High Leak-off of the Electronic Unit Injector on C6.6 and C4.

4 Engines {1251, 1290}

2016/02/29
(KENR6938-09)

SMCS - 1251, 1290 i06614138

Asphalt Compactor
CB44B (S/N: TWC1-UP) PSP
-
202 0006
CB54B (S/N: 4631-UP; S4P1-UP)

3 3
12: 07/2 872
/
Asphalt Paver
AP-500D (S/N: B3D1-UP)
AP1000E (S/N: DKH1-UP)
07: 1
AP1055E (S/N: TRS1-UP)
KE 43+
AP500E (S/N: JWK1-UP) NR 03:
©2
AP500F (S/N: 5031-UP; 4491-UP) 693 00
AP555E (S/N: A5D1-UP) 023 8
AP555F (S/N: AP51-UP; 5F51-UP) Cat
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AP600D (S/N: TFM1-UP; TFZ1-UP)

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AP655D (S/N: GNN1-UP; MAN1-UP; MAT1-UP; GNZ1-UP)

BG500E (S/N: B5E1-UP)

BG555E (S/N: B5P1-UP)
c.
BG600D (S/N: B6K1-UP)

BG655D (S/N: BPA1-UP)

BG655D MTS (S/N: B5D1-UP)

CB54 (S/N: JLM1-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)

Compact Wheel Loader

910H (S/N: SAT1-UP)
914G2 (S/N: KNP1-UP)

Excavator
320D (S/N: JZA1-UP; MZD1-UP)

320D L (S/N: KZF1-UP)

323D L (S/N: NZF1-UP)
M313D (S/N: D3W1-UP)

M315D (S/N: D5W1-UP)

Generator Set
C4.4 GEN SET (S/N: D4B1-UP; D4D1-UP; GLD1-UP; GLE1-UP)
C6.6 DE150E2/DE (S/N: GTM1-UP)
C6.6 GEN SET (S/N: LC61-UP; SDA1-UP; N6D1-UP; MRW1-UP)

Industrial Engine
PSP
-
C4.4 (S/N: 4441-UP)

C6.6 (S/N: 6661-UP)

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12: 07/2 872
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Integrated Toolcarrier
IT14G2 (S/N: ERP1-UP)

IT38H (S/N: JNJ1-UP) 07: 1

Knuckleboom Loader KE 43+
C6.6 (S/N: 5591-UP)
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Load Haul Dump ©2 693 00
023
R1300G Series II (S/N: RSL1-UP)
8
Mobile Hydraulic Power Unit
Cat
M316D MHPU (S/N: KMA1-UP)
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Motor Grader
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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)

c.
Pipelayer
PL61 (S/N: WGS1-UP)
Pneumatic Compactor
CW34 (S/N: C341-UP; J3H1-UP)

Soil Compactor
CP54B (S/N: 5461-UP; P5F1-UP; PFM1-UP)
CP56B (S/N: 4381-UP; M5P1-UP)
CP68B (S/N: 6841-UP; SDT1-UP)
CP74B (S/N: 7441-UP; M7B1-UP)
CP76 (S/N: C7L1-UP; JCP1-UP)

CS54B (S/N: 5441-UP; M5B1-UP; MFC1-UP)

CS56 (S/N: JMM1-UP)
CS56B (S/N: 4371-UP; M4M1-UP)
CS64B (S/N: DH61-UP)
CS68B (S/N: 4391-UP; MBF1-UP)
CS74B (S/N: 4411-UP; E7E1-UP)
CS76 XT (S/N: JCS1-UP; CYX1-UP)

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

CS79B (S/N: C791-UP)
Track Loader
953D (S/N: LBP1-UP)
963D (S/N: LCS1-UP)
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Track-Type Tractor
D3K (S/N: FFF1-UP)
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D3K LGP (S/N: JTD1-UP; LLL1-UP)
D4K LGP (S/N: RRR1-UP)
07: 1
D4K XL (S/N: MMM1-UP)
KE 43+
D5K (S/N: JLF1-UP)
NR 03:
D5K LGP (S/N: YYY1-UP)
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D5K XL (S/N: WWW1-UP)
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D5R LGP (S/N: D5L1-UP)
Cat
D5R XL (S/N: D5X1-UP)
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D6K (S/N: NCF1-UP)
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D6K LGP (S/N: DHA1-UP) r In
D6K XL (S/N: HMG1-UP; FBH1-UP) c.
D6N LGP (S/N: GHS1-UP; DJY1-UP)

