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Bienvenido: r050sxmo
Producto: WHEEL LOADER
Modelo: 938H WHEEL LOADER JKM
Configuracin: 938H Wheel Loader JKM00001-UP (MACHINE) POWERED BY C6.6 Engine
Instruccin Especial
High Leakoff of the Electronic Unit Injector on C6.6 and C4.4 Engines{1251, 1290}
Nmero de medio-KENR6938-07
Fecha de publicacin -04/10/2012
Fecha de actualizacin -04/10/2012
i05117850
High Leakoff of the Electronic Unit Injector on C6.6 and C4.4 Engines
{1251, 1290}
SMCS - 1251; 1290
Asphalt Compactor:
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:
420 Series E (S/N: DJL1-UP; DAN1-UP)
420E (S/N: PRA1-UP; PHC1-UP)
430 Series E (S/N: MXB1-UP; SWC1-UP)
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:
https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/productsearc...
1/21/2014
938H Wheel Loader JKM00001-UP (MACHINE) POWERED BY C6.6 Engine(SEBP4673 - 19) - Sis... Pgina 2 de 25
IT38H (S/N: JNJ1-UP)
Load Haul Dump:
R1300G Series II (S/N: RSL1-UP)
Motor Grader:
120M (S/N: B9C1-UP; B9N1-UP; B9W1-UP; D9W1-UP)
12M (S/N: B9F1-UP; B9R1-UP)
Mobile Hydraulic Power Unit:
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:
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; NCF1-UP; FBH1-UP)
D6N (S/N: DJA1-UP; JAH1-UP; LJR1-UP; GHS1-UP; MLW1-UP; DJY1-UP)
Compact Wheel Loader:
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.
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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.
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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
300-4988
Fuel Leakoff Kit
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
Active Diagnostic Codes that are present
Atmospheric Pressure
1/21/2014
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.
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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.
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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
336-8174
Fuel Injection Line
336-8175
Fuel Injection Line
336-8176
Fuel Injection Line
336-8177
Fuel Injection Line
336-8178
Fuel Injection Line
336-8179
Fuel Injection Line
278-4138
Fuel System Protection Gp
Table 3
Required Parts for the Four Cylinder Engine
Part Number
Description
Qty
362-9754
Test Kit
333-4732
Fuel Injection Line
333-4733
Fuel Injection Line
322-3745
Fuel Injection Line
322-3746
Fuel Injection Line
278-4138
Fuel System Protection Gp
1/21/2014
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
Test Procedure
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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.
2. Remove the fuel injection lines. Refer to Disassembly and Assembly, "Fuel Injection Lines - Remove" for the
correct procedure.
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938H Wheel Loader JKM00001-UP (MACHINE) POWERED BY C6.6 Engine(SEBP4673 - 19) - ...
Illustration 3
Pgina 10 de 25
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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Pgina 11 de 25
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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Pgina 12 de 25
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
Fuel Injection Pump MCP (Minimum Cranking Pressure)
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Pgina 13 de 25
Engine Speed (rpm)
150-174
175-199
200-224
225-249
250-274
275-300
Minimum Cranking
Pressure for six cylinder
engines
9391 kPa
(1362 psi)
11935 kPa
(1731 psi)
14713 kPa
(2134 psi)
17713 kPa
(2569 psi)
20926 kPa
(3035 psi)
24352 kPa
(3532 psi)
Minimum Cranking
Pressure for four
cylinder engines
5550 kPa
(805 psi)
7970 kPa
(1156 psi)
9253 kPa
(1342 psi)
10583 kPa
(1535 psi)
11956 kPa
(1734 psi)
6729 kPa
(976 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.
1/21/2014
Illustration 6
Pgina 14 de 25
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.
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Pgina 15 de 25
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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Pgina 16 de 25
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 kPa
pressure correction
(41 psi)
896 kPa
(130 psi)
1455 kPa
(211 psi)
2013 kPa
(292 psi)
2572 kPa
(373 psi)
3130 kPa
(454 psi)
3689 kPa
(535 psi)
Four cylinder
159 kPa
pressure correction
(23 psi)
510 kPa
(74 psi)
834 kPa
(121 psi)
1151 kPa
(167 psi)
1469 kPa
(213 psi)
1793 kPa
(260 psi)
2110 kPa
(306 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" ".
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Illustration 8
Pgina 17 de 25
g03019616
Typical example
1. Remove the cap from cylinder number 3 and reconnect the existing fuel line. Refer to illustration 8.
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
5. Determine injector number 3 pressure correction. Use the same procedure as the procedure in ""Measure
6. Calculate injector number 3 leakage ratio. Use the same procedure as the procedure in ""Measure Electronic
Unit Injector Number 5 Leakage (if applicable)" ".
Measure Electronic Unit Injector Number 5 Leakage (if applicable)
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Illustration 9
Pgina 18 de 25
g03019636
Typical example
Unit Injector Number 6 Leakage (if applicable)" ".
Measure Electronic Unit Injector Number 6 Leakage (if applicable)
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Illustration 10
Pgina 19 de 25
g03019656
Typical example
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Illustration 11
Pgina 20 de 25
g03019657
Typical example
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Illustration 12
Pgina 21 de 25
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.
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
Fuel
Injection
Pump Tests
Pump
Test Rail
Pressure
Pump Test
Engine
Speed
Minimum
Cranking
Pressure
(MCP)
Service
1/21/2014
From
Pump Test
Datalog
From Pump
Test Datalog
where peak
rail pressure
occurs
Pgina 22 de 25
Use speed and

