Injector Bypass Fuel Flow - Test: Previous Screen

336E L Excavators BZY00001-UP (MACHINE) POWERED BY C9.3 Engine(SEBP561...
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Welcome: p230mag1
Product: EXCAVATOR
Model: 336E L EXCAVATOR BZY
Configuration: 336E L Excavators BZY00001-UP (MACHINE) POWERED BY C9.3 Engine
Testing and Adjusting

C9.3 Engines for Caterpillar Built Machines
Media Number -KENR9368-24 Publication Date -01/09/2015 Date Updated -09/10/2018
i07426304
Injector Bypass Fuel Flow - Test

SMCS - 1290-081
Required Parts
Table 1
Required Tooling Quantity
323-3949 Test Kit 1
356-0828 Fuel Injection Line As 1
9S-8927 Plugs 2
8S-4950 Caps 3
9S-5518 Plugs 2
9L-8493 Flared Caps 2
NOTICE
Fuel injection lines MUST only be used once. Discard all fuel injection
lines after use.
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Illustration 1 g02039499
323-3949 Test Kit
(1) 356-2468 Foam Lid
(2) 356-2470 Graduated Cylinder
(3) 356-2466 Plastic Case
(4) 323-3950 Discharge Orifice As
(5) 323-8301 Pump Drain Hose
(6) 355-8794 Gage Pin
(7) 356-2469 Foam Block
(8) 355-8626 Nut
(9) 323-3951 Rail Plug As
Test Procedure
Contact with high pressure fuel may cause personal injury or death.
Wait 60 seconds after the engine has stopped to allow fuel pressure to
purge before any service or repair is performed on the engine fuel lines.
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.
Note: Use the gage pin (6) or an aerosol cleaner to ensure that the orifice is clean before performing this procedure.
Channel 1 Video (QR Code And Link)
For supplemental information on this procedure, refer to the following video:
Note: A CWS login is required to access Caterpillar Channel 1. Scan the QR code below with a QR enabled device or
copy the link below.
Table 2
Caterpillar Channel 1
Media
CATU1017
Number:
Title: C9.3 Injector Bypass Fuel Flow - Test
Channel 1 https://channel1.mediaspace.kaltura.com/media/C9.3+and+C13+Injector+Bypass+Fuel+Flow+-
URL: +Test/0_ax73hvx2;
Test Step 1: Measure the Fuel Leak From the Pressure Relief Valve (PRV)
(1) Low-pressure fuel line
(2) Cylinder head cooling flow inlet port
1. Disconnect low-pressure fuel line (1) from the high-pressure fuel pump that goes to cooling flow inlet port (2) on
the rear of the cylinder head.
(3) 8S-4950 Cap
(4) 9S-8927 Plug
a. Cap and plug the connections from the fuel line and cooling inlet port using cap (3) and plug (4).
Note: The low-pressure fuel line and cylinder head cooling flow inlet port in the cylinder head will stay
capped off until "Test Step 5: Verification of the Repair" of this procedure.
(5) Pressure Relief Valve (PRV) fuel line
2. Remove fuel return line (5) from the PRV on the high-pressure fuel rail to the low-pressure regulator block.
a. Cap the port at the regulator block using the 9L-8493 Flared Cap.
b. Route the PRV fuel line into graduated cylinder (6).
Note: Ensure that the PRV fuel line does not have any obstructions or residual fuel.
3. Use the Cat® Electronic Technician (ET) "Injection Disable Override" to disable the fuel injectors or disconnect the
fuel injectors electrical connector on the side of the cylinder head.
Note: Leave the injectors disabled during the test.
4. Crank the engine for 20 seconds and record the fuel volume that collects in the graduated cylinder.
a. If the measured volume of fuel is more than 5 drops, replace the PRV. Repeat the test to verify the repair.
Proceed to Test Step 5.
b. If the measured volume of fuel is fewer than 5 drops, reinstall the PRV fuel line to the low-pressure regulator
block. Proceed to Test Step 2.
Test Step 2: Measure the High-Pressure Pump Flow
Note: If the machine is equipped with an electronic fuel delivery pump, disconnect the pump before performing the step
below.
(7) High-pressure fuel supply line
1. Disconnect high-pressure fuel supply line (7) from the high-pressure fuel pump.
a. Connect pump drain hose (8) to the high-pressure fuel pump outlet.
b. Route the hose to graduated cylinder (6).
2. Crank the engine for 20 seconds and record the fuel volume.
a. The volume of the fuel is less than 40 mL (1.4 oz). Replace the high-pressure fuel pump. Proceed to Test
Step 5.
Note: Ensure that the low-pressure fuel system is providing a minimum of 210 kPa (30.5 psi) during the
cranking process.
b. The volume of the fuel is greater than 40 mL (1.4 oz). Replace the previous fuel line that connects the high-
pressure fuel pump to the fuel rail with a new line. Proceed to Test Step 3.
Test Step 3: Measure the Pressure of the Fuel Rail while Cranking