D6N XL (S/N: DJA1-UP; JAH1-UP; LJR1-UP; MLW1-UP)

Vibratory Compactor
CB54 (S/N: K3J1-UP)
CB64 (S/N: CB51-UP; DJM1-UP)
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)

CS-533F (S/N: C5X1-UP)

CS44 (S/N: M4C1-UP; M4S1-UP)

CS54 (S/N: C5R1-UP; C5W1-UP)

CS56 (S/N: C5S1-UP; FCS1-UP)
CS64 (S/N: C7F1-UP; C6S1-UP; WSW1-UP)
CS74 (S/N: C8F1-UP; C8S1-UP)
Wheel Feller Buncher
2470C (S/N: W471-UP; W2M1-UP)
553C (S/N: W531-UP; PGR1-UP)
Wheel Loader
924H (S/N: HXC1-UP; JTM1-UP; KLN1-UP; RRS1-UP; LKW1-UP)

PSP
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)
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930H (S/N: DHC1-UP; FTD1-UP)

07: 1
938H (S/N: MCC1-UP; MJC1-UP; JKM1-UP; LKM1-UP)
Wheel Tractor Scraper
KE 43+
NR 03:
613G (S/N: ESB1-UP; YCB1-UP; DBE1-UP)
Wheeled Excavator
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M313D (S/N: J3A1-UP; K3D1-UP; W3H1-UP) 00
023
M315D (S/N: J5B1-UP; K5E1-UP; W5M1-UP) 8
M315D2 (S/N: CH31-UP) Cat
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M316D (S/N: W6A1-UP; P6K1-UP; D6W1-UP)
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M317D2 (S/N: CH51-UP)
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M318D (S/N: P8L1-UP; W8P1-UP; D8W1-UP)
M318D MH (S/N: P9M1-UP; W8R1-UP; D9X1-UP)
c.
M322D (S/N: W2S1-UP; P2T1-UP; D2W1-UP)
M322D MH (S/N: W2T1-UP; P3W1-UP; D3X1-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 to
compensate for the leak-off 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
Cranks but Will Not Start". The procedure will help to assess the amount of fuel pressure leak-off
within the high-pressure fuel system.

Note: The engine may start, but you may still have high leak-off within the high-pressure fuel
system.

NOTICE
Do not perform any procedure in this Special Instruction until

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you read this information and you understand this information.

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Note: If the electronic unit injectors are replaced, ensure that the valve bridge is seated in the

/ 0
12:
correct position. Failure to carry out this procedure correctly may result in engine failure. For
7/2 2
further information, refer to Engine News, SEBD9574, "Improved Valve Bridges" and Service
07: 1
Magazine, SEPD0975, "Improved Valve Bridges".
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NR 03:
Note: If applicable, a completed service report (form number 089479-00) must be included with

©2 693 00
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

023 8
replacement parts are to be completed and packaged with parts being returned.

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Refer to Special Instruction, REHS7790, "Improved Fuel System Diagnostic Test Documentation

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for Certain C4.4 and C6.6 Engines" for additional diagnostic test documentation.

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Test Procedure for Measuring High Leak-off
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Unit Injectors
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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 cleanliness information on the
fuel system.
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 on the bottom of the fuel
transfer pump.

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Illustration 1
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Typical example

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

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Note: Tooling (A) will replace the banjo bolt that was removed in Step 1. Do not substitute

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Tooling (A). Tooling (A) is specially designed for the test.

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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

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

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Intake Manifold Pressure
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Requested Desired Engine Speed

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Fuel Volume for the Smoke Limit
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07: 1
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Fuel Volume for the Torque Limit

Engine Load Factor

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NOTICE 023 8
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After 30 seconds of cranking the engine, release the starter

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switch or button and wait 2 minutes to allow the starting motor

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to cool before attempting to start the engine again.

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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 leak-off
 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 leak-off 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 leak-off of the electronic unit injectors.

Refer to Troubleshooting, "Engine Cranks but Will Not Start" 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 leak-off 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 leak-off of the electronic unit injectors.

Refer to Troubleshooting, "Engine Cranks but Will Not Start" to diagnose the problem.

11. Remove Tooling (A). Install the banjo bolt and two new washers to the fuel transfer pump.
Tighten the banjo bolt to a torque of 21 N·m (186 lb in).

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 Leak-off for the Individual Electronic Unit
Injector".

