May CAT (Máy phụ trên tàu thủy)

Main components in Air inlet and exhaust system: Primary Air Filter.. Air manifold Inlet air from air cleaners Boost air Inlet air from air cleaners Exhaust out Main components in Air i

Lession 1 - MECHANICAL

The 3500 diesel engines entered production

in 1980 and have been available in 8, 12 and

16 cylinder configuration

All had the standard

4.3 liters per cylinder

displacement

High voltage:

Automatic starting:

Read the manual before

General hazard information:

Pressure air and water

Asbestos information:

Burn prevention:

1 Crankcase breather

2 To muffler

3 Air filter indicator

4 Air filter housing

5 Auxiliary water pump

6 Distribution box

7 Starting motor

8 Battery disconnect switch

1 Engine oil filler

2 Dipstick

3 Engine oil cooler

4 Engine oil pump

5 Water pump

5 4

5 Air filter element

 Cylinders arrangement: 60 degree Vee16.

 Valve per cylinder: 4/1 Cylinder.

 Air Inlet And Exhaust system

 Cooling system

 Lubrication system

 Fuel system

Purpose of air inlet and exhaust system:

 Provide enough clean air for combustion

 Remove heat and combustion gases, and

provide for efficient operation of turbochargers

 Any reduction in the flow of air or combustion

gases through systems reduces engine

performance

 Discharges spent gases to the atmosphere

7 Turbocharger (cartridge)

8 Turbocharger turbine

wheel

9 Exhaust Outlet

Main components in Air inlet and exhaust system:

 Primary Air Filter

 Secondary Air Filter

Air manifold

Inlet air from air cleaners Boost air

Inlet air from air cleaners Exhaust out

Main components in Air inlet and exhaust system:

Helps prevent smaller dirt and debris from entering the engine

Turbocharger:

Main components in Air inlet and exhaust system:

Helps maintain engine power at

high altitude, and increase

horsepower because it provides

the engine with more air,

enabling the fuel to burn more

Waste-gate

Main components in Air inlet and exhaust system:

 Waste gates are part of some turbochargers If

boost is higher than recommended, thewaste

gate opens to vent exhaust around turbine

 The reduced air flow slows down the turbine

After cooler:

Aftercooler is used to remove

heat from the inlet air

Main components in Air inlet and exhaust system:

After cooler:

Main components in Air inlet and exhaust system:

After cooler:

1 Jacket Water Aftercooled (JWAC)

2 Air To Air Aftercooled (ATAAC)

3 Separate Circuit Aftercooled (SCAC)

Main components in Air inlet and exhaust system:

Inlet manifold

Main components in Air inlet and exhaust system:

1 Emergency manual shutoff knob

2 Reset Knob

3 Hydraulic valve for the engine oil

Air Shutoff:

Lubrication oil protects engine components from

wear caused by movement, friction and heat

Schematic of lubrication system:

1 Main oil gallery

2 Camshaft oil gallery

3 Piston cooling jet gallery

4 Piston cooling jet gallery

5 Camshaft oil gallery

6 Turbocharger oil supply

11 Engine oil cooler

12 Engine oil cooler bypass valve

13 Engine oil relief valve

14 Engine oil pump

Oil pan:

Main components in lubrication system:

Oil pump and bypass valve:

Main components in lubrication system:

Oil cooler and bypass valve:

Main components in lubrication system:

Oil filter and bypass valve:

Main components in lubrication system:

Piston cooling jet:

Main components in lubrication system:

Crankcase breather:

Main components in lubrication system:

Purpose of cooling system:

The engine temperature need to be controlled

within a desire operating range to maximize fuel

combustion effeciency and to ensure that the

heat related damage does not occur When the

engine is cold, components also wear out faster

Typical Diesel engine heat balance:

Schematic of cooling system:

Radiator

By pass line

Expansion Tank Regulator Housing

Cylinder Head

1 Water pump

2 Oil cooler

3 Cylinder block and heads

4 Water manifold

5 Aftercooler

6 Water

Jacket water aftercooling:

Cooling system operation:

1 Engine Block

2 Engine Oil cooler

3 Water temperature regulator housing

4 Jacket water pump

5 Coolant tank for the Jacket water

6 After cooler

7 Thermostatic valve

8 Separate circuit water pump

 Passages in engine block and cylinder head

 Water temperature regulator and water

temperature regulator housing

 Radiator and cap

 Water lines

Main components in cooling system:

Water pump (Jacket water circuit):

Water pump provides flow in

the cooling system It takes

cooler liquid from the bottom

of the radiator and pushes it

through the system

Main components in cooling system:

Water pump (Separate circuit):

Main components in cooling system:

Oil cooler:

The oil cooler removes

heat from the lubricating

oil, which preserves the oil

‘s lubricating properties

Main components in cooling system:

Passages in the engine block and cylinder head:

These cavities that are

in the engine block and

cylinder head are

called the water jacket

Main components in cooling system:

Regulator (Thermostat)

The regulator controls

temperature It regulates the flow

of the coolant to the radiator

Main components in cooling system:

How the regulator works?

Regulator (Thermostat)

The regulator maintains a proper range of

operating temperatures To do this, the

regulator shunts coolant flow through the

radiator, or through a bypass tube back to

the water pump.

Main components in cooling system:

Purpose of fuel system:

Deliver clean fuel, at the right time and in the

right quantity, to meet the engine horsepower

demand.

Types of fuel systems:

1 Pump and line

2 Mechanical Unit Injector

1

2 3

4

5

6

12 11

10 9 8 7

10 Secondary fuel filter

11 Pressure regulating valve

12 Fuel Injection pump

Schematic of fuel system (pump and

line):

Fuel Systems Overview

-Pump & Lines System

• Multi-plunger, high pressure pump, fuel lines & fuel nozzles

• Flyweights and springs control fuel rate and timing

linkage and fuel

rack in fuel off

-• As the rack moves in

the fuel-on direction,

the scroll is rotated to

allow more fuel to be

injected

• As the rack moves in

the fuel-off direction,

the scroll is rotated to

Fuel Systems Overview Pump & Lines System

-• Limiting Factors:

 High pressure fuel

lines limit fuel injection pressure

 Fuel rate & timing

Fuel Systems Overview

-MUI System

• Advantages:

 High pressure fuel

lines are eliminated

6 Fuel return to tank.

7 Primary fuel filter

8 Fuel transfer pump

9 Fuel line to filter

10 Fuel supply line from the primary fuel filter

11 Fuel line to priming pump

Fuel system on 3516B engine:

Fuel pressure regulator and fuel priming pump:

Fuel transfer pump:

1 Fuel Tank.

2 Primary Fuel Filter

3 Fuel Transfer Pump

4 ECM

5 Secondary Fuel Filter

6 Injector

7 Pressure regulating valve

ADEM 2000 ADEM 2000 3406E Truck 3406E 3406E 3406E 14L 3406E 14L C-15

3176 2YG 3176 7LG 3176B Truck 3176B 3176B Added 16L 3406E 16L C-16

3456 C-10 C-10/3176C C-10/3176C C-10/3176C C-12 C-12/3196 C-12/3196 C-12/3196

3508 EUI D11, 777

3512/16 EUI 3500B

3116 HEUI 3116 HEUI C-9 HEUI

3126 HEUI 3126 HEUI 3126B HEUI 3126E HEUI

3400 V HEUI

Perkins 3000 MAK

3408 / 12 PEEC 3400 V PEEC

3512 PEEC MUI 3512 PEEC MUI

3600 PEEC 3406B PEEC 3406C PEEC

ADEM 2000 ADEM 2000 3406E Truck 3406E 3406E 3406E 14L 3406E 14L C-15

3176 2YG 3176 7LG 3176B Truck 3176B 3176B Added 16L 3406E 16L C-16

3456 C-10 C-10/3176C C-10/3176C C-10/3176C C-12 C-12/3196 C-12/3196 C-12/3196

3508 EUI D11, 777

3512/16 EUI 3500B

3116 HEUI 3116 HEUI C-9 HEUI

3126 HEUI 3126 HEUI 3126B HEUI 3126E HEUI

3400 V HEUI

Perkins 3000 MAK

Why Electronic Control?

