Clase 4

MODULO 6
Sistema de
Admisión y
escape
Objetivos esperados del Modulo 6.
 El objetivo de este modulo es familiarizarnos con el sistema de admisión y escape los nuevos
componentes y turboalimentadores que trae la aplicación.

• Vista general del sistema

• Sistema de Admisión
• Filtros primarios
• Filtros secundarios
• Sistema Escape
• Bellows
• Wastegate, flujo y funcionalidad
• Análisis Parámetros

186
Modulo 6.1
Sistema de admisión.

Have Fun
187
Especificaciones de sistemas.

188
Intake and Exhaust: High Pressure Turbochargers – Single & 2 Stage

• Model HE800 High Pressure Turbochargers

• Qty 4 - HE800’s, wastegated, on single stage
• Qty 2 - HE800’s, wastegated, on two stage

• Utilizes coolant cooled bearing housing

• Coolant supply from water manifold
• Coolant returns to Thermostat Housing
Single Stage
• Oil supply from oil manifold in flywheel housing.
• Oil drain through block drains.

• Utilizes turbo speed sensor

• 4 on Single stage
• 2 on 2 stage

Two Stage
Intake and Exhaust: Low Pressure Turbochargers - 2 Stage

• Model HE1000 Low pressure

Turbochargers (Qty 2 on 2 stage)

• Used as a mounting location for the Intake

NOx sensor

• Exhaust outlet piping must be at least 8

inches in diameter

• Oil Cooled Only

Sistema de admision y escape: Arreglo del Sistema. Doble etapa
simplificado

• 4 Turbochargers
• 2 HE800 HP
• 2 HE1000 LP
• Smaller Intercoolers
• New Front and Rear oil
cooler cover plates
• Provide HTC coolant
supply and return for
Intercoolers

Larger Aftercoolers for T4:

• Single Stage and Two Stage.
• Holds 30% more coolant than T2
• Less restrictive than T2
Sistema de admision y escape: Arreglo del Sistema. Doble
etapa simplificado
Vistas generales.

Views.

193
Vistas generales motor doble etapa
Flujo sistema de admisión motor
doble etapa
Intake and Exhaust: 2 stage Intercoolers

Be Careful on install.
Make sure intercooler
is lined up with LP
Turbo so as to not
damage orings and
create a boost leak.
Ejemplo Sensores de restricción Aire
(FIT)

198
Intake and Exhaust: Factory Supplied Valves (ASOV)

• Air Shutoff Valve (ASOV)

• AMOT Valve
• Dedicated Circuit Breaker/Relay
• Currently has a 600 Hour Maintenance
Timer/Check however suggest check be
performed at each oil change interval to
avoid faults. FC logs if check not performed.
• FC5292 – Excessive Time since last engine air
shutoff maintenance test – condition exists
• Safety Device
• Option is offered from the plant
• No longer a sole aftermarket upfit
Intake and Exhaust: Factory Supplied Valves (ASOV)
2
• 4 major components:
1. Valve body
• Includes integrated male/female Marmon
flanges.
2. Actuator
• Sealed housing with solenoid activated latch
system. Actuator also has a position switch to
indicate the state of the valve (open/closed).
3. Reset Handle/Torsional Spring
• Manual way of closing or resetting the Gate.
(Knurled Handle)
4. Gate
• Metal disc that blocks air flow

4
3 1
Intake and Exhaust: Factory Supplied ASO Valves

• Power-to-close device

• When valve solenoid is energized, the actuator unlatches allowing

the gate to close under the force of the torsional spring.

• If a normal overspeed shutdown signal from the controller does not

shut down the engine, a secondary overspeed signal triggers an air
shut off shutdown. Fuel is shut off at the same time and the beacon
on top of the Customer Interface Box (C.I.B) will come on.

• The valves must be manually reset by rotating the reset handle until
the actuator clicks and holds the gate open

• The engine ECM prevents engine start when one or more air shutoff
valves is closed.

• Both shut off valves can be manually closed by pushing the E-stop
button on the power module control panel.
• (NOTE: this is an emergency action ONLY and should not be
utilized for normal shutdown of the engine)
Intake and Exhaust: ASOV Controls

• Mounted to the left bank rear aftercooler housing.

