REHS3819-02 Procedure For Troubleshooting and Cleaning The Oil Rail System For The HEUI

 

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Special Instruction  Procedure for Troubleshooting and Cleaning the Oil Rail System for the Hydraulic Electronic Unit Injector (HEUI) {1100, Media Number -REHS3819-02

1126, 1250, 1251, 1261,Date 1290}   Publication -15/05/2008

Date Updated -15/05/2008

 

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Procedure for Troubleshooting Troubleshooting and Cleaning the Oil Rail System for the Hydraulic Electronic Unit Injector (HEUI) {1100, 1126, 1250, 1251, 1261, 1290} SMCS - 1100-535; - 1100-535; 1126-535; 1250-535; 1251-535; 1261-535; 1290-535 On-Highway Engine: C7 TRUCK/BUS (S/N: YPG1-UP) C7 (S/N: WAX1-UP; C7T1-UP; SAP1-UP; KAL1-UP) C9 (S/N: 9DG1-UP; LFE1-UP; MTB1-UP) Agriculturall Tractor: Agricultura MT755 (S/N: ALM1-UP) MT765 MTS (S/N: AMS1-UP) MTC755 MTS (S/N: 8141-UP) MTC765 MTS (S/N: 8151-UP) Asphalt Paver: AP-1000D (S/N: EAD1-UP) AP-1055D (S/N: FAC1-UP; A6P1-UP) AP-755 (S/N: B3T1-UP) BG-2455D (S/N: BNW1-UP) BG-260D (S/N: BPW1-UP) Cold Planer: PM-102 (S/N: Z2X1-UP) Combine: Lexion 470 R COMBINE HARVESTER (S/N: 7651-UP; 4ZF1-UP) Lexion 475 R COMBINE HARVESTER (S/N: 7671-UP) Landfill Compactor: 816F Series 2 (S/N: BZR1-UP) Soil Compactor: 815F Series 2 (S/N: BYN1-UP) Generator Set: C9 GEN SET (S/N: X3R1-UP; C9E1-UP) C9 MARINE GEN (S/N: SJB1-UP) C9 MARINE GS (S/N: C9A1-UP) Industrial Engine: C7 (S/N: JRA1-UP; JTF1-UP) C-9 (S/N: CLJ1-UP) C9 INDUSTRIAL (S/N: JSC1-UP; MBD1-UP; JLW1-UP) Marine Engine: C7 MARINE (S/N: M7A1-UP; C7B1-UP; C7D1-UP; M7G1-UP; C7X1-UP; C7Z1-UP) C9 MARINE (S/N: C9B1-UP; CSN1-UP; X9X1-UP; Z9X1-UP; X9Y1-UP) Petroleum Engine: C7 PETROLEUM (S/N: C7P1-UP; K2A1-UP) C9 PETROLEUM (S/N: P9L1-UP; KLW1-UP) Excavator:

 

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324D L (S/N: LAB1-UP) 324D LN (S/N: EJC1-UP) 324D L (S/N: T2D1-UP; BYE1-UP; JJG1-UP) 324D (S/N: ECH1-UP) 324D L (S/N: SYM1-UP) 324D (S/N: AWN1-UP) 324D L (S/N: DFP1-UP) 324D FOREST MACHINE (S/N: JKR1-UP) 324D LL FOREST MACHINE (S/N: JLS1-UP) 324D (S/N: CJX1-UP) 325D L (S/N: GPB1-UP; KBE1-UP) 325D LN (S/N: PKE1-UP) 325D (S/N: KDG1-UP; DBH1-UP) 325D FOREST MACHINE (S/N: C7K1-UP) 325D (S/N: RJK1-UP) 325D LL FOREST MACHINE (S/N: C8L1-UP) 325D L (S/N: LAL1-UP) 325D (S/N: MCL1-UP) 325D L (S/N: PAL1-UP) 325D (S/N: CJM1-UP) 325D LL FOREST MACHINE (S/N: C9M1-UP) 325D L (S/N: DAP1-UP; A3R1-UP) 325D MH (S/N: GBR1-UP) 325D L (S/N: SCR1-UP; T2S1-UP) 328D LCR (S/N: GTN1-UP; MKR1-UP) 330C L (S/N: CYA1-UP; HAA1-UP) 330C (S/N: MCA1-UP; JAB1-UP; D3C1-UP; JCD1-UP) 330C L (S/N: KDD1-UP) 330C (S/N: GAG1-UP; RBH1-UP; B1K1-UP) 330C L (S/N: JNK1-UP) 330C (S/N: B2L1-UP; BTM1-UP) 330C L (S/N: MKM1-UP) 330C (S/N: B4N1-UP) 330C L (S/N: CAP1-UP; GKX1-UP; DKY1-UP) 330C LN (S/N: CGZ1-UP) 330D L (S/N: RDA1-UP) 330D (S/N: KAB1-UP; PFC1-UP) 330D L (S/N: NBD1-UP) 330D LN (S/N: GGE1-UP) 330D L (S/N: NEF1-UP; B6H1-UP) 330D (S/N: EAH1-UP; LCJ1-UP) 330D L (S/N: THJ1-UP) 330D LL FOREST MACHINE (S/N: E4K1-UP) 330D L (S/N: FFK1-UP) 330D LL FOREST MACHINE (S/N: H3K1-UP) 330D FOREST MACHINE (S/N: L2K1-UP) 330D (S/N: PCK1-UP; LEM1-UP) 330D L (S/N: LRM1-UP; ERN1-UP; JLP1-UP; MWP1-UP; LDR1-UP; HAS1-UP; RAS1-UP) 330D (S/N: MEY1-UP) 330D L (S/N: T2Y1-UP) M325D MH (S/N: EDF1-UP) M325D MH L (S/N: KGG1-UP; KAY1-UP) Track Feller Buncher: 511 (S/N: 5111-UP) 521 (S/N: 5211-UP) 522 (S/N: 5221-UP) 541 (S/N: 5411-UP) TK711 (S/N: 1011-UP) TK721 (S/N: 1021-UP) TK722 (S/N: 1031-UP) TK732 (S/N: 1041-UP) TK741 (S/N: 2021-UP)

