Additional Information On The Low Pressure Fuel System

320D2 Excavator DFM00001-UP (MACHINE) POWERED BY C7.1 E... https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?return...
Welcome: j210mm38
Product: EXCAVATOR
Model: 320D2 EXCAVATOR DFM01190
Configuration: 320D2 Excavator DFM00001-UP (MACHINE) POWERED BY
C7.1 Engine
Special Instruction
Additional Information on the Low Pressure Fuel System for Certain Excavators{0706, 0782}
Media Number -SEHS0122-00 Publication Date -18/06/2015 Date Updated -18/06/2015
i06200893
Additional Information on the Low Pressure Fuel System for

Certain Excavators{0706, 0782}
SMCS - 0706; 0782
Excavator:
312D2 (S/N: EAB1-UP; FAB1-UP; KLE1-UP; DGF1-UP; HBF1-UP; MGJ1-UP; WHJ1-UP;
GWN1-UP; MPP1-UP; BRW1-UP; TJY1-UP; RXZ1-UP)
313D2 (S/N: ZAA1-UP; PLD1-UP; GAJ1-UP; RKN1-UP)
318D2 (S/N: JEB1-UP; HAH1-UP; XAH1-UP; DPJ1-UP; WGR1-UP; TZS1-UP; XGS1-UP)
320D2 (S/N: GBA1-UP; LCA1-UP; LMA1-UP; XBA1-UP; YEA1-UP; YGA1-UP; PBB1-UP;
XBB1-UP; ZBD1-UP; PFE1-UP; YBE1-UP; NBF1-UP; TMF1-UP; WBF1-UP; ESG1-UP; DGH1-
UP; ZBH1-UP; MDJ1-UP; WDJ1-UP; FKK1-UP; EAL1-UP; TTL1-UP; DFM1-UP; HDM1-UP;
JFM1-UP; STN1-UP; TDN1-UP; DNP1-UP; ZKP1-UP; KHR1-UP; RAR1-UP; DNS1-UP; KBS1-
UP; ZCS1-UP; EKT1-UP; NBT1-UP; SFW1-UP; RDZ1-UP; SDZ1-UP; TDZ1-UP)
323D2 (S/N: FLC1-UP; KCE1-UP; JEG1-UP; XBK1-UP; PJP1-UP; YCR1-UP; TDT1-UP;
KBX1-UP)
326D2 (S/N: REC1-UP; JFL1-UP; XAM1-UP; MGW1-UP; WBW1-UP; NBX1-UP; KGY1-UP)
329D2 (S/N: RGA1-UP; KJB1-UP; SHJ1-UP; TMJ1-UP; WDT1-UP; THW1-UP)
330D2 (S/N: PTE1-UP; ZBF1-UP; WFG1-UP; YBG1-UP; RCK1-UP; SZK1-UP; TNL1-UP;
XDR1-UP)
336D2 (S/N: MFA1-UP; WDC1-UP; YCF1-UP; NAH1-UP; XBH1-UP; NBN1-UP; ELR1-UP;
FAR1-UP; EFT1-UP; ZCT1-UP; TLY1-UP)
340D2 (S/N: HHK1-UP)
349D2 (S/N: XAC1-UP; PFD1-UP; YAE1-UP; TAH1-UP; SDM1-UP; RAN1-UP)
374F (S/N: NFJ1-UP; MFL1-UP; AT21-UP; AP41-UP)
390F (S/N: HJD1-UP; TYE1-UP; HSM1-UP; GAY1-UP)
Introduction
This System Operation and Troubleshooting manual provides additional information on the low-pressure fuel
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system for the above machines.
System Operation
This engine is electronically controlled. Each cylinder has an electronic unit injector. The Electronic Control
Module (ECM) sends a signal to each injector solenoid in order to control the operation of the fuel injection
system.
Electronic Controls
The electronic system consists of the following components: the ECM, the Mechanically Actuated
Electronically Controlled Unit Injectors (MEUI), the wiring harness, the switches and the sensors. The ECM
is the computer. The flash file is the software for the computer. The flash file contains the operating maps. The
operating maps define the following characteristics of the engine:
Horsepower
Torque curves
The ECM determines the timing and the amount of fuel that is delivered to the cylinders.
The ECM compares the desired engine speed to the actual engine speed. The actual engine speed is
determined through a signal from the following:
Throttle signal
Other input signals from sensors
Certain diagnostic codes
If the desired engine speed is greater than the actual engine speed, the ECM injects more fuel in order to
increase the actual engine speed.
Cold Mode
The ECM limits engine power during cold mode operation and the ECM modifies injection timing during
cold mode operation. Cold mode operation provides the following benefit:
Reduced warm-up time
Cold mode is activated whenever the engine temperature falls below a predetermined value. Cold mode
remains active until the engine temperature rises above a predetermined value or until a time limit is
exceeded.
Fuel Injection
The ECM controls the amount of fuel that is injected by varying the signals to the injectors. The injector will
pump fuel only if the injector solenoid is energized. The ECM sends a high voltage signal to the solenoid.
This high voltage signal energizes the solenoid. By controlling the timing and the duration of the high voltage
