Model Outline Mesin 2KD-FTV Chassis Body Body Electrical

Keseluruhan Mesin
2KD-FTV
– Mesin Diesel D-4D, 2.5 liter, in-line
4-cylinder, 16 valve DOHC dengan turbocharger

2KD-FTV
Model Outline Mesin 2KD-FTV Chassis Body Body Electrical
Referensi
 Umum
– Keuntungan common-rail system

Tekanan injeksi, volume dan timing

dikontrol secara elektronik Kontrol mesin yg akurat

Bahan bakar tekanan tinggi Atomisasi lebih baik

Menyimpan bahan bakar Injeksi tekanan tinggi

tekanan tinggi disemua kecepatan mesin

• High performance dan fuel economy

• Suara dan getaran rendah
• Emisi lebih bersih
Model Outline Mesin 2KD-FTV Chassis Body Body Electrical

ECU

ECU
Model Outline Mesin 2KD-FTV Chassis Body Body Electrical
Common-rail System
Lokasi
Depan

Injection Pipe Injector

Fuel Inlet Pipe

Common-rail
•Fuel Pressure Sensor
Supply Pump •Pressure Limiter
•SCV (Suction Control Valve)
•Fuel Temp. Sensor
Model Outline Mesin 2KD-FTV Chassis Body Body Electrical
Sistem Bahan Bakar
Fitur
NE Signal
Engine EDU
G Signal ECU Injector
Injector
Various compensation
compensation
Max.
Max. 160MPa
160MPa Pressure
Signals code
code
Limiter

HP3
HP3 Type
Type Fuel Common-rail
Supply
Supply Pressure
Pump
Pump Sensor

Pressure
Switch Injector

Fuel
Filter

SCV
Supply Pump
Replacement
Replacement Fuel Filter Warning
Warning lightlight
filter Fuel Tank Warning Light for
for fuel
fuel filter
filter
filter element
element Detects
only Detects clogging
clogging and
and
only filter
filter fuel
fuel sedimenter
sedimenter
clogging
clogging
Model Outline Mesin 2KD-FTV Chassis Body Body Electrical

Decides opening time of injector Controls opening

by final injection volume timing of injector

NE Signal Engine
EDU
G Signal ECU
Various
Signals
Pressure
Limiter
Common-rail
From
Supply Pump
Fuel Pressure Sensor Injector
Model Outline Mesin 2KD-FTV Chassis Body Body Electrical
Common-rail System
Supply Pump
– Bukaan SCV mengontrol volume pemompaan untuk
mengontrol tekanan bahan bakar
[Fuel Pressure Control]
Fuel Pressure
Sensor

Common-rail
pressure
SCV (Feedback)
Controls Crankshaft
SCV Perhitungan Position Sensor
opening target injection
pressure
Accelerator Pedal
Position Sensor
Engine ECU
Model Outline Mesin 2KD-FTV Chassis Body Body Electrical
Common-rail System
Supply Pump
– Mengirimkan tekanan tinggi ke common-rail
– Digerakkan oleh crankshaft

To Common-rail
(Outlet)
From Fuel Filter
(Inlet)

To Fuel Tank
(Return)

SCV
(Suction Control Valve)
Model Outline Mesin 2KD-FTV Chassis Body Body Electrical
Common-rail System
Supply Pump
– Konstruksi

Check Eccentric and Delivery

Valve Ring Cam Valve

Plunger
Feed
Pump

Fuel
Temp.
Sensor
SCV (Suction
Control Valve)
Model Outline Mesin 2KD-FTV Chassis Body Body Electrical
Common-rail System
Supply Pump
– Konstruksi
Ke fuel tank
(kembali)

Ring Cam

Plunger

Eccentric
Cam
Model Outline Mesin 2KD-FTV Chassis Body Body Electrical
Common-rail System
Supply Pump
– Aliran Bahan Bakar
Ke common-rail

Dari Fuel
Tank
Model Outline Mesin 2KD-FTV Chassis Body Body Electrical
Common-rail System
Supply Pump
– Aliran Bahan Bakar (referensi)

