Tài liệu đào tạo Động cơ Power Tec D6CA

Learning Goals (You can…)  Understand Major Features Of Powertec Engine  Understand Overall Mechanical Structure Of The Powertec Engine  Understand Fuel Delivery System  Install Each Timing Gear Correctly  Adjust Injector Pre Stroke, Valve Clearance, Jake Brake Clearance  State Input Element Of The Engine Management System  State Output Element Of The Engine Management System  Understand Sensors’ Functions  Understand How To Use Hi-scan Pro  Read Trouble Codes  Troubleshoot With/Without Scan Tool  Repair Powertec Engine Table of Contents General Structure 11 Lubrication System 26 Intake & Exhaust System 29 Fuel System 32 Jake Brake System 47 Engine Management System 52 Question Discussion General General Electronic Diesel Control - Injection amount and timing is controlled by computer - Increased fuel consumption ratio and extremely decreased smoke Maintenanceability - Engine Check and Warning System - Limp Home Function - Self -Diagnosis Drivability - Automatic Cruise Control - PTO Control - Speed Limit Device System Layout Cam shaft Position Sensor Unit Injector Coolant Temperature Sensor Intake Air Temperature & Pressure Sensor Engine Harness ECU Vehicle Harness Crank shaft Position Sensor System Layout Fuel Filter D6CA ECU ECU Fuel Pump D6CB Specifications Items Description Model D6CA D6CB Displacement (cc) 12,920 12,300 Max output power(ps/rpm) 440/1900 440/1800 Max Torque (kg·m/rpm) 197/1,400 206/1,200 Cylinder I.D × Stroke 133×155 130×155 Length 1520.3 1520.3 Width 897.5 966.1 Weight (dry) 1202.2 1217 Engine Dimension Specifications Items Description No of cylinder Compression Ratio 17:1 Firing Order 1-5-3-6-2-4 Air Intake Turbo-Charger ＋ Intercooler Coolant Quantity (L) 30 Engine Idle Speed (RPM) 500 Starter Motor (V-kw) 24-7 Oil Quantity (L) Bus : 30, Truck : 24 Tightening Torque of Major Parts Items Cylinder head Bolt Torque (kgm) New Re-use 16 ＋ 60˚ ＋ 60˚ EUI Harness flange nut 0.2 Fly wheel bolt 19+30˚ Injector New 1.5+90˚+90˚ clamp bolt Re-use 1.5+60˚ (2min later) Vehicle Speed Limit Control Function Injection rate is controlled to get the speed in the limited speed - BUS : 100Km/H - TRUCK : 80Km/h Control method Driving downhill road, if the vehicle speed exceeds the set(maximum)speed, exhaust brake or engine brake (JAKE) is engaged later Exception Soft road speed limit It is allowed to exceeds the limit target speed for a while to get the effective driving while diving uphill and downhill (option) Safety Control ☆ Purpose - Accelerator interlock : when the door is open, Accelerator pedal fuel injection is limited - bus - PTO : Emergency engine shut down Engine shut down switch - Special purpose vehicle (aircraft wrecker ) - truck ENGINE RPM ACCEL PEDAL ECU BA TT MIDDLE DOOR SW EUI Fail Safe Pedal Sensor Failure Case 1) One of Idle Switch is damaged  Use normal idle switch Case 2) Both idle switches are damaged  Use pedal sensor Case 3) Pedal sensor is damaged  Limp Home Mode Case 4) Pedal sensor and both Idle Switches are damaged  Idle in all rang Fail Safe Item- sensor Cranking (starting) Coolant control as -10℃ control as 87℃ control as -10℃ control as 30℃ Air Temperature Air Pressure control as 150Kpa Fuel Temperature control as 40℃ Fuel Pressure control as 150Kpa Running (idling) control as 150Kpa control as 40℃ control as 150Kpa Fail Safe Item Engine Statue Cam Sensor controlled by crank position sensor Crank Sensor controlled by cam position sensor Vehicle Speed Sensor Speed limit is controlled by engine RPM sensor but it is impossible to control PTO and CRUISE system– relayed with vehicle speed PTO Control Function Keep constant engine speed regardless of engine load Condition - Vehicle speed > APV ( 20 km/h) - CRUISE/PTO enable switch is ON - PTO governor switch is ON Operation The PTO governor makes the engine get PTO initial speed after second of APV time by the operation switch And the PTO warning lamp is lit Release CRUISE/PTO enable switch OFF ->engine speed slow down to idle speed PTO Operation PTO modes is governed by PTO configuration APV according to In-cab mode or Remote mode Accelerator pedal function PTO Engine speed increases by accelerating , Release – return to PTO speed Clutch/Brake pedal function Release initial PTO speed -> PTO speed Switch ON Release EUI EUI EUI EUI BOOST PRES & TEMP E24 RETURN FUEL PRES & TEMP 1999 25 COOL TEMP SENSOR RETURN COOLANT TEMP RETURN BOOST PRES SENSOR BOOST PRES SENSOR E6 E19 E8 E21 E4 E7 BOOST TEMP SENSOR 5V SUPPLY E10 BOOST PRES SENSOR E32 E31 E33 E25 E11 E22 E39 E38 E46 E29 E45 E30 E43 E37 ENG CONNECTOR 5V SUPPLY SCREEN CRANK SIGNAL RETURN CRANK SIGNAL SCREEN CAM SIGNAL CAM SIGNAL RETURN INJECTOR6 LOW SIDE INJECTOR5 LOW SIDE INJECTOR4 LOW SIDE EUI CRANK BASE2 HIGH SIDE INJECTOR3 LOW SIDE INJECTOR2 LOW SIDE INJECTOR1 LOW SIDE EUI CAM BASE1 HIGH SIDE A12 A14 A6 A11 A4 V2 S2 S1 L5 L6 L4 H2 L1 L2 L3 H1 Wiring – Engine Side E T C ECU GND