4/13/2021 SIS 2.

Troubleshooting the Hydraulic Electronic Unit Injection (HEUI) Fuel System

2021/03/17
On C7 and C9 Engines {1250} (REHS5031)

SMCS - 1250 i08415524

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)

Engine
C7 (S/N: JTF1-UP; RMF1-UP; FML1-UP; FMM1-UP; JRT1-UP; WAX1-UP; PRY1-UP)

C9 (S/N: LFE1-UP; 9DG1-UP; CKP1-UP; LFR1-UP; X3R1-UP; C9Y1-UP)

Excavator
324D (S/N: LAB1-UP; EJC1-UP; MND1-UP; T2D1-UP; BYE1-UP; JJG1-UP; ECH1-UP;
TRH1-UP; BTK1-UP; AWN1-UP; TSN1-UP; DFP1-UP; JZR1-UP; JAT1-UP; PYT1-UP;
CJX1-UP)

325D (S/N: GPB1-UP; NAC1-UP; KBE1-UP; PKE1-UP; KDG1-UP; C4H1-UP; DBH1-

UP; ERK1-UP; RJK1-UP; LAL1-UP; MCL1-UP; DAP1-UP; A3R1-UP; GBR1-UP;
SCR1-UP)

328D (S/N: BYH1-UP; GTN1-UP; MKR1-UP)

329D (S/N: MNB1-UP; XDB1-UP; BFC1-UP; BBF1-UP; CZF1-UP; DJF1-UP; JHJ1-UP;

RSK1-UP; WDK1-UP; EBM1-UP; TPM1-UP; BYS1-UP; WLT1-UP; LFW1-UP; YFW1-
UP; SCY1-UP; TAY1-UP; DTZ1-UP)

330D (S/N: PFC1-UP; NBD1-UP; R2D1-UP; GGE1-UP; NEF1-UP; B6H1-UP; EAH1-

UP; LCJ1-UP; THJ1-UP; C5K1-UP; E4K1-UP; FFK1-UP; H3K1-UP; L2K1-UP; RDK1-
UP; PEL1-UP; JJM1-UP; LEM1-UP; LRM1-UP; ERN1-UP; JLP1-UP; MWP1-UP;
RAS1-UP; MEY1-UP)
336D (S/N: SKE1-UP; J2F1-UP; JBF1-UP; PRF1-UP; LMG1-UP; MYG1-UP; KDJ1-UP;
W3K1-UP; WRK1-UP; MPL1-UP; PPN1-UP; MYP1-UP; JER1-UP; DTS1-UP; NLS1-
UP; JBT1-UP; KKT1-UP; M4T1-UP; WET1-UP; PGW1-UP)
Forest Machine
324D FM (S/N: JKR1-UP; JLS1-UP)

325D FM (S/N: C8L1-UP)

Forwarder
584 (S/N: PAK1-UP)
584HD (S/N: PBK1-UP)

Generator Set
C18 GEN SET (S/N: STM1-UP)
C9 GEN SET (S/N: C9E1-UP)

C9 MARINE GEN (S/N: SJB1-UP)

C9 MARINE GS (S/N: C9A1-UP)

Industrial Engine
C9 INDUSTRIAL (S/N: JSC1-UP; REH1-UP; JLW1-UP)

Integrated Toolcarrier
IT62H (S/N: M5G1-UP)

Landfill Compactor
816F Series 2 (S/N: BZR1-UP)
Marine Engine
C7 MARINE (S/N: M7A1-UP)
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C9 MARINE (S/N: CSN1-UP; X9Y1-UP)
keyword=boost&tab=3&serialNumber=C9E00700&infoType=15&serviceMediaNumber=REHS5031&serviceIeSystemControlNumber=i04186693
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Material Handler
M325D MH (S/N: EDF1-UP; KGG1-UP; KAY1-UP)
Mobile Hydraulic Power Unit
323D MHPU (S/N: DCY1-UP)
324D MHPU (S/N: KJR1-UP)
325D MHPU (S/N: SRC1-UP; C3N1-UP; H3N1-UP; X3N1-UP)

329D MHPU (S/N: J9D1-UP; L5H1-UP)

330D MHPU (S/N: D3D1-UP; H3D1-UP; M3D1-UP; GMN1-UP)
336D MHPU (S/N: J6D1-UP; M3N1-UP; M2P1-UP; L5X1-UP)
Motor Grader
120K (S/N: SZN1-UP; JAP1-UP)

