ДЕТРОИТ ДИЗЕЛЬ -40 Е

OLYMPIAN GENERATOR SETS
1300 Series Electronic Engine

MDLC Fuel Systems 1
Course Content
•HEUI fuel/Oil system function and operation
•ECM management system
•Fault finding using the MPSI
•Fault finding using PC software
•Service and maintenance
MDLC Fuel Systems 2

Shaping the Future

• Optimised performance characteristics
• Improved engine emissions
• Engine packaging
• New reliability and durability features
• Expanded options range
• New service solutions
MDLC Fuel Systems 3

Engine Performance
• Efficient combustion system
• Fully optimised power, torque and fuel curves for

optimum performance
• No engine power loss due to high fuel temperatures
• Improved transient conditions
• Unaided cold start of -20ºC (-4ºF)
• Stabilised idle
MDLC Fuel Systems 4

Engine Emissions
• Compliant to EPA and EC Stage 1
emissions legislation
• Excellent platform for stage 2

emissions legislation and beyond
• No visible smoke
• Up to 3.5 dBA quieter, which equates

to over a 50% improvement in
perceived noise
MDLC Fuel Systems 5

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,
which are the first two letters of the engine number as indicated below.
CODE LETTERS CAPACITY ASPIRATION SYSTEM
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
high pressure oil pump.
An example of the engine number is :
WK1296N123456B
WK Model code letters
1296 Build list number
N Built in the USA
123456 Engine serial No.
B Year of Build code
MDLC Fuel Systems 6