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signal, the ECM can control injection timing and the engine RPM.
The flash file inside the ECM sets certain limits on the amount of fuel that can be injected. The "FRC Fuel
Limit" is used to control the air/fuel ratio for control of emissions. The "FRC Fuel Limit" is a limit that is
based on the turbocharger outlet pressure. A higher turbocharger outlet pressure indicates that there is more
air in the cylinder. When the ECM senses a higher turbocharger outlet pressure, the ECM increases the "FRC
Fuel Limit". When the ECM increases the "FRC Fuel Limit", the ECM allows more fuel into the cylinder. The
"FRC Fuel Limit" is programmed into the ECM at the factory. The "FRC Fuel Limit" cannot be changed.
The "Rated Fuel Limit" is a limit that is based on the power rating of the engine and on engine rpm. The
"Rated Fuel Limit" is similar to the rack stops and to the torque spring on a mechanically governed engine.
The "Rated Fuel Limit" provides the power curves and the torque curves for a specific engine family and for a
specific engine rating. The "Rated Fuel Limit" is programmed into the ECM at the factory. The "Rated Fuel
Limit" cannot be changed.
Once the ECM determines the amount of fuel that is required, the ECM must determine the timing of the fuel
injection. The ECM calculates the top center position of each cylinder from signal of the engine speed/timing
sensor. The ECM decides when fuel injection should occur relative to the top center position and the ECM
provides the signal to the injector at the desired time. The ECM adjusts timing for optimum engine
performance, for optimum fuel economy, and for optimum control of white smoke.
Programmable Parameters
Certain parameters that affect the engine operation may be changed with Cat® Electronic Technician (ET).
The parameters are stored in the ECM, and some parameters are protected from unauthorized changes by
passwords. These passwords are called factory passwords.
Passwords
Several system configuration parameters and most logged events are protected by factory passwords. Factory
passwords are available only to Caterpillar dealers. Refer to Troubleshooting, "Factory Passwords" for
additional information.
Troubleshooting
Use this procedure in order to troubleshoot low fuel pressure. Also, use this procedure if one of the following
event codes is active.
If the warning message is displayed on the monitor before 500 service hours, the fuel is dirty. Perform the
following actions:
Clean the fuel tank
Drain the water daily from the primary filter
Follow the fuel filter maintenance interval, even if the warning message regarding the Low Pressure Fuel
System (LPFS) is not displayed on monitor.
If fuel level is zero or the fuel priming is not enough, the LPFS diagnostic will not work correctly due to air in
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the fuel system.
If monitor message is displayed, change the fuel filter by following the Tables 1 through 4 and check the
monitor display.
Check the fuel in the fuel tank. Error can occur by sucking air into the fuel system when fuel tank level
is low. Add refill. Air bleeding from fuel filters if needed.
Check the fuel lines for leaks. Repair the fuel leaks.
Check the fuel for contamination and water. Drain the contamination and water from the primary fuel
filter (water separator).
Check the fuel hose for cracks, kinks, plugging and twists. Correct the fuel line routing. Replace fuel
hose.
Check the connections for the electric priming pump, electric transfer pump and sensors. Reconnect
connectors. Check the voltage to the electrical pumps and sensors. Replace damaged electrical pumps
or sensors.
Note: Stop action when the monitor message and display are deleted.
312D2, 318D2, and 320D2 Series
Illustration 1 g03810997
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312D2 with 3054C Tier 2, 318D2 with 3054C Tier 2, 320D2 with C7.1m Tier 2, 320D2 GC with 3054C Tier 2, and 320D2 C7.1m
