Bomba Terracan Electronica

7/24/2019 Bomba Terracan Electronica

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1

TERRACAN

D4BH (2.5 TCI) Diesel Engine

Fuel System (COVEC-F)


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2Engine Specification

ITEMS 2.5 T/C

DISPLACEMENT(cc) 2476

BORE STROKE(mm) 91.1 95

FIRING ORDER 1-3-4-2

COMPRESSION RATIO 21

INJECTION TIMING( ) CAM Lift 10.03mm

INJECTION TYPE INDIRECTION

NUMBER OF CYLINDER 4

IDLE RPM 750

PREHEATING DEVICE GLOW PLUG

INTAKE SYSTEM TURBO


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3Outline

Electronic fuel injection pump (Covec-F) has the same fuel intake and

compression system as mechanical injection pump has.

However, it uses an electronic governor(GE Actuator) instead of a fly-weight

and uses control unit cable instead of a control lever. In checking engine cycle,

mechanical pump uses gear of fly weight holder, but electronic pump uses

sensing gear plate with 4 projections, installed on the driveshaft. A timing

control valve(TCV), which adjust pressure to moot optimal injection timing,

installed between high and low pressure chambers of the timer at lower part of

the main pump body, in mechanical injection pumps, check valves are installed

in part of the inside of the overflow valves. In electronic injection pumps,

however, check valve are installed at all valves, enabling to hold over-flows

until the pressure is stabilized. A timer position sensor(TPS), which senses

location of timer piston is also installed in electric injection.

Fuel Cut Sol.

GE Actuator

Timer Control Valve.

Np Sensor


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4ECM Input/ Output

GE(Governor Electric) Actuator

GE actuator is attached to the governor chamber at the upper part of the

injection pump. Governor chamber and pump chamber are connected with a

magnetic filter in between. Coil is cooled by the fuel coming into the governor

chamber. A magnetic filter prevents foreign material(ferrous ingredients) fromentering the chambers. Eccentric ball pin that are inserted into control sleeve

holes are placed at the end of the shaft forced into the rotor.

The electronic governor actuator is a magnetic field type. Once the coil

receives electric current, it generates a magnetic field and rotates the rotor until

it reaches the designated range.

The strength of magnetic field at coil is proportional to the strength of input

current and rotates the rotor to the relative position of the return spring ,enabling the control sleeve to make linear movements.


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5ECM Input/ Output

GE (Governor Electric) Actuator

F.I.P

Connector

No.6 GE+

No.10 GE-

Specification

No.6 ~ No.10: 0.6

Connection with ECMNo.6 ECM Pin No. 1, 14

No.10 ECM Pin No. 2, 15

Waveform

ECM Pin No. 1, 14 ECM Pin No. 2, 15


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6ECM Input/ Output

TCV (Timing Control Valve)

The TCV is located at the lower part of the injection pump. Two holes ( A and

B ) in the pump housing connect to the TCV. Hole A connects the timer piston's

high pressure chamber to the fuel inlet side of the TCV. A filter is installed at

this inlet to exclude foreign mater Hole B connects the timer piston's low

pressure chamber to the outlet at the tip of he TCV.

Installed between the timer piston's high and low pressure chambers, the TCV

adjusts high pressure chamber pressure by opening and closing the needle.

When current is not flowing to the TCV, the tip of the needle completely

separates the high and low pressure chambers. Then current is supplied,

needle tip seat is opened, the high and low pressure chamber are connected,

and the high pressure chamber pressure decreases. The timer piston is then

moved by timer spring to a piston that balances the high pressure chamber

pressure. Accompanying this roller holder rotates to vary the injection timing.

Injection timing can therefore be varied by utilizing the ON-OFF duty ratio of

the current flowing to the TCV. Injection timing is controlled by duty. Allcharacteristics and TCV drive signal duty ratios. Also, he frequency of the TCV

drive signal can be varied to correspond to the frequency of injection pump

speed.

Duty ratio is the ratio the time that the timing control valve is closed per unit of

time (i. e. per cycle).

Duty ratio = to / T x 100 (%)

Injection timing is related when the duty ratio decreases from 100%.

When electric current flows at Timing Control Valve, the needle is pulled lift by

magnet, and seat part of the hall is opened. TCV is located between high

pressure and low pressure chambers and adjusts pressure by opening and

closing of the needle.