Intake and Exhaust: ASOV Controls – FC 5292 Information

• Fault Description (QSK50 O&G Example)

• Excessive Time Since Last Engine Air Shutoff Maintenance Test -Condition Exists
• Current ASO maintenance timer is 600 Hours (Calibration CW60008.08)
• Suggest procedure be performed at each oil change interval (500 hrs) to avoid faults on job locations.
• How to Clear Fault:
• With engine running at idle speed - Depress and Hold Overspeed Verify momentary switch on local
panel (see picture on next slide).
• Increase engine speed > 1200 RPM.
• Engine fueling will stay on and ASO’s will close after crossing 1200 RPM speed threshold. This is
different than E-kill button where fueling is turned off in addition to closing ASO valves. Leaving fuel on
ensures valves are fully closing and air is truly being cut-off to engine.
• After a successful shutdown – turn off ignition switch prior to manually resetting ASO valves. F/C
5221 will result otherwise!
• After resetting both ASO valves manually, turn ignition back on.
• Fault code 5292 should be inactive
• Operate unit normally
Modulo 6.2
Sistema de escape.

Have Fun
205
Sistema de escape tipo pulsante igual a los
utilizados en los motores tier 1 y tier 2
Ubicación válvula WG
Posicion de las válvulas WG. Funcion
 La válvula WasteGate: Como trabaja?
 Ubicada en el lado de la descarga del Variable WG Valve.

turbo compresor
 Una simple válvula de mariposa que
cuando abre desvía parte del flujo de los
gases de escape hacia el turbo.
 Al bypasear el flujo de los gases de
escape se reduce la velocidad del turbo y
esto por lo tanto, reduce el flujo del aire.
Waste Gate Variable Waste Gate
Valve Module
Waste Gate
Actuator

La válvula es ajustable electrónicamente desde totalmente cerrada a totalmente

abierta. Una apertura total provocara que mas gases de escape sean baypaseados
resultando en una reducción en la presión de turbo.
Exhaust
Turbine
Compressor Wheel
Intake and Exhaust System - Wastegates
• 2 utilized on 2 stage
• Bypasses exhaust flow around HP turbo to LP
turbo

• 4 utilized on single stage

• Bypasses exhaust flow around each HE800
turbo to exhaust outlet

• Uses a Brushless Motor to actuate the

wastegate

• Spring loaded to the closed position.

• Does about 4 open/close sweeps at key off
and an autozero span check at key on.

• Actuator is coolant cooled by LTA circuit

Ubicación válvula WG
Postratamiento. Sistema SCR
FC associates to Wastegate.
•
Cummins Fault
Code
SPN FMI Description Lamp
Los códigos presentados están disponibles para
251 1189 7 Engine Turbocharger Wastegate Actuator 2 Position Control - Mechanical System Not Responding or Out of Adjustment AMBER
las válvulas 1 /2
• Considera igualmente que aun no esta
545 1188 7 Engine Turbocharger Wastegate Actuator 1 Position - Mechanical System Not Responding or Out of Adjustment AMBER
disponible el manual de controles para confirmar
3919 5372 15 Engine Turbocharger Wastegate Actuator 1 Temperature - Data Valid But Above Normal Operating Range - Least Severe Level AMBER
estos códigos por lo tanto es un borrador de las
3925 1188 2 Engine Turbocharger Wastegate Actuator 1 Position - Data Erratic, Intermittent, or Incorrect AMBER
posibles fallas que podríamos encontrar en este
3969 1188 6 Engine Turbocharger Wastegate Actuator 1 Position - Current Above Normal or Grounded Circuit AMBER tipo de válvulas
3971 1188 5 Engine Turbocharger Wastegate Actuator 1 Position - Current Below Normal or Open Circuit AMBER • Confirma en el manual los FC
3972 1189 2 Engine Turbocharger Wastegate Actuator 2 Position - Data Erratic, Intermittent, or Incorrect AMBER
asociados a la válvula de compuerta
3973 1189 6 Engine Turbocharger Wastegate Actuator 2 Position Circuit - Current Above Normal or Grounded Circuit AMBER

3974 1189 5 Engine Turbocharger Wastegate Actuator 2 Position Circuit - Current Below Normal or Open Circuit AMBER

5329 1188 13 Engine Turbocharger Wastegate Actuator 1 Position - Out of Calibration AMBER

5331 1188 31 Engine Turbocharger Wastegate Actuator 1 Position - Condition Exists None

5332 1189 13 Engine Turbocharger Wastegate Actuator 2 Position - Out of Calibration AMBER

5333 1189 31 Engine Turbocharger Wastegate Actuator 2 Position - Condition Exists None

5594 1188 12 Engine Turbocharger Wastegate Actuator 1 - Bad Intelligent Device or Component AMBER

5595 1189 12 Engine Turbocharger Wastegate Actuator 2 - Bad Intelligent Device or Component AMBER

5598 1188 9 Engine Turbocharger Wastegate Actuator 1 - Abnormal Update Rate AMBER

5599 1189 9 Engine Turbocharger Wastegate Actuator 2 - Abnormal Update Rate AMBER

