Olympian Product Entrenamiento _ ~ 5 tf Motor Electronico Serie1300ENGINE IDENTIFICATION The engines consist of a range of six cylinder in-line engines which are turbocharged or turbocharged / intercooled. These engines have an electronic management system. In these notes, we will refer to the different engines types by their code letters, h are the first two letters of the engine number as indicated below. CODE LETTE! CAPACITY ASPIRATION SYSTEM WK 7,6 Litre Turbocharged WL 7,6 Litre Turbocharged / intercooled WM 8,7 Litre Turbocharged WN 8,7 Litre Turbocharged / intercooled WP 7,6 Litre Turbocharged WQ 7,6 Litre Turbocharged / intercooled WR 8,7 Litre Turbocharged WS 8,7 Litre Turbocharged / intercooled ENGINE NUMBERS The engine number is stamped on the left side of the cylinder block, behind the igh pressure oil pump. An example of the engine number is : WK1296N123456B WK Model code letters 1296 Build list number Built in the USA 123456 Engine serial No. B Year of Build code1300 Series Electronic Engine General Data Number of cylindrs.. Cylinder arrangement. Turbocharged or Turbocharged /Intercooled Direct injection 109, 2mm (4.301 in) 135, 9mm (5.350 in} 12,9mm (4.301 in) mm (4.590 in) ..0,64mm (0.025 in) 104 kpa (15 1bf sq in) +276 kpa (40 Ibf sq in) - Maximum no load engine speed & normal temp... oil capacity 22,7 litres (40.0 UK pints) Direction of rotation. Valve seat anglOlympian 1300EDi Models Model Engine Rating Build (HP) List D150P4 1306-E87T 215 WR D200P4 1306-E87TA 300 WS D230P4 1306-E87TA 330 WS* Compliant to EPA and EC Stage 1 emissions legislation « Excellent platform for stage 2 emissions legislation and beyond ¢ No visible smoke * Upto 3.5 dBA quieter, which equates to over a 50% improvement in perceived noiseHEU! SYSTEM svs-sesses ydraulically Actuated i | Lectronically controlled CS. it i njectorHEU! SYSTEM sxsxsren The 1300 series electronic engine uses injector units, which are hydraulically actuated and electronically controlled. This offers vastly improved performance over mechanical systems by controlling the following areas: *Rate Control The rate of injection can be controlled to meet any engine condition, due to the injector being hydraulically actuated rather than mechanically. The rate of injection and injection pressure does not depend on engine speed. ¢Timing Control Both start and end of injection is electronically controlled, unlike conventional electronically controlled mechanically actuated unit injectors, the plunger does not move until the solenoid is energised. This means that plunger movement is not limited to the speed or duration of a cam lobe.HEU! SYSTEM svn-sesrex Injector Unit The injector uses the hydraulic energy of the pressurised oil to Electronic cause injection. The pressure of the incoming oil controls the speed of the intensifier piston and therefore, the rate of injection. The amount Intensifier of fuel injected is determined by Piston the duration of the pulse from the ECM and how long it keeps the solenoid energised. As long as the solenoid is energised and the poppet valve is off its seat, oil Valve continues to push down the intensifier and plunger until the tensifier reaches the bottom of its bore. Solenoid Nozzle AssemblyHEU! SYSTEM sss Injector Unit Top Section Solenoid Armature Poppet Wire to ECMHEU! SYSTEM sss Injector Unit Mid Section +— Oil Outlet Port TW An intensifier piston in the injector OW unit multiplies hydraulic force on | the plunger. By varying the hydraulic input pressure, injection pressure can be controlled ina range from — pjynger 3,000 to 21,000 psi. oT { _— Oil Feed Port Spill Port Fuel PortHEU! SYSTEM sss Injector Unit Bottom Section Spill Port closed during injectionHEU! SYSTEM sss Injector Unit Bottom Section Each injection is made up of two stages. + Pilot Injection * Main Injection Injection Pressure can be as high as 21,000 Psi.HEU! SYSTEM sss Injector Pilot Injection Pilot Injection Delay PeriodSYSTEM OPERATION Engine oil is drawn from the sump by the engine oil pump and flows through the oil cooler and filter to the high pressure supply pump. The supply pump pressurizes the oil to between 450 and 3,000 psi. Pump outlet pressure is determined by the injection pressure regulator valve (IPR) which dumps excess oil to drain. The pressure maintained by the IPR is determined by a variable electrical signal supplied by the Electronic Control Module (ECM).SYSTEM OPERATION High pressure oil is supplied to a pressure rail attached to the cylinder head, and by drillings in the head is available to all injectors. The energised solenoid lifts the injector poppet valve off its seat. High pressure oil from the rail then enters the injector causing injection to occur. Injection ends when the ECM switches off the current to the solenoid. The poppet spring