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11/4/2015 C7IndustrialEngine(SEBP443656)Documentacin
Pantallaanterior
Bienvenido:cr080rhm
Producto:INDUSTRIALENGINE
Modelo:C7INDUSTRIALENGINETEF
Configuracin:C7IndustrialEngineTEF00001UP
OperacindeSistemas
C7IndustrialEngines
NmerodemedioRENR980301 Fechadepublicacin01/07/2014 Fechadeactualizacin11/07/2014

i02908853
FuelSystem
SMCS1250
Introduction
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Illustration1 g01447542
FuelSystemDiagram
(1)Unitinjectorhydraulicpump
(2)Oilflowtoengine
(3)Oilfilter
(4)Engineoilpump
(5)Injectors
(6)ConnectorfortheIAPcontrolvalve
(7)Oilcooler
(8)Highpressureoilpassage
(9)IAPsensor
(10)Fuelsupplypassage
(11)Fueltransferpump
(12)Secondaryfuelfilter
(13)Primaryfuelfilter/waterseparator
(14)Fueltank
(15)Fuelpressureregulator
(16)Backofcamshaftgear
(17)Speed/timingsensors
(18)ECM
(19)Boostpressuresensor
(20)Enginecoolanttemperaturesensor
(21)Engineoilpressuresensor
(22)Inletairtemperaturesensor
(23)Engineoillevelswitch
(24)Atmosphericairpressuresensor
(25)Wastegatecontrolvalve
TheoperationoftheHydraulicElectronicUnitInjector(HEUI)fuelsystemiscompletelydifferentfromany
othertypeoffuelsystemthatisactuatedmechanically.TheHEUIfuelsystemiscompletelyfreeof
adjustment.Adjustmentstothecomponentsthataremechanicalcannotbemade.Changesinperformance
aremadebyinstallingdifferentsoftwareinElectronicControlModule(ECM)(18).
Thisfuelsystemconsistsofsixbasiccomponents:
HydraulicElectronicUnitInjector(HEUI)(5)
ElectronicControlModule(ECM)(18)
Unitinjectorhydraulicpump(1)
Fueltransferpump(11)
InjectionActuationPressuresensor(9)
Note:ThecomponentsoftheHEUIfuelsystemarenotserviceable.Thesefuelsystemcomponentsmustnot
bedisassembled.Disassemblywilldamagethecomponents.Ifthecomponentshavebeendisassembled,
CaterpillarmaynotallowawarrantyclaimorCaterpillarmayreducethewarrantyclaim.
ComponentDescription
HydraulicElectronicUnitInjector
TheHEUIfuelsystemutilizesahydraulicallyactuatedelectronicallycontrolledunitinjector(5).
Allfuelsystemsfordieselenginesuseaplungerandbarrelinordertopumpfuelunderhighpressureinto
thecombustionchamber.Thisfuelispumpedintothecombustionchamberinpreciseamountsinorderto
controlengineperformance.TheHEUIusesengineoilunderhighpressureinordertopowertheplunger.
Allotherfuelsystemsuseafuelinjectionpumpcamshaftlobeinordertopowertheplunger.Becausethe
HEUIismuchdifferent,atechnicianmustusedifferenttroubleshootingmethods.
TheHEUIusesenginelubricationoilthatispressurizedfrom6MPa(870psi)to28MPa(4050psi)inorder
topumpfuelfromtheinjector.TheHEUIoperatesinthesamewayasahydrauliccylinderinorderto
multiplytheforceofthehighpressureoil.Bymultiplyingtheforceofthehighpressureoil,theHEUIcan
produceinjectionpressuresthatareveryhigh.Thismultiplicationofpressureisachievedbyapplyingthe
forceofthehighpressureoiltoapiston.Thepistonislargerthantheplungerbyapproximatelysixtimes.
Thepistonthatispoweredbyenginelubricationoilunderhighpressurepushesontheplunger.Thisengine
lubricationoilunderhighpressureiscalledtheactuationpressureoftheoil.Theactuationpressureoftheoil
generatestheinjectionpressurethatisdeliveredbytheunitinjector.Injectionpressureisgreaterthan
actuationpressureoftheoilbyapproximatelysixtimes.
Lowactuationpressureoftheoilresultsinlowinjectionpressureofthefuel.Duringconditionsoflow
speedsuchasidleandstart,lowinjectionpressureisutilized.
