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The document provides information about service training for the 3400 HEUI engine used in large track type tractors. It includes diagrams and descriptions of the key components and operation of the HEUI fuel system, including the hydraulic supply pump group, injectors, fuel injection cycle, pressure control, start-up process, and destroke process. The document is intended to train service technicians on testing and adjusting the 3400 HEUI engine.

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Service Training MALAGA Large Track Type Tractors 1 ENGINE CONTROL 3400 HEUI 1. Components Layout 2. Operation 3. Testing & Adjusting Adolfo May 1997
Page: 1-2 HIGH PRESSURE OIL MANIFOLD High Pressure 40 to 210 BAR Oil Pump HEUI FUEL SYSTEM CHAPTER : 3400 HEUI Regulator Fuel Return Line Pressure Large Track Type Tractors Control Valve Engine System Fuel Filter ECM Oi Fuel lS Trans Oil Oil u Vehicle Pump Oil Filter Cooler Pump m System p LOW PRESSURE 3 BAR Fuel Tank
Large Track Type Tractors CHAPTER : 3400 HEUI HEUI FUEL SYSTEM The electronic components in the HEUI fuel system are very similar to those used in other EUI systems. However, in the HEUI system, the injectors are not actuated by a camshaft The seven major types of components in the HEUI fuel system are: • Hydraulic Supply Pump Group containing: - High pressure hydraulic pump - Pump control valve - Transfer pump • ECM • Throttle Control • Speed/Timing Sensor • Injector • Temperature Sensor • Pressure Sensor Page: 1-3
Large Track Type Tractors CHAPTER : 3400 HEUI INJECTOR COMPONENTS SPACER SLEEVE ARMATURE VALVE VALVE BODY SOLENOID SHIM BARREL ADAPTER PISTON WASHER UPPER FUEL SEAL PLUNGER FUEL INLET CHECK VALVE PIN SLEEVE SPACER LOWER FUEL SEAL CHECK NOZZLE Page: 1-4
Large Track Type Tractors CHAPTER : 3400 HEUI INJECTION CYCLE Page: 1-5
Large Track Type Tractors CHAPTER : 3400 HEUI POPPET VALVE OPEN ARMATURE SCREW POPPET SPRING Page: 1-6
Large Track Type Tractors CHAPTER : 3400 HEUI DRAIN CYCLE Page: 1-7
Large Track Type Tractors CHAPTER : 3400 HEUI POPPET VALVE CLOSED POPPET VALVE SOLENOID ARMATURE INLET EXHAUST VALVE SEAT VALVE SEAT Page: 1-8
Large Track Type Tractors CHAPTER : 3400 HEUI NOZZLE GROUP NOZZLE GROUP REVERSE FLOW CHECK VALVE CHECK VALVE FUEL ATOMIZATION Page: 1-9
Large Track Type Tractors CHAPTER : 3400 HEUI PRIME RATE SHAPING CROSS SECTION OF PLUNGER FINAL START OF INJECTION PRESSURE DROP PRESSURE INCREASE INJECTION RATE START OF END OF INJECTION DURATION INJECTION TIME (MILLISECONDS) Page: 1-10
Large Track Type Tractors CHAPTER : 3400 HEUI VENTING INTERNAL LEAKS INTENSIFIER PISTON INTENSIFIER PISTON SEAL BARREL VENTING CHECK VALVE During the normal injection cycle, the pressure of the oil supplied to the top of the intensifier piston can increase to 22800 kPa (3300 psi). A seal is installed to minimize leakage past the piston. Some oil which is necessary for lubrication of the intensifier piston may pass the seal and settle momentarily below the piston. Also, a small amount of fuel may leak past the plunger and barrel. This fuel will settle momentarily in the cavity below the intensifier piston. If the fluids which accumulate below the piston are not vented, a hydraulic lock could occur. As the piston moves down, the fuel is ejected past the barrel ball check valve to the low pressure inlet. The check valve then closes during the plunger and piston upstroke. Page: 1-11
Large Track Type Tractors CHAPTER : 3400 HEUI INJECTOR CHECK VALVES BARREL GROUP NOZZLE GROUP FUEL INLET CHECK VALVE VENTING CHECK VALVE REVERSE FLOW CHECK VALVE NOZZLE CHECK VALVE FUEL ATOMIZATION The Fuel Inlet Check Valve allows fuel to fill the barrel below the plunger, but closes as the plunger moves down and pressure increases. The Venting Check Valve vents fluids from below the intensifier piston. The Reverse Flow Check Valve prevents combustion gasses from flowing back through the injector from the nozzle. The Nozzle Check Valve controls valve opening pressure by preventing the flow of fuel through the nozzle holes until sufficient pressure is available to lift the valve from its seat Page: 1-12
Large Track Type Tractors CHAPTER : 3400 HEUI PRESSURE CONTROL INJECTION PRESSURE HEUI MECHANICALLY ACTUATED FUEL SYSTEM IDLE ENGINE SPEED Page: 1-13
Page: 1-14 TO LUBE SYSTEM HEUI HYDRAULIC TEMPERATURE SENSOR COLD START OIL FLUID MANIFOLD RESERVOIR OIL PRESSURE HYDRAULIC PASSAGE SENSOR COOL DOWN FUEL HYDRAULIC HYDRAULIC CIRCUIT TEMPERATURE PRESSURE SUPPLY SENSOR SENSOR PUMP OIL GROUP FILTER FLUID MANIFOLD HYDRAULIC PASSAGE LOW PRESSURE OIL (HYDR.) SUPPLY CHAPTER : 3400 HEUI Large Track Type Tractors PUMP CONTROL HEUI VALVE ECM OIL COOLER FUEL TRANSFER SECONDARY PRESSURE PUMP FUEL REGULATING LUBE OIL PUMP FILTER VALVE PRIMARY FUEL FILTER WATER SEPARATOR OIL SUMP FUEL TANK
Page: 1-15 TO LUBE SYSTEM HEUI HYDRAULIC TEMPERATURE SENSOR COLD START OIL FLUID MANIFOLD RESERVOIR OIL PRESSURE HYDRAULIC PASSAGE SENSOR COOL DOWN FUEL HYDRAULIC HYDRAULIC CIRCUIT TEMPERATURE PRESSURE SUPPLY SENSOR SENSOR PUMP OIL GROUP FILTER FLUID MANIFOLD HYDRAULIC PASSAGE PUMP CONTROL HEUI VALVE ECM OIL COOLER FUEL TRANSFER SECONDARY PRESSURE PUMP FUEL REGULATING LUBE OIL FILTER VALVE PUMP PRIMARY CHAPTER : 3400 HEUI FUEL FILTER WATER SEPARATOR OIL HIGH PRESSURE HYDRAULICS SUMP FUEL TANK Large Track Type Tractors
Large Track Type Tractors CHAPTER : 3400 HEUI REVERSE FLOW CHECK VALVE (END VIEW) SEAT FROM PUMP SEAT CHECK SPRING VALVE BLOCK FITTING INJECTORS TO Page: 1-16
