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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
servicedfF
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 ineeS 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 OneCOS
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 tsrstonChecklist TwoCO 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
7385718Reference 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