Day: January 16, 2019

INSTANT DOWNLOAD

Complete workshop & service manual with electrical wiring diagrams for Caterpillar 3304B & 3306B Engines. It’s the same service manual used by dealers that guaranteed to be fully functional and intact without any missing page.

This Caterpillar 3304B & 3306B Engines service & repair manual (including maintenance, overhaul, disassembling & assembling, adjustment, tune-up, operation, inspecting, diagnostic & troubleshooting…) is divided into different sections. Each section covers a specific component or system with detailed illustrations. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. The printer-ready PDF documents work like a charm on all kinds of devices.

MANUAL LIST:
SENR2569 – Testing & Adjusting (3304B & 3306B Industrial & Marine Engines).pdf
SENR1189 – Disassembly & Assembly (3304B & 3306B Industrial & Marine Engines)
SENR5598 – Disassembly & Assembly (3304B and 3306B Engines for Caterpillar Built Machines)
SENR2569 – Systems Operation (3304B & 3306B Industrial & Marine Engines).pdf

EXCERPT:
1. Install washer (1) and bolt (2). Ensure that the cover of the fuel pump housing is removed. Turn the fuel pump camshaft in the direction of the engine rotation until Tool (A) can be installed in the notch of the camshaft.
2. Install Tool (A) and (B) into position. Install the weight assembly for the timing advance on the fuel injection pump camshaft.
3. Use Tool (D) on the automatic timing advance and maintain a constant torque of 68 N·m (50 lb ft). Tighten the bolt that fastens the automatic timing advance to the fuel pump camshaft to a torque of 270 ± 25 N·m (200 ± 18 lb ft).
4. Remove Tools (A), (B), (C) and (D). Install the starting motor. End By: Install the front housing. Refer to Disassembly and Assembly, “Front Housing – Install”.
…

INSTANT DOWNLOAD

Complete digital official shop manual contains service, maintenance, and troubleshooting information for the Caterpillar 3304, 3306 Engine. Diagnostic and repair procedures are covered in great detail to repair, maintain, rebuild, refurbish or restore your Engine like a professional mechanic in local service/repair workshop. This cost-effective quality manual is 100% complete and intact as should be without any missing pages. It is the same factory shop manual used by dealers that guaranteed to be fully functional to save your precious time.

This manual for Caterpillar 3304, 3306 Engine is divided into different sections. Each section covers a specific component or system and, in addition to the standard service procedures, includes disassembling, inspecting, and assembling instructions. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. It is in the cross-platform PDF document format so that it works like a charm on all kinds of devices. You do not need to be skilled with a computer to use the manual.

FILELIST:
UEG0797S – Parts Book (3304 Vehicular Engine).pdf
REG00974 – Disassembly & Assembly (3304 Vehicular Engine for 920 & 930 Wheel Loaders)
SENR2149 – Disassembly & Assembly (3306 Vehicular Engine for 966D Wheel Loader)
SENR2252 – Specifications (3304 Direct Injection Vehicular Engine with New Scroll Fuel)
SENR2254 – Disassembly & Assembly (3304 Vehicular Engine for 950B Wheel Loader)
SENR2428 – Specifications (3304 Vehicular Engine for 930R Wheel Loader)
SENR2430 – Disassembly & Assembly (3304 Vehicular Engine for 930R Wheel Loader)
SENR3074 – Disassembly & Assembly (3304 Vehicular Engine for 930T & 936 Wheel Loaders)
SENR5559 – Disassembly & Assembly (3304 & 3306 Diesel Engines)
SENR7590 – Specifications (3304 Vehicular Engine)
SENR2147 – Specifications (3306 Direct Injection Vehicular Engine with New Scroll Fuel).pdf
SENR2253 – Systems Operation (3304 Direct Injection Vehicular Engine with New Scroll Fuel).pdf
SENR2253 – Testing & Adjusting (3304 Direct Injection Vehicular Engine with New Scroll Fuel).pdf
SENR2429 – Systems Operation (3304 Vehicular Engine for 930R Wheel Loader).pdf
SENR2429 – Testing & Adjusting (3304 Vehicular Engine for 930R Wheel Loader).pdf
SENR7590 – Specifications (3304 Vehicular Engine).pdf
SENR7591 – Systems Operation (3304 Vehicular Engine).pdf
SENR7591 – Systems Operation + Testing & Adjusting (3304 Vehicular Engine).pdf
SENR7591 – Testing & Adjusting (3304 Vehicular Engine).pdf
…

