3.

Install a clear plastic hose (1). Place the opposite end of the plastic hose into a suitable container that is clean.

  • 4. Connect the electronic service tool to the diagnostic connector.

  • 5. Disconnect the three harness connectors for the electronic unit injectors at the valve mechanism cover base to prevent starting the engine.

  • 6. Perform a data log of the following parameters at a sample rate of 240 samples per minute. ECM Parameters

◦ Active Diagnostic Codes that are present

◦ Atmospheric Pressure

◦ Battery Voltage

◦ Delivered Fuel Volume

◦ Desired Engine Speed

◦ Desired Fuel Rail Pressure

◦ Diagnostic Clock

◦ Engine Coolant Temperature

◦ Engine Oil Pressure

◦ Derate of Engine Power

◦ Engine Speed

◦ Fuel Rail Pressure

◦ Inlet Air Temperature

◦ Intake Manifold Pressure

◦ Requested Desired Engine Speed

◦ Fuel Volume for the Smoke Limit

◦ Fuel Volume for the Torque Limit

◦ Engine Load Factor

  • 7. Start the data log. Crank the engine for 30 seconds.

  • 8. End the data log.

  • 9. Record the amount of fuel that has been collected in the container from the leakoff connector on the cylinder head. Conduct the test three times. Calculate the average of the three values.

10. Refer to step 10.a or step 10.b for the relevant values for your engine.

  • a. For six cylinder engines, if more than 38 mL (1.3 oz) of fuel has been collected during the 30 second crank test, then there is high leakoff of the electronic unit injectors. For six cylinder engines, if less than 38 mL (1.3 oz) of fuel has been collected for the 30 second crank test, then there is not high leakoff of the electronic unit injectors. Refer to Troubleshooting, "Engine Cranks but Will Not Start" in order to diagnose the problem.

  • b. For four cylinder engines, if more than 25 mL (0.85 oz) of fuel has been collected during the 30 second crank test, then there is high leakoff of the electronic unit injectors. For four cylinder engines, if less than 25 mL (0.85 oz) of fuel has been collected for the 30 second crank test, then there is not high leakoff of the electronic unit injectors. Refer to Troubleshooting, "Engine Cranks but Will Not Start" in order to diagnose the problem.

  • 11. Remove Tooling (A). Install the banjo bolt and two new washers to the fuel transfer pump.

  • 12. End of the test. If there is high leakage of the high-pressure fuel system, proceed to ""Measuring the Fuel Injection Pump Flow and High Leakoff for the Individual Electronic Unit Injector" ".

Measuring the Fuel Injection Pump Flow and High Leakoff for the Individual Electronic Unit Injector

This procedure provides a method to evaluate the internal leakage condition of the following components:

• Fuel injection pump

• Fuel pressure relief valve

• Electronic unit injectors

The procedure provides a method to compare internal fuel leakage to a precision calibrated orifice.

Use the ""Test Kit Data Sheet" " for recording the test data. For an example of the test process calculations refer to ""Example Calculations Sheet" ".

Use the checklist form provided with the replacement component to document the test results.

Do not discard this form. A completed checklist is required to be included in the claim story. A completed checklist is to be included with any fuel injection system component returned for credit.

Use the following procedure to aid in the diagnosing of the following conditions:

• The engine cranks but the engine does not start

• The fuel rail pressure is low

• There has been a low rail-pressure event

• The engine fuel injection system has excessive internal fuel pressure leakage

Verify the following before continuing with this procedure:

• No fuel injection pump or electronic unit injector diagnostic trouble codes are active

• No external high-pressure leaks exist

• The cranking speed of the engine is at least 150 rpm

Note: A battery booster is essential to maintain consistent cranking speed of at least 150 rpm for all fuel injection pump and electronic unit injector tests.

The low-pressure fuel system is providing a minimum of 50 kPa (7 psi) of pressure to the fuel injection pump.

Determine if the pressure in the fuel manifold (rail) during engine cranking is less than 22 MPa (3200 psi). This will assist when conducting the procedure in Troubleshooting, "Engine Cranks but Will Not Start".

If troubleshooting for low rail-pressure event, first warm up the engine to improve the test results.

