PRESION ACTUCION 330C

download PRESION ACTUCION 330C

of 13

Transcript of PRESION ACTUCION 330C

  • 7/27/2019 PRESION ACTUCION 330C

    1/13

    Shutdown S

    Previous Screen

    Product: EXCAVATOR

    Model: 330C L EXCAVATOR CYA

    Configuration: 330C L Excavator CYA00001-UP (MACHINE) POWERED BY C-9 Engine

    TroubleshootingC-9 Engine for the 330C Excavator and for the 330C Mobile Hydraulic Power Unit

    Media Number -SENR9506-06 Publication Date -01/07/2009 Date Updated -07/07/2

    i0378

    Injection Actuation Pressure - Test

    SMCS - 1714-038

    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 eastep. 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 inncorrect 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)

    Pgina 130C L Excavator CYA00001-UP (MACHINE) POWERED BY C-9 Engine(SEBP3397 - 35) - Systems & Components

    26/09tps://sisweb.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/productsearch/productheaderinfof...

  • 7/27/2019 PRESION ACTUCION 330C

    2/13

    (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, 164-03, 164-04, 164-11, 42-11, 94-1 and 911.

    Connect the Caterpillar Electronic Technician (ET) to the data link connector.A.

    Turn the keyswitch to the ON position. DO NOT START THE ENGINE.B.

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

    Check for active diagnostic codes or logged diagnostic codes. The diagnostic codes should become active within 30 seconds.D.

    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.

    E.

    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.Rto Troubleshooting, "Injection Actuation Pressure Sensor - Test" if 164-02 is active or logged.Refer to Troubleshooting, "InjectionActuation Pressure Control Valve Circuit - Test" if 42-11 is active or logged. Refer to System Operation, Test and Adjusting, "FueSystem 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

    Inspect the engine for oil leaks in the HEUI oil rail. Repair leaks before proceeding. Clearly mark all leaks on returned parts.A.

    Note: Inspect the area near the high pressure oil rail and the unit injector hydraulic pump. If leakage is found between the transferpump and the hydraulic pump, refer to Special Instruction, REHS3830 for details. If leakage is found between the hydraulic pump the front housing, refer to Special Instruction, REHS3830 for details on replacing the seal.

    Check the engine oil level. If the engine oil level is low, add oil to the engine. Do not overfill the engine.B.

    Try to start the engine.C.

    Expected Result:

    The engine starts.

    Results:

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

    Pgina 230C L Excavator CYA00001-UP (MACHINE) POWERED BY C-9 Engine(SEBP3397 - 35) - Systems & Components

    26/09tps://sisweb.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/productsearch/productheaderinfof...

  • 7/27/2019 PRESION ACTUCION 330C

    3/13

    Not OK - The engine does not start. Proceed to Test Step 3.

    Test Step 3. Verify the Operation of the Injection Actuation Pressure Sensor

    Disconnect the connector for the injection actuation pressure sensor. Check for evidence of moisture in the connector. Refer toTroubleshooting, "Electrical Connectors - Inspect" for troubleshooting details.

    A.

    Try to start the engine.B.

    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 TStep 4.

    Not OK - The engine starts.

    Repair: The injection actuation pressure sensor may be faulty. Replace the sensor and reconnect the connector. Clear all diagnosticodes. 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

    Observe the status for "Engine Speed", "Actual Injection Actuation Pressure" and "Engine Oil Pressure" on Cat ET while the engincranking. Record the following data:

    A.

    ________ 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 iscranking.

    Results:

    OK - The observed engine speed is above 100 rpm and the actual injection actuation pressure is at least 6 MPa (870 psi) while theengine 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

    Pgina 330C L Excavator CYA00001-UP (MACHINE) POWERED BY C-9 Engine(SEBP3397 - 35) - Systems & Components

    26/09tps://sisweb.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/productsearch/productheaderinfof...

  • 7/27/2019 PRESION ACTUCION 330C

    4/13

    Not OK - The observed engine speed is above 100 rpm and the observed engine oil pressure is above 14 kPa (2 psi) and the actualinjection 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 g01330859

    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

    Pgina 430C L Excavator CYA00001-UP (MACHINE) POWERED BY C-9 Engine(SEBP3397 - 35) - Systems & Components

    26/09tps://sisweb.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/productsearch/productheaderinfof...