 

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Integrated Toolcarrier: IT62H CUSTOM (S/N: M5G1-UP) Motor Grader: 12H (S/N: CBK1-UP; AMZ1-UP; 1251-UP) 140M (S/N: B9D1-UP; B9M1-UP) 160M (S/N: B9E1-UP; B9L1-UP) Mobile Hydraulic Power Unit: 324D MHPU LN (S/N: KJR1-UP) 325D MHPU L (S/N: C3N1-UP) 330C MHPU (S/N: MSD1-UP; MSL1-UP) 330D MHPU L (S/N: D3D1-UP; H3D1-UP) Paving Compactor: CS74 (S/N: CZJ1-UP) Track-Type Loader: 973C HD (S/N: BCP1-UP) 973C (S/N: LDX1-UP) 973D (S/N: LCP1-UP) Track-Type Tractor: D6R Series II DS LGP (S/N: BNC1-UP) D6R Series II PS DD (S/N: AFD1-UP) D6R Series II XL FTC (S/N: CAD1-UP) D6R Series II DS LGP (S/N: ADE1-UP) D6R Series II FTC (S/N: BLE1-UP) D6R Series II DS XW (S/N: DAE1-UP) D6R Series II LGP FTC (S/N: ACJ1-UP) D6R Series II STD FTC (S/N: BMJ1-UP; BRJ1-UP; BMK1-UP) D6R (S/N: BNL1-UP) D6R Series Series II II DS STDSTD FTC (S/N: AEM1-UP) D6R Series II DS STD (S/N: AFM1-UP) D6R Series II STD FTC (S/N: AGM1-UP) D6R Series II DS STD (S/N: BPM1-UP) D6R Series II DS XW (S/N: AEP1-UP) D6R Series II LGP FTC (S/N: BPP1-UP) D6R Series II XL FTC (S/N: BPS1-UP) D6R Series II DS STD (S/N: BLT1-UP) D6R Series II DS XL (S/N: FDT1-UP; AAX1-UP; BMY1-UP) D6R Series II DS LGP (S/N: BPZ1-UP) D6R Series II DS XL (S/N: BRZ1-UP) D6R Series III (S/N: GJB1-UP; WCB1-UP; HDC1-UP) D6R Series III XL (S/N: RFC1-UP) D6R Series III (S/N: TBC1-UP; HCD1-UP; HKE1-UP; WRG1-UP) D6R Series III XW (S/N: MTJ1-UP) D6R Series III (S/N: DMK1-UP; JEK1-UP; EXL1-UP; JDL1-UP) D6R Series III LGP (S/N: DLM1-UP) D6R Series III (S/N: LFM1-UP; LGP1-UP; DPS1-UP; GMT1-UP; MRT1-UP) D6T STD (S/N: JHB1-UP; SMC1-UP) D6T PAT (S/N: JWD1-UP) D6T XL (S/N: LAE1-UP) D6T PAT (S/N: DJG1-UP; WCG1-UP; WFH1-UP) D6T LGP (S/N: LKJ1-UP; KJL1-UP) D6T XW (S/N: SKL1-UP) D6T XL (S/N: GCT1-UP; LAY1-UP) D6T STD (S/N: PEZ1-UP) Wheel Dozer: 814F Series 2 (S/N: BXG1-UP) Wheel Loader: 950H CUSTOM (S/N: N1A1-UP) 950H (S/N: M1G1-UP; J5J1-UP; K5K1-UP) 962H CUSTOM (S/N: N4A1-UP) 962H (S/N: M3G1-UP; J6J1-UP; K6K1-UP) Wheel Skidder: 525C (S/N: 5251-UP)

 

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535C (S/N: 5351-UP) 545C (S/N: 5451-UP) Wheel Tractor-Scraper: 627G (S/N: DBD1-UP) 637G (S/N: DFJ1-UP)

