2Engine.PDF

Service TrainingMALAGA

992G WHEEL LOADER

AdolfoOctober 1997

2. ENGINE CONTROL

1. Components Layout2. Operation3. Testing & Adjusting

CHAPTER : ENGINE CONTROL

992G WHEEL LOADER

2-2Page:

ENGINE OIL COOLER

COOLANT FLOW SWITCHENGINE OIL PUMP


992G WHEEL LOADER

2-3Page:

FUEL PRIMING PUMP SECONDARY FUEL FILTERS

PRIMARY FUEL FILTERS ENGINE ECM

CH

AP

TE

R : E

NG

INE

CO

NT

RO

L

992G W

HE

EL

LO

AD

ER

2-4P

age:

CYLINDER HEADSMUI AND EUI

MUI EUI

CH

AP

TE

R : E

NG

INE

CO

NT

RO

L

992G W

HE

EL

LO

AD

ER

2-5P

age:

PRIMARYFILTER

TRANSFERPUMP

SECONDARYFILTER

FUEL TANK

ECM

FUEL TANK

FUELPRESSURE

REGULATOR

CH

AP

TE

R : E

NG

INE

CO

NT

RO

L

992G W

HE

EL

LO

AD

ER

2-6P

age:

FUELTANK

PRIMARYFUELFILTER

SECONDARYFUEL FILTERS

FUELPRESSURE

REGULATOR

FUELTRANSFER

PUMP ECM

CYLINDERHEAD

PRIMING PUMP SUPPLY

DIFFERENTIALPRESSURE

SWITCH

RETURN FUEL

3508B FUEL SUPPLY CIRCUIT

CH

AP

TE

R : E

NG

INE

CO

NT

RO

L

992G W

HE

EL

LO

AD

ER

2-7P

age:

GROUNDBOLT

15 AMPBREAKER

KEY STARTSWITCH

24 V

SPEED/TIMINGSENSOR

MACHINEINTERFACE

CONNECTOR

COOLANTTEMPERATURE

SENSOR

8/12/16INJECTORS

GROUND BOLT

P26 T/C CONNECTOR

J2

J1

ECM

UNFILTERED OILPRESSURE

SENSOR

AFTERCOOLERTEMPERATURE

SENSOR

CRANKCASEPRESSURE

SENSOR

RIGHTTURBOCHARGERINLET PRESSURE

SENSOR

LOW OILLEVEL

SWITCH

ATMOSPHERICPRESSURE

SENSOR

FUEL FILTERDIFFERENTIAL

PRESSURE SWITCH

TURBOCHARGEROUTLET

PRESSURE SENSOR

COOLANTFLOW

SWITCH

FILTERED OILPRESSURE

SENSOR

LEFTTURBOCHARGER

EXHAUSTTEMPERATURE

SENSOR

RIGHTTURBOCHARGER

EXHAUSTTEMPERATURE

SENSOR

LEFTTURBOCHARGERINLET PRESSURE

SENSOR

THROTTLEPOSITIONSENSOR

THROTTLEBACK-UPSWITCH

USER DEFINED SHUTDOWN

GROUNDLEVEL

SHUTDOWNSWITCH

BATTERY

ENGINE FANCONTROLSOLENOID

A/C ONSWITCH

FAN PRESSURE SENSOR

+ BATTERY

RELAYCYLINDER

ENGINE

ETHER START VALVE

STARTINGAID SWITCH

BASIC ENGINE BLOCK DIAGRAM APPLICATION BLOCK DIAGRAM

ELECTRONIC SERVICETOOL CONNECTOR

DISCONNECTSWITCH

15 AMPBREAKER

COOLANTTEMPERATURE

SENSOR

RELAY

CAT Data Link

CH

AP

TE

R : E

NG

INE

CO

NT

RO

L

992G W

HE

EL

LO

AD

ER

2-8P

age:

ENGINE COOLANTTEMPERATURE SENSOR

ENGINE OILPRESSURE SENSOR

+V ANALOGANALOG RETURNSIGNAL


TURBO OUTLETPRESSURE SENSOR


RIGHT TURBO INLET PRESSURE SENSOR


ATMOSPHERICPRESSURE SENSOR


LEFT TURBO INLETPRESSURE SENSOR


3630


CRANKCASEPRESSURE SENSOR


FAN PUMPPRESSURE SENSOR

ABC

ABC

ABC

ABC

ABC

ABC

ABC

ABC

5 ± 0.5 VOLTS

+V ANALOG SUPPLYANALOG RETURN

ECM

CH

AP

TE

R : E

NG

INE

CO

NT

RO

L

992G W

HE

EL

LO

AD

ER

2-9P

age:

+ V DIGITAL SUPPLY- V DIGITAL RETURN

2935

P1 J1

ABC

J31 P31+V DIGITAL

DIGITAL RETURNSIGNAL

RIGHT EXHAUST TEMPERATURE SENSOR

ABC

J35 P35THROTTLE

POSITION SENSOR

+V DIGITALDIGITAL RETURN

SIGNAL

8 ± 0.5 VOLTS

ABC

J30 P30+V DIGITAL


LEFT EXHAUST TEMPERATURE SENSOR

ABC

J84 P84+V DIGITAL


SPEED TIMING SENSOR

ECM

+ 12V SPD//TIM SNSR SUPPLY32

P1 J1 ENGINE ECM

ENG SPEED/TIMING SNSR3829 DIGITAL RETURN

12 ± 1 VOLTS


992G WHEEL LOADER

2-10Page:

ENGINE DERATES

ALTITUDE COMPENSATION

-DERATES APPROX 1% PER kPa TO A MAX OF 24% (if above 10000

feet)

AIR INLET RESTRICTION

- CALCULATES DIFFERENCE BETWEEN ATMOSPHERIC PRESSURE SENSOR AND TURBO INLET PRESSURE

-FUEL LIMITED BY 1% IF RESTRICTION 25 INCHES WATER (6,5kPa)

MAXIMUM DERATE 20%

EXHAUST TEMPERATURE DERATE

-- TORQUE MAP REDUCED BY 2% WHEN TURBINE (LEFT OR RIGHT) IS ABOVE 750˚C FOR 60 SECS

- MAXIMUM DERATE 20%

DATA LINK TRANSMISSION ERROR DERATE

-- CAT DATA LINK ERROR (296-09) INDICATES INFORMATION FROM POWERTRAIN IS RECEIVED INCORRECTLY

- FAULT 296-09 FOR FIVE MINUTES CAUSES 20% DERATE

CH

AP

TE

R : E

NG

INE

CO

NT

RO

L

992G W

HE

EL

LO

AD

ER

2-11P

age:

100%

98%

96%

94%

92%

90%

88%

86%

84%

82%

80%

78%

76%

74%

77 76 75 74 73 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53

8,210

8,920

9,630

10,340

11,050

11,760

12,470

13,890

14,600

15,310

16,020

16,730

17,440

13,180

7,500

72%

ACCORDING TO ATMOSPHERIC PRESSURE

ATMOSPHERIC PRESSURE IN kPa

PE

RC

EN

T O

F F

ULL

LO

AD

PO

WE

R

ALT

ITU

DE

IN F

EE

T

CH

AP

TE

R : E

NG

INE

CO

NT

RO

L

992G W

HE

EL

LO

AD

ER

2-12P

age:

OIL

PR

ES

SU

RE

IN k

Pa

600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800

60

80

100

120

140

160

180

200

220

240

260

280

300

ENGINE RPM

1900

320

340

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

49.3

OIL

PR

ES

SU

RE

IN P

SI

kPa x 0.145 = PSI

2000

5040

44

94LOW OIL PRESSURE REGION

300

250

TRIP LINERESET LIN

E

CH

AP

TE

R : E

NG

INE

CO

NT

RO

L

992G W

HE

EL

LO

AD

ER

2-13P

age:

PART No.

TRADE MARK

SERIAL No.

TRIM CODE SERIAL No. BAR CODE

E-T

RIM

CO

DE

S


992G WHEEL LOADER

2-14Page:

ECM automaticalty stop injectionto non- firing injectors until theengine warm up based on water temp.

ECM cutout each cylinder for abrief amount of time to see if thatinjector is contributing to power.If not, injection will be stop to thatcylinder, ECM will retest any cutoutcylinder every so often.

HELPS REDUCE WHITE SMOKE DURING ENGINE WARM UP

COLD START LOGIC

CH

AP

TE

R : E

NG

INE

CO

NT

RO

L

992G W

HE

EL

LO

AD

ER

2-15P

age:

ENGINE ECM FEATURES

• Throttle Lock

• Fan Control

• Ether Injection System

CH

AP

TE

R : E

NG

INE

CO

NT

RO

L

992G W

HE

EL

LO

AD

ER

2-16P

age:

F706-PU

ECMP1 J1

13192927142024

Throttle Lock RH Brake (NO)Throttle Lock RH Brake (NC)Digital ReturnThrottle Lock ON LampThrottle Lock Set/DeclerateThrottle Lock Resume/AccelerateThrottle Lock ON/OFF

