Large Soil Compactors Fuel System{1250, 1251, 1274} Caterpillar

Paving Compactor:

CP-563E (S/N: BWE1-UP; CNT1-UP)

CP-573E (S/N: ASY1-UP; ASZ1-UP)

CP-663E (S/N: ASF1-UP; DAF1-UP)

CS-563E (S/N: ASA1-UP; CNG1-UP)

CS-573E (S/N: CEB1-UP; CNN1-UP)

CS-583E (S/N: DAJ1-UP; CNX1-UP)

CS-663E (S/N: ASB1-UP; DAG1-UP)

CS-683E (S/N: DAD1-UP; ASG1-UP)

Introduction

The problem that is identified below does not have a known permanent solution. Until a permanent solution is known, use the solution that is identified below.

Problem

The engine runs rough at high idle or under load.

Solution

Check for restriction of fuel flow between the outlet for the fuel tank and the water separator.

Illustration 1	g01253368

This engine had signs of fuel restriction. Note the discoloration of the exhaust manifold for cylinders one, two, five, and six. Cylinders three and four are cooler due to lack of fuel. The temperature difference is a result of fuel restriction. The temperature between the cylinders varies depending on the amount of fuel restriction and engine load. The temperature difference between the cylinders will be approximately 100 °C (212 °F) to 350 °C (662 °F).

Connect a Electronic Technician to the engine. Collect data logs regarding the fuel delivery and engine speed.

Note that there is little variance in engine speed when the fuel delivery is correct. The engine speed is erratic when the fuel delivery is restricted.

Note that the fuel flow is even when the delivery of the fuel is correct. The flow of the fuel will be erratic when the delivery of the fuel is restricted. The Electronic Technician will show a significantly higher fuel flow rate with the restricted fuel inlet. The actual fuel delivery is lower because the pistons in the fuel injection pump are not allowed to become completely filled due to the fuel restriction.

Illustration 2	g01253395
Proper Function

Illustration 3	g01253405
Malfunction of Fuel Delivery

Illustration 4	g01253411
Proper Function

Illustration 5	g01253440
Malfunction of Fuel Delivery

Troubleshooting Hints

Replace the water separator and the fuel filter in order to ensure that the water separator and the fuel filter are not restricting fuel flow.

Bypass the fuel cooler by removing the hose from the fuel tank to the fuel cooler and attaching the hose directly to the water separator. If the engine returns to normal operation, the fuel cooler must be cleaned or replaced.

Illustration 6	g01253520

Remove the tube assembly for fuel from the fuel tank. Check the condition of the following components for possible blockage: the fuel pickup tube, the fuel hose from the pickup to the fuel cooler and the hose from the fuel cooler to the water separator. An example of debris at the intake of the fuel hose is shown in Illustration 6.

Check the fuel delivery from the fuel lift pump by testing fuel pressure. Refer to Service Manual, RENR2416, "3056E Engine for Caterpillar Built Machines CPT" and Service Manual, RENR2417, "3054E and 3056E Industrial Engines and Engine for Cat Built Machines 304, 356, CPT, CRX" for the correct procedure.

Check for air leaks. Refer to Technical Information Bulletin, TIBU4593.