Rating:
Information spring, timer, out Denso
Include in ##:
Number on scheme 048
19600-04930
as SPRING, TIMER, OUT
Cross reference number
Part num
Firm num
Firm
Name
09620-82860
SPRING, TIMER, OUT
Information:
Introduction
Do not perform any procedure in this Special Instruction until you read this information and you understand this information.This procedure is used when there is a failure of a fuel injector for a 3500 engine and the fuel injector is being returned to Caterpillar for failure analysis. The information for the injector from the field is incomplete many times, or the information for the injector from the field is not provided. Because of the lack of information, determining the root cause for the failure is much more difficult. "No Fault Found" is determined for the injector. This is frustrating for the customer, for the dealer and for Caterpillar. Following the procedures below and accurately documenting the results will provide the failure analysis group with the information that is needed to determine the root cause for the failure of an injector. This should reduce the amount of injectors that are determined "No Fault Found". A copy of the completed worksheet needs to be included in a separate sealed plastic bag with injectors that are being returned for failure analysis.This worksheet is used in conjunction with the troubleshooting steps that are outlined in the literature for the Caterpillar product that is being serviced. Using the Worksheet
Fill out the initial informationThere are five symptoms. Table 3 provides suggestions for the cause and suggestions in order to fix the problem.For example, a customer indicates that an engine is smoking. Refer to Troubleshooting, "Troubleshooting without a Diagnostic Code". After you refer to the Troubleshooting manual, and you still suspect that the fuel injectors are causing the smoke, follow the suggestions that are listed in Table 3.Initial Information
Table 1
Dealer Name Date
Dealer Contact Name RMA Number
Contact Phone Number Engine Serial Number Symptoms
Table 2
Low Power High Power Fuel Dilution Engine Misfire Smoke Worksheet
Table 3
Symptom Check Reference Information Results
Low power
High power
Engine misfire
Smoke Connect the Caterpillar Electronic Technician (ET)
Refer to Troubleshooting
Ensure to perform engine speed/timing sensor calibration Use the Cat ET help button with the software, if necessary.
Refer to related information about Cat ET within Troubleshooting Any problems found?
Yes / No
Explain if Yes
Low power
High power
Engine misfire
Smoke Additional Cat ET diagnostic tips can be found in the Service Training Tips Newsletter Refer to "Service Training Tech Tips Newsletter, No. 27" (1) Any problems found?
Yes / No
Explain if Yes
Engine misfire Does the ECM function properly?
(Solenoids are actuated during the injector solenoid test) Refer to engine Troubleshooting, "Injector Solenoid Test" Did each injector solenoid audibly "click?"
Yes / No
Low power
Engine misfire Check for a sufficient fuel supply, sufficient fuel transfer pump pressure.
Check manifold (if multiple engines use the same fuel tank) Use a 1U-5450 Monitor Arrangement to check for adequate fuel flow. Fuel transfer
pump pressure
Flow
Low power Inspect the fuel system
Fuel line: leaks, damaged line, galled pressure regulator
Do not perform any procedure in this Special Instruction until you read this information and you understand this information.This procedure is used when there is a failure of a fuel injector for a 3500 engine and the fuel injector is being returned to Caterpillar for failure analysis. The information for the injector from the field is incomplete many times, or the information for the injector from the field is not provided. Because of the lack of information, determining the root cause for the failure is much more difficult. "No Fault Found" is determined for the injector. This is frustrating for the customer, for the dealer and for Caterpillar. Following the procedures below and accurately documenting the results will provide the failure analysis group with the information that is needed to determine the root cause for the failure of an injector. This should reduce the amount of injectors that are determined "No Fault Found". A copy of the completed worksheet needs to be included in a separate sealed plastic bag with injectors that are being returned for failure analysis.This worksheet is used in conjunction with the troubleshooting steps that are outlined in the literature for the Caterpillar product that is being serviced. Using the Worksheet
Fill out the initial informationThere are five symptoms. Table 3 provides suggestions for the cause and suggestions in order to fix the problem.For example, a customer indicates that an engine is smoking. Refer to Troubleshooting, "Troubleshooting without a Diagnostic Code". After you refer to the Troubleshooting manual, and you still suspect that the fuel injectors are causing the smoke, follow the suggestions that are listed in Table 3.Initial Information
Table 1
Dealer Name Date
Dealer Contact Name RMA Number
Contact Phone Number Engine Serial Number Symptoms
Table 2
Low Power High Power Fuel Dilution Engine Misfire Smoke Worksheet
Table 3
Symptom Check Reference Information Results
Low power
High power
Engine misfire
Smoke Connect the Caterpillar Electronic Technician (ET)
Refer to Troubleshooting
Ensure to perform engine speed/timing sensor calibration Use the Cat ET help button with the software, if necessary.
Refer to related information about Cat ET within Troubleshooting Any problems found?
Yes / No
Explain if Yes
Low power
High power
Engine misfire
Smoke Additional Cat ET diagnostic tips can be found in the Service Training Tips Newsletter Refer to "Service Training Tech Tips Newsletter, No. 27" (1) Any problems found?
Yes / No
Explain if Yes
Engine misfire Does the ECM function properly?
(Solenoids are actuated during the injector solenoid test) Refer to engine Troubleshooting, "Injector Solenoid Test" Did each injector solenoid audibly "click?"
Yes / No
Low power
Engine misfire Check for a sufficient fuel supply, sufficient fuel transfer pump pressure.
Check manifold (if multiple engines use the same fuel tank) Use a 1U-5450 Monitor Arrangement to check for adequate fuel flow. Fuel transfer
pump pressure
Flow
Low power Inspect the fuel system
Fuel line: leaks, damaged line, galled pressure regulator