Large Track Type Tractors CHAPTER : 3400 HEUI REVERSE FLOW CHECK VALVE The hydraulic supply pump group has two outlet ports, each connected by steel tubes to a hydraulic supply manifold. An integral reverse flow check valve is located in each outlet port. This view shows that pressure surges travelling back from the injectors toward the pump will cause the check valve to close and block any interference between the banks. In normal operation, the valve will oscillate at high frequency as it blocks the pressure surges. The valve check fits loosely on the shaft to allow oil flow from the reservoir during the cooling process. If the check valves were not in the system, pressure surges between the banks would cause erratic operation of the injectors by adversely affecting timing. The pressure surge causes the poppet valves to open prematurely. This condition would start fuel injection earlier than normal, thereby advancing the timing. Page: 1-17
Page: TO LUBE 1-18 SYSTEM HEUI HYDRAULIC TEMPERATURE SENSOR COLD START OIL FLUID MANIFOLD RESERVOIR OIL PRESSURE HYDRAULIC PASSAGE SENSOR COOL DOWN FUEL HYDRAULIC HYDRAULIC CIRCUIT TEMPERATURE PRESSURE SUPPLY SENSOR SENSOR PUMP OIL GROUP FILTER FLUID MANIFOLD HYDRAULIC PASSAGE PUMP CONTROL HEUI VALVE ECM OIL COOLER FUEL TRANSFER SECONDARY CHAPTER : 3400 HEUI PUMP PRESSURE LUBE FUEL FILTER REGULATING OIL PUMP (2 MICRON) VALVE PRIMARY FUEL FILTER LOW PRESSURE FUEL SUPPLY WATER SEPARATOR Large Track Type Tractors OIL SUMP FUEL TANK
Large Track Type Tractors CHAPTER : 3400 HEUI LOW PRESSURE FUEL SUPPLY On a HEUI equipped engine, the lubrication pump has two functions: 1. Provides lubrication to the engine 2. Provides low pressure charge oil to the HEUI hydraulic pump The engine lubrication pump has been enlarged to provide the required increase in flow. During normal operation conditions, oil is pressurized between 5000 and 21500 kPa (725 and 3100 psi) by the high pressure hydraulic pump to actuate the injectors. The pressure regulating valve regulates fuel pressure between 310 and 415 kPa (45 and 60 psi). The ratio of fuel between combustion and fuel return to the tank is about 1:3 (i.e. four times the volume required for combustion is supplied to the system for combustion and injector cooling purposes). Page: 1-19
Page: HIGH PRESSURE HYDRAULIC OIL 1-20 INJECTOR OIL INJECTOR CLAMP ADAPTER JUMPER TUBE ROCKER ARM BASE INJECTOR LUBE OIL PASSAGE HIGH PRESSURE HYDRAULIC PASSAGE CHAPTER : 3400 HEUI FLUID SUPPLY INJECTOR FLUID FLOW MANIFOLD Large Track Type Tractors CYLINDER HEAD INJECTOR SLEEVE CYLINDER HEAD LOW PRESSURE FUEL SUPPLY COOLANT CYLINDER BLOCK METAL WASHER
Page: 1-21 INJECTOR UPPER INJECTOR UPPER SLEEVE O-RING SEAL O-RING SEAL CYLINDER HEAD INJECTOR SLEEVE FLUID SUPPLY MANIFOLD LOWER SLEEVE O-RING SEAL INJECTOR FUEL SUPPLY CHAPTER : 3400 HEUI Large Track Type Tractors LOW PRESSURE FUEL SUPPLY CYLINDER HEAD METAL-TO- METAL LOWER INJECTOR CONTACT O-RING SEAL
Page: COMPENSATOR 1-22 PRIMING PORT VALVE ORIFICE VALVE BASE DRAIN PASSAGE TRANSFER PUMP RESERVOIR HEUI PUMP CHAPTER : 3400 HEUI Large Track Type Tractors SWASHPLATE
Page: 1-23 TO LEFT OIL TO RIGHT OIL TO LUBE COLD START MANIFOLD RESERVIOR MANIFOLD SYSTEM DISPLACEMENT CONTROL PISTON CHECK VALVE PRESSURE LIMITER SUPPLY PUMP SPOOL START-UP CHAPTER : 3400 HEUI SOLENOID LOAD Large Track Type Tractors (ENERGIZED) SENSING SPOOL OIL SUMP PUMP CONTROL VALVE PUMP CASE DRAIN
Page: PRESSURE LIMITER SPOOL 1-24 ORIFICE PUMP CONTROL VALVE LOAD SENSING SPOOL CHECK VALVE FROM DISPLACEMENT CONTROL PISTON START-UP CHAPTER : 3400 HEUI DRAIN ORIFICE Large Track Type Tractors TO CASE DRAIN TO CASE DRAIN REVERSE FLOW CHECK VALVES
Large Track Type Tractors CHAPTER : 3400 HEUI START-UP The displacement of the pump is controlled to maintain the desired operating pressure at the flow rate required by the injectors. The displacement is regulated by an electro-hydraulic control. Displacement of the pump is varied by pivoting the swashplate from 0 degrees to a maximum angle of 15.5 degrees. When the engine is not running, the swashplate is at the maximum angle. During operation, the displacement control piston adjusts the swashplate position to meet the system flow demand. During initial cranking, the swashplate is at full displacement until the supply pressure increases to 6200 kPa (900 psi). The spring at the end of the load sensing spool regulates this pressure. Then, the specification programmed into the ECM for normal cranking will override this pressure. Until this point, the control valve solenoid is fully energized for the pressure increase. During START-UP, pressure from the pump enters the compensator assembly. The Pump Control Valve is energized for quick pressure build-up. Pressure is felt at both ends of the Load Sensing Spool. The spool is shifted to the right and oil from the Displacement Control Piston is vented to case drain. The swashplate is at maximum angle. The drain orifice below the Pump Control Valve provides a small amount of restriction to improve valve stability Page: 1-25
Page: 1-26 TO LEFT OIL TO RIGHT OIL TO LUBE COLD START MANIFOLD RESERVIOR MANIFOLD SYSTEM DISPLACEMENT CONTROL PISTON CHECK VALVE PRESSURE LIMITER SUPPLY PUMP SPOOL DESTROKE CHAPTER : 3400 HEUI LOAD SOLENOID SENSING Large Track Type Tractors (DE-ENERGIZED) SPOOL OIL SUMP PUMP CONTROL VALVE PUMP CASE DRAIN
Page: 1-27 PRESSURE LIMITER SPOOL ORIFICE PUMP CONTROL VALVE LOAD SENSING SPOOL DESTROKE CHAPTER : 3400 HEUI CHECK VALVE Large Track Type Tractors TO DISPLACEMENT CONTROL PISTON DRAIN ORIFICE TO CASE DRAIN