Highactuationpressureoftheoilresultsinhighinjectionpressureofthefuel.Duringconditionsofhigh
speedsuchashighidleandacceleration,highinjectionpressureisutilized.
Therearemanyotheroperatingconditionswhentheinjectionpressureisbetweentheminimumandthe
maximum.Regardlessofthespeedoftheengine,theHEUIfuelsystemprovidesinfinitecontrolofinjection
pressure.
ElectronicControlModule(ECM)
ElectronicControlModule(ECM)(18)islocatedontheleftsideoftheengine.TheECMisapowerful
computerthatprovidestotalelectroniccontrolofengineperformance.TheECMusesdatafromengine
performancethatisgatheredbyseveralsensors.Then,theECMusesthisdatainordertomakeadjustments
tothefueldelivery,injectionpressureandinjectiontiming.TheECMcontainsprogrammedperformance
maps(software)inordertodefinehorsepower,torquecurvesandrpm.Thissoftwareiscommonlycalledthe
personalitymodule.
Theenginedoesnothaveareplaceablepersonalitymodule.Thepersonalitymoduleisapermanentpartof
theECM.ThepersonalitymodulefortheenginecanbereprogrammedbyCaterpillarElectronicTechnician
(CatET).
ECM(18)logsfaultsofengineperformance.Also,theECMiscapableofrunningseveraldiagnostictests
automaticallywhentheECMisusedwithanelectronicservicetoolsuchastheCatETortheElectronic
ControlAnalyzerProgrammer(ECAP).
UnitInjectorHydraulicPump
Unitinjectorhydraulicpump(1)(highpressureoilpump)islocatedattheleftfrontcorneroftheengine.
Theunitinjectorhydraulicpumpisavariabledeliverypistonpump.Theunitinjectorhydraulicpumpusesa
portionoftheenginelubricationoil.Theunitinjectorhydraulicpumppressurizestheenginelubricationoil
totheinjectionactuationpressurethatisrequiredinordertopowertheHEUIinjectors.
PumpPressureRegulator
Thepumppressureregulatorisinternaltotheunitinjectorhydraulicpump.Thepumppressureregulatorisa
valveofhighprecisionthatcontrolspumpoutletpressure(actuationpressure)bychangingpumpoutlet
flow.TheperformancemapsintheECM(18)containadesiredactuationpressureforeveryengine
operatingcondition.TheECMsendsacontrolcurrenttothepumppressureregulator.Thecontrolcurrent
shouldmaketheactualactuationpressureequaltothedesiredactuationpressure.
ThepumppressureregulatorisanactuatorthatconvertsanelectricalsignalfromtheECMtothemechanical
controlofplungersleevesinordertochangethepumpoutletflowandthepumpoutletpressure.
FuelTransferPump
Unitinjectorhydraulicpump
Fueltransferpump(11)ismountedonthebackofunitinjectorhydraulicpump(1).Thefueltransferpump
isusedinordertodrawfuelfromfueltank(14).Also,thefueltransferpumpisusedinordertopressurize
thefuelto450kPa(65psi).Thepressurizedfuelissuppliedtoinjectors(5).
Thefueltransferpumpisagearpump.Thepumpismountedonthebackoftheunitinjectorhydraulic
pump.Thefueltransferpumpisdrivenbytheshaftoftheunitinjectorhydraulicpump.Areliefvalveinthe
fueltransferpumplimitstheoutletpressureto68969kPa(10010psi).Fuelisdrawnfromthetankto
theinletportofthepump.Therotationofthegearscausesthefueltoflowoutofthepumpoutletport
throughthesecondaryfuelfilter(12)andtothefuelsupplypassage(10)thatislocatedinthecylinderhead.
InjectionActuationPressureSensor(IAP)
(9)IAPsensor
IAPSensor(9)isinstalledinthehighpressureoilmanifold.Thehighpressureoilmanifoldsupplies
actuationoilinordertopowertheunitinjectors.TheIAPSensormonitorsinjectionactuationpressure.The
IAPSensorsendsacontinuousvoltagesignalbacktoECM(18).TheECMinterpretsthesignal.TheECM
isawareoftheinjectionactuationpressureatalltimes.
