C-16 Truck Engine W1A00001-UP(SEBP3679 - 56) - Documentación Page 1 of 10

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Bienvenido: p230mag1

Producto: TRUCK ENGINE

Modelo: C16 TRUCK ENGINE W1A
Configuración: C-16 Truck Engine W1A00001-UP

Instrucción Especial
Determining the Cause of Fuel Dilution of Engine Oil {1101, 1124, 1251, 1280, 1290}
Número de medio -REHS3007-14 Fecha de publicación -08/12/2014 Fecha de actualización -09/04/2020

i08063367

Determining the Cause of Fuel Dilution of Engine Oil {1101, 1124,

1251, 1280, 1290}
SMCS - 1101; 1124; 1251; 1280; 1290

Caterpillar Products
All

Introduction
Table 1
Revision History
Revision Summary of Changes
14 Changes throughout the document.

This special instruction includes the recommended methods for verifying and measuring fuel dilution, and
troubleshooting for sources of fuel dilution of the engine oil.

Before you perform any procedure in this Special Instruction, read the information and understand the
information that is contained in this instruction.

Safety
Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially
hazardous situations before an accident occurs.

A person must be alert to potential hazards. This person should also have the necessary training, skills, and
tools to perform these functions properly.

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Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings
are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate
every possible circumstance that might involve a potential hazard.

Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive.
Ensure that any tool, procedure, work method, or operating technique you use that is not recommended by
Caterpillar is safe.

Ensure that the product will not be damaged or the product will not be made unsafe by the operation,
lubrication, maintenance, or repair procedures used.

Do not operate or work on this product unless you have read and
understood the instruction and warnings in the relevant Operation and
Maintenance Manuals and relevant service literature. Failure to follow
the instructions or heed the warnings could result in injury or death.
Proper care is your responsibility.

Failure to follow all safety guidelines prescribed in this document and

by governing authorities and regulatory agencies may result in severe
injury or death of personnel or machine damage.

Personal injury or death can result from improper maintenance

procedures. To avoid injury or death, follow the procedures exactly as
stated below.

Required Tools
Table 2
Required Tools
Qty Part Number Part Name
1 1U-5566 Ultraviolet Lamp Gp

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1 1U-5575 Additive
19 L (5 US gal) - Container for Fuel
164-3310
or
1 164-3320 Infrared Thermometer Gp
or
166-9030

Verifying and Measuring Fuel Dilution

Always determine fuel dilution by analyzing combination of low oil viscosity and percent of fuel in oil. The
flash test does not accurately detect fuel dilution. Perform the two tests listed below to verify fuel dilution:

• Oil Viscosity Test at 100° C (212° F)

• Percent fuel content using Gas Chromatograph Fuel Dilution Test

Note: Both the tests should be performed to analyze and compare the result for verifying fuel dilution.

Fuel in oil in excess of 6% is required before troubleshooting fuel dilution.

If a gas chromatograph dilution test cannot be performed at the dealership, an oil sample can be submitted to
a Caterpillar regional SOS Service lab for analysis.

Note: Low viscosity does not necessarily mean fuel dilution.

Refer to Table 3 for minimum viscosity by oil grade.

Table 3
Step 1 Step 2 Step 3
Viscosity Oil Viscosity Fuel Dilution as
Grade at 100° C Measured by Gas Action
(212° F) Chromatograph
0W-40
5W-40 Less than 11.0
Greater than 6% If conditions in Step 1 AND Step 2 are both
10W-40 cSt
met, investigate the cause of fuel dilution or
reduce the engine oil change interval.
15W-40
0W-30 Refer to Section "Troubleshooting for
Less than 8.0 Sources of Fuel Dilution".
5W-30 Greater than 6%
cSt
10W-30

Troubleshooting for Sources of Fuel Dilution

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The following troubleshooting procedures can be performed to find the source of fuel dilution:

Note: Caterpillar recommends performing these procedure one after the other and record the values to help
further troubleshooting, if required.

• Duty cycle of the Engine/Machine

• Fuel system

• Oil quality

Duty Cycle of the Engine/Machine

For engines operating normally, the machine application or the duty cycle may be contributing to
unacceptable fuel dilution.

• Engines with higher idle time

• Engines with higher fuel and ambient temperatures

• Engines that run cold

• Engines operating under light loads

Use the following procedure to determine the cause:

1. Verify the fuel dilution by low viscosity and gas chromatograph fuel dilution test. The fuel dilution
percent must be equal to or greater than 6%. Refer to Table 3 for minimum viscosity by oil grade.

2. Initially, reduce the engine oil change interval by 50 hours. Submit oil samples for evaluation at one
half of the new interval and at the time of the new interval.

3. If the reduced interval produces acceptable results from the oil analysis, continue operation with the
same interval.

4. If viscosity and fuel dilution are still unacceptable, reduce the service by another 50 hours. Evaluate
the results from each oil sample. Refer to Step 2.

5. Continue the above process until acceptable results for gas chromatograph fuel dilution test and oil
viscosity are obtained.

Investigating Fuel System Leaks

Use the following procedure to determine the locations or sources of fuel dilution around the electronic unit
injectors under the valve cover.

