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Special Instruction
High Leakoff of the Electronic Unit Injector on C6.6 and C4.4 Engines{1251, 1290}
Media Number -KENR6938-08 Publication Date -18/12/2014 Date Updated -18/12/2014

i06024501

High Leakoff of the Electronic Unit Injector on C6.6 and


C4.4 Engines{1251, 1290}
SMCS - 1251; 1290

Asphalt Compactor:
CB64 (S/N: DJM1-UP; CB51-UP)
Asphalt Paver:
AP-500D (S/N: B3D1-UP)
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)
BG500E (S/N: B5E1-UP)
BG555E (S/N: B5P1-UP)
BG600D (S/N: B6K1-UP)
BG655D (S/N: BPA1-UP)
BG655D MTS (S/N: B5D1-UP)
Backhoe Loader:
420E (S/N: PRA1-UP; PHC1-UP; GEK1-UP; DJL1-UP; DAN1-UP)
430E (S/N: MXB1-UP; SWC1-UP; SCD1-UP; RLN1-UP)
450E (S/N: RBA1-UP; EBL1-UP; LYR1-UP)
Electric Power Generation:
C6.6 GEN SET (S/N: SDA1-UP; N6D1-UP; MRW1-UP)
Engine:
C4.4 (S/N: 4441-UP)
C6.6 (S/N: 6661-UP; 5591-UP)
Excavator:
320D (S/N: JZA1-UP; MZD1-UP)
320D L (S/N: KZF1-UP)
323D L (S/N: NZF1-UP)
M313D (S/N: J3A1-UP; K3D1-UP; W3H1-UP; D3W1-UP)
M315D Series 2 (S/N: CH31-UP)
M315D (S/N: J5B1-UP; K5E1-UP; W5M1-UP; D5W1-UP)
M316D (S/N: W6A1-UP; P6K1-UP; D6W1-UP)
M317D Series 2 (S/N: CH51-UP)

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M318D (S/N: P8L1-UP)


M318D MH (S/N: P9M1-UP)
M318D (S/N: W8P1-UP)
M318D MH (S/N: W8R1-UP)
M318D (S/N: D8W1-UP)
M318D MH (S/N: D9X1-UP)
M322D (S/N: W2S1-UP; P2T1-UP)
M322D MH (S/N: W2T1-UP)
M322D (S/N: D2W1-UP)
M322D MH (S/N: P3W1-UP; D3X1-UP)
Wheel Feller Buncher:
2470C (S/N: W2M1-UP; W471-UP)
553C (S/N: PGR1-UP; W531-UP)
Integrated Toolcarrier:
IT38H (S/N: JNJ1-UP)
Load Haul Dump:
R1300G Series II (S/N: RSL1-UP)
Motor Grader:
120M (S/N: R9A1-UP; PJB1-UP; B9C1-UP; R9C1-UP; NJD1-UP; B9N1-UP; CBS1-
UP; B9W1-UP; D9W1-UP; RMY1-UP)
12M (S/N: R9B1-UP; B9F1-UP; B9R1-UP)
Mobile Hydraulic Power Unit:
M316D MHPU (S/N: KMA1-UP)
Pneumatic Compactor:
CW34 (S/N: J3H1-UP; C341-UP)
Paving Compactor:
CS-533F (S/N: C5X1-UP)
Vibratory Asphalt Compactor:
CB44B (S/N: TWC1-UP)
CB54 (S/N: K3J1-UP; JLM1-UP)
CB54B (S/N: S4P1-UP)
Pipelayer:
PL61 (S/N: WGS1-UP)
Vibratory Soil Compactor:
CP44 (S/N: MPC1-UP; M4P1-UP)
CP54 (S/N: C5Y1-UP)
CP54B (S/N: P5F1-UP; PFM1-UP; 5461-UP)
CP56 (S/N: C5P1-UP; FCP1-UP)
CP56B (S/N: M5P1-UP; 4381-UP)
CP64 (S/N: P7F1-UP; C6P1-UP)
CP68B (S/N: SDT1-UP; 6841-UP)
CP74 (S/N: P8F1-UP)
CP74B (S/N: M7B1-UP; 7441-UP)
CP76 (S/N: C7L1-UP; JCP1-UP)
CS44 (S/N: M4C1-UP; M4S1-UP)
CS54 (S/N: C5R1-UP; C5W1-UP)
CS54B (S/N: M5B1-UP; MFC1-UP; 5441-UP)
CS56 (S/N: JMM1-UP; C5S1-UP; FCS1-UP)
CS56B (S/N: M4M1-UP; 4371-UP)
CS64 (S/N: C7F1-UP; C6S1-UP; WSW1-UP)
CS64B (S/N: DH61-UP)
CS68B (S/N: MBF1-UP; 4391-UP)
CS74 (S/N: C8F1-UP; C8S1-UP)
CS74B (S/N: E7E1-UP; 4411-UP)
CS76 (S/N: JCS1-UP; CYX1-UP)

