troubleshooting the hydraulic electronic unit injection (heui) fuel system on c7 and c9...

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Cerrar SIS Pantalla anterior Producto: NO SE HA ESCOGIDO NINGUN EQUIPO Modelo: NO SE HA ESCOGIDO NINGUN EQUIPO Configuración: NO SE HA ESCOGIDO NINGUN EQUIPO I nstrucción Especial Troubleshooting the Hydraulic Electronic Unit I njection (HEUI ) Fuel System On C7 and C9 Engines{ 1250} Número de medio -REHS5031-02 Fecha de publicación -09/ 08/ 2011 Fecha de actualización -09/ 08/ 2011 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; 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) 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 MARINE GS (S/N: C9A1-UP) I ndustrial Engine: C9 INDUSTRIAL (S/N: JSC1-UP; JLW1-UP) M arine Engine: C7 MARINE (S/N: M7A1-UP) C9 MARINE (S/N: CSN1-UP; X9Y1-UP) Truck Engines: C7 TRUCK ENGINE (S/N: LBM1-UP) Excavator: Página 1 de 11 Búsqueda del medio - REHS5031 - Troubleshooting the Hydraulic Electronic Unit Inje... 11/01/2012 https://sisweb.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/s...

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Troubleshooting del sistema HEUI

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Page 1: Troubleshooting the hydraulic electronic unit injection (heui) fuel system on c7 and c9 engines{1250}

Cerrar SIS

Pantalla anterior

Producto: NO SE HA ESCOGI DO NI NGUN EQUI PO

Modelo: NO SE HA ESCOGI DO NINGUN EQUIPO

Configuración: NO SE HA ESCOGIDO NI NGUN EQUI PO

I nstrucción Especia lTroubleshoot ing the Hydraulic Elect ronic Unit I nject ion ( HEUI ) Fuel System On C7 andC9 Engines{ 1 2 5 0 }Núm ero de m edio - REHS5 0 3 1 - 0 2 Fecha de publicación - 0 9 / 0 8 / 2 0 1 1 Fecha de actualización - 0 9 / 0 8 / 2 0 1 1

i04514090

Troubleshooting the Hydraulic Electronic Unit Injection(HEUI) Fuel System On C7 and C9 Engines{1250}SMCS- 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; 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)

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; JLW1-UP)

Marine Engine:C7 MARINE (S/N: M7A1-UP)C9 MARINE (S/N: CSN1-UP; X9Y1-UP)

Truck Engines:C7 TRUCK ENGINE (S/N: LBM1-UP)

Excavator:

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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; 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; 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; JBF1-UP; J2F1-UP; PRF1-UP; LMG1-UP; MYG1-UP; KDJ1-UP;WRK1-UP; W3K1-UP; MPL1-UP; PPN1-UP; MYP1-UP; M2P1-UP; JER1-UP; DTS1-UP; NLS1-UP; JBT1-UP; KKT1-UP; M4T1-UP; WET1-UP; PGW1-UP; L5X1-UP)M325D (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)

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

Motor Grader:120K (S/N: SZN1-UP; JAP1-UP)120M Series I I (S/N: M9H1-UP)12K (S/N: JJA1-UP; SZP1-UP)140K (S/N: JPA1-UP; SZL1-UP)140M Series I I (S/N: M9D1-UP; M9J1-UP)140M (S/N: B9D1-UP; B9G1-UP; D9G1-UP; B9M1-UP)160K (S/N: SZM1-UP; JBP1-UP)160M Series I I (S/N: M9E1-UP; M9K1-UP)160M (S/N: B9E1-UP; B9L1-UP; B9T1-UP; D9T1-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)

Petroleum Engine:C7 PETROLEUM (S/N: K2A1-UP; C7P1-UP)C9 PETROLEUM (S/N: P9L1-UP; KLW1-UP)

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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; 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)

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: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)

IntroductionThis Special Instruction is intended to give information for troubleshooting C7 and C9 HEUI enginefuel systems. Read all of the instruction before performing any of the procedures listed in thisinstruction.

Low Pressure Fuel System RequirementsIncreasing fuel supply pressure and effectively removing water and abrasive particles hasdemonstrated injector durability increases from 200 percent to as high as 1,000 percent in severeapplications. More aggressive filtration and monitoring is required to maximize fuel injector life andmeet increasing reliability and durability expectations. Conversely, reliability and durability goalscannot 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 belocated 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 maintenancerequirement for decades.

Advanced Tank Breather Filter

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

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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 prematureclogging 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 dueto incomplete fuel fill.

Major Factors Which Negatively Affect Fuel System WearAbrasive Contaminants

Increased injection pressure acting on the same level of abrasive contaminants in the fuel results inaccelerated injector abrasive wear. This abrasive wear cannot be eliminated by using improvedmaterials 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 hasinadequate film strength to prevent metal-to-metal contact between the plunger and barrel, resulting inplunger scuffing or seizure. Water can be effectively by the use and regular maintenance of a waterseparator or bulk fuel filter/water coalescer. Removal of excess latent water is essential to preventscuffing with the upcoming injection pressure increases and subsequent hydraulic loading of internalinjector parts.

Solution

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

Excessive Fuel Temperature

Increasing fuel temperatures reduces fuel viscosity and resultant fuel film strength. Reduced filmstrength increases the probability of injector plunger and barrel scuffing or seizure. Limiting the

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maximum fuel temperature will become even more critical with the increase of use if low sulfur fuelwhich has a lower film strength and common rail fuel systems which run elevated fuel temperatures.Fuel temperaturesalso play in diesel and biodiesel fuel degradation.

Solution

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

Customer Maintenance Practices

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

C7 and C9 HEUI Fuel System DiagramNote: The following illustration identifies components that may be included in many differentarrangements. Refer to the Service Information System (SIS) for the correct components for theengine that is being serviced.

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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

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(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 RequiredNote: This Special Instruction is used for troubleshooting the HEUI fuel system. This form is to aidthe 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 HydraulicElectronic Unit Injector." For further diagnostic support, contact your Technical Communicator.

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Illustration 2 g02385696

Checklist One

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Illustration 3 g02385703

Checklist Two

Illustration 4 g02385718

Reference MaterialReference 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 causeaccelerated 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 ora set of all seven booklets.

Copyright 1993 - 2012 Caterpillar I nc.

Todos los derechos reservados.

Red pr ivada para licenciados del SIS.

Wed Jan 11 07: 36: 06 EST 2012

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