Tier 3 low-pressure fuel system
(1) Injector leakoff
(2) 305-6873 Pressure Sensor Gp
(3) Main fuel filter and electric lift pump
(4) 381-9064 Mechanical Indicator
(5) 438-5386 Primary Filter
(6) 423-6434 Water In Fuel (WIF) Switch
(7) High-pressure fuel pump
(8) 4I-0379 Shutoff Valve
(9) Fuel pump to injectors
(10) Fuel
(11) Mechanical drive
E232 (2) Monitor indicator only.
E390 (2) Buzzer, lamp, monitor indicator, and machine power down (derate).
Note: E390 can be generated by the delta pressure sensor (2), detects certain value of low pressure in 2nd fuel
filter system.
323D2, 326D2, and 329D2 Series
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323D2, 326D2, and 329D2 Unity Tier 2 and Tier 3 low-pressure fuel system
(1) High-pressure fuel pump
(2) Fuel rail
(3) Fuel injector
(4) 305-6873 Pressure Sensor Gp
(5) 233-9821 Check Valve
(6) 390-4679 Electric Priming Pump (EPP)
(7) 438-5386 Primary Filter
(8) Fuel
(9) 368-6658 Shutoff Valve
(10) 423-6434 Water In Fuel (WIF) Switch
(11) 169-9763 Connector
(12) Fuel cooler
(13) Fuel transfer pump
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(14) 238-0112 Temperature Sensor Gp
(15) 320-3060 Pressure Sensor Gp (Inlet)
(16) 421-5689 Fuel Filter Gp
(17) 320-3060 Pressure Sensor Gp (Outlet)
E232 (2) Monitor indicator and lamp.
Note: E198 can be generated by the pressure sensor (17), detects the high pressure fuel pump.
Note: E1129 can be generated by the pressure sensor (4), detects certain value of outlet pressure sensor from
the primary fuel filter.
Note: E390 can be generated by the delta pressure sensor (15) and (17), detects certain value of low pressure
in 2nd dual fuel filter system.
336D2 Series
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336D2 C8.8 low-pressure fuel system
(1) Pressure sensor
(2) Electric priming pump (EPP)
(3) Primary filter
(4) Water in fuel (WIF) switch
(5) Pressure switch
(6) Tertiary filter
(7) Secondary filter
(8) Temperature Sensor
(9) Shutoff valve
E198 (1) Supported by Cat ET only. Not available on the display monitor.
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Note: E390 can be generated by delta pressure switch (5), detects certain value of low pressure in 2nd fuel
filter.
374F and 390F Series
374F and 390F with C15 and C18 low-pressure fuel system
(1) Electric priming pump (EPP)
(2) Check valve
(3) Pressure sensor
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(4) Primary filter
(5) Water in fuel (WIF) switch
(6) Shutoff valve
(7) Secondary filter
(8) Temperature Sensor
(9) Tertiary filter
(10) Pressure sensor (inlet)
(11) Pressure sensor (outlet)
E198 (2) Lamp, monitor indicator, and machine power down (derate).
E232 (2) Monitor indicator and lamp.
Note: E198 can be generated by the pressure sensor (11), detects certain value of high-pressure fuel pump.
Note: E390 can be generated by the delta pressure sensors (10) and (11), detect certain value of low pressure
in 2nd fuel filter system.
Note: E1129 can be generated by the pressure sensor (3), detects certain value of outlet pressure sensor from
the primary fuel filter.
Monitors
Monitor Type 1
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D-Monitor
Monitor Type 2
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F-Monitor : Needle Gauge (E-Monitor : Segment Gauge)
Monitor Type 3
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Mini Monitor
Event Codes
Event Codes for Monitor Type 1
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(1) 1st Fuel Filter is also called the "Primary Filter"
Event Codes for Monitor Types 2 and 3
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(1) 1st Fuel Filter is also called the "Primary Filter"
Troubleshooting Charts
312D2, 318D2 and 320D2 Series
Table 1
Primary Fuel Filter Low Fuel Main Fuel Filter Actions
Plugged Pressure Plugged
1. Check the general troubleshooting

