Service Training
MALAGA
ELECT. ENG. CONTROL
CLAUDE SEPT. 1997
VI. 3400 HEUI
- SYSTEM - INJECTOR
- PRIME RATE SHAPING - COMPONENTS
CHAPTER : 3400 HEUI HEUI SYSTEM
ELECT
. ENG. CONTROL
2 Page: High Pressure Oil PumpHIGH PRESSURE OIL MANIFOLD
Fuel Return Line
ECM Fuel Filter Fuel Trans Pump Fuel Tank Oil Pump Oi lS u m p Oil Cooler Oil
Filter VehicleSystem
Engine System Regulator Pressure Control Valve 40 to 210 BAR
CHAPTER : 3400 HEUI INJECTOR COMPONENTS
ELECT. ENG. CONTROL
3 Page: BARREL PISTON VALVE FUEL INLET CHECK VALVE PIN SPACER SLEEVE VALVE BODY CHECK SHIM ADAPTER SPACER ARMATURE SOLENOID WASHER PLUNGER SLEEVE
LOWER FUEL SEAL UPPER FUEL SEAL
CHAPTER : 3400 HEUI INJECTION CYCLE
ELECT. ENG. CONTROL
4 Page:
CHAPTER : 3400 HEUI DRAIN CYCLE
ELECT. ENG. CONTROL
5 Page:
CHAPTER : 3400 HEUI NOZZLE GROUP
ELECT. ENG. CONTROL
6 Page:
FUEL
ATOMIZATION
NOZZLE GROUP
CHECK VALVE
REVERSE FLOW
CHECK VALVE
CHAPTER : 3400 HEUI PRIME RATE SHAPING
ELECT. ENG. CONTROL
7 Page:
CROSS SECTION OF PLUNGER
START OF INJECTION PRESSURE DROP
INJECTION RATE START OF INJECTION DURATION FINAL PRESSURE INCREASE TIME (MILLISECONDS) END OF INJECTION
CHAPTER : 3400 HEUI FUEL SYSTEM
ELECT
. ENG. CONTROL
8 Page: TO LUBE SYSTEM HYDRAULIC MANIFOLD FUEL TRANSFER PUMP PUMP CONTROL VALVE OIL FILTER OIL COOLER HEUI HEUI OIL SUMP HYDRAULIC PRESSURE SENSOR HYDRAULIC TEMPERATURE SENSOR OIL PRESSURE SENSOR ECM HYDRAULIC MANIFOLD COOL DOWN CIRCUIT FUEL TANK FUEL TEMPERATURE SENSOR PRESSURE REGULATING VALVE SECONDARY FUEL FILTER PRIMARY FUEL FILTER WATER SEPARATOR LUBE OIL PUMP COLD START OIIL RESERVOIR HYDRAULIC SUPPLY PUMP GROUPCHAPTER : 3400 HEUI OIL SYSTEM
ELECT
. ENG. CONTROL
9 Page: TO LUBE SYSTEM HYDRAULIC MANIFOLD FUEL TRANSFER PUMP PUMP CONTROL VALVE OIL FILTER OIL COOLER HEUI HEUI OIL SUMP HYDRAULIC PRESSURE SENSOR HYDRAULIC TEMPERATURE SENSOR OIL PRESSURE SENSOR ECM HYDRAULIC MANIFOLD COOL DOWN CIRCUIT FUEL TANK FUEL TEMPERATURE SENSOR PRESSURE REGULATING VALVE SECONDARY FUEL FILTER PRIMARY FUEL FILTER WATER SEPARATOR LUBE OIL PUMP COLD START OIL RESERVOIR HYDRAULIC SUPPLY PUMP GROUP CHECK VALVESCHAPTER : 3400 HEUI PRESSURE CONTROL
ELECT. ENG. CONTROL
10 Page: IDLE
INJECTION PRESSURE
MECHANICALLY ACTUATED FUEL SYSTEMH E U I
ENGINE SPEEDCHAPTER : 3400 HEUI
FLUID FLOW MANIFOLD
ELECT
. ENG. CONTROL
11 Page: LOW PRESSURE FUEL SUPPLY FLUID SUPPLY MANIFOLD INJECTOR INJECTOR OIL ADAPTER JUMPER BLOCK HIGH PRESSURE HYDRAULIC PASSAGE LUBE OIL PASSAGECHAPTER : 3400 HEUI HIGH PRESSURE PUMP
ELECT. ENG. CONTROL
12 Page: PRIMING PORT ORIFICE RESERVOIR SWASHPLATE TRANSFER PUMP COMPENSATOR VALVE VALVE BASE DRAIN PASSAGE
CHAPTER : 3400 HEUI PUMP CONTROL V A L V E
ELECT
. ENG. CONTROL
13 Page: ADAPTER CAGE RING SHELL PIN STATOR SEAL SEAT PIN POPPET SOLENOID ARMATURE STOP TO CASE DRAIN FROM HYDRAULIC PUMP VALVE BLOCK COIL ASSEMBLY EDGE FILTER SPRING RETAINERCHAPTER : 3400 HEUI
HYDRAULIC CONTROL SYSTEM (start)
ELECT
. ENG. CONTROL
14 Page: TO LUBE SYSTEM TO RIGHT OIL MANIFOLD TO LEFT OIL MANIFOLD PUMP CONTROL VALVE LOAD SENSING SPOOL PRESSURE LIMITER SPOOL DISPLACEMENT CONTROL PISTON COLD START RESERVIORPUMP CASE DRAIN OIL SUMP
SOLENOID (ENERGIZED)
CHAPTER : 3400 HEUI SYSTEM LIMITS & DERATE
ELECT. ENG. CONTROL
15 Page:
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
16 Page:
TURBO OUTLET PRESS. SENSOR SECONDARY SPEED/TIMING SENSOR PRIMARY SPEED/TIMING SENSOR HYDRAULIC PRESSURE SENSOR ENGINE HARNESS
PUMP CONTROL VALVE
COOLANT TEMP. SENSOR
ATMOSPHERIC PRESS. SENSOR
OIL PRESSURE SENSOR
HYDRAULIC TEMP. SENSOR
COOLANT FLOW SWITCH
8 OR 12 INJECTORS TDC SERVICE PROBE ACCESS MACHINE HARNESS
CHAPTER : 3400 HEUI
SENSORS, ANALOG DIGITAL
ELECT. ENG. CONTROL
17 Page:
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
18 Page:
HYDRAULIC PRESSURE SENSOR PUMP CONTROL VALVE
ENGINE HARNESS 8 OR 12 INJECTORS MACHINE HARNESS
This sensor is used to give the ACTUAL HYDRAULIC
ACTUATION PRESSURE to the ECM .
The ECM uses this pressure to control the displacement
of the Hydraulic pump via the control valve, (DESIRED
HYDRAULIC ACTUATION PRESSURE ) .
CHAPTER : 3400 HEUI
COOLANT TEMPERATURE SENSOR
ELECT. ENG. CONTROL
19 Page: ENGINE HARNESS 8 OR 12 INJECTORS MACHINE HARNESS
High coolant temperature EVENT LOGGED above
107 C (225 F)
Engine Warning, Derate 15% when 107 C (225 F)
is exeeded
CHAPTER : 3400 HEUI
ATMOSPHERIC PRESSURE SENSOR
ELECT. ENG. CONTROL
20 Page: ENGINE HARNESS 8 OR 12 INJECTORS MACHINE HARNESS
All pressure measurements require the atmospheric pressure sensor 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 on the key start switch without starting the engine for five second
CHAPTER : 3400 HEUI
TURBO IN & OUT PRESSURE SENSOR
ELECT. ENG. CONTROL
21 Page: ENGINE HARNESS 8 OR 12 INJECTORS MACHINE HARNESS
The turbo INLET is use with the atmospheric sensor
to measure the air filter restriction
The turbo OUTLET is used with the atmospheric sensor
to give the BOOST pressure . Failure of this sensor can
cause as much as a 60% Derate of the engine as the ECM
will read a zero boost condition
TURBO INLET OUTLET PRESSURE
CHAPTER : 3400 HEUI
OIL PRESSURE MAP
ELECT
. ENG. CONTROL
22 Page: 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 60 80 1900 8.7 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 49.3OIL PRESSURE IN PSI
2000
ENGINE RPM
If the oil pressure decrease below the lower line
an event , warning and engine 15 % derate are generated
OIL PRESSURE 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
23 Page: ENGINE HARNESS 8 OR 12 INJECTORS MACHINE HARNESS HYDRAULIC TEMPERATURE SENSOR
This sensor is used to compensate for effects of oil temperature on injector timing and fuel delivery .
It will activate the cold mode strategy if oil temperature is below 60 C ( 140F)
CHAPTER : 3400 HEUI FUEL TEMP SENSOR
ELECT. ENG. CONTROL
24 Page: ENGINE HARNESS 8 OR 12 INJECTORS MACHINE HARNESS
This sensor is used to make correction to fuel rate in
order to maintain power . This feature is called
FUEL TEMPERATURE COMPENSATION
FUEL TEMP.ERATURE SENSOR
CHAPTER : 3400 HEUI
THROTTLE POSITION, PUMP CONT VAL
ELECT. ENG. CONTROL
25 Page:
The throttle position sensor provides engine speed control to the operator .
The pump control valve is used to control the swach plate angle in the hydraulic pump
ENGINE HARNESS
PUMP CONTROL VALVE
8 OR 12 INJECTORS MACHINE HARNESS THOTTLE SENSOR
CHAPTER : 3400 HEUI TIMING WHEEL
ELECT. ENG. CONTROL
26 Page:
SINGLE
50/50 TOOTH
TDC
CYL No. 1
CHAPTER : 3400 HEUI W A VE FORM
