Service Training

MALAGA

ELECT. ENG. CONTROL

VI. 3400 HEUI

- SYSTEM
- INJECTOR
- PRIME RATE SHAPING
- COMPONENTS
- SENSORS
CLAUDE
SEPT. 1997

Page:
2

HIGH PRESSURE OIL MANIFOLD

40 to 210 BAR

High Pressure
Oil Pump

Oil
Filter

Oil
Cooler

LOW PRESSURE 3 BAR

Oil
Pump

Oi
lS
u
m
p

ECM
Vehicle
System

Fuel
Trans
Pump

Fuel Tank

ELECT. ENG. CONTROL

Fuel
Filter

CHAPTER : 3400 HEUI

Engine System

HEUI SYSTEM

Fuel Return Line

Regulator
Pressure
Control
Valve

ELECT. ENG. CONTROL

CHAPTER : 3400 HEUI
INJECTOR COMPONENTS

SPACER

SLEEVE

ARMATURE
VALVE
SOLENOID

VALVE BODY

SHIM
BARREL
ADAPTER

PISTON

WASHER
UPPER FUEL SEAL

PLUNGER
FUEL INLET
CHECK VALVE

PIN
SLEEVE
SPACER
LOWER FUEL SEAL
CHECK
NOZZLE

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ELECT. ENG. CONTROL

CHAPTER : 3400 HEUI
INJECTION CYCLE

Page:

ELECT. ENG. CONTROL

CHAPTER : 3400 HEUI
DRAIN CYCLE

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ELECT. ENG. CONTROL

CHAPTER : 3400 HEUI
NOZZLE GROUP

NOZZLE GROUP

REVERSE FLOW
CHECK VALVE

CHECK VALVE
FUEL
ATOMIZATION

Page:

ELECT. ENG. CONTROL

CHAPTER : 3400 HEUI
PRIME RATE SHAPING

CROSS SECTION
OF PLUNGER

START OF INJECTION

PRESSURE DROP

FINAL
PRESSURE INCREASE

INJECTION
RATE

START OF
INJECTION

DURATION
TIME (MILLISECONDS)

Page:

END OF
INJECTION

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8

TO LUBE
SYSTEM
HEUI
HYDRAULIC
TEMPERATURE
SENSOR
COLD START
OIIL
RESERVOIR

OIL
FILTER

HYDRAULIC MANIFOLD

OIL PRESSURE
SENSOR
COOL DOWN
CIRCUIT

HYDRAULIC
SUPPLY
PUMP
GROUP

HYDRAULIC
PRESSURE
SENSOR

FUEL
TEMPERATURE
SENSOR

OIL
COOLER
FUEL
TRANSFER
PUMP

LUBE OIL
PUMP

SECONDARY
FUEL
FILTER

PRIMARY
FUEL FILTER
WATER
SEPARATOR
OIL
SUMP

FUEL TANK

PRESSURE
REGULATING
VALVE

ELECT. ENG. CONTROL

HEUI
ECM

CHAPTER : 3400 HEUI

PUMP
CONTROL
VALVE

FUEL SYSTEM

HYDRAULIC MANIFOLD

Page:
9

TO LUBE
SYSTEM
HEUI
HYDRAULIC
TEMPERATURE
SENSOR
COLD START
OIL
RESERVOIR

OIL
FILTER

HYDRAULIC MANIFOLD

OIL PRESSURE
SENSOR
COOL DOWN
CIRCUIT

HYDRAULIC
SUPPLY
PUMP
GROUP

FUEL
TRANSFER
PUMP

LUBE OIL
PUMP

SECONDARY
FUEL
FILTER

PRIMARY
FUEL FILTER
WATER
SEPARATOR
OIL
SUMP

FUEL TANK

PRESSURE
REGULATING
VALVE

ELECT. ENG. CONTROL

OIL
COOLER

CHAPTER : 3400 HEUI

HEUI
ECM

OIL SYSTEM

HYDRAULIC MANIFOLD

CHECK
VALVES
PUMP
CONTROL
VALVE

HYDRAULIC
PRESSURE
SENSOR

FUEL
TEMPERATURE
SENSOR

ELECT. ENG. CONTROL

CHAPTER : 3400 HEUI

INJECTION PRESSURE

PRESSURE CONTROL

HEUI

MECHANICALLY ACTUATED
FUEL SYSTEM

IDLE

Page:

10

ENGINE SPEED

Page:
11

INJECTOR OIL
ADAPTER

INJECTOR

JUMPER BLOCK

LUBE OIL PASSAGE

COOLANT

ELECT. ENG. CONTROL

LOW PRESSURE
FUEL SUPPLY

CHAPTER : 3400 HEUI

FLUID SUPPLY
MANIFOLD

FLUID FLOW MANIFOLD

HIGH
PRESSURE
HYDRAULIC
PASSAGE

ELECT. ENG. CONTROL

CHAPTER : 3400 HEUI
HIGH PRESSURE PUMP

PRIMING PORT

ORIFICE
DRAIN PASSAGE
RESERVOIR

SWASHPLATE

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12

COMPENSATOR
VALVE

VALVE BASE
TRANSFER PUMP

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13

COIL
ASSEMBLY

STOP

PIN POPPET ADAPTER SEAL

SEAT CAGE

FROM
HYDRAULIC
PUMP

STATOR
EDGE FILTER

SHELL

RING

TO
CASE DRAIN

VALVE
BLOCK

ELECT. ENG. CONTROL

PIN

CHAPTER : 3400 HEUI

ARMATURE SOLENOID

PUMP CONTROL VALVE

SPRING
RETAINER

Page:
14

TO LUBE
SYSTEM
COLD START
RESERVIOR

DISPLACEMENT
CONTROL PISTON

PRESSURE
LIMITER
SPOOL

TO LEFT OIL
MANIFOLD

OIL SUMP

PUMP
CONTROL
VALVE

PUMP CASE DRAIN

ELECT. ENG. CONTROL

SOLENOID
(ENERGIZED)

CHAPTER : 3400 HEUI

TO RIGHT OIL
MANIFOLD

HYDRAULIC CONTROL SYSTEM (start)

LOAD
SENSING
SPOOL

ELECT. ENG. CONTROL

CHAPTER : 3400 HEUI
SYSTEM LIMITS & DERATE

FUEL SYSTEM LIMITS

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
SYSTEM DERATES
DERATES
FUEL
AUTOMATIC ALTITUDE COMPENSATION
AUTOMATIC
ALTITUDE COMPENSATION
( Altitude derate)
( Altitude derate)

AUTOMATICFILTER
FILTERCOMPENSATION
COMPENSATION
AUTOMATIC

( Derateforforairairfilter
filterrestriction
restrictionif ifinstalled
insatalled
( Derate
)
At 6.25 kPa (30 inc of water) the engine will
derate 2%
of its powerDERATE
per 1 kPa until a maxi 20%
ENGINE
WARNING
Event is logged if exeeds 30 inch of water )
( Derates for LOW OIL PRESSURE, HIGH COOLANT TEMP
not install in HEUI at the time)

ENGINE WARNING DERATE

( Derates for LOW OIL PRESSURE , HIGH COOLANT TEMP

not installed yet on HEUI)

Page:

15

ELECT. ENG. CONTROL

CHAPTER : 3400 HEUI
COMPONENTS DIAGRAM

8 OR 12
INJECTORS

ENGINE
HARNESS
MACHINE
HARNESS
PUMP CONTROL VALVE
HYDRAULIC
PRESSURE SENSOR
PRIMARY
SPEED/TIMING SENSOR
SECONDARY
SPEED/TIMING SENSOR
COOLANT TEMP. SENSOR