HEUIFuelSystemOperation
(5)Injectors
(10)Fuelsupplypassage
(12)Secondaryfuelfilter
(13)Primaryfuelfilter/waterseparator
(14)Fueltank
(15)Fuelpressureregulator
LowPressureFuelSystem
Thelowpressurefuelsystemservesthreefunctions.Thelowpressurefuelsystemsuppliesfuelfor
combustiontoinjectors(5).Also,thelowpressurefuelsystemsuppliesexcessfuelflowinordertocoolthe
unitinjectorsandthelowpressurefuelsystemsuppliesexcessfuelflowinordertoremoveairfromthe
system.
Thelowpressurefuelsystemconsistsoffourbasiccomponents:
Fueltank(14)
Primaryfuelfilter/waterseparator(13)
Twomicronsecondaryfuelfilter(12)
Fueltransferpump(11)
Fuelpressureregulator(15)
Fueltransferpump(11)ismountedonthebackofunitinjectorhydraulicpump(1).
Fuelisdrawnfromfueltank(14)andflowsthroughathirteenmicronfuelfilter/waterseparator(13).The
primaryfuelfilter/waterseparatorremoveslargedebrisfromthefuel.Thedebrismayhaveenteredthefuel
tankduringfueling.Thedebrismayhavealsoenteredthefueltankthroughtheventforthefueltank.The
primaryfilterelementalsoseparateswaterfromthefuel.Thewateriscollectedinthebowlatthebottomof
theprimaryfuelfilter/waterseparator.
Fuelflowsfromfuelfilter(12)totheinletsideoffueltransferpump(11).Aninletcheckvalveintheinlet
portofthefueltransferpumpopensinordertoallowtheflowoffuelintothepump.Afterthefuelflowhas
stopped,theinletcheckvalveclosesinordertopreventfuelflowoutoftheinletport.Fuelflowsfromthe
inletportinthepumptotheoutletport,whichalsohasacheckvalve.Theoutletcheckvalveopensinorder
toallowpressurizedfuelflowoutofthepump.Theoutletcheckvalveclosesinordertopreventpressurized
fuelleakagebackthroughthepump.
Fuelflowsfromtheoutletportoffueltransferpump(11)tothefuelsupplypassageinthecylinderhead.
Thefuelsupplypassageisadrilledholewhichbeginsatthefrontofthecylinderhead.Thefuelsupply
passageextendstothebackofthecylinderhead.Thispassageconnectswitheachunitinjectorboreinorder
tosupplyfueltounitinjectors(5).Fuelfromthetransferpumpflowsthroughthecylinderheadtoallofthe
unitinjectors.Excessfuelflowsoutofthebackofthecylinderhead.Aftertheexcessflowsoutoftheback
ofthecylinderhead,thefuelflowsintofuelpressureregulator(15).
Fuelpressureregulator(15)consistsofanorificeandacheckvalvethatisspringloaded.Theorificeisa
flowrestrictionthatpressurizesthesupplyfuel.Thecheckvalvethatisspringloadedopensat35kPa(5psi)
inordertoallowthefuelwhichhasflowedthroughtheorificetoreturntofueltank(14).Whentheengineis
offandnofuelpressureispresent,thecheckvalvethatisspringloadedcloses.Thecheckvalvethatis
springloadedclosesinordertopreventthefuelinthecylinderheadfromdrainingbacktothefueltank.
InjectionActuationSystem
(2)Oilflow
(3)Oilfilter
(4)Engineoilpump
(5)Injectors
(7)Oilcooler
ActuationOilFlow
Theinjectionactuationsystemservestwofunctions.Theinjectionactuationsystemsupplieshighpressure
oilinordertopowerHEUIinjectors(5).Also,theinjectionactuationsystemcontrolstheinjectionpressure
thatisproducedbytheunitinjectorsbychangingtheactuationpressureoftheoil.
Theinjectionactuationsystemconsistsoffourbasiccomponents:
Engineoilpump(4)
Engineoilfilter(3)
Unitinjectorhydraulicpump(1)
InjectionActuationPressuresensor(9)
Oilfromengineoilpump(4)suppliestheneedsoftheenginelubricationsystem.Also,oilfromtheengine
oilpumpsuppliestheneedsofunitinjectorhydraulicpump(1)forthefuelsystem.Thecapacityofthe
engineoilpumphasbeenincreasedinordertomeettheadditionalflowrequirementthatisnecessary.
Oilthatisdrawnfromthesumpispressurizedtothelubricationsystemoilpressurebyengineoilpump(4).
