Table of Contents XTX Series Tractors Service/Diagnostic Manual SM 8-15002 1 GENERAL Safety Rules, General Information and Torque Specifications ............................1001 SM 2 ENGINE NOTE: For Service and Overhaul procedures refer to your Engine Service Manual. SM Error Codes: Tier 2 Tier 3 3 FUEL NOTE: For Service and Overhaul procedures refer to your Engine Service Manual. 4 ELECTRICAL Electrical Troubleshooting and Schematics.........................................................4001 SM Instrument Cluster Programming.........................................................................4002 SM Battery Servicing and Testing..............................................................................4004 SM 5 STEERING Steering Column and Steering Hand Pump Removal .........................................5001 SM Rexroth Steering Hand Pump..............................................................................5002 SM 6 TRANSMISSION Transmission How it Works .......................................................................................6 Guidelines for Separating the Speed and Range Transmissions .......................6003 SM 8 Speed Powershift Transmission Servicing .......................................................6006 SM Range Transmission Servicing ...........................................................................6007 SM Differential and Differential Lock Servicing .........................................................6012 SM MFD Clutch Servicing .........................................................................................6017 SM Rear Axle Removal .............................................................................................6018 SM PTO Servicing - shiftable/reversible ....................................................................6019 SM MFD Front Axle (20.29 Rigid Axle) .....................................................................6021 SM MFD Front Axle (20.43 Rigid Axle) ................................................................. 6021-A SM MFD Front Axle (20.29 Suspended Axle) ...........................................................6022 SM MFD Front Axle (20.43 Suspended Axle) ....................................................... 6022-A SM 7 BRAKES Brakes How it Works................................................................................................. 7 Service Brakes ................................................................................................... 7002 SM 8 HYDRAULICS Hydraulics How it Works ........................................................................................... 8 Hydraulic Troubleshooting and Schematic ......................................................... 8001 SM Charge/Lubrication Pump ................................................................................... 8003 SM Remote Valves........................................................................................... ......... 8008 SM 9 CHASSIS Pedal, Lever and Switch Adjustments ................................................................ 9001 SM
10CONTROLLER SYSTEMS Electrical Controllers How it Works......................................................................... 10 Auxiliary/Remote Valve Controller - Error Codes, Troubleshooting and Schematics ................................................................. 10001 SM Hitch/PTO Controller - Error Codes, Troubleshooting and Schematics ................................................................. 10002 SM Independent Front Suspension Axle Controller - Calibration, Error Codes, Troubleshooting and Schematics............................................. 10003 SM Transmission and Cab Controller - Calibration, Error Codes, Troubleshooting and Schematics ................................................................. 10006 SM Instrument Cluster Controller - Error Codes, Troubleshooting and Schematics ................................................................. 10009 SM Controller Reprogramming (Using The McCormick Diagnostic Centre) .................................................. 10010 SM Cab Suspension Controller - Calibration, Error Codes, Troubleshooting and Schematics ................................................................. 10011 SM Automatic Temperature Control - Error Codes, Troubleshooting and Schematics ................................................................. 10012 SM NOTE: Information contained in this manual may cover features that are not available in all markets worldwide. NOTE: References throughout this manual may be made to sections currently not available. These Sections will be made available at a later date.
1001
Section 1001 SAFETY, GENERAL INFORMATION AND STANDARD TORQUE SPECIFICATIONS
SM 8-10080
© 2001 McCormick Tractors International Limited. March 2001
2
SECTION 1001
TABLE OF CONTENTS SAFETY ................................................................................................................................................................... 3 GENERAL INFORMATION Cleaning ............................................................................................................................................................... 5 Inspection ............................................................................................................................................................. 5 Bearings ............................................................................................................................................................... 5 Needle Bearings .................................................................................................................................................. 5 Gears ................................................................................................................................................................... 5 Oil Seals, O-Rings And Gaskets .......................................................................................................................... 5 Shafts ................................................................................................................................................................... 5 Service Parts ........................................................................................................................................................ 5 Lubrication ........................................................................................................................................................... 5 STANDARD TORQUE DATA FOR NUTS AND BOLTS Chart 1 (Plain Nuts/Bolts) .................................................................................................................................... 6 Chart 2 (Phosphate Coated Nuts/Bolts) ............................................................................................................... 6 Chart 3 (Zinc or Cadmium Plated Nuts/Bolts) ...................................................................................................... 7
SM 8-10080
Issued 03-2001
SECTION 1001
3
SAFETY This symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED. The message that follows the symbol contains important information about safety. Carefully read the message. Make sure you fully understand the causes of possible injury or death.
!
To prevent injury always follow the Warning, Caution and Danger notes in this section and throughout the manual. Put a warning tag as shown below on the key for the key switch when carrying out servicing or repairs to the tractor. Warning tags (publication number 2-1000) are available from your McCormick dealer.
!