  • 7/27/2019 PRESION ACTUCION 330C

    5/13

    Illustration 3 g01330939

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

    (1) Connector at the valve cover

    (2) J2/P2 ECM connectors

    Turn the key to the "OFF" position. An electrical shock hazard is present if the key is not in the "OFF" position.A.

    Disconnect the connector for the injector harness at the valve cover. Check for evidence of moisture in the connector. Refer toTroubleshooting, "Electrical Connectors - Inspect" for troubleshooting details.

    B.

    Crank the engine for 15 seconds.C.

    Check Cat ET for logged diagnostic codes that are related to the injector solenoids.D.

    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 ECM and the fuel injectors. Turn the key to the "OFF" position. Reconnect the connector for the injector harness. Clear all diagnoscodes. 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 codfor the injector solenoid. Turn the key to the "OFF" position. Reconnect the connector for the injector harness. Clear any diagnosticcodes or event codes. Refer to Troubleshooting, "Injector Solenoid Circuit - Test".

    STOP

    Test Step 6. Check the Pressure of the Low Pressure Fuel System

    Pgina 530C L Excavator CYA00001-UP (MACHINE) POWERED BY C-9 Engine(SEBP3397 - 35) - Systems & Components

    26/09tps://sisweb.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/productsearch/productheaderinfof...

  • 7/27/2019 PRESION ACTUCION 330C

    6/13

    Observe the status for "Fuel Pressure" on Cat ET while the engine is cranking. Record the fuel pressure.A.

    ________ 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 cliccan 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 benergized. Replace injectors that do not produce an audible click. Verify the repair. If all injectors produce an audible click and theengine 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

    Disconnect the J500/P500 IAPCV connector from the unit injector hydraulic pump.A.

    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 telamp 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.

    Insert a 186-3735 Connector Pin into each of the P500 harness connector sockets .B.

    Connect a voltage test lamp to the connector pins that are inserted in the P500 connector.C.

    Crank the engine and watch the test lamp.D.

    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 isOK. 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 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.

    Pgina 630C L Excavator CYA00001-UP (MACHINE) POWERED BY C-9 Engine(SEBP3397 - 35) - Systems & Components

    26/09tps://sisweb.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/productsearch/productheaderinfof...

  • 7/27/2019 PRESION ACTUCION 330C

    7/13

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

    Remove the valve cover and inspect the high pressure oil system for excessive oil leaks or discharge.A.

    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 aexcessive discharge of oil. All six injectors should discharge the same amount of oil. Excessive leakage or discharge can cause issuwith the system pressure. Record the following data:

    B.

    ________ Any injectors with excessive leakage or discharge

    Turn the key to the "OFF" position. A electrical shock hazard is present if the key is not turned to the "OFF" position.C.

    Disconnect the connector for the injector harness at the valve cover. Check for evidence of moisture in the connector. Refer toTroubleshooting, "Electrical Connectors - Inspect" for troubleshooting details.

    D.

    Crank the engine. Observe the injector bores for any signs of leakage. Inspect the spill ports on the injectors for an excessive dischaof 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:

    E.

    ________ Any injectors with excessive leakage or discharge

    ________Actual injection actuation pressure

    Clear any diagnostic codes that are logged.F.

    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 theinjector.

    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 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 pressurewas 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 identifiedwith 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.

    Pgina 730C L Excavator CYA00001-UP (MACHINE) POWERED BY C-9 Engine(SEBP3397 - 35) - Systems & Components

    26/09tps://sisweb.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/productsearch/productheaderinfof...

  • 7/27/2019 PRESION ACTUCION 330C

    8/13

    Turn the key to the "OFF" position. A electrical shock hazard is present if the key is not in the "OFF" position.A.

    Reconnect the connector for the injector harness at the valve cover and install the valve cover.B.

    Try to start the engine. Observe the status for "Actual Injection Actuation Pressure" on Cat ET while the engine is cranking. Recorthe actual injection actuation pressure.

    C.

