Bomba Terracan Electronica
-
Upload
jenny-mora-leon -
Category
Documents
-
view
236 -
download
0
Transcript of Bomba Terracan Electronica
-
7/24/2019 Bomba Terracan Electronica
1/39
1
TERRACAN
D4BH (2.5 TCI) Diesel Engine
Fuel System (COVEC-F)
-
7/24/2019 Bomba Terracan Electronica
2/39
2Engine Specification
ITEMS 2.5 T/C
DISPLACEMENT(cc) 2476
BORE STROKE(mm) 91.1 95
FIRING ORDER 1-3-4-2
COMPRESSION RATIO 21
INJECTION TIMING( ) CAM Lift 10.03mm
INJECTION TYPE INDIRECTION
NUMBER OF CYLINDER 4
IDLE RPM 750
PREHEATING DEVICE GLOW PLUG
INTAKE SYSTEM TURBO
-
7/24/2019 Bomba Terracan Electronica
3/39
3Outline
Electronic fuel injection pump (Covec-F) has the same fuel intake and
compression system as mechanical injection pump has.
However, it uses an electronic governor(GE Actuator) instead of a fly-weight
and uses control unit cable instead of a control lever. In checking engine cycle,
mechanical pump uses gear of fly weight holder, but electronic pump uses
sensing gear plate with 4 projections, installed on the driveshaft. A timing
control valve(TCV), which adjust pressure to moot optimal injection timing,
installed between high and low pressure chambers of the timer at lower part of
the main pump body, in mechanical injection pumps, check valves are installed
in part of the inside of the overflow valves. In electronic injection pumps,
however, check valve are installed at all valves, enabling to hold over-flows
until the pressure is stabilized. A timer position sensor(TPS), which senses
location of timer piston is also installed in electric injection.
Fuel Cut Sol.
GE Actuator
Timer Control Valve.
Np Sensor
-
7/24/2019 Bomba Terracan Electronica
4/39
4ECM Input/ Output
GE(Governor Electric) Actuator
GE actuator is attached to the governor chamber at the upper part of the
injection pump. Governor chamber and pump chamber are connected with a
magnetic filter in between. Coil is cooled by the fuel coming into the governor
chamber. A magnetic filter prevents foreign material(ferrous ingredients) fromentering the chambers. Eccentric ball pin that are inserted into control sleeve
holes are placed at the end of the shaft forced into the rotor.
The electronic governor actuator is a magnetic field type. Once the coil
receives electric current, it generates a magnetic field and rotates the rotor until
it reaches the designated range.
The strength of magnetic field at coil is proportional to the strength of input
current and rotates the rotor to the relative position of the return spring ,enabling the control sleeve to make linear movements.
-
7/24/2019 Bomba Terracan Electronica
5/39
5ECM Input/ Output
GE (Governor Electric) Actuator
F.I.P
Connector
No.6 GE+
No.10 GE-
Specification
No.6 ~ No.10: 0.6
Connection with ECMNo.6 ECM Pin No. 1, 14
No.10 ECM Pin No. 2, 15
Waveform
ECM Pin No. 1, 14 ECM Pin No. 2, 15
-
7/24/2019 Bomba Terracan Electronica
6/39
6ECM Input/ Output
TCV (Timing Control Valve)
The TCV is located at the lower part of the injection pump. Two holes ( A and
B ) in the pump housing connect to the TCV. Hole A connects the timer piston's
high pressure chamber to the fuel inlet side of the TCV. A filter is installed at
this inlet to exclude foreign mater Hole B connects the timer piston's low
pressure chamber to the outlet at the tip of he TCV.
Installed between the timer piston's high and low pressure chambers, the TCV
adjusts high pressure chamber pressure by opening and closing the needle.
When current is not flowing to the TCV, the tip of the needle completely
separates the high and low pressure chambers. Then current is supplied,
needle tip seat is opened, the high and low pressure chamber are connected,
and the high pressure chamber pressure decreases. The timer piston is then
moved by timer spring to a piston that balances the high pressure chamber
pressure. Accompanying this roller holder rotates to vary the injection timing.
