AV Spare

Create a motion

Main Autodata Caterpillar

Injection Actuation Pressure - Test... C-9 Engine

for TK711, TK721, TK722, TK732, TK741, TK751,
and TK752 Track Feller Bunchers Caterpillar

Usage:
TK711 101 TK721 102 TK722 103 TK732 104 12H 125 TK741 202 TK751 301 TK752 302
C-9 4ZF 511 511 521 521 522 522 525C 525 532 532 535C 535 541 541 545C 545 551
551 552 552 MTC735 812 MTC745 813 MTC755 814 MTC765 815 C9 9DG 325D L A3R
AP-1055D A6P D6R II AAX D6R II ACJ D6R II ADE D6R II AEM D6R II AEP D6R II AFM D6R II
AGM MT735 AKN MT745 ALA MT755 ALM MT765 AMS 12H AMZ 324D AWN 325D L AZP
330C FM B1K 330C FM B2L 330C FM B3M AP-755 B3T 330C FM B4N 330D L B6H 12M
B92 140M B9D 160M B9E 140M B9G 160M B9L
System Operation Description:
Use the steps that follow to check the operation of the HEUI fuel system. Circle the appropriate
answers within the "Results" section of each step. Complete the pages. Provide completed pages
with any returned part. Return the parts through the normal channels.
Results from the test must be included in the claim for related repairs. Failure to follow the proper
sequence of this procedure may result in incorrect results. The standard warranty may not cover
repairs that are performed while using this procedure incorrectly.

Illustration 1

g01181491

Left side of engine (typical example)

(1) "J500/P500" Connector for the injection actuation pressure control valve
(2) Injection actuation pressure sensor

Test Step 1. Symptoms

The following symptoms may occur if there is a problem with the HEUI fuel system:
The engine cranks but the engine will not start.
The engine runs rough.
The engine is erratic or unstable at idle or running.
Low power
The following diagnostic codes might be active codes or logged codes: 164-00, 164-02, 16403, 164-04, 164-11, 42-11, 94-1 and 94-11.
1. Connect the Caterpillar Electronic Technician (ET) to the data link connector.
2. Turn the keyswitch to the ON position. DO NOT START THE ENGINE.

3. Print the "Lifetime Totals" and the "Configuration" screen.

4. Check for active diagnostic codes or logged diagnostic codes. The diagnostic codes should
become active within 30 seconds.
5. Verify that the engine coolant temperature sensor is operating properly. Verify through CAT
ET. Refer to Testing and Adjusting, "Cooling System - Test" or Testing and Adjusting, "Test
For The Water Temperature Gauge" for the proper procedure.
Document all active diagnostic codes or logged diagnostic codes.________
Expected Result:
Diagnostic codes are not active or logged when electrical power is restored to the ECM and the
engine is not running.
Results:
OK - There are no active codes or logged codes. Proceed to Test Step 2.
Not OK - Active codes or logged codes are present.
Repair: Refer to Troubleshooting, "Engine Pressure Sensor Open or Short Circuit - Test" if
164-03 or 164-04 is active or logged.Refer to Troubleshooting, "Injection Actuation Pressure
Sensor - Test" if 164-02 is active or logged.Refer to Troubleshooting, "Injection Actuation
Pressure Control Valve Circuit - Test" if 42-11 is active or logged. Refer to System Operation,
Test and Adjusting, "Fuel System Pressure - Test" if 94-1 is active or logged. Proceed to Test
Step 2 if 164-00, 164-11 or 94-11 is active or logged.
STOP
Test Step 2. Start the Engine
1. Inspect the engine for oil leaks in the HEUI oil rail. Repair leaks before proceeding. Clearly
mark all leaks on returned parts.
Note: Inspect the area near the high pressure oil rail and the unit injector hydraulic pump. If
leakage is found between the transfer pump and the hydraulic pump, refer to Special
Instruction, REHS3830 for details. If leakage is found between the hydraulic pump and the
front housing, refer to Special Instruction, REHS3830 for details on replacing the seal.
2. Check the engine oil level. If the engine oil level is low, add oil to the engine. Do not overfill
the engine.
3. Try to start the engine.
Expected Result:
The engine starts.
Results:

OK - The engine starts. Proceed to Test Step 10.

