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Special Instruction
Procedure for Troubleshooting and Cleaning the Oil Rail System for the Hydraulic Electronic Unit
Injector (HEUI) {1100, 1126, 1250, 1251, 1261, 1290}
Media Number -REHS3819-02 Publication Date -15/05/2008 Date Updated -15/05/2008

i02986779

Procedure for Troubleshooting and Cleaning the Oil Rail System for
the Hydraulic Electronic Unit Injector (HEUI) {1100, 1126, 1250, 1251,
1261, 1290}
SMCS - 1100-535; 1126-535; 1250-535; 1251-535; 1261-535; 1290-535

On-Highway Engine:
C7 TRUCK/BUS (S/N: YPG1-UP)
C7 (S/N: WAX1-UP; C7T1-UP; SAP1-UP; KAL1-UP)
C9 (S/N: 9DG1-UP; LFE1-UP; MTB1-UP)
Agricultural Tractor:
MT755 (S/N: ALM1-UP)
MT765 MTS (S/N: AMS1-UP)
MTC755 MTS (S/N: 8141-UP)
MTC765 MTS (S/N: 8151-UP)
Asphalt Paver:
AP-1000D (S/N: EAD1-UP)
AP-1055D (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 (S/N: Z2X1-UP)
Combine:
Lexion 470 R COMBINE HARVESTER (S/N: 7651-UP; 4ZF1-UP)
Lexion 475 R COMBINE HARVESTER (S/N: 7671-UP)
Landfill Compactor:
816F Series 2 (S/N: BZR1-UP)
Soil Compactor:
815F Series 2 (S/N: BYN1-UP)
Generator Set:
C9 GEN SET (S/N: X3R1-UP; C9E1-UP)
C9 MARINE GEN (S/N: SJB1-UP)
C9 MARINE GS (S/N: C9A1-UP)
Industrial Engine:
C7 (S/N: JRA1-UP; JTF1-UP)
C-9 (S/N: CLJ1-UP)
C9 INDUSTRIAL (S/N: JSC1-UP; MBD1-UP; JLW1-UP)
Marine Engine:
C7 MARINE (S/N: M7A1-UP; C7B1-UP; C7D1-UP; M7G1-UP; C7X1-UP; C7Z1-UP)
C9 MARINE (S/N: C9B1-UP; CSN1-UP; X9X1-UP; Z9X1-UP; X9Y1-UP)
Petroleum Engine:
C7 PETROLEUM (S/N: C7P1-UP; K2A1-UP)
C9 PETROLEUM (S/N: P9L1-UP; KLW1-UP)
Excavator:

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324D L (S/N: LAB1-UP)

324D LN (S/N: EJC1-UP)
324D L (S/N: T2D1-UP; BYE1-UP; JJG1-UP)
324D (S/N: ECH1-UP)
324D L (S/N: SYM1-UP)
324D (S/N: AWN1-UP)
324D L (S/N: DFP1-UP)
324D FOREST MACHINE (S/N: JKR1-UP)
324D LL FOREST MACHINE (S/N: JLS1-UP)
324D (S/N: CJX1-UP)
325D L (S/N: GPB1-UP; KBE1-UP)
325D LN (S/N: PKE1-UP)
325D (S/N: KDG1-UP; DBH1-UP)
325D FOREST MACHINE (S/N: C7K1-UP)
325D (S/N: RJK1-UP)
325D LL FOREST MACHINE (S/N: C8L1-UP)
325D L (S/N: LAL1-UP)
325D (S/N: MCL1-UP)
325D L (S/N: PAL1-UP)
325D (S/N: CJM1-UP)
325D LL FOREST MACHINE (S/N: C9M1-UP)
325D L (S/N: DAP1-UP; A3R1-UP)
325D MH (S/N: GBR1-UP)
325D L (S/N: SCR1-UP; T2S1-UP)
328D LCR (S/N: GTN1-UP; MKR1-UP)
330C L (S/N: CYA1-UP; HAA1-UP)
330C (S/N: MCA1-UP; JAB1-UP; D3C1-UP; JCD1-UP)
330C L (S/N: KDD1-UP)
330C (S/N: GAG1-UP; RBH1-UP; B1K1-UP)
330C L (S/N: JNK1-UP)
330C (S/N: B2L1-UP; BTM1-UP)
330C L (S/N: MKM1-UP)
330C (S/N: B4N1-UP)
330C L (S/N: CAP1-UP; GKX1-UP; DKY1-UP)
330C LN (S/N: CGZ1-UP)
330D L (S/N: RDA1-UP)
330D (S/N: KAB1-UP; PFC1-UP)
330D L (S/N: NBD1-UP)
330D LN (S/N: GGE1-UP)
330D L (S/N: NEF1-UP; B6H1-UP)
330D (S/N: EAH1-UP; LCJ1-UP)
330D L (S/N: THJ1-UP)
330D LL FOREST MACHINE (S/N: E4K1-UP)
330D L (S/N: FFK1-UP)
330D LL FOREST MACHINE (S/N: H3K1-UP)
330D FOREST MACHINE (S/N: L2K1-UP)
330D (S/N: PCK1-UP; LEM1-UP)
330D L (S/N: LRM1-UP; ERN1-UP; JLP1-UP; MWP1-UP; LDR1-UP; HAS1-UP; RAS1-UP)
330D (S/N: MEY1-UP)
330D L (S/N: T2Y1-UP)
M325D MH (S/N: EDF1-UP)
M325D MH L (S/N: KGG1-UP; KAY1-UP)
Track Feller Buncher:
511 (S/N: 5111-UP)
521 (S/N: 5211-UP)
522 (S/N: 5221-UP)
541 (S/N: 5411-UP)
TK711 (S/N: 1011-UP)
TK721 (S/N: 1021-UP)
TK722 (S/N: 1031-UP)
TK732 (S/N: 1041-UP)
TK741 (S/N: 2021-UP)

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Integrated Toolcarrier:
IT62H CUSTOM (S/N: M5G1-UP)
Motor Grader:
12H (S/N: CBK1-UP; AMZ1-UP; 1251-UP)
140M (S/N: B9D1-UP; B9M1-UP)
160M (S/N: B9E1-UP; B9L1-UP)
Mobile Hydraulic Power Unit:
324D MHPU LN (S/N: KJR1-UP)
325D MHPU L (S/N: C3N1-UP)
330C MHPU (S/N: MSD1-UP; MSL1-UP)
330D MHPU L (S/N: D3D1-UP; H3D1-UP)
Paving Compactor:
CS74 (S/N: CZJ1-UP)
Track-Type Loader:
973C HD (S/N: BCP1-UP)
973C (S/N: LDX1-UP)
973D (S/N: LCP1-UP)
Track-Type Tractor:
D6R Series II DS LGP (S/N: BNC1-UP)
D6R Series II PS DD (S/N: AFD1-UP)
D6R Series II XL FTC (S/N: CAD1-UP)
D6R Series II DS LGP (S/N: ADE1-UP)
D6R Series II FTC (S/N: BLE1-UP)
D6R Series II DS XW (S/N: DAE1-UP)
D6R Series II LGP FTC (S/N: ACJ1-UP)
D6R Series II STD FTC (S/N: BMJ1-UP; BRJ1-UP; BMK1-UP)
D6R Series II DS STD (S/N: BNL1-UP)
D6R Series II STD FTC (S/N: AEM1-UP)
D6R Series II DS STD (S/N: AFM1-UP)
D6R Series II STD FTC (S/N: AGM1-UP)
D6R Series II DS STD (S/N: BPM1-UP)
D6R Series II DS XW (S/N: AEP1-UP)
D6R Series II LGP FTC (S/N: BPP1-UP)
D6R Series II XL FTC (S/N: BPS1-UP)
D6R Series II DS STD (S/N: BLT1-UP)
D6R Series II DS XL (S/N: FDT1-UP; AAX1-UP; BMY1-UP)
D6R Series II DS LGP (S/N: BPZ1-UP)
D6R Series II DS XL (S/N: BRZ1-UP)
D6R Series III (S/N: GJB1-UP; WCB1-UP; HDC1-UP)
D6R Series III XL (S/N: RFC1-UP)
D6R Series III (S/N: TBC1-UP; HCD1-UP; HKE1-UP; WRG1-UP)
D6R Series III XW (S/N: MTJ1-UP)
D6R Series III (S/N: DMK1-UP; JEK1-UP; EXL1-UP; JDL1-UP)
D6R Series III LGP (S/N: DLM1-UP)
D6R Series III (S/N: LFM1-UP; LGP1-UP; DPS1-UP; GMT1-UP; MRT1-UP)
D6T STD (S/N: JHB1-UP; SMC1-UP)
D6T PAT (S/N: JWD1-UP)
D6T XL (S/N: LAE1-UP)
D6T PAT (S/N: DJG1-UP; WCG1-UP; WFH1-UP)
D6T LGP (S/N: LKJ1-UP; KJL1-UP)
D6T XW (S/N: SKL1-UP)
D6T XL (S/N: GCT1-UP; LAY1-UP)
D6T STD (S/N: PEZ1-UP)
Wheel Dozer:
814F Series 2 (S/N: BXG1-UP)
Wheel Loader:
950H CUSTOM (S/N: N1A1-UP)
950H (S/N: M1G1-UP; J5J1-UP; K5K1-UP)
962H CUSTOM (S/N: N4A1-UP)
962H (S/N: M3G1-UP; J6J1-UP; K6K1-UP)
Wheel Skidder:
525C (S/N: 5251-UP)

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535C (S/N: 5351-UP)

545C (S/N: 5451-UP)
Wheel Tractor-Scraper:
627G (S/N: DBD1-UP)
637G (S/N: DFJ1-UP)

Introduction
Do not perform any procedure in this Special Instruction until you have read this information and you understand
this information.

This Special Instruction provides guidance for a standard repair procedure to address the process for cleaning the
oil rail. Before cleaning the oil rail, the dealer that is completing the repair must perform the standard
troubleshooting procedure for the pump for the hydraulic electronic unit injector (HEUI) and the injector for the
HEUI. Refer to the correct Troubleshooting manual for your machine.

All warranty guidelines must be followed. If the fuel pump from the HEUI fuel system or the injectors are
replaced during the troubleshooting, Caterpillar will inspect all of the pumps and the injectors. If the fuel pump
from the HEUI fuel system or the injectors are found to be acceptable, the pump and the injectors will be returned
to the dealer that is making the repairs and the warranty claim will be debited.

Tooling
Table 1

Tooling
Part Number Description Quantity
1P-5573 Brush (1) 1
9U-7080 Tapered Cap/Plug 31.750 mm (1.25 inch) Plugs for the Injector bore 6
Shop vacuum 1
Air supply 1
222-3117 Brake Cleaner 1
Protective face shield 1
(1) The brush must be a nylon bristle.

Troubleshooting Procedure

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Illustration 1 g01500513
All warranty guidelines must be followed. If the fuel pump from the HEUI fuel system or the injectors are replaced during the
troubleshooting, Caterpillar will inspect all of the pumps and the injectors. If the fuel pump from the HEUI fuel system or the injectors
are found to be acceptable, the pump and the injectors will be returned to the dealer that is making the repairs and the warranty claim
will be debited.

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Illustration 2 g01546516
(1) Plug

(2) Port hole in cylinder head

Note: Earlier versions of the plug (1) in Illustration 2 may not be hollow in the center.

Illustration 3 g01546517
Debris in the hollow plug

Note: The debris in the hollow plug that is shown in Illustration 3 is from a HEUI pump from a HEUI fuel system.
The debris in the plug was generated by the HEUI pump. Illustration 3 is only an example. The actual amount of
the debris may vary.

Cleaning Procedure
1. Remove the fuel injectors. Refer to Disassembly and Assembly for your specific machine.

Note: Contain any oil and cleaner that will flow from the cylinder and the lines during the following
process. Properly dispose of the oil and the cleaner when the work is completed.

2. Remove the plugs for the main oil gallery at the front and the rear of the cylinder head.

Note: In certain applications, one plug may be inaccessible. Shop vacuum may be used in order to
completely clean the system.

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3. Remove the pressure sensor from the cylinder head. Protect the pressure sensor.

4. Install six plugs 9U-7080 Tapered Cap/Plug into the lower injector bores in order to keep oil and fuel from
entering the cylinder.

5. Insert a tube directly into the port for the oil supply. The port is located in each injector bore. Use 222-3117
Brake Cleaner to begin cleaning the system.

6. Use the 1P-5573 Brush As to clean the bore of the main oil gallery. Use 222-3117 Brake Cleaner to flush
the main oil gallery. Use compressed air to remove the brake cleaner.

Note: The oil supply passage to the injector is above the fuel passage. This passage should be flushed from
the injector bore downward to the oil rail on the HEUI fuel system. Then flush the oil rail in the HEUI fuel
system from the front of the cylinder head to the rear.

Illustration 4 g01546515
(3) Oil Rail for a HEUI fuel system

(4) Oil passage to injector bore

(5) Fuel passage

(6) Injector bore

7. Repeat Steps 5 and 6 until there is no debris in the system.

8. Clean the oil filter bypass valve. Reassemble the oil filter bypass valve.

9. Refer to Truck Engine News, SEBD6764, "A New Spring for the Oil Filter Bypass Valve and for the Oil
Cooler Bypass Valve is Now in Production ", Service Magazine, SEPD0718, "A New Spring for the Oil
Filter Bypass Valve and for the Oil Cooler Bypass Valve is Now in Production ", and Engine News,
SEBD9329, "A New Spring for the Oil Filter Bypass Valve and for the Oil Cooler Bypass Valve is Now in
Production " for the correct selection of the springs for the bypass relief valve for the oil cooler.

10. Remove any fluid that remains in the injector bores and any fluid that remains in the cylinder.

11. Clean the bores for the fuel injector.

12. Reinstall all components.

13. Replace the engine oil and the oil filter. Refer to Operation and Maintenance Manual for your specific
machine in order to determine refill capacities.

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Copyright 1993 - 2008 Caterpillar Inc. Thu Jun 5 09:11:17 UTC+0200 2008
All Rights Reserved.
Private Network For SIS Licensees.

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