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Product: EXCAVATOR
Model: 320D EXCAVATOR FAL
Configuration: 320D & 320D L Excavators FAL00001-UP (MACHINE)
POWERED BY C6.4 Engine

Testing and Adjusting

C4.2 and C6.4 Engines for Caterpillar Built Machines
Media Number -KENR6741-04 Publication Date -01/10/2007 Date Updated -30/10/2007

i02765155

Air in Fuel - Test

SMCS - 1280-081

Table 1

Required Tools
Tool Part Number Part Description Qty
124-6275 Hose clamp 4
215-9513 Connector 2
158-6067 Hose 2
A 102-5758 Hose end 2
3P-2234 Nipple 2
3P-2233 Coupler 2
2P-8278 Sight gauge 1
6V-1739 Tee 1
8T-0854 Pressure indicator 1
B
3P-2234 Nipple 1
3P-2233 Coupler 1

NOTICE

Ensure that all adjustments and repairs that are carried out to the fuel
system are performed by authorised personnel that have the correct
training.

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.

Note: Ensure that the tools are stored with the caps in place. Store the tools in a clean plastic bag.

1. Ensure that the fuel level in the fuel tank is above the level of the suction pipe in the fuel tank.

2. Inspect the fuel system thoroughly for leaks. If necessary, repair the fuel system.

3. Check all low pressure fuel lines from the fuel tank for restrictions. Replace any damaged components.

4. Install new fuel filters. Refer to Operation and Maintenance Manual for the correct procedures.

5. Run the engine. Check if the problem has been resolved. Stop the engine. Refer to Operation and
Maintenance Manual for the correct procedure.

Illustration 1 g01323442
Typical example

6. Remove the connection (1) from the top of the secondary fuel filter base. Insert the end of the connection into
a suitable container.

7. Fit a suitable tube to the top of the secondary fuel filter base. Insert the other end of the tube into a suitable
container.
 8. Prime the fuel system. Refer to Operation and Maintenance Manual, "Fuel System - Prime" for the correct
procedure. Check that fuel is flowing from the secondary fuel filter base. If there is no flow of fuel, check the
operation of the fuel priming pump. If there is still no flow of fuel, replace the secondary fuel filter base.
Refer to Disassembly and Assembly, "Fuel Filter Base - Remove and Install - Secondary Fuel Filter" for the
correct procedure.

9. Stop the engine. Refer to Operation and Maintenance Manual for the correct procedure. Remove the suitable
tube at the top of the secondary fuel filter base. Install the connection (1) to the top of the secondary fuel filter
base.

10. Remove the low pressure fuel line from the inlet connection (2) of the secondary fuel filter base.

Illustration 2 g01323443
Typical example

11. Connect Tooling (A) and (B) to the low pressure fuel line. Insert the open end of the tube into a suitable
container.

12. Prime the fuel system to flush fuel through Tooling (A) and (B). This will minimize the risk of contaminating
the system by introducing dirt from the service tool. Refer to Operation and Maintenance Manual, "Fuel
System - Prime" for the correct procedure.

13. Connect the open end of the tube to the inlet connection (2) of the secondary fuel filter base. Prime the fuel
system. Refer to Operation and Maintenance Manual, "Fuel System - Prime" for the correct procedure.

14. Ensure that Tooling (A) and Tooling (B) are secured and clear of rotating parts.

15. Start the engine. Refer to Operation and Maintenance Manual for the correct procedure. Refer to steps 15.a to
15.c for the procedure for testing the fuel pressure. Refer to steps 15.d to 15.h for the procedure for testing the
air in fuel.

Note: The pressure at the fuel transfer pump should not be measured when the engine is cranked. The
pressure will be low and inconsistent. The engine should still start even if transfer pressure is zero. The
fuel injection pump will deliver residual fuel in the fuel injection pump and the secondary fuel filter.

a. Run the engine at a speed of 1000 rpm. The fuel pressure should be 300 to 550 kPa (44 to 80 psi).
 b. If the fuel pressure is more than 600 kPa (87 psi), there is a problem with the pressure regulator for the
fuel transfer pump. Replace the fuel transfer pump. Refer to Disassembly and Assembly, "Fuel
Transfer Pump - Remove" for the correct procedure.

c. If the pressure is less than 300 kPa (44 psi), check for restrictions in the low pressure fuel lines between
the fuel transfer pump and the secondary fuel filter base. Check for excessive air in the fuel. If no faults
are found, replace the fuel transfer pump. Refer to Disassembly and Assembly, "Fuel Transfer Pump -
Remove" for the correct procedure.

d. Run the engine at high idle.

e. Run the engine for two minutes. There should be no air in the fuel flow through the sight tube. Small
bubbles that are spaced more than 2.5 cm (1.0 inch) are acceptable. Do not manipulate the connections
during the test for the air in fuel.

f. The presence of large bubbles or a continuous stream of bubbles indicates a leak before the transfer
pump.

g. Investigate potential leaks and rectify any potential leaks in the low pressure fuel system between the
fuel tank and the inlet at the fuel transfer pump.

h. Inspect the primary filter base for damaged connections. Inspect the main fuel inlet connection from
the fuel tank. Ensure that all the connections are correctly installed. If necessary, replace the
connections.

16. Remove Tooling (A) and (B). Reconnect the low pressure lines.

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