WARNING: Before starting engine, study Operator’s Manual safety messages. Read all safety signs on machine. Clear the area of other persons. Learn and practice safe use of controls before operating. It is your responsibility to understand and follow manufacturers instructions on machine operation, service, and to observe pertinent laws and regulations. Operator’s and Service Manuals may be obtained from you McCormick dealer.
!
WARNING: If you wear clothing that is too loose or do not use the correct safety equipment for your job, you can be injured. Always wear clothing that will not catch on objects. Extra safety equipment that can be required includes hard hat, safety shoes, ear protection, eye or face protection, heavy gloves and reflector clothing.
!
WARNING: When working in the area of the fan belt with the engine running, avoid loose clothing if possible, and use extreme caution.
!
WARNING: When doing checks and tests on the equipment hydraulics, follow the procedures as they are written. DO NOT change the procedure.
!
WARNING: When putting the hydraulic cylinders on this machine through the necessary cycles to check operation or to remove air from a circuit, make sure all people are out of the way.
!
WARNING: Use insulated gloves mittens when working with hot parts.
REASON/RAISON
!
VERNUNFT/RAZON
DO NOT OPERATE NE PAS UTILISER NICHT BETREIBEN NO UTILIZAR
2-1000
!
WARNING: Read the operators manual to familiarize yourself with the correct control functions.
!
WARNING: Operate the machine and equipment controls from the seat position only. Any other method could result in serious injury.
!
WARNING: This is one a man machine, no riders allowed
SM 8-10080
.
or
Issued 03-2001
4
SECTION 1001
!
CAUTION: Lower all attachments to the ground or use stands to safely support the attachments before you do any maintenance or service.
!
CAUTION: Pin sized and smaller streams of hydraulic oil under pressure can penetrate the skin and result in serious infection. If hydraulic oil under pressure does penetrate the skin, seek medical treatment immediately. Maintain all hoses and tubes in good condition. Make sure all connections are tight. Make a replacement of any tube or hose that is damaged or thought to be damaged. DO NOT use your hand to check for leaks, use a piece of cardboard or wood.
!
CAUTION: When removing hardened pins such as a pivot pin, or a hardened shaft, use a soft head (brass or bronze) hammer or use a driver made from brass or bronze and a steel head hammer.
!
CAUTION: When using a hammer to remove and install pivot pins or separate parts using compressed air or using a grinder, wear eye protection that completely encloses the eyes (approved goggles or other approved eye protectors).
!
CAUTION: Use suitable floor (service) jacks or chain hoist to raise wheels or tracks off the floor. Always block machine in place with suitable safety stands.
SM 8-10080
!
CAUTION: When servicing or repairing the machine. Keep the shop floor and operator’s compartment and steps free of oil, water, grease, tools, etc. Use oil absorbing material and or shop cloths as required. Use safe practices at all times.
!
CAUTION: Some components of this machine are very heavy. Use suitable lifting equipment or additional help as instructed in this Service Manual.
!
DANGER: Engine exhaust fumes can cause death. If it is necessary to start the engine in a closed place, remove the exhaust fumes from the area with an exhaust pipe extension. Open the doors and get outside air into the area.
!
DANGER: When the battery electrolyte is frozen, the battery can explode if (1), you try to charge the battery, or (2), you try to jump start and run the engine. To prevent that battery electrolyte from freezing, try to keep the battery at full charge. If you do not follow these instructions, you or others in the area can be injured.
!
DANGER: Batteries contain acid and explosive gas. Explosions can result from sparks, flames or wrong cable connections. To connect the jumper cables correctly to the battery of this machine see the Operator’s Manual. Failure to follow these instructions can cause serious injury or death.
Issued 03-2001
SECTION 1001
5
GENERAL INFORMATION Cleaning
Gears
Clean all metal parts except bearings, in mineral spirits or by steam cleaning. Do not use caustic soda for steam cleaning. After cleaning dry and put oil on all parts. Clean oil passages with compressed air. Clean bearings in kerosene, dry the bearings completely and put oil on the bearings.
Check all gears for wear and damage. Replace gears that have wear or damage.
Inspection Check all parts when the parts are disassembled. Replace all parts that have wear or damage. Small scoring or grooves can be removed with a hone or crocus cloth. Complete visual inspection for indications of wear, pitting and the replacement of parts necessary will prevent early failures.
Bearings Check bearings for easy action. If bearings have a loose fit or rough action replace the bearing. Wash bearings with a good solvent or kerosene and permit to air dry. DO NOT DRY BEARINGS WITH COMPRESSED AIR.
Needle Bearings Before you press needle bearings in a bore always remove any metal protrusions in the bore or edge of the bore. Before you press bearings into position put petroleum jelly on the inside and outside diameter of the bearings.
SM 8-10080
Oil Seals, O-Rings And Gaskets Always install new oil seals, o-rings and gaskets. Put petroleum jelly on seals and o-rings.
Shafts Check all shafts that have wear or damage. Check the bearing and oil seal surfaces of the shafts for damage.
Service Parts Always install genuine McCormick service parts, when ordering refer to the Parts Catalog for the correct part number of the genuine McCormick replacement items. Failures due to the use of other than genuine McCormick replacement parts are not covered by warranty.