The required tools are listed below:

• 1U-5566 Ultraviolet Lamp Gp

• 1U-5575 Additive

• 19 L (5 US gal) container for fuel

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Note: The engine must be at the operating temperature or nearly close to the operating temperature to
perform this test.

Note: Do not exceed 745 kPa (108 psi) of fuel pressure in the rail of the cylinder head when pressurizing the
fuel system with a priming pump.

1. Add dye to the fuel in the container as per the instructions for the dye and mix well.

2. Put the inlet and return lines for the fuel in the container with dyed fuel.

3. Start the engine. Operate the engine until at least 11 L (3 US gal) of fuel is used, or operate the engine
until the dyed fuel has returned to the container. Stop the engine.

4. Remove the valve covers.

5. Cap the fuel line and pressurize the fuel system with a priming pump.

Illustration 1 g06534309
(A) Normal leak as viewed with dyed fuel

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Illustration 2 g06534313
(B) Leak from O-rings as viewed with dyed fuel

6. Use the black light to inspect all the unit injectors. A leak is indicated by a definite streak of dyed fuel
at the leaking location.

The areas on the unit injector where leaks are normal is shown in Illustration 1 shows . The areas on
the unit injector where service may be needed is shown in Illustration 2.

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Illustration 3 g06534306
(C) Area A
(D) Weep hole
(E) O-ring seal
(F) Lower O-ring seals

• Replace the fuel injector if fuel is leaking in Area A (C).

• Weep hole (D) fuel leakage is normal.

• Replace the O-ring seal (E) if fuel is leaking in this area. Do not replace the fuel injector.

• Worn out lower O-ring seals (F) will not cause fuel to oil leak.

Check the torque for the unit injector clamp retaining bolts. - Ensure that the unit injectors are properly
installed into the cylinder head.

Leaking from the Cracked Body of the Unit Injector. - Confirm the leak is from a damaged unit injector
body. Remove injectors that are suspected of having a damaged body and inspect the injectors for visible
cracks.

Excessive Leakage from the Unit Injector Tip or a Broken Unit Injector Tip. - Look for signs of
damage to the unit injectors. If necessary, replace the unit injectors that have damaged tips. Use 164-3310

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Infrared Thermometer Gp, or 164-3320 Infrared Thermometer Gp, or 166-9030 Infrared Thermometer Gp to
identify excessive tip leakage while the engine is running.

Low-Pressure Fuel System Sources for Increased Fuel Dilution

Verify system pressures at idle, high idle, and immediately after shutdown -

Measure the fuel pressure at the following locations to ensure that the pressure meet the Application and
Installation Guide specifications.

• Inlet to cylinder head

• Outlet of cylinder head before return pressure regulator

• Outlet of return pressure regulator

Verify that there are no restrictions -

• Excessive restrictions may cause elevated system operating pressure, which would result in increased
leakage rate. Verify that there is no debris lodged in the pressure regulator.

If pressure is maintained on the head after shutdown -

• Verify that the electric priming pump (if equipped) is not powered when the key is off.

• Verify that the purge orifice in the pressure regulator is not plugged.

Leakage of the Drive Shaft Seal on the Fuel Transfer Pump

Ensure that the weep hole for the fuel transfer pump is not plugged. Inspect the front of the pump for signs
of leakage. If necessary, repair the fuel transfer pump or replace the fuel transfer pump.

Illustration 4 g06534430

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Fuel transfer pump

For complete inspection, fuel transfer pump may need to be removed to inspect seal on the input shaft.

Cracked Cylinder Head or Leaking Cylinder Head Gasket

Check for symptoms of a damaged cylinder head or a damaged cylinder head gasket. Inspect the cooling
system for contamination of fuel. Inspect the crankcase for dilution of the engine oil. Dilution may be a sign
of a cracked cylinder head or a leaking cylinder head gasket.

C27 and C32 Cylinder Heads

Illustration 5 g06534450
(G) Holes

Plug the side of the cylinder head that returns the fuel. Ensure that the fuel rail is full of fuel. Pressurize the
fuel rail from the intake side of the head. Do not exceed 550 kPa (80 psi). Check under the valve covers for
fuel that is leaking from holes (G).

Low viscosity without fuel dilution

For low viscosity fuel dilution, perform the following checks:

1. Verify oil type.

a. Viscosity grade of oil (example 10W-30, 15W-40, and so on).

b. Performance level (example – Cl4 , CK4, and so on).

c. New oil viscosity from storage tank or dispensing container.

2. Ensure that the oil type meets Operation and Maintenance Manual recommendations for performance
and viscosity.

3. Verify that oil sump has not been contaminated with lower viscosity fluids such as hydraulic fluids,
cleaningfluids, and so on.

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4. Determine oil hang up from previous oil change is not lowering oil viscosity. Make sure that oil pan is
completely empty when oil is drained.

5. Verify that oil change interval is not impacting low oil viscosity.

Copyright 1993 - 2020 Caterpillar Inc. Thu Sep 17 15:35:47 CDT 2020
Todos los derechos reservados. p230mag1
Red privada para licenciados del SIS.

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