Injection timing can therefore be varied by utilizing the ON-OFF duty ratio of
the current flowing to the TCV. Injection timing is controlled by duty. Allcharacteristics and TCV drive signal duty ratios. Also, he frequency of the TCV
drive signal can be varied to correspond to the frequency of injection pump
speed.
Duty ratio is the ratio the time that the timing control valve is closed per unit of
time (i. e. per cycle).
Duty ratio = to / T x 100 (%)
Injection timing is related when the duty ratio decreases from 100%.
When electric current flows at Timing Control Valve, the needle is pulled lift by
magnet, and seat part of the hall is opened. TCV is located between high
pressure and low pressure chambers and adjusts pressure by opening and
closing of the needle.
-
7/24/2019 Bomba Terracan Electronica
7/39
7ECM Input/ Output
TCV (Timer Control Valve)
-
7/24/2019 Bomba Terracan Electronica
8/39
8ECM Input/ Output
TCV
F.I.P
Connector
No.5 TCV+
No.9 TCV-
Specification
No.5 ~ No.9: 111.1
Connection with OthersNo.5 IG. Key(B+)
No.9 ECM Pin No. 13
Waveform
At idle At acceleration
TCV (Timer Control Valve)
-
7/24/2019 Bomba Terracan Electronica
9/39
9ECM Input/ Output
TPS (Timer Position Sensor)
TPS is attached on the low-pressure side of the timer and is consisted of core
rod and bobbin. It checks position of the timer piston electrically. TPS checks
inductance changes with the core rod and measures position of the timer
piston.
TPS
TPS
Connector
-
7/24/2019 Bomba Terracan Electronica
10/39
10ECM Input/ Output
TPS (Timer Position Sensor)
TCV
F.I.P
Connector
No.3 TPS
MDL
No.2 TPS +
No.1 TPS -
Specification
No.2 ~ No.3, No.1 ~ No.3: 822
Connection with Others
No.1 ECM Pin No. 53
No.2 ECM Pin No. 46
No.3 ECM Pin No. 52
Waveform
ECM Pin No. 52, 46 at idle ECM Pin No. 52, 53 at idle
-
7/24/2019 Bomba Terracan Electronica
11/39
11ECM Input/ Output
Np (Pump Speed) Sensor
NP Sensor checks pump rpm and relays signal to PCM. NP sensor is
consisted of permanent magnets, steel core and coils. It detects electric
voltage generated by the changes in the machine going through the sensing
gear, through rotation signal.
When the 4 projections of the sensing gear plate go through the magnetic field,
while the drive-shaft is rotating, alternating current is generated, which is then
changed into a pulse signal and used as a rotation signal.
Np Sensor
-
7/24/2019 Bomba Terracan Electronica
12/39
12ECM Input/ Output
Np (Pump Speed) Sensor
F.I.P
Connector
No.3
Signal
No.2
ECM GND
No.1 Shield GND
Specification
No.2 ~ No.3: 1.020.16k
Connection with OthersNo.1 Wiring harness Shield GND
No.2 ECM Pin No. 38 GND
No.3 ECM Pin No. 30 Signal
Waveform
Np Signal at idle Np Signal with CKP Sensor at idle
-
7/24/2019 Bomba Terracan Electronica
13/39
13ECM Input/ Output
Q Compensation Resistance
Q Compensation Resistance is to prevent the different injection amount due to
the different characteristic resistance of fuel injection pump affecting to
injection amount controlled by ECM.
The resistance of Q Compensation is decided by below table. The
compensation resistance number is related to the resistance measured
between terminal D & G.
Q Adjustment
Resistance
No.1 945 0.18(k)
No.2 946 0.3(k)
No.3 947 0.43(k)
No.4 948 0.62(k)
No.5 949 0.82(k)
No.6 950 1.1(k)
No.7 951 1.15(k)
No.8 952 2(k)
No.9 953 2.7(k)
No.10 954 3.9(k)
No.11 955 5.6(k)
No.12 956 8.2(k
)No.13 957 15(k)
NumberMeasured
Resistance
Q Comp.