    ________ 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 neebe cranked for a significant length of time in order to fill the pump with oil after the pump has been replaced. Clear all diagnosticcodes.

    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 technicalcommunicator 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 additivepackage 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.

    Start the engine.A.

    Observe the status for "Fuel Pressure" and "Engine Oil Pressure" on Cat ET while the engine is running. Record the following dataB.

    ________ 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.

    Pgina 830C L Excavator CYA00001-UP (MACHINE) POWERED BY C-9 Engine(SEBP3397 - 35) - Systems & Components

    26/09tps://sisweb.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/productsearch/productheaderinfof...

  • 7/27/2019 PRESION ACTUCION 330C

    9/13

    Repair: Refer to Systems Operation, Testing and Adjusting, "Fuel System Pressure - Test" and Systems Operation/Testing andAdjusting, "Engine Oil Pressure - Test" in order to verify that the observed fuel pressure and engine oil pressures are acceptable.If -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 SysteOperation, 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 filtOil changes are not covered by the warranty. After the engine oil and the oil filter have been changed, operate the engine until norm

    operating temperature has been reached. Operate the engine at 1200 to 1500 rpm for 15 minutes. This will purge any trapped air ordebris 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

    Install the 8T-0852 Pressure Gauge in an accessible port in the high pressure part of the injection actuation system.A.

    Start the engine.B.

    Access the "Injection Actuation Pressure Test" in the "Diagnostics Menu" of Cat ET and begin the test.C.

    Note: The "Injection Actuation Pressure Test" can be used to increase the injection actuation pressure. Also, the "Injection Actuati

    Pressure Test" can be used to decrease the injection actuation pressure. The test adjusts the oil pressure of the injection actuationsystem in predefined steps. Step forward through all predefined steps in the test. Next, step backward through all predefined steps ithe test.

    Record the pressure readings from the pressure gauge and from Cat ET in Table1.D.

    Step Manual pressure gauge Actual injection actuation pressure from Cat ET Difference

    1

    2

    3

    4

    3

    2

    1

    Table 1

    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 13kPa (200 psi).

    Note: Under some situations, the injection actuation pressure may not change. This step compares the pressure reading from the pressuregauge 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 stepwithin 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 eachstep are not within 1379 kPa (200 psi).

    Pgina 930C L Excavator CYA00001-UP (MACHINE) POWERED BY C-9 Engine(SEBP3397 - 35) - Systems & Components

    26/09tps://sisweb.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/productsearch/productheaderinfof...

  • 7/27/2019 PRESION ACTUCION 330C

    10/13

    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

    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.

    A.

    Note: There may be a short lag in the reaction to the injection pressure. The pressure change should occur within two seconds of eacommand.

    Record the actual injection actuation pressure, the desired injection actuation pressure and the percent output from Cat ET in TableB.

    Low Idle

    Step Actual injection actuation pressurefrom Cat ET (A)

    Desired injection actuationpressure from Cat ET (B)

    Difference (A-B)

    Percent Output froCat ET

    1

    2

    3

    4

    3

    2

    1

    Table 2

    Expected Result:

    The actual injection actuation pressure is no more than 1379 kPa (200 psi) above the desired injection actuation pressure for each step. Alshe 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 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 actuationpressure 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 asignificant length of time in order to fill the pump with oil. Clear all diagnostic codes or event codes. Verify that the repair eliminatthe 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.

    Remove the valve cover and inspect the high pressure oil system for excessive oil leaks or discharge.A.

    Pgina 1030C L Excavator CYA00001-UP (MACHINE) POWERED BY C-9 Engine(SEBP3397 - 35) - Systems & Components

    26/09tps://sisweb.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/productsearch/productheaderinfof...

  • 7/27/2019 PRESION ACTUCION 330C

    11/13

    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 theinjectors for an excessive discharge of oil. All six injectors should discharge the same amount of oil. Excessive leakage or dischargcan cause issues with the system pressure.

    B.

    While the engine is at low idle, perform the "Injection Actuation Pressure Test" in Cat ET. Run the test at the highest pressure in orto maximize any possible leaks. Observe the status for "Actual Injection Actuation Pressure" on Cat ET. Record the following data

    C.

