Diesel Engine Troubleshooting

Caterpillar EMS Hydraulic/electronic unit injector

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HEUI evolved from the EUI, and since mid-1994 has been used on Caterpillar, International T444E, DT466E, 1530E, certain Perkins models, and, most famously, on the Ford (International) Power Stroke. Unlike conventional camshaft-driven unit injectors, HEUIs are actuated by high-pressure crankcase oil. Since injection is no longer tied to camshaft motion, fuel can be injected at any crank angle. At higher-than-idle speeds, injector pressure is independent of engine rpm and can attain values of 30,000 psi.

Figure 6-18 illustrates the general layout of the Cat system that differs only in detail from Ford and other HEUI applications. Figure 6-19 shows the arrangement of the piping for the 3126B truck engine, which is the focus of this discussion. The high-pressure oil pump delivers crankcase oil to the injectors at cranking pressures of 500 psi that increase to as much as 3300 psi under speed and load. The computer-controlled injector actuation pressure control valve (IAPCV) regulates oil pressure by shunting pump output to the crankcase. Fuel pressure is regulated to 55 psi minimum.

HEUI schematic Caterpillar EMS Hydraulic/electronic unit injector

HEUI plumbing Caterpillar EMS Hydraulic/electronic unit injector

HEUI consists of five major components—a solenoid, poppet valve, mushroom shaped intensifier piston, barrel, and a seven-hole nozzle assembly (Fig. 6-20). Approximately 4A is required to energize the solenoid and 1.5A holds it open.

Upon command, the solenoid opens the poppet valve to admit high-pressure lube oil to the upper end of the intensifier piston (6 in Fig. 6-20). The oil forces the piston and plunger (7) down against fuel trapped in the injector body by a ball check valve. The fuel end of the plunger is smaller in diameter than the upper, or oil, end. The difference in cross-sectional area multiplies the hydraulic force acting on the fuel 7.5 times, to produce injection pressures of 3000–30,000 psi. Pressurized fuel lifts a second check valve, enters the cavity on the lower right of the drawing, and reacts against the needle shoulder to overcome spring tension. Nozzle-opening pressure (NOP) varies with the application. Some Cat injectors have an NOP of 4500 psi. Rebuilders of Power Stroke HEUIs look for 2750 +/_ 75 psi.

HEUI injector Caterpillar EMS Hydraulic/electronic unit injector

Note that both band width (the time the injector is open) and actuator-oil pressure determine the amount of fuel delivery.

HEUI injectors have undergone constant refinement. The most significant change is the split-shot PRIME (preinjection metering) version that first appeared on 1994 California Ford F series trucks and has since become almost universal.

These injectors work like other HEUIs, except that the plunger incorporates a radial groove that receives fuel through six bleed ports drilled in the face of the plunger. As the piston moves downward, the groove aligns with a spill port in the barrel, shunting pressure. The output-side check ball seats and injection stops. Further piston movement masks the port and injection resumes.

Written by Ed

February 14th, 2011 at 2:38 am

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