Service TrainingMALAGA

ELECT. ENG. CONTROL

CLAUDESEPT. 1997

VI. 3400 HEUI- SYSTEM- INJECTOR- PRIME RATE SHAPING- COMPONENTS- SENSORS

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High PressureOil Pump

HIGH PRESSURE OIL MANIFOLD

Fuel Return Line

ECM

FuelFilter

FuelTransPump

Fuel Tank

OilPump

OilSump

OilCooler

OilFilter

VehicleSystem

Engine System

RegulatorPressureControlValve

40 to 210 BAR

LOW PRESSURE 3 BAR

CHAPTER : 3400 HEUI

INJECTOR COMPONENTS

ELECT. ENG. CONTROL

3Page:

BARREL

PISTON

VALVE

FUEL INLETCHECK VALVE

PIN

SPACER

SLEEVE

VALVE BODY

CHECK

SHIM

ADAPTER

SPACER

ARMATURE

SOLENOID

WASHER

PLUNGER

SLEEVE

LOWER FUEL SEAL

UPPER FUEL SEAL

NOZZLE

CHAPTER : 3400 HEUI

INJECTION CYCLE

ELECT. ENG. CONTROL

4Page:

CHAPTER : 3400 HEUI

DRAIN CYCLE

ELECT. ENG. CONTROL

5Page:

CHAPTER : 3400 HEUI

NOZZLE GROUP

ELECT. ENG. CONTROL

6Page:

FUEL ATOMIZATION

NOZZLE GROUP

CHECK VALVE

REVERSE FLOWCHECK VALVE

CHAPTER : 3400 HEUI

PRIME RATE SHAPING

ELECT. ENG. CONTROL

7Page:

CROSS SECTIONOF PLUNGER

START OF INJECTION PRESSURE DROP

INJECTIONRATE

START OFINJECTION DURATION

FINALPRESSURE INCREASE

TIME (MILLISECONDS)

END OFINJECTION

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TO LUBESYSTEM

HYDRAULIC MANIFOLD

FUELTRANSFER

PUMP

PUMPCONTROL

VALVE

OILFILTER

OILCOOLER

HEUI

HEUI

OILSUMP

HYDRAULICPRESSURE

SENSOR

HYDRAULICTEMPERATURE

SENSOR

OIL PRESSURESENSOR

ECM

HYDRAULIC MANIFOLD

COOL DOWNCIRCUIT

FUEL TANK

FUELTEMPERATURE

SENSOR

PRESSUREREGULATING

VALVE

SECONDARYFUEL

FILTERPRIMARY

FUEL FILTERWATER

SEPARATOR

LUBE OILPUMP

COLD STARTOIIL

RESERVOIR

HYDRAULICSUPPLYPUMP

GROUP

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TO LUBESYSTEM

HYDRAULIC MANIFOLD

FUELTRANSFER

PUMP

PUMPCONTROL

VALVE

OILFILTER

OILCOOLER

HEUI

HEUI

OILSUMP

HYDRAULICPRESSURE

SENSOR

HYDRAULICTEMPERATURE

SENSOR

OIL PRESSURESENSOR

ECM

HYDRAULIC MANIFOLD

COOL DOWNCIRCUIT

FUEL TANK

FUELTEMPERATURE

SENSOR

PRESSUREREGULATING

VALVE

SECONDARYFUEL

FILTERPRIMARY

FUEL FILTERWATER

SEPARATOR

LUBE OILPUMP

COLD STARTOIL

RESERVOIR

HYDRAULICSUPPLYPUMP

GROUP

CHECKVALVES

CHAPTER : 3400 HEUI

PRESSURE CONTROL

ELECT. ENG. CONTROL

10Page:

IDLE

INJE

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PR

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MECHANICALLY ACTUATEDFUEL SYSTEM

