RING 0860255 - Caterpillar

System Operation Description:Perform this procedure under conditions that are identical to the conditions that exist when the problem occurs. Typically, problems with the injector solenoid occur when the engine is warmed up and/or when the engine is under vibration (heavy loads).The engines use Hydraulic Electronic Unit Injectors that are hydraulically actuated and electronically energized. The solenoid is mounted on top of the fuel injector body."Cylinder Cutout Test"The "Cylinder Cutout Test" on the Caterpillar Electronic Technician (Cat ET) should be used to diagnose a bad injector while the engine is running. All active diagnostic codes must be repaired before running the "Cylinder Cutout Test". When a good injector is cut out, the "Fuel Position" should change. The change in the fuel position is caused by the other cylinders that are compensating for the cut out cylinder. If a bad cylinder is cut out, the "Fuel Position" will not change. The "Cylinder Cutout Test" should be used to isolate the bad cylinder in order to avoid replacement of good injectors."Injector Solenoid Test"The "Injector Solenoid Test" on Cat ET should be used 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". An open circuit or a short circuit in the common wire will cause two cylinders to have diagnostic codes.Note: The "Injector Solenoid Test" will not help find leaks in the high pressure oil system.
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Left side view and top view of engine
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Circuit schematic for the injectors
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P2 ECM connector
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P300 Injector harness connectorTest Step 1. Inspect Electrical Connectors and Wiring
Electrical shock hazard. The electronic unit injector system uses 90-120 volts.
Turn the key switch to the OFF position. A strong electrical shock hazard is present if the key switch is not turned off.
Thoroughly inspect the J2/P2 ECM connector and the J300/P300 injector harness connector. 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 and the J300/P300 injector harness connector that are associated with injector solenoids.
Check the ECM connector (allen head screw) for the proper torque of 6.0 N m (55 lb in).
Check the J300/P300 injector harness connector in order to ensure the proper mating of the connector.
Check the harness and wiring for abrasion and pinch points from the injectors to the ECM.Expected Result:All connectors, pins, and sockets should be completely coupled and/or inserted and the harness and wiring should be free of corrosion, abrasion, or pinch points.Results:
OK - Proceed to Test Step 2.
Not OK - Repair: Perform the following repair:Repair the connectors or wiring and/or replace the connectors or wiring. Ensure that all of the seals are properly in place and ensure that the connectors are completely coupled.Verify that the repair eliminates the problem.STOPTest Step 2. Check for Logged Diagnostic Codes Regarding Injector Solenoids
Connect Cat ET to