Resistance
F.I.P
ConnectorNo.2
No.3
-
7/24/2019 Bomba Terracan Electronica
14/39
14ECM Input/ Output
CSP (Control Sleeve Position) Sensor
The control Sleeve Position Sensor(CSP) at upper part of GE actuator detects
the position of control sleeve and feeds it back to ECU.
The fixed plate compensates changes of inductance caused by temperature.
The CSP sensor calculates the difference of the inductance at the two sensor
coils(upper and lower sensor coils) into angles and feeds them back to ECU,
and ECU compares its target angle with the actual one, if there is a difference
between the two angles, the ECU adjusts electric currents until the actual angle
equals the target angle.
-
7/24/2019 Bomba Terracan Electronica
15/39
15ECM Input/ Output
F.I.P
Connector
No.4 CDP +
No.8 CSP
MDL
Specification
No.4 ~ No.8, No.12 ~ No. 8: 5.8k
Connection with ECM
No.4 ECM Pin No. 43, 49
No.8 ECM Pin No. 44, 50
No.12 ECM Pin No.45, 51
Waveform
CSP (Control Sleeve Position) Sensor
No.12 CSP -
ECM Pin No. 43, 44 at idle ECM Pin No. 43, 45 at idle
-
7/24/2019 Bomba Terracan Electronica
16/39
16ECM Input/ Output
TF (Temperature Fuel) Sensor
This sensor detects the temperature of fuel.
If TF Sensor value is beyond 0.1V~4.6V for 5 second, ECM regards TF Sensor
as failed and sets fuel temperature to 50
F.I.P
Connector
No.7 Signal
No.11 GND
Specification
No.7 ~ No.11: 20.1k at 25
Connection with ECM
No.7 ECM Pin No. 18
No.11 Wiring harness GND
Waveform
ECM Pin No. 18 at
normal operating
Temperature
-
7/24/2019 Bomba Terracan Electronica
17/39
17ECM Input/ Output
WTS (Water Temperature Sensor) Sensor
If Sensor value is beyond 0.1V~4.6V for 5 second, ECM regards WTS Sensor
as failed and sets coolant temperature from TF Sensor at starting. When TF
Sensor is failed, sets the temperature to 20 .
Connection with ECM
No.2 ECM Pin No. 17
No.1 Wiring harness GND
Waveform
ECM Pin No. 17 at
normal operating
Temperature
Temp.( ) Resistance(k
) Voltage(V)-20 16 4.3
0 5.9 3.4
20 2.5 2.4
40 1.2 1.5
60 0.6 0.9
80 0.3 0.5
100 0.2 0.3
Specification
-
7/24/2019 Bomba Terracan Electronica
18/39
18
No.4 BPS Sig.
No.1 GNDNo.2 TA Sig.
No.3 Ref. Voltage 5V
ECM Input/ Output
BPS (Booster Pressure Sensor) / TA (Intake-Air-Temperature)
SensorThese two sensors are integrated into one. Located after the intercooler. BPS
detects the intake air pressure and TA sensor detects the temperature of intake
air.
If BPS value is beyond 0.2V~4.8V for 1. second, ECM regards BPS as failed and
fixes boost pressure to 760mmHg and prohibits EGR operation.
If TA sensor value is beyond 0.1V~4.6V for 5 second, ECM regards TA Sensor as
failed and fixes air temperature to 60 .