998-BR

RIGHT BRAKE PEDAL SWITCH

F721-GYF722-OR

THROTTLELOCK LAMP

J3 P3

2113-OR BATT+

F717-YLF718-BUF719-BR

998-BR

998-BR

998-BR

998-BR

998-BR

THROTTLE LOCKSET/DECLERATION SW

THROTTLE LOCKRESUME/ACCLERATION SW

THROTTLE LOCK SW

THROTTLE LOCK CIRCUIT


992G WHEEL LOADER

2-17Page:

THROTTLE LOCK CIRCUIT

SIMILAR TO CRUISE CONTROL

USES ENGINE SPEED AS REFERENCE (Not vehicle speed)

COMPONENTS

- THROTTLE LOCK SWITCH

- Sets throttle lock ON/OFF

- THROTTLE LOCK LAMP

- SET/DECELERATION SWITCH

-Sets desired speed

-Speed loweredby 20 rpm every time switch pressed

-Speed lowered by 50 rpm / sec holding switch down

- RESUME / ACCELERATION SWITCH

--Speed increased by 20 rpm every time switch pressed

-Speed increased by 50 rpm / sec holding switch down

-Resumes set speed if throttle lockcancelled with brake

- RIGHT BRAKE PEDAL SWITCH

-Dissables throttle lock

-Invalid brake signal also dissables throttle lock


992G WHEEL LOADER

2-18Page:

995-BU

ENGINE ECMP2 J2

1907

HYDRAULIC FANPWM DRIVE AND SOL RETURN

P86 J86

21

HYDRAULIC FANSOLENOID VALVE

E799-BRF700-BU

997OR993BRCOOLANT TEMP

SENSOR3009

36 +5V ANALOG SUPPLYANALOG SENSOR RETURNCOOLANT TEMP SENSOR

HYDRAULIC ENGINE FAN CONTROL CIRCUIT

IMPLEMENT OILTEMP SENSOR

I/F 1 DATA LINK

SOLENOID VALVE CONTROLS OIL SUPPLY TO MOTOR- INCREASES OR DECREASES FAN SPEED

- PROPORTIONAL VALVE (RECEIVES PWM SIGNAL)

INPUT COOLANT TEMP SENSOR - ABOVE 98 °C FAN SPEED MAXIMUM

- BELOW 95° C FAN SPEED MINIMUM

-FAN SPEED CHANGES AS HYD PUMP VARIES WITH ENGINE SPEED

IMPUT IMPLEMENT OIL TEMP SENSOR- DESIRED TEMPERATURE 70˚C

FAN SPEED GOES TO MAXIMUM - OVERSPEED- ELECTRICAL FAULT IN FAN CIRCUIT

FAN SPEED GOES TO MINIMUM- LUG- ACCELERATION

CAN BE OVERRIDEN BY SERVICE TOOL FOR TESTING


992G WHEEL LOADER

2-19Page:

28291940

CONTROL GROUP(3408E/E3412E)

ETHER SWITCH

308-YL

200-BK

P1 J1

ETHER SW LAMPDIGITAL RETURNETHER REQUESTETHER CONTROL

P2 J2

F708-YL998-BR721-GY710-BR

J3 P323 93921

RELAY

12

+24V

+310-PK

200-BK P37 J37

ETHERSTART VALVE

TO ENGINE

FROMCYLINDER

ETHER INJECTION SYSTEMSPEED TIMING

SENSOR

COOLANTTEMP SENSOR

ETHER INJECTION SYSTEM

- CONTROLLED BY ENGINE ECM

- INPUTS FROM SPEED/TIMING AND COOLANT TEMP SENSOR

- FLOW DETERMINED BY ENGINE SPEED AND TEMPERATURE

- ENABLED IF COOLANT TEMP < 10°C & SPEED BETWEEN 50 & 1900 RPM

- MANUAL MODE IF ABOVE PARAMETERS PERMIT

-FIVE SECS MAX BEFORE ENGINE CRANKED

-AS LONG AS MANUAL SWITCH IS PRESSED IF RPM BELOW 1900

- STATUS READ ON ET

CH

AP

TE

R : E

NG

INE

CO

NT

RO

L

992G W

HE

EL

LO

AD

ER

2-20P

age:

CH

AP

TE

R : E

NG

INE

CO

NT

RO

L

992G W

HE

EL

LO

AD

ER

2-21P

age:

CH

AP

TE

R : E

NG

INE

CO

NT

RO

L

992G W

HE

EL

LO

AD

ER

2-22P

age:

CH

AP

TE

R : E

NG

INE

CO

NT

RO

L

992G W

HE

EL

LO

AD

ER

2-23P

age:

2Engine.PDF

Documents

Transcript of 2Engine.PDF