120M Series 2 (S/N: M9H1-UP)

12K (S/N: JJA1-UP; SZP1-UP)
140K (S/N: JPA1-UP; SZL1-UP)
140M (S/N: B9D1-UP; B9G1-UP; D9G1-UP; B9M1-UP)

140M Series 2 (S/N: M9D1-UP; M9J1-UP)

160K (S/N: SZM1-UP; JBP1-UP)
160M (S/N: B9E1-UP; B9L1-UP; B9T1-UP; D9T1-UP)
160M Series 2 (S/N: M9E1-UP; M9K1-UP)
Petroleum Engine
C7 PETROLEUM (S/N: K2A1-UP; C7P1-UP)
C9 PETROLEUM (S/N: P9L1-UP; KLW1-UP)
Petroleum Power Train Package
TH31-C9I (S/N: PAZ1-UP)
Soil Compactor
815F Series 2 (S/N: BYN1-UP)
Track Feller Buncher
2390 (S/N: P3H1-UP)
2491 (S/N: P5J1-UP)
511 (S/N: 5111-UP)

521 (S/N: 5211-UP)

522 (S/N: 5221-UP)
532 (S/N: 5321-UP)
552 (S/N: 5521-UP)

Track-Type Loader
973C (S/N: LDX1-UP)
973D (S/N: LCP1-UP)
Track-Type Tractor
D6R Series III (S/N: JEK1-UP; EXL1-UP; LGP1-UP; EXW1-UP)
D6T (S/N: JHB1-UP; ZEB1-UP; SMC1-UP; LBD1-UP; LAE1-UP; DJG1-UP; WCG1-UP;
WFH1-UP; LKJ1-UP; SNK1-UP; KJL1-UP; SKL1-UP; GCT1-UP; RLW1-UP; LAY1-UP;
PEZ1-UP)

Truck Engines
C7 TRUCK ENGINE (S/N: LBM1-UP)
Wheel Dozer
814F Series 2 (S/N: BXG1-UP)
Wheel Loader
950H (S/N: N1A1-UP; M1G1-UP; J5J1-UP; K5K1-UP)

962H (S/N: N4A1-UP; M3G1-UP; J6J1-UP; K6K1-UP; MAL1-UP)

Wheel Skidder
https://sis2.cat.com/#/detail?
525C (S/N: 5251-UP)
keyword=boost&tab=3&serialNumber=C9E00700&infoType=15&serviceMediaNumber=REHS5031&serviceIeSystemControlNumber=i04186693
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4/13/2021 SIS 2.0

535C (S/N: 5351-UP)

545C (S/N: 5451-UP)

Wheel Tractor-Scraper
627G (S/N: DBD1-UP)
637G (S/N: DFJ1-UP)

Revision History:
Revision Summary of Changes
03 Added serial number prefix S/N:REH

Table 1

Introduction
This Special Instruction is intended to give information for troubleshooting C7 and C9
HEUI engine fuel systems. Read all of the instruction before performing any of the
procedures listed in this instruction.

Low Pressure Fuel System Requirements

Increasing fuel supply pressure and effectively removing water and abrasive particles has
demonstrated injector durability increases from 200 percent to as high as 1,000 percent
in severe applications. More aggressive filtration and monitoring is required to maximize
fuel injector life and meet increasing reliability and durability expectations. Conversely,
reliability and durability goals cannot be achieved without the following improved filtration
and monitoring features.

Fuel Tank Drain

Fuel tank drains are used to drain water and sediment from the fuel tank daily. The drain
must be located on the lowest part of the fuel tank where the containments collect.

Note: Daily draining of water and sediment from the fuel tank has been a standard
maintenance requirement for decades.

Advanced Tank Breather Filter

Preventing short fuel system life by keeping dust from entering the fuel tank.

Water Separators
Water separators are required to remove large quantities of latent water from the fuel.

Primary Fuel Filters

Primary fuel filters are required to remove large abrasives from the fuel supply and
prevent premature clogging of the 4-micron secondary filters from excessive debris.

Secondary Fuel Filters

Series filtration more than doubles wear life over single filtration.

Electronic Unit Injectors (EUI)

An adequate fuel supply pressure is essential to prevent cavitation of internal injector
components due to incomplete fuel fill.