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7ECM Input/ Output

TCV (Timer Control Valve)


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8ECM Input/ Output

TCV

F.I.P

Connector

No.5 TCV+

No.9 TCV-

Specification

No.5 ~ No.9: 111.1

Connection with OthersNo.5 IG. Key(B+)

No.9 ECM Pin No. 13

Waveform

At idle At acceleration

TCV (Timer Control Valve)


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9ECM Input/ Output

TPS (Timer Position Sensor)

TPS is attached on the low-pressure side of the timer and is consisted of core

rod and bobbin. It checks position of the timer piston electrically. TPS checks

inductance changes with the core rod and measures position of the timer

piston.

TPS

TPS

Connector


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10ECM Input/ Output

TPS (Timer Position Sensor)

TCV

F.I.P

Connector

No.3 TPS

MDL

No.2 TPS +

No.1 TPS -

Specification

No.2 ~ No.3, No.1 ~ No.3: 822

Connection with Others

No.1 ECM Pin No. 53

No.2 ECM Pin No. 46

No.3 ECM Pin No. 52

Waveform

ECM Pin No. 52, 46 at idle ECM Pin No. 52, 53 at idle


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11ECM Input/ Output

Np (Pump Speed) Sensor

NP Sensor checks pump rpm and relays signal to PCM. NP sensor is

consisted of permanent magnets, steel core and coils. It detects electric

voltage generated by the changes in the machine going through the sensing

gear, through rotation signal.

When the 4 projections of the sensing gear plate go through the magnetic field,

while the drive-shaft is rotating, alternating current is generated, which is then

changed into a pulse signal and used as a rotation signal.

Np Sensor


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12ECM Input/ Output

Np (Pump Speed) Sensor

F.I.P

Connector

No.3

Signal

No.2

ECM GND

No.1 Shield GND

Specification

No.2 ~ No.3: 1.020.16k

Connection with OthersNo.1 Wiring harness Shield GND

No.2 ECM Pin No. 38 GND

No.3 ECM Pin No. 30 Signal

Waveform

Np Signal at idle Np Signal with CKP Sensor at idle


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13ECM Input/ Output

Q Compensation Resistance

Q Compensation Resistance is to prevent the different injection amount due to

the different characteristic resistance of fuel injection pump affecting to

injection amount controlled by ECM.

The resistance of Q Compensation is decided by below table. The

compensation resistance number is related to the resistance measured

between terminal D & G.

Q Adjustment

Resistance

No.1 945 0.18(k)

No.2 946 0.3(k)

No.3 947 0.43(k)

No.4 948 0.62(k)

No.5 949 0.82(k)

No.6 950 1.1(k)

No.7 951 1.15(k)

No.8 952 2(k)

No.9 953 2.7(k)

No.10 954 3.9(k)

No.11 955 5.6(k)

No.12 956 8.2(k

)No.13 957 15(k)

NumberMeasured

Resistance

Q Comp.

Resistance

F.I.P

ConnectorNo.2

No.3


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14ECM Input/ Output

CSP (Control Sleeve Position) Sensor

The control Sleeve Position Sensor(CSP) at upper part of GE actuator detects

the position of control sleeve and feeds it back to ECU.

The fixed plate compensates changes of inductance caused by temperature.

The CSP sensor calculates the difference of the inductance at the two sensor

coils(upper and lower sensor coils) into angles and feeds them back to ECU,

and ECU compares its target angle with the actual one, if there is a difference

between the two angles, the ECU adjusts electric currents until the actual angle

equals the target angle.


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15ECM Input/ Output

F.I.P

Connector

No.4 CDP +

No.8 CSP

MDL

Specification

No.4 ~ No.8, No.12 ~ No. 8: 5.8k

Connection with ECM



No.12 ECM Pin No.45, 51

Waveform

CSP (Control Sleeve Position) Sensor

No.12 CSP -

ECM Pin No. 43, 44 at idle ECM Pin No. 43, 45 at idle


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16ECM Input/ Output

TF (Temperature Fuel) Sensor

This sensor detects the temperature of fuel.