Connection with ECM
No.1 ECM Pin No. 41 GND
No.2 ECM Pin No. 19 TA Signal
No.3 ECM Pin No. 33 Reference Voltage 5V
No.4 ECM Pin No. 34 BPS Signal
Temp.( ) Resistance(k) Voltage(V)
-20 16 4.3
0 5.9 3.4
20 2.5 2.4
40 1.2 1.560 0.6 0.9
80 0.3 0.5
100 0.2 0.3
TA Sensor Specification
-
7/24/2019 Bomba Terracan Electronica
19/39
19ECM Input/ Output
BPS (Booster Pressure Sensor) / TA (Intake-Air-Temperature
SensorWaveform
ECM Pin No. 34 BPS
Signal at acceleration
from idle to 4200rpm
ECM Pin No. 19
TA Sensor Signal
ECM Pin No. 34
BPS Signal at idle
ECM Pin No. 34 BPS
Signal at 4200rpm
-
7/24/2019 Bomba Terracan Electronica
20/39
20ECM Input/ Output
APS (Accelerator Pedal Sensor)
This sensor detects the angle of accelerator pedal.
If sensor value is beyond 0.2V~4.93V for 1. second, ECM regards APS as
failed. If ECM detects APS malfunction, ECM fix accelerator opening to 0%
and prohibit EGR operation.
Connection with ECM
No.1 ECM Pin No. 32 V ref
No.2 ECM Pin No.40 APS Sig.
No.3 ECM Pin No.8 Idle SW Sig.
No.4 Wiring harness GND Idle SW. GND
No.5 ECM Pin No.39 GND
When only idle SW. is good, ECM can increase the accelerator opening to 30%
slowly. (equal to approx 1.5V)
In the event of complete failure, No throttle response
-
7/24/2019 Bomba Terracan Electronica
21/39
21ECM Input/ Output
APS (Accelerator Pedal Sensor)
ECM Pin No. 8 at acceleration
ECM Pin No. 40 from idle to Max.
Good conditionIdle Switch ON
Accelerator Pedal Sensor
-
7/24/2019 Bomba Terracan Electronica
22/39
22APS (Accelerator Pedal Sensor)
APS output signal failed, Idle Switch good, At Max. Throttle
ECM increases RPM slowly to 30% (4000rp)m
Good condition (Max. Throttle)
-
7/24/2019 Bomba Terracan Electronica
23/39
23ECM Input/ Output
CPS (Crankshaft Position Sensor)
This sensor detects the position of crankshaft.
If there is no signal from sensor for 20 consecutive times of Np Sensor, ECM
regards CPS as failed and controls engine with Np (inj pump) Sensor signal.
Note: In this condition Twice ignition applies to start engine
DTC P0335 will be set
Connection with ECM
No.1 Shield GND No.2 ECM Pin No.29 Signal
No.3 ECM Pin No.37 GND
Waveform
CPS
1mm
-
7/24/2019 Bomba Terracan Electronica
24/39
24ECM Input/ Output
ECM Pin No. 29 at idle CPS signal with Np signal at idle
-
7/24/2019 Bomba Terracan Electronica
25/39
25ECM Input/ Output
FC (Fuel Cut) Valve
When the IG. Key is On, ECM supplies B+ Voltage to open fuel line.
When Immobilizer is on ECM inhibits the connection, (vale remains closed)
Connection with ECMNo.1 ECM Pin No.26 Signal
Waveform
FC Valve signal at idle
F.I.P
Connector
FC Valve
No.1 FC
Valve
-
7/24/2019 Bomba Terracan Electronica
26/39
26
Terminal Component Remarks
1 FCV Fuel Cut Valve
2 Adj (-) Adjustment resistor (-)
3 Adj (+) Adjustment resistor (+)
4 CSP Oscillate (+)
5 TCV (+) Timer Control Valve (+)
6 GE (+) GE (+)
7 TF (+) Fuel temperature (+)
8 CSP MDL
9 TCV (-) Timer Control Valve (-)
10 GE- GE (-)11 TF (-) Fuel Temperature (-)
12 CSP Oscillate (-)
61
127
Diagnosis Reference chart
(Checking Pump Components, Ignition off plug disconnected)
Note: Pin arrangement is different to H-1
Pumps are not interchangeable
-
7/24/2019 Bomba Terracan Electronica
27/39
27
Component Plug (No of pins) Terminal Resistance Temp C
Fuel Cut 12 pin black 1--Ground 7 ~ 9 Ohms 23 +- 5Actuator 12 pin black 6 ~ 10 0.71 0.13 Ohms 23 +- 5
TCV 12 pin black 5 ~ 9 11 1.1 Ohms 23 +- 5
TPS 3 pin black 2 ~ 3 82 2 Ohms 23 +- 5
1 ~3 82 2 Ohms 23 +- 5
Speed Sensor 3 pin grey 2 ~ 3 1.020.16 KOhms 23 +- 5
Trim Resistor 12 pin black 3 ~2 same as resistor 23 +- 5CSP 3 pin 4 ~ 8 5.9 0.3 Ohms 23 +- 5
8 ~ 12 5.9 0.3 Ohms 23 +- 5
Fuel Temp 12 pin black 11 ~ 7 0.1 Kohms 25
Diagnosis Reference chart
(Checking Pump Components)
-
7/24/2019 Bomba Terracan Electronica
28/39
28ECM Input/ Output
EGR (Emission Gas Re-circulation) Solenoid Valve
There are two EGR Solenoid Valves. One is controlled by duty signal from
ECM and connected from vacuum tank or atmosphere to the other EGR
Solenoid Valves. The other is controlled by On/Off signal from ECM and
connected to EGR Control valve.