    ________ Any injectors with excessive leakage or discharge

    ________ Actual injection actuation pressure at low idle

    Turn the key to the "OFF" position. A electrical shock hazard is present if the key is not turned to the "OFF" position.D.

    Disconnect the connector for the injector harness at the valve cover. Check for evidence of moisture in the connector. Refer toTroubleshooting, "Electrical Connectors - Inspect" for troubleshooting details.

    E.

    Crank the engine. Observe the injector bores for any signs of leakage. Inspect the spill ports on the injectors for an excessive dischaof oil. The injectors are now disabled and the injectors should discharge very little oil, which is normal.

    F.

    While the engine is cranking, perform the "Injection Actuation Pressure Test" in Cat ET. Run the test at the highest pressure in ordmaximize any possible leaks. Observe the status for "Actual Injection Actuation Pressure" on Cat ET. Record the following data:

    G.

    ________ Any injectors with excessive leakage or discharge

    ________ Actual injection actuation pressure while the engine is cranking

    Clear any diagnostic codes that are logged.H.

    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 theinjector. 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 theinjector.

    Repair: Replace the O-ring on the injector(s) that is leaking around the bore(s) or replace the damaged injector(s) that is identifiedwith 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)

    Turn the key to the "OFF" position. A electrical shock hazard is present if the key is not turned to the "OFF" position.A.

    Reconnect the connector for the injector harness at the valve cover and install the valve cover.B.

    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.

    Install the 8T-0852 Pressure Gauge in an accessible port in the high pressure portion of the injection actuation system.C.

    Disconnect the connector for the injection actuation pressure sensor and plug a spare injection actuation pressure sensor into theengine harness. Allow the spare sensor to hang on the side of the engine.

    D.

    Pgina 1130C L Excavator CYA00001-UP (MACHINE) POWERED BY C-9 Engine(SEBP3397 - 35) - Systems & Components

    26/09tps://sisweb.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/productsearch/productheaderinfof...

  • 7/27/2019 PRESION ACTUCION 330C

    12/13

    Note: This configuration allows the unit injector hydraulic pump to build maximum pressure. The engine will not start in thisconfiguration.

    Install a 224-9282 Adapter Cable As in series with the P500 connector. Reconnect the P500/J500 connector.E.

    Note: There must be a continuous electrical connection between the ECM and the unit injector hydraulic pump. The improperconnection or the incomplete connection of the adapter cable may provide incorrect results.

    Connect a multimeter that is capable of measuring current that is 0 to 1,000 milliampere in series with the adapter cable. Select thelowest current range for the multimeter that is greater than one amp.

    F.

    Note: If the multimeter is not set to the correct scale, the following measurement may provide misleading results.

    Crank the engine and record the following data:G.

    ________ 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 configuratioand 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 anreuse the pump. After the pump has been replaced, the engine will need to be cranked for a significant length of time in order to fil

    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

    Disconnect the J500/P500 connector at the unit injector hydraulic pump.A.

    Crank the engine and record the following data.B.

    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.

    Pgina 1230C L Excavator CYA00001-UP (MACHINE) POWERED BY C-9 Engine(SEBP3397 - 35) - Systems & Components

    26/09tps://sisweb.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/productsearch/productheaderinfof...

  • 7/27/2019 PRESION ACTUCION 330C

    13/13

    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 asignificant length of time in order to fill the pump with oil. Clear all diagnostic codes or event codes. Verify that the repair eliminatthe 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)

    Perform a cylinder cutout procedure if the test has not already been performed or if any other repairs have been completed since thmost recent cylinder cutout procedure. Refer to Troubleshooting, "Injector Solenoid Circuit - Test" for troubleshooting details.

    A.

    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 stillpresent.

    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 localtechnical communicator for assistance.

    STOP

    Copyright 1993 - 2012 Caterpillar Inc.

    All Rights Reserved.

    Private Network For SIS Licensees.

    Wed Sep 26 17:19:53 EST 2

    Pgina 1330C L Excavator CYA00001-UP (MACHINE) POWERED BY C-9 Engine(SEBP3397 - 35) - Systems & Components