Click!
Movie
Model Outline Mesin 2KD-FTV Chassis Body Body Electrical
Common-rail System
Supply Pump
– Penghisapan dan pemompaan

Plunger A: Hisap Plunger A: Pompa

Plunger B: Pompa Plunger B: Hisap
Check
Valve
Plunger A

SCV

Plunger B

: Dari Feed Pump : Ke Common-rail

Model Outline Mesin 2KD-FTV Chassis Body Body Electrical
Common-rail System
Supply Pump
– Penghisapan dan pemompaan

Click!
Movie
Model Outline Mesin 2KD-FTV Chassis Body Body Electrical
Common-rail System
Supply Pump
– Kerja Fuel control (bukaan SCV kecil)

Fuel
Pumping
Mass
Model Outline Mesin 2KD-FTV Chassis Body Body Electrical
Common-rail System
Supply Pump
– Kerja Fuel control (bukaan SCV besar)

Fuel
Pompa
Mass
Model Outline Mesin 2KD-FTV Chassis Body Body Electrical
Referensi
 Supply Pump
– Plunger membuat Negative
Pressure
kevakuman untuk
menghisap bahan bakar
sampai gelembung hilang
Model Outline Mesin 2KD-FTV Chassis Body Body Electrical
Common-rail System
Supply Pump
– Kerja Fuel control (bukaan SCV kecil)

Click!
Movie
Model Outline Mesin 2KD-FTV Chassis Body Body Electrical
Common-rail System
Supply Pump
– Kerja Fuel control (bukaan SCV besar)

Click!
Movie
Model Outline Mesin 2KD-FTV Chassis Body Body Electrical

Solenoid
From Coil
Common-rail
Return to
Fuel Tank

Piston

Nozzle
Spring

Nozzle
Needle
Model Outline Mesin 2KD-FTV Chassis Body Body Electrical
Common-rail System
Injector
– Dikontrol signal dari ECU

Solenoid
Solenoid

TWV
Small
Orifice Return
From
Common-rail Large
Orifice

Click!
Movie
Model Outline Mesin 2KD-FTV Chassis Body Body Electrical
Common-rail System
Injector
– Konstruksi

Solenoid Coil

Dari
Kembali ke
Fuel Tank Common-rail

Piston

Nozzle
Spring

Nozzle
Needle
Model Outline Mesin 2KD-FTV Chassis Body Body Electrical
Common-rail System
Injector
– Injeksi tekanan tinggi untuk atomisasi yang lebih baik

Injector
Compensation
Code
Kembali ke
Fuel Tank Dari Common-rail

0.14 mm
Model Outline Mesin 2KD-FTV Chassis Body Body Electrical
Common-rail System
Common-rail
– Menyimpan tekanan tinggi (Max. 160 MPa) yang
dikirim oleh supply pump
Pressure
Limiter

Fuel
Pressure
Sensor

Common-rail

Dari
Ke Injector Ke Fuel Tank
Supply Pump
Model Outline Mesin 2KD-FTV Chassis Body Body Electrical
Service Point
 Common-rail Replacement
– Common-rail tak boleh di bongkar
(Penggantian Assembly)

To Injector From Supply Pump

Common-rail

[Fuel Pressure Sensor]

Pressure
Sensor Tip Limiter

Common-rail
Pressure
Model Outline Mesin 2KD-FTV Chassis Body Body Electrical

Basic Parameters
Crankshaft Position Sensor (Ne)
Accelerator Pedal Position Sensor (VA)
Injector
Correction Parameters

Intake Air Temp. Sensor (THA) EDU

Water Temp. Sensor (THW)
Fuel Temp. Sensor (THF) EGR Valve
Engine
Turbo Pressure Sensor (PIM)
ECU
Vehicle Speed Sensor (SPD) •
Fuel Pressure Sensor (PCR) •
•
Ignition Switch (STA)
Blower Switch (BLW)
A/C Amplifier (AC) DLC3