Oilflowsfromtheengineoilpumpthroughengineoilcooler(7),throughengineoilfilter(3),andthento
themainoilgallery.Aseparatecircuitfromthemainoilgallerydirectsaportionofthelubricationoilin
ordertosupplytheunitinjectorhydraulicpump(1).Asteeltubeontheleftsideoftheengineconnectsthe
mainoilgallerywiththeinletportoftheunitinjectorhydraulicpump.
Oilflowsintotheinletportofunitinjectorhydraulicpump(1)andtheoilfillsthepumpreservoir.The
pumpreservoirprovidesoiltotheunitinjectorhydraulicpumpduringstartup.Also,thepumpreservoir
providesoiltotheunitinjectorhydraulicpumpuntiltheengineoilpumpcanincreasepressure.
Thepumpreservoiralsoprovidesmakeupoiltothehighpressureoilpassageinthecylinderhead.Whenthe
engineisoffandtheenginecoolsdown,theoilshrinks.Acheckvalveinthepumpallowsoiltobedrawn
fromthepumpreservoirinordertokeepthehighpressureoilpassagefull.
Oilfromthepumpreservoirispressurizedintheunitinjectorhydraulicpump(1).Theoilisthenpushedout
oftheoutletportofthepumpunderhighpressure.Oilthenflowsfromtheoutletportoftheunitinjector
hydraulicpumptothehighpressureoilpassageinthecylinderhead.
Thehighpressureoilpassageconnectswitheachunitinjectorboreinordertosupplyhighpressure
actuationoiltotheunitinjectors(5).Actuationoilthatisunderhighpressureflowsfromunitinjector
hydraulicpump(1)throughthecylinderheadtoalloftheinjectors.Oiliscontainedinthehighpressureoil
passageuntiltheoilisusedbytheunitinjectors.Oilthathasbeenexhaustedbytheunitinjectorsisexpelled
underthevalvecovers.Thisoilreturnstothecrankcasethroughtheoildrainholesinthecylinderhead.
ActuationOilPressureControl
(26)Controlvalvesolenoid
(27)Poppetvalve
(28)Armature
(29)Actuatorspring
(30)Slidingsleeve
(31)Actuatorpiston
(32)Eccentricdriveplate
(33)Idler
(34)Spillport
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(35)Pumpoutletports
(36)Drivegear
(37)Checkvalve
(38)Piston
Theunitinjectorhydraulicpumpisavariabledeliverypistonpump.Thevariablepistonpumpusesan
angleddriveplatewhichrotates.Thepistonsdonotrotate.Thepistonsmoveinrelationtotheangleddrive
plate.Thepistonsmoveintheslidingsleeves.
Theunitinjectorhydraulicpumpisdrivenbythegeartrainonthefrontoftheengine.Thedrivegearonthe
frontofthepumpturnsthecommonshaft.Theangleddriveplateismountedonthecommonshaft.The
rotationoftheangleddriveplatecausesthepumppistontomoveinandoutwithintheslidingsleeves.
Asthepistonsmoveoutoftheslidingsleeves,oilisdrawnintotheinsideofthepistonsthroughthepassage
inthedriveplate.Oilisforcedoutofthepistonwhenthepistonispushedbackintotheslidingsleeveand
theportsareexposed.
Changingtherelativepositionoftheslidingsleevetothespillportchangesthevolumeofoilinthepiston.
Thelocationoftheslidingsleeveiscontinuouslychanging.Thelocationoftheslidingsleeveisdetermined
bytheECM.Changingthelocationoftheslidingsleeveschangestheflowofthepump.Theresultisthe
amountofoilthatcanbepressurized.
Thepressureoftheinjectionactuationsystemiscontrolledbymatchingpumpoutletflowandresulting
pressuretothepressuredemandfortheinjectionactuationsystem.Thepositionoftheslidingsleevesis
changedinordertocontrolthepumpoutletflow.Movingthesleevestotheleftcoversthespillportfora
longerdistance.Thisincreaseseffectivepumpingstrokeandpumpoutletflow.Movingthesleevestothe
rightcoversthespillportsforashorterdistancewhichreducestheeffectivepumpingstroke.Thisalso
reducesthepumpoutletflow.
Theslidingsleevesareconnectedbyanidler.Onesleeveisconnectedtoanactuatorpiston.Movingthe
actuatorpistonrightorleftcausestheidlerandsleevestomovethesamedistancetotherightortotheleft.
ControlpressureisdeterminedbytheamountofcurrentfromtheECMtothesolenoid.Asmallamountof
pumpoutletflowgoesthroughasmallpassageintheactuatorpiston.Thissmallamountgoesoutofan
orificeandintothecontrolpressurecavity.Thepressureinthiscavityislimitedbyasmallpoppetvalve.