Large Track Type Tractors CHAPTER : 3400 HEUI DESTROKE After the engine starts and pressure increases, the ECM will signal the control valve to match the actual with the desired pressure by momentarily de-energizing and then regulating the current flow to the pump control valve solenoid. The decrease in current applied to the pump control valve solenoid lowers the pressure required to initiate flow through the pump control valve. This lower cracking pressure on the pump control valve creates a force imbalance on the load sensing spool, causing the spool to move toward the spring end of the compensator. This spool motion connects the displacement control piston to pump output flow, allowing the swashplate to decrease the displacement of the pump. The decreased displacement lowers the pump output to the pressure level required by the ECM. During DESTROKE, the ECM momentarily de-energizes the Pump Control Valve causing a pressure drop in the spring chamber of the Load Sensing Spool. Unbalanced pressures force the spool to the left, allowing the oil to enter the Displacement Control Piston and move the swashplate toward minimum angle. Page: 1-28
Page: 1-29 TO LEFT OIL TO RIGHT OIL TO LUBE COLD START MANIFOLD MANIFOLD SYSTEM RESERVIOR DISPLACEMENT CONTROL PISTON CHECK VALVE PRESSURE LIMITER SUPPLY PUMP SPOOL UPSTROKE CHAPTER : 3400 HEUI LOAD SOLENOID SENSING Large Track Type Tractors (ENERGIZED) SPOOL OIL SUMP PUMP CONTROL VALVE PUMP CASE DRAIN
Page: 1-30 PRESSURE LIMITER SPOOL ORIFICE PUMP CONTROL VALVE LOAD SENSING SPOOL CHECK VALVE UPSTROKE CHAPTER : 3400 HEUI Large Track Type Tractors FROM DISPLACEMENT CONTROL PISTON DRAIN ORIFICE TO CASE DRAIN
Large Track Type Tractors CHAPTER : 3400 HEUI UPSTROKE As the load on the engine increases and higher pressure is required, the ECM will signal the control valve to increase pressure by increasing the current flow to the pump control valve solenoid. The increase in current applied to the pump control valve solenoid raises the pressure setting of the pump control valve. This higher pressure at the pump control valve creates a force imbalance on the load sensing spool, causing the spool to move toward the supply signal line end of the compensator. This spool motion vents the displacement control piston to case drain, allowing the spring to move the swashplate to increase the displacement of the pump. The increased displacement raises the pump output to the desired pressure level required by the ECM. As the load is applied to the engine, the ECM increases current to the Pump Control Valve. Pressure is felt at both ends of the Load Sensing Spool. The spool moves to the right (due to spring force) and oil from the Displacement Control Piston is vented to case drain, which allows the swashplate to momentarily go to maximum angle and build pressure quickly. Page: 1-31
Page: 1-32 TO LEFT OIL TO RIGHT OIL TO LUBE COLD START MANIFOLD RESERVIOR MANIFOLD SYSTEM DISPLACEMENT CONTROL PISTON PRESSURE LIMITER SUPPLY PUMP SPOOL PRESSURE LIMITER OPERATION CHAPTER : 3400 HEUI LOAD SOLENOID SENSING Large Track Type Tractors (DE-ENERGIZED) SPOOL PLUGGED ORIFICE OIL SUMP PUMP CONTROL VALVE PUMP CASE DRAIN
Page: 1-33 PRESSURE LIMITER SPOOL PUMP CONTROL VALVE ORIFICE RESTRICTION LOAD SENSING SPOOL PRESSURE LIMITER OPERATION CHAPTER : 3400 HEUI CHECK VALVE Large Track Type Tractors TO DISPLACEMENT CONTROL PISTON DRAIN ORIFICE TO CASE DRAIN
Large Track Type Tractors CHAPTER : 3400 HEUI PRESSURE LIMITER OPERATION If the load sensing spool or pump control valve sticks or otherwise malfunctions to create higher than desired operating pressures, the maximum pressure limiter spool is utilized. In this schematic, a plugged orifice is simulated. (This example represents an actual condition which was caused by debris being introduced during a field replacement of the compensator valve.) The Pressure Limiter Spool directs pump outlet flow to the displacement control piston and reduces the stroke of the pump if the system pressure exceeds 25600 kPa (3700 psi). During these conditions, the pump will develop 24800 to 25600 kPa (3600 to 3700 psi) maximum pressure, regardless of the desired hydraulic pressure. The Check Engine Lamp will be ON, indicating a fault. A Pump Control Valve Test will verify the control valve operation. This test enables the technician to manually ramp the pressure up and down using the ET service tool. This procedure will also be useful when evaluating the condition of the hydraulic system. If the supply pressure exceeds 25600 kPa (3700 psi), the force acts on the Pressure Limiter Spool and shifts it to the left. This movement compresses the spring and allows oil to unseat the check valve and pressurize the displacement control piston. The swashplate moves to minimum angle to decrease flow and limit system pressure. Page: 1-34
Page: 1-35 NO CURRENT FLOW FROM LOAD COIL POPPET SENSING SPOOL ASSEMBLY VALVE ADAPTER SEAL SEAT CAGE VALVE EDGE FILTER STOP STATOR PUMP CONTROL VALVE CHAPTER : 3400 HEUI Large Track Type Tractors VALVE TO SPRING ARMATURE SOLENOID PIN SHELL RING BLOCK CASE DRAIN RETAINER
Page: 1-36 HIGH CURRENT FLOW FROM LOAD COIL POPPET SENSING SPOOL ASSEMBLY VALVE ADAPTER SEAL SEAT CAGE VALVE EDGE FILTER STOP STATOR PUMP CONTROL VALVE CHAPTER : 3400 HEUI Large Track Type Tractors VALVE TO SPRING ARMATURE SOLENOID PIN SHELL RING BLOCK CASE DRAIN RETAINER
Page: 1-37 8 OR 12 INJECTORS ADEM II ELECTRONIC CONTROL ENGINE MODULE DISCONNECT SWITCH (ECM) GROUND HARNESS BOLT 24 V MAIN KEY MACHINE 15 AMP POWER RELAY SWITCH HARNESS BREAKER PUMP CONTROL VALVE MACHINE HYDRAULIC INTERFACE PRESSURE SENSOR CONNECTOR TDC SERVICE PRIMARY PROBE ACCESS THROTTLE SPEED/TIMING SENSOR ACCELERATOR SENSOR PEDAL SECONDARY COMPONENTS DIAGRAM CHAPTER : 3400 HEUI SPEED/TIMING SENSOR THROTTLE BACK-UP, ELEVATED LOW IDLE ENABLE, AND GROUND LEVEL SHUTDOWN (2) SWITCHES Large Track Type Tractors COOLANT TEMP. SENSOR TURBO INLET PRESSURE SENSOR FAN CONTROL VALVE TURBO OUTLET PRESS. SENSOR FAN SPEED SENSOR FAN ATMOSPHERIC PRESS. SENSOR CAT DATA LINK OIL PRESSURE SENSOR ELECTRONIC SERVICE TOOL EPTC II TRANSMISSION CONTROL HYDRAULIC TEMP. SENSOR AUTO RETARDER CONTROL FUEL TEMPERATURE SENSOR INSTRUMENT PANEL COOLANT FLOW SWITCH
