0395367 JOHNSON CYLINDER & CRANKCASE ASSY.

Illustration 1 g02795516
Location of the low-pressure fuel temperature sensor (view of the fuel manifold that is mounted to the high-pressure fuel pump)
Use this procedure in order to troubleshoot high fuel temperature. Also, use this procedure if one of the following event codes is active. Refer to Troubleshooting, "Event Codes" for information about event codes. Access the engine monitoring system on Caterpillar Electronic Technician (ET) in order to view the current trip points for these codes. For information on the engine monitoring system, refer to Troubleshooting, "Engine Monitoring System".
Table 1
Event Code
CDL Code and Description Conditions which Generate this Code System Response
E363(1) High Fuel Supply Temperature The fuel temperature of the low-pressure fuel system is above the trip point for the programmed delay time. The code is logged.
E363(2) High Fuel Supply Temperature The code is logged.
Engine power will be derated. Probable Causes
Diagnostic codes and event codes
Fuel pressure regulating valve for the high-pressure fuel pump
Injector bypass fuel flow
Fuel temperature sensorRecommended Actions
Diagnostic Codes and Event Codes
Connect Cat (ET) to the service tool connector. Check for active diagnostic codes.Look for active and logged diagnostic codes that are related to the low-pressure fuel system. Use the appropriate circuit test to troubleshoot any active diagnostic codes before continuing.Pressure Relief Valve for the High-Pressure Fuel Pump
Illustration 2 g02795794
Location of the plugs in the high-pressure fuel pump and pump adapter (typical example)
(1) Valve block
(2) Head for the high-pressure fuel pump
(3) Location of the block assembly that contains the in-line high-pressure fuel filter element Perform the following procedure to check the pressure relief valve for leakage:Engine at normal operating temperature, high engine idle, engine load at least 1.5 MW (2012 hp). Use the 192-3755 Temperature Measuring Gp to measure the temperature difference between valve block (1) and pump head (2).If the temperature difference is less than 20° C (68° F), the pressure relief valve is operating properly.If the temperature difference is greater than 20° C (68° F), the pressure relief valve is bypassing too much fuel. Replace the in-line high-pressure fuel filter element that is in block assembly (3).Again, measure the temperature difference between the valve block and the pump head.If the temperature difference is greater than 20° C (68° F), the pressure relief valve is bypassing too much fuel. There is a problem with the high-pressure fuel pump. Replace the high-pressure fuel pump.Injector Bypass Fuel Flow
Excessive injector bypass fuel flow is returned to the tank through the fuel manifold. This return fuel may be the cause of an active E363 event. Perform the following procedure to check for excessive injector bypass flow:
Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death.
Personal injury or death can result from improperly checking for a leak.Always use a board or cardboard when checking for a leak. Escaping air or fluid under pressure, even a pin-hole size leak, can penetrate body tissue causing serious injury, and possible death.If fluid is injected into your skin, it must be treated immediately by a doctor familiar with this type of injury.
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat products.Dispose of all fluids according to local regulations and mandates.
Ensure that all adjustments and repairs that are performed on the fuel system are performed by authorized personnel. Ensure that these personnel have had the correct training.Before beginning 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, "Cleanliness of Fuel System Components" for detailed information that is related to the standards of cleanliness that must be observed during all work on the fuel system.
Note: The fuel pressure in the fuel system must be below 1 MPa (145 psi) before the fuel system can be serviced. Refer to Systems Operation/Testing and Adjusting, "Fuel Rail Pressure - Release".
Illustration 3 g02798176
(4) Fuel return line from the fuel injectors
(5) Fuel manifold
Disconnect the fuel injector fuel return line (4) from fuel manifold (5) at the high-pressure fuel pump. Obtain a piece of plastic tubing that can be attached to the end of the return line. Connect one end of the tubing to the loose return line. Place the other end of the tube into a suitable container that can be used to measure the fuel discharge from the return line.
Start the engine. Allow the engine to stabilize at a steady engine rpm.
Measure the flow rate that drains from the return line for 1 minute.
Stop the engine. Maximum fuel flow rate for a 50 Hz application operating at 1500 rpm ... 1.75 L/min (0.46 US gpm)Maximum fuel flow rate for a 60 Hz application operating at 1800 rpm