Troubleshootingthehydraulicelectronicunitinjectionheuifuelsystemonc7andc9engines1250 130804223028 Phpapp02 PDF

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Product o: NO SE HA ESCOGI DO NI NGUN EQUI PO

Modelo: NO SE HA ESCOGI DO NI NGUN EQUI PO
Configuración: NO SE HA ESCOGI DO NI NGUN EQUI PO
I n st r u cción Espe cia l

Tr ou b le sh oot in g t h e H yd r a u lic Ele ct r on ic Un it I n j e ct ion ( H EUI ) Fu e l Syst e m On C7 a n d
C9 En gin e s{ 1 2 5 0 }
N ú m e r o de m e dio - REH S5 0 3 1 - 0 2 Fech a de pu blica ción - 0 9 / 0 8 / 2 0 1 1 Fe ch a de a ct u a liz a ción - 0 9 / 0 8 / 2 0 1 1
i04514090
Troubleshooting the Hydraulic Electronic Unit I njection

(HEUI ) Fuel System On C7 and C9 Engines{1250}
SM CS - 1250-035
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)
Landfill Compactor:
816F Series 2 (S/N: BZR1-UP)
Soil Compactor:
815F Series 2 (S/N: BYN1-UP)
Engine:
C7 (S/N: JTF1-UP; RM F1-UP; FM L1-UP; FM M 1-UP; JRT1-UP; WAX1-UP; PRY1-UP)
C9 (S/N: LFE1-UP; 9DG1-UP; CKP1-UP; LFR1-UP; X3R1-UP; C9Y1-UP)
Generator Set:
C18 GEN SET (S/N: STM 1-UP)
C9 GEN SET (S/N: C9E1-UP)
C9 M ARI NE GEN (S/N: SJB1-UP)
C9 M ARI NE GS (S/N: C9A1-UP)
I ndustrial Engine:
C9 I NDUSTRI AL (S/N: JSC1-UP; JLW1-UP)
M arine Engine:
C7 M ARI NE (S/N: M 7A1-UP)
C9 M ARI NE (S/N: CSN1-UP; X9Y1-UP)
Truck Engines:
C7 TRUCK ENGI NE (S/N: LBM 1-UP)
Excavator:
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324D (S/N: LAB1-UP; EJC1-UP; M ND1-UP; T2D1-UP; BYE1-UP; JJG1-UP; ECH1-UP;

TRH1-UP; BTK1-UP; AWN1-UP; TSN1-UP; DFP1-UP; JKR1-UP; JZR1-UP; JLS1-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; C8L1-UP; LAL1-UP; M CL1-UP; DAP1-UP; A3R1-UP; GBR1
-UP; SCR1-UP)
328D (S/N: BYH1-UP; GTN1-UP; M KR1-UP)
329D (S/N: M NB1-UP; XDB1-UP; BFC1-UP; BBF1-UP; CZF1-UP; DJF1-UP; JHJ1-UP;
RSK1-UP; WDK1-UP; EBM 1-UP; TPM 1-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; JJM 1-UP; LEM 1-UP; LRM 1-UP; ERN1-UP; JLP1-UP; M WP1-UP; RAS1-
UP; M EY1-UP)
336D (S/N: SKE1-UP; JBF1-UP; J2F1-UP; PRF1-UP; LM G1-UP; M YG1-UP; KDJ1-UP;
WRK1-UP; W3K1-UP; M PL1-UP; PPN1-UP; M YP1-UP; M 2P1-UP; JER1-UP; DTS1-
UP; NLS1-UP; JBT1-UP; KKT1-UP; M 4T1-UP; WET1-UP; PGW1-UP; L5X1-UP)
M 325D (S/N: EDF1-UP; KGG1-UP; KAY1-UP)
Forwarder:
584 (S/N: PAK1-UP)
584HD (S/N: PBK1-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)
I ntegrated Toolcarrier:
I T62H (S/N: M 5G1-UP)
M otor Grader:
120K (S/N: SZN1-UP; JAP1-UP)
120M Series I I (S/N: M 9H1-UP)
12K (S/N: JJA1-UP; SZP1-UP)
140K (S/N: JPA1-UP; SZL1-UP)
140M Series I I (S/N: M 9D1-UP; M 9J1-UP)
140M (S/N: B9D1-UP; B9G1-UP; D9G1-UP; B9M 1-UP)
160K (S/N: SZM 1-UP; JBP1-UP)
160M Series I I (S/N: M 9E1-UP; M 9K1-UP)
160M (S/N: B9E1-UP; B9L1-UP; B9T1-UP; D9T1-UP)
M obile Hydraulic Power Unit:
323D M HPU (S/N: DCY1-UP)
324D M HPU (S/N: KJR1-UP)
325D M HPU (S/N: SRC1-UP; C3N1-UP; H3N1-UP; X3N1-UP)
329D M HPU (S/N: J9D1-UP; L5H1-UP)
330D M HPU (S/N: D3D1-UP; H3D1-UP; M 3D1-UP; GM N1-UP)
336D M HPU (S/N: J6D1-UP; M 3N1-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)
Track-Type Loader:
973C (S/N: LDX1-UP)
973D (S/N: LCP1-UP)
Track-Type Tractor:
D6R Series I I I (S/N: JEK1-UP; EXL1-UP; LGP1-UP; EXW1-UP)
D6T (S/N: JHB1-UP; ZEB1-UP; SM C1-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)
Wheel Dozer:
814F Series 2 (S/N: BXG1-UP)
Wheel Loader:
950H (S/N: N1A1-UP; M 1G1-UP; J5J1-UP; K5K1-UP)
962H (S/N: N4A1-UP; M 3G1-UP; J6J1-UP; K6K1-UP; M AL1-UP)
Wheel Skidder:
525C (S/N: 5251-UP)
535C (S/N: 5351-UP)
545C (S/N: 5451-UP)
Wheel Tractor-Scraper:
627G (S/N: DBD1-UP)
637G (S/N: DFJ1-UP)
I ntroduction
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 I njectors (EUI )

An adequate fuel supply pressure is essential to prevent cavitation of internal injector components due
to incomplete fuel fill.
M ajor 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 abrasives from the fuel.
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 M aintenance 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.
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 I nformation 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.
Checklist One
Búsqueda del medio - REHS5031 - Troubleshooting the Hydraulic Electronic Unit In... Página 10 de 11
Checklist Two
Reference M aterial
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
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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.
Copyright 1993 - 2012 Cat erpillar I nc. Wed Jan 11 07: 36: 06 EST 2012
Todos los derechos reservados.
Red privada para licenciados del SI S.

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Product o: NO SE HA ESCOGI DO NI NGUN EQUI PO

I n st r u cción Espe cia l

Troubleshooting the Hydraulic Electronic Unit I njection

324D (S/N: LAB1-UP; EJC1-UP; M ND1-UP; T2D1-UP; BYE1-UP; JJG1-UP; ECH1-UP;

Petroleum Power Train Package:

Low Pressure Fuel System Requirements

Fuel Tank Drain

Advanced Tank Breather Filter

Primary Fuel Filters

Secondary Fuel Filters

Electronic Unit I njectors (EUI )

M ajor Factors Which Negatively Affect Fuel System Wear

Excessive Fuel Temperature

Customer M aintenance Practices

C7 and C9 HEUI Fuel System Diagram

(1) Fuel injection pump

(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

(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 I nformation Required

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