Connection with ECM
EGR Vacuum Sol. Valve No.1 ECM Pin No.58 Signal
EGR Vacuum Sol. Valve No.2 Main Relay B+
EGR Sol. Valve No. 1 ECM Pin No.68 Signal
EGR Sol. Valve No. 2 Main Relay B+
EGR Vacuum
Sol. Valve
Atmosphere
Port
From Vacuum
Pump
To EGRControl Valve
EGR Sol. ValveEGR Vacuum Sol.
Valve Out port
-
7/24/2019 Bomba Terracan Electronica
29/39
29ECM Input/ Output
ECM Pin No. 68 at acceleration
EGR (Exhuast Gas Re-circulation) Solenoid Valve
Waveform
ECM Pin No.58 at accelerationECM Pin No. 58 at idle
-
7/24/2019 Bomba Terracan Electronica
30/39
30ECM Input/ Output
I/C (Inter Cooler) Fan Motor Relay
Terracan has a intercooler fan motor controlled by ECM. Intercooler fan motoris operated when vehicle speed is under 60Km/h and intake air temperature is
over 58 and engine speed is over 550rpm.
Grow Plug Relay
ECM controls the glow plug to heat the intake air through glow plug relay.
According to the condition, the heating time is as below.
Connection with ECMI/C Fan Motor Relay No.85 ECM Pin No.35
Coolant Temp. Heating time
60 2Sec.
-15 8Sec.
-20 10Sec.
-25 15Sec.
-40 24.5Sec.
Coolant Temp. Heating time
60 3Sec.
0 3Sec.
-10 3Sec.
-20 5Sec.
-40 5Sec.
Preheating Post heating
Connection with ECMGlow Plug Relay No.85 ECM Pin No.55
-
7/24/2019 Bomba Terracan Electronica
31/39
31ECM Input/ Output
Others
Main relay control
ECM controls Main relay to provide the B+ voltage to actuators like EGR Sol.
Valves, Grow Plug and A/C fan relay etc.
Lamps
ECM controls Engine check lamp and Glow lamp
A/C Fan Motor Relay & A/C Comp. Relay
Connection with ECM
Main Relay No.85 ECM Pin No.73
Engine check lamp ECM Pin No.62
Glow lamp ECM Pin No.63
A/C Fan Motor Relay No.85 ECM Pin No.59
A/C Comp. Relay ECM Pin No.72
-
7/24/2019 Bomba Terracan Electronica
32/39
32ECM Controls
Q(Injection amount) ControlsExample)
Injection Quantity
Eng. speed Pump speed
ECM3,000 RPM
37mg/stroke
Accel. Position
50%
Fuel Injection
GE Actuator
2.8 Volt
Control Sleeve
Position Check
CSP
Feedback
CPS
APS
Np Sensor when CPS is failed
IT (Injection Timing) Controls
Injection Timing
Pump speed
Eng. speedECM
Injection Quantity
Duty(%) ControlTCV
InjectionTiming Check
TPS
Feedback
CPS
ECM
Np Sensor when CPS is failed
-
7/24/2019 Bomba Terracan Electronica
33/39
33Basic Adjustments (Injection pump timing)
1. Engine stop
2. Turn the crankshaft to place in No.1 Cylinder at top dead center oncompression stroke3. Loosen injection pipe4. Loosen injection mounting bolts and nuts5. Remove timing check plug from injection pump head
6. Attach the special tool and a dial gauge7. Turn crankshaft to such a position that the notch on pulley is at
approximately 30 before top dead center. Then , set dial indicator to
zero.