• To satisfy customers demand for:

 increased horsepower

 better fuel economy

 better reliability

 easier serviceability

Main components in Electronic control system:

Electronic Components

• Control

 Personality Module

• Software that defines the horsepower and

torque of the engine

 Parameters

• Setting in the Personality Module

– Influence the overall operation or performance

Electronic Components

• Control

 Electronic Control Module (ECM)

• Can not be repaired and acts as a housing

for the electronic circuitry

 Data Links

• Used as a two way communication between

the engine and other electronic vehicle control systems

• The student will be able to properly

recognize the various electronic

• Require power from the ECM

• Must be powered to check operation

• 3 wire sensors: speed, speed/timing

• 4 wire sensors: PEEC position, level

• Requires break-out Tee to troubleshoot

Passive Sensors:

• Don't require power from the ECM; can

be checked while unplugged with VOM

• 2 wire: temp, speed, speed/timing

• Fewer wires - more cost efficient and

less mass

• May ohm sensor or use break-out Tee

Position Sensors

• Position sensors convert mechanical

component position into an electrical

signal for the ECM

 Throttle position sensor

 Rack position sensor

 Coolant level sensor

Throttle Position Sensor

• Provides continuous

“desired speed”

information from the

operator to the ECM

Pulse width modulated signals

• The operator uses a throttle lever,

accelerator pedal, rotary dial speed

control, or some other device to set a

“desired engine speed”

• The throttle position sensor or control

module (speed brick) generates a Pulse

Width Modulated signal (PWM) to

as the Duty Cycle

Pulse width modulated signals

• Sensor output is a

constant frequency

signal

• Pulse width (duty

cycle) varies with

pedal position

• Duty cycle = % of

time on vs % time

Throttle Position Sensors

• 1990 / 1993 - pedal mount, 12 volt, 3

wire, not painted

 Eliminated linkage problems

 Pulse width modulated signal

 HD connector with sockets

 Calibration can be done with service tool

 Low idle 10% to 22% High idle 75% to

90%

Throttle Position Sensors

• 1993 & up - pedal mount, 8

volt, 3 wire, painted

 DT connector with pins

 <5% or >95% will show code (ET)

• Same sensor used for many

applications

Position Sensors

 “A” wire is supply (red)

 “B” wire is ground (black)

 “C” wire is signal (white)

 “A” wire is supply (red)

 “B” wire is ground (black)

 “C” wire is signal (white)

Coolant Level Sensor

Temperature Sensors

Coolant temperature

• 5 volt active sensor

• High coolant temp.

• Very high coolant temp.

• “Cold Mode”

• Cooling fan driver

Temperature Sensors

Air inlet Temperature

• 5 volt active sensor

• Will warn operator if

intake manifold

temperature is high

• Will not cause derate

or shutdown of engine

Pressure Sensors

• Oil Pressure sensors

• Measures oil pressure

in the oil gallery

• Low oil pressure

warning

• Very low oil pressure

warning

Speed Timing Sensor

• The engine speed /

timing sensor

provides pulse

signals to the ECM

• The signals are

created as the

camshaft timing

Speed Timing Sensor

• Both active and passive speed & timing sensors

• Active:

 3176 & 3500 (all “fat” ECMs) 12.5 V, brass

 C-10, C-12, 3406E, 3500B, 3400 HEUI 13.2 V steel alloy

• Passive:

 1998 3126B HEUI

 1999 C-10, C-12, 3406E

 ADEM II 3126

 All ADEM III

Speed Timing Sensor

• 3176, 3176B, 3406E, 3456, C-10, C-12, 3126, 3500

and 3500B

 A unique tooth pattern on the camshaft timing gear

allows the ECM to determine camshaft position and

engine speed

 Cam timing reference gear – 24 teeth, 21 large, 3

small

1 After cooler temperature sensor.

2 Connector.

3 Speed / timing sensor.

Input:

Speed / timing sensor and

Input:

1 Timing wheel.

2 Speed timing sensor.

3 Dowel pin.

4 50/50 size slot and tooth.