Lubrication Only use the oils and lubricants specified in the Operators or Service Manual. Failures due to the use of non specified oils and lubricants are not covered by warranty.
Issued 03-2001
6
SECTION 1001
STANDARD TORQUE DATA FOR NUTS AND BOLTS NOTE: A “click type” torque wrench is recommended for the bolt torques listed below.
Chart 1 (Plain Nuts/Bolts) BOLT SIZE (mm) M4 M5 M6 M8 M10 M12 M14 M16 M20 M22 M24 M30 M36
TYPE 8.8 MIN lb ft 3.0 4.8 8.2 20.0 40.0 69.0 110.0 175.0 345.0 475.0 600.0 1190.0 2080.0
TYPE 10.9 MAX
Nm 4.0 6.5 11.0 27.0 54.0 94.0 150.0 235.0 470.0 640.0 810.0 1615.0 2825.0
lb ft 3.4 5.5 9.2 22.5 45.0 78.0 125.0 190.0 390.0 530.0 675.0 1340.0 2340.0
Nm 4.5 7.5 12.5 31.0 61.0 106.0 170.0 260.0 530.0 720.0 915.0 1815.0 3175.0
MIN lb ft 4.3 7.0 11.8 28.7 56.0 100.0 160.0 245.0 480.0 655.0 830.0 1645.0 2875.0
MAX Nm 5.8 9.5 16.0 39.0 77.0 134.0 215.0 335.0 650.0 890.0 1125.0 2235.0 3900.0
lb ft 4.8 7.8 13.3 32.3 64.0 110.0 180.0 275.0 540.0 735.0 930.0 1855.0 3235.0
Nm 6.5 10.5 18.0 44.0 87.0 151.0 240.0 375.0 730.0 1000.0 1265.0 2515.0 4390.0
Chart 2 (Phosphate Coated Nuts/Bolts) BOLT SIZE (mm) M4 M5 M6 M8 M10 M12 M14 M16 M20 M22 M24 M30 M36
SM 8-10080
TYPE 8.8 MIN lb ft 2.3 3.6 6.2 15.0 30.0 52.0 83.0 131.0 259.0 355.0 450.0 893.0 1560.0
TYPE 10.9 MAX
Nm 3.0 4.9 8.3 20.3 41.0 71.0 113.0 176.0 353.0 480.0 608.0 1211.0 2119.0
lb ft 2.6 4.1 6.9 16.9 34.0 59.0 94.0 143.0 293.0 400.0 506.0 1005.0 1755.0
Nm 3.4 5.6 9.4 23.3 46.0 80.0 126.0 195.0 400.0 540.0 686.0 1361.0 2381.0
MIN lb ft 3.2 5.2 8.9 21.5 42.0 75.0 120.0 185.0 360.0 490.0 625.0 1235.0 2156.0
MAX Nm 4.4 7.1 12.0 29.2 58.0 101.0 161.0 251.0 490.0 665.0 845.0 1675.0 2925.0
lb ft 3.6 5.9 10.0 24.2 48.0 83.0 135.0 205.0 405.0 550.0 700.0 1390.0 2425.0
Nm 4.9 8.0 13.5 32.8 65.0 113.0 180.0 280.0 550.0 750.0 950.0 1885.0 3295.0
Issued 03-2001
SECTION 1001
7
Chart 3 (Zinc or Cadmium Plated Nuts/Bolts) BOLT SIZE (mm) M4 M5 M6 M8 M10 M12 M14 M16 M20 M22 M24 M30 M36
SM 8-10080
TYPE 8.8 MIN lb ft 2.6 4.1 7.0 17.0 34.0 59.0 94.0 149.0 293.0 400.0 510.0 1010.0 1770.0
TYPE 10.9 MAX
Nm 3.5 5.6 9.5 23.1 46.0 80.0 128.0 200.0 400.0 545.0 690.0 1375.0 2400.0
lb ft 2.9 4.6 7.8 19.1 38.3 66.0 106.0 161.0 330.0 450.0 575.0 1140.0 1990.0
Nm 3.9 6.3 10.6 25.9 52.0 90.0 145.0 220.0 450.0 615.0 780.0 1545.0 2700.0
MIN lb ft 3.7 5.9 10.0 24.4 48.0 85.0 136.0 208.0 408.0 555.0 705.0 1400.0 2445.0
MAX Nm 5.0 8.0 13.6 33.1 65.0 114.0 183.0 285.0 555.0 755.0 955.0 1900.0 3315.0
lb ft 4.1 6.6 11.3 27.4 54.0 94.0 153.0 235.0 460.0 625.0 790.0 1580.0 2750.0
Nm 5.6 9.0 15.3 37.2 74.0 128.0 205.0 320.0 620.0 850.0 1075.0 2140.0 3730.0
Issued 03-2001
Service Manual Electronic Common Rail 6 Cylinder (Tier 2) Engines
SM 8-12900
Š 2003 McCormick Tractors International Limited. November 2003
i
This publication provides the features, data and correct method of repair operations that can be performed on every single component of the engine. Following the instructions given and using the special tools will ensure correct repairing, within the scheduled times, while also protecting operators against possible accidents. Before starting any repair work, make sure that all accident-prevention equipment is close at hand and in efficient conditions. Therefore, check and wear the items specified by the rules of safety: goggles, helmet, gloves, shoes. Before use, check all the working, hoisting and handling equipment.
