KIT-ENGINE OVERHAUL 4505260 - Caterpillar

Recommended Actions
Note: The procedures have been listed in order of probability. Complete the procedures in order.
Table 1
Troubleshooting Test Steps Values Results
1. Diagnostic Codes
Note: Certain diagnostic codes and/or event codes indicate the cause of high fuel consumption.
A. Use the electronic service tool to check for active or logged codes.
Diagnostic codes
Result: A diagnostic code is present.
Repair: Troubleshoot the diagnostic code and then verify that the fuel consumption is normal. Refer to Troubleshooting, "Diagnostic Trouble Codes".
Result: A diagnostic code is not present.
Proceed to Test Step 2.
2. Misreading of Fuel Level
Note: Misreading of the fuel gauge can give a false indication of fuel consumption.
A. Monitor the fuel consumption over a period of 50 engine hours.
Fuel level
Result: Fuel consumption is normal for the operating conditions.
Return the unit to service.
Result: Fuel consumption is high for the operating conditions.
Proceed to Test Step 3.
3. Fuel Leakage
A. Check the engine for signs of fuel leakage.
Fuel leaks
Result: Evidence of a fuel leak is found.
Repair: Repair or replace the component that is leaking fuel.
Result: No evidence of a fuel leak is found.
Proceed to Test Step 4.
4. Fuel Quality
Note: The grade of the fuel affects the rate of fuel consumption. Refer to the engines Operation and Maintenance Manual for additional information.
Cold weather adversely affects the characteristics of the fuel. Refer to the Operation and Maintenance Manual for information on improving the characteristics of the fuel during cold-weather operation.
A. Check the fuel quality. Refer to Systems Operation, Testing, and Adjusting, "Fuel Quality - Test".
B. Refer to Operation and Maintenance Manual for information on the proper characteristics of the fuel for the engine.
Fuel quality
Result: The fuel quality does not meet specifications.
Repair: Drain the fuel system and replace the fuel filters. Refer to the Operation and Maintenance Manual, "Fuel System Primary Filter (Water Separator) Element - Replace" and Operation and Maintenance Manual, "Fuel System Filter - Replace".
Fill the fuel system with fuel that meets the standard in the Operation and Maintenance Manual, "Fluid Recommendations".
Prime the fuel system. Refer to the Operation and Maintenance Manual, "Fuel System - Prime".
Result: The fuel quality meets specifications.
Proceed to Test Step 5.
5. Quality of Oil
Note: The nominal viscosity of the lubricating oil that is used in the engine will affect the rate of fuel consumption. The viscosity of lubricating oil is defined by the SAE grade of the lubricating oil. The grade of the lubricating oil must be correct for the ambient conditions. Lubricating oil for high ambient temperatures will affect fuel consumption in cold ambient temperatures.
A. Check that the engine oil meets the required specification. Refer to "Engine Oil" in the Operation and Maintenance Manual, "Refill Capacities".
Engine oil quality
Result: The engine oil does not meet the required specification.
Repair: Refill the oil system with oil of an acceptable quality. Refer to the applicable sections in the Operation and Maintenance Manual.
Result: The engine oil meets the required specification.
Proceed to Test Step 6.
6. Engine Accessories and Transmission
A. Check that the engine accessories and transmission are operating correctly.
B. Remove and inspect any engine accessories that may be adding unexpected load to