2. ENGINE CONTROL 1. Components Layout 2. Operation 3. Testing & Adjusting Adolfo October 1997
992G WHEEL LOADER CHAPTER : ENGINE CONTROL
ENGINE OIL COOLER
ENGINE OIL PUMP
Page:
2-2
COOLANT FLOW SWITCH
992G WHEEL LOADER CHAPTER : ENGINE CONTROL
FUEL PRIMING PUMP
PRIMARY FUEL FILTERS
Page:
2-3
SECONDARY FUEL FILTERS
ENGINE ECM
Page:
2-4
CYLINDER HEADS MUI AND EUI
EUI MUI
992G WHEEL LOADER CHAPTER : ENGINE CONTROL
Page: 2-5
ECM TRANSFER PUMP FUEL TANK PRIMARY FILTER FUEL TANK
992G WHEEL LOADER
FUEL PRESSURE REGULATOR
CHAPTER : ENGINE CONTROL
SECONDARY FILTER
Page: 2-6
3508B FUEL SUPPLY CIRCUIT FUEL PRESSURE REGULATOR
RETURN FUEL
CYLINDER HEAD
PRIMING PUMP SUPPLY
FUEL TRANSFER PUMP
ECM
992G WHEEL LOADER
FUEL TANK
PRIMARY FUEL FILTER
SECONDARY FUEL FILTERS
CHAPTER : ENGINE CONTROL
DIFFERENTIAL PRESSURE SWITCH
Page:
BASIC ENGINE BLOCK DIAGRAM
CAT Data Link
P26 T/C CONNECTOR
ECM
2-7 SPEED/TIMING SENSOR COOLANT TEMPERATURE SENSOR
J1 GROUND BOLT
15 AMP BREAKER
MACHINE INTERFACE CONNECTOR
UNFILTERED OIL PRESSURE SENSOR
AFTERCOOLER TEMPERATURE SENSOR
FILTERED OIL PRESSURE SENSOR
LOW OIL LEVEL SWITCH
ATMOSPHERIC PRESSURE SENSOR
THROTTLE POSITION SENSOR
BATTERY
24 V
KEY START SWITCH GROUND LEVEL SHUTDOWN SWITCH
THROTTLE BACK-UP SWITCH + BATTERY
COOLANT FLOW SWITCH
RIGHT TURBOCHARGER INLET PRESSURE SENSOR
LEFT TURBOCHARGER EXHAUST TEMPERATURE SENSOR
TURBOCHARGER OUTLET PRESSURE SENSOR CRANKCASE PRESSURE SENSOR ENGINE FAN CONTROL SOLENOID
A/C ON SWITCH FAN PRESSURE SENSOR
RELAY ENGINE ETHER START VALVE USER DEFINED SHUTDOWN ELECTRONIC SERVICE TOOL CONNECTOR
992G WHEEL LOADER
LEFT TURBOCHARGER INLET PRESSURE SENSOR
CYLINDER STARTING AID SWITCH
CHAPTER : ENGINE CONTROL
FUEL FILTER DIFFERENTIAL PRESSURE SWITCH
RIGHT TURBOCHARGER EXHAUST TEMPERATURE SENSOR
DISCONNECT SWITCH
GROUND BOLT
J2 8/12/16 INJECTORS
APPLICATION BLOCK DIAGRAM
Page: 2-8
A B C
ENGINE OIL PRESSURE SENSOR
+V ANALOG ANALOG RETURN SIGNAL
A B C
TURBO OUTLET PRESSURE SENSOR
+V ANALOG ANALOG RETURN SIGNAL
A B C
RIGHT TURBO INLET PRESSURE SENSOR
+V ANALOG ANALOG RETURN SIGNAL
A B C
36 30
ECM +V ANALOG SUPPLY ANALOG RETURN
5 ± 0.5 VOLTS +V ANALOG ANALOG RETURN SIGNAL
A B C
LEFT TURBO INLET PRESSURE SENSOR
+V ANALOG ANALOG RETURN SIGNAL
A B C
CRANKCASE PRESSURE SENSOR
+V ANALOG ANALOG RETURN SIGNAL
A B C
+V ANALOG ANALOG RETURN SIGNAL
A B C
FAN PUMP PRESSURE SENSOR
992G WHEEL LOADER
ATMOSPHERIC PRESSURE SENSOR
CHAPTER : ENGINE CONTROL
ENGINE COOLANT TEMPERATURE SENSOR
+V ANALOG ANALOG RETURN SIGNAL
Page:
8 ± 0.5 VOLTS
2-9 THROTTLE POSITION SENSOR
J35 P35
+V DIGITAL DIGITAL RETURN SIGNAL
A B C
LEFT EXHAUST TEMPERATURE SENSOR +V DIGITAL DIGITAL RETURN SIGNAL
+ V DIGITAL SUPPLY - V DIGITAL RETURN
J30 P30 A B C
J31 P31 A B C