ENGINE – GENERATOR SET
Model Prefix
3304 GEN SET ENGINE 3TC
3304 GEN SET ENGINE 4PC
3304 GEN SET ENGINE 6YB
3304 GEN SET ENGINE 83Z
3304B GEN SET ENGINE 1YF
3304B GEN SET ENGINE 2KK
3304B GEN SET ENGINE 3TC
3304B GEN SET ENGINE 83Z
3304B GEN SET ENGINE 9HK
3304B GENERATOR SET DED

ENGINE – INDUSTRIAL
Model Prefix
3304 INDUSTRIAL ENGINE 02B
3304 INDUSTRIAL ENGINE 04B
3304 INDUSTRIAL ENGINE 10E
3304B INDUSTRIAL ENGINE 4XB

ENGINE – MACHINE
Model Prefix
3304 ENGINE – MACHINE 07Z
3304 ENGINE – MACHINE 09Z
3304 ENGINE – MACHINE 10E
3304 ENGINE – MACHINE 12Z
3304 ENGINE – MACHINE 43V
3304 ENGINE – MACHINE 46V
3304 ENGINE – MACHINE 48V
3304 ENGINE – MACHINE 4TJ
3304 ENGINE – MACHINE 4XB
3304 ENGINE – MACHINE 4YD
3304 ENGINE – MACHINE 59Z
3304 ENGINE – MACHINE 78P
3304 ENGINE – MACHINE 9CB
3304 ENGINE – MACHINE 9CG
3304 ENGINE – MACHINE H4G

MARINE PRODUCTS
Model Prefix
3304 MARINE ENGINE 05B
3304 MARINE ENGINE 13E
3304B MARINE ENGINE 13E
3304B MARINE ENGINE 1NS
3304B MARINE ENGINE 1PS
3304B MARINE ENGINE 8XL

EXCERPT:
Systems Operation
N3 Series Brushless Alternators Media Number -SENR2082-01 Publication Date -01/03/2002 Date Updated -12/03/2002

Normal Operation
SMCS – 1405

The field winding uses DC voltage to create a magnetic field. The magnetic field is used to magnetize the rotor. The stator is a stationary component that surrounds the rotor. When the rotor rotates voltage is produced. The stator will then send the voltage to the rectifier. The rectifier changes the AC voltage into DC voltage. Part of the DC voltage returns to the field winding in order to maintain the magnetic field. The remainder of the DC voltage is supplied to the battery. Electrical components on the machine will then receive the voltage from the battery. The regulator limits the DC voltage at the battery terminals to 28 ± 1 volts by controlling the current in the field winding.

Alternator Operation Schematics

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Illustration 1 g00866883

Electrical schematic of the N3 series alternator (35 amperes)

B- – Frame to battery ground

B+ – Alternator to battery positive terminal

D+ – Output for the excitation circuit and regulator input

D- – Ground for the alternator and regulator

DF – Alternator output and regulator input

G – Field winding

R – Auxiliary terminal

U – Stator winding

V – Stator winding

W – Stator winding

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Illustration 2 g00866887

Electrical schematic of the N3 series alternator (50 amperes)

(1) Diodes for protection against load dump

B- – Frame to battery ground

B+ – Alternator to battery positive terminal

D+ – Output for the excitation circuit and regulator input

D- – Ground for the alternator and regulator

DF – Alternator output and regulator input

G – Field winding

R – Auxiliary terminal

U – Stator winding

V – Stator winding

W – Stator winding

Note: The “R” terminal may be used by one of the following components:

Charge indicator

Tachometer

Hour meter

Electronic control module

Illustrations 1 and 2 show the electrical schematics for the N3 series alternators.

The alternator has two circuits: the charging circuit and the excitation circuit. The charging circuit functions during normal operation. The excitation circuit functions during normal operation and during start-up. An independent circuit exists for each phase of the stator. Phases are noted as “U”, “V”, and “W”. The 50 amp alternator has two extra diodes. Diodes are connected to the neutral point of the stator. Diodes also add extra current to the output. However, the 35 ampere alternator lacks the extra diodes.