• If possible run at high speed and load to duplicate the low rail-pressure event conditions

If it is not possible to put load on engine, run the "Fuel System Verification Test". This will increase the desired rail-pressure to help get the fuel injection pump and electronic unit injectors warm.

Proceed with the test procedure while the fuel injection pump and electronic unit injectors are still warm.

Required Parts

Table 2

Required Parts for the Six Cylinder Engine

 

Part Number

Description

Qty

362-9754

Test Kit

1

336-8174

Fuel Injection Line

1

336-8175

Fuel Injection Line

1

336-8176

Fuel Injection Line

1

336-8177

Fuel Injection Line

1

336-8178

Fuel Injection Line

1

336-8179

Fuel Injection Line

1

278-4138

Fuel System Protection Gp

1

Table 3

Required Parts for the Four Cylinder Engine

 

Part Number

Description

Qty

362-9754

Test Kit

1

333-4732

Fuel Injection Line

1

333-4733

Fuel Injection Line

1

322-3745

Fuel Injection Line

1

322-3746

Fuel Injection Line

1

278-4138

Fuel System Protection Gp

1

Table 3 Required Parts for the Four Cylinder Engine Part Number Description Qty 362-9754 Test Kit

Typical example of 362-9754 Test kit (1) 356-2466 Case (2) 356-2470 Cylinder – Collection (3) 362-9749 Orifice As - Discharge (4) 362-9753 Pin - Gauge (5) 362-9751 Plug As - Rail

Test Procedure

Typical example of 362-9754 Test kit (1) 356-2466 Case (2) 356-2470 Cylinder – Collection (3) 362-9749

Electrical Shock Hazard. The electronic unit injectors use DC voltage. The ECM sends this voltage to the electronic unit injectors. Do not come in contact with the harness connector for the electronic unit injectors while the engine is operating. Failure to follow this instruction could result in personal injury or death.

NOTICE
NOTICE

Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorized personnel that have the correct training.

Before beginning ANY work on the fuel system, refer to Operation and Maintenance Manual, "General Hazard Information and High Pressure Fuel Lines" for safety information.

Refer to System Operation, Testing and Adjusting, "Cleanliness of Fuel System Components" for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.

Note: The pressures generated during this test are lower than those generated during normal operation. During this test, the fuel injection lines may be removed and reused when performing this procedure due to the lower pressures that are generated during the testing. This is the only condition where reuse of a fuel injection line is allowed.

Note: All connections must be clean prior to assembly. Carefully inspect all connections, caps, and lines before each use. When not in use, caps, plugs, and orifice from the kit must be capped to prevent damage and debris entry.

Use the gauge pin and an aerosol cleaner to ensure that the orifice is clean before performing this procedure.

Measure the Pressure of the Fuel Injection Pump

This part of the process will set up the test components and determine if the fuel injection pump or the fuel pressure relief valve is defective for internal leakage.

  • 1. Obtain the Test Kit Data Sheet. Use the Test Kit Data Sheet to record all test measurements.

  • 2. Remove the fuel injection lines. Refer to Disassembly and Assembly, "Fuel Injection Lines - Remove" for the correct procedure.

Illustration 3 g03017858 Typical example
Illustration 3
g03017858
Typical example
  • 3. Connect one of the fuel injection lines (1) to the fuel manifold (rail) at cylinder number 1 fuel outlet connection. Connect the discharge orifice assembly (2) to the other end of the fuel injection line. Install the rail plug assemblies onto the fuel manifold (rail) for all remaining cylinder fuel outlet connections. Note: The collecting cylinder must be mounted at a position lower than the fuel manifold (rail) on the engine.

  • 4. Insert the drain hose (3) from the outlet of the discharge orifice assembly into the collecting cylinder. Refer to illustration 3.

  • 5. Disable all electronic unit injectors by disconnecting the injector harness connectors. Leave the electronic unit injectors disabled for the duration of the test.

Illustration 4
Illustration 4

Typical example

  • 6. Set 240 samples/minute for the electronic service tool graphing utility, "Data Log Recorder".

  • 7. Record the fuel pressure in the fuel manifold (rail) and engine speed while cranking for 10 seconds. Note: Make sure that there are no connection leaks during this test as the measurement will be invalid.

