COMPONENT CODE A0

PARTS & SERVICE REF NO.

DATE
AT03093
Jun. 3, 2003
NEWS Page 1 of 15

SUBJECT: INTRODUCTION OF INVESTIGATION PROCEDURE WHEN E97b, E97c

WERE INDICATED ON THE MONITOR ON CRI ENGINES

PURPOSE: To introduce the investigation procedure when the non-force feed errors (E97b
and E97c) were indicated on the monitor on CRI ENGINES

APPLICATION: Engines on which the common rails are mounted

(125 and 140 Series Engines)

FAILURE CODE: A010MA

DESCRIPTION:

1. Introduction
When the titled failures occur, carry out the troubleshooting by this service news.

Printed in Japan AT03093

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Causes investigation procedures when the common rail engine

non-force feed errors (Error codes; E97b and E97c) were issued.

Non-force feed errors (Error code; E97b and E97c) are as follows. The abnormal
state is that the supply pump on the common rail injection group functions at the upper
limit state of the discharge ability.

For these causes, the following are assumed. Therefore, take the investigation according to the
procedures.
The following procedures are lined- up by the order of investigation easiness.
(Refer together to the investigation method matrix and the fuel system circuit diagram, which are
included in this service news.)
As for each portion, refer to the fuel system circuit diagram and the figures of the part catalog.
In addition, when investigating the failure, use the investigation sheet. As for the jigs, etc for the
measurement, refer to the pages 5 and 6.

Procedures for the cause investigation

1. Confirm whether the suitable fuel, which is based on the fuel recommendation described
in Operation and Maintenance Manual, is used.
For example, if the cold weather fuel is used in the hot season, this means that the low viscous fuel
is used in the hot state. For this sake, the internal leakage volume at each portion of the injection
system is increased, and the margin of discharge ability does not exist. And as the result, the non-
force feed error may be temporarily issued. When this status is judged, change to the suitable fuel.

2. Confirm whether the looseness is found at the tightening portion of the fuel piping, and
whether the fuel leaks to the outside.
After stopping the engine, confirm whether the fuel leaks from the high pressure fuel circuit and the
low pressure fuel circuit, or whether the looseness is found at the fuel piping. Especially as for the
piping at the suction side from the fuel tank to the feed pump, if it is loosened, the fuel does not leak.
Therefore, take the special care for this.
On the other hand, never inspect the fuel leakage by approaching the engine when it is running. For
this reason, if the large amount of fuel leaks, it is very dangerous.

3. Confirm whether the fuel filter is clogged.

The replacing periodical time of the fuel filter is usually 500 hours. In the case that the sulfur is
much in the fuel, when the content is 0.5 to 1.0%, it is 250 hours, and when the content is more than
1.0%, it is 125 hours. Refer to Operation and Maintenance Manual.
When the clogging is suspected, replace with the new fuel filter.

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4. At the upper-stream side of the fuel filter, as shown by the circuit diagram, the gauze filter
1 and the tank strainer 2 are installed. For the sake, remove them respectively, and
confirm whether they are clogged by the foreign maters such as dusts. In addition, de-
pending on the area, the additional fuel filter for the degraded fuel is installed. Therefore,
confirm whether it is also clogged.
When the gauze filter or the tank strainer is clogged by the foreign matters, clean them.
(On the hydraulic excavators and the bulldozers, two filters and one strainer are installed. Except
their models, one filter and one strainer are installed.)
The replacing periodical time of the additional fuel filter is usually 500 hours.
When the clogging is suspected, replace with the new fuel filter.

5. Inspect the air breather of fuel tank.

When the air breather of fuel tank is clogged, the fuel supply is short. Therefore, the failure occurs.
At this time, clean the air breather as quickly as possible, and do the action so that the hoses are
prevented from deforming.

6. Confirm the error codes, again. Especially, confirm whether the error codes except the
non-force feed error, which indicate that the electric line is disconnected or insufficiently
connected, are issued.
When the disconnection or the insufficient connection of connector portions occurs in the pressure
sensor 3 circuit shown in the circuit diagram, this state is mistakenly judged as that the pressure
within the common rail is low. Therefore, the discharge volume of the supply pump is increased in
order to compensate the shortage.
In this case, the actual pressure within the common rail is excessively increased and as a result, the
pressure limiter 4 is opened. For this sake, the margin of the discharge ability for the supply pump
does not exist and the non-force feed error is issued.
When the state is judged so, remove and insert the connectors in order to avoid the insufficient
connection. In addition, confirm whether the disconnection or the insufficient connection of each
harness exists

7. Disconnect the PCV connector 5 at the one side of supply pump, and try to run the engine
on the reduced cylinders, and confirm whether the engine starts. If the engine does not
start, the probability, that the connected PCV is abnormal, is high.
When the state is judged so, replace the supply pump with the new one.
In addition, when the engine runs on the reduced cylinders, the disconnection error code is issued.
For this reason, after canceling this code indication, try to run the engine on the reduced cylinder at
the other side of supply pump. (This is the action which avoids the misjudgment.)
As for the canceling method of the error code, refer to Shop Manual of each model.