Theopeningofthepoppetvalveallowsaportionoftheoilinthecavitytoflowtodrain.Aforceholdsthe
poppetvalveclosed.Thisforceonthepoppetvalveiscreatedbyamagneticfieldthatactsonanarmature.
Thestrengthofthemagneticfielddeterminestherequiredpressureinordertoovercometheforceofthe
actuatorspring.
Anincreaseofcurrenttothesolenoidcausesanincreasetothefollowingitems:
Thestrengthofthemagneticfield
Theforceonthearmatureandpoppetvalve
Thecontrolpressurewhichcausestheactuatorpistontomovetoapositionthatresultsinmoreflow
Areductionofcurrenttothesolenoidcausesareductiontothefollowingitems:
Thestrengthofthemagneticfield
Theforceonthearmatureandpoppetvalve
Thecontrolpressurewhichcausestheactuatorpistontomovetoapositionthatresultsinlessflow
TheECMmonitorsactuationpressure.TheECMconstantlychangescurrenttothepumpcontrolvalvein
ordertocontrolactuationpressure.Threecomponentsworktogetherinaclosedloopcircuitinorderto
controlactuationpressure:
ECM
SensorfortheInjectionActuationPressure(IAP)
Pumpcontrolvalve
Theclosedloopcircuitworksinthefollowingmanner:
TheECMdeterminesadesiredactuationpressurebygatheringinformationfromsensorinputsand
softwaremaps.
TheECMmonitorsactualactuationpressurethroughaconstantsignalvoltagefromtheIAPsensor.
TheECMconstantlychangescontrolcurrenttothepumpcontrolvalve.Thischangesthepumpoutlet
flow.
Therearetwotypesofactuationpressure:
Desiredactuationpressure
Actualactuationpressure
Desiredactuationpressureistheinjectionactuationpressurethatisrequiredbythesystemforoptimum
engineperformance.ThedesiredactuationpressureisestablishedbytheperformancemapsintheECM.The
ECMselectsthedesiredactuationpressure.Theselectionisbasedonthesignalinputsfrommanysensors.
TheECMisgettingsignalinputsfromsomeofthefollowingsensors:throttlepositionsensor,boost
pressuresensor,speedtimingsensorsandcoolanttemperaturesensor.Thedesiredactuationpressureis
constantlychanging.Thechangeisbasedonvarioussignalinputs.Thechangingenginespeedandengine
loadalsocausethedesiredactuationpressuretochange.Thedesiredactuationpressureisonlyconstant
understeadystateconditions(steadyenginespeedandload).
Actualactuationpressureistheactualsystempressureoftheactuationoilthatispoweringtheinjectors.The
ECMandthepumppressureregulatorareconstantlychangingtheamountofpumpoutletflow.This
constantchangingmakestheactualactuationpressureequaltothedesiredactuationpressure.
PumpControlValveOperation
Thepumpcontrolvalvehasthefollowingthreestages:
Valveoperation(engineoff)
Valveoperation(crankingtheengine)
Valveoperation(runningengine)
ValveOperation(ENGINEOFF)
Whentheengineisoff,thereisnopumpoutletpressurefromthepumpandthereisnocurrenttothecontrol
valvesolenoidfromtheECM.Theactuatorspringpushestheactuatorpistoncompletelytotheleft.The
idlerwhichisnotshownandtheslidingsleevesaremovedtotheleftalso.Atthispoint,thepumpisinthe
positionofmaximumoutput.
ValveOperation(ENGINECRANKING)
Duringenginestartup,approximately6MPa(870psi)ofinjectionactuationpressureisrequiredinorderto
activatetheunitinjector.Thislowinjectionactuationpressuregeneratesalowfuelinjectionpressureof
about35MPa(5000psi).Thislowfuelinjectionpressureaidscoldstarting.