If TF Sensor value is beyond 0.1V~4.6V for 5 second, ECM regards TF Sensor

as failed and sets fuel temperature to 50

F.I.P

Connector

No.7 Signal

No.11 GND

Specification

No.7 ~ No.11: 20.1k at 25

Connection with ECM

No.7 ECM Pin No. 18

No.11 Wiring harness GND

Waveform

ECM Pin No. 18 at

normal operating

Temperature


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17ECM Input/ Output

WTS (Water Temperature Sensor) Sensor

If Sensor value is beyond 0.1V~4.6V for 5 second, ECM regards WTS Sensor

as failed and sets coolant temperature from TF Sensor at starting. When TF

Sensor is failed, sets the temperature to 20 .

Connection with ECM

No.2 ECM Pin No. 17

No.1 Wiring harness GND

Waveform

ECM Pin No. 17 at

normal operating

Temperature

Temp.( ) Resistance(k

) Voltage(V)-20 16 4.3

0 5.9 3.4

20 2.5 2.4

40 1.2 1.5

60 0.6 0.9

80 0.3 0.5

100 0.2 0.3

Specification


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No.4 BPS Sig.

No.1 GNDNo.2 TA Sig.

No.3 Ref. Voltage 5V

ECM Input/ Output

BPS (Booster Pressure Sensor) / TA (Intake-Air-Temperature)

SensorThese two sensors are integrated into one. Located after the intercooler. BPS

detects the intake air pressure and TA sensor detects the temperature of intake

air.

If BPS value is beyond 0.2V~4.8V for 1. second, ECM regards BPS as failed and

fixes boost pressure to 760mmHg and prohibits EGR operation.

If TA sensor value is beyond 0.1V~4.6V for 5 second, ECM regards TA Sensor as

failed and fixes air temperature to 60 .

Connection with ECM

No.1 ECM Pin No. 41 GND

No.2 ECM Pin No. 19 TA Signal

No.3 ECM Pin No. 33 Reference Voltage 5V

No.4 ECM Pin No. 34 BPS Signal

Temp.( ) Resistance(k) Voltage(V)

-20 16 4.3

0 5.9 3.4

20 2.5 2.4

40 1.2 1.560 0.6 0.9

80 0.3 0.5

100 0.2 0.3

TA Sensor Specification


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19ECM Input/ Output

BPS (Booster Pressure Sensor) / TA (Intake-Air-Temperature

SensorWaveform

ECM Pin No. 34 BPS

Signal at acceleration

from idle to 4200rpm

ECM Pin No. 19

TA Sensor Signal

ECM Pin No. 34

BPS Signal at idle

ECM Pin No. 34 BPS

Signal at 4200rpm


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20ECM Input/ Output

APS (Accelerator Pedal Sensor)

This sensor detects the angle of accelerator pedal.

If sensor value is beyond 0.2V~4.93V for 1. second, ECM regards APS as

failed. If ECM detects APS malfunction, ECM fix accelerator opening to 0%

and prohibit EGR operation.

Connection with ECM

No.1 ECM Pin No. 32 V ref

No.2 ECM Pin No.40 APS Sig.

No.3 ECM Pin No.8 Idle SW Sig.

No.4 Wiring harness GND Idle SW. GND

No.5 ECM Pin No.39 GND

When only idle SW. is good, ECM can increase the accelerator opening to 30%

slowly. (equal to approx 1.5V)

In the event of complete failure, No throttle response


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21ECM Input/ Output

APS (Accelerator Pedal Sensor)

ECM Pin No. 8 at acceleration

ECM Pin No. 40 from idle to Max.

Good conditionIdle Switch ON

Accelerator Pedal Sensor


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22APS (Accelerator Pedal Sensor)

APS output signal failed, Idle Switch good, At Max. Throttle

ECM increases RPM slowly to 30% (4000rp)m

Good condition (Max. Throttle)


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23ECM Input/ Output

CPS (Crankshaft Position Sensor)

This sensor detects the position of crankshaft.

If there is no signal from sensor for 20 consecutive times of Np Sensor, ECM

regards CPS as failed and controls engine with Np (inj pump) Sensor signal.

Note: In this condition Twice ignition applies to start engine

DTC P0335 will be set

Connection with ECM

No.1 Shield GND No.2 ECM Pin No.29 Signal

No.3 ECM Pin No.37 GND

Waveform

CPS

1mm


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24ECM Input/ Output

ECM Pin No. 29 at idle CPS signal with Np signal at idle


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25ECM Input/ Output

FC (Fuel Cut) Valve

When the IG. Key is On, ECM supplies B+ Voltage to open fuel line.