Not OK - The engine does not start. Proceed to Test Step 3.
Test Step 3. Verify the Operation of the Injection Actuation Pressure Sensor
1. Disconnect the connector for the injection actuation pressure sensor. Check for evidence of
moisture in the connector. Refer to Troubleshooting, "Electrical Connectors - Inspect" for
troubleshooting details.
2. Try to start the engine.
Expected Result:
The engine does not start.
Results:
OK - The engine does not start. Reconnect the connector for the actuation pressure sensor.
Clear all diagnostic codes. Proceed to Test Step 4.
Not OK - The engine starts.
Repair: The injection actuation pressure sensor may be faulty. Replace the sensor and
reconnect the connector. Clear all diagnostic codes. Verify that the repair eliminates the
problem.
If the problem still exists, proceed to Test Step 4.
Test Step 4. The Engine Cranks but the Engine Will not Start
1. Observe the status for "Engine Speed", "Actual Injection Actuation Pressure" and "Engine Oil
Pressure" on Cat ET while the engine is cranking. Record the following data:
________ Engine Speed
________ Actual injection actuation pressure
________ Desired injection actuation pressure
________ Engine oil pressure
________ Fuel pressure
________ Engine coolant temperature
________ Observed "Injection Actuation Output Percent"
Expected Result:
The observed engine speed is above 100 rpm and the actual injection actuation pressure is at
least 6 MPa (870 psi) while the engine is cranking.
Results:

OK - The observed engine speed is above 100 rpm and the actual injection actuation
pressure is at least 6 MPa (870 psi) while the engine is cranking.
Repair: If a 94-11 code is active or logged, there is a problem with the fuel supply system.
Refer to System Operation, Test and Adjusting, "Fuel System Pressure - Test".
If a 94-11 code is not active or logged, refer to Test Step 5.
Not OK - The observed engine speed is below 100 rpm.
Repair: Refer to Troubleshooting, "Engine Cranks but Will Not Start".
STOP
Not OK - The observed engine speed is above 100 rpm and the observed engine oil pressure
is below 14 kPa (2 psi).
Repair: There is a problem with the engine oil supply. Refer to System Operation, Test and
Adjusting, "Engine Oil Pressure - Test".
STOP
Not OK - The observed engine speed is above 100 rpm and the observed engine oil pressure
is above 14 kPa (2 psi) and the actual injection actuation pressure is below 6 MPa (870 psi).
Proceed to Test Step 7.
Test Step 5. Verify Communication Between the ECM and the Fuel Injectors

Electrical shock hazard. The electronic unit injector system uses 90-120 volts.

Illustration 2
Location of the connectors for the injector solenoids ( C7 engines)
(1) Connector at the valve cover
(2) J2/P2 ECM connectors
(3) Rubber grommet for the injector harness at the valve cover

g01330859

Illustration 3

g01330939

Location of the connectors for the injector solenoids ( C9 engines)

(1) Connector at the valve cover
(2) J2/P2 ECM connectors

1. Turn the key to the "OFF" position. An electrical shock hazard is present if the key is not in
the "OFF" position.
2. Disconnect the connector for the injector harness at the valve cover. Check for evidence of
moisture in the connector. Refer to Troubleshooting, "Electrical Connectors - Inspect" for
troubleshooting details.
3. Crank the engine for 15 seconds.
4. Check Cat ET for logged diagnostic codes that are related to the injector solenoids.
Expected Result:
There are logged diagnostic codes for injector solenoids in all cylinders.
Results:

OK - There are logged diagnostic codes for injector solenoids in all cylinders. The logged
codes indicate communication between the ECM and the fuel injectors. Turn the key to the
"OFF" position. Reconnect the connector for the injector harness. Clear all diagnostic codes.
Proceed to Test Step 6.
Not OK - At least one cylinder does not indicate a logged diagnostic code for the injector
solenoid.
Repair: There may be a problem with the engine harness or ECM. Record the numbers that
do not indicate a logged diagnostic code for the injector solenoid. Turn the key to the "OFF"
position. Reconnect the connector for the injector harness. Clear any diagnostic codes or
event codes. Refer to Troubleshooting, "Injector Solenoid Circuit - Test".
STOP
Test Step 6. Check the Pressure of the Low Pressure Fuel System
1. Observe the status for "Fuel Pressure" on Cat ET while the engine is cranking. Record the fuel
pressure.
________ Fuel Pressure
Expected Result:
Observed fuel pressure is above 175 kPa (25 psi) while the engine is cranking.
Results:
OK - Observed fuel pressure is above 175 kPa (25 psi) while the engine is cranking.
Repair: Access the "Injector Solenoid Test" in Cat ET. Activate the test. As each solenoid is
energized by the ECM an audible click can be heard at the valve cover. Listen for a click at
the valve cover. Cat ET will indicate the cylinder number as each solenoid is being energized.
Replace injectors that do not produce an audible click. Verify the repair. If all injectors
produce an audible click and the engine will not start, refer to Troubleshooting, "Engine
Cranks but Will Not Start".
STOP
Not OK - Observed fuel pressure is below 175 kPa (25 psi) while the engine is cranking.
Repair: There is a problem with the fuel supply system. Refer to System Operation, Test and
Adjusting, "Fuel System Pressure - Test".
STOP
Test Step 7. Use a Test Lamp to Check for the Presence of Current
1. Disconnect the J500/P500 IAPCV connector from the unit injector hydraulic pump.
Note: Do not insert any wire that is larger than 18 AWG into the P500 harness connector. Do
not insert the probe for the voltage test lamp into the P500 harness connector. These actions

will spread the sockets of the connector which will damage the connector. Damaged
connectors could cause intermittent connections.
2. Insert a 186-3735 Connector Pin into each of the P500 harness connector sockets .
3. Connect a voltage test lamp to the connector pins that are inserted in the P500 connector.
4. Crank the engine and watch the test lamp.
Expected Result:
The test lamp illuminates while the engine is cranking.
Results:
OK - The test lamp illuminates while the engine is cranking. The ECM is operating correctly
and the wiring harness to the pump is OK. Proceed to Test Step 8.
Not OK - The test lamp does not illuminate while the engine is cranking.
Repair: Refer to Troubleshooting, "Injection Actuation Pressure Control Valve Circuit - Test"
for information on troubleshooting the circuit.
STOP
Test Step 8. Check the High Pressure Oil System for Leaks

Hot oil and components can cause personal injury.

Do not allow hot oil or components to contact skin.

Electrical shock hazard. The electronic unit injector system uses 90-120 volts.

1. Remove the valve cover and inspect the high pressure oil system for excessive oil leaks or
discharge.
2. Look at the injector bores for any signs of oil leakage while the engine is being cranked.
Inspect the spill ports on the injectors for an excessive discharge of oil. All six injectors
should discharge the same amount of oil. Excessive leakage or discharge can cause issues

with the system pressure. Record the following data:

________ Any injectors with excessive leakage or discharge
3. Turn the key to the "OFF" position. A electrical shock hazard is present if the key is not turned
to the "OFF" position.
4. Disconnect the connector for the injector harness at the valve cover. Check for evidence of
moisture in the connector. Refer to Troubleshooting, "Electrical Connectors - Inspect" for
troubleshooting details.
5. Crank the engine. Observe the injector bores for any signs of leakage. Inspect the spill ports
on the injectors for an excessive discharge of oil. The injectors are now disabled and the
injectors should discharge very little oil, which is normal. Observe the status for the "Actual
Injection Actuation Pressure" on Cat ET while the engine is cranking. Record the following
data:
________ Any injectors with excessive leakage or discharge
________Actual injection actuation pressure
6. Clear any diagnostic codes that are logged.
Expected Result:
There are no excessive oil leaks around injector bores. Also, there is no excessive discharge of oil
from the spill ports of the injector.
Results:
OK - There are no excessive oil leaks around injector bores. Also, there is no excessive
discharge of oil from the spill ports of the injector.
Repair: If the unit injector hydraulic pump has not been replaced during this procedure,
replace the pump and repeat steps "E" and "F". The engine will need to be cranked for a
significant length of time in order to fill the pump with oil after the pump is replaced. Clear all
diagnostic codes.
If the unit injector hydraulic pump has been replaced during this procedure, and the actual
injection actuation pressure was at least 6 MPa (870 psi) in Step "E", proceed to Test Step 9.
OK - If the unit injector hydraulic pump has already been replaced during this procedure and
the actual injection actuation pressure was below 6 MPa (870 psi) in Step "E", consult your
local technical communicator for assistance.
Not OK - There are excessive oil leaks around the injector bores or excessive discharge of oil
out of the spill port of the injector.
Repair: Replace the O-ring on the injector(s) that is leaking around the bore(s) or replace the
damaged injector(s) that is identified with excessive discharge out of the spill ports.

Proceed to Test Step 9.

Test Step 9. Try to Start the Engine

Electrical shock hazard. The electronic unit injector system uses 90-120 volts.

1. Turn the key to the "OFF" position. A electrical shock hazard is present if the key is not in the
"OFF" position.
2. Reconnect the connector for the injector harness at the valve cover and install the valve
cover.
3. Try to start the engine. Observe the status for "Actual Injection Actuation Pressure" on Cat ET
while the engine is cranking. Record the actual injection actuation pressure.
________ Actual injection actuation pressure
Expected Result:
The engine starts.
Results:
OK - The engine starts.STOP
Not OK - The engine does not start and actual injection actuation pressure is above 6 MPa
(870 psi). Proceed to Test Step 5.
Not OK - The engine does not start and actual injection actuation pressure is below 6 MPa
(870 psi).
Repair: If the unit injector hydraulic pump has not been replaced, replace the pump and try to
start the engine. The engine will need to be cranked for a significant length of time in order to
fill the pump with oil after the pump has been replaced. Clear all diagnostic codes.
If the engine does not start, proceed to Test Step 5.
Not OK - If the unit injector hydraulic pump has already been replaced in a previous test, stop
and consult your local technical communicator for assistance.
Test Step 10. Check the Low Pressure Fuel and Oil System Pressures
Extended oil drain intervals may cause elevated levels of soot in the engine oil. The elevated levels
of soot may also deplete the additive package of the oil. This can affect the operation of the high
pressure oil system.

Note: Refer to the engine's Operation and Maintenance Manual for the recommended engine oil
change interval and refill capacities.

Escaping fluid under pressure, even a pinhole size leak, can penetrate body tissue,
causing serious injury, and possible death. If fluid is injected into your skin, it must be
treated immediately by a doctor familiar with this type of injury.
Always use a board or cardboard when checking for a leak.

1. Start the engine.

2. Observe the status for "Fuel Pressure" and "Engine Oil Pressure" on Cat ET while the engine
is running. Record the following data:
________ Observed fuel pressure from Cat ET
________ Observed engine oil pressure from Cat ET
________ Drain interval
________ Miles or Kilometers since the last oil change
Expected Result:
The customer has not exceeded the suggested oil change interval.
Results:
OK - The customer has not exceeded the suggested oil change interval.
Repair: Refer to Systems Operation, Testing and Adjusting, "Fuel System Pressure - Test" and
Systems Operation/Testing and Adjusting, "Engine Oil Pressure - Test" in order to verify that
the observed fuel pressure and engine oil pressures are acceptable.If a 94-1 diagnostic code
is active or if a 94-1 diagnostic code is logged, a problem in the fuel supply system has
occurred. Refer to Systems Operation, Testing and Adjusting, "Fuel System Pressure - Test".
Make necessary repairs. Verify that the repair eliminates the problem.
If the problem still exists, proceed to Test Step 11.
Not OK - The customer has exceeded the suggested oil change interval.
Repair: If the customer has exceeded the suggested oil change interval, ask the customer to
authorize an oil change with a new filter. Oil changes are not covered by the warranty. After
the engine oil and the oil filter have been changed, operate the engine until normal operating
temperature has been reached. Operate the engine at 1200 to 1500 rpm for 15 minutes. This

will purge any trapped air or debris that is in the system.