(7) High-pressure fuel supply line
Note: Illustration 8 shows discharge orifice assembly (9) attached to injector supply line number 3. The discharge
orifice assembly can be installed to any injector supply line as long as the other 5 injectors ports are plugged on the
fuel rail.
1. Remove the fuel lines for the injectors from the fuel rail.
2. Install the 323-3951 Rail Plug As on the rail for cylinders 1, 2, 4, 5, and 6.
3. Use the 355-8794 Gage Pin to ensure that the discharge orifice is free of any obstruction.
4. Install discharge orifice assembly (9) on injector port 3. Route the discharge orifice assembly hose to the 356-2470
Graduated Cylinder.
5. Use the Cat® Electronic Technician (ET) "Injection Disable Override" to disable the fuel injectors or disconnect the
fuel injectors electrical connector on the side of the cylinder head.
Note: Leave the injectors disabled for the duration of the test.
6. Navigate in Cat ET to the "Status Parameters > Fuel Delivery" screen. Record the "Fuel Rail Pressure" and "Engine
Speed" while the engine cranks for 10 seconds. Refer to Table for the minimum values for fuel rail pressure in
relation to the engine speed.
Table 3
Engine Speed
150-174 175-199 200-224 225-250 250-274 275-300
Range (rpm)
Minimum
3640 kPa 5620 kPa 7600 kPa 10260 kPa 12910 kPa 16000 kPa
Cranking Pressure
(528 psi) (815 psi) (1102 psi) (1488 psi) (1872 psi) (2320 psi)
(Mpa/psi)
a. The fuel rail pressure remains less than the minimum fuel rail pressure rated against the engine speed listed in
the table. Replace the high-pressure fuel pump. Proceed to Test Step 5.
b. The fuel rail pressure is greater than or equal to the minimum fuel rail pressure rated against the engine speed
listed in the table. Proceed to Test Step 4.
7. Remove the discharge orifice assembly from the fuel rail.
Test Step 4: Measure the Leakage for Individual Injectors
(10) Injector 3 fuel supply port
(11) Injector 4 fuel supply line
1. Connect the fuel supply line for one of the injectors (11) to the high-pressure fuel rail. Plug the other 5 injector
ports using the 323-3951 Rail Plug As.
Note: Leave the injectors disabled for the duration of the test.
(12) Fuel return line
2. Remove fuel return line (12) from the cylinder head cooling flow outlet and the low-pressure regulator block.
Install and tighten the 8S-4950 Cap on the regulator block after removal of the fuel return line.
3. Install pump drain hose (8) onto the cylinder head cooling outlet port. Route the pump drain hose into graduated
cylinder (6).
Note: The pump drain hose needs to be pushed onto the outlet port. The hose does not contain threads for
installation.
4. Crank the engine for 30 seconds then stop. Then crank the engine for an additional 30 seconds and stop. Measure
the fuel collected from the total 60 second duration.
Note: The fuel measured is the leakage of the fuel injectors.
a. The fuel leakage from the injector should be below 30 mL (1.02 oz) from the 60 second cranking duration.
b. Perform Steps 1 through 3 on each individual injector and record the leakage results.
c. If an injector leaks more than 30 mL (1.02 oz), then replace the injector. Proceed to Test Step 5.
Test Step 5: Verification of the Repair
1. Replace and torque all of the high pressure fuel rail lines that were loosened during the procedure.
Note: The high pressure fuel rail lines are one time use lines.
2. Reconnect and torque the fuel cooling flow supply and return lines for the cylinder head.
3. After inspection/repair of the fuel system, perform the "Fuel System Functional Test" using Cat ET to confirm that
the system is operating properly.
Copyright 1993 - 2020 Caterpillar Inc. Thu Sep 17 13:01:22 CDT 2020
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336E L Excavators BZY00001-UP (MACHINE) POWERED BY C9.3 Engine(SEBP561...

Testing and Adjusting

Injector Bypass Fuel Flow - Test

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

Channel 1 Video (QR Code And Link)

For supplemental information on this procedure, refer to the following video:

b. Route the PRV fuel line into graduated cylinder (6).

Note: Leave the injectors disabled during the test.

Test Step 2: Measure the High-Pressure Pump Flow

b. Route the hose to graduated cylinder (6).

7. Remove the discharge orifice assembly from the fuel rail.

Test Step 4: Measure the Leakage for Individual Injectors

Note: The fuel measured is the leakage of the fuel injectors.

Test Step 5: Verification of the Repair

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