Large Track Type Tractors CHAPTER : 3400 HEUI SENSORS - ANALOG & DIGITAL ANALOG SENSORS - HYDRAULIC PRESSURE - COOLANT TEMPERATURE - ATMOSPHERIC PRESSURE - TURBOCHARGER INLET PRESSURE - TURBOCHARGER OUTLET PRESSURE - LUB. OIL PRESSURE - HYDRAULIC TEMPERATURE - FUEL TEMPERATURE DIGITAL SENSORS - THROTTLE POSITION - PUMP CONTROL VALVE SIGNAL - EXHAUST TEMPERATURE (not installed on machine engines at this time) Page: 1-38
Large Track Type Tractors CHAPTER : 3400 HEUI SYSTEM POWER SUPPLIES The HEUI system has six power supplies with various voltages as shown. EXTERNAL POWER SUPPLY ECM power supply 24 Volts INTERNAL POWER SUPPLIES Speed/Timing Sensor power supply 12.5 Volts Injector power supply 105 Volts Analog Sensor power supply 5 Volts Digital Sensor power supply 8 Volts Pump Control Valve power supply 0 to 24 Volts The power supply to the ECM and the system is drawn from the 24-Volt machine battery. The principle components in this circuit are: - Battery - Key Start Switch - Main Power Relay - 15 Amp Breaker - Ground Bolt - ECM Connector (P1/JI) - Machine Interface Connector (J3/P3) If the supply voltage exceeds 32.5 Volts or is less than 9.0 Volts, a diagnostic code is logged. (See the Troubleshooting Guide for complete details on voltage event logging.) NOTE: The ground bolt is the only power supply component mounted on the engine. Page: 1-39
Large Track Type Tractors CHAPTER : 3400 HEUI LOGGED EVENTS Logged events are abnormal to the operation of the engine (for example: high temperature, low pressure or excessive engine speed). These conditions would not normally be caused by an electronic problem. Some of the parameters listed in this presentation are used in the ET events list. They are: - High coolant temperature above 107°C (225°F) - Loss of coolant flow - Low (lubrication) oil pressure (according to the oil pressure map) - Abnormal injection actuation hydraulic pressure (low or high) - Injection actuation pressure system fault - User defined shutdown (if installed) - Air inlet restriction (if installed) - Engine overspeed histogram - Low fuel pressure (industrial engine only) Events are not logged if an electronic fault is detected. Passwords are required to clear events. This process would normally be performed during an engine overhaul. At other times, the events would be left as a record of the engine history prior to overhaul time. Page: 1-40
Large Track Type Tractors CHAPTER : 3400 HEUI SYSTEM LIMITS & DERATE FUEL SYSTEM LIMITS MAXIMUM HORSEPOWER TORQUE LIMIT ( Determines torque rise characteristics) FUEL RATIO CONTROL ( Limits fuel until sufficient boost ) COLD MODE ( Limits fuel to control white smoke ) CRANKING FUEL ( Limits fuel during cranking ) FUEL SYSTEM DERATES FUEL SYSTEM DERATES AUTOMATIC ALTITUDE COMPENSATION AUTOMATIC ALTITUDE COMPENSATION ( Altitude derate) ( Altitude derate) AUTOMATIC FILTER COMPENSATION AUTOMATIC FILTER COMPENSATION ( Derate for air filter restriction installed ) ( Derate for air filter restriction if if insatalled At 6.25 kPa (30 inc of water) the engine will ENGINE 2% of its powerDERATE until a maxi 20% derate WARNING per 1 kPa Event is logged if exeeds 30 inch of water ) ( Derates for LOW OIL PRESSURE, HIGH COOLANT TEMP not install in HEUI at the time) ENGINE WARNING DERATE ( Derates for LOW OIL PRESSURE , HIGH COOLANT TEMP not installed yet on HEUI) Page: 1-41
Page: REF 1-42 TDC SECONDARY REF TDC SINGLE 4 50/50 TOOTH SPEED/TIMING SENSOR TDC CYLINDER No. 1 3 8 REF PRIMARY SPEED/TIMING SENSOR TDC REF TIMING TIMING WHEEL CHAPTER : 3400 HEUI 1 CALIBRATION 6 RANGE ± 10° Large Track Type Tractors TDC REF TIMING WHEEL ROTATION TDC REF 5 2 7 REF TDC REF TDC
Page: 1-43 TIMING GEAR TOOTH TABLE TABLE PWM DUTY CYLINDER ENTRY CYCLE REFERENCE A 80 % NONE IDENTIFIED B 80 % C 80 % D 80 % E 80 % F 80 % G 80 % H 50 % CRANKING CHAPTER : 3400 HEUI Large Track Type Tractors 80/20 % 80/20 % 80/20 % 80/20 % 80/20 % 80/20 % 50/50% A B C D E F G H TIMING WHEEL ROTATION
Page: 1-44 TIMING GEAR TOOTH TABLE TABLE PWM DUTY CYLINDER ENTRY CYCLE REFERENCE A 80 % NO B 80 % CYL NO. 3 C 80 % NO D 80 % NO E 80 % CYL NO. 4 F 80 % NO G 80 % NO H 50 % CYL NO. 8 AFTER PATTERN RECOGNITION CHAPTER : 3400 HEUI Large Track Type Tractors TIMING WHEEL ROTATION A B C D E F G H CYL NO. 3 CYL NO. 3 CYL NO. 4 CYL NO. 4 CYL NO. 8 REFERENCE TDC REFERENCE TDC REFERENCE EDGE EDGE EDGE
Page: TIMING GEAR TOOTH TABLE 1-45 TABLE PWM DUTY CYLINDER ENTRY CYCLE REFERENCE A 80 % NO B 80 % CYL NO. 3 C 80 % NO D 80 % NO E 80 % CYL NO. 4 F 80 % NO G 80 % NO H 50 % CYL NO. 8 TIMING WHEEL ROTATION NORMAL OPERATION CHAPTER : 3400 HEUI Large Track Type Tractors A B C D E F G H 62° BTDC (EEPROM) 62° BTDC (EEPROM) DES TIMING DES TIMING DELAY NO. 3 DELAY NO. 4 INJECTION INJECTION ASSUMED ASSUMED TDC TDC CYL NO. 3 CYL NO. 4 CYL NO. 3 ACTUAL TDC CYL NO. 4 ACTUAL TDC (REFERENCE) (CALIBRATED) (REFERENCE) (CALIBRATED)
Page: 1-46 TIMING WHEEL REFERENCE EDGE TO TDC DISTANCE REFERENCE EDGE ASSUMED ACTUAL TIMING CALIBRATION CHAPTER : 3400 HEUI CYL. NO. 1 TDC CYL. NO. 1 TDC Large Track Type Tractors -10° +10° TIMING REFERENCE TIMING CALIBRATION ± 10° OFFSET SENSOR SIGNAL MAXIMUM TIMING REFERENCE OFFSET ± 10 DEGREES
Large Track Type Tractors CHAPTER : 3400 HEUI INJECTION CURRENT WAVEFORM 5 4 TIME (MILLISECONDS) HOLD-IN PEAK CURRENT 3 ONE CYCLE 2 PULL-IN PEAK CURRENT 1 0 CURRENT FLOW Page: 1-47
Large Track Type Tractors CHAPTER : 3400 HEUI POPPET VALVE MOVEMENT 5 4 CURRENT TIME (MILLISECONDS) 3 2 POPPET 1 LIFT 0 CURRENT FLOW Page: 1-48
Page: 1-49 POPPET INJECTION LIFT RATE CURRENT FLOW CURRENT WAVEFORM & RESP. CHARACTERISTICS CHAPTER : 3400 HEUI Large Track Type Tractors DURATION 0 1 2 3 4 5 START OF TIME (MILLISECONDS) END OF INJECTION INJECTION

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sistema-heui-caterpillar

  • 1.
    Service Training MALAGA Large TrackType Tractors 1 ENGINE CONTROL 3400 HEUI 1. Components Layout 2. Operation 3. Testing & Adjusting Adolfo May 1997
  • 2.