The descriptions that follow show the N3 series alternator (35 ampere).

Charging Circuit
The charging circuit supplies current to the battery and to the electrical systems during normal operation. Stator windings in the alternator generate three-phase AC voltage. Positive diodes and the negative diodes change the AC voltage into DC voltage. DC voltage allows the current to flow to the battery terminals.

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Illustration 3 g00825118

Charging circuit with phase angle of 120°

The flow of current at a 120° phase angle is shown in Illustration 3. The polarity for the stator winding is described below:

Positive at the output of winding “U”

Zero at the output of winding “V”

Negative at the output of winding “W”

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Illustration 4 g00825120

Charging circuit with phase angle of 150°

The flow of current at a 150° phase angle is shown in Illustration 4. The polarity for the stator winding is described below:

Positive at the output of winding “U”

Positive at the output of winding “V”

Negative at the output of winding “W”

Excitation Circuit (Normal)
The N3 series alternator is self-excited. The excitation circuit supplies current to the field winding (exciter) during normal operation. The rotor contains an iron core that acts as a rotating magnet. The rotating magnetic field induces voltages in the stator windings. Stator windings generate three-phase AC voltage. Exciter diodes and negative diodes change the AC voltage into DC voltage. DC voltage allows current to flow in the field winding. The current induces a stationary magnetic field in the field winding that will keep the rotor core magnetized. This process continues as the rotor operates normally.

INSTANT DOWNLOAD

Complete digital official shop manual contains service, maintenance, and troubleshooting information for the Caterpillar 3208 Engine. Diagnostic and repair procedures are covered in great detail to repair, maintain, rebuild, refurbish or restore your engine like a professional mechanic in local service/repair workshop. This cost-effective quality manual is 100% complete and intact as should be without any missing pages. It is the same factory shop manual used by dealers that guaranteed to be fully functional to save your precious time.

This manual for Caterpillar 3208 Engine is divided into different sections. Each section covers a specific component or system and, in addition to the standard service procedures, includes disassembling, inspecting, and assembling instructions. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. It is in the cross-platform PDF document format so that it works like a charm on all kinds of devices. You do not need to be skilled with a computer to use the manual.

MANAUL LIST:
SENR3581 – Specifications (3208 Marine Engine).pdf
SEBR0541 – Service Manual (3208 Diesel Truck Engine)
SEGV3008 – Systems Operation (Fundamentals Electrical System for All Caterpillar Products)
SENR2131 – Specifications (3208 Marine Engine)
SENR2133 – Specifications (3208 Marine Engine Attachments)
SENR2135 – Disassembly and Assembly (3208 Marine Engine)
SENR3130 – Torque Specifications
SENR3581 – Disassembly and Assembly (3208 Marine Engine)
SENR3581 – Systems Operation (3208 Marine Engine)
SENR3581 – Testing and Adjusting (3208 Marine Engine)
SENR3581 – Troubleshooting (3208 Marine Engine)
SEBU6090 – Engine Safety (3208 Marine Engine).pdf
SEBU6090 – Maintenance Intervals (3208 Marine Engine).pdf
SENR2132 – Systems Operation (3208 Marine Engine).pdf
SENR2132 – Testing & Adjusting (3208 Marine Engine).pdf
SENR2134 – Systems Operation (3208 Marine Engine Attachments).pdf
SENR2134 – Testing & Adjusting (3208 Marine Engine Attachments).pdf
RENR1377 – Systems Operation (Electric Protection System Energize-To-Run for Generator Set, Industrial & Marine Diesel Engines)
RENR1377 – Testing & Adjusting (Electric Protection System Energize-To-Run for Generator Set, Industrial & Marine Diesel Engines)
SENR3981 – Schematic – Fluid Power & Electrical Graphic Symbols
UENR3262 – Disassembly & Assembly – Seal Installation
SEBF9050 – Applied Failure Analysis – Engine Valve Failure Modes{1100, 1105}.pdf
SEBU6875 – Owner’s Manual (Caterpillar Driver Information Display).pdf
SENR2995 – Product Safety.pdf
SENR3130 – Specifications (Torque Specifications for All Caterpillar Products).pdf
Spec+Sheets Cat+3208+Propulsion.pdf
Spec+Sheets+-+Cat+3208+Propulsion.pdf
…

