Fuel System Diagnostic Test Documentation

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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
Improved Fuel System Diagnostic Test Documentation for Certain C4.4 and C6.6
Engines{1250, 1280}
Número de medio -REHS7790-03 Fecha de publicación -08/01/2013 Fecha de actualización -08/01/2013
i05219039
Improved Fuel System Diagnostic Test Documentation for

Certain C4.4 and C6.6 Engines{1250, 1280}
SMCS - 1250-081-FI; 1280-081-FI
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)
Backhoe Loader:
420 Series E (S/N: DJL1-UP; DAN1-UP)
430 Series E (S/N: MXB1-UP; SWC1-UP)
430E (S/N: SCD1-UP; RLN1-UP)
450E (S/N: EBL1-UP)
Electric Power Generation:
C4.4 GEN SET (S/N: D4B1-UP; D4D1-UP; GLD1-UP)
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)
Industrial Engine:
C4.4 (MECH) (S/N: 4461-UP)
Excavator:
320D (S/N: A6F1-UP)
M313D (S/N: J3A1-UP; W3H1-UP)
M315D (S/N: J5B1-UP; W5M1-UP)
https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/... 09-sep-16
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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:
IT14G (S/N: FWL1-UP; KZN1-UP)
Load Haul Dump:
R1300G Series II (S/N: RSL1-UP)
Motor Grader:
120M (S/N: PJB1-UP; B9C1-UP; R9C1-UP; NJD1-UP; B9N1-UP; CBS1-UP; B9W1-UP;
D9W1-UP; RMY1-UP)
12M (S/N: B9F1-UP; B9R1-UP)
Mobile Hydraulic Power Unit:
M316D MHPU (S/N: KMA1-UP)
Vibratory Soil Compactor:
CP44 (S/N: MPC1-UP; M4P1-UP)
CP56 (S/N: C5P1-UP; FCP1-UP)
CP64 (S/N: P7F1-UP; C6P1-UP)
CP74 (S/N: P8F1-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: 5441-UP)
CS56 (S/N: C5S1-UP; FCS1-UP)
CS56B (S/N: 4371-UP)
CS64 (S/N: C7F1-UP; C6S1-UP; WSW1-UP)
CS74 (S/N: C8F1-UP; C8S1-UP)
CS76 (S/N: JCS1-UP; CYX1-UP)
Telehandler:
TL943 (S/N: TBL1-UP)
Track-Type Loader:
953D (S/N: LBP1-UP)
963D (S/N: LCS1-UP)
Track-Type Tractor:
D3K (S/N: JTD1-UP; FFF1-UP; LLL1-UP)
D4K (S/N: MMM1-UP; RRR1-UP)
D5K (S/N: JLF1-UP; WWW1-UP; YYY1-UP)
D6K (S/N: DHA1-UP; FBH1-UP)
D6N (S/N: DJA1-UP; JAH1-UP; LJR1-UP; GHS1-UP; MLW1-UP; DJY1-UP)
Compact Wheel Loader:
908H (S/N: L5T1-UP)
914G (S/N: PDF1-UP)
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)
928HZ (S/N: BYD1-UP; CXK1-UP)
930H (S/N: DHC1-UP; FTD1-UP)
938H (S/N: MCC1-UP; JKM1-UP; LKM1-UP)
Wheel Tractor-Scraper:
613G (S/N: DXA1-UP; YCB1-UP)
Introduction
Unacceptable quantities of CR200 injectors and CR200 high pressure fuel injection pumps from C4.4
and C6.6 engines are being returned as failures. The factory failure analysis result is "Failure not
Repeated" or "No Fault Found".
This Special Instruction gives the dealer improved diagnostic test documentation to define excessive
injector control valve leakage failures and confirm high-pressure pump fuel flow capability.
This special instruction is to be used as supplement to Troubleshooting Guide, "Engine Cranks but
Does Not Start" for the proper engine application. For further diagnostic support, contact your DSN
Technical Communicator (TC) when directed by the procedures. The graphic pictured is for reference
only. For the most accurate information consult SIS Web with the serial number of the engine or
machine in question.
Safety Section
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.
Required Parts
Table 1
Quantity Part Number Part Name Description
1 362-9754 Test Kit New leak down test kit
Low-Pressure Fuel System Requirements

Increasing fuel supply pressure and effectively removing water and abrasive particles has
demonstrated injector durability increases from 200% to as high as 1,000% in severe applications.
More aggressive filtration and monitoring are required to maximize injector life and meet rapidly
increasing reliability and durability expectations. Conversely, reliability and durability goals cannot
be achieved without the following improved filtration and monitoring features.
Fuel Tank Drain
Fuel tank drains are used to drain water and sediment from the fuel tank daily. The drain must be
located on the lowest part of the fuel tank where the containments collect.
Note: Daily draining of water and sediment from the fuel tank has been a standard maintenance
requirement for decades.
Advanced Tank Breather Filter
Preventing short fuel system life by keeping dust from entering the fuel tank.
Water Separators
Water separators are required to remove large quantities of latent water from the fuel.
Primary Fuel Filters
Primary fuel filters are required to remove large abrasives from the fuel supply and prevent premature
clogging of the 4-micron secondary filters from excessive debris.
Secondary Fuel Filters
Series filtration more than doubles wear life over single filtration.
Electronic Unit Injectors (EUI)
An adequate fuel supply pressure is essential to prevent cavitation of internal injector components due
to incomplete fuel fill.
Major Factors Which Negatively Affect Fuel System Wear

