HEAT EXCHANGER GP-SEA WATER 4674045 - Caterpillar

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.
Illustration 1 g03705140
Table 3
Troubleshooting Test Steps Values Results
6. Fuel Rail Pressure Relief Valve (PRV)
A. Turn the keyswitch to the OFF position.
B. Disconnect plastic tube assembly (4) from fuel manifold (1). Refer to Disassembly and Assembly, "Fuel Manifold (Rail) - Remove and Install".
C. Securely seal the end of plastic tube assembly (4).
Note: Plastic tube assembly (4) must be sealed to prevent air ingress into the fuel system.
D. Attach a length of hose to fuel manifold (1) and secure with a clip at position (3).
E. Place the other end of the hose into a container that is suitable for fuel. Ensure that the hose is secure and will not come out of the container when the engine is running.
F. Turn the keyswitch to the ON position.
G. If the engine will start, use the electronic service tool to perform the "High Rail Pressure Test". This service test will run the engine with an elevated fuel rail pressure for a limited time. At this pressure, a PRV that is functioning correctly will remain closed. If the engine will not start, crank the engine for a maximum of 30 seconds.
H. After the engine has stopped, check the container for fuel.
Fuel in container
Result: Fuel is present in the container.
Repair: Install a replacement fuel Pressure Relief Valve (PRV). Refer to Disassembly and Assembly, "Fuel Manifold (Rail) - Remove and Install".
When the PRV has been replaced, use the electronic service tool to perform the "Rail Pressure Valve Learn Reset".
When reset is complete, turn the keyswitch to the OFF position and wait for 2 minutes or until the "Wait to Disconnect" indicator switches off (if installed). Turn the keyswitch to the ON position.
Result: No fuel is present in the container.
Proceed to Test Step 7.
7. Cylinder Cutout Test
A. Use the electronic service tool to perform the "Cylinder Cutout Test".
Click "Change" for an individual cylinder to switch off that cylinder manually. The cylinder will be automatically re-energized 10 seconds after the cylinder has been switched off. Wait a further 10 seconds before disabling the next cylinder.
B. Listen for a change in the sound of the engine as each cylinder is disabled. If a cylinder is operating correctly, there will be a change in the sound of the engine as that cylinder is disabled. If a cylinder is disabled and there is no change in the sound of the engine, there may be a fault in that cylinder.
Make a note of any cylinder that indicates a fault.
Cylinder cutout test
Result: At least one of the cylinders indicate a fault.
Repair: Replace the fuel injector for any suspect cylinder. refer to Disassembly and Assembly, Electronic Unit Injector - Remove and Disassembly and Assembly, Electronic Unit Injector - Install.
Result: None of the cylinders indicate a fault.
Proceed to Test Step 8.
8. Low Battery Voltage
A. Check that the charging circuit is operating