The possibility exists that the information given in this manual may not be up to date as a result of modifications adopted by the Manufacturer at any time for reasons of a technical or commercial nature or to adjust to the laws in force in the different Countries. The reproduction, even only in part, of the text and illustrations is forbidden.
1
ED. NOVEMBER 2003
CONTENT OF SECTIONS General information
1
Fuel
2
Duty - Industrial applications Common Rail Engines
3
Overhaul and technical specifications
4
Tools
5
Safety prescriptions
Appendix
PREFACE TO USER’S GUIDELINE MANUAL Section 1 describes the engine illustrating its features and working in general. Section 2 describes the type of fuel feed. Section 3 relates to the specific duty and is divided in four separate parts: 1 1.. Mechanical part,
related to the engine overhaul, limited to those components with different characteristics based on the relating specific duty. 2 2.. Electrical part, concerning wiring harness, electrical and electronic equipment with different characteristics based on the relating specific duty. 3 3.. Maintenance planning and specific overhaul. 4 4.. Troubleshooting part dedicated to the operators who, being entitled to provide technical assistance, shall have simple and direct instructions to identify the cause of the major inconveniences. Sections 4 and 5 illustrate the overhaul operations of the engine overhaul on stand and the necessary equipment to execute such operations. The appendix reports general safety prescriptions to be followed by all operators whether being in-charge of installation or maintenance, in order to avoid serious injury.
22
ED.
2003
NOVEMBER 2003
NEF
ENGINES
3
ED. NOVEMBER 2003
SPECIAL REMARKS
Where possible, the same sequence of procedures has been followed for easy reference. Diagrams and symbols have been widely used to give a clearer and more immediate illustration of the subject being dealt with, (see next page) instead of giving descriptions of some operations or procedures.
Example Ø 1 = housing for connecting rod small end bush
1
2
Ø 2 = housing for connecting rod bearings
§
Tighten to torque Tighten to torque + angular value
4
ED. NOVEMBER 2003
Graph and symbols Removal Disconnection
Intake
Refitting Connection
Exhaust
Removal Disassembly
Operation
Fitting in place Assembly
§
!
¸
Compression ratio
Tighten to torque
Tolerance Weight difference
Tighten to torque + angle value
Rolling torque
Press or caulk
Replacement Original spare parts
Regulation Adjustment
Rotation
Warning Note
Angle Angular value
Visual inspection Fitting position check
Preload
Measurement Value to find Check
Number of revolutions
Equipment
Temperature
Surface for machining Machine finish Interference Strained assembly Thickness Clearance Lubrication Damp Grease Sealant Adhesive Air bleeding
bar
Pressure Oversized Higher than}. Maximum, peak Undersized Less than}. Minimum Selection Classes Oversizing Temperature < 0 qC Cold Winter Temperature > 0 qC Hot Summer
ED. NOVEMBER 2003
1
SECTION 1 - GENERAL SPECIFICATIONS
SECTION 1 General Specifications
Page ENGINE ID. CODE
3
LUBRICATING CIRCUIT, 4 AND 6 CYLINDERS
5
OIL VAPOUR RECIRCULATING SYSTEM
7
COOLING CIRCUIT SYSTEM, 4 AND 6 CYLINDERS
8
AIR INDUCTION BOOST DIAGRAM
12
2
SECTION 1 - GENERAL SPECIFICATIONS
ED. NOVEMBER 2003
ED. NOVEMBER 2003
SECTION 1 - GENERAL SPECIFICATIONS 3
ENGINE IDENTIFICATION CODE
F
4
A
E
0
6
8
4
F
*
D
+
Exhaust emiss. level Homologation power Duty No. Injection Cylinder No. Engine cycle â&#x20AC;&#x201D; cylinder position Engine
Engine series
Type of Engine Block A =Not struct. B = Not struct C =Struct
0 = 4-stroke, vertical 4 = 4 cylind. 6 = 6 cylind. 8 = DI. TCA
0 = Different between the following applications 1 = Truck 2 = Bus 3 = Rail rood 4 = M.T. vehicles and tractors
X
Y
Y
Y
X = 1 Common Rail 4 valve
Y
5 = Genset 6 = Marine 7 = Industrial and fork lift truck 8 = Cars and similar 9 = Army
Y
Y
Y
Model No. within D.B.
Y
Y
4
SECTION 1 - GENERAL SPECIFICATIONS
ED. NOVEMBER 2003
SPECIFIC ENGINE CODE
Y
XX
Y
Y
Y
.
Y
XX
.
