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Special Instruction
Measuring Fuel Leakage Past the Fuel Injectors{0782, 1251, 1254, 1290, 1713}
Media Number -REHS3428-07 Publication Date -10/02/2010 Date Updated -10/02/2010

i03855790

Measuring Fuel Leakage Past the Fuel Injectors{0782, 1251, 1254,

1290, 1713}
SMCS - 0782; 1251; 1254; 1290; 1713

Excavator:
315D (S/N: JKH1-UP)
320D (S/N: GDC1-UP)

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

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. The high pressure pump cannot
generate enough fuel flow or volume to compensate for the leakoff rates above the critical value 38 mL (1.3
oz) per 30 seconds of cranking for six cylinder engines at a speed of 150 rpm. The high pressure pump cannot
generate enough fuel flow or volume to compensate for the leakoff rates above the critical value 25 mL (0.85
oz) per 30 seconds of cranking for four cylinder engines 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".

Test Procedure

NOTICE

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Before begining 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.

Table 1
Required Tools

Tool Part Number Part Description Qty

A 334-3221 Fuel Leakoff Kit 1

1. Ensure that the engine is shut down.

Illustration 1 g02103090

Injector harness

2. Disconnect the injector harness (1) from the front of the engine.

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Illustration 2 g02103093

Typical example

Note: Direct any leaking fuel into a suitable container.

3. Remove the bolt (2) from the "fuel relief block" and save the bolt for reinstallation.

Illustration 3 g02103095

Fuel leakoff kit

(A) Tooling

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(3) Clear plastic hose

4. Install tooling (A) to the "fuel relief block".

a. Slide the tooling through the banjo bolt in order to replace the bolt that was removed in the
previous step.

b. Thread the tooling into the "fuel relief block" and slightly tighten the tooling.

5. Connect a plastic hose (3) onto the tooling. Place the opposite end of the plastic hose into a suitable
container that is clean.

6. Crank the engine with the starting motor for 30 seconds.

7. Record the amount of fuel that has been collected. Conduct the test three times. Calculate the average of
the three values.

8. 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 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. If this is the case, replace the electronic unit injectors and the
fuel injection lines. Return the original electronic unit injectors and the fuel injection lines to the parts
return center.

9. 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. For four cylinder engines, if less than
25 mL (0.85 oz) of fuel has been collected for the 30 second crank test, 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.

10. Remove the tooling. Reinstall the bolt (2) and two new washers to the "fuel relief block".

11. Reconnect the injector harness (1) at the front of the engine.

12. Send the leakoff measurements to the Technical Communicator at your Caterpillar dealer.

Copyright 1993 - 2017 Caterpillar Inc. Tue Sep 05 2017 19:06:11 GMT+0700 (SE Asia Standard Time)
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