815279 5 Mercury VOLTAGE REGULATOR

Introduction
Unacceptable quantities of CR200 injectors and CR200 high pressure fuel injection pumps from C4.4 and C6.6 engines are being returned as failures. The factory failure analysis result is "Failure not Repeated" or "No Fault Found".This Special Instruction gives the dealer improved diagnostic test documentation to define excessive injector control valve leakage failures and confirm high-pressure pump fuel flow capability.This special instruction is to be used as supplement to Troubleshooting Guide, "Engine Cranks but Does Not Start" for the proper engine application. For further diagnostic support, contact your DSN Technical Communicator (TC) when directed by the procedures. The graphic pictured is for reference only. For the most accurate information consult SIS Web with the serial number of the engine or machine in question.Safety Section
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, Testing and Adjusting, "Cleanliness of Fuel System Components" for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.
Required Parts
Table 1
Quantity     Part Number     Part Name     Description    
1     362-9754     Test Kit     New leak down test kit    Low-Pressure Fuel System Requirements
Increasing fuel supply pressure and effectively removing water and abrasive particles has demonstrated injector durability increases from 200% to as high as 1,000% in severe applications. More aggressive filtration and monitoring are required to maximize injector life and meet rapidly increasing reliability and durability expectations. Conversely, reliability and durability goals cannot be achieved without the following improved filtration and monitoring features.Fuel Tank Drain
Fuel tank drains are used to drain water and sediment from the fuel tank daily. The drain must be located on the lowest part of the fuel tank where the containments collect.Note: Daily draining of water and sediment from the fuel tank has been a standard maintenance requirement for decades.Advanced Tank Breather Filter
Preventing short fuel system life by keeping dust from entering the fuel tank.Water Separators
Water separators are required to remove large quantities of latent water from the fuel.Primary Fuel Filters
Primary fuel filters are required to remove large abrasives from the fuel supply and prevent premature clogging of the 4-micron secondary filters from excessive debris.Secondary Fuel Filters
Series filtration more than doubles wear life over single filtration.Electronic Unit Injectors (EUI)
An adequate fuel supply pressure is essential to prevent cavitation of internal injector components due to incomplete fuel fill.Major Factors Which Negatively Affect Fuel System Wear
Abrasive Contaminants
Increased injection pressure acting on the same level of abrasive contaminants in the fuel results in accelerated injector abrasive wear. This abrasive wear cannot be eliminated by using improved materials or processes. Abrasive wear only can be reduced by removing abrasives from the fuel. Solution
Single or series High Efficiency fuel filters and/or bulk fuel filter/water coalescer.Water in Fuel
An excessive amount of latent water in the fuel is a key cause of injector failure. Water has inadequate film strength to prevent metal-to-metal contact between the plunger and barrel, resulting in plunger scuffing or seizure. Water can be effectively by the use and regular maintenance of a water separator or bulk fuel filter/water coalescer. Removal of excess latent water is essential to prevent scuffing with the upcoming injection pressure increases and subsequent hydraulic loading of internal injector parts.Solution
Proper maintenance of fuel tank drains, water separators and/or use of a bulk fuel filter/water coalescer.Excessive Fuel Temperature
Increasing fuel temperatures reduces fuel viscosity and resultant fuel film strength. Reduced film strength increases the probability of injector plunger and barrel scuffing or seizure. Limiting the maximum fuel temperature will become even more critical with the increase of use if low sulfur fuel which has a lower film strength and common rail fuel systems which run elevated fuel temperatures. Fuel temperatures also play in diesel and biodiesel fuel degradation.Solution
Properly maintain fuel filters and fuel coolers where needed. Ensure proper consideration for materials used in fuel coolers as zinc, copper, lead, and tin can have adverse effects on fuel degradation.Customer Maintenance Practices
Fuel system performance, sophistication, and complexity continue to increase at a rapid pace. It is more important than ever for the user to maintain fuel filters in order to prevent filter restriction and the problems caused by low fuel pressure. It is also important to use quality Advanced Efficiency filters in order to trap and hold microscopic abrasive debris, which causes accelerated wear in modern fuel systems.