XX
Engineering code Exhaust emiss. level Power: A = Not superch. S = Supercharging T = Supercharging with aftercooler
Feed system: M = Mechanical E = Electronic Total displacement or n. of cylinders Engine series: N = Engine
EXAMPLES: N40ENT.C N = Engine 40 = 4 liters E = Electronic N = Type of Engine block T = Supercharger with aftercooler C = Euro3
Engine block: N = Not struct. S = Struct.
C = Euro3. E = E (NRMM) U = EPA USA G = Gas M = Marine
ED. NOVEMBER 2003
SECTION 1 - GENERAL SPECIFICATIONS
5
LUBRICATION (4 CYLINDERS)
Lubrication by forced circulation is achieved through oil rotary expansion pump (1), placed in the front part of the basement, driven by the straight-tooth gear splined to the shaftâ&#x20AC;&#x2122;s bar hold. From the pan, the lubrication oil flows to the driving shaft, to the camshaft and to the valve drive.
Lubrication involves the heat exchanger as well, the turboblower and the eventual compressor for any eventual compressed air system. All these components may often vary according to the specific duty and will therefore be examined in the specific section.
Figure 1
Oil recover from the turbo-blower To the exchanger and to the turbo-blower
1
Routing of oil under pressure Routing of oil return by gravity to sump Introduction of oil
LUBRICATION SYSTEM LAYOUT
6
SECTION 1 - GENERAL SPECIFICATIONS
ED. NOVEMBER 2003
LUBRICATION (6 CYLINDERS)
Even for the 6 cylinders version lubrication is obtained by forced circulation and achieved through an oil rotary expansion pump similar to the 4 cylindersâ&#x20AC;&#x2122; one.
Also in this case, the components such as the oil exchanger, the turbo-blower and the eventual compressor are specifically studied and made out to suit the equipment or the duty for which the engine has been developed.
Figure 2
Oil recover from the turbo-blower
To the exchanger and to the turbo-blower
Routing of oil under pressure Routing of oil return by gravity to sump Introduction of oil
LUBRICATION SYSTEM LAYOUT
ED. NOVEMBER 2003
SECTION 1 - GENERAL SPECIFICATIONS
7
OIL VAPOUR RECYCLING Figure 3
70484
Oil condensate Oil vapours 1. Pre-separator - 2. Exhaust to the outside (temporary) - 3. Filter - 4. Return to engine The tappet cover houses the pre-separator (1), whose shape and position determines an increase in oil vapour outlet speed and condenses a part of vapours at the same time. Condensate oil returns to the oil sump whereas the residual vapours are ducted, collected and filtered in the blow-by (3). In the blow-by (3), part of the vapours condense and return to the oil sump whereas the remaining part is put into cycle again through pipe (2).
8
SECTION 1 - GENERAL SPECIFICATIONS
ED. NOVEMBER 2003
COOLING SYSTEM (4 CYLINDERS)
The engine cooling system, closed circuit forced circulation type, generally incorporates the following components: - Expansion tank; placement, shape and dimensions are subject to change according to the engine’s equipment. - Radiator, which has the duty to dissipate the heat subtracted to the engine by the cooling liquid. Also this component will have specific peculiarities based on the equipment developed, both for what concerns the placement and the dimensions. - Viscous pusher fan, having the duty to increase the heat dissipating power of the radiator. This component as well will be specifically equipped based on the engine’s development. - Heat exchanger to cool the lubrication oil: even this component is part of the engine’s specific equipment. - Centrifugal water pump, placed in the front part of the engine block. - Thermostat regulating the circulation of the cooling liquid. - The circuit may eventually be extended to the compressor, if this is included in the equipment.
ED. NOVEMBER 2003
SECTION 1 - GENERAL SPECIFICATIONS
9
Figure 4
EXPANSION TANK
EXPANSION TANK HEATER (Optional)
RADIATOR
RADIATOR
Water coming out from thermostat Water recirculating in engine Water coming into pump
COOLING SYSTEM LAYOUT
74194
10
SECTION 1 - GENERAL SPECIFICATIONS
ED. NOVEMBER 2003
COOLING SYSTEM (6 CYLINDERS)
The engine cooling system, closed circuit forced circulation type, is of a similar design as the 4 cylinders engine. It incorporates necessary components such as the radiator, the heat exchanger, the expansion tank and some ancillary components such as the heater or the compressor for the compressed air. Such components always vary according to the engineâ&#x20AC;&#x2122;s equipment and duty.