ENGINE – GENERATOR SET
Model Prefix
3208 GEN SET ENGINE 29A
3208 GEN SET ENGINE 2HG
3208 GEN SET ENGINE 30A
3208 GEN SET ENGINE 5YF

ENGINE – INDUSTRIAL
Model Prefix
3208 INDUSTRIAL ENGINE 03Z
3208 INDUSTRIAL ENGINE 90N
3208 REMAN ENGINE 9WC

ENGINE – MACHINE
Model Prefix
3208 ENGINE – MACHINE 03Z
3208 ENGINE – MACHINE 79V
3208 ENGINE – MACHINE 90N
3208 ENGINE – MACHINE 93Z

ENGINE – TRUCK
Model Prefix
3208 REMAN ENGINE 5CD
3208 REMAN ENGINE 62W
3208 TRUCK ENGINE 02Z
3208 TRUCK ENGINE 32Y
3208 TRUCK ENGINE 40S
3208 TRUCK ENGINE 51Z

MARINE PRODUCTS
Model Prefix
3208 MARINE ENGINE 01Z
3208 MARINE ENGINE 75V

EXCERPT:

Fuel Injection Pump Housing And Governor
SMCS – 1286-11; 1286-12

Remove Fuel Injection Pump Housing And Governor

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start by:

a) remove air cleaner

b) remove fuel injection lines

c) Remove air inlet manifold

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1. Remove plug from cover in fuel injection pump housing and install tool (A). Turn the crankshaft (clockwise) until the timing pin drops into the groove (slot) in the fuel injection pump camshaft.

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2. Remove two nuts (2) and the tachometer drive housing (1).

3. Remove tachometer drive shaft (3).

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4. Install tooling (B) into the camshaft drive gear for the fuel injection pump. Turn bolts (4) evenly until the drive gear is free of the shaft. Remove tooling (B).

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5. Remove the plug from the timing hole in the front cover and install a 5/16″-18 NC bolt (5) 2 1/2 in. long. The cover bolt from hole (6) can be used. Turn the crankshaft (clockwise) until bolt can be installed into the timing gear and is in the center of the timing hole. The camshaft for the fuel injection pump is now in correct time to the engine.

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6. Remove line (7). Remove bolts (8) from base of the fuel injection pump housing.

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7. Remove the fuel injection pump housing and governor as a unit.

Install Fuel Injection Pump Housing And Governor

1. Put the fuel injection pump housing and governor in position on the engine. Install the bolts and lines.

2. Install the tachometer drive shaft and tighten it to a torque of 110 ± 10 lb. ft. (149 ± 14 N·m).

3. To check the timing, remove the timing pin and the bolt. Turn the crankshaft (clockwise) two revolutions and install the timing pin and bolt back in place. If the timing pin or bolt can not be installed, the fuel injection pump camshaft must be put into time again before Step 4 is done.

4. Remove the bolt from the timing gear. Install the plug into the timing hole.

5. Remove the timing pin from the timing groove (slot) in the fuel injection pump camshaft.

6. Install the tachometer drive housing.

end by:

a) install air inlet manifold

b) install fuel injection lines

c) install air cleaner
…

INSTANT DOWNLOAD

Complete workshop & service manual with electrical wiring diagrams for Caterpillar 3204 Engines. It’s the same service manual used by dealers that guaranteed to be fully functional and intact without any missing page.

This Caterpillar 3204 Diesel Engines service & repair manual (including maintenance, overhaul, disassembling & assembling, adjustment, tune-up, operation, inspecting, diagnostic & troubleshooting…) is divided into different sections. Each section covers a specific component or system with detailed illustrations. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. The printer-ready PDF documents work like a charm on all kinds of devices.

