CAT(Perkins) C4.4 Will NOT Start | Injector Replacement

[@contrarianthinker]

I have this same problem and I couldn’t figure it out man you are heaven sent

[@tonybell6985]

Very cool video keep them coming.

[@industrialiron90]

Thanks Tony, will do!

[@CodiganKelly1983]

Good small emgines for the most part

[@clarke6436]

For us non mechanical minded people who want to learn can you give us more detailed explanation of what your doing, different parts your looking at and things to look out for please.

[@industrialiron90]

Will do!

[@michaelflores820]

How many hours were on the engine? looks pretty new to need injectors, was it poor stale moisture rich fuel that caused the failure?

[@ShainAndrews]

I know this is the internet... and everybody questions everything. I didn't see a hint of smoke during cranking. Leading me to believe the injectors were not firing. Leading me to question rail pressure or electrical connectivity. Your bypass volume test would have me questioning the pressure relief valve (or what ever Perkins/Cat) calls it. Short of an injection pump self destructing I never see every injector die. When injectors fail from FOD the oil sump is almost always over full. I'm guessing this is warranty or some sort of service contract? What else was replaced? You do good work man. I just want to know exact failures, not what the book says to replace.

[@industrialiron90]

@ShainAndrews - Thank you for your comment, I'll try and answer all of your questions. To start, I like you, fully thought it was going to be something wrong on the electrical side of the injection system. The problem ended up being one for sure but maybe more injectors free flowing fuel back to the return side. Having dismantled this engine I nor the customer wanted to replace only one injector, with it being torn apart I might as well replace them all. -I don't know why you wouldn't follow failure procedures, even if it was from a book. I followed the troubleshooting off of CAT SIS, so technically electronic. I also had a full fuel system test kit for CAT/Perkins engines. There is and was nothing wrong with the injection pump hence no FOD and a stable or normal oil level. I am not a Perkins guru as I normally work on large bore engines, but allowing almost 400% fuel return over what is recommended would lead me to believe that very little if any fuel at all was actually being injected into the cylinders, hence no smoke. As I am sure you are aware liquid like anything else is going to take the path of least resistance and expecting an injection pump to flow 400% over return and still keep rail pressure is a lot to ask in my book. -Yes, you are correct, every injector did not fail. Myself and the customer decided we were not going to take the time to run singular injector failure tests, only to be back out 3 months later changing another injector. Nothing is/was wrong with the injection pump. I've also never seen a failed or grenaded injector pump magically start working again either. When they fail and send the stripper dust they don't start working again afterword. -There was nothing else replaced, not even the sensor or valve that I pointed out at the beginning of the video. To sum this up, like I stated earlier, I did not believe that these injectors would be the issue. Some of my coworkers who work on these more than I do assured me it would either be injection pump or injectors, and if it had been injection pump I'd be replacing lines and injectors as well. I in bad faith decided to follow what they said, in hopes of proving them wrong, and tested the pump and injectors. There is an overall surface level test for both the injection pump and all of the injectors at the same time, the injection pump tested fine, the overall injector test failed. There is another test to pinpoint the EXACT problem injector/s, I did not do that and replaced all the injectors. After replacement of the injectors I immediately attempted to start the engine and it responded. There were no other parts changed or replaced on this engine. -This piece of equipment is under a service contract, no it is not under warranty. I worked on this engine in June or July of last year, making this job 6 months old at this point. This engine runs a minimum of 1 hour per week to exercise, which means this engine has at least 20-24 hours of run time after this repair was completed and that doesn't include actual power outages. -I do apologize for not documenting the process in its entirety, to include the diagnostic, this is something I will work on for future projects. At the end of the day my number one concern is getting customers equipment back operational and I tend to forget about filming.

[@contrarianthinker]

What happened if you see smoke 💨

[@jaywyatt7476]

Hey dude, do you have to do trim files on those injectors.

[@dmensah25]

Can sent me the torque specs