    Page: 1-2 HIGH PRESSURE OIL MANIFOLD High Pressure 40 to 210 BAR Oil Pump HEUI FUEL SYSTEM CHAPTER : 3400 HEUI Regulator Fuel Return Line Pressure Large Track Type Tractors Control Valve Engine System Fuel Filter ECM Oi Fuel lS Trans Oil Oil u Vehicle Pump Oil Filter Cooler Pump m System p LOW PRESSURE 3 BAR Fuel Tank
  • 3.
    Large Track TypeTractors CHAPTER : 3400 HEUI HEUI FUEL SYSTEM The electronic components in the HEUI fuel system are very similar to those used in other EUI systems. However, in the HEUI system, the injectors are not actuated by a camshaft The seven major types of components in the HEUI fuel system are: • Hydraulic Supply Pump Group containing: - High pressure hydraulic pump - Pump control valve - Transfer pump • ECM • Throttle Control • Speed/Timing Sensor • Injector • Temperature Sensor • Pressure Sensor Page: 1-3
  • 4.
    Large Track TypeTractors CHAPTER : 3400 HEUI INJECTOR COMPONENTS SPACER SLEEVE ARMATURE VALVE VALVE BODY SOLENOID SHIM BARREL ADAPTER PISTON WASHER UPPER FUEL SEAL PLUNGER FUEL INLET CHECK VALVE PIN SLEEVE SPACER LOWER FUEL SEAL CHECK NOZZLE Page: 1-4
  • 5.
    Large Track TypeTractors CHAPTER : 3400 HEUI INJECTION CYCLE Page: 1-5
  • 6.
    Large Track TypeTractors CHAPTER : 3400 HEUI POPPET VALVE OPEN ARMATURE SCREW POPPET SPRING Page: 1-6
  • 7.
    Large Track TypeTractors CHAPTER : 3400 HEUI DRAIN CYCLE Page: 1-7
  • 8.
    Large Track TypeTractors CHAPTER : 3400 HEUI POPPET VALVE CLOSED POPPET VALVE SOLENOID ARMATURE INLET EXHAUST VALVE SEAT VALVE SEAT Page: 1-8
  • 9.
    Large Track TypeTractors CHAPTER : 3400 HEUI NOZZLE GROUP NOZZLE GROUP REVERSE FLOW CHECK VALVE CHECK VALVE FUEL ATOMIZATION Page: 1-9
  • 10.
    Large Track TypeTractors CHAPTER : 3400 HEUI PRIME RATE SHAPING CROSS SECTION OF PLUNGER FINAL START OF INJECTION PRESSURE DROP PRESSURE INCREASE INJECTION RATE START OF END OF INJECTION DURATION INJECTION TIME (MILLISECONDS) Page: 1-10
  • 11.
    Large Track TypeTractors CHAPTER : 3400 HEUI VENTING INTERNAL LEAKS INTENSIFIER PISTON INTENSIFIER PISTON SEAL BARREL VENTING CHECK VALVE During the normal injection cycle, the pressure of the oil supplied to the top of the intensifier piston can increase to 22800 kPa (3300 psi). A seal is installed to minimize leakage past the piston. Some oil which is necessary for lubrication of the intensifier piston may pass the seal and settle momentarily below the piston. Also, a small amount of fuel may leak past the plunger and barrel. This fuel will settle momentarily in the cavity below the intensifier piston. If the fluids which accumulate below the piston are not vented, a hydraulic lock could occur. As the piston moves down, the fuel is ejected past the barrel ball check valve to the low pressure inlet. The check valve then closes during the plunger and piston upstroke. Page: 1-11
  • 12.
    Large Track TypeTractors CHAPTER : 3400 HEUI INJECTOR CHECK VALVES BARREL GROUP NOZZLE GROUP FUEL INLET CHECK VALVE VENTING CHECK VALVE REVERSE FLOW CHECK VALVE NOZZLE CHECK VALVE FUEL ATOMIZATION The Fuel Inlet Check Valve allows fuel to fill the barrel below the plunger, but closes as the plunger moves down and pressure increases. The Venting Check Valve vents fluids from below the intensifier piston. The Reverse Flow Check Valve prevents combustion gasses from flowing back through the injector from the nozzle. The Nozzle Check Valve controls valve opening pressure by preventing the flow of fuel through the nozzle holes until sufficient pressure is available to lift the valve from its seat Page: 1-12
  • 13.
    Large Track TypeTractors CHAPTER : 3400 HEUI PRESSURE CONTROL INJECTION PRESSURE HEUI MECHANICALLY ACTUATED FUEL SYSTEM IDLE ENGINE SPEED Page: 1-13
  • 14.
    Page: 1-14 TO LUBE SYSTEM HEUI HYDRAULIC TEMPERATURE SENSOR COLD START OIL FLUID MANIFOLD RESERVOIR OIL PRESSURE HYDRAULIC PASSAGE SENSOR COOL DOWN FUEL HYDRAULIC HYDRAULIC CIRCUIT TEMPERATURE PRESSURE SUPPLY SENSOR SENSOR PUMP OIL GROUP FILTER FLUID MANIFOLD HYDRAULIC PASSAGE LOW PRESSURE OIL (HYDR.) SUPPLY CHAPTER : 3400 HEUI Large Track Type Tractors PUMP CONTROL HEUI VALVE ECM OIL COOLER FUEL TRANSFER SECONDARY PRESSURE PUMP FUEL REGULATING LUBE OIL PUMP FILTER VALVE PRIMARY FUEL FILTER WATER SEPARATOR OIL SUMP FUEL TANK
  • 15.
    Page: 1-15 TO LUBE SYSTEM HEUI HYDRAULIC TEMPERATURE SENSOR COLD START OIL FLUID MANIFOLD RESERVOIR OIL PRESSURE HYDRAULIC PASSAGE SENSOR COOL DOWN FUEL HYDRAULIC HYDRAULIC CIRCUIT TEMPERATURE PRESSURE SUPPLY SENSOR SENSOR PUMP OIL GROUP FILTER FLUID MANIFOLD HYDRAULIC PASSAGE PUMP CONTROL HEUI VALVE ECM OIL COOLER FUEL TRANSFER SECONDARY PRESSURE PUMP FUEL REGULATING LUBE OIL FILTER VALVE PUMP PRIMARY CHAPTER : 3400 HEUI FUEL FILTER WATER SEPARATOR OIL HIGH PRESSURE HYDRAULICS SUMP FUEL TANK Large Track Type Tractors
  • 16.
    Large Track TypeTractors CHAPTER : 3400 HEUI REVERSE FLOW CHECK VALVE (END VIEW) SEAT FROM PUMP SEAT CHECK SPRING VALVE BLOCK FITTING INJECTORS TO Page: 1-16
  • 17.
    Large Track TypeTractors CHAPTER : 3400 HEUI REVERSE FLOW CHECK VALVE The hydraulic supply pump group has two outlet ports, each connected by steel tubes to a hydraulic supply manifold. An integral reverse flow check valve is located in each outlet port. This view shows that pressure surges travelling back from the injectors toward the pump will cause the check valve to close and block any interference between the banks. In normal operation, the valve will oscillate at high frequency as it blocks the pressure surges. The valve check fits loosely on the shaft to allow oil flow from the reservoir during the cooling process. If the check valves were not in the system, pressure surges between the banks would cause erratic operation of the injectors by adversely affecting timing. The pressure surge causes the poppet valves to open prematurely. This condition would start fuel injection earlier than normal, thereby advancing the timing. Page: 1-17
  • 18.