Illustration 5 Typical example (1) Pump test pressure measured at peak (2) Pump test engine speed

Illustration 5 Typical example (1) Pump test pressure measured at peak (2) Pump test engine speed measured when peak pressure occurs (3) 2 to 5 second typical for pressure to build (4) More than 5 seconds with pressure build required to capture peak

  • 8. Determine the fuel pressure in the fuel manifold (rail) and the engine speed where the peak pressure was selected. Typically, pressure will start building after 2 to 5 sec and then there should be samples taken for 5 more seconds. Illustration 5 shows an example of selecting the peak pressure and corresponding speed.

Table 4

Fuel Injection Pump MCP (Minimum Cranking Pressure)

 

Engine Speed

150-174

175-199

200-224

225-249

250-274

275-300

(rpm)

Minimum Cranking Pressure

9391

11935

14713

17713

20926

24352

kPa

kPa

kPa

kPa

kPa

kPa

for six cylinder

(1362

(1731

(2134

(2569

(3035

(3532

engines

psi)

psi)

psi)

psi)

psi)

psi)

Minimum Cranking Pressure for four cylinder engines

5550

kPa (805

psi)

6729 kPa

(976 psi)

7970 kPa

(1156

psi)

9253 kPa

(1342

psi)

10583

kPa

(1535

11956

kPa

(1734

psi)

psi)

  • 10. If the fuel pressure in the fuel manifold (rail) is less than the Minimum Cranking Pressure (MCP), inspect the Pressure Relief Valve (PRV) for leakage and retest. The PRV can be checked for leakage by inspecting the outlet of the valve for any fuel leakage. Refer to Special Instruction, REHS5712, "Inspecting the Fuel Rail High Pressure Relief Valve" for the correct procedure.

  • 11. If the Pressure Relief Valve (PRV) does not leak, and fuel pressure in the fuel manifold (rail) displayed in the electronic service tool graph is less than the Minimum Cranking Pressure (MCP), remove, clean, and inspect the outlet check valves and retest. Refer to Special Instruction, REHS3751, "Servicing the Outlet Check Plugs on the Fuel Injection Pump" for the correct procedure.

  • 12. Determine the new MCP based on the retest speed. If the fuel pressure in the fuel manifold (rail) displayed in the electronic service tool graph is still less than MCP, replace the fuel injection pump. Refer to Disassembly and Assembly for the correct procedures.

  • 13. If the fuel pressure in the fuel manifold (rail) is greater than MCP, record the fuel pressure in the fuel manifold (rail) and peak pump rail pressure engine speed, which will be used for injector testing. proceed to ""Measure Electronic Unit Injector Number 2 Leakage" ".

Measure Electronic Unit Injector Number 2 Leakage

This part of the procedure will determine if individual electronic unit injectors are defective for internal leakage.

Note: It is possible to measure the individual electronic unit injectors for leakage in any order. Use the order that is easiest for the engine in a particular application.

Note: If the test speed for the electronic unit injector number 2 changes by more than 25 rpm from the measurement of Pump Test speed or drops below 150 rpm, the use of a battery booster is essential to maintain uniform speed with the pump test. This will improve the accuracy of test results. Make sure that there are no leaks during the test as the measurement will be invalid.

Note: When 3 or more electronic unit injectors are found to have excessive leakage, stop the test. Record the results of the leak rate for each electronic unit injector tested. Then replace all electronic unit injectors. Refer to Disassembly and Assembly for the correct procedure.

Illustration 6 g03018160 Typical example
Illustration 6
g03018160
Typical example
  • 1. Install existing fuel injection line for number 2 cylinder. Refer to Disassembly and Assembly, "Fuel Injection Lines - Install" for the correct procedure. Refer to illustration 6.

  • 2. Record fuel rail pressure and engine speed with the electronic service tool "Data Log Recorder" while cranking for 10 seconds. Note: Make sure that there are no connection leaks during this test as the measurement will be invalid.