Alternator (ALT)
Model Outline Mesin 2KD-FTV Chassis Body Body Electrical

NE Signal Engine
EDU
G Signal ECU
Other Injectors
Various
Signals
Pressure
Fuel Pressure Limiter
Sensor Common-rail

Injector
Pressure
Switch

Fuel Cooler
Fuel
SCV Fuel SystemFilter
Supply Pump Fuel Tank
Warning Light
Model Outline Mesin 2KD-FTV Chassis Body Body Electrical
Common-rail System
Umum
– System ini dapat memberikan tekanan injeksi tinggi di
setiap kecepatan mesin.
NE Signal EDU
Engine
(Operates injector
G Signal ECU at high-speed)
Pressure
Various Limiter
Signals Common-rail
(Stores high-pressure fuel)
Fuel Pressure
Sensor

Injector
(Injects high-pressure fuel)

SCV
Supply Pump
(Generates high-pressure fuel) Fuel Tank

: High-pressure (Max. 160 Mpa/1631 kg/cm2)

Model Outline Mesin 2KD-FTV Chassis Body Body Electrical

 EDU
150V

Voltage
Battery 0V
EDU Time
+B COM1

High
Voltage
Generation
Circuit
High
Voltage
IJT#1
INJ#1
IJT#2
Control INJ#2
IJT#3
Circuit INJ#3
IJT#4
Engine INJ#4
IJF
ECU

GND GND
Model Outline Mesin 2KD-FTV Chassis Body Body Electrical
Common-rail System
EDU (Electronic Driver Unit)
– Mengendalikan injector saat kecepatan tinggi

EDU
Battery High
DC / DC Voltage
Converter

Command
Pulse
IJT
#1-4
Control
Circuit High-speed
IJF
operation
Confirmation
Engine Pulse Injector
ECU
Model Outline Mesin 2KD-FTV Chassis Body Body Electrical
Referensi
Accelerator Pedal
– Non-contact type accelerator pedal position sensor

Accelerator Pedal
Position Sensor
Model Outline Mesin 2KD-FTV Chassis Body Body Electrical
Referensi
 AcceleratorPedal
– Using magnet dan hall IC

VCP1
Magnets
VPA1

Output Voltage (V)

EP1 5

VPA2
VCP2

Hall
IC VPA2
VPA1
EP2 0
Full Close Full Open
Accelerator Engine Accelerator Pedal Depressed Angle
Pedal Position ECU
Sensor
Model Outline Mesin 2KD-FTV Chassis Body Body Electrical
Sistem Intake dan Exhaust
Intake Shutter Valve
– Konstruksi

Rotary Solenoid
Rotary Solenoid
Intake Shutter Valve Type Motor
Intake Shutter Valve Type Motor
Position Sensor
Position Sensor
Steel Layer
Steel Layer
Magnet
Magnet
Hall IC
Hall IC

Magnet
Magnet
Magnet
Magnet
Model Outline Mesin 2KD-FTV Chassis Body Body Electrical
Referensi
Intake Shutter Valve
– Intake shutter valve position sensor

Magnet
Hall IC 5

Output Voltage (V)

VC 3.51

VLU
Engine
ECU 1
0.71
E2 0
0 20 70 100
(Full Close) (Full Open)
Intake Shutter
Intake Shutter Intake Shutter Valve
Valve Position
Valve Position Opening Angle (°)
Sensor
Sensor
Model Outline Mesin 2KD-FTV Chassis Body Body Electrical
Common-rail System
System Outline
Common-rail Diesel Conventional Diesel
Constant high pressure Instantaneously high pressure
Common-rail Pressure
Sensor

System
SCV Governor
Timer
ECU

Injection
Injector Pump
Supply Pump Nozzle
Injection Volume
ECU (Injector) Pump (Governor)
Control
Injection Timing
ECU (Injector) Pump (Timer)
Control
Injection Pressure According to rotational speed
Supply Pump (SCV)
Control and injection quantity
Pressurization Supply Pump Pump
Distribution Common-rail Pump
Injection Pressure Max. 160 MPa Approx. 15 MPa
Model Outline Mesin 2KD-FTV Chassis Body Body Electrical
Service Point
 Common-rail Replacement
– Common-rail tak boleh di bongkar
(Penggantian Assembly)