    Page: TO LUBE 1-18 SYSTEM HEUI HYDRAULIC TEMPERATURE SENSOR COLD START OIL FLUID MANIFOLD RESERVOIR OIL PRESSURE HYDRAULIC PASSAGE SENSOR COOL DOWN FUEL HYDRAULIC HYDRAULIC CIRCUIT TEMPERATURE PRESSURE SUPPLY SENSOR SENSOR PUMP OIL GROUP FILTER FLUID MANIFOLD HYDRAULIC PASSAGE PUMP CONTROL HEUI VALVE ECM OIL COOLER FUEL TRANSFER SECONDARY CHAPTER : 3400 HEUI PUMP PRESSURE LUBE FUEL FILTER REGULATING OIL PUMP (2 MICRON) VALVE PRIMARY FUEL FILTER LOW PRESSURE FUEL SUPPLY WATER SEPARATOR Large Track Type Tractors OIL SUMP FUEL TANK
  • 19.
    Large Track TypeTractors CHAPTER : 3400 HEUI LOW PRESSURE FUEL SUPPLY On a HEUI equipped engine, the lubrication pump has two functions: 1. Provides lubrication to the engine 2. Provides low pressure charge oil to the HEUI hydraulic pump The engine lubrication pump has been enlarged to provide the required increase in flow. During normal operation conditions, oil is pressurized between 5000 and 21500 kPa (725 and 3100 psi) by the high pressure hydraulic pump to actuate the injectors. The pressure regulating valve regulates fuel pressure between 310 and 415 kPa (45 and 60 psi). The ratio of fuel between combustion and fuel return to the tank is about 1:3 (i.e. four times the volume required for combustion is supplied to the system for combustion and injector cooling purposes). Page: 1-19
  • 20.
    Page: HIGH PRESSURE HYDRAULIC OIL 1-20 INJECTOR OIL INJECTOR CLAMP ADAPTER JUMPER TUBE ROCKER ARM BASE INJECTOR LUBE OIL PASSAGE HIGH PRESSURE HYDRAULIC PASSAGE CHAPTER : 3400 HEUI FLUID SUPPLY INJECTOR FLUID FLOW MANIFOLD Large Track Type Tractors CYLINDER HEAD INJECTOR SLEEVE CYLINDER HEAD LOW PRESSURE FUEL SUPPLY COOLANT CYLINDER BLOCK METAL WASHER
  • 21.
    Page: 1-21 INJECTOR UPPER INJECTOR UPPER SLEEVE O-RING SEAL O-RING SEAL CYLINDER HEAD INJECTOR SLEEVE FLUID SUPPLY MANIFOLD LOWER SLEEVE O-RING SEAL INJECTOR FUEL SUPPLY CHAPTER : 3400 HEUI Large Track Type Tractors LOW PRESSURE FUEL SUPPLY CYLINDER HEAD METAL-TO- METAL LOWER INJECTOR CONTACT O-RING SEAL
  • 22.
    Page: COMPENSATOR 1-22 PRIMING PORT VALVE ORIFICE VALVE BASE DRAIN PASSAGE TRANSFER PUMP RESERVOIR HEUI PUMP CHAPTER : 3400 HEUI Large Track Type Tractors SWASHPLATE
  • 23.
    Page: 1-23 TO LEFT OIL TO RIGHT OIL TO LUBE COLD START MANIFOLD RESERVIOR MANIFOLD SYSTEM DISPLACEMENT CONTROL PISTON CHECK VALVE PRESSURE LIMITER SUPPLY PUMP SPOOL START-UP CHAPTER : 3400 HEUI SOLENOID LOAD Large Track Type Tractors (ENERGIZED) SENSING SPOOL OIL SUMP PUMP CONTROL VALVE PUMP CASE DRAIN
  • 24.
    Page: PRESSURE LIMITER SPOOL 1-24 ORIFICE PUMP CONTROL VALVE LOAD SENSING SPOOL CHECK VALVE FROM DISPLACEMENT CONTROL PISTON START-UP CHAPTER : 3400 HEUI DRAIN ORIFICE Large Track Type Tractors TO CASE DRAIN TO CASE DRAIN REVERSE FLOW CHECK VALVES
  • 25.
    Large Track TypeTractors CHAPTER : 3400 HEUI START-UP The displacement of the pump is controlled to maintain the desired operating pressure at the flow rate required by the injectors. The displacement is regulated by an electro-hydraulic control. Displacement of the pump is varied by pivoting the swashplate from 0 degrees to a maximum angle of 15.5 degrees. When the engine is not running, the swashplate is at the maximum angle. During operation, the displacement control piston adjusts the swashplate position to meet the system flow demand. During initial cranking, the swashplate is at full displacement until the supply pressure increases to 6200 kPa (900 psi). The spring at the end of the load sensing spool regulates this pressure. Then, the specification programmed into the ECM for normal cranking will override this pressure. Until this point, the control valve solenoid is fully energized for the pressure increase. During START-UP, pressure from the pump enters the compensator assembly. The Pump Control Valve is energized for quick pressure build-up. Pressure is felt at both ends of the Load Sensing Spool. The spool is shifted to the right and oil from the Displacement Control Piston is vented to case drain. The swashplate is at maximum angle. The drain orifice below the Pump Control Valve provides a small amount of restriction to improve valve stability Page: 1-25
  • 26.
    Page: 1-26 TO LEFT OIL TO RIGHT OIL TO LUBE COLD START MANIFOLD RESERVIOR MANIFOLD SYSTEM DISPLACEMENT CONTROL PISTON CHECK VALVE PRESSURE LIMITER SUPPLY PUMP SPOOL DESTROKE CHAPTER : 3400 HEUI LOAD SOLENOID SENSING Large Track Type Tractors (DE-ENERGIZED) SPOOL OIL SUMP PUMP CONTROL VALVE PUMP CASE DRAIN
  • 27.
    Page: 1-27 PRESSURE LIMITER SPOOL ORIFICE PUMP CONTROL VALVE LOAD SENSING SPOOL DESTROKE CHAPTER : 3400 HEUI CHECK VALVE Large Track Type Tractors TO DISPLACEMENT CONTROL PISTON DRAIN ORIFICE TO CASE DRAIN
  • 28.
    Large Track TypeTractors CHAPTER : 3400 HEUI DESTROKE After the engine starts and pressure increases, the ECM will signal the control valve to match the actual with the desired pressure by momentarily de-energizing and then regulating the current flow to the pump control valve solenoid. The decrease in current applied to the pump control valve solenoid lowers the pressure required to initiate flow through the pump control valve. This lower cracking pressure on the pump control valve creates a force imbalance on the load sensing spool, causing the spool to move toward the spring end of the compensator. This spool motion connects the displacement control piston to pump output flow, allowing the swashplate to decrease the displacement of the pump. The decreased displacement lowers the pump output to the pressure level required by the ECM. During DESTROKE, the ECM momentarily de-energizes the Pump Control Valve causing a pressure drop in the spring chamber of the Load Sensing Spool. Unbalanced pressures force the spool to the left, allowing the oil to enter the Displacement Control Piston and move the swashplate toward minimum angle. Page: 1-28
  • 29.