12 ± 1 VOLTS SPEED TIMING SENSOR +V DIGITAL DIGITAL RETURN SIGNAL
J84 P84 A B C
P1 J1 32 29 38
ENGINE ECM + 12V SPD//TIM SNSR SUPPLY DIGITAL RETURN ENG SPEED/TIMING SNSR
992G WHEEL LOADER
+V DIGITAL DIGITAL RETURN SIGNAL
29 35
ECM
CHAPTER : ENGINE CONTROL
RIGHT EXHAUST TEMPERATURE SENSOR
P1 J1
992G WHEEL LOADER CHAPTER : ENGINE CONTROL
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
Page:
2-10
Page: 2-11 98%
8,210
96%
8,920
94%
9,630
92%
10,340
90%
11,050
88%
11,760
86%
12,470
84%
13,180
82%
13,890
80%
14,600
78%
15,310
76%
16,020
74%
16,730
72%
17,440 77
76
75
74
73
72
71
70
69
68
67
66
65
64
63
62
61
60
ATMOSPHERIC PRESSURE IN kPa
59
58
57
56
55
54
53
ALTITUDE IN FEET
7,500
992G WHEEL LOADER
100%
CHAPTER : ENGINE CONTROL
PERCENT OF FULL LOAD POWER
ACCORDING TO ATMOSPHERIC PRESSURE
Page: 2-12 340
49.3
320
46.4
300
300
43.5
250
260
E IN
240 220
ET
200
L
R
NE
94
26.1
LI
23.2
LOW OIL PRESSURE REGION
20.3 17.4 14.5
80 60 50 40
11.6 8.7
44
600
700
800
900
1000
1100
1200
1300
1400
ENGINE RPM kPa x 0.145 = PSI
1500
1600
1700
1800
1900
2000
992G WHEEL LOADER
P
I TR
140
100
31.9 29
160
120
34.8
ES
180
37.7
OIL PRESSURE IN PSI
40.6
CHAPTER : ENGINE CONTROL
OIL PRESSURE IN kPa
280
Page:
2-13
TRADE MARK
992G WHEEL LOADER CHAPTER : ENGINE CONTROL
E-TRIM CODES
SERIAL No. BAR CODE
TRIM CODE
SERIAL No. PART No.
992G WHEEL LOADER CHAPTER : ENGINE CONTROL
COLD START LOGIC
ECM automaticalty stop injection to non- firing injectors until the engine warm up based on water temp.
ECM cutout each cylinder for a brief amount of time to see if that injector is contributing to power. If not, injection will be stop to that cylinder, ECM will retest any cutout cylinder every so often.
HELPS REDUCE WHITE SMOKE DURING ENGINE WARM UP
Page:
2-14
Page: 2-15
ENGINE ECM FEATURES • Throttle Lock 992G WHEEL LOADER
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
Page:
2-17
992G WHEEL LOADER CHAPTER : ENGINE CONTROL
HYDRAULIC ENGINE FAN CONTROL CIRCUIT
HYDRAULIC FAN SOLENOID VALVE
2 1
COOLANT TEMP SENSOR
ENGINE ECM
P2 J2
P86 J86 F700-BU E799-BR
997OR 993BR 995-BU
IMPLEMENT OIL TEMP SENSOR I/F 1
19 07
HYDRAULIC FAN PWM DRIVE AND SOL RETURN
36 30 09
+5V ANALOG SUPPLY ANALOG SENSOR RETURN COOLANT TEMP SENSOR
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 Page:
2-18
992G WHEEL LOADER CHAPTER : ENGINE CONTROL
P2 J2
ETHER INJECTION SYSTEM ETHER SWITCH
J3
SPEED TIMING SENSOR
P1 J1
P3
23 9 39 21
CONTROL GROUP (3408E/E3412E)
F708-YL 998-BR 721-GY 710-BR
28 29 19 40
ETHER SW LAMP DIGITAL RETURN ETHER REQUEST ETHER CONTROL
COOLANT TEMP SENSOR
200-BK 200-BK +
308-YL
+24V
310-PK
P37 J37 1 2
RELAY
FROM CYLINDER
ETHER START VALVE
TO ENGINE
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