H E U I

ENGINE SPEED

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LOW PRESSUREFUEL SUPPLY

FLUID SUPPLYMANIFOLD

INJECTOR

INJECTOR OILADAPTER

JUMPER BLOCK

HIGHPRESSUREHYDRAULICPASSAGE

LUBE OIL PASSAGE

COOLANT

CHAPTER : 3400 HEUI

HIGH PRESSURE PUMP

ELECT. ENG. CONTROL

12Page:

PRIMING PORT

ORIFICE

RESERVOIR

SWASHPLATE

TRANSFER PUMP

COMPENSATORVALVE

VALVE BASE

DRAIN PASSAGE

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ADAPTER CAGE

RINGSHELLPIN

STATOR

SEAL SEATPIN POPPET

SOLENOIDARMATURE

STOP

TOCASE DRAIN

FROMHYDRAULIC

PUMP

VALVEBLOCK

COILASSEMBLY

EDGE FILTER

SPRINGRETAINER

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TO LUBESYSTEM

TO RIGHT OILMANIFOLD

TO LEFT OILMANIFOLD PUMP

CONTROLVALVE

LOADSENSINGSPOOL

PRESSURELIMITERSPOOL

DISPLACEMENTCONTROL PISTON

COLD STARTRESERVIOR

PUMP CASE DRAINOIL SUMP

SOLENOID(ENERGIZED)

CHAPTER : 3400 HEUI

SYSTEM LIMITS & DERATE

ELECT. ENG. CONTROL

15Page:

FUEL SYSTEM DERATES

AUTOMATIC ALTITUDE COMPENSATION( Altitude derate)

AUTOMATIC FILTER COMPENSATION( Derate for air filter restriction if installed )

ENGINE WARNING DERATE ( Derates for LOW OIL PRESSURE, HIGH COOLANT TEMP not install in HEUI at the time)

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 LIMITS

FUEL SYSTEM DERATES

AUTOMATIC ALTITUDE COMPENSATION( Altitude derate)

AUTOMATIC FILTER COMPENSATION ( Derate for air filter restriction if insatalled At 6.25 kPa (30 inc of water) the engine will derate 2% of its power per 1 kPa until a maxi 20% Event is logged if exeeds 30 inch of water )

ENGINE WARNING DERATE ( Derates for LOW OIL PRESSURE , HIGH COOLANT TEMP not installed yet on HEUI)

CHAPTER : 3400 HEUI

COMPONENTS DIAGRAM

ELECT. ENG. CONTROL

16Page:

TURBO OUTLET PRESS. SENSOR

SECONDARYSPEED/TIMING SENSOR

PRIMARYSPEED/TIMING SENSOR

HYDRAULICPRESSURE SENSOR

ENGINEHARNESS

PUMP CONTROL VALVE

COOLANT TEMP. SENSOR

ATMOSPHERIC PRESS. SENSOR

OIL PRESSURE SENSOR

HYDRAULIC TEMP. SENSOR

COOLANT FLOW SWITCH

8 OR 12INJECTORS

TDC SERVICEPROBE ACCESS

MACHINEHARNESS

FUEL TEMPERATURE SENSOR

CHAPTER : 3400 HEUI

SENSORS, ANALOG DIGITAL

ELECT. ENG. CONTROL

17Page:

ANALOG SENSORS

- HYDRAULIC PRESSURE

- COOLANT TEMPERATURE

- ATMOSPHERIC PRESSURE

- TURBOCHARGER INLET PRESSURE

- TURBOCHARGER OUTLET PRESSURE

- OIL PRESSURE

- HYDRAULIC TEMPERATURE

- FUEL TEMPERATURE

- COOLANT FLOW

DIGITAL SENSORS

- THROTTLE POSITION

- PUMP CONTROL VALVE

- EXHAUST TEMPERATURE

CHAPTER : 3400 HEUI

HYDRAULIC PRESSURE SENSOR

ELECT. ENG. CONTROL

18Page:

HYDRAULICPRESSURE SENSOR

PUMP CONTROL VALVE

ENGINEHARNESS

8 OR 12INJECTORS

MACHINEHARNESS

This sensor is used to give the ACTUAL HYDRAULICACTUATION PRESSURE to the ECM .