Illustration 7 Typical example (1) Injector test pressure measured at peak (2) Injector test engine speed

Illustration 7 Typical example (1) Injector test pressure measured at peak (2) Injector test engine speed measured when peak pressure occurs (3) 2 to 5 second typical for pressure to build (4) More than 5 seconds with pressure build required to capture peak

  • 3. Determine the injector number 2 test rail pressure and the injector number 2 test engine speed (where the peak pressure was selected). Typically, pressure will start building after 2 to 5 sec and then there should be sampling for 5 more seconds. Illustration 7 shows an example of selecting the peak pressure and corresponding speed.

Injector number 2 test speed change equals injector number 2 test engine speed minus pump test engine speed.

  • 5. Determine injector number 2 pressure correction using the injector number 2 test speed change and table 5. This will correct for pressure change as speed changes.

Table 5

 

Injector Pressure Correction Based on Speed Change

 

Engine speed

             

change (rpm)

0-5

6-10

11-15

16-20

21-25

26-30

31-35

Six cylinder

283

896

1455

2013

2572

3130

3689

pressure

kPa

kPa

kPa

kPa

kPa

kPa

kPa

correction

(41

(130

(211

(292

(373

(454

(535

psi)

psi)

psi)

psi)

psi)

psi)

psi)

Four cylinder

159

   

1151

1469

1793

2110

pressure

correction

kPa

(23

510

kPa (74

psi)

834 kPa

(121

psi)

kPa

(167

kPa

(213

kPa

(260

kPa

(306

psi)

psi)

psi)

psi)

psi)

  • 6. If injector number 2 test engine speed is lower than pump test engine speed, then correct the injector number 2 pressure by adding the correction as follows: Injector number 2 corrected pressure equals injector number 2 test pressure plus injector number 2 pressure correction.

  • 7. If injector number 2 test engine speed is higher than pump test engine speed (as can happen when a battery booster is used) then correct the injector number 2 test pressure by subtracting the pressure correction as follows: Injector number 2 corrected pressure equals injector number 2 test pressure minus injector number 2 pressure correction.

  • 8. Calculate injector number 2 leakage ratio as follows: Injector number 2 leakage ratio equals injector number 2 corrected pressure divided by pump test Rail pressure. If the Injector number 2 leakage ratio is less than 0.85, the injector needs to be replaced, if the injector leakage is greater than 0.85 the injector is ok. Remove the fuel line. Replace the cap on the fuel manifold (rail) and injector. Proceed to ""Measure Electronic Unit Injector Number 3 Leakage" ".

Measure Electronic Unit Injector Number 3 Leakage

Illustration 8 g03019616 Typical example
Illustration 8
g03019616
Typical example
  • 1. Remove the cap from cylinder number 3 and reconnect the existing fuel line. Refer to illustration 8.

  • 2. Record fuel rail pressure and engine speed with the electronic service tool "Data Log Recorder" while cranking for 10 seconds. Note: Make sure that there are no connection leaks during this test as the measurement will be invalid.

  • 3. Determine the injector number 3 test rail pressure and the injector number 3 test engine speed. Use the same procedure as the procedure in ""Measure Electronic Unit Injector Number 2 Leakage" ".

  • 4. Calculate the speed change of the injector number 3. Use the same procedure as the procedure in ""Measure Electronic Unit Injector Number 2 Leakage" ".

  • 5. Determine injector number 3 pressure correction. Use the same procedure as the procedure in ""Measure Electronic Unit Injector Number 2 Leakage" ".

  • 6. Calculate injector number 3 leakage ratio. Use the same procedure as the procedure in ""Measure Electronic Unit Injector Number 2 Leakage" ". Remove the fuel line. Replace the cap on the fuel manifold (rail) and injector. Proceed to ""Measure Electronic Unit Injector Number 5 Leakage (if applicable)" ".

Measure Electronic Unit Injector Number 5 Leakage (if applicable)

Illustration 9 g03019636 Typical example
Illustration 9
g03019636
Typical example
  • 1. Remove the cap from cylinder number 5 and reconnect the existing fuel line. Refer to illustration 9.

  • 2. Record fuel rail pressure and engine speed with the electronic service tool "Data Log Recorder" while cranking for 10 seconds. Note: Make sure that there are no connection leaks during this test as the measurement will be invalid.