Inordertostarttheenginequickly,theinjectionactuationpressuremustrisequickly.Becausetheunit
injectorhydraulicpumpisbeingturnedatenginecrankingspeed,pumpflowisverylow.TheECMsendsa
strongcurrenttothecontrolvalvesolenoidinordertokeepthepoppetvalveclosed.Withthepoppetvalve
intheclosedposition,alloftheflowtothedrainisblocked.Thehydraulicforcesthatactoneachsideofthe
actuatorpistonareequal.Theactuatorspringholdstheactuatortotheleft.Thepumpproducesmaximum
flowuntilthe6MPa(870psi)desiredpressureisreached.Now,theECMreducesthecurrenttothe
pressureregulatorsolenoidinordertoreducecontrolpressure.Thereducedcontrolpressureallowsthe
actuatorpistontomovetotheright.Thisreducespumpoutletflowinordertomaintainthe6MPa(870psi)
desiredpressure.
Note:Iftheengineisalreadywarm,thepressurethatisrequiredtostarttheenginemaybehigherthan6
MPa(870psi).Thevaluesforthedesiredactuationpressuresarestoredintheperformancemapsofthe
ECM.Thevaluesfordesiredactuationpressuresvarywithenginetemperature.
Oncetheunitinjectorsbegintooperate,theECMcontrolsthecurrenttothecontrolvalve.TheECMandthe
controlvalvesolenoidwillmaintaintheactuationpressureat6MPa(870psi)untiltheenginestarts.The
ECMmonitorstheactualactuationpressurethroughtheIAPSensorthatislocatedinthehighpressureoil
manifold.TheECMestablishesdesiredactuationpressurebymonitoringseveralelectricalinputsignalsand
theECMsendsapredeterminedcurrenttothecontrolvalvesolenoid.TheECMalsocomparesthedesired
actuationpressuretotheactualactuationpressureinthehighpressureoilpassage.TheECMadjuststhe
currentlevelstothecontrolvalvesolenoidinordertomaketheactualactuationpressureequaltothedesired
actuationpressure.
ValveOperation(RUNNINGENGINE)
Oncetheenginestarts,theECMcontrolsthecurrenttothepumpcontrolvalveinordertomaintainthe
desiredactuationpressure.TheIAPSensormonitorstheactualactuationpressureinthehighpressureoil
passageinthecylinderhead.TheECMcomparestheactualactuationpressuretothedesiredactuation
pressure67timespersecond.TheECMadjuststhecurrentlevelstothepumpcontrolvalvewhentheactual
actuationpressureandthedesiredactuationpressuredonotmatch.Theseadjustmentsmaketheactual
injectionactuationpressureequaltothedesiredinjectionactuationpressure.
OilFlow(ENGINERUNNING)
Asmallamountofpumpoutletflowflowsthroughtheactuatorpistonandintothecontrolpressurecavity.
Controlpressureincreasesandtheincreasedpressureunseatsthepoppetvalve.Theopenpoppetvalve
allowsflowtothedrain.TheECMchangescontrolpressurebyincreasingorreducingthecurrenttothe
controlvalvesolenoidandresultantforceonthepoppet.
Thefollowingitemscreateaclosedloopsystem:
ECM
IAP
PressureRegulator
Thisclosedloopsystemprovidesinfinitelyvariablecontrolofpumpoutletpressure.Thispumpoutlet
pressurehasarangefrom6MPa(870psi)to28MPa(4061psi).
HEUIInjector(Components)
TheHEUIinjectorservesfourfunctions.TheHEUIinjectorpressurizessupplyfuelfrom450kPa(65psi)to
175MPa(25382psi).TheHEUIinjectorfunctionsasanatomizerbypumpinghighpressurefuelthrough
orificeholesintheunitinjectortip.TheHEUIinjectordeliversthecorrectamountofatomizedfuelintothe
combustionchamberandtheHEUIinjectordispersestheatomizedfuelevenlythroughoutthecombustion
chamber.
CrosssectionofHEUIinjector
(39)Solenoid
(40)Armaturespring
(41)Armature
(42)Seatedpin
(43)Spoolspring
(44)Spoolvalve
(45)Checkballforintensifierpiston
(46)Intensifierpiston
(47)Returnspring
(48)Plunger
(49)Barrel
(50)Nozzlecase
(51)Inletfillcheck
(52)Stop
(53)Nozzlespring
(54)Checkpiston
(55)Sleeve
(56)Reverseflowcheckvalve
(57)Nozzlecheck
(58)Nozzletip
RefertoIllustration8.TheHEUIinjectorconsistsofthreemajorparts:
Upperend,oractuator(A)
Middle,orpumpingunit(B)
Lowerend,ornozzleassembly(C)
Theupperend(A)consistsofthefollowingitems:
Solenoid(39)
Armaturespring(40)
Armature(41)
Seatedpin(42)
Spoolspring(43)
Spoolvalve(44)
Checkballforintensifierpiston(45)
Themiddleoftheinjector(B)containsthefollowingitems:
Intensifierpiston(46)
Returnspring(47)
Plunger(48)
Barrel(49)
Thelowerendoftheinjector(C)consistsofthefollowingitems:
Nozzlecase(50)
Inletfillcheck(51)
Stop(52)
Nozzlespring(53)
Checkpiston(54)
Sleeve(55)
Reverseflowcheckvalve(56)
Nozzlecheck(57)
Nozzletip(58)
Thesecomponentsworktogetherinordertoproducedifferentratesforfuelinjection.Theratesforfuel
injectionareelectronicallycontrolledbyperformancesoftwareintheECM.