    Page: 1-29 TO LEFT OIL TO RIGHT OIL TO LUBE COLD START MANIFOLD MANIFOLD SYSTEM RESERVIOR DISPLACEMENT CONTROL PISTON CHECK VALVE PRESSURE LIMITER SUPPLY PUMP SPOOL UPSTROKE CHAPTER : 3400 HEUI LOAD SOLENOID SENSING Large Track Type Tractors (ENERGIZED) SPOOL OIL SUMP PUMP CONTROL VALVE PUMP CASE DRAIN
  • 30.
    Page: 1-30 PRESSURE LIMITER SPOOL ORIFICE PUMP CONTROL VALVE LOAD SENSING SPOOL CHECK VALVE UPSTROKE CHAPTER : 3400 HEUI Large Track Type Tractors FROM DISPLACEMENT CONTROL PISTON DRAIN ORIFICE TO CASE DRAIN
  • 31.
    Large Track TypeTractors CHAPTER : 3400 HEUI UPSTROKE As the load on the engine increases and higher pressure is required, the ECM will signal the control valve to increase pressure by increasing the current flow to the pump control valve solenoid. The increase in current applied to the pump control valve solenoid raises the pressure setting of the pump control valve. This higher pressure at the pump control valve creates a force imbalance on the load sensing spool, causing the spool to move toward the supply signal line end of the compensator. This spool motion vents the displacement control piston to case drain, allowing the spring to move the swashplate to increase the displacement of the pump. The increased displacement raises the pump output to the desired pressure level required by the ECM. As the load is applied to the engine, the ECM increases current to the Pump Control Valve. Pressure is felt at both ends of the Load Sensing Spool. The spool moves to the right (due to spring force) and oil from the Displacement Control Piston is vented to case drain, which allows the swashplate to momentarily go to maximum angle and build pressure quickly. Page: 1-31
  • 32.
    Page: 1-32 TO LEFT OIL TO RIGHT OIL TO LUBE COLD START MANIFOLD RESERVIOR MANIFOLD SYSTEM DISPLACEMENT CONTROL PISTON PRESSURE LIMITER SUPPLY PUMP SPOOL PRESSURE LIMITER OPERATION CHAPTER : 3400 HEUI LOAD SOLENOID SENSING Large Track Type Tractors (DE-ENERGIZED) SPOOL PLUGGED ORIFICE OIL SUMP PUMP CONTROL VALVE PUMP CASE DRAIN
  • 33.
    Page: 1-33 PRESSURE LIMITER SPOOL PUMP CONTROL VALVE ORIFICE RESTRICTION LOAD SENSING SPOOL PRESSURE LIMITER OPERATION CHAPTER : 3400 HEUI CHECK VALVE Large Track Type Tractors TO DISPLACEMENT CONTROL PISTON DRAIN ORIFICE TO CASE DRAIN
  • 34.
    Large Track TypeTractors CHAPTER : 3400 HEUI PRESSURE LIMITER OPERATION If the load sensing spool or pump control valve sticks or otherwise malfunctions to create higher than desired operating pressures, the maximum pressure limiter spool is utilized. In this schematic, a plugged orifice is simulated. (This example represents an actual condition which was caused by debris being introduced during a field replacement of the compensator valve.) The Pressure Limiter Spool directs pump outlet flow to the displacement control piston and reduces the stroke of the pump if the system pressure exceeds 25600 kPa (3700 psi). During these conditions, the pump will develop 24800 to 25600 kPa (3600 to 3700 psi) maximum pressure, regardless of the desired hydraulic pressure. The Check Engine Lamp will be ON, indicating a fault. A Pump Control Valve Test will verify the control valve operation. This test enables the technician to manually ramp the pressure up and down using the ET service tool. This procedure will also be useful when evaluating the condition of the hydraulic system. If the supply pressure exceeds 25600 kPa (3700 psi), the force acts on the Pressure Limiter Spool and shifts it to the left. This movement compresses the spring and allows oil to unseat the check valve and pressurize the displacement control piston. The swashplate moves to minimum angle to decrease flow and limit system pressure. Page: 1-34
  • 35.
    Page: 1-35 NO CURRENT FLOW FROM LOAD COIL POPPET SENSING SPOOL ASSEMBLY VALVE ADAPTER SEAL SEAT CAGE VALVE EDGE FILTER STOP STATOR PUMP CONTROL VALVE CHAPTER : 3400 HEUI Large Track Type Tractors VALVE TO SPRING ARMATURE SOLENOID PIN SHELL RING BLOCK CASE DRAIN RETAINER
  • 36.
    Page: 1-36 HIGH CURRENT FLOW FROM LOAD COIL POPPET SENSING SPOOL ASSEMBLY VALVE ADAPTER SEAL SEAT CAGE VALVE EDGE FILTER STOP STATOR PUMP CONTROL VALVE CHAPTER : 3400 HEUI Large Track Type Tractors VALVE TO SPRING ARMATURE SOLENOID PIN SHELL RING BLOCK CASE DRAIN RETAINER
  • 37.
    Page: 1-37 8 OR 12 INJECTORS ADEM II ELECTRONIC CONTROL ENGINE MODULE DISCONNECT SWITCH (ECM) GROUND HARNESS BOLT 24 V MAIN KEY MACHINE 15 AMP POWER RELAY SWITCH HARNESS BREAKER PUMP CONTROL VALVE MACHINE HYDRAULIC INTERFACE PRESSURE SENSOR CONNECTOR TDC SERVICE PRIMARY PROBE ACCESS THROTTLE SPEED/TIMING SENSOR ACCELERATOR SENSOR PEDAL SECONDARY COMPONENTS DIAGRAM CHAPTER : 3400 HEUI SPEED/TIMING SENSOR THROTTLE BACK-UP, ELEVATED LOW IDLE ENABLE, AND GROUND LEVEL SHUTDOWN (2) SWITCHES Large Track Type Tractors COOLANT TEMP. SENSOR TURBO INLET PRESSURE SENSOR FAN CONTROL VALVE TURBO OUTLET PRESS. SENSOR FAN SPEED SENSOR FAN ATMOSPHERIC PRESS. SENSOR CAT DATA LINK OIL PRESSURE SENSOR ELECTRONIC SERVICE TOOL EPTC II TRANSMISSION CONTROL HYDRAULIC TEMP. SENSOR AUTO RETARDER CONTROL FUEL TEMPERATURE SENSOR INSTRUMENT PANEL COOLANT FLOW SWITCH
  • 38.
    Large Track TypeTractors CHAPTER : 3400 HEUI SENSORS - ANALOG & DIGITAL ANALOG SENSORS - HYDRAULIC PRESSURE - COOLANT TEMPERATURE - ATMOSPHERIC PRESSURE - TURBOCHARGER INLET PRESSURE - TURBOCHARGER OUTLET PRESSURE - LUB. OIL PRESSURE - HYDRAULIC TEMPERATURE - FUEL TEMPERATURE DIGITAL SENSORS - THROTTLE POSITION - PUMP CONTROL VALVE SIGNAL - EXHAUST TEMPERATURE (not installed on machine engines at this time) Page: 1-38
  • 39.
