Injector Prerssure Test

C7 Industrial Engine JTF00001-UP(SEBP4436 - 42) - Documentation Page 1 of 18
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Product: INDUSTRIAL ENGINE

Model: C7 INDUSTRIAL ENGINE JTF
Configuration: C7 Industrial Engine JTF00001-UP
Troubleshooting
C7 and C9 Industrial Engines and C7 Petroleum Engine
Media Number -RENR2418-08 Publication Date -01/07/2009 Date Updated -16/07/2009
i03781969
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 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.
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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, 164
-03, 164-04, 164-11, 42-11, 94-1 and 94-11.
A. Connect the Caterpillar Electronic Technician (ET) to the data link connector.
B. Turn the keyswitch to the ON position. DO NOT START THE ENGINE.
C. Print the "Lifetime Totals" and the "Configuration" screen.
D. Check for active diagnostic codes or logged diagnostic codes. The diagnostic codes should
become active within 30 seconds.
E. 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
A. 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.
B. Check the engine oil level. If the engine oil level is low, add oil to the engine. Do not
overfill the engine.
C. 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
A. 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.
B. 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
A. 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.
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
Location of the connectors for the injector solenoids ( C9 engines)
(1) Connector at the valve cover
(2) J2/P2 ECM connectors
A. Turn the key to the "OFF" position. An electrical shock hazard is present if the key is not in
the "OFF" position.
B. Disconnect the connector for the injector harness at the valve cover. Check for evidence of
C. Crank the engine for 15 seconds.
D. 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.
• 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
A. 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
A. 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.
B. Insert a 186-3735 Connector Pin into each of the P500 harness connector sockets .
C. Connect a voltage test lamp to the connector pins that are inserted in the P500 connector.
D. 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.
volts.
A. Remove the valve cover and inspect the high pressure oil system for excessive oil leaks or
discharge.
B. 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
C. 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
E. 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:
________Actual injection actuation pressure
F. 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.
Test Step 9. Try to Start the Engine
volts.
A. Turn the key to the "OFF" position. A electrical shock hazard is present if the key is not in
the "OFF" position.
B. Reconnect the connector for the injector harness at the valve cover and install the valve
cover.
C. 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.
A. Start the engine.
B. 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.
• 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
A. Install the 8T-0852 Pressure Gauge in an accessible port in the high pressure part of the
injection actuation system.
B. Start the engine.
C. 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.
D. Record the pressure readings from the pressure gauge and from Cat ET in Table1.
Table 1
Step Manual pressure Actual injection actuation pressure Difference
gauge from Cat ET
1
2
3
4
3
2
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 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.
• 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
A. 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.
B. 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
Actual injection Desired injection Percent
Step Difference
actuation pressure actuation pressure Output from
(A-B)
from Cat ET (A) from Cat ET (B) Cat ET
1
2
3
4
3
2
1
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.
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.
A. Remove the valve cover and inspect the high pressure oil system for excessive oil leaks or
discharge.
B. 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.
C. 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:
________ Actual injection actuation pressure at low idle
D. Turn the key to the "OFF" position. A electrical shock hazard is present if the key is not
E. Disconnect the connector for the injector harness at the valve cover. Check for evidence of
F. 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.
G. 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:
________ Actual injection actuation pressure while the engine is cranking
H. 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)
A. Turn the key to the "OFF" position. A electrical shock hazard is present if the key is not
B. 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.
C. Install the 8T-0852 Pressure Gauge in an accessible port in the high pressure portion of the
injection actuation system.
D. 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.
E. 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.
F. 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.
G. 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
A. Disconnect the J500/P500 connector at the unit injector hydraulic pump.
B. 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)
A. 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
Copyright 1993 - 2017 Caterpillar Inc. Wed Nov 8 00:34:52 UTC+0200 2017
All Rights Reserved.
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C7 Industrial Engine JTF00001-UP(SEBP4436 - 42) - Documentation Page 1 of 18

Product: INDUSTRIAL ENGINE

Injection Actuation Pressure - Test

System Operation Description:

Left side of engine (typical example)

(2) Injection actuation pressure sensor

Test Step 1. Symptoms

• The engine cranks but the engine will not start.

• The engine runs rough.

• The engine is erratic or unstable at idle or running.

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

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

Document all active diagnostic codes or logged diagnostic codes.________

• OK - There are no active codes or logged codes. Proceed to Test Step 2.

• Not OK - Active codes or logged codes are present.

Test Step 2. Start the Engine

C. Try to start the engine.

The engine starts.

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

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

B. Try to start the engine.

The engine does not start.

• Not OK - The engine starts.

If the problem still exists, proceed to Test Step 4.

________ Engine Speed

________ Actual injection actuation pressure

________ Desired injection actuation pressure

________ Engine oil pressure

________ Fuel pressure

________ Engine coolant temperature

________ Observed "Injection Actuation Output Percent"

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".

Location of the connectors for the injector solenoids ( C7 engines)

(1) Connector at the valve cover

(2) J2/P2 ECM connectors

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

(1) Connector at the valve cover

(2) J2/P2 ECM connectors

C. Crank the engine for 15 seconds.

________ Fuel Pressure

D. Crank the engine and watch the test lamp.

The test lamp illuminates while the engine is cranking.

Repair: Refer to Troubleshooting, "Injection Actuation Pressure Control Valve Circuit -

Hot oil and components can cause personal injury.

Do not allow hot oil or components to contact skin.

________ Any injectors with excessive leakage or discharge

________ Any injectors with excessive leakage or discharge

________Actual injection actuation pressure

F. Clear any diagnostic codes that are logged.

Proceed to Test Step 9.

Test Step 9. Try to Start the Engine

________ Actual injection actuation pressure

The engine starts.

• OK - The engine starts.STOP

If the engine does not start, proceed to Test Step 5.

Always use a board or cardboard when checking for a leak.

A. Start the engine.

________ Observed fuel pressure from Cat ET

________ Observed engine oil pressure from Cat ET

________ Drain interval

________ Miles or Kilometers since the last oil change

If the problem still exists, proceed to Test Step 11.