  • 3. Determine the injector number 5 test rail pressure and the injector number 5 test engine speed. Use the same procedure as the procedure in ""Measure Electronic Unit Injector Number 2 Leakage" ".

  • 4. Calculate the speed change of the injector number 5. Use the same procedure as the procedure in ""Measure Electronic Unit Injector Number 2 Leakage" ".

  • 5. Determine injector number 5 pressure correction. Use the same procedure as the procedure in ""Measure Electronic Unit Injector Number 2 Leakage" ".

  • 6. Calculate injector number 5 leakage ratio. Use the same procedure as the procedure in ""Measure Electronic Unit Injector Number 2 Leakage" ". Remove the fuel line. Replace the cap on the fuel manifold (rail) and injector. Proceed to ""Measure Electronic Unit Injector Number 6 Leakage (if applicable)" ".

Measure Electronic Unit Injector Number 6 Leakage (if applicable)

Illustration 10 g03019656 Typical example
Illustration 10
g03019656
Typical example
  • 1. Remove the cap from cylinder number 6 and reconnect the existing fuel line. Refer to illustration 10.

  • 2. Record fuel rail pressure and engine speed with the electronic service tool "Data Log Recorder" while cranking for 10 seconds. Note: Make sure that there are no connection leaks during this test as the measurement will be invalid.

  • 3. Determine the injector number 6 test rail pressure and the injector number 6 test engine speed. Use the same procedure as the procedure in ""Measure Electronic Unit Injector Number 2 Leakage" ".

  • 4. Calculate the speed change of the injector number 6. Use the same procedure as the procedure in ""Measure Electronic Unit Injector Number 2 Leakage" ".

  • 5. Determine injector number 6 pressure correction. Use the same procedure as the procedure in ""Measure Electronic Unit Injector Number 2 Leakage" ".

  • 6. Calculate injector number 6 leakage ratio. Use the same procedure as the procedure in ""Measure Electronic Unit Injector Number 2 Leakage" ". Remove the fuel line. Replace the cap on the fuel manifold (rail) and injector. Proceed to ""Measure Electronic Unit Injector Number 4 Leakage" ".

Measure Electronic Unit Injector Number 4 Leakage

Illustration 11 g03019657 Typical example
Illustration 11
g03019657
Typical example
  • 1. Remove the cap from cylinder number 4 and reconnect the existing fuel line. Refer to illustration 11.

  • 2. Record fuel rail pressure and engine speed with the electronic service tool "Data Log Recorder" while cranking for 10 seconds. Note: Make sure that there are no connection leaks during this test as the measurement will be invalid.

  • 3. Determine the injector number 4 test rail pressure and the injector number 4 test engine speed. Use the same procedure as the procedure in ""Measure Electronic Unit Injector Number 2 Leakage" ".

  • 4. Calculate the speed change of the injector number 4. Use the same procedure as the procedure in ""Measure Electronic Unit Injector Number 2 Leakage" ".

  • 5. Determine injector number 4 pressure correction. Use the same procedure as the procedure in ""Measure Electronic Unit Injector Number 2 Leakage" ".

  • 6. Calculate injector number 6 leakage ratio. Use the same procedure as the procedure in ""Measure Electronic Unit Injector Number 2 Leakage" ". Remove the fuel line. Replace the cap on the fuel manifold (rail) and injector. Proceed to ""Measure Electronic Unit Injector Number 1 Leakage" ".

Measure Electronic Unit Injector Number 1 Leakage

Illustration 12 g03019676 Typical example
Illustration 12
g03019676
Typical example
  • 1. If necessary, remove the discharge orifice assembly from the outlet connection for number 1 cylinder. If necessary, remove the cap from cylinder number 1 and reconnect the existing fuel line. Refer to illustration 12.

  • 2. Record fuel rail pressure and engine speed with the electronic service tool "Data Log Recorder" while cranking for 10 seconds. Note: Make sure that there are no connection leaks during this test as the measurement will be invalid.

  • 3. Determine the injector number 1 test rail pressure and the injector number 1 test engine speed. Use the same procedure as the procedure in ""Measure Electronic Unit Injector Number 2 Leakage" ".