MANUAL LIST:
SENR4978 – Testing And Adjusting (DELCO Remy 20-SI Series Alternator).pdf
SENR3003 – Specifications (3204 Industrial Engines)
SENR3004 – General Service Information (3204 Industrial Engines)
SENR3007 – Disassembly and Assembly (3204 Industrial Engines)
SENR3230 – Disassembly and Assembly (3204 Vehicular Engines)
SENR4214 – Disassembly and Assembly (3204 Vehicular Engine for 943 & 953 Track-Type Loaders)
SENR4978 – Disassembly and Assembly (DELCO Remy 20-SI Series Alternator).pdf
SENR4978 – Specifications (DELCO Remy 20-SI Series Alternator).pdf
SENR4978 – Systems Operation (DELCO Remy 20-SI Series Alternator).pdf

EXCERPT:
NOTE: The center and two end main journals have no oil hole. To remove these bearings, put a thin piece of soft material that will not damage the crankshaft journal against the end of the bearing opposite the tab. Hit the bearing with the soft material until the tab of the bearing is free from the groove in the cylinder block. Remove the upper half of the main bearing.
4. Remove the upper half of the other main bearings as follows:
a. Turn the crankshaft until tool (B) can be installed in the crankshaft journal. Install tool (B).
b. Turn the crankshaft in the direction which will push the upper main bearing out, tab end first.
c. Check the condition of the bearings. (See Guideline For Reusable Parts, Main And Connecting Rod Bearings, Form No. SEBF8009.)
5. Remove crankshaft thrust bearings (2) from each side of the No. 3 main bearing saddle.
NOTE: Install the main bearings dry when the clearance checks are made. Put clean engine oil on the main bearings for final assembly. Also, be sure the tabs on the back side of the main bearings fit in the grooves of the main bearing caps and cylinder block.
…

INSTANT DOWNLOAD

Complete digital official shop manual contains service, maintenance, and troubleshooting information for the Caterpillar 3126B, 3126E Engine. Diagnostic and repair procedures are covered in great detail to repair, maintain, rebuild, refurbish or restore your 3126 Engine like a professional mechanic in local service/repair workshop. This cost-effective quality manual is 100% complete and intact as should be without any missing pages. It is the same factory shop manual used by dealers that guaranteed to be fully functional to save your precious time.

This manual for Caterpillar 3126B, 3126E Engine is divided into different sections. Each section covers a specific component or system and, in addition to the standard service procedures, includes disassembling, inspecting, and assembling instructions. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. It is in the cross-platform PDF document format so that it works like a charm on all kinds of devices. You do not need to be skilled with a computer to use the manual.

MANUAL LIST (376 MB PDF):
KENR6698 – Schematic (3126B Industrial Engine Electrical System)
RENR2242 – Schematic (3126B Marine Engine Electrical System)
RENR2243 – Troubleshooting (3126B Marine Engines)
RENR2247 – Specifications (3126B Marine Engine)
RENR2248 – Systems Operation (3126B Marine Engine)
RENR2248 – Testing & Adjusting (3126B Marine Engine)
RENR2249 – Disassembly & Assembly (3126B Marine Engine)
SEBU7242 – Operation & Maintenance Manual (3126B Marine Engine)
SENR9577 – Schematic (3126B Engine for Claas Combine Applications Electrical System)
SENR9579 – Specifications (3126B Engine for Caterpillar Built Machines)
SENR9580 – Systems Operation (3126B Engines for CaterpillarBuilt Machines)
SENR9580 – Testing & Adjusting (3126B Engines for CaterpillarBuilt Machines)
SENR9581 – Disassembly & Assembly (3126B Engines for Caterpillar Built Machines)
SENR9587 – Specifications (3126B Industrial Engine)
SENR9588 – System Operation (3126B Industrial Engine)
SENR9588 – Testing & Adjusting (3126B Industrial Engine)
SENR9589 – Disassembly & Assembly (3126B Industrial Engine)
SENR9590 – Schematic (3126B Industrial Engine Electrical System)
SENR9591 – Troubleshooting (3126B Industrial Engine)
SENR9631 – Systems Operation (3126E Truck Engines)
SENR9631 – Testing and Adjusting (3126E Truck Engines)
SENR9632 – Specifications (3126E Truck Engine)
SENR9633 – Disassembly and Assembly (3126E On-highway Engine)
SENR9637 – Troubleshooting (3126E On-highway Engine)
SENR9638 – Schematic (3126E Truck Engine Electrical System)
RENR1368 – Schematic (3126B and 3126E On-highway Engines).pdf
Cooling System (3126B & 3126E).pdf
Fuel System (3126B & 3126E).pdf
Intake, Exhaust & Turbocharger (3126B & 3126E).pdf
Lubrication (3126B & 3126E).pdf
Mechanical (3126B & 3126E).pdf
Troubleshooting (3126B & 3126E).pdf
…
CD-ROM (3126B & 3126E Truck Engines) RENR1361-11
Service Manual RENR1360
3126B and 3126E Truck Engines
BKD1-Up, G3E1-Up, DPF1-Up, 1AJ1-Up, 8YL1-UP, CKM1-Up, CRP1-Up, 7AS1-UP, 8SZ1-UP, 9SZ1-Up