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Measuring the Fuel Injection Pump Flow and High Leak-off
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for the Individual Electronic Unit Injector

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This procedure provides a method to evaluate the internal leakage condition of the following

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components:
12: 7/2 2
Fuel injection pump 07: 1
KE 43+
Fuel pressure relief valve
NR 03:
©2
Electronic unit injectors
693 00
023 8
The procedure provides a method to compare internal fuel leakage to a precision calibrated
orifice.
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Use the"Test Kit Data Sheet" to record the test data. For an example of the test process
calculations refer to "Example Calculations Sheet".
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Use the checklist form provided with the replacement component to document the test results.

Do not discard this form. A completed checklist is required with 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.

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If possible run at high speed and load to duplicate the low rail-pressure event conditions

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If it is not possible to put load on engine, run the "Fuel System Verification Test". This will

3 387
increase the desired rail-pressure to help get the fuel injection pump and electronic unit

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12: 7
injectors warm.

07: /2 2
1
Proceed with the test procedure when the fuel injection pump and electronic unit injectors

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are still warm.
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Required Parts NR 03:
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Table 2
023 8
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Required Parts for the Six Cylinder Engine

Part Number Description

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362-9754 Test Kit

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336-8174 Fuel Injection Line r In

1

336-8175 Fuel Injection Line 1 c.

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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

322-3745 Fuel Injection Line 1

322-3746 Fuel Injection Line 1

278-4138 Fuel System Protection Gp 1

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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
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(5) 362-9751 Plug As - Rail

Test Procedure 202 0006

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Electrical Shock Hazard. The electronic unit injectors use DC
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voltage. The ECM sends this voltage to the electronic unit

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injectors. Do not come in contact with the harness connector for

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the electronic unit injectors while the engine is operating. Failure

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to follow this instruction could result in personal injury or death.

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NOTICE illa
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Ensure that all adjustments and repairs that are carried out to

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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 -
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Remove" for the correct procedure.

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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 seconds 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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202 -0006
Fuel Injection Pump MCP (Minimum Cranking Pressure)

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 PSP
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Engine Speed (rpm) 150-174
3 3
175-199 200-224 225-249 250-274 275-300

Minimum Cranking 12: 07/2 872

/
Pressure for six
07: 1
9391 kPa 11935 kPa 14713 kPa 17713 kPa 20926 kPa 24352 kPa

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(1362 psi) (1731 psi) (2134 psi) (2569 psi) (3035 psi) (3532 psi)
cylinder engines
KE
Minimum Cranking
NR
5550 kPa 03:
6729 kPa 7970 kPa 9253 kPa 10583 kPa 11956 kPa
Pressure for four
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(805 psi) 00
(976 psi) (1156 psi) (1342 psi) (1535 psi) (1734 psi)

023
cylinder engines
8
Cat
10. If the fuel pressure in the fuel manifold (rail) is less than the Minimum Cranking Pressure

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(MCP), inspect the Pressure Relief Valve (PRV) for leakage and retest. The PRV can be checked

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for leakage by inspecting the outlet of the valve for any fuel leakage. Refer to Special
Instruction, REHS5712, "Checking the High-Pressure Relief Valve for Leakage" for the correct
procedure. r In
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11. If the PRV does not leak, and fuel pressure in the fuel manifold (rail) displayed in the
electronic service tool graph is less than the 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, Fuel Injection Pump - Remove and
Disassembly and Assembly, Fuel Injection Pump - Install 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 Leakage" section.
Note: Do not remove the test kit. The test kit is required for the remainder of this procedure.

Measure Electronic Unit Injector Leakage

This part of the procedure will determine if individual electronic unit injectors are defective for
internal leakage.

Note: The electronic unit injectors can be checked for leakage in any order, use the order that is
best suited to your engine application.

Note: If the test speed for the electronic unit injector changes by more than 25 rpm from the
measurement of Pump Test speed or drops below 150 rpm, a battery booster must be used to
maintain uniform speed with the Pump Test. Maintaining a uniform cranking speed 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 half or more of the 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

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 PSP
electronic unit injectors. Refer to Disassembly and Assembly, Electronic Unit Injector - Remove and
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Disassembly and Assembly, Electronic Unit Injector - Install for the correct procedures.