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8. Measure the pressure of the low pressure fuel circuit 6, and confirm whether the value is
0.15 ~ 0.3 Mpa (1.5 ~ 3.0 kg/cm2). (Measure at the high idling.)
If this pressure is low, there is the probability that the fuel suction ability is insufficient due to the
feed pump 7 wear. When the state is judged so, it is required that the supply pump assy is replaced.

9. Measure the spill volume of the injector spill circuit 8, and confirm whether it is more
than the value which is described in Shop Manual.
If the spill volume is more, there is the probability that the spill volume is excessive due to the wear
of the injector two-way valve 9.
When the state is judged so, it is required that the injector assy is replaced.

10. Measure the drain volume of the common rail pressure limiter circuit !0, and confirm
whether it is less than 10 cc/Min.
If the drain volume is more, there is the probability that the drain volume is excessive due to the wear
of the pressure limiter 4.
When the state is judged so, it is required that the common rail assy is replaced.

11. Confirm the tightening torque for the PCV main body of the supply pump.
(Spec: 17 1 kgm)
When the tightening torque is loose, it is not required to replace the parts, but tighten by the specified
torque.

The investigation procedures, which are described above, are thought as the most
efficient ones.
When executing the investigation of each item, refer to Shop Manual, too.

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 Cause investigation method for Measurement method
1 2 3 5
the non-force feed error issue Portion Fuel piping Fuel filter (Std. filter) Common rail
(Continuous on the next page.) Measurement of Measurement of
Contents Investigation for the kind of fuel Visual check the fuel pressure at the fuel flow from
the clean side the pressure limiter
The low viscous fuel The high asphaltene fuel
Abnormal
equivalent to the equivalent to the A Leakage is found. Less than 1.5 kg/cm2 More than 10 cc/min
value
kerosene is used. heavy oil is used.
Measure- Stall (relief) point Stall (relief) point
ment (When the non-force feed (When the non-force
Field action condition error does not exist.) feed error occurs.)
By using the low viscous fuel at the high temperature
When the temperature is high, use
1 state, the internal leakage volume is much, and the
the high viscous fuel.
force feed ability of the supply pump is short.
Due to the fuel leakage from the fuel pipes or the fuel
2 pipe tightening portions, the fuel supply is short.
Repair the fuel leakage.
3 The standard fuel filter is clogged. Replace the fuel filter cartridge.
The additional fuel filter for the degraded fuelarea is Replace the fuel filter cartridge, and
4 clogged, or the tank strainer or the gauze filter is clogged. clean the strainer and the gauze filter.
5 The air breather of fuel tank is clogged. Clean the air breather.
Check the connector looseness.
The connection of harness connector is insufficient or
6 the sensor malfunctions.
Replace the connectors and the
sensors.
By using the low viscous fuel such as the kerosene, the
Replace the supply pump assy
supply pump PCV (Pressure Control Valve) wears
or replace only the PCV.
7 abnormally.
The internal part of the supply pump PCV is abnormal Replace the supply pump assy
(Malfunctioning). or replace only the PCV.
By using the low viscous fuel such as the kerosene,
8 the supply pump (feed pump) wears abnormally.
Replace the supply pump assy.
Due to the foreign matters, the injector two-way valve
9 wears abnormally.
Replace the injector.

Due to the repetition of pressure limiter opening/closing,

10 the seat wear progresses. The valve cracking pressure Replace the pressure limiter.
is decreased.
The tightening torque of the supply pump PCV
11 (Pressure Control Valve) is short.
Retighten the PCV.

Remarks
Measurement jigs Measurement jigs
are required. are required.
Spacer (shim),
Special tool PM clinic kit
measuring cup
The measurement is
Measure-
executed at the PT1/8 The fuel is measured
ment
plug portion of the fuel by the measuring cup.
method

Page 5 of 15
filter head.
The fuel may be merged
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with the fuel from the

over-flow and the spill.
Precaution
In this case, separate
the flow, and measure
independently.
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Cause investigation method for Measurement method
6 7 8 9
the non-force feed error issue Portion Supply pump Injector Supply pump Common rail
(Continuous from the previous page.) Operation on the Fuel flow
Tightening torque Voltage measurement
Contents reduced cylinder for measurement on
of PCV is inspected. of the pressure sensor
the PVC the spill circuit
More than 1000 cc/min
Abnormal Engine starting is (diesel fuel) More than 4V
value impossible. More than 1500 cc/min Less than 1V
(kerosene)
Measure- Stall (relief) point Stall (relief) point
ment (When the non-force (When the non-force
Field action condition feed error does not exist.) feed error does not exist.)
By using the low viscous fuel at the high temperature
When the temperature is high, use
1 state, the internal leakage volume is much, and the
the high viscous fuel.
force feed ability of the supply pump is short.
Due to the fuel leakage from the fuel pipes or the fuel
2 pipe tightening portions, the fuel supply is short.
Repair the fuel leakage.

