Service Training

MALAGA

992G WHEEL LOADER

2. ENGINE CONTROL
1. Components Layout
2. Operation
3. Testing & Adjusting

Adolfo
October 1997
 992G WHEEL LOADER
CHAPTER : ENGINE CONTROL

ENGINE OIL COOLER

COOLANT FLOW SWITCH

ENGINE OIL PUMP

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 992G WHEEL LOADER
CHAPTER : ENGINE CONTROL

FUEL PRIMING PUMP SECONDARY FUEL FILTERS

PRIMARY FUEL FILTERS ENGINE ECM

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 992G WHEEL LOADER
CHAPTER : ENGINE CONTROL
EUI
CYLINDER HEADS
MUI AND EUI
MUI
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Page:
2-5

CHAPTER : ENGINE CONTROL

SECONDARY FUEL
FILTER PRESSURE

992G WHEEL LOADER

REGULATOR
ECM
TRANSFER
PUMP
FUEL TANK
PRIMARY
FILTER

FUEL TANK
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2-6

3508B FUEL SUPPLY CIRCUIT

FUEL
RETURN FUEL PRESSURE
REGULATOR
CYLINDER
HEAD

PRIMING PUMP SUPPLY

CHAPTER : ENGINE CONTROL

DIFFERENTIAL SECONDARY

992G WHEEL LOADER

PRESSURE FUEL FILTERS
SWITCH

PRIMARY
FUEL FUEL
FILTER TRANSFER
FUEL PUMP ECM
TANK
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BASIC ENGINE BLOCK DIAGRAM CAT Data Link
APPLICATION BLOCK DIAGRAM
P26 T/C CONNECTOR
ECM
DISCONNECT
2-7

GROUND SWITCH BATTERY

BOLT
J2

J1
8/12/16 GROUND BOLT 24 V
INJECTORS 15 AMP
BREAKER
MACHINE
INTERFACE
CONNECTOR
SPEED/TIMING
SENSOR
THROTTLE
POSITION
COOLANT UNFILTERED OIL SENSOR
TEMPERATURE KEY START
PRESSURE SWITCH
SENSOR SENSOR
GROUND
LEVEL
AFTERCOOLER FILTERED OIL THROTTLE SHUTDOWN
TEMPERATURE PRESSURE BACK-UP SWITCH
SENSOR SENSOR SWITCH
+ BATTERY

LOW OIL ATMOSPHERIC

LEVEL PRESSURE CYLINDER

CHAPTER : ENGINE CONTROL

SWITCH SENSOR STARTING RELAY
AID SWITCH ENGINE
FUEL FILTER LEFT
DIFFERENTIAL TURBOCHARGER ETHER START VALVE
INLET PRESSURE

992G WHEEL LOADER

PRESSURE SWITCH
SENSOR USER DEFINED SHUTDOWN

COOLANT RIGHT
TURBOCHARGER ELECTRONIC SERVICE
FLOW TOOL CONNECTOR
SWITCH INLET PRESSURE
SENSOR

LEFT TURBOCHARGER
TURBOCHARGER OUTLET
EXHAUST PRESSURE SENSOR
TEMPERATURE
SENSOR CRANKCASE
PRESSURE
SENSOR
RIGHT
TURBOCHARGER ENGINE FAN
EXHAUST CONTROL
TEMPERATURE SOLENOID
SENSOR

A/C ON
SWITCH
FAN PRESSURE SENSOR
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ECM
+V ANALOG A 36 +V ANALOG SUPPLY
ENGINE COOLANT ANALOG RETURN
2-8

ANALOG RETURN B 30
TEMPERATURE SENSOR SIGNAL C

+V ANALOG A
ENGINE OIL ANALOG RETURN B
PRESSURE SENSOR SIGNAL C

+V ANALOG A
TURBO OUTLET ANALOG RETURN B
PRESSURE SENSOR SIGNAL C

+V ANALOG A
RIGHT TURBO INLET ANALOG RETURN B
PRESSURE SENSOR SIGNAL C

CHAPTER : ENGINE CONTROL

5 0.5 VOLTS
+V ANALOG A
ATMOSPHERIC

992G WHEEL LOADER

ANALOG RETURN B
PRESSURE SENSOR SIGNAL C

+V ANALOG A
LEFT TURBO INLET ANALOG RETURN B
PRESSURE SENSOR SIGNAL C

+V ANALOG A
CRANKCASE ANALOG RETURN B
PRESSURE SENSOR SIGNAL C

+V ANALOG A
FAN PUMP ANALOG RETURN B
PRESSURE SENSOR SIGNAL C
 8 0.5 VOLTS
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2-9