EXCERPT:
Binder SENR2300 14.26 6.43
Binder Label RENR1359 03 .30 .30
Safety SENR2995 03 .30 .05
Service Manual Contents RENR1361 05 .30 .30
Torque Specifications SENR3130 06 3.40 2.00
Engine Index Tab SENR2870 .30 .30
Specifications 3126B and 3126E Truck Engines RENR1270 02 6.50 5.28
Systems Operations, Testing & Adjusting 3126B and 3126E Truck Engines RENR1271 02 15.50 8.06
Disassembly & Assembly 3126B and 3126E Truck Engines RENR1369 02 15.50 8.06
Service Manual Bendix Air Compressors SENR6455 00 6.50 5.28
Service Manual Midland Air Compressors SENR7594 03 6.50 5.28
Service Manual Bendix Air Compressors SENR5122
Service Manual Wabco Air Compressors RENR2314 00 3.40 2.78
Attachments Index Tab SENR2876 .30 .30
Owner’s Manual Caterpillar Driver Information Display SEBU6875 04 9.52 8.88
Screen Map Cat ID Screen Map SENR6503 04 3.40 2.78
Service Manual PTO Installation & Application
Instruction
RENR1282 00 15.50 8.06
Troubleshooting Index Tab SENR3987 .30 .30
Electrical Schematic 3126E Truck Engine SENR9675
Electrical Schematic 3126B and 3126E Truck Engines RENR1368 02 15.50 12.53
Troubleshooting 3126B and 3126E Truck Engines RENR1367 01 39.70 32.21
Maintenance Index Tab SENR2874 .30 .30
Operation & Maintenance 3126B and 3126E Truck Engines SEBU7011
…

Introduction

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Illustration 1 g00457847

Diagram of components for the HEUI fuel system

(1) Unit injector hydraulic pump

(2) Oil flow to engine

(3) Oil filter

(4) Engine oil pump

(5) Oil cooler

(6) IAP sensor

(7) Injectors

(8) Fuel supply rail

(9) Fuel pressure regulator

(10) IAP control valve

(11) Fuel filter

(12) Fuel tank

(13) Back of cam gear

(14) Speed/timing sensors

(15) ECM

(16) Boost pressure sensor

(17) Accelerator pedal

(18) Accelerator pedal position sensor

(19) Batteries

(20) Coolant temperature sensor

(21) Data link

(22) Exhaust brake relay

(23) Inlet air temperature sensor

(24) Transmission relay

(25) Vehicle speed sensor

(26) Inlet air heater relay

(27) Inlet air heater lamp

(28) Fast idle lamp

(29) Check engine lamp

(30) Speedometer and tachometer

(31) Cruise ON/OFF switch and Cruise SET/RESUME switch

(32) PTO ON/OFF switch and SET/RESUME switch

(33) Service brake switches

(34) Neutral and clutch switches

(35) Fuel transfer pump

The operation of the Hydraulic Electronic Unit Injector (HEUI) fuel system is completely different from any other type of fuel system that is actuated mechanically. The HEUI fuel system is completely free of adjustment. Adjustments to the components that are mechanical can not be made. Changes in performance are made by installing different software in Engine Control Module (ECM) (15) .

This fuel system consists of six basic components:

Hydraulic Electronic Unit Injector (HEUI) (7)

Engine Control Module (ECM) (15)

Unit injector hydraulic pump (1)

Injection Actuation Pressure Control Valve (10)

Fuel Transfer Pump (35)

Injection Actuation Pressure Sensor (6)

Note: The components of the HEUI fuel system are not serviceable. These fuel system components must not be disassembled. Disassembly will damage the components. If the components have been disassembled, Caterpillar may not allow a warranty claim or Caterpillar may reduce the warranty claim.