  • 4. Calculate the speed change of the injector number 1. Use the same procedure as the procedure in ""Measure Electronic Unit Injector Number 2 Leakage" ".

  • 5. Determine injector number 1 pressure correction. Use the same procedure as the procedure in ""Measure Electronic Unit Injector Number 2 Leakage" ".

  • 6. Calculate injector number 6 leakage ratio. Use the same procedure as the procedure in ""Measure Electronic Unit Injector Number 2 Leakage" ".

  • 7. Remove components of 362-9754 Test Kit from the engine. Replace any fuel injection lines that were removed during the procedures. Refer to Disassembly and Assembly for the correct procedures.

  • 8. Reconnect the electronic unit injector harness connectors.

Test Kit Data Sheet

Table 6

 

Pump

Pump

Minimum

 

Test Rail

Test

Cranking

Pressure

Engine

Pressure

Speed

(MCP)

 

Fuel

 

From

 

Injection

Pump

Pump

 

Service

From

Test

Use speed

 

Tests

Pump

Datalog

and table 4

 

Test

where

Datalog

peak rail

 

pressure

occurs

Pump Test

     

If peak pressure less than MCP inspect

1

PRV

Pump Test

       

2

(after

If peak pressure less than MCP inspect

PRV

outlet check valves

service)

Pump Test

       

3

(after

outlet

If peak pressure less than MCP replace fuel

check

injection pump

valve

clean)

     

Injector

Injector

   

Electronic

Injector

Test Rail

Pressure

Injector

Test

Engine

Speed

Test

Engine

Speed

Change

Test

Pressure

Correction

Injector Corrected/Pump Pressure Ratio

Unit

 

From

     

Service

 

Injector

Injector

Last Pump

Tests

From

Test

Test Speed

Corrected Injector

 

Injector

Test

Datalog

Datalog

where

peak rail

subtract

Injector

Test Speed

Using speed

change and

table 5

Pressure divided by Latest Pump Pressure

pressure

occurs

           

If less

than

Injector

Number 2

Test

0.85

replace

Injector

2

Injector

Number 3

         

If less

than

Test

0.85

replace

Injector 3 If less than Injector 0.85 Number 5 replace Test Injector 5 If less than
Injector
3
If less
than
Injector
0.85
Number 5
replace
Test
Injector
5
If less
than
Injector
0.85
Number 6
replace
Test
Injector
6
If less
than
Injector
0.85
Number 4
replace
Test
Injector
4
If less
than
Injector
0.85
Number 1
replace
Test
Injector
1

Example Calculations Sheet

Fuel Injection Pump Test

Illustration 13 Typical example of pump pressure and speed measurement Pump Test Rail Pressure (1) is

Illustration 13 Typical example of pump pressure and speed measurement

Pump Test Rail Pressure (1) is 14148 kPa (2052 psi). Pump Test Engine Speed (2) is 162 rpm.

With Pump Test Engine Speed of 162 rpm, Minimum Cranking Pressure (MCP) from table 4 is 9391 kPa (1362 psi).

Pump Test Rail Pressure of 14148 kPa (2052 psi) is larger than MCP of 9391 kPa (1362 psi), so fuel injection pump is OK.

Electronic Unit Injector Test

Illustration 14 Typical example of injector Test pressure and speed measurement Injector Rail Pressure (1) is

Illustration 14 Typical example of injector Test pressure and speed measurement

Injector Rail Pressure (1) is 10721 kPa (1555 psi). Injector Test Engine Speed (2) is 144 rpm.

Injector Engine Speed Change is 162 minus 144 equals 18 rpm.

Injector Pressure Correction from table 5 is 2013 kPa (292 psi).

Speed is higher than pump test speed so add the correction: Injector Corrected Pressure equals 10721 kPa (1555 psi) add 2013 kPa (292 psi) equals 12735 kPa (1847 psi).

Injector Leakage Ratio is 1847 divided by 2052 equals 0.90.

Injector Leakage Ratio of 0.90 is larger than injector ratio threshold of 0.85, so the injector leakage is OK.

Copyright 1993 - 2014 Caterpillar Inc. Todos los derechos reservados. Red privada para licenciados del SIS.

Fri Oct 17 23:43:53 EST 2014

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