HEUIFuelInjector(Operation)
TheHEUIinjectoroperateswithasplitinjectioncycle.Thesplitinjectioncyclehasfivephasesofinjection:
Preinjection
Pilotinjection
Injectiondelay
Maininjection
Fill
PreInjection
Crosssectionofpreinjectioncycle
(40)Armaturespring
(41)Armature
(42)Seatedpin
(43)Spoolspring
(44)Spoolvalve
(48)Plunger
(54)Checkpiston
(57)Nozzlecheck
RefertoIllustration9.Theinjectorisinthephaseofpreinjectionwhentheengineisrunningandthe
injectorisbetweenfiringcycles.Plunger(48)andtheintensifierpiston(46)areatthetopofthepistonbore.
Thecavitybelowtheplungerisfulloffuel.
Intheupperend,thearmature(41)andtheseatedpin(4)arehelddownbythearmaturespring(40).High
pressureactuationoilflowsintotheinjector.Theoilthenflowsaroundtheseatedpintothetopofthecheck
piston(54).Thisprovidesapositivedownwardforceonthenozzlecheck(57)atalltimeswhenfuelisnot
beinginjected.
Thespoolvalve(44)isheldinthetopoftheboreforthespoolvalvebythespoolspring(43).Inthis
position,thespoolvalveblocksactuationoilfromreachingtheintensifierpiston.Actuationpressureisfelt
onboththetopandbottomofthespool,sohydraulicforcesonthespoolarebalanced.Thespoolvalveis
heldintheuppositionortheclosedpositionbytheforceofthespoolspring.
PilotInjection
Crosssectionofpilotinjectioncycle
(39)Solenoid
(41)Armature
(42)Seatedpin
(44)Spoolvalve
(48)Plunger
(53)Nozzlespring
(54)Checkpiston
(57)Nozzlecheck
(58)Nozzletip
(59)Drain
RefertoIllustration10.PilotinjectionoccurswhentheECMsendsacontrolcurrenttothesolenoid(39).
Thecurrentcreatesamagneticfieldwhichliftsthearmature(41)andtheseatedpin(42).Theseatedpinhas
alowerseatandanupperseat.Whentheseatedpinisliftedbythearmature,theupperseatclosesoffthe
flowofactuationpressuretothecheck.Thelowerseatopens.Thisallowstheactuationoilontopofcheck
piston(54)toflowtodrain(59).Actuationoilthatistrappedbelowspool(44)willalsoflowtodrain(59).
Theactuationoildrainsthroughaventholeinthesideoftheinjector.
Thedropinpressureunderthespoolcausesahydraulicdifferencethatactsonthespool.Thespoolmoves
intotheopenpositionwhenhydraulicpressureactsonthetopofthespool.Thishydraulicpressureforces
thespooldownward.Thedownwardmovementofthespoolisstoppedwhenthespoolandthepinforcethe
checkball(45)fortheintensifierpistonontotheballseatintheclosedposition.Thispreventsanyactuation
pressurefromescapingfromthecavityfortheintensifierpiston(46).Thisdropintheactuationpressure
alsoremovesthedownwardforceonthecheckpiston.
Actuationoilnowflowspasttheopenspoolandtothetopoftheintensifierpiston.Thedownward
movementofthepistonandplunger(48)pressurizesthefuelintheplungercavitytothenozzletip(58).
Pilotinjectionbeginswhentheinjectionpressureincreasesinordertoovercometheforceofthenozzle
spring(53)whichliftsthenozzlecheck(57).
Pilotinjectionwillcontinueifthefollowingconditionsexist:
Thesolenoidisenergized.
Thespoolremainsopen.
Thereisnoactuationpressureontopofthecheckpiston.