3 The standard fuel filter is clogged. Replace the fuel filter cartridge.
The additional fuel filter for the degraded fuelarea is Replace the fuel filter cartridge, and
4 clogged, or the tank strainer or the gauze filter is clogged. clean the strainer and the gauze filter.
5 The air breather of fuel tank is clogged. Clean the air breather.
Check the connector looseness.
The connection of harness connector is insufficient or
6 the sensor malfunctions.
Replace the connectors and the
sensors.
By using the low viscous fuel such as the kerosene, the
Replace the supply pump assy
supply pump PCV (Pressure Control Valve) wears
or replace only the PCV.
7 abnormally.
The internal part of the supply pump PCV is abnormal Replace the supply pump assy
(Malfunctioning). or replace only the PCV.
By using the low viscous fuel such as the kerosene,
8 the supply pump (feed pump) wears abnormally.
Replace the supply pump assy.

Due to the foreign matters, the injector two-way valve

9 wears abnormally.
Replace the injector.
Due to the repetition of pressure limiter opening/closing,
10 the seat wear progresses. The valve cracking pressure Replace the pressure limiter.
is decreased.
The tightening torque of the supply pump PCV
11 (Pressure Control Valve) is short.
Retighten the PCV.
Remarks
Measurement jigs Measurement jigs
are required. are required.
Spacer (shim), Torque wrench, T branch
Special tool
measuring cup socket (42 mm)
Measure-
The fuel is measured
ment
by the measuring cup.
method
The fuel may be merged
with the fuel from the
pressure limiter.
Precaution
In this case, separate
the flow, and measure
independently.
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Common Rail Injection Group Fuel System and Electronic Control System

Two-way valve 9
Bar filter (30 )
8

Injector

Pressure sensor 3 Fuel filter (5 ) 6

Common rail
Pressure limiter 4 Additional fuel filter
Engine Valve cracking pressure
Pressure Control Valve (PCV) Valve cracking for the degraded fuel
controller (1450 kg/cm2)
pressure
Supply pump
5.0 kg/cm2
5 Feed pump
7

!0 Rotation sensor
(G sensor) *Gauze filter (30 mesh) 1
2
Overflow valve
Strainer (60 mesh)
Valve cracking pressure (2.6 kg/cm2)
Inlet strainer
*Gauze filter (30 mesh) 1 (40 mesh)

Rotation sensor (NE sensor)

Fuel tank

* In case of PC600, PC750 (PC800) and D155, these are installed to two places
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Attached fig.: Designation of the common rail portions

Pressure limiter
4 Pressure sensor
Common rail
main body 3

Attached fig.: Gauze filter position

7
Supply pump main body

1
Gauze filter

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Attached fig.: Gauze filter position

1
Gauze filter

Priming
pump

Fuel filter head

PT1/8 portion

7
Supply pump

This gauze filter is applied for D155, PC600, PC750 (PC800) and D275.

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Attached fig.: Tank strainer

2
Fuel tank strainer

This figure indicates PC600. As for the other models, confirm the configuration by their part manuals, etc.

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Attached fig.: PCV valve

PCV connector
(Used during the operation
on the reduced cylinder.)

5
PCV valve

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Attached fig.: Spill circuit (140 engine piping)

Spill pipe
8

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Attached fig.: Injector

Injector
(2-way valve)

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Attached fig.: Pressure limiter piping

Pressure limiter pipe

!0

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Failure Investigation Items of Non-force Feed Error for the Common Rail Mounted Engines
Model name Machine Ser. No.
Special specification Delivery date
Engine type Engine Ser. No.
Controller part No. Controller Ser. No.
SMR Occurrence day & time
Jobsite DB name
User name Work contents
Used fuel Used oil
Status of failure occurrence

Measurement
Li Hi Stall (relief) Stall + Relief
method
Engine speed Monitor
Injection volume
Injection timing
Rail pressure (actual)
Rail pressure
(indicated pressure)
Boost pressure
Acceleration opening
Fuel temperature
Spill flow Measurement
Overflow
Common rail relief flow
Fuel filter pressure
Single bank operation result

Filter replacing interval

Error code indication

Note) (1) WA500, WZ4000, CS360 and GS500 have not the monitoring function. Therefore, only
the measurement items can be measured.
(2) When measuring each flow, separate the merged pipes.
(3) As for the measurement of the relief flow, measure it as possible as can when the failure
(non-force feed error) occurs.
(4) When measuring each flow, measure simultaneously 1 Engine speed, 2 Injection vol-
ume and 3 Injection pressure (both).

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