When Immobilizer is on ECM inhibits the connection, (vale remains closed)

Connection with ECMNo.1 ECM Pin No.26 Signal

Waveform

FC Valve signal at idle

F.I.P

Connector

FC Valve

No.1 FC

Valve


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26

Terminal Component Remarks

1 FCV Fuel Cut Valve

2 Adj (-) Adjustment resistor (-)

3 Adj (+) Adjustment resistor (+)

4 CSP Oscillate (+)

5 TCV (+) Timer Control Valve (+)

6 GE (+) GE (+)

7 TF (+) Fuel temperature (+)

8 CSP MDL

9 TCV (-) Timer Control Valve (-)

10 GE- GE (-)11 TF (-) Fuel Temperature (-)

12 CSP Oscillate (-)

61

127

Diagnosis Reference chart

(Checking Pump Components, Ignition off plug disconnected)

Note: Pin arrangement is different to H-1

Pumps are not interchangeable


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Component Plug (No of pins) Terminal Resistance Temp C

Fuel Cut 12 pin black 1--Ground 7 ~ 9 Ohms 23 +- 5Actuator 12 pin black 6 ~ 10 0.71 0.13 Ohms 23 +- 5

TCV 12 pin black 5 ~ 9 11 1.1 Ohms 23 +- 5

TPS 3 pin black 2 ~ 3 82 2 Ohms 23 +- 5

1 ~3 82 2 Ohms 23 +- 5

Speed Sensor 3 pin grey 2 ~ 3 1.020.16 KOhms 23 +- 5

Trim Resistor 12 pin black 3 ~2 same as resistor 23 +- 5CSP 3 pin 4 ~ 8 5.9 0.3 Ohms 23 +- 5

8 ~ 12 5.9 0.3 Ohms 23 +- 5

Fuel Temp 12 pin black 11 ~ 7 0.1 Kohms 25

Diagnosis Reference chart

(Checking Pump Components)


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28ECM Input/ Output

EGR (Emission Gas Re-circulation) Solenoid Valve

There are two EGR Solenoid Valves. One is controlled by duty signal from

ECM and connected from vacuum tank or atmosphere to the other EGR

Solenoid Valves. The other is controlled by On/Off signal from ECM and

connected to EGR Control valve.

Connection with ECM

EGR Vacuum Sol. Valve No.1 ECM Pin No.58 Signal

EGR Vacuum Sol. Valve No.2 Main Relay B+

EGR Sol. Valve No. 1 ECM Pin No.68 Signal

EGR Sol. Valve No. 2 Main Relay B+

EGR Vacuum

Sol. Valve

Atmosphere

Port

From Vacuum

Pump

To EGRControl Valve

EGR Sol. ValveEGR Vacuum Sol.

Valve Out port


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29ECM Input/ Output

ECM Pin No. 68 at acceleration

EGR (Exhuast Gas Re-circulation) Solenoid Valve

Waveform

ECM Pin No.58 at accelerationECM Pin No. 58 at idle


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30ECM Input/ Output

I/C (Inter Cooler) Fan Motor Relay

Terracan has a intercooler fan motor controlled by ECM. Intercooler fan motoris operated when vehicle speed is under 60Km/h and intake air temperature is

over 58 and engine speed is over 550rpm.

Grow Plug Relay

ECM controls the glow plug to heat the intake air through glow plug relay.

According to the condition, the heating time is as below.

Connection with ECMI/C Fan Motor Relay No.85 ECM Pin No.35

Coolant Temp. Heating time

60 2Sec.

-15 8Sec.

-20 10Sec.

-25 15Sec.

-40 24.5Sec.

Coolant Temp. Heating time

60 3Sec.

0 3Sec.

-10 3Sec.

-20 5Sec.

-40 5Sec.

Preheating Post heating

Connection with ECMGlow Plug Relay No.85 ECM Pin No.55


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31ECM Input/ Output

Others

Main relay control

ECM controls Main relay to provide the B+ voltage to actuators like EGR Sol.

Valves, Grow Plug and A/C fan relay etc.