InjectionDelay
Crosssectionofinjectiondelay
(39)Solenoid
(40)Armaturespring
(41)Armature
(42)Seatedpin
(43)Spoolspring
(44)Spoolvalve
(48)Plunger
(54)Checkpiston
(57)Nozzlecheck
RefertoIllustration11.Injectiondelaybeginswhenthecontrolcurrenttothesolenoid(39)stopsandthe
solenoidisdeenergized.Thearmature(41)isheldintheuppositionbyamagneticfield.Whenthe
magneticfieldisdeenergized,thearmaturespring(40)pushesthearmatureandtheseatedpin(42)
downward.Theseatedpinclosesthelowerseatandtheseatedpinopenstheupperseat.Thisallowsthe
actuationpressuretoflowtothetopofthecheckpiston(16).Thehydraulicforceonthecheckpiston
quicklyovercomestheinjectionpressureandthenozzlecheck(57)closes.Injectionstopsatthispoint.
Actuationpressureincreasesunderthespoolvalve(44)thatcreatesthebalanceofhydraulicforceonthetop
andbottomofthespool.Theweakspoolspring(43)nowactsonthespool.Thisclosesthespoolvery
slowly.Asthespoolremainsopen,actuationpressurecontinuestoflowpastthespooltointensifierpiston
(46)andtoplunger(48).Theinjectionpressureinthenozzleandintheplungercavityincreasesvery
quicklywhenthenozzlecheckisheldintheclosedposition.
MainInjection
Crosssectionofmaininjectioncycle
(39)Solenoid
(41)Armature
(42)Seatedpin
(44)Spoolvalve
(54)Checkpiston
(57)Nozzlecheck
(60)Drain
RefertoIllustration12.Maininjectionbeginswhenthesolenoid(39)isreenergized.Themagneticfieldis
instantlycreatedandtheforceofthemagneticfieldliftsthearmature(41)andtheseatedpin(42).Theupper
seatclosesofftheflowofactuationpressureandtheupperseatopensthecheckpiston(54)andthebottom
ofthespool(44)tothedrain(22).Thehydraulicforcethatholdsthenozzlecheck(57)closedquickly
dissipatesandtheinjectionpressureopensthenozzlecheck.Thisisthestartofmaininjection.Adifference
inhydraulicforcesonthespoolisalsocreated.Thisdifferenceforcesthespooldownward.Thecheckball
(45)fortheintensifierpistonisheldintheclosedpositionwhenthespoolisinthisposition.Maininjection
continuesifthesolenoidremainsenergized.
Fill
Crosssectionoffillcycle
(39)Solenoid
(40)Armaturespring
(41)Armature
(42)Seatedpin
(43)Spoolspring
(44)Spoolvalve
(47)Returnspring
(48)Plunger
(54)Checkpiston
(56)Reverseflowcheckvalve
(57)Nozzlecheck
RefertoIllustration13.Thefillcyclebeginswhenthesolenoid(39)isdeenergized.Thearmature(41)and
theseatedpin(42)areforceddownbythearmaturespring(40).Theseatedpinclosesthelowerseatandthe
seatedpinopenstheupperseat.Actuationpressureisrestoredtothetopofthecheckpiston(54).Thiscloses
thenozzlecheck(57)andinjectionends.Actuationpressureisalsofeltunderthevalvespool(44).This
restoresthehydraulicbalanceonthespool.Thevalvespring(43)slowlyclosesthespool.Thisstopsthe
flowofactuationoiltotheintensifierpiston(48).
Asthespoolraises,thecheckball(45)fortheintensifierpistonisnolongerheldclosed.Oilinthecavityfor
theintensifierpistonliftsthecheckofftheseatandflowstothedrain(60)throughaventholeinthesideof
theinjector.Returnspring(47)pushesupplunger(48)andtheintensifierpiston.Thispushesalloftheoil
outofthecavityfortheintensifierpiston.Thecheckvalve(56)forthefuelinletistakenoffofthevalveseat
astheplungerliftsup.Thisallowssupplyfueltoflowintotheplungercavity.Thefillcycleiscomplete
whentheplungerandthepistonareatthetopoftheboreandtheplungercavityisfulloffuel.
Copyright19932015CaterpillarInc. SatApr11201519:57:01GMT0500(Horaest.Pacfico,Sudamrica)
Todoslosderechosreservados.
cr080rhm
RedprivadaparalicenciadosdelSIS.

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