Red/ Not
Mechanical --- guidance.
Yellow Applied Normal ---
Indicator 2. Reset the manual gauge. Check the
manual gauge while running the engine
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at high and low idle.

3. Change the primary filter.

guidance.
E390 2. Reset the manual gauge. Check the
Red/ Not
Mechanical --- Pressure (1) manual gauge while running the engine
Yellow Applied
Indicator Low E390 at high and low idle.
(2) 3. Change the primary filter.
4. Change the secondary filter.
5. Electric lift pump failure.

guidance.
E390
Not 2. Reset the manual gauge. Check the
Mechanical --- Pressure (1)
Green Applied manual gauge while running the engine
Indicator Low E390
at high and low idle.
(2)
3. Change the secondary filter.
4. Electric lift pump failure.
323D2, 326D2 and 329D2 Series
Table 2
Primary Fuel Filter Low Fuel Pressure Main Fuel Filter Actions
Plugged Plugged
E1192
1. Check the general
Pressure (1)
Normal --- Normal --- troubleshooting guidance.
Low E1192
(2)

troubleshooting guidance.
E1192 E390 2. Change the primary filter.
Pressure (1) Pressure E198 (1) 3. Change the main filters.
Normal
Low E1192 Low (1) E390 4. Check/change the electric
(2) (2) priming pump.
5. Check/change the transfer
pump.

Pressure (1) Delta P (1) 3. Change the secondary and
Normal ---
Low E1192 High E390 tertiary filters.
(2) (2) 4. Check/change the electric
priming pump.
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pump.

E1192 E390
3. Change the secondary and
Pressure (1) Pressure E198 Delta P (1)
tertiary filters.
Low E1192 Low (1) High E390
4. Check/change the electric
(2) (2)
priming pump.
pump.

E390 troubleshooting guidance.
Pressure E198 Delta P (1) 2. Change the secondary and
Normal ---
Low (1) High E390 tertiary filters.
(2) 3. Check/change the transfer
pump.

Pressure E198 troubleshooting guidance.
Normal --- Normal ---
Low (1) 2. Change the secondary and
tertiary filters.
E390 1. Check the general

(1) troubleshooting guidance.
Normal --- Normal --- High
E390 2. Change the secondary and
(2) tertiary filters.
336D2 Series
Table 3
Plugged Plugged
E1192
Pressure (1)
Low E1192
(2)

Pressure (1) Pressure E198 (1) 3. Change the secondary and
Normal tertiary filters.
Low E1192 Low (1) E390
(2) (2) 4. Check/change the electric
priming pump.
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pump.

E1192 E390
Pressure (1) Delta P (1)
Normal --- tertiary filters.
Low E1192 High E390
(2) (2)
priming pump.
pump.