Introduction Do not perform any procedure in this Special Instruction until you have read this information and you understand this information. This Special Instruction provides guidance for a standard repair procedure to address the process for cleaning the oil rail. Before cleaning the oil rail, the dealer that is completing the repair must perform the standard troubleshooting procedure for the pump for the hydraulic electronic unit injector (HEUI) and the injector for the HEUI. Refer to the correct Troubleshooting manual for your machine. All warranty guidelines must be followed. If the fuel pump from the HEUI fuel system or the injectors are replaced during the troubleshooting, Caterpillar will inspect all of the pumps and the injectors. If the fuel pump from the HEUI fuel system or the injectors are found to be acceptable, the pump and the injectors will be returned to the dealer that is making the repairs and the warranty claim will be debited.

Tooling Table 1 Tooling  Tooling  Part Number  Number 

Description   Description

Quantity   Quantity

1P-5573

Brush (1) 

1

9U-7080 Tapered Cap/Plug

31.750 mm (1.25 inch) Plugs for the Injector bore

6

Shop vacuum

1

Air supply

1

Brake Cleaner

1

Protective face shield

1

222-3117

(1)

The brush must be a nylon bristle.

Troubleshooting Procedure  

 

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  Illustration 1

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All warranty guidelines must be followed. If the fuel pump from the HEUI fuel system or the injectors are replaced during the troubleshooting, Caterpillar will inspect all of the pumps and the injectors. If the fuel pump from the HEUI fuel system or the injectors are found to be acceptable, the pump and the injectors will be returned to the dealer that is making the repairs and the warranty claim will be debited. 

 

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Illustration 2

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(1) Plug (2) Port hole in cylinder head

Note: Earlier versions of the plug (1) in Illustration 2 may not be hollow in the center.

Illustration 3 Debris in the hollow plug 

g01546517

rom a HEUI pump from a HEUI fuel system. Note: The debris in the hollow plug that is shown in Illustration 3 is ffrom The debris in the plug was generated by the HEUI pump. Illustration 3 is only an example. The actual amount of the debris may vary.

Cleaning Procedure 1. Remove Remove the fuel injectors. injectors. Refer Refer to Disassembly Disassembly and Assembly Assembly for your specific specific mac machine. hine. Note: Contain any oil and cleaner that will flow from the cylinder and the lines during the following  process. Properly dispose dispose of the oil and the cleaner when the work is completed. 2. Remove Remove the plugs for the the main oil gallery gallery at the the front and the rrear ear of the cylinder cylinder head. head. Note: In certain applications, one plug may be inaccessible. Shop vacuum may be used in order to completely clean the system.

 

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3. Remove Remove the pressure pressure sensor sensor from the cylinde cylinderr head. Pro Protect tect the the pressure pressure senso sensor. r. 4. In Inst stal alll si six x pl plug ugss 9U-7080 Tapered Cap/Plug into the lower injector bores in order to keep oil and fuel from entering the cylinder. 5. Insert a tube tube directly into into the port for the oil supply. The port is located located in each each injector bore. Use 222-3117 Brake Cleaner to begin cleaning the system. 6. Use the 1P-5573 Brush As to clean the bore of the main oil gallery. Use 222-3117 Brake Cleaner to flush the main oil gallery. Use compressed air to remove the brake cleaner. Note: The oil supply passage to the injector is above the fuel passage. This passage should be flushed from the injector bore downward to the oil rail on the HEUI fuel system. Then flush the oil rail in the HEUI fuel system from the front of the cylinder head to the rear.

Illustration 4

g01546515

(3) Oil Rail for a HEUI fuel system (4) Oil passage to injector bore (5) Fuel passage (6) Injector bore

7. Repeat Repeat Steps Steps 5 and 6 until there there is is no debris debris in the the sys system. tem. 8. Clean Clean the oil filter filter bypass valve. valve. Reassemb Reassemble le the oil filter filter bypa bypass ss valve. valve. 9. Refer Refer to Truck Engine Engine News, SEBD6764 SEBD6764,, "A New Sprin Spring g for the Oil Filter Filter Bypass Bypass Valve and for for the Oil Cooler Bypass Valve is Now in Production ", Service Magazine, SEPD0718, "A New Spring for the Oil Filter Bypass Valve and for the Oil Cooler Bypass Valve is Now in Production ", and Engine News, SEBD9329, "A New Spring for the Oil Filter Bypass Valve and for the Oil Cooler Bypass Valve is Now in Production " for the correct selection of the springs for the bypass relief valve for the oil cooler. 10. Remove Remove any fluid that that remains remains in the injector injector bores and and any fluid that that remains remains in the cylinder. cylinder. 11. Cle Clean an the the bores bores for the the fuel fuel injecto injector. r. 12. Reinst Reinstall all all compon component ents. s. 13. Replace the engine oil and the oil filter. Refer to Operation and and Maintenance Manual for your specific machine in order to determine refill capacities.

 

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