Major Factors Which Negatively Affect Fuel

System Wear
Abrasive Contaminants
Increased injection pressure acting on the same level of abrasive contaminants in the fuel
results in accelerated injector abrasive wear. This abrasive wear cannot be eliminated by
using improved materials or processes. Abrasive wear only can be reduced by removing
https://sis2.cat.com/#/detail?
abrasives from the fuel.
keyword=boost&tab=3&serialNumber=C9E00700&infoType=15&serviceMediaNumber=REHS5031&serviceIeSystemControlNumber=i04186693
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4/13/2021 SIS 2.0

Solution
Single or series High Efficiency fuel filters and/or bulk fuel filter/water coalescer.

Water in Fuel
An excessive amount of latent water in the fuel is a key cause of injector failure. Water
has inadequate film strength to prevent metal-to-metal contact between the plunger and
barrel, resulting in plunger scuffing or seizure. Water can be effectively by the use and
regular maintenance of a water separator or bulk fuel filter/water coalescer. Removal of
excess latent water is essential to prevent scuffing with the upcoming injection pressure
increases and subsequent hydraulic loading of internal injector parts.

Solution
Proper maintenance of fuel tank drains, water separators and/or use of a bulk fuel
filter/water coalescer.

Excessive Fuel Temperature

Increasing fuel temperatures reduces fuel viscosity and resultant fuel film strength.
Reduced film strength increases the probability of injector plunger and barrel scuffing or
seizure. Limiting the maximum fuel temperature will become even more critical with the
increase of use if low sulfur fuel which has a lower film strength and common rail fuel
systems which run elevated fuel temperatures. Fuel temperatures also play in diesel and
biodiesel fuel degradation.

Solution
Properly maintain fuel filters and fuel coolers where needed. Ensure proper consideration
for materials used in fuel coolers as zinc, copper, lead, and tin can have adverse effects
on fuel degradation.

Customer Maintenance Practices

Fuel system performance, sophistication, and complexity continue to increase at a rapid
pace. It is more important than ever for the user to maintain fuel filters in order to prevent
filter restriction and the problems caused by low fuel pressure. It is also important to use
quality Advanced Efficiency filters in order to trap and hold microscopic abrasive debris,
which causes accelerated wear in modern fuel systems.

C7 and C9 HEUI Fuel System Diagram

Note: The following illustration identifies components that may be included in many
different arrangements. Refer to the Service Information System (SIS) for the correct
components for the engine that is being serviced.

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4/13/2021 SIS 2.0

Illustration 1 g02385638
(1) Fuel injection pump
(2) To engine
(3) Oil filter
(4) Engine oil pump
(5) Injection actuation pressure sensor
(6) Fuel injectors
(7) Fuel supply passage
(8) 2 micron breather filter
(9) Fuel tank
(10) Fuel pressure regulator
(11) Intake air heater lamp
(12) Fast idle lamp
(13) Check engine lamp
(14) 2 micron secondary fuel filters
(15) Primary fuel filter and water separator
(16) Fuel drain
(17) Batteries
(18) Electronic Control Module (ECM)
(19) Accelerator pedal position sensor
(20) Accelerator pedal
(21) Injection actuation oil temperature sensor
(22) Engine boost pressure sensor
(23) Engine coolant temperature sensor
(24) Intake manifold air temperature sensor
(25) Barometric pressure sensor
(26) Engine oil pressure sensor
(27) Fuel pressure sensor
(28) Water in fuel sensor
(29) Intake air heater
(30) Intake air heater relay
(31) Data link

General Information Required

Note: This Special Instruction is used for troubleshooting the HEUI fuel system. This form
is to aid the service technician with the diagnostics of the HEUI fuel system along with
Special Instruction, REHS3819, "Procedure for Troubleshooting and Cleaning the Oil Rail
System for the Hydraulic Electronic Unit Injector." For further diagnostic support, contact
your Technical Communicator.

https://sis2.cat.com/#/detail?
Illustration 2 g02385696
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4/13/2021 SIS 2.0

Checklist One

Illustration 3 g02385703

Checklist Two

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4/13/2021 SIS 2.0

Illustration 4 g02385718

Reference Material
Reference Special Publication, SENR9620, "Improving Component Durability" for more
information. This series of high-quality booklets contains full color graphics and easy to
understand explanations of wear and failure in major system components. Special
attention is given to practices that cause accelerated wear, and how to improve
component life in many applications.

Note: This reference material is available only in paper and can only be ordered in
packages of 10 or a set of all seven booklets.

PIP-10231166
2021/04/14
02:46:33-05:00
i04186693
© 2021 Caterpillar Inc.
Caterpillar:
Confidential Green

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