Injection Actuation Pressure - Test: Troubleshooting

120K Motor Grader JAP00001-UP (MACHINE) POWERED BY C7 Engine(SEBP4989 ...
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Product: MOTOR GRADER

Model: 120K MOTOR GRADER JAP
Configuration: 120K Motor Grader JAP00001-UP (MACHINE) POWERED BY C7 Engine
Troubleshooting
C7 Engine for 12K, 120K, 120K Series 2, 140K, 140K Series 2, and 160K Motor Graders
Media Number -KENR5407-04 Publication Date -01/01/2011 Date Updated -03/01/2011
i07519164
Injection Actuation Pressure - Test

SMCS - 1290-038-PX; 1925-038
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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120K Motor Grader JAP00001-UP (MACHINE) POWERED BY C7 Engine(SEBP4989 ... Page 2 of 19
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
120K Motor Grader JAP00001-UP (MACHINE) POWERED BY C7 Engine(SEBP498... Page 10 of 19
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
Manual pressure Actual injection actuation pressure from
Step Difference
gauge 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
Difference
Step actuation pressure actuation pressure Output from
(A-B)
from Cat ET (A) from Cat ET (B) Cat ET
1
2
3
4
3
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. 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 turned
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 turned
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
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Injection Actuation Pressure - Test: Troubleshooting

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120K Motor Grader JAP00001-UP (MACHINE) POWERED BY C7 Engine(SEBP4989 ...

Product: MOTOR GRADER

Injection Actuation Pressure - Test

System Operation Description:

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.

Refer to Troubleshooting, "Injection Actuation Pressure Sensor - Test" if 164-02 is active or

Proceed to Test Step 2 if 164-00, 164-11 or 94-11 is active or logged.

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".

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.

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.

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.

B. Start the engine.

Repair: Do not replace the sensor.

Proceed to Test Step 12.

If the problem still exists, proceed to Test Step 13.

Hot oil and components can cause personal injury.

Do not allow hot oil or components to contact skin.