: a CATERPILLAR’ 95 061 AY? penssass.ce U (09 August 2011 4 v Special Instruction Troubleshooting the Hydraulic Electronic Unit Injection (HEUI) Fuel System On C7 and C9 Engines SMCS Code: 1250-035 Asphalt Paver AP-1000D (S/N: EAD1-Up) AP-1058D (S/N: FAC1-Up; A6P1-Up) AP-755 (S/N: B3T1-Up) BG-2455D (S/N: BNW1-Up) BG-260D (S/N: BPW1-Up) Cold Planer PM-102 (SIN: Z2X1-Up) Landfill Compactor 816F Series 2 (S/N: BZR1-Up) Soil Compactor 815F Series 2 (SIN: BYN1-Up) Engine C7 (SIN: JTF4-Up; RMF1-Up; FML1-Up; FMM1-Up; JRT1-Up; WAX1-Up; PRY1-Up) C9 (SIN: LFE1-Up; 9DG1-Up; CKP1-Up; LFR1-Up; X3R1-Up; C9Y1-Up) Generator Set C18 GEN SET (S/N: STM1-Up) C9 GEN SET (S/N: C9E1-Up) C9 MARINE GEN (S/N: SJB1-Up) C9 MARINE GS (S/N: C9A1-Up) Industrial Engine C9 INDUSTRIAL (S/N: JSC1-Up; JLW1-Up) Marine Engine C7 MARINE (S/N: M7A1-Up) C9 MARINE (S/N: CSN1-Up; X9Y1-Up) Truck Engines C7 TRUCK ENGINE (S/N: LBM1-Up) Excavator 324D (S/N: LAB1-Up; EJC1-Up; MND1-Up; T2D1-Up; BYE1-Up; JJG1-Up; ECH1-Up; TRH1-Up; BTK1-Up; AWN1-Up; TSN1-Up; DFP1-Up; JKR1-Up; JZR1-U JLS1-Up; JAT1-Up; PYT1-Up; CJX1-Up) 325D (SIN: GPB1-Up; NAC1-Up; KBE1-Up; PKE1-Up; KDG1-Up; C4H1-Up; DBH1-Up; ERK1-Up; RJK1-Up; C8L1-Up; LAL1-U; MCL1-Up; DAP1-Up; A3R1-Up; GBR1-Up; SCR1-Up) 328D (S/N: BYH1-Up; GTN1-Up; MKR1-Up) 329D (S/N: MNB1-Up; XDB1-Up; BFC1-Up; BBF1-Up; CZF1-Up; WDK1-Up; EBM1-Up; TPM1- BYS1-Up; WLT1-Up; LFW1-Up; YEW1-Up; SCY1-Up; TAY1-Up; DTZ1-Up) 330D (S/N: PFC1-Up; NBD1-Up; R2D1-Up; GGE1-Up; NEF1-Up: B6H1-Up; EAH1-Up; LCJ1-U| THJ1-Up; C5K1-Up; E4K1-Up; FFK1-Up; H3K1-Up; L2K1-Up; RDK1-Up; PEL1-Up; JJM1-U| LEM1-Up; LRM1-Up; ERN1-Up; JLP1-Up; MWP1-Up; RAS1-Up; MEY1-Up) 336D (S/N: SKE1-Up; JBF1-Up; J2F1-Up; PRF1-Up; LMG1-Up; MYG1-Up; KDJ1-Up; WRK1-Up; W3K1-Up; MPL1-Up; PPN1-Up; MYP1-Up; M2P1-Up; JER1-Up; DTS1-Up; NLS1-Up; JBT1-Up; KKT1-Up; M4T1-Up; WET1-Up; PGW1-Up; L5X1-Up) M325D (S/N: EDF1-Up; KGG1-Up; KAY1-Up)Forwarder 584 (S/N: PAK1-Up) 584HD (S/N: PBK1-Up) Track Feller Buncher 2390 (S/N: P3H1-Up) 2491 (SIN: P5J1-Up) 511 (S/N: 5111-Up) 521 (SIN: 5211-Up) 522 (S/N: 5221-Up) 32 (S/N: 5321-Up) 852 (SIN: 5521-Up) Integrated Toolcarrier IT62H (S/N: M5G1-Up) Motor Grader 120K (S/N: SZN1-Up; JAP1-Up) 120M Series II (S/N: M9H1-Up) 12K (SIN: JJA1-Up; SZP1-Up) 140K (SIN: JPA1-Up; SZL1-Up) 140M Series II (S/N: M9D1-Up; M9J1-Up) 140M (SIN: B9D1-Up; B9G1-Up; D9G1-Up; BIM1-Up) 460K (S/N: SZM1-Up; JBP1-Up) 160M Series II (S/N: M9E1-Up; M9K1-Up) 160M (S/N: B9E1-Up; B9L1-Up; B9T1-Up; D9T1-Up) Mobile Hydraulic Power Uni 323D MHPU (S/N: DCY1-Up) 324D MHPU (S/N: KJR1-Up) 325D MHPU (S/N: SRC1-Up; C3N1-Up; H3N1-Up; X3N1-Up) 329D MHPU (S/N: J9D1-Up; L5H1-Up) 330D MHPU (S/N: D3D1-Up; H3D1-Up; M3D1-Up; GMN1-Up) 336D MHPU (S/N: J6D1-Up; M3N1-Up) Petroleum Engine C7 PETROLEUM (SIN: K2A1-Up; C7P1-Up) C9 PETROLEUM (S/N: P9L1-Up; KLW1-Up) Petroleum Power Train Package TH31-C9l (S/N: PAZ1-Up) Track-Type Loader 973C (SIN: LDX1-Up) 973D (SIN: LCP1-Up) Track-Type Tractor D6R Series III (S/N: JEK1-Up; EXL1-Up; LGP1-Up; EXW1-Up) DET (S/N: JHB1-Up; ZEB1-Up; ‘SMC1-Up; LBD1-Up; LAE1-U DJG1-Up; WCG1-Up; WFH1-Up; LKJ1-Up; SNK1-Up; KJL1-Up; ‘SKL1-Up; GCT1-Up; RLW1-Up; LAY1-Up; PEZ1-Up) Wheel Dozer 814F Series'2 (SIN: BXG1-Up) Wheel Loader 950H (S/N: N1A1-Up; M1G1-Up; J5J1-Up; KSK1-Up) 962H (S/N: N4A1-Up; M3G1-Up; J6J1-Up; K6K1-Up; MAL1-Up) Wheel Skidder 525C (S/N: 5251-Up) 536C (S/N: 5351-Up) 545C (S/N: 5451-Up) Wheel Tractor-Scraper 627G (S/N: DBD1-Up) 637G (S/N: DFJ1-Up) Table of Contents Introduction : fe oi Low Pressure Fuel System Requirements Fuel Tank Drain ‘Advanced Tank Breather Filter Water Separators Primary Fuel Filters... ‘Secondary Fuel Filters .. Electronic Unit Injectors (EUI) Major Factors Which Negatively Affect Wear ... =m Abrasive Contaminants Solution Water in Fuel Solution : Excessive Fuel Temperature Solution mae Customer Maintenance Practices C7 and C9 HEU! Fuel System Diagram General Information Required Checklist One sss Checklist Two Reference Material Beooweon a 3 Seoarssvvwwwee Introduction This Special Instruction is intended to give information for troubleshooting C7 and C9 HEUI engine fuel systems. Read all of the instruction before performing any of the procedures listed in this instruction.Low Pressure Fuel System Requirements Increasing fuel supply pressure and effectively removing water and abrasive particles has demonstrated injector durability increases from 200 percent to as high as 1,000 percent in severe applications. More aggressive filtration and ‘monitoring is required to maximize fuel injector life and meet 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 iatent water from the fuel. Primary Fuel Filters Primary fuel fiters 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 fil, 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 fue! fitertwater 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 fiteriwater coalescer. Exces: e Fuel Temperature Increasing fuel temperatures reduces fuel viscosity and resultant fue film strength. Reduced fim strength increases the probabilly 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 fiters in order to prevent fiter 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. C7 and C9 HEUI Fuel System Diagram Note: The following illustration identifies components that may be included in many different arrangements, Refer to the Service Information System (SIS) for the correct components for the engine that is being servicedfF 4 Iustration 4 (1) Fue! injection pump (13) Check engine lamp (2) To engine (18) 2 micron secondary fuel fiters () on ter (15) Primary fe! fiter and water (4) Engine oil pump separator (6) Injection actuation pressure sensor (18) Fuel drain (6) Fue! injectors (17) Bateries (7) Foe! supply passage (18) Electronic Control Module (ECM) (8) 2 micron breather fier (18) Accelerator pedal poston sensor (9) Fuel tank (20) Accelerator pedal (10) Fuel pressure regulator (21) Injection actuatin ol temperature (1) Intake air eater lamp sensor (12) Fast dle amp (22) Engine boost pressure sensor General Information Required Note: This Special Instruction is used for troubleshooting the HEUI fuel system. This form is to aid the service technician with the diagnostics of the HEUI fuel system along with Special instruction, REHS3819, “Procedure for Troubleshooting and Cleaning the Oil Rail System for the Hydraulic. Electronic Unit Injector.” For further diagnostic, support, contact your Technical Communicator. 902005638 (23) Engine coolant tomporature sensor (2a) Intake maniold ai emperatre (25) Berometic pressure sensor (26) Engine ol pressure sensor (27) Fuel presse sensor (28) Watern fuel sensor (20) ako air eater (30) lta aichester relay (31) Dae ineeS a ray Date of repir Engi seit nome: ies EID Use te boxes to answer! Yes and “No™quostons and il ont ll roquosodoaings Are you using te mastcurere Servic Information Systm (SIS Web publeation updates? (Rat hepsisiscatcoml +010 or er Speil Insevcion "RESTS + 2010(r ar Tovblesnoutin “ection Actuation Pressure Test stration 2 ‘poRES605 Checklist OneCOS Cc HE 1. xeral it iaks near HEU ump o high pressure ola 2. Fuel rassure:____ KPa ft Fun Systm Prssuro Tes") 5 Engine ol pressures KPa) Rt “Egin Presse Tot) {Engine coolant temperate sensor OK (Re. Cooling System Test) 5 HEUI pump resistance OK resistance = 2oms):____ ohms [EIB 5.11 