TURBO OUTLET PRESS. SENSOR

ATMOSPHERIC PRESS. SENSOR

OIL PRESSURE SENSOR
HYDRAULIC TEMP. SENSOR
FUEL TEMPERATURE SENSOR
COOLANT FLOW SWITCH

Page:

16

TDC SERVICE
PROBE ACCESS

ELECT. ENG. CONTROL

CHAPTER : 3400 HEUI
SENSORS, ANALOG DIGITAL

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
Page:

17

ELECT. ENG. CONTROL

CHAPTER : 3400 HEUI
HYDRAULIC PRESSURE SENSOR

8 OR 12
INJECTORS

ENGINE
HARNESS
MACHINE
HARNESS
PUMP CONTROL VALVE
HYDRAULIC
PRESSURE SENSOR

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 ) .

Page:

18

ELECT. ENG. CONTROL

CHAPTER : 3400 HEUI
COOLANT TEMPERATURE SENSOR

8 OR 12
INJECTORS

ENGINE
HARNESS
MACHINE
HARNESS

COOLANT TEMP. SENSOR

High coolant temperature EVENT LOGGED above

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

Page:

19

ELECT. ENG. CONTROL

CHAPTER : 3400 HEUI
ATMOSPHERIC PRESSURE SENSOR

8 OR 12
INJECTORS

ENGINE
HARNESS
MACHINE
HARNESS

ATMOSPHERIC PRESS. SENSOR

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

Page:

20

ELECT. ENG. CONTROL

CHAPTER : 3400 HEUI
TURBO IN & OUT PRESSURE SENSOR

8 OR 12
INJECTORS

ENGINE
HARNESS
MACHINE
HARNESS

TURBO
INLET
OUTLET
PRESSURE

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

Page:

21

Page:
22
300

43.5

280

40.6

260

37.7

240

34.8

220

31.9

200

29

180

26.1

160

23.2

140

20.3

120

17.4

100

14.5

80

11.6
8.7

60
600

700

800

900

1000

1100

1200

1300

1400

1500

1600

1700

1800

ENGINE RPM
If the oil pressure decrease below the lower line
an event , warning and engine 15 % derate are generated

1900

2000

ELECT. ENG. CONTROL

46.4

CHAPTER : 3400 HEUI

320

OIL PRESSURE MAP

49.3

OIL PRESSURE IN PSI

OIL PRESSURE IN kPa

340

ELECT. ENG. CONTROL

CHAPTER : 3400 HEUI
HYDRAULIC OIL TEMP SENSOR

8 OR 12
INJECTORS

ENGINE
HARNESS
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)

Page:

23

ELECT. ENG. CONTROL

CHAPTER : 3400 HEUI
FUEL TEMP SENSOR

8 OR 12
INJECTORS

ENGINE
HARNESS
MACHINE
HARNESS

FUEL TEMP.ERATURE
SENSOR

This sensor is used to make correction to fuel rate in

order to maintain power . This feature is called
FUEL TEMPERATURE COMPENSATION

Page:

24

ELECT. ENG. CONTROL

CHAPTER : 3400 HEUI
THROTTLE POSITION, PUMP CONT VAL

8 OR 12
INJECTORS

ENGINE
HARNESS
MACHINE
HARNESS
PUMP CONTROL VALVE

THOTTLE
SENSOR

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

Page:

25

ELECT. ENG. CONTROL

CHAPTER : 3400 HEUI
TIMING WHEEL

TDC
CYL No. 1
SINGLE
50/50 TOOTH

Page:

26

Page:
27

INJECTION
RATE
POPPET
LIFT

CURRENT

CU
RR
EN
T
FLO
W

START OF
LOGIC

1
START OF
INJECTION

TIME (MILLISECONDS)

ELECT. ENG. CONTROL

CHAPTER : 3400 HEUI

DURATION

WAVE FORM

END OF
INJECTION