The ECM uses this pressure to control the displacementof the Hydraulic pump via the control valve, (DESIREDHYDRAULIC ACTUATION PRESSURE ) .

CHAPTER : 3400 HEUI

COOLANT TEMPERATURE SENSOR

ELECT. ENG. CONTROL

19Page:

ENGINEHARNESS

8 OR 12INJECTORS

MACHINEHARNESS

High coolant temperature EVENT LOGGED above107 C (225 F)

Engine Warning, Derate 15% when 107 C (225 F)is exeeded

COOLANT TEMP. SENSOR

CHAPTER : 3400 HEUI

ATMOSPHERIC PRESSURE SENSOR

ELECT. ENG. CONTROL

20Page:

ENGINEHARNESS

8 OR 12INJECTORS

MACHINEHARNESS

All pressure measurements require the atmospheric pressuresensor to calculate the GAUGE pressure.

This sensor is use as well for

- Automatic altitude compensation

- Automatic air filter compensation ( Atmospheric - turbo inlet = filter delta P )

- Reference for pressure sensor calibration

Calibration can be accomplished using ET or by turning onthe key start switch without starting the engine for five second

ATMOSPHERIC PRESS. SENSOR

CHAPTER : 3400 HEUI

TURBO IN & OUT PRESSURE SENSOR

ELECT. ENG. CONTROL

21Page:

ENGINEHARNESS

8 OR 12INJECTORS

MACHINEHARNESS

The turbo INLET is use with the atmospheric sensorto measure the air filter restriction

The turbo OUTLET is used with the atmospheric sensorto give the BOOST pressure . Failure of this sensor cancause as much as a 60% Derate of the engine as the ECMwill read a zero boost condition

TURBOINLET

OUTLETPRESSURE

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600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 180060

80

19008.7

11.6

14.5

17.4

20.3

23.2

26.1

29

31.9

34.8

37.7

40.6

43.5

46.4

49.3

OIL P

RE

SS

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PS

I

2000

ENGINE RPM

If the oil pressure decrease below the lower linean event , warning and engine 15 % derate are generated

OIL P

RE

SS

UR

E IN

kPa

100

120

140

160

180

200

220

240

260

280

300

320

340

CHAPTER : 3400 HEUI

HYDRAULIC OIL TEMP SENSOR

ELECT. ENG. CONTROL

23Page:

ENGINEHARNESS

8 OR 12INJECTORS

MACHINEHARNESS

HYDRAULIC TEMPERATURE SENSOR

This sensor is used to compensate for effects of oil temperatureon injector timing and fuel delivery .It will activate the cold mode strategy if oil temperature isbelow 60 C ( 140F)

CHAPTER : 3400 HEUI

FUEL TEMP SENSOR

ELECT. ENG. CONTROL

24Page:

ENGINEHARNESS

8 OR 12INJECTORS

MACHINEHARNESS

This sensor is used to make correction to fuel rate inorder to maintain power . This feature is calledFUEL TEMPERATURE COMPENSATION

FUEL TEMP.ERATURESENSOR

CHAPTER : 3400 HEUI

THROTTLE POSITION, PUMP CONT VAL

ELECT. ENG. CONTROL

25Page:

The throttle position sensor provides engine speed controlto the operator .

The pump control valve is used to control the swach plateangle in the hydraulic pump

ENGINEHARNESS

PUMP CONTROL VALVE

8 OR 12INJECTORS

MACHINEHARNESS

THOTTLESENSOR

CHAPTER : 3400 HEUI

TIMING WHEEL

ELECT. ENG. CONTROL

26Page:

SINGLE50/50 TOOTH

TDCCYL No. 1

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0 1 2 3 4

CU

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TIME (MILLISECONDS)

CURRENT

POPPETLIFT

INJECTIONRATE

START OFINJECTION

DURATION

5

END OFINJECTION

START OFLOGIC