Lamps

ECM controls Engine check lamp and Glow lamp

A/C Fan Motor Relay & A/C Comp. Relay

Connection with ECM

Main Relay No.85 ECM Pin No.73

Engine check lamp ECM Pin No.62

Glow lamp ECM Pin No.63

A/C Fan Motor Relay No.85 ECM Pin No.59

A/C Comp. Relay ECM Pin No.72


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32ECM Controls

Q(Injection amount) ControlsExample)

Injection Quantity

Eng. speed Pump speed

ECM3,000 RPM

37mg/stroke

Accel. Position

50%

Fuel Injection

GE Actuator

2.8 Volt

Control Sleeve

Position Check

CSP

Feedback

CPS

APS

Np Sensor when CPS is failed

IT (Injection Timing) Controls

Injection Timing

Pump speed

Eng. speedECM

Injection Quantity

Duty(%) ControlTCV

InjectionTiming Check

TPS

Feedback

CPS

ECM

Np Sensor when CPS is failed


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33Basic Adjustments (Injection pump timing)

1. Engine stop

2. Turn the crankshaft to place in No.1 Cylinder at top dead center oncompression stroke3. Loosen injection pipe4. Loosen injection mounting bolts and nuts5. Remove timing check plug from injection pump head

6. Attach the special tool and a dial gauge7. Turn crankshaft to such a position that the notch on pulley is at

approximately 30 before top dead center. Then , set dial indicator to

zero.


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34

8. Slightly turn crankshaft clockwise and counterclockwise to make sure

that dial indicator pointer does not deviate from zero position.9. Turn the crankshaft in the normal direction and position the notch of

crankshaft pulley at 5 ATDC. (N/A : 5 T/C : 7 TCI : 7 )

10. If the dial indicator does not indicate the specified value.

Tilt the injection pump body to the right or left until the indicator doesindicate the standard value.

11. Tighten mounting bolt of injection bolts and nuts.

12. Remove special tool and dial gauge

13. Install timing check plug with new copper gasket

Basic Adjustments (Injection pump timing)


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1. Warm up temperature

2. Remove upper timing belt cover and rocker cover

3. Turn the crankshaft clockwise and align the timing mark on the

camshaft sprocket with the timing mark

4. Check the valve clearance indicated in the

diagram(A)

Standard clearance : 0.25mm(0.098in)

5. If not within the standard value, adjust the valve clearance with theadjusting screw and the thickness gauge

6. Rotate clockwise the crankshaft one complete turn (360 )

7. Check the valve clearance indicated in the diagram(B)

Standard clearance : 0.25mm(0.098in)

Basic Adjustments (Valve clearances)


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36HI-Scan


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37HI-Scan

Current Data

See Page 39


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38HI-Scan

Actuation Test


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39HI-Scan DTC List

No DTC No Conents MIL

1 P0105 BAROMETRIC SENSOR - MAL X

2 P0110 INT - AIR TEMP CIRCUIT - NAL X

3 P0115 ENG COOLANT TEMP - MAL O

4 P0120 ACCEL P. SENSOR - MAL X

5 P0121 APS. RANGE / PERFORMANCE - MAL O

6 P0180 FUEL TEMP. SENSOR - CIRCUIT-MAL X

7 P0320 ENGINE SPEED INPUT CIRCUIT - MAL X

8 P0335 CRANKSHAFT P. SENSOR - MAL X

9 P0500 VEHICLE SPEED SENSOR - MAL X

10 P0600 IMMOBILZER COMMUNICATION - MAL O

11 P0605 CONTROL MODULE (EEPROM) - ROM MAL X

12 P0613 ECU - MALFUNCTION X

13 P1116 BOOST PRESSURE SENSOR - MAL O

14 P1120 ELECTRIC GOVERNOR - MAL O

15 P1122 BOOST PRESSURE CONTROL VALVE - MAL O

16 P1123 TIMER POSITION SENSOR - MAL X

17 P1127 CONTOL SLEEVE POSITION SENSOR - MAL O

18 P1131 INJECTION QUANTITY ADJUST - MAL X

19 P1135 INJECTION TIMING SERVO - MAL X

20 P1324 GLOW RELAY - MALFUNCTION O

21 P1522 BATTERY VOLTAGE ERROR O

22 P1525 5V SOURCE VOLTAGE X

23 P1621 FUEL CUT VALVE - MAL O

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Bomba Terracan Electronica