table 4
Pump Test 1
If peak pressure less than MCP inspect PRV
Pump Test 2
(after PRV
service)
If peak pressure less than MCP inspect outlet

check valves
Pump Test 3
(after outlet
check valve
clean)
If peak pressure less than MCP replace fuel

injection pump
Injector
Test Rail
Pressure
Electronic
Unit Injector
Tests
From
Injector
Test
Datalog
Injector
Test Engine
Speed
From
Injector Test
Datalog
where peak
rail pressure
occurs
Injector Test Injector Test

Engine Speed
Pressure
Change
Correction
Last Pump
Test Speed
subtract
Injector Test
Speed
Injector
Corrected/Pump
Pressure Ratio
Service
Using speed
change and
table 5
Corrected Injector
Pressure divided by
Latest Pump Pressure
Injector
Number 2
Test
If less
than 0.85
replace
Injector 2
Injector
Number 3
Test
If less
than 0.85
replace
Injector 3
Injector
Number 5
Test
If less
than 0.85
replace
Injector 5
Injector
Number 6
Test
If less
than 0.85
replace
Injector 6
Injector
Number 4
Test
If less
than 0.85
replace
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Pgina 23 de 25
Injector 4
Injector
Number 1
Test
If less
than 0.85
replace
Injector 1
Example Calculations Sheet

Fuel Injection Pump Test
Illustration 13
g03019697
Typical example of pump pressure and speed measurement
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Pgina 24 de 25
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
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).
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Pgina 25 de 25
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.
Tue Jan 21 12:13:58 UTC-0300 2014
Todos los derechos reservados.
r050sxmo
Red privada para licenciados del SIS.
1/21/2014

Medicion Presiones y Fugas C6 y C4

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Medicion Presiones y Fugas C6 y C4

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938H Wheel Loader JKM00001-UP (MACHINE) POWERED BY C6.6 Engine(SEBP4673 - 19) - Sis...

Fecha de publicacin -04/10/2012

Fecha de actualizacin -04/10/2012

Fuel Leakoff Kit

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

Fuel Injection Line

Fuel Injection Line

Fuel Injection Line

Fuel Injection Line

Fuel Injection Line

Fuel Injection Line

Fuel System Protection Gp

Fuel Injection Line

Fuel Injection Line

Fuel Injection Line

Fuel Injection Line

Fuel System Protection Gp

Typical example of 362-9754 Test kit

Measure the Pressure of the Fuel Injection Pump

Engine Speed (rpm)

Measure Electronic Unit Injector Number 2 Leakage

Measure Electronic Unit Injector Number 3 Leakage

Measure Electronic Unit Injector Number 5 Leakage (if applicable)

Measure Electronic Unit Injector Number 6 Leakage (if applicable)

Measure Electronic Unit Injector Number 4 Leakage

Measure Electronic Unit Injector Number 1 Leakage

Test Kit Data Sheet

Use speed and

If peak pressure less than MCP inspect PRV

If peak pressure less than MCP inspect outlet

If peak pressure less than MCP replace fuel

Injector Test Injector Test

Example Calculations Sheet

Typical example of pump pressure and speed measurement

Electronic Unit Injector Test

Typical example of injector Test pressure and speed measurement

Tue Jan 21 12:13:58 UTC-0300 2014

Todos los derechos reservados.

Red privada para licenciados del SIS.

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