Jangan
Dibuka
Fuel Pressure !
Sensor

Pressure
Limiter
Model Outline Mesin 2KD-FTV Chassis Body Body Electrical
Common-rail System
Common-rail
– Fuel pressure sensor
• Mendeteksi internal fuel pressure di common-rail

Output characteristic
Sensor Tip

Output Voltage (V)

4.04

2.44

1.0

0 90 190
Common-rail Pressure (MPa)
Common-rail
Pressure
Model Outline Mesin 2KD-FTV Chassis Body Body Electrical
Common-rail System
Injector
– Pilot injection mengurangi NOx dan suara mesin

Main
Injection Pilot
Volume

NOx dan
engine noise

Nilai
Pelepasan
Panas

TDC TDC

Pilot Conventional
Injection Control Injection Control
Model Outline Mesin 2KD-FTV Chassis Body Body Electrical
Service Point
 Program ulang Injector Compensation Code
– Jika injector atau ECU mesin diganti, perlu
memprogram ulang nilai injector compensation
Ganti Nomor
Injektor Injektor baru

Program ulang
data

ECU mesin
Masukan
nomor
Ganti ECU
mesin

Semua nomor
injektor
Model Outline Mesin 2KD-FTV Chassis Body Body Electrical
Service Point
 Program ulang Injector Compensation Code
– Garis besar proses registrasi

Ketika menganti injector(s) Ketika mengganti ECU

Catat data compensation code

Ganti injector(s)
code data

Masukan code compensation

baru secara manual
Ganti ECU
Input
Set
Masukkan compensation codes yg
sudah dicatat
Saved data

Hapus DTC P1601 Hapus DTC P1601

Registrasi selesai Registrasi selesai

Model Outline Mesin 2KD-FTV Chassis Body Body Electrical
Service Point
 Fuel Filter Warning
– Buka elemen Saringan Bahan Bakar

Inlet hose

Fuel
Level

Drain
Cock
Lepas Keluarkan bahan bakar untuk
konektor menurunkan permukaan nya
dan hose
Model Outline Mesin 2KD-FTV Chassis Body Body Electrical
Service Point
 Fuel Filter Warning
– Buka elemen Saringan Bahan Bakar

Obeng

Longgarkan pengunci Lepas dengan tangan

Model Outline Mesin 2KD-FTV Chassis Body Body Electrical
Service Point
 Fuel Filter Warning
– Buka/Pasang Saringan Bahan Bakar element

Element Pasang Saringan

Bahan Bakar

Rumah Element

Pasang O-ring baru

Buka tutupnya, lepas

elemen
Model Outline Mesin 2KD-FTV Chassis Body Body Electrical
Service Point
 Fuel Filter Warning
– Pasang Saringan Bahan Bakar

Tanda

Tanda

Elemen
baru

Pasang elemen baru dan

pasang tutup filter Kencangkan pengunci sampai
(luruskan tanda) tanda nya lurus
Model Outline Mesin 2KD-FTV Chassis Body Body Electrical
Service Point
 Fuel Filter Warning
– Pasang Saringan Bahan Bakar

Inlet Hose

Kencangkan tutup
bahan bakar
Hubungkan
Model Outline Mesin 2KD-FTV Chassis Body Body Electrical
Service Point
 Fuel Filter Warning
– Pasang Saringan Bahan Bakar / Reset warning light

Reset warning light

dalam
3 - 60 detik 3 detik.

IG ON
OFF

Pasang
Model Outline Mesin 2KD-FTV Chassis Body Body Electrical
Service Point
 Fuel Filter Warning
– Pasang Saringan Bahan Bakar / Reset warning light

Keluarkan udara pada

Sistem Bahan Bakar

pompa

Selesai