then causes the poppet to close. As the poppet closes, the high pressure supply oil from the rail is blocked and the intensifier piston cavity is connected to drain through the armature cavity.SYSTEM OPERATION The plunger return spring then pushes the intensifier and plunger back to their original position. The upward movement of the plunger lifts the fill check valve off its seat and draws fuel into the plunge cavity for the next stroke. Fuel is drawn from the fuel tank by a mechanical fuel pump and flows through a filter to the pressure rail attached to the cylinder head, via drillings in the head to the injectors. Excess fuel flows back to the tank via a spring loaded valve, which maintains a positive fuel pressure in the pressure rail.HEU! SYSTEM sss P HEUI Injectors Fuel Filter Fuel Transfer Pump (Lift Pump)FUEL FLOW INJECTOR FUEL . MANIFOLD \ REGULATOR ss ss oY ¥ ¥ ¥ RETURN BLEEDER VALVE/TEST POINT 0 PRIMER PUMP . CHECK BALL PuMP STRAINER - FILTER. Ml NEGATIVE PRESSURE 4s lll PRIMARY TRANSFER PRESSURE (UNFILTERED) lll PRIMARY TRANSFER PRESSURE (FILTERED) lll RETURN PRESSURE1 Micron — 100,000 INCH tna ed( its aM ane Human HairFuel Transfer PumpFuel specification Cetane number. 50 minimum Viscosity 2.0/4.5 centistokes at 40°C Density 0,835/0,855 kg/litre Sulphur 0.2% of mass, maximum Distillation 85% at 350°CINJECTOR REMOVAL *Drain Fuel gallery *Drain Oil Gallery -Disconnect Oil Deflection Guard/Wiring Support «Loosen Injector Support Bolt Remove Injector -Fit new seals (allow 15 minutes for seals to contract) +Fit Injector and ReassembleHl FE U | SYSTEM OIL SYSTEM High Pressure Oil Supply Pump (Rexroth) Engine Oil Pump High Pressure Oil Rail To Engine Lubrication Injection pressure regulator valve System ! P 3 HEUI Injectors 0 v4 Y Oil Cooler and Filterye]SOWOY 8 149/009 I!0 dung 49}!4 110 m 3 2 Ss ® QHEUI SYSTEM onsusn fh hal j «a>. High Pressure Oil Rail~. FROM MAIN A GALLERY ip OIL LINE HIGH-PRESSURE OIL PUMP OIL. RESERVOIR DRILLED SUPPLY _ PASSAGE OIL MANIFOLD ~ INJECTION CONTROL PRESSURE SENSOR ~ INJECTION PRESSURE REGULATOR—=— IE Ul SYSTEM OIL SYSTEMHydraulic Pump ¢ Provides oil to the hydraulic Pump during start up ¢ Provides make-up oil to the cylinder headENGINE OIL TEMPERATURE SENSOR FEED TO HIGH PRESSURE PUMP. OLYMPIANOil specification When available API CG-4 or API CH-4 When NOT available API CF-4HEU! SYSTEM Service and maintenance Ref. User’s Handbook 1300 series EdiHEU! SYSTEM ECM management systemEngine Sensors in Ps Oil Pressure Injection Control Pressure Coolant Temperature Boost Pressure Oil Camshaft Temperature PositionHEU! SYSTEM Electronic Control Module Stop / Start Switch HEUI Injectors SensorsCamshaft position sensor Narrow Vain 24 vanes 1 narrow vain Sends engine speed to ECM Sends engine position to ECMCam position sensor Hall effect : Narrow 6 5 4 Volts 3 2 1 0 DegreesHEU! SYSTEM onsvstem wy Ice sensor High pressure oil feeding injectors le Rexroth oil pump IPR valveYIOAYSS3Y SATVA HOLVIND3AY SYNSSAYd NOILOSPNI TOYULNOD dOO71 daso19 YOSNAS SYNSS3ud TOULNOD NOILOSPNI YOLOZPNI MIOJINVWW AYNSS3ud HOIH INALSAS SAHYNSS3AYd TOYULNOD NOILOAPNIHEUI SYSTEM Temperature sensors Thermistor sensors * Oil temp * Coolant temp ¢ Air tempHEU! SYSTEM Pressure sensors Gives ECM information on: ¢ Oil pressure ¢ Injection control pressure * Boost pressure * Barometric pressureFlashing Lights To interrogate the ECM’s memory or identify a fault, the self test button (Red) should be depressed. The (Green) button should be momentarily depressed to initiate the active and inactive fault tests. If there are any active faults, the red lamp will flash once, followed by the amber lamp flashing a numerical code. If more than one active fault code is stored in the ECM’s memory, there will be a short pause after the first code and then the next code will be indicated. When all of the active codes have been indicated the red light will flash twice and the inactive fault codes will be flashed. At the end of the sequence the red light will flash three times to signal the end of the test.Flashing Lights Active Faults @o0d0od = 111 (No Faults) Each active fault will be proceeded by a red flash. Inactive Faults @@o0od = 111 (No Faults) OCC test @ © Both red and amber lights are momentarily on during the output circuit continuity test.Flashing Lights It is possible to perform an output circuit continuity test (OCC) with the the use of the red and green push button on the top of the side panel by : Pressing and holding both buttons for the duration of the test. Push Buttons OCC test Both red and amber lights are Lamps @ © momentarily on during the output circuit continuity test. red amberOlympian Electrical DWG reoeT, EeHEU! SYSTEM Fault finding using the MPSIHEU! SYSTEM Fault finding using PC software Part number 994 - 487 and 994 - 485