-
7/24/2019 Bomba Terracan Electronica
34/39
34
8. Slightly turn crankshaft clockwise and counterclockwise to make sure
that dial indicator pointer does not deviate from zero position.9. Turn the crankshaft in the normal direction and position the notch of
crankshaft pulley at 5 ATDC. (N/A : 5 T/C : 7 TCI : 7 )
10. If the dial indicator does not indicate the specified value.
Tilt the injection pump body to the right or left until the indicator doesindicate the standard value.
11. Tighten mounting bolt of injection bolts and nuts.
12. Remove special tool and dial gauge
13. Install timing check plug with new copper gasket
Basic Adjustments (Injection pump timing)
-
7/24/2019 Bomba Terracan Electronica
35/39
35
1. Warm up temperature
2. Remove upper timing belt cover and rocker cover
3. Turn the crankshaft clockwise and align the timing mark on the
camshaft sprocket with the timing mark
4. Check the valve clearance indicated in the
diagram(A)
Standard clearance : 0.25mm(0.098in)
5. If not within the standard value, adjust the valve clearance with theadjusting screw and the thickness gauge
6. Rotate clockwise the crankshaft one complete turn (360 )
7. Check the valve clearance indicated in the diagram(B)
Standard clearance : 0.25mm(0.098in)
Basic Adjustments (Valve clearances)
-
7/24/2019 Bomba Terracan Electronica
36/39
36HI-Scan
-
7/24/2019 Bomba Terracan Electronica
37/39
37HI-Scan
Current Data
See Page 39
-
7/24/2019 Bomba Terracan Electronica
38/39
38HI-Scan
Actuation Test
-
7/24/2019 Bomba Terracan Electronica
39/39
39HI-Scan DTC List
No DTC No Conents MIL
1 P0105 BAROMETRIC SENSOR - MAL X
2 P0110 INT - AIR TEMP CIRCUIT - NAL X
3 P0115 ENG COOLANT TEMP - MAL O
4 P0120 ACCEL P. SENSOR - MAL X
5 P0121 APS. RANGE / PERFORMANCE - MAL O
6 P0180 FUEL TEMP. SENSOR - CIRCUIT-MAL X
7 P0320 ENGINE SPEED INPUT CIRCUIT - MAL X
8 P0335 CRANKSHAFT P. SENSOR - MAL X
9 P0500 VEHICLE SPEED SENSOR - MAL X
10 P0600 IMMOBILZER COMMUNICATION - MAL O
11 P0605 CONTROL MODULE (EEPROM) - ROM MAL X
12 P0613 ECU - MALFUNCTION X
13 P1116 BOOST PRESSURE SENSOR - MAL O
14 P1120 ELECTRIC GOVERNOR - MAL O
15 P1122 BOOST PRESSURE CONTROL VALVE - MAL O
16 P1123 TIMER POSITION SENSOR - MAL X
17 P1127 CONTOL SLEEVE POSITION SENSOR - MAL O
18 P1131 INJECTION QUANTITY ADJUST - MAL X
19 P1135 INJECTION TIMING SERVO - MAL X
20 P1324 GLOW RELAY - MALFUNCTION O
21 P1522 BATTERY VOLTAGE ERROR O
22 P1525 5V SOURCE VOLTAGE X
23 P1621 FUEL CUT VALVE - MAL O