ED. NOVEMBER 2003
Figure 5
EXPANSION TANK
EXPANSION TANK HEATER (Optional)
RADIATOR
RADIATOR
Water coming out from thermostat Water recirculating in engine Water coming into pump
COOLING SYSTEM LAYOUT
SECTION 1 - GENERAL SPECIFICATIONS
11
12
SECTION 1 - GENERAL SPECIFICATIONS
ED. NOVEMBER 2003
AIR INDUCTION - BOOST DIAGRAM Figure 6
4 Cylinders version
TURBOCHARGER
AIR FILTRE
EXHAUST
RADIATOR
6 Cylinders version
TURBOCHARGER
AIR FILTRE
EXHAUST
RADIATOR 74195
Description
The turbocharger is composed by the following main parts: one turbine, one transforming valve to regulate the boost feeding pressure , one main body and one compressor. During engine working process, the exhaust emissions flow through the body of the turbine, causing the turbine disk wheelâ&#x20AC;&#x2122;s rotation. The compressor rotor, being connected by shaft to the turbine disk wheel, rotates as long as this last one rotates, compressing the drawn air through the air filter. The above mentioned air is then cooled by the radiator and flown through the piston induction collector.
The turbocharger is equipped with a transforming valve to regulate the pressure , that is located on the exhaust collector before the turbine and connected by piping to the induction collector. Itâ&#x20AC;&#x2122;s funchon is to restrict the exhaust of the emissions , releasing part of them directly to the exhaust tube when the boost feeding pressure, over the compressor, reaches the prescribed bar value. The cooling process and the lubrication of the turbocharger and of the bearings is made by the oil of the engine.
ED. NOVEMBER 2003
SECTION
2
1
- FUEL
SECTION 2 Fuel
Page COMMON RAIL
3
WORKING PROCESS
5
FUEL SYSTEM LAYAUT
6
MECHANICAL FUEL PUMP
8
CP3 HIGH PRESSURE PUMP
9
RAIL (PRESSURE ACCUMULATOR)
13
BOOST GAUGE VALVE
14
FLOW LIMITERS
15
ELECTRO-INJECTOR
16
PRESSURE LIMITER FOR FUEL RETURN
17
2
SECTION 2 - FUEL
ED. NOVEMBER 2003
ED. NOVEMBER 2003
3
SECTION 2 - FUEL
COMMON RAIL General Specifications
In order to reduce PARTICULATES emissions, very high injection pressures are required. The Common Rail system allows injecting the fuel up to pressures reaching 1450 bar, at the same time, the injection precision, obtained by the electronic system control, optimizes the engine performance, reducing emissions and consumption. System description Electric system Figure 1
1
6
2
7 8
3
9
4
10 5
11 74168
1. Connection to Electro-injectors - 2. Sensor monitoring temperature of engineâ&#x20AC;&#x2122;s cooling liquid - 3. Fuel pressure sensor cable - 4. Sensor of engineâ&#x20AC;&#x2122;s oil temperature and pressure - 5. Driving shaft sensor - 6. Electro-injector - 7. Temperature and air pressure sensor - 8. Camshaft sensor - 9. Fuel heater cable and fuel temperature sensor - 10. Pressure gauge cable 11. EDC 7 gearbox. Through the sensors, present on the engine, the ECU controls the engine operation.
The outlet voltage is proportional to the pressure or temperature obtained by the sensor.
Air pressure/temperature sensor
Engine oil temperature and pressure sensor
It is a component integrating a temperature sensor and a pressure sensor. Fitted on the intake manifold, it measures the max. inlet air capacity to calculate precisely the fuel quantity to inject at every cycle.
Same as air pressure/temperature sensor, it is fitted on the engine oil filter, in a horizontal position. It measures engine oil temperature and pressure.
4
SECTION 2
- FUEL
ED. NOVEMBER 2003
Fuel pressure sensor
Assembled on a rail end, it measures the fuel pressure in the rail in order to determine the injection pressure. The injection pressure value is used to control the pressure and to determine the electric injection control length. Fuel temperature sensor
It is a sensor that is equal to the previous one. It measures fuel temperature to provide the control unit with an index of the diesel fuel thermal state. Coolant temperature sensor
It is a variable-resistance sensor suitable to measure the coolant temperature to provide the control unit with an index of the engine thermal state. Output shaft sensor
It is an inductive sensor placed on the front engine part. Signals generated through the magnetic flow that is closed on the phonic wheel, change their frequencies depending on output shaft rotation speed. Timing sensor
It is an inductive sensor placed on the engine rear left part. It generates signals obtained from magnetic flow lines that are closed through holes obtained on the keyed gear on the camshaft. The signal generated by this sensor is used by the ECU as injection phase signal. Though being equal to the flywheel sensor, it is NOT interchangeable since it has a different outside shape. System functionality Self-diagnosis
The ECU self-diagnostic system checks signals coming from sensors by comparing them with threshold data. Code recognition
The EDC7 control unit communicates with the Immobilizer control unit (if fitted) to obtain the startup consent. Engine pre-heating resistance check
The pre-post heating is activated when even only one of the water, air or fuel temperature sensors signals a temperature that is less than 5 qC. Phase recognition
By means of signals coming from camshaft sensor and flywheel sensor, the cylinder on which fuel must be injected is recognised upon startup.