If the problem still exists, or if the problem reoccurs in a short period of time, repeat Test
Step 10.
Test Step 11. Use "Injection Actuation Pressure Test" on Cat ET to Check the System
1. Install the 8T-0852 Pressure Gauge in an accessible port in the high pressure part of the
injection actuation system.
2. Start the engine.
3. Access the "Injection Actuation Pressure Test" in the "Diagnostics Menu" of Cat ET and begin
the test.
Note: The "Injection Actuation Pressure Test" can be used to increase the injection actuation
pressure. Also, the "Injection Actuation Pressure Test" can be used to decrease the injection
actuation pressure. The test adjusts the oil pressure of the injection actuation system in
predefined steps. Step forward through all predefined steps in the test. Next, step backward
through all predefined steps in the test.
4. Record the pressure readings from the pressure gauge and from Cat ET in Table1.
Table 1
Step

Manual pressure

Actual injection actuation pressure from

Difference

gauge

Cat ET

Expected Result:
The pressure that is measured with the pressure gauge for each step and the pressure that is
displayed on Cat ET for each step are within 1379 kPa (200 psi).
Note: Under some situations, the injection actuation pressure may not change. This step
compares the pressure reading from the pressure gauge to the pressure reading that is displayed
on Cat ET.

Results:
OK - The pressure that is measured with the pressure gauge for each step and the pressure
that is displayed on Cat ET for each step are within 1379 kPa (200 psi). The injection
actuation pressure sensor is operating properly.
Repair: Do not replace the sensor.
Proceed to Test Step 12.
Not OK - The pressure that is measured with the pressure gauge for each step and the
pressure that is displayed on Cat ET for each step are not within 1379 kPa (200 psi).
Repair: The injection actuation pressure sensor may be faulty. Replace the sensor and repeat
this test step.
If the problem still exists, verify the accuracy of the pressure gauge. Reinstall the original
sensor and proceed to Test Step 12.
Test Step 12. Perform the "Injection Actuation Pressure Test" at Low Idle
1. Start the engine. Run the "Injection Actuation Pressure Test" at low idle only. Step forward
through all predefined steps in the test. Next, step backward through all the predefined steps
in the test.
Note: There may be a short lag in the reaction to the injection pressure. The pressure change
should occur within two seconds of each command.
2. Record the actual injection actuation pressure, the desired injection actuation pressure and
the percent output from Cat ET in Table 2.
Table 2
Low Idle
Step

Actual injection actuation

pressure from Cat ET (A)

Desired injection actuation

pressure from Cat ET (B)

Difference
(A-B)

Percent
Output from
Cat ET

Expected Result:
The actual injection actuation pressure is no more than 1379 kPa (200 psi) above the desired
injection actuation pressure for each step. Also, the injection actuation pressure does not fluctuate
more than 1000 kPa (145 psi).
Results:
OK - The actual injection actuation pressure is no more than 1379 kPa (200 psi) above the
desired injection actuation pressure for each step. Also, the actual injection actuation
pressure does not fluctuate more than 1000 kPa (145 psi). Proceed to Test Step 13.
Not OK - One of the actual injection actuation pressures is more than 1379 kPa (200 psi)
above the desired injection actuation pressure on at least one step, or the actual injection
actuation pressure fluctuates more than 1000 kPa (145 psi).
Repair: Replace the unit injector hydraulic pump. After the pump has been replaced, the
engine will need to be cranked for a significant length of time in order to fill the pump with
oil. Clear all diagnostic codes or event codes. Verify that the repair eliminates the problem.
If the problem still exists, proceed to Test Step 13.
Test Step 13. Check the High Pressure Oil System for Excessive Leaks

Hot oil and components can cause personal injury.