Component Description

Hydraulic Electronic Unit Injector
The HEUI fuel system utilizes a hydraulically actuated electronically controlled unit injector (7) .

All fuel systems for diesel engines use a plunger and barrel in order to pump fuel under high pressure into the combustion chamber. This fuel is pumped into the combustion chamber in precise amounts in order to control engine performance. The HEUI uses engine oil under high pressure in order to power the plunger. All other fuel systems use a fuel injection pump camshaft lobe in order to power the plunger. Because the HEUI is much different, a technician must use different troubleshooting methods.

The HEUI uses engine lubrication oil that is pressurized from 6 MPa (870 psi) to 27.5 MPa (4000 psi) in order to pump fuel from the injector. The HEUI operates in the same way as a hydraulic cylinder in order to multiply the force of the high pressure oil. By multiplying the force of the high pressure oil, the HEUI can produce injection pressures that are very high. This multiplication of pressure is achieved by applying the force of the high pressure oil to a piston. The piston is larger than the plunger by approximately six times. The piston that is powered by engine lubrication oil under high pressure pushes on the plunger. This engine lubrication oil under high pressure is called the actuation pressure of the oil. The actuation pressure of the oil generates the injection pressure that is delivered by the unit injector. Injection pressure is greater than actuation pressure of the oil by approximately six times.

Low actuation pressure of the oil results in low injection pressure of the fuel. During conditions of low speed such as idle and start, low injection pressure is utilized.

High actuation pressure of the oil results in high injection pressure of the fuel. During conditions of high speed such as high idle and acceleration, high injection pressure is utilized.

There are many other operating conditions when the injection pressure is between the minimum and the maximum. Regardless of the speed of the engine, the HEUI fuel system provides infinite control of injection pressure.

Engine Control Module (ECM)
Engine Control Module (ECM) (15) is located on the left side of the engine. The ECM is a powerful computer that provides total electronic control of engine performance. The ECM uses data from engine performance that is gathered by several sensors. Then, the ECM uses this data in order to make adjustments to the fuel delivery, injection pressure and injection timing. The ECM contains programmed performance maps (software) in order to define horsepower, torque curves and rpm. This software is commonly called the personality module.

Some engines use Engine Control Modules (ECM) (15) with a replaceable computer chip. The software has already been installed in the replaceable computer chip. The 3126B and 3126E diesel truck engines do not have a replaceable personality module. The 3126B and 3126E diesel truck engine’s personality module are a permanent part of the ECM. The 3126B and 3126E diesel truck engine’s personality module can be reprogrammed. Reprogramming of the personality module requires the use of Caterpillar Electronic Technician (Cat ET). The flash function of Cat ET will be used during the reprogramming.

ECM (15) logs faults of engine performance. Also, the ECM is capable of running several diagnostic tests automatically when the ECM is used with an electronic service tool such as the Cat ET.

Unit injector hydraulic pump
…
INJECTOR SYNCHRONIZATION
Injector synchronization is setting of all injector racks to a reference position so each injector gives the same amount of fuel to each cylinder. This is done by setting each injector to the same position while control linkage is in a fixed position (called the synchronizing position). Control linkage is at synchronizing position when cylinder No. 1 injector is at fuel shutoff. Since injector No. 1 is reference point for other injectors, no synchronizing adjustment is made to injector No. 1.
Always synchronize an injector when it has been removed and reinstalled.
1. Turn off engine and shut off engine’s electrical system. Remove fuel shutoff solenoid to allow injector rack control linkage to move freely during injector synchronization. Remove fuel shutoff solenoid using Spanner Wrench (4C4734). See Fig. 2.
2. Remove valve cover from intake manifold. Remove 4 bolts and cylinder No. 1 rocker arm assembly. See Fig. 3.
Fig. 3: Removing Fuel Shutoff Solenoid
3. Apply a small amount of clean engine oil to top of injector. Install Injector Spring Compressor (1U6675) to cylinder head and injector. See Fig. 4. Tighten bolt on Spring Compressor (1V6675) which is threaded into cylinder head hole for rocker arm assembly. This compresses injector. Tap lightly with a soft hammer on spring compressor directly above injector to ensure free movement of injector rack bar.
…