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CS78B (S/N: M8M1-UP; 4431-UP)


CS79B (S/N: C791-UP)
Track-Type Loader:
953D (S/N: LBP1-UP)
963D (S/N: LCS1-UP)
Track-Type Tractor:
D3K LGP (S/N: JTD1-UP)
D3K (S/N: FFF1-UP)
D3K LGP (S/N: LLL1-UP)
D4K XL (S/N: MMM1-UP)
D4K LGP (S/N: RRR1-UP)
D5K (S/N: JLF1-UP)
D5K XL (S/N: WWW1-UP)
D5K LGP (S/N: YYY1-UP)
D5R LGP (S/N: D5L1-UP)
D5R XL (S/N: D5X1-UP)
D6K LGP (S/N: DHA1-UP)
D6K (S/N: NCF1-UP)
D6K XL (S/N: HMG1-UP; FBH1-UP)
D6N XL (S/N: DJA1-UP; JAH1-UP; LJR1-UP)
D6N LGP (S/N: GHS1-UP)
D6N XL (S/N: MLW1-UP)
D6N LGP (S/N: DJY1-UP)
Compact Wheel Loader:
914G2 (S/N: KNP1-UP)
IT14G2 (S/N: ERP1-UP)
Wheel Loader:
910H (S/N: SAT1-UP)
924H (S/N: HXC1-UP; JTM1-UP; KLN1-UP; RRS1-UP; LKW1-UP)
924HZ (S/N: RCB1-UP; WLB1-UP; PED1-UP; JRL1-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: MCC1-UP; MJC1-UP; JKM1-UP; LKM1-UP)
Wheel Tractor-Scraper:
613G (S/N: ESB1-UP; YCB1-UP; DBE1-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

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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.

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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

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

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◦ 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.

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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

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• 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

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322-3745 Fuel Injection Line 1


322-3746 Fuel Injection Line 1
278-4138 Fuel System Protection Gp 1

Illustration 2 g03019476

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

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Test Procedure

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

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.

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

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.

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Illustration 4 g03017878

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.

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Illustration 5 g03017918

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.

9. Use the engine speed where the fuel pressure in the fuel manifold (rail) was selected from
step 8 to determine the Minimum Cranking Pressure (MCP). Refer to table 4 for engine size
and cranking rpm.

Table 4

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Fuel Injection Pump MCP (Minimum Cranking Pressure)


Engine Speed 150-174 175-199 200-224 225-249 250-274 275-300
(rpm)

Minimum
9391 11935 14713 17713 20926 24352
Cranking Pressure
kPa kPa kPa kPa kPa kPa
for six cylinder
(1362 (1731 (2134 (2569 (3035 (3532
engines
psi) psi) psi) psi) psi) psi)

Minimum
10583 11956
Cranking Pressure 5550 6729 kPa 7970 kPa 9253 kPa
kPa kPa
for four cylinder kPa (805 (976 psi) (1156 (1342
(1535 (1734
engines psi) psi) psi)
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" ".

Note: Do not remove the test kit. The test kit is required for the remainder of this procedure.

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.

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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.

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Illustration 7 g03019497

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.

4. Calculate the speed change of the injector number 2 test as follows:

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

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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
0-5 6-10 11-15 16-20 21-25 26-30 31-35
change (rpm)

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


510 834 kPa
pressure kPa kPa kPa kPa kPa
kPa (74 (121
correction (23 (167 (213 (260 (306
psi) psi)
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

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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)

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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)

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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

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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

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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

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Table 6
Pump Pump Minimum
Test Rail Test Cranking
Pressure Engine Pressure
Speed (MCP)
Fuel From
Injection Pump Service
Pump From Test
Tests Use speed
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
Injector Injector
Test Test Injector
Test Rail Test
Engine Pressure Corrected/Pump
Pressure Engine
Speed Correction Pressure Ratio
Speed
Change
Electronic
Unit From Service
Injector Injector Last Pump
Tests From Test Test Speed Corrected Injector
Using speed
Injector Datalog subtract Pressure divided
change and
Test where Injector by Latest Pump
table 5
Datalog peak rail Test Speed Pressure
pressure
occurs
If less
than
Injector
0.85
Number 2
replace
Test
Injector
2

Injector If less
Number 3 than
Test 0.85
replace

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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

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Illustration 13 g03019697

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

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Illustration 14 g03019781

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.

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Copyright 1993 - 2017 Caterpillar Inc. Fri Jun 2 00:45:55 UTC-0430 2017
All Rights Reserved.
Private Network For SIS Licensees.

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