Service Training

MALAGA

ELECT. ENG. CONTROL

VI. 3400 HEUI

- SYSTEM
- INJECTOR
- PRIME RATE SHAPING
- COMPONENTS
- SENSORS

CLAUDE
SEPT. 1997
Page:

HIGH PRESSURE OIL MANIFOLD

2

High Pressure
40 to 210 BAR
Oil Pump

HEUI SYSTEM

CHAPTER : 3400 HEUI

Regulator Fuel Return Line
Pressure
Control

ELECT. ENG. CONTROL

Valve
Engine System
Fuel
Filter

ECM
Oi Fuel
lS Trans
Oil Oil u Vehicle Pump
Oil
Filter Cooler Pump
m System
p

LOW PRESSURE 3 BAR Fuel Tank

 ELECT. ENG. CONTROL
CHAPTER : 3400 HEUI

INJECTOR COMPONENTS

SPACER
SLEEVE
ARMATURE

VALVE

VALVE BODY SOLENOID

SHIM
BARREL
ADAPTER

PISTON WASHER

UPPER FUEL SEAL

PLUNGER

FUEL INLET
CHECK VALVE

PIN
SLEEVE
SPACER

LOWER FUEL SEAL

CHECK
NOZZLE

Page: 3
 ELECT. ENG. CONTROL
CHAPTER : 3400 HEUI

INJECTION CYCLE

Page: 4
 ELECT. ENG. CONTROL
CHAPTER : 3400 HEUI

DRAIN CYCLE

Page: 5
 ELECT. ENG. CONTROL
CHAPTER : 3400 HEUI

NOZZLE GROUP

NOZZLE GROUP

REVERSE FLOW
CHECK VALVE

CHECK VALVE

FUEL
ATOMIZATION

Page: 6
 ELECT. ENG. CONTROL
CHAPTER : 3400 HEUI

PRIME RATE SHAPING

CROSS SECTION
OF PLUNGER

FINAL
START OF INJECTION PRESSURE DROP PRESSURE INCREASE

INJECTION
RATE

START OF END OF
INJECTION DURATION INJECTION

TIME (MILLISECONDS)
Page: 7
Page:

TO LUBE
8

SYSTEM

HEUI
HYDRAULIC
TEMPERATURE
SENSOR
COLD START
OIIL
RESERVOIR HYDRAULIC MANIFOLD
OIL PRESSURE
SENSOR
COOL DOWN FUEL HYDRAULIC
HYDRAULIC CIRCUIT TEMPERATURE PRESSURE
SUPPLY SENSOR SENSOR
PUMP
OIL GROUP
FILTER
HYDRAULIC MANIFOLD

FUEL SYSTEM

CHAPTER : 3400 HEUI

ELECT. ENG. CONTROL
PUMP
CONTROL HEUI
VALVE ECM
OIL
COOLER

FUEL
TRANSFER SECONDARY PRESSURE
LUBE OIL PUMP FUEL REGULATING
PUMP FILTER VALVE
PRIMARY
FUEL FILTER
WATER
SEPARATOR

OIL
SUMP FUEL TANK
Page:

TO LUBE
9

SYSTEM

HEUI
HYDRAULIC
TEMPERATURE
SENSOR
COLD START
OIL
RESERVOIR OIL PRESSURE HYDRAULIC MANIFOLD
SENSOR
COOL DOWN FUEL HYDRAULIC
HYDRAULIC CIRCUIT TEMPERATURE PRESSURE
SUPPLY SENSOR SENSOR
PUMP
OIL GROUP
FILTER
HYDRAULIC MANIFOLD

OIL SYSTEM

CHAPTER : 3400 HEUI

CHECK
VALVES

ELECT. ENG. CONTROL

PUMP
CONTROL HEUI
VALVE ECM
OIL
COOLER

FUEL
TRANSFER SECONDARY PRESSURE
LUBE OIL PUMP FUEL REGULATING
PUMP FILTER VALVE
PRIMARY
FUEL FILTER
WATER
SEPARATOR

OIL
SUMP FUEL TANK
 ELECT. ENG. CONTROL
CHAPTER : 3400 HEUI

PRESSURE CONTROL
INJECTION PRESSURE

HEUI

MECHANICALLY ACTUATED
FUEL SYSTEM

IDLE
ENGINE SPEED

Page: 10
Page:
11

INJECTOR OIL
ADAPTER
JUMPER BLOCK

INJECTOR LUBE OIL PASSAGE

HIGH
PRESSURE
HYDRAULIC
PASSAGE

CHAPTER : 3400 HEUI

FLUID FLOW MANIFOLD
FLUID SUPPLY
MANIFOLD

ELECT. ENG. CONTROL

LOW PRESSURE
FUEL SUPPLY

COOLANT
 ELECT. ENG. CONTROL
CHAPTER : 3400 HEUI

HIGH PRESSURE PUMP

COMPENSATOR
PRIMING PORT
VALVE

ORIFICE VALVE BASE

DRAIN PASSAGE
TRANSFER PUMP
RESERVOIR

SWASHPLATE

Page: 12
Page:
13

FROM
COIL HYDRAULIC
ASSEMBLY PIN POPPET ADAPTER SEAL SEAT CAGE PUMP

STOP STATOR

EDGE FILTER

PUMP CONTROL VALVE

CHAPTER : 3400 HEUI

ELECT. ENG. CONTROL
SPRING
RETAINER

TO VALVE
ARMATURE SOLENOID PIN SHELL RING CASE DRAIN BLOCK
Page:
14

TO LUBE
SYSTEM
COLD START DISPLACEMENT
RESERVIOR CONTROL PISTON PRESSURE
LIMITER
SPOOL

LOAD

HYDRAULIC CONTROL SYSTEM (start)

CHAPTER : 3400 HEUI

SENSING
SPOOL

ELECT. ENG. CONTROL

TO RIGHT OIL
MANIFOLD SOLENOID
(ENERGIZED)
TO LEFT OIL
MANIFOLD PUMP
CONTROL
VALVE

PUMP CASE DRAIN

OIL SUMP
 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
FUEL SYSTEM DERATES
DERATES

AUTOMATIC ALTITUDE COMPENSATION

AUTOMATIC ALTITUDE COMPENSATION
( Altitude derate)
( Altitude derate)
AUTOMATICFILTER
AUTOMATIC FILTERCOMPENSATION
COMPENSATION
( Derateforforairairfilter
( Derate filterrestriction
restrictionif ifinstalled
insatalled
)
At 6.25 kPa (30 inc of water) the engine will
derate 2%
ENGINE of its powerDERATE
WARNING per 1 kPa until a maxi 20%
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
TDC SERVICE
PROBE ACCESS
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
 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

340 49.3

320 46.4

300 43.5

280 40.6

OIL PRESSURE IN PSI

OIL PRESSURE IN kPa

260 37.7

240 34.8

220 31.9

200 29
180 26.1

OIL PRESSURE MAP

CHAPTER : 3400 HEUI

160 23.2

140 20.3

ELECT. ENG. CONTROL

120 17.4
100 14.5

80 11.6

60 8.7
600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000

ENGINE RPM

If the oil pressure decrease below the lower line

an event , warning and engine 15 % derate are generated
 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

WAVE FORM

CHAPTER : 3400 HEUI

ELECT. ENG. CONTROL
END OF
INJECTION
FLO
CU
RR
EN

W
T

DURATION

0 1 2 3 4 5
START OF START OF TIME (MILLISECONDS)
LOGIC INJECTION