pump debris found 68, Photo of debris attached to warranty report (See Example “A“) and replace pump Gb, Auto cylinder cutout test OK (Run at operating temperature and stable load with pass/fail results) 6c. Injector trim files OK and ECM softwere uptodate £84, Manual ylindor cutout test OK (Run at varying temperatures and loads fr ful deliveries) 6. Oral fush procedure performed eee Gt Auto cylinder cutout test OK 6g. Injector trim files OK and ECM flash upto date 6h, Manuel cylinder cutouttest OK Ft. Troubleshooting “Injection Actuation Pressure - Test”. 7. ETfaultcodes present __ (Soo Examplo‘o thorn) [ilies shales tsar [s/Fa2] 8 Engine oil level OK 8. Engine oil change interval exceeded ———— ' 10. Manual gauge VAP within 1379 kPa (200 psi of Cat ET AP at each step (See Example “B") Manual Pressure Tajo Actuation Pressure Gauge Read ‘tom Cat Daten 11 Cat ET IAP test OK (IAP 1379 KP {< 200 pil above Desired IAP] IAP variation < /- 1000 KPa < #/- 145 pill Tijotn Rotation Prosure | Desired ijeavan Actuation Prassre Trjocion Aeioaton Outpt Fa step from Cat nom Cate Diteronce | icine rom cater 12 Injectors wath excessive ol leakage or discharge under valve cover 18. High-pressure pump test OK MAP > 285 MPa (> 4278 psi] Current > 400 mA}: ap. [MPa (psi, Carent. mA 1M. Pump disconnect tost OK IAP < 8MPa c 1180 psil:1AP_ MPa (psi) 15. Gylnder cutout test OK (Ret. “Ijector Solenoid Circuit ~ Test") 16, Road test End of Troubleshooting - complaint isnot esolved..Contact “To” Pr tsrstonChecklist TwoCO SES eS TT Os Og 1. External oil leaks near HEU! pur or high-pressure ol rail Ret Troubleshooting “Injction Actuation Pressure - Test” (Steps 17). 2.ET faut codes present (S00 Example tothe vight) 3. Engine ol evel OK 4 Engine starts with IAP sensor disconnected — 5. ranking parameters OK (Engine speed > 10 rpm) IAP>6 MPa > 60 pil Oi pressure >14 a > 2 psi: Engine spood: ‘pe, JAP MPa psi) Oil pressure __kPa psi} lit Engine speed> 00 pm, AP 2 psi: Goto TAP Step 7) 6 ECMinjctor communications OK 7. Cranking fel pressure OX Fuel pressure > 175 kPa (> 25 psi: Fuel pressure ka psi) It fust pressure »175 KPa > 25 pik: Injactr solenoid test OK Fel. Special instruction “REHS3B19" 8. HEU! pump test lamp OK Rel. Special Instruction “REHS3B1S. 8. HEU! pump resistence OK resistance == 2ahmsh____ 10 HEU! pur debris found 10a, Photo of bis etached to warrenty report (See Examplo “A” and replace pump 0b, Auto cylinder cutout test OK fun at operating temperature and stable load with pass results) 10c. injector rm es OK and EGM software upto dato "0d, Manual elinder cutout test OK (Run a varying temperatures and loads or uel deliveries) 16, Oiralush procedure performed 11" to 10. HEU! ump debris found. ple a0 10. Injectors with excessive ollleakage or cscharge under vale cover 10g, Cranking AP OKUIAP> 6 MPa (> 870 psi: AP___ MPa (psi) ‘Dn. EoMPinjactor communications OK 101, Cranking fel pressure OX ful presure> 175 kPa > 25 psi: Fuel pressure ___ Wa (ps) 11 Fuel pressure> 175 kPa (> 25 pi: Injector solenoid test OK 10}, Roadtest End of Troubleshooting -H complaints not resolved..Contact “TC~ stration 4 7385718Reference Material Reference Special Publication, SENR9620, "Improving Component Durability” for more information. This series of high-quality booklets contains full color graphics and easy to understand explanations of wear and failure in major system components. Special attention is given to practices that cause accelerated wear, and how to improve ‘component lfe in many applications, Note: This reference material is available only in paper and can only be ordered in packages of 10 or a set of all seven booklets. 10