THROTTLE
POSITION SENSOR J35 P35 P1 J1 ECM
+V DIGITAL A 29 + V DIGITAL SUPPLY
DIGITAL RETURN B 35 - V DIGITAL RETURN
SIGNAL C

LEFT EXHAUST
TEMPERATURE SENSOR J30 P30
+V DIGITAL A
DIGITAL RETURN B
SIGNAL C

CHAPTER : ENGINE CONTROL

RIGHT EXHAUST
TEMPERATURE SENSOR J31 P31
+V DIGITAL A

992G WHEEL LOADER

DIGITAL RETURN B
SIGNAL C

12 1 VOLTS
SPEED TIMING SENSOR
J84 P84 P1 J1 ENGINE ECM
+V DIGITAL A 32 + 12V SPD//TIM SNSR SUPPLY
DIGITAL RETURN B 29 DIGITAL RETURN
SIGNAL C 38 ENG SPEED/TIMING SNSR
 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 750C 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

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ACCORDING TO ATMOSPHERIC PRESSURE

100% 7,500

98% 8,210

96% 8,920
PERCENT OF FULL LOAD POWER

94% 9,630

92% 10,340

ALTITUDE IN FEET
90% 11,050

88% 11,760

CHAPTER : ENGINE CONTROL

86% 12,470

84% 13,180

992G WHEEL LOADER

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 59 58 57 56 55 54 53

ATMOSPHERIC PRESSURE IN kPa

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2-12

340 49.3

320 46.4

300
300 43.5

280 40.6

250
OIL PRESSURE IN kPa

OIL PRESSURE IN PSI

260 37.7

240 E 34.8

220 LIN 31.9

200 ET 29

RES
NE
180 26.1

CHAPTER : ENGINE CONTROL

160
LI 23.2

140 I P LOW OIL PRESSURE REGION 20.3

TR

992G WHEEL LOADER

120 17.4
94
100 14.5

80 11.6

60 8.7
50 44
40

600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000

ENGINE RPM
kPa x 0.145 = PSI
 992G WHEEL LOADER
CHAPTER : ENGINE CONTROL
E-TRIM CODES
SERIAL No. BAR CODE
SERIAL No.
TRADE MARK

TRIM CODE
PART No.
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 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

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2-15

ENGINE ECM FEATURES

Throttle Lock

CHAPTER : ENGINE CONTROL

992G WHEEL LOADER
Fan Control

Ether Injection System

Page:
2-16

THROTTLE LOCK CIRCUIT

RIGHT BRAKE PEDAL SWITCH

P1 J1 ECM
998-BR F722-OR 13 Throttle Lock RH Brake (NO)
F721-GY 19 Throttle Lock RH Brake (NC)
998-BR 998-BR 29 Digital Return
J3 P3 F706-PU 27 Throttle Lock ON Lamp

CHAPTER : ENGINE CONTROL

THROTTLE F717-YL 14 Throttle Lock Set/Declerate
2 F718-BU 20 Throttle Lock Resume/Accelerate
LOCK LAMP 113-OR BATT+ F719-BR 24 Throttle Lock ON/OFF

992G WHEEL LOADER

998-BR
THROTTLE LOCK
SET/DECLERATION SW
998-BR
THROTTLE LOCK
RESUME/ACCLERATION SW

998-BR
THROTTLE LOCK SW
 992G WHEEL LOADER
CHAPTER : ENGINE CONTROL

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
ENGINE ECM
P86 J86 P2 J2

2 F700-BU 19 HYDRAULIC FAN

1 E799-BR 07 PWM DRIVE AND SOL RETURN

997OR 36 +5V ANALOG SUPPLY

COOLANT TEMP 993BR 30 ANALOG SENSOR RETURN
SENSOR 995-BU 09 COOLANT TEMP SENSOR

IMPLEMENT OIL
TEMP SENSOR
I/F 1 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 70C

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 CONTROL GROUP
(3408E/E3412E) SPEED TIMING
SENSOR
ETHER SWITCH J3 P3 P1 J1
23 F708-YL 28 ETHER SW LAMP
9 998-BR 29 DIGITAL RETURN
39 ETHER REQUEST
721-GY 19
21 COOLANT
710-BR 40 ETHER CONTROL TEMP SENSOR
200-BK

200-BK FROM
P37 J37
+ CYLINDER
308-YL 310-PK 1
2

+24V RELAY ETHER

TO ENGINE
START VALVE

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 < 10C & 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

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 992G WHEEL LOADER
CHAPTER : ENGINE CONTROL
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 992G WHEEL LOADER
CHAPTER : ENGINE CONTROL
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 992G WHEEL LOADER
CHAPTER : ENGINE CONTROL
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 992G WHEEL LOADER
CHAPTER : ENGINE CONTROL
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