Injection control
The control unit, depending on information coming from sensors, controls the pressure regulator, and changes pre-injection and main injection modes. Closed-loop control for injection pressure
Depending on engine load, measured by processing signals coming from various sensors, the control unit controls the regulator in order to always have the optimum pressure. Pilot and main injection spark advance control
The control unit, depending on signals coming from various sensors, computes the optimum injection point according to an internal mapping. Idle speed control
The control unit processes signals coming from various sensors and adjusts the amount of injected fuel. It controls the pressure regulator and changes the injection time of injectors. Within certain thresholds, it also takes into account the battery voltage. Maximum speed limiting
At 2700 rpm, the controlunit limits fuel flow-rate by reducing the injectors opening time. Over 3000 rpm it deactivates the injectors. Cut Off
Fuel cut off upon release is controlled by the control unit performing the following logics: - it cuts off injectors supply; - it re-activates the injectors shortly before idle speed is reached; - it controls fuel pressure regulator. Smoke control upon acceleration
With strong load requests, the control unit, depending on signals received by air inlet meter and engine speed sensor, controls the pressure regulator and changes the injectors actuation time, in order to avoid exhaust smoke. Fuel temperature control
When the fuel temperature exceeds 75 qC (measured by the sensor placed on fuel filter) the control unit intervenes by reducing injection pressure. If the temperature exceeds 90 qC, the power is reduced to 60%. AC compressor engagement control (if fitted)
The control unit is able to drive engagement and disengagement of the electromagnetic compressor clutch depending on coolant temperature. If the coolant temperature reaches about 105 qC, it disengages the clutch. After Run
The control unit microprocessor allows storing certain EPROM data, among which failure memory and Immobilizer information, in order to make them available upon the following startup.
ED. NOVEMBER 2003
5
SECTION 2 - FUEL
WORKING PROCESS Figure 2
High Pressure Low Pressure
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1. Injector - 2. Common Rail - 3. Pressure limiter for fuel return - 4. Rail overpressure valve - 5. Prefilter assembled on chassis - 6. High-pressure pump - 7. Mechanical rotor pump - 8. Fuel filter. The Common Rail system has a special pump that continuously keeps fuel at high pressure, independently from stroke and cylinder that has to receive the injection and accumulates fuel in a common duct for all injectors. Therefore, fuel at the injection pressure computed by the ECU is always available at the injectors inlet. When an injector solenoid valve is energised by the electronic control unit, the injection of fuel directly taken from rail takes place in the related cylinder. The hydraulic system is implemented by a low-pressure circuit and a high-pressure circuit. The high-pressure circuit is composed of the following pipings: - piping connecting high-pressure pump outlet to rail; - pipings supplying injectors from rail. The low-pressure circuit is composed of the following pipings: - fuel suction piping from tank to prefilter; - pipings supplying the mechanical supply pump through the control unit heat exchanger, manual priming pump and prefilter; - pipings supplying the high-pressure pump through the fuel filter. The fuel draining circuit from rail and from injectors and the high-pressure pump cooling circuit complete the system.
6
SECTION 2 - FUEL
ED. NOVEMBER 2003
FUEL SYSTEM LAYOUT
This fuel system is a Common Rail injection with CP3 high pressure pump and this layout is for 4 cylinder version. (The 6 cylinder version is similar design as the 4 cylinder engine). The pressure regulator, placed upstream of the high-pressure pump, adjusts the fuel flow that is necessary on the low-pressure system. Afterwards, the high-pressure pump takes care of supplying the rail properly. This arrangement, by pressurising the necessary fuel only, improves the energetic efficiency and limits fuel heating in the system. Function of the pressure relief valve (2), assembled on the high-pressure pump, is keeping the pressure, at the pressure regulator inlet, constant at 5 bars, independently from the efficiency of the fuel filter and of the system set upstream. The pressure relief valve (2) intervention brings about a fuel flow increase in the high-pressure pump cooling circuit, through inlet and drain piping (16) from piping (8). The pressure relief valve housed on the cylinder head, assembled on injector return (3), limits the fuel return flow from injectors at a pressure of 1.3 to 2 bars. Two by-pass valves are placed in parallel with the mechanical supply pump. The by-pass valve (18) allows fuel to flow from mechanical pump outlet to its inlet, when the fuel filter inlet pressure exceeds the allowed threshold value. The by-pass valve (17) allows filling the supply system through the manual priming pump (10).
1. High-pressure pump. — 2. Pressure relief valve on high-pressure pump, 5 bars. — 3. Pressure relief valve assembled on fuel return from injectors, 1.3 to 2 bars. — 4. Rail overpressure valve. — 5. Common Rail. — 6. Pressure sensor. — 7. Injector. — 8. Return piping. — 9. Control unit heat exchanger. — 10. Mechanical priming pump. — 11. Prefilter assembled on chassis. — 12. Fuel tank. — 13. Mechanical supply pump. — 14. Fuel filter. — 15. Pressure regulator. — 16. High-pressure pump cooling piping. — 17. By-pass valve. — 18. By-pass valve.