E1192 E390
Pressure (1) Pressure E198 Delta P (1)
tertiary filters.
Low E1192 Low (1) High E390
(2) (2)
priming pump.
pump.

E390 2. Change the secondary and
Pressure E198 Delta P (1) tertiary filters.
Normal ---
Low (1) High E390 3. Check/change the electric
(2) priming pump.
pump.

tertiary filters.
E390 1. Check the general

Delta P (1) troubleshooting guidance.
High E390 2. Change the secondary and
(2) tertiary filters.
374F and 390F Series
Table 4
Plugged Plugged
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E1192
Pressure (1)
Low E1192
(2)

E1192
Pressure (1) Pressure E198
Normal --- tertiary filters.
Low E1192 Low (2)
(2)
priming pump.
pump.

E1192
E390 (1) troubleshooting guidance.
Pressure (1)
Normal --- High E390 (2) 2. Change the primary filter.
Low E1192
(2)
tertiary filters.

E1192
E390 (1) 3. Change the secondary and
Pressure (1) Pressure E198
High E390 (2) tertiary filters.
Low E1192 Low (2)
(2)
priming pump.
pump.

E390 (1)
Pressure E198 2. Change the secondary and
Normal --- High E390 (2)
Low (2) tertiary filters.
pump.

tertiary filters.

E390 (1)
Normal --- Normal --- High E390 (2)
tertiary filters.
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320D2 Excavator DFM00001-UP (MACHINE) POWERED BY C7.1 E... https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?return...

Additional Information on the Low Pressure Fuel System for

system for the above machines.

Other input signals from sensors

Certain diagnostic codes

Reduced warm-up time

Clean the fuel tank

Drain the water daily from the primary filter

the fuel system.

312D2, 318D2, and 320D2 Series

(1) Injector leakoff

(2) 305-6873 Pressure Sensor Gp

(3) Main fuel filter and electric lift pump

(4) 381-9064 Mechanical Indicator

(5) 438-5386 Primary Filter

(6) 423-6434 Water In Fuel (WIF) Switch

(7) High-pressure fuel pump

(8) 4I-0379 Shutoff Valve

(9) Fuel pump to injectors

(11) Mechanical drive

E232 (2) Monitor indicator only.

E390 (1) Monitor indicator only.

323D2, 326D2, and 329D2 Series

(1) High-pressure fuel pump

(2) Fuel rail

(3) Fuel injector

(4) 305-6873 Pressure Sensor Gp

(5) 233-9821 Check Valve

(6) 390-4679 Electric Priming Pump (EPP)

(7) 438-5386 Primary Filter

(9) 368-6658 Shutoff Valve

(10) 423-6434 Water In Fuel (WIF) Switch

(11) 169-9763 Connector

(12) Fuel cooler

(13) Fuel transfer pump

(14) 238-0112 Temperature Sensor Gp

(15) 320-3060 Pressure Sensor Gp (Inlet)

(16) 421-5689 Fuel Filter Gp

(17) 320-3060 Pressure Sensor Gp (Outlet)

E198 (1) Monitor indicator only.

E232 (1) Monitor indicator only.

E232 (2) Monitor indicator and lamp.

E390 (1) Monitor indicator only.

E1129 (1) Monitor indicator only.

336D2 C8.8 low-pressure fuel system

(1) Pressure sensor

(2) Electric priming pump (EPP)

(3) Primary filter

(4) Water in fuel (WIF) switch

(5) Pressure switch

(6) Tertiary filter

(7) Secondary filter

(8) Temperature Sensor

(9) Shutoff valve

E232 (2) Monitor indicator only.

E390 (1) Monitor indicator only.

374F and 390F Series

(1) Electric priming pump (EPP)

(2) Check valve

(3) Pressure sensor

(4) Primary filter

(5) Water in fuel (WIF) switch

(6) Shutoff valve