KIT-HYDRAULIC CYLINDER SEAL 7X2715 - Caterpillar

System Operation Description:Use this procedure to troubleshoot any suspect problems with the injector solenoids.Use this procedure for the following diagnostic codes:
0001-05 Cylinder #1 Injector current below normal
0001-06 Cylinder #1 Injector current above normal
0002-05 Cylinder #2 Injector current below normal
0002-06 Cylinder #2 Injector current above normal
0003-05 Cylinder #3 Injector current below normal
0003-06 Cylinder #3 Injector current above normal
0004-05 Cylinder #4 Injector current below normal
0004-06 Cylinder #4 Injector current above normalPerform this procedure under conditions that are identical to the conditions that exist when the fault occurs. Typically, faults with the injector solenoid occur when the engine is warmed up and/or when the engine is under vibration (heavy loads).The engine has Electronic Unit Injectors (EUI) that are mechanically actuated and electronically controlled. The Engine Control Module (ECM) sends a pulse to each injector solenoid. The pulse is sent at the correct time and at the correct duration for a given engine load and speed. The solenoid is mounted on top of the fuel injector body.If an open circuit is detected in the solenoid circuit, a diagnostic code is generated. The ECM continues to try to fire the injector. If a short circuit is detected, a diagnostic code is generated. The ECM will disable the solenoid circuit. The ECM will periodically try to fire the injector. If the short circuit remains this sequence of events will be repeated until the fault is corrected."Injector Solenoid Test"Use the "Injector Solenoid Test" in the electronic service tool to aid in diagnosing an open circuit or a short circuit diagnostic code while the engine is not running. The "Injector Solenoid Test" will send a signal to each solenoid. The electronic service tool will indicate the status of the solenoid as "OK", "Open", or "Short".
Illustration 1 g01423833
Fuel injector
Illustration 2 g01459129
Schematic for the injector solenoid circuit
Illustration 3 g01459137
Pin locations for the injectors on the P2 connector
(57) Injector Cylinder (No. 1)
(35) Injector (No. 1 Cylinder Return)
(58) Injector Cylinder (No. 2)
(34) Injector (No. 2 Cylinder Return)
(59) Injector Cylinder (No. 3)
(33) Injector (No. 3 Cylinder Return)
(64) Injector Cylinder (No. 4)
(8) Injector (No. 4 Cylinder Return)
Illustration 4 g01237524
Fuel injector harness connector
Illustration 5 g01237558
Connector in the valve mechanism cover
Test Step 1. Inspect Electrical Connectors and Wiring
Electrical shock hazard. The electronic unit injector system uses 67-73 volts.
Turn the keyswitch to the OFF position. A strong electrical shock hazard is present if the keyswitch is not turned OFF.
Thoroughly inspect connector P2. Thoroughly inspect the connectors at the valve cover base. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
Perform a 45 N (10 lb) pull test on each of the wires in the ECM connector that are associated with injector solenoids.
Check the screw for the ECM connector for the correct torque of 5.0 N m (44 lb in).
Check the harness and wiring for abrasion and for pinch points from the injectors to the ECM. Expected Result:All connectors, pins, and sockets are completely coupled and/or inserted and the harness is free of corrosion, of abrasion and of pinch points.Results:
OK - The harness is OK. Proceed to Test Step 2.
Not OK