ED. NOVEMBER 2003
Figure 3
SECTION2 - FUEL
7
8
SECTION 2
- FUEL
ED. NOVEMBER 2003
Jettison condition
MECHANICAL FEEDING PUMP
Gear pump, placed on rear part of the high pressure pump, whose function is to feed the high pressure pump. It is driven by the high pressure pumpâ&#x20AC;&#x2122;s shaft.
Figure 6
Ordinary working condition Figure 4
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A- Fuel entry flowing from the tank. B- Fuel exhaust to filter, I - 2 By-pass valves in close position.
The dump by-pass valve (2) is activated in case, when the engine is off, it is necessary to fill the feeding system through the priming pump. In this condition the by pass valve (I) keeps closed while the dump by-pass valve (2) opens up due to the pressure effect on the entry unit so the fuel flows to the exhaust unit B.
Overpressure condition in Exhaust unit Figure 5
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The by-pass valve (I) is activated in case of overpressure on B Exhaust unit. The actual pressure, overcoming the resistance of the valveâ&#x20AC;&#x2122;s spring (I), connects the exhaust with the entry through the gallery (2).
The mechanical feeding pump cannot be replaced separately, therefore it must not be disassembled from the high pressure pump.
ED. NOVEMBER 2003
9
SECTION2 - FUEL
CP3 HIGH PRESSURE PUMP
Pump provided with 3 radial pumping elements driven by the timing system gear, no need of timing. The mechanical feeding pump driven by the high pressure pumpâ&#x20AC;&#x2122;s shaft is assembled to the rear side of the high pressure pump.
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The high pressure pump unit - feeding pump is not subject to overhaul , therefore it must not be disassembled neither the fixing screws must be tampered.The only operation allowed is the replacement of the driving gear.
Figure 7
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1. Fuel exhaust connector to rail - 2. High pressure pump - 3. Pressure regulating gauge - 4. Driving gear - 5. Connector to fuel entry flowing from filter - 6. Connector to fuel exhaust to filter support - 7. Connector to fuel entry flowing from engine control module heat exchanger - 8. Connector to fuel exhaust flowing from mechanic pump to filter - 9. Mechanical feeding pump.
10
SECTION 2
- FUEL
ED. NOVEMBER 2003
High pressure pump-inside structure Figure 8
Sec. B-B
Sec. C-C
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1. Cylinder. — 2. Three-lobe element. — 3. Cap intake valve. — 4. Ball delivery valve. — 5. Piston. — 6- Pump shaft. — 7. Low-pressure fuel inlet. — 8. Pumping elements supplying fuel ducts. Every pumping unit is composed of: - a piston (5) actuated by a three-lobe element (2) floating on the pump shaft (6). The element (2), being floating on a misaligned part of the shaft (6), when the shaft rotates, does not rotate therewith but is only translated in a circular movement along a wider radius, with the resulting alternate actuation of the three pumping elements;
-
cap intake valve (3); ball delivery valve (4).
ED. NOVEMBER 2003
SECTION 2 - FUEL
11
Working principle Figure 9
Sec. B - B
72597
Sec. D - D
1. Cylinder. — 2. Three-lobe element. — 3. Cap intake valve. — 4. Ball delivery valve. — 5. Piston. — 6- Pump shaft. — 7. Low-pressure fuel inlet. — 8. Pumping elements supplying fuel ducts. The pumping element (3) is orientated towards the pump’s camshaft (4). During the intake phase, the pumping element is fed through the feeding line (5). The quantity of fuel to flow to the pumping element is determined by the pressure regulating gauge (7). The pressure regulating gauge, according to the PWM command received by the engine control module, stops the fuel flow to the pumping element.
During compression phase of the pumping element, the fuel achieves the level of pressure determining the opening of the by-pass valve to common rail (2), feeding it through the exhaust unit (I).
12
SECTION 2
- FUEL
ED. NOVEMBER 2003
Figure 10
Figure 11
72601
72598
Sec. C - C
Sec. A - A
1. Cylinder. — 2. Three-lobe element. — 3. Cap intake valve. — 4. Ball delivery valve. — 5. Piston. — 6- Pump shaft. — 7. Low-pressure fuel inlet. — 8. Pumping elements supplying fuel ducts.
1. Fuel exhaust flue - 2. Fuel exhaust gallery - 3 Fuel exhaust flowing from pump with connector to high pressure pipe for common rail.
Picture 10 shows the fuel runs at low pressure inside the pump; the following elements are clearly visible: the main feeding line to the pumping elements (4); the feeding lines to the pumping elements (1-3-6), the duct lines run for the pump lubrication (2), the pressure gauge (5), the flow limiting valve to 5 bar (8) and the fuel exhaust flue (7). The pump shaft is lubricated by the fuel through the feeding and recovery lines. The pressure gauge (5) determines the quantity of fuel to feed the pumping elements: the fuel in excess flows through the exhaust gallery (9). The limiting valve to 5 bar, in addition to recovering fuel exhaust as a collector has also function to keep the pressure constant to 5 bar limit at gauge entry.
Picture 11 shows the fuel flow under high pressure running through the exhaust galleries of the pumping elements.
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