Input:

Timing wheel:

12 10

1 Left turbocharger inlet pressure sensor

2 Exhaust temperature sensor (LH)

3 Connector for the CAN data link

4 Engine ECM

Location of the 3516B Engine sensors:

11 ECM Connector J2 / P2).

12 ECM Connector J1 / P1)

Location of the 3516B Engine sensors:

1

12 11 10

9 8 7

14 Exhaust temperature sensor (RH)

15 Crankcase pressure sensor

16 Connector for the

Location of the 3516B Engine sensors:

20 Turbocharger outlet pressure sensor.

21 Rear after cooler temperature sensor

Location of the 3516B Engine sensors:

Exhaust Temperature Sensor

Location of the 3516B Engine sensors:

Location of the 3516B Engine sensors:

Turbo Inlet Pressure Sensor

Crankcase Pressure Sensor

Location of the 3516B Engine sensors:

Fuel Pressure Sensors

Filtered

Unfiltered

Output:

EUI - Injector Fill

• Without pressure

from the rocker arm,

a spring keeps the plunger retracted

• Fuel flows into the

injector through the fill / spill port, past the poppet valve and into the barrel

EUI - Mechanical Stroke

• As the cam rotates, it drives the plunger downward

• Until the ECM signals the start

of injection, fuel

EUI - Injection

• On a signal from the ECM, the solenoid closes the poppet valve

• Pressure elevates

at the tip to the 5,500 psi needed

to unseat the nozzle check / tip

• Injection begins

EUI - Injection

• Fuel continues to inject until the ECM signals the solenoid to open the valve

• Injection timing and duration is controlled by the

EUI - Injector Fill

• Without pressure

from the rocker arm,

a spring keeps the plunger retracted

• Fuel flows into the

injector through the fill / spill port, past the poppet valve and into the barrel

Operation:

Pre-injection Injection End Injection Fill

Electronic Control Modules

Objectives:

• The student will understand the basic

functions of the Electronic Control

Modules.

• The student will be able to recall the

Electronic Control Module

• Do we need to know exactly how an ECM

works? …… NO

 We can’t work on it or fix it

• We need to know …

 How it interacts with the engine

 How to use it to troubleshoot wiring harness

and sensor problems

 How it can be used to get the most from the

engine

Concerns

– but how it interacts with the engine

• Focus

 Steps needed to troubleshoot the ECM

 Wiring harnesses or sensors

 How parameters can optimize the

performance of the ECM

Electronic Control Module

To work an ECM needs …

• Power from the battery

• A personality module

• Parameters

• Input from sensors

ECM Main Function

• Powers the components

necessary for proper operation

• Monitors their input

through a return signal

• After Powering and

• 1995 up – FLASH only (truck)

Points on the ADEM II

• Introduced in 1993

• First ECM to have two connectors

• At first – a personality module that

could be FLASHED

• OEM and Caterpillar connections (two

40 pin connectors)

• Dual 16 bit microprocessors

Points on the ADEM II

• On truck from 1993 to 1998

• Non Truck 1994 to 2001

• 1995 no longer produces engines

with removal personality modules

• Fuel directed through

the ECM housing

 Maintains a constant ECM temperature

Second Circuit Board

• Allows the ECM

to be used on larger engines

Main Circuit Board

Processor Circuit Board

ECM Monitoring

• Includes engine monitoring:

 Engine oil pressure

 Coolant temperature

 Inlet manifold air

temperature

ECM Monitoring

• Coolant level sensor:

 Only sensor that can be

individually selected for Engine Monitoring

 Off Mode

 Warning Mode

 Derate and Shutdown Mode

ADEM - III

ADEM – III (ADEM 2000)

• Dual 70 Pin Connector

• All on-highway truck

• 3126B/E HEUI

• Personality Module:

 FLASH Only

• Fuel passage may or may not be

connected to ECM housing

ADEM – III (ADEM 2000)

• Not possible to take ECM from 3126E to use on C-10

• HEUI ECM has a different part number

• Different I/O because of the IAPC Valve and HEUI Sensor

• Wrong FLASH file given will