C2.6 and C3.3B Engines for Caterpillar Built Machines Caterpillar

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

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Hydraulic circuits must be adequately bled of any residual pressure before proceeding with hydraulic repairs. Make sure adequate personal protective equipment (safety glasses, face shield, gloves) is being worn when initially disconnecting hydraulic fittings. Insure that there is no load resting on the circuit to prevent serious injury or death due to falling loads. Pressurized hydraulic fluid can penetrate the skin, resulting in serious illness or death.

Introduction

This test procedure is to inspect the injector for leakage and observe the injection spray pattern for uneven spray.

Required Tools

Injector Test Kit Contents

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440-6907 Test Kit

Nozzle Tester Group and Fuel Collector

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Nozzle Test Group

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Nozzle Test Group

Use the correct nozzle tester or pop tester that is able to build 34474 kPa (5000 psi) fuel pressure.

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8S-2270 Fuel Collector

Use the fuel collector to contain the spray from the injector. Refer above the mentioned container or use the suitable container.

Test Preparation

Required Injector Adapter to Build

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Injector Adapter Harness C3.3 (1) Injector Adapter Harness C3.3 (2) Injector Adapter Harness C3.8 (3) Injector Male Spade Terminals

There are two options to build injector adapter harness for C3.3.

1. If available, use an injector connector removed from C3.3 harness (1) cut back both the wires 100 mm (3.9 inch) from the connector and attach the bullet terminals that fit in injector adapter harness C3.8 (2) terminal from the injector test kit.

2. If no harness is available, build harness with the two female spade terminals to fit the injector male spade terminal (3), two pieces of 16 gauge wire cut at 100 mm (3.9 inch), two bullet terminals that fit in injector adapter harness C3.8 (2) terminal from the injector test kit.

Illustration 7	g06349872
Injector Adapter Harness C2.4 (4) Injector Adapter Harness C2.4 (2) Injector Adapter Harness C3.8 (6) Injector Male Spade Terminals

There are two options to build injector adaptor harness for C2.4.

1. If available, use an injector connector removed from C2.4 harness (4) cut back both the wires 100 mm (3.9 inch) from the connector and attach the bullet terminals that fit in injector adapter harness C3.8 (2) terminals from the injector test kit.

2. If no harness is available, build harness with the two female spade terminals to fit the Injector male spade terminal (5), two pieces of 16 gauge wire cut at 100 mm (3.9 inch), two bullet terminals that fit in Injector adapter harness C3.8 (2) terminal from the injector test kit.

Injector Test Setup

Illustration 8	g06349024
Mounted Nozzle Test Group (6) High-Pressure Hose Assembly

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Mounted Nozzle Test Group (7) Fuel Line Adapter

1. Find a suitable stable surface to either mount or place the nozzle test group. Fill the fuel container with diesel and follow the steps are given below as,

   • Install the high-pressure hose assembly (6) use the adaptors if needed based on nozzle tester, torque to 34 N·m (25 lb ft).

   • Install the fuel line adapter (7) to allow connection to the Injector to 34 N·m (25 lb ft).
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   440-6907 Test Kit (8) Clear Fuel Shield with screws (9) Injector Holder

2. Take 440-6907 Test Kit and removed parts to assemble the injector assembly (10).
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   (8) Clear Fuel Shield with screws (9) Injector Holder (T1) Alan Wrench

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   (8a) Screw (T1) Alan Wrench

3. Take clear fuel shield with screws (8) and injector holder (9) from the kit assembly and remove the screws (8a) using alan wrench (T1) as shown in Illustration 12.
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   (8) Clear Fuel Shield with screws (8a) Screw (9) Injector Holder (T1) Alan Wrench

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   (8) Clear Fuel Shield with screws (8a) Screw (T1) Alan Wrench

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   (8) Clear Fuel Shield with screws (9) Injector Holder

4. Assemble the clear fuel shield (8) is on the bottom and mount the injector holder (9) on the top with using the screws (8a).
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   Illustration 16	g06349535
   Fuel Collector and Injector Holder (10) Injector Holder Assembly (11) Fuel Collector

5. Place the injector holder assembly (10) onto the fuel collector (11) or other container to contain the injection spray.
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   Illustration 17	g06349537
   (10) Injector Holder Assembly (11) Fuel Collector (12) Injector

6. Install the injector (12) to be tested into the opening at the top of the injector holder (10).
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   (12) Injector (13) Return Fuel Drain Hose

7. Attach the return hose fuel drain hose (13) to the injector (12).
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   (13) Return Fuel Drain Hose (14) Fuel Collector

8. Route the return fuel drain hose (13) to the fuel collector (14).
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   (12) Injector (15) Harness Adapter

9. Make the harness connection using correct harness adapter (15) for C2.4, 3.3, and C3.8.
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   Illustration 21	g06349540
   (16) Injector Adapter Harness (17) Injector Pulse Tool

10. Connect the injector adapter harness (16) and the injector pulse tool (17).
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    Illustration 22	g06349542
    Injector Setup and Harness Connection (15) Harness Adapter (16) Injector Adapter Harness (17) Injector Pulse Tool

11. Connect the injector adapter harness (16) and the injector pulse tool (17) and connect to the harness adapter (15).
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    Illustration 23	g06350621
    Complete Setup Nozzle Tester and Injector Test Kit (7) Fuel Line Adapter (12) Injector

12. Once the injector test kit and the nozzle tester group are arranged, connect the fuel line adapter (7) that is installed onto the high-pressure hose assembly (6) as refer to the Illustration 8 and Illustration 9 connect to the injector (12) that is being tested and leave loose. Start to actuate the lever on the nozzle test group until small amount of the fuel drips from the connection will allow air to purge from the setup. Tighten the fuel line adapter (7) at the injector (12) to 34 N·m (25 lb ft).

Test Procedure

Injector Test Procedure

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Mounted Nozzle Test Group

Note: Follow all warnings from the introduction.

• First inspection for the injector (12) will be the leak or the drip test. Using lever on the nozzle tester group as shown in Illustration 3 and Illustration 4 to build the injection fuel pressure to 34474 kPa (5000 psi). Using the locking valve knobble turn to insure there is no leakage back through tester.

• Let set for a few minutes and observe the tip of the injector (12) that will be visible through the clear plastic shield, look for any leakage from the tip of the injector (12). If leakage or dripping is seen, then the injector (12) has tested bad.

• If the injector (12) is not leaking or dripping, then the injector spray pattern will be tested next. Using 12V supply from the battery, connect the injector pulse tool (17) to the correct terminals using gator clips. The module should light green, aim the strobe lights (on the bottom of injector pulse tool (17)) toward the injector tip orifice inside the fuel shield. Use the red button to trigger the spray. The injector (12) will pulse seven times and the strobe will light up the spray pattern. There should be eight distinct sprays for a full 360 degrees. If injection is not uniform or is only to one side, then the injector (12) has tested bad.