    Large Track TypeTractors CHAPTER : 3400 HEUI SYSTEM POWER SUPPLIES The HEUI system has six power supplies with various voltages as shown. EXTERNAL POWER SUPPLY ECM power supply 24 Volts INTERNAL POWER SUPPLIES Speed/Timing Sensor power supply 12.5 Volts Injector power supply 105 Volts Analog Sensor power supply 5 Volts Digital Sensor power supply 8 Volts Pump Control Valve power supply 0 to 24 Volts The power supply to the ECM and the system is drawn from the 24-Volt machine battery. The principle components in this circuit are: - Battery - Key Start Switch - Main Power Relay - 15 Amp Breaker - Ground Bolt - ECM Connector (P1/JI) - Machine Interface Connector (J3/P3) If the supply voltage exceeds 32.5 Volts or is less than 9.0 Volts, a diagnostic code is logged. (See the Troubleshooting Guide for complete details on voltage event logging.) NOTE: The ground bolt is the only power supply component mounted on the engine. Page: 1-39
  • 40.
    Large Track TypeTractors CHAPTER : 3400 HEUI LOGGED EVENTS Logged events are abnormal to the operation of the engine (for example: high temperature, low pressure or excessive engine speed). These conditions would not normally be caused by an electronic problem. Some of the parameters listed in this presentation are used in the ET events list. They are: - High coolant temperature above 107°C (225°F) - Loss of coolant flow - Low (lubrication) oil pressure (according to the oil pressure map) - Abnormal injection actuation hydraulic pressure (low or high) - Injection actuation pressure system fault - User defined shutdown (if installed) - Air inlet restriction (if installed) - Engine overspeed histogram - Low fuel pressure (industrial engine only) Events are not logged if an electronic fault is detected. Passwords are required to clear events. This process would normally be performed during an engine overhaul. At other times, the events would be left as a record of the engine history prior to overhaul time. Page: 1-40
  • 41.
    Large Track TypeTractors CHAPTER : 3400 HEUI SYSTEM LIMITS & DERATE FUEL SYSTEM LIMITS MAXIMUM HORSEPOWER TORQUE LIMIT ( Determines torque rise characteristics) FUEL RATIO CONTROL ( Limits fuel until sufficient boost ) COLD MODE ( Limits fuel to control white smoke ) CRANKING FUEL ( Limits fuel during cranking ) FUEL SYSTEM DERATES FUEL SYSTEM DERATES AUTOMATIC ALTITUDE COMPENSATION AUTOMATIC ALTITUDE COMPENSATION ( Altitude derate) ( Altitude derate) AUTOMATIC FILTER COMPENSATION AUTOMATIC FILTER COMPENSATION ( Derate for air filter restriction installed ) ( Derate for air filter restriction if if insatalled At 6.25 kPa (30 inc of water) the engine will ENGINE 2% of its powerDERATE until a maxi 20% derate WARNING per 1 kPa Event is logged if exeeds 30 inch of water ) ( Derates for LOW OIL PRESSURE, HIGH COOLANT TEMP not install in HEUI at the time) ENGINE WARNING DERATE ( Derates for LOW OIL PRESSURE , HIGH COOLANT TEMP not installed yet on HEUI) Page: 1-41
  • 42.
    Page: REF 1-42 TDC SECONDARY REF TDC SINGLE 4 50/50 TOOTH SPEED/TIMING SENSOR TDC CYLINDER No. 1 3 8 REF PRIMARY SPEED/TIMING SENSOR TDC REF TIMING TIMING WHEEL CHAPTER : 3400 HEUI 1 CALIBRATION 6 RANGE ± 10° Large Track Type Tractors TDC REF TIMING WHEEL ROTATION TDC REF 5 2 7 REF TDC REF TDC
  • 43.
    Page: 1-43 TIMING GEAR TOOTH TABLE TABLE PWM DUTY CYLINDER ENTRY CYCLE REFERENCE A 80 % NONE IDENTIFIED B 80 % C 80 % D 80 % E 80 % F 80 % G 80 % H 50 % CRANKING CHAPTER : 3400 HEUI Large Track Type Tractors 80/20 % 80/20 % 80/20 % 80/20 % 80/20 % 80/20 % 50/50% A B C D E F G H TIMING WHEEL ROTATION
  • 44.
    Page: 1-44 TIMING GEAR TOOTH TABLE TABLE PWM DUTY CYLINDER ENTRY CYCLE REFERENCE A 80 % NO B 80 % CYL NO. 3 C 80 % NO D 80 % NO E 80 % CYL NO. 4 F 80 % NO G 80 % NO H 50 % CYL NO. 8 AFTER PATTERN RECOGNITION CHAPTER : 3400 HEUI Large Track Type Tractors TIMING WHEEL ROTATION A B C D E F G H CYL NO. 3 CYL NO. 3 CYL NO. 4 CYL NO. 4 CYL NO. 8 REFERENCE TDC REFERENCE TDC REFERENCE EDGE EDGE EDGE
  • 45.
    Page: TIMING GEAR TOOTH TABLE 1-45 TABLE PWM DUTY CYLINDER ENTRY CYCLE REFERENCE A 80 % NO B 80 % CYL NO. 3 C 80 % NO D 80 % NO E 80 % CYL NO. 4 F 80 % NO G 80 % NO H 50 % CYL NO. 8 TIMING WHEEL ROTATION NORMAL OPERATION CHAPTER : 3400 HEUI Large Track Type Tractors A B C D E F G H 62° BTDC (EEPROM) 62° BTDC (EEPROM) DES TIMING DES TIMING DELAY NO. 3 DELAY NO. 4 INJECTION INJECTION ASSUMED ASSUMED TDC TDC CYL NO. 3 CYL NO. 4 CYL NO. 3 ACTUAL TDC CYL NO. 4 ACTUAL TDC (REFERENCE) (CALIBRATED) (REFERENCE) (CALIBRATED)
  • 46.
    Page: 1-46 TIMING WHEEL REFERENCE EDGE TO TDC DISTANCE REFERENCE EDGE ASSUMED ACTUAL TIMING CALIBRATION CHAPTER : 3400 HEUI CYL. NO. 1 TDC CYL. NO. 1 TDC Large Track Type Tractors -10° +10° TIMING REFERENCE TIMING CALIBRATION ± 10° OFFSET SENSOR SIGNAL MAXIMUM TIMING REFERENCE OFFSET ± 10 DEGREES
  • 47.
    Large Track TypeTractors CHAPTER : 3400 HEUI INJECTION CURRENT WAVEFORM 5 4 TIME (MILLISECONDS) HOLD-IN PEAK CURRENT 3 ONE CYCLE 2 PULL-IN PEAK CURRENT 1 0 CURRENT FLOW Page: 1-47
  • 48.
    Large Track TypeTractors CHAPTER : 3400 HEUI POPPET VALVE MOVEMENT 5 4 CURRENT TIME (MILLISECONDS) 3 2 POPPET 1 LIFT 0 CURRENT FLOW Page: 1-48
  • 49.
    Page: 1-49 POPPET INJECTION LIFT RATE CURRENT FLOW CURRENT WAVEFORM & RESP. CHARACTERISTICS CHAPTER : 3400 HEUI Large Track Type Tractors DURATION 0 1 2 3 4 5 START OF TIME (MILLISECONDS) END OF INJECTION INJECTION