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Illustration 6 g03018160
Typical example

1. Install an existing fuel injection line for the cylinder you have selected. Refer to Disassembly
and Assembly, "Fuel Injection Lines - Install" for the correct procedure. Ensure that all outlets
from the fuel manifold (rail) are capped. 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 fuel rail pressure and the injector test engine speed (where the peak pressure
was selected). Typically, pressure will start building after 2 to 5 seconds 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 test as follows:

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

5. Determine injector pressure correction using the injector 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
pressure PSP
283 kPa 896 kPa 1455 kPa 2013 kPa 2572 kPa 3130 kPa 3689 kPa
(41 psi) (130 psi) (211 psi) (292 psi) (373 psi) (454 psi) (535 psi)
correction

Four-cylinder
-
202 0006
pressure
159 kPa 510 kPa
3 /0
(23 psi) (74 psi) 387
834 kPa
(121 psi)
1151 kPa 1469 kPa 1793 kPa 2110 kPa
(167 psi) (213 psi) (260 psi) (306 psi)
correction
12: 7/2 2
07: 1
6. If the injector test engine speed is lower than pump test engine speed, then correct the
KE 43+
injector pressure by adding the correction as follows:

NR 03:
Injector corrected pressure equals injector test pressure plus injector pressure correction.

©2 693 00
7. If the injector test engine speed is higher than pump test engine speed (as can happen when
023 8
a battery booster is used), then correct the injector test pressure by subtracting the pressure
correction as follows:
Cat
erp
Injector corrected pressure equals injector test pressure minus injector pressure correction.

illa
8. Calculate injector leakage ratio as follows:

r In
Injector leakage ratio equals injector corrected pressure divided by pump test rail pressure.

c.
If the Injector leakage ratio is less than 0.85, the injector must be replaced, if the injector
leakage is greater than 0.85 the injector is within the required parameters.

Remove the fuel line. Replace the cap on the fuel manifold (rail) and injector.

9. Proceed to the next injector to be checked. Repeat Step 1 through Step 8 for the remaining
electronic unit injectors to be tested.

10. 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, Fuel Injection
Lines - Install for the correct procedure.

11. Reconnect the electronic unit injector harness connectors.

Test Kit Data Sheet

Table 6

Minimum
Pump Pump Test
Cranking
Test Rail Engine
Pressure
Fuel Pressure Speed
(MCP)
Injection
Pump From Pump Service
From
Tests Test Datalog
 Pump where peak Use speed
Test rail pressure and table 4
Datalog occurs

Pump Test If peak pressure less than MCP inspect

1 PRV

Pump Test
2 (after PRV
PSP If peak pressure less than MCP inspect
outlet check valves

-
service)

Pump Test
202 0006
3 (after
3 /0 387 If peak pressure less than MCP replace
outlet
check valve 12: 7/2 2 fuel injection pump

clean) 07: 1
KE 43+ Injector Test Injector
Injector
NR
Injector Test
03: Engine Test
Injector

©2 693 00
Test Rail Engine Corrected/Pump
Speed Pressure
Electronic Pressure Speed Pressure Ratio
Unit 023
From Injector 8
Change

Last Pump
Correction
Service
Injector
Tests
From
Cat
Test Datalog Test Speed
Using Corrected
Injector
Test
where peak
erp subtract
speed Injector Pressure
change and divided by Latest
Datalog
rail pressure
illa
Injector Test
table 5 Pump Pressure
occurs
r In
Speed

Injector
c. If less
than
0.85
Number 2
replace
Test
Injector
2

If less
than
Injector
0.85
Number 3
replace
Test
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

PSP 4

Injector
-
202 0006
If less
than

Number 1
3 /0 387 0.85
replace
Test
12: 7/2 2 Injector

07: 1 1

Example Calculations EN 43+0

KSheet
Fuel Injection Pump©Test R69 3:00
202 38
3C
ater
pill
ar I
nc.
 PSP
-
202 0006
3 /0 387
12: 7/2 2
07: 1
KE 43+
NR 03:
©2 693 00
023 8
Cat
erp
Illustration 8
illa g03019697

r In
Typical example of pump pressure and speed measurement

c.
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

 PSP
-
202 0006
3 /0 387
12: 7/2 2
07: 1
KE 43+
NR 03:
©2 693 00
023 8
Illustration 9
Cat g03019781

erp
Typical example of injector Test pressure and speed measurement

illa
Injector Rail Pressure (1) is 10721 kPa (1555 psi). Injector Test Engine Speed (2) is 144 rpm.

r In
Injector Engine Speed Change is 162 minus 144 equals 18 rpm.

c.
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.

PSP-00063872
2023/07/21
12:05:07+03:00
i02810762
© 2023 Caterpillar Inc.