5613 5385 15 Engine Turbocharger Wastegate Actuator 2 Temperature - Data Valid But Above Normal Operating Range - Least Severe Level AMBER

5638 6889 3 Engine Turbocharger Wastegate Actuator 1 Power Supply - Voltage Above Normal or Shorted to High Source AMBER

5639 6889 4 Engine Turbocharger Wastegate Actuator 1 Power Supply - Voltage Below Normal or Shorted to Low Source AMBER

5641 6889 18 Engine Turbocharger Wastegate Actuator 1 Power Supply - Data Valid But Below Normal Operating Range - Moderately Severe Level AMBER

5644 6890 18 Engine Turbocharger Wastegate Actuator 2 Power Supply - Data Valid But Below Normal Operating Range - Moderately Severe Level AMBER
Tipos de falla que tiene la válvula.
• SISTEM MECANICO NO RESPONDE
• DATO VALIDO PERO POR SOBRE EL RANGO DE OPERACIÓN NORMAL (TEMPERTAURA) valvula (1)
• DATO ERRATICO INTERMITENTE O INCORRECTO
• CORRIENTE POR SOBRE LO NORMAL O CIRCUITO A MASA (POSICIÓN)
• POSICIÓN, FUERA DE CALIBRACIÓN
• POSICIÓN, CONDICIÓN EXISTE
• DISPOSITIVO O COMPONENTE DEFECTUOSO
• VELOCIDAD DE ACTUALIZACIÓN ANORMAL (1)
• DATO VALIDO PERO POR SOBRE EL RANGO DE OPERACIÓN NORMAL (TEMPERTAURA) valvula (2)
• POWER SUPPLY CORTO ALTO (1)
• POWER SUPPLY CORTO BAJA (1)
• DATO VALIDO PERO POR DEBAJO DEL RANGO DE OPERACIÓN NORMAL (1)
• FUERA DE RANGO DATO BAJA CONDICION NORMAL(2)
Bonus Track (parameters & FC CM2350).

Cummins
SPN FMI Description Lamp
Fault Code

155 105 0 Intake Manifold 1 Temperature - Data Valid But Above Normal Operating Range - Most Severe Level RED
158 1131 0 Intake Manifold 2 Temperature - Data Valid But Above Normal Operating Range - Most Severe Level RED
783 105 10 Intake Manifold 1 Temperature - Abnormal Rate of Change RED
2157 1131 10 Intake Manifold 2 Temperature - Abnormal Rate of Change RED
5114 3562 1 Engine Intake Manifold 2 Pressure - Data Valid But Below Normal Operating Range - Most Severe Level RED
5945 1319 0 Engine Intake Manifold Pressure Bank Imbalance - Data Valid But Above Normal Operating Range - Most Severe Level RED

Cummins
SPN FMI Description Lamp
Fault Code
122 102 3 Intake Manifold 1 Pressure Sensor Circuit - Voltage Above Normal or Shorted to High Source AMBER
123 102 4 Intake Manifold 1 Pressure Sensor Circuit - Voltage Below Normal or Shorted to Low Source AMBER
153 105 3 Intake Manifold 1 Temperature Sensor Circuit - Voltage Above Normal or Shorted to High Source AMBER
154 105 4 Intake Manifold 1 Temperature Sensor Circuit - Voltage Below Normal or Shorted to Low Source AMBER
156 1131 3 Intake Manifold 2 Temperature Sensor Circuit - Voltage Above Normal or Shorted to High Source AMBER
157 1131 4 Intake Manifold 2 Temperature Sensor Circuit - Voltage Below Normal or Shorted to Low Source AMBER
488 105 16 Intake Manifold 1 Temperature - Data Valid But Above Normal Operating Range - Moderately Severe Level AMBER
1636 1128 3 Intake Manifold 2 Pressure Sensor Circuit - Voltage Above Normal or Shorted to High Source AMBER
1637 1128 4 Intake Manifold 2 Pressure Sensor Circuit - Voltage Below Normal or Shorted to Low Source AMBER
1984 1131 16 Intake Manifold 2 Temperature - Data Valid But Above Normal Operating Range - Moderately Severe Level AMBER
5944 1319 16 Engine Intake Manifold Pressure Bank Imbalance - Data Valid But Above Normal Operating Range - Moderately Severe Level AMBER

216
Agenda y resumen de Modulo 6.
• Diagnostic Test :
 Preguntas en el test (Dudas, consultas)
• Revisemos lo aprendido, Highlight modulo 6:

• Vista general del sistema

• Kit FIT
• Sistema de Admisión
• Diámetros de piping
• Descripción de los componentes
• Diagrama de flujo
• Sistema Escape
• Bellows
• Wastegate, flujo y funcionalidad
• Descripción de los componentes
• Diagrama de flujo

217