Abrasive Contaminants
Increased injection pressure acting on the same level of abrasive contaminants in the fuel results in
accelerated injector abrasive wear. This abrasive wear cannot be eliminated by using improved
materials or processes. Abrasive wear only can be reduced by removing abrasives from the fuel.
Solution
Single or series High Efficiency fuel filters and/or bulk fuel filter/water coalescer.
Water in Fuel
An excessive amount of latent water in the fuel is a key cause of injector failure. Water has
inadequate film strength to prevent metal-to-metal contact between the plunger and barrel, resulting in
plunger scuffing or seizure. Water can be effectively by the use and regular maintenance of a water
separator or bulk fuel filter/water coalescer. Removal of excess latent water is essential to prevent
scuffing with the upcoming injection pressure increases and subsequent hydraulic loading of internal
injector parts.
Solution
Proper maintenance of fuel tank drains, water separators and/or use of a bulk fuel filter/water
coalescer.
Excessive Fuel Temperature
Increasing fuel temperatures reduces fuel viscosity and resultant fuel film strength. Reduced film
strength increases the probability of injector plunger and barrel scuffing or seizure. Limiting the
maximum fuel temperature will become even more critical with the increase of use if low sulfur fuel
which has a lower film strength and common rail fuel systems which run elevated fuel temperatures.
Fuel temperatures also play in diesel and biodiesel fuel degradation.
Solution
Properly maintain fuel filters and fuel coolers where needed. Ensure proper consideration for
materials used in fuel coolers as zinc, copper, lead, and tin can have adverse effects on fuel
degradation.
Customer Maintenance Practices
Fuel system performance, sophistication, and complexity continue to increase at a rapid pace. It is
more important than ever for the user to maintain fuel filters in order to prevent filter restriction and
the problems caused by low fuel pressure. It is also important to use quality Advanced Efficiency
filters in order to trap and hold microscopic abrasive debris, which causes accelerated wear in modern
fuel systems.
Reference Material
Reference Special Publication, SENR9620 English, SRNR9620 Russian, S8NR9620 Bahasa, "FUEL
SYSTEMS ", "Improving Component Durability" for more information. This series of high-quality
booklets contains full color graphics and easy to understand explanations of wear and failure in major
system components. Special attention is given to practices that cause accelerated wear, and how to
improve component life in many applications.
Note: This reference material is available only in paper and can only be ordered in packages of 10 or
a set of all seven booklets.
C4.4 and C6.6 Fuel System Diagram
Note: The following illustration identifies components that may be included in many different
arrangements. Refer to the Service Information System (SIS) for the correct components for the
engine that is being serviced.
Illustration 1 g03144996
(1) HP relieve valve
(2) High-pressure fuel rail
(3) Fuel pressure sensor
(4) Fuel temperature sensor
(5) Fuel return
(6) Injectors
(7) Fuel return
(8) Diagnostic connection
(9) Machine interface connection
(10) High-pressure fuel pump
(11) Fuel supply
(12) Fuel cooled ECM
(13) Power supply
(14) Electronic Control Module (ECM)
(15) Speed/Timing sensor
(16) Fuel bleed/leak-off line
(17) Relay 12/24 V
(18) Lube oil In
(19) Lube oil Out
(20) 2 micron Secondary filter (final)
(21) Electrical Pump
(22) 10 micron Primary pre-filter & water separator (vehicle mounted module)
(23) Fuel Supply
(24) Fuel tank
(25) Ignition
(26) Engine coolant temperature
(27) Intake air-manifold temperature
(28) Throttle position
(29) Engine speed/engine timing
(30) Intake air-manifold pressure
(31) Fuel return
(32) Regulator (engine mounted)
General Information Required

Note: This special instruction is to be used as supplement to Troubleshooting Guide, "Cranks but will
not Start" for the proper engine application. For further diagnostic support, contact your DSN
Technical Communicator (TC) when directed by the procedures. The graphic pictured is for reference
only. For the most accurate information consult SIS Web with the serial number of the engine or
machine in question.
Checklist One
Checklist Two
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Copyright 1993 - 2016 Caterpillar Inc. Fri Sep 9 01:49:54 EST 2016
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Producto: NO SE HA ESCOGIDO NINGUN EQUIPO

Improved Fuel System Diagnostic Test Documentation for

M316D (S/N: W6A1-UP; D6W1-UP)

Refer to Systems Operation, Testing and Adjusting, "Cleanliness of

Low-Pressure Fuel System Requirements

Fuel Tank Drain

Advanced Tank Breather Filter

Primary Fuel Filters

Secondary Fuel Filters

Electronic Unit Injectors (EUI)

Major Factors Which Negatively Affect Fuel System Wear

Excessive Fuel Temperature

Customer Maintenance Practices

C4.4 and C6.6 Fuel System Diagram

(1) HP relieve valve

(2) High-pressure fuel rail

(3) Fuel pressure sensor

(4) Fuel temperature sensor

(5) Fuel return

(7) Fuel return

(8) Diagnostic connection

(9) Machine interface connection

(10) High-pressure fuel pump

(11) Fuel supply

(12) Fuel cooled ECM

(13) Power supply

(14) Electronic Control Module (ECM)

(15) Speed/Timing sensor

(16) Fuel bleed/leak-off line

(17) Relay 12/24 V

(18) Lube oil In

(19) Lube oil Out

(20) 2 micron Secondary filter (final)

(21) Electrical Pump

(23) Fuel Supply

(24) Fuel tank

(26) Engine coolant temperature

(27) Intake air-manifold temperature

(28) Throttle position

(29) Engine speed/engine timing

(30) Intake air-manifold pressure

(31) Fuel return

(32) Regulator (engine mounted)

General Information Required

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