A1 - DDCSN
Contents
1. I L Option 1 Remove the fuel line from the outlet side of the fuel pump and connect the fuel system testers line in this fuel hose fitting This hook up location will require the fuel system shut off valve to remain in the open position during testing About 3 8 liters 1 gallon of test fuel will be necessary to charge the engine s fuel system from this hook up location Test fuel will not harm the engine s fuel filters and may remain in the fuel system at the conclusion of testing CL Option 2 Remove the fuel line from the outlet side of the fuel by pass filter adapter and connect the fuel testers line in this fuel hose fitting It is recommended that the fuel system shut off valve be placed in the closed position before removing the engine fuel line and remain closed until reinstalled About 1 9 liter 0 5 gallon of test fuel will be necessary to charge the engine s fuel system from this hook up location 3 Remove rocker cover and disconnect the fuel outlet line at a convenient location between the cylinder head and the fuel tank Install an appropriate size pipe plug loose in the fuel outlet line end and place it in a container to catch the fuel while priming the cylinder head If equipped Jake Brakes should be removed to allow for the visual examination of the injectors during fuel leak testing and if necessary on engine injector Pop test 4 Slowly open the fuel tester s shut off valve and charge the cylinder head fuel galley When2. test fuel is flowing from the fuel return line and air has been purged from the system tighten the pipe plug at the engine fuel outlet line fitting 5 With the fuel tester shut off valve completely open and the cylinder head galley pressurized to 345 kPa 50 psi visually monitor the overhead using a black light for five minutes if the test time goes beyond five minutes it will become more difficult to determine the faulty injector due to expected leakage at the injector plunger body Pay special attention to any leaks at the injector body high and low pressure body plugs All information subject to change without notice 6SE483 0303 Copyright 2003 DETROIT DIESEL CORPORATION From Bulletin 6 60 03 13 78c 13 14A DETECTING INTERNAL FUEL LEAKS see Figure 13 22b and see Figure 13 22d injector nut to body and nut to tube seals see Figure 13 22c and stop valve cover see Figure 13 22e NOTICE Injector plunger body leakage at the follower spring area is normal and expected during this test NOTICE The figures that follow do not illustrate amount of fuel leakage but rather its origin or location If injector s are removed and reinstalled in the head the injector nut O ring seals should be replaced with new parts NOTICE If pressurization testing does not reveal the leaking injector proceed to section Injector Pop test On Engine with J 37050 A 1 Fuel Leakage at Low Pressure Body Plug f Figure 13 22b
3. SERIES 60 SERVICE MANUAL 13 14A DETECTING INTERNAL FUEL LEAKS Used lube oil analysis can identify a potential source of engine trouble before it occurs program such as the Detroit Diesel Oil Analysis Program is recommended for roa crankcase oil in all engines One of the most serious conditions used oil analysis can uncover is the presence of excessive fuel in the lube oil which should not exceed 2 5 maximum of oil volume reference Detroit Diesel s Publication 7SE270 Engine Requirements for Lubricating Oil Fuel and Filters While used oil analysis can uncover the presence of excessive fuel in the lube oil other methods must be used to determine its source Three particularly effective tests involve the use of special test fuel containing dye additives the J 37050 A on engine Injector Pop tester and the J 34760 A Injector Pop N Fixture with the J 34760 147A adaptor 13 14a 1 Prepare Test Fuel The use of J 28431 B Fluorescent dye is effective in fuel leak detection and should be the technician s choice in preparing a test fuel mixture However if a Black light or fluorescent dye are not available red LTO 1140 may be substituted Prepare Fluorescent Dye J 28431 B as follows L Mix 118 ml four ounces of fluorescent dye additive with 15 1 liters four gallons of diesel fuel in a clean container marked with the words Test Fuel Prepare Red LTO 1140 as follows L Mix 59 ml two ounces of Red LTO 1140 dye addit
4. Unacceptable Fuel Leakage at Low Pressure Body Plug All information subject to change without notice 13 78d From Bulletin 6 60 03 6SE483 0303 Copyright 2003 DETROIT DIESEL CORPORATION SERIES 60 SERVICE MANUAL 1 Fuel Leakage at Injector Nut to Tube O Ring Seal Figure 13 22c Unacceptable Fuel Leakage at Injector Nut toTube O Ring Seal WG U 1 Fuel Leakage at High Pressure Body Plug and or Body Crack Figure 13 22d Unacceptable Fuel Leakage at High Pressure Body Plug and or Body Crack All information subject to change without notice 6SE483 0303 Copyright 2003 DETROIT DIESEL CORPORATION From Bulletin 6 60 03 13 78e 13 14A DETECTING INTERNAL FUEL LEAKS as wee _ NA AA I 1 Fuel Leakage at Injector Stop Valve Cover Figure 13 22e Unacceptable Fuel Leakage at Injector Stop Valve Cover 6 Correct the cause of any abnormal fuel leaks 7 Bleed the pressure from the accumulator tank and remove the pipe plug from the fuel outlet line Reinstall the fuel outlet line in the engine s fuel system Disconnect the fuel tester and reinstall the fuel inlet line in the engine s fuel system 8 Completely open the engine s fuel shut off valve and assure that all fuel connections are tight Reinstall the rocker cover and start engine to purge the air from the fuel system If the engine fails to start it may be necessary to prime the fuel system Perform this test if injector lea
5. e of the LED amps readout window indicates the injector solenoid is OPEN C indicates CLOSED The pistol grip trigger must be released and depressed for each time the injector solenoid is activated To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 8 Using the vehicle starter motor the engine while energizing the injector solenoid It should only be necessary to cycle the solenoid once or twice to pressurize the injector Energize only one injector at a time NOTICE While activating the injector solenoid cylinder detonation may occur when motoring the engine This occurrence will not harm the engine It should be noted again that if the 5 way injector connectors are not disconnected at the ECM the engine may start 9 With the vehicle start switch in the OFF position or remote starter cable disabled visually examine each suspect injector for abnormal fuel leakage using a black light or look for evidence of red dye if LTO test fuel is used 10 Repeat the above procedure for each injector being tested 11 Correct the cause of any abnormal fuel leakage 12 Refer to Fuel Leak Tester instruction items 7 and 8 All information subject to change without notice 6SE483 0303 Copyright 2003 DETROIT DIESEL CORPORATION From Bulletin 6 60 03 13 78g 13 14A DETECTING INTERNAL FUEL LEAKS 13 14a 5 Injector Be
6. ive with 18 9 liters five gallons of diesel fuel in a clean container marked with the words Test Fuel 13 14a 2 Fuel Leak Tests Injectors Installed Engine Off To locate a leaking injector the tests below should be completed in the sequence indicated and stopped at a point when the leaking injector is diagnosed If a leaking injector is found do not arbitrarily replace more than that injector as multiple injector malfunctions are rare on the same engine Multiple injector returns under WARRANTY will require verification by the servicing outlet using the J 34760 A Pop N Fixture All information subject to change without notice 6SE483 0303 Copyright 2003 DETROIT DIESEL CORPORATION From Bulletin 6 60 03 13 78a 13 14A DETECTING INTERNAL FUEL LEAKS NOTICE During fuel pressure testing engine off 5 minutes at 50 psi fuel leakage will be evident at the injector body plunger spring seat area see Figure 13 22a Factory tests have shown that accumulation of fuel at each injector approximately a tablespoon may be evident during these tests Evidence of fuel in this area is expected as there is no other place for it to go when the injector cavities are pressurized forcing fuel between the injector body and plunger 1 Acceptable Fuel Leakage Figure 13 22a Acceptable Fuel Leakage Between injector Plunger and Body 13 14a 3 Fuel Pressure Test Since there is no known fuel leak tester available in the commercial market
7. kage cannot be identified after pressure testing the cylinder head Energizing and stoking the suspect injector s will produce the internal fuel pressures created during engine operation thus increasing any abnormal fuel leakage Refer to manufacture s instructions supplied with the J 37050 A tester for set up procedure Perform the following steps for the Injector Pop Test 1 Wipe down the overhead to remove any test fuel generated from previous testing 2 Disconnect both 5 way injector harness connectors at the ECM 3 Connect alligator clips from the tester cable to the EUI It is not necessary to disconnect the solenoid terminal leads from the EUI engine wiring harness if the 5 way injector harness connectors have been removed from the ECM a 13 14a 4 Injector Pop Test On Engine With J 37050 A i i i All information subject to change without notice 13 78f From Bulletin 6 60 03 6SE483 0303 Copyright 2003 DETROIT DIESEL CORPORATION SERIES 60 SERVICE MANUAL 4 Connect power supply clips to the vehicles 12 volt battery Red to Positive and Black to Negative 5 Option 1 Connect remote starter cable to the vehicle starter motor 7 Depress and hold trigger on tester s pistol grip start button while rotating current control 6 Option 2 Operate vehicle starter switch from drivers seat in the cab i knob clockwise to increase current to the injector solenoid j NOTICE The Letter O at the left sid
8. nch Test with J 34760 A Pop N Fixture If multiple injectors are removed for fuel leakage each should be bench tested using the J 34760 A Pop N Fixture Fuel leakage may be more easily observed while performing this bench test Refer to manufacture s instructions supplied with the J 34760 A Pop N Fixture for set up and test procedures Wash wipe down and allow injector to dry before mounting in test fixture Fuel leakage will be more recognizable by adding fluorescent dye to the fixture s fuel reservoir and using a black light to examine the injector during testing All information subject to change without notice 13 78h From Bulletin 6 60 03 6SE483 0303 Copyright 2003 DETROIT DIESEL CORPORATION
9. today one must be fabricated Use the following guidelines to help in fabricating CL Although test fuel can be pressurized by variety of methods Detroit Diesel recommends an air fuel accumulator design capable of safely withstanding a minimum pressure of 345 kPA 50 psi C The tester should have a capacity of 9 5 liters 2 5 gallons of test fuel and provide for contamination free storage of the test fuel when not in use Regulated shop air may be used to charge the accumulator tank and maintain a constant test fuel pressure A shut off valve should be installed at the accumulator outlet to start and stop pressurization during the test sequence All information subject to change without notice 13 78b From Bulletin 6 60 03 6SE483 0303 Copyright 2003 DETROIT DIESEL CORPORATION SERIES 60 SERVICE MANUAL A CAUTION To avoid injury from the sudden release of a high pressure hose connection wear a face shield or goggles To avoid injury from tank rupture or a sudden air hose failure do not use unregulated air pressure or an accumulator tank with an inadequate pressure rating Fuel Leak Tester 1 Fill fuel system tester with the fluorescent or red dye fuel mixture approximately 9 5 liters 2 5 gallons 2 Charge tester outlet valve closed with shop air regulated at 345 kPA 50 psi Tester hook up to engine fuel system There are two options for fuel tester to engine hook up as determined by the ease of access I I I
Download Pdf Manuals
Related Search