Do not allow hot oil or components to contact skin.

1. Remove the valve cover and inspect the high pressure oil system for excessive oil leaks or
discharge.
2. Start the engine and allow the engine to idle. Look at the injector bores for any signs of oil
leakage. Inspect the spill ports on the injectors for an excessive discharge of oil. All six
injectors should discharge the same amount of oil. Excessive leakage or discharge can
cause issues with the system pressure.
3. While the engine is at low idle, perform the "Injection Actuation Pressure Test" in Cat ET. Run
the test at the highest pressure in order to maximize any possible leaks. Observe the status
for "Actual Injection Actuation Pressure" on Cat ET. Record the following data:
________ Any injectors with excessive leakage or discharge

________ Actual injection actuation pressure at low idle

4. Turn the key to the "OFF" position. A electrical shock hazard is present if the key is not turned
to the "OFF" position.
5. Disconnect the connector for the injector harness at the valve cover. Check for evidence of
moisture in the connector. Refer to Troubleshooting, "Electrical Connectors - Inspect" for
troubleshooting details.
6. Crank the engine. Observe the injector bores for any signs of leakage. Inspect the spill ports
on the injectors for an excessive discharge of oil. The injectors are now disabled and the
injectors should discharge very little oil, which is normal.
7. While the engine is cranking, perform the "Injection Actuation Pressure Test" in Cat ET. Run
the test at the highest pressure in order to maximize any possible leaks. Observe the status
for "Actual Injection Actuation Pressure" on Cat ET. Record the following data:
________ Any injectors with excessive leakage or discharge
________ Actual injection actuation pressure while the engine is cranking
8. Clear any diagnostic codes that are logged.
Expected Result:
There are no excessive oil leaks around injector bores. Also, there is no excessive discharge of oil
from the spill ports of the injector.
Results:
OK - There are no excessive oil leaks around injector bores. Also, there is no excessive
discharge of oil from the spill ports of the injector. Proceed to Test Step 14.
Not OK - There are excessive oil leaks around injector bores or there is an excessive
discharge of oil from the spill ports of the injector.
Repair: Replace the O-ring on the injector(s) that is leaking around the bore(s) or replace the
damaged injector(s) that is identified with excessive discharge out of the spill ports. .
Verify that the repair eliminates the problem. If the problem remains after the repair, proceed
to Test Step 14.
Test Step 14. Check the Oil Pressure at the Pump (High Pressure Pump Test)
1. Turn the key to the "OFF" position. A electrical shock hazard is present if the key is not turned
to the "OFF" position.
2. Reconnect the connector for the injector harness at the valve cover and install the valve
cover.

Escaping fluid under pressure, even a pinhole size leak, can penetrate body tissue,
causing serious injury, and possible death. If fluid is injected into your skin, it must be
treated immediately by a doctor familiar with this type of injury.
Always use a board or cardboard when checking for a leak.

3. Install the 8T-0852 Pressure Gauge in an accessible port in the high pressure portion of the
injection actuation system.
4. Disconnect the connector for the injection actuation pressure sensor and plug a spare
injection actuation pressure sensor into the engine harness. Allow the spare sensor to hang
on the side of the engine.
Note: This configuration allows the unit injector hydraulic pump to build maximum pressure.
The engine will not start in this configuration.
5. Install a 224-9282 Adapter Cable As in series with the P500 connector. Reconnect the
P500/J500 connector.
Note: There must be a continuous electrical connection between the ECM and the unit
injector hydraulic pump. The improper connection or the incomplete connection of the
adapter cable may provide incorrect results.
6. Connect a multimeter that is capable of measuring current that is 0 to 1,000 milliampere in
series with the adapter cable. Select the lowest current range for the multimeter that is
greater than one amp.
Note: If the multimeter is not set to the correct scale, the following measurement may
provide misleading results.
7. Crank the engine and record the following data:
________ Observed pressure reading from the pressure gauge
Note: If the gauge fluctuates use the average.
________ Observed engine speed from Cat ET
________ Observed "Injection Actuation Output Percent" from Cat ET
________ Current reading from the multimeter
Expected Result:
The oil pressure is above 29.5 MPa (4278 psi) and the current is above 400 mA.

Results:
OK - The oil pressure is above 29.5 MPa (4278 psi) and the current is above 400 mA. Leave
the system in the present configuration and proceed to Test Step 15.
Not OK - The oil pressure is below 29.5 MPa (4278 psi) and the current is above 400 mA.
Repair: Replace the unit injector hydraulic pump. If the drive gear on the pump is loose, do
not attempt to tighten the drive gear and reuse the pump. After the pump has been replaced,
the engine will need to be cranked for a significant length of time in order to fill the pump
with oil. Clear all diagnostic codes or event codes. Verify that the repair eliminates the
problem.If the problem still exists, consult your local technical communicator for assistance.
STOP
Not OK - The current is below 400 mA.
Repair: Refer to Troubleshooting, "Injection Actuation Pressure Control Valve Circuit - Test".
STOP
Test Step 15. Disconnect J500/P500 and Check the Oil Pressure
1. Disconnect the J500/P500 connector at the unit injector hydraulic pump.
2. Crank the engine and record the following data.
Note: The pressure readings may vary between gauges.
________ Observed pressure reading from the pressure gauge
________ Observed engine speed from Cat ET
________ Observed "Injection Actuation Output Percent" from Cat ET
Expected Result:
The oil pressure is below 8 MPa (1160 psi).
Results:
OK - The oil pressure is below 8 MPa (1160 psi). Return the system to the original
configuration and proceed to Test Step 16.
Not OK - The oil pressure is above 8 MPa (1160 psi). The unit injector hydraulic pump is
faulty.
Repair: Replace the unit injector hydraulic pump. After the pump has been replaced, the
engine will need to be cranked for a significant length of time in order to fill the pump with
oil. Clear all diagnostic codes or event codes. Verify that the repair eliminates the problem. If
the problem still exists, consult your local technical communicator for assistance.
STOP

Test Step 16. Use the "Cylinder Cutout Test" on Cat ET to Check the Fuel Injectors
The troubleshooting indicates that the unit injector hydraulic pump is working properly. Record the
following data:
________ Engine symptoms (misfire, excessive smoke, low power, runs rough)
________ Conditions when the engine symptom occurs, (high load, idle, cold start, acceleration, etc)
________ The frequency of the engine symptoms (intermittent, constant, etc)
1. Perform a cylinder cutout procedure if the test has not already been performed or if any other
repairs have been completed since the most recent cylinder cutout procedure. Refer to
Troubleshooting, "Injector Solenoid Circuit - Test" for troubleshooting details.
Expected Result:
The injectors are operating properly according to the "Injector Solenoid Circuit - Test". Also, the
engine symptoms are still present.
Results:
OK - The injectors are operating properly according to the "Injector Solenoid Circuit - Test".
Also, the engine symptoms are still present.
Repair: Consult your local technical communicator for assistance.
STOP
Not OK - The "Injector Solenoid Circuit - Test" indicates faulty injectors.
Repair: Replace the faulty injectors. Verify that the repair eliminates the problem. If the
problem still exists, consult your local technical communicator for assistance.
STOP

PARTS
Caterpillar
Hitachi
Volvo pro

AUTODATA
Caterpillar SIS
Volvo Impact
Volvo Prosis

 Hitachi HOP
Bosch ESPI
Part list

Spare parts
The names Cat, Caterpillar, John Deere, Komatsu, Volvo, Hitachi, Doosan, JCB, Hyundai or any
other original equipment manufacturers are registered trademarks of the respective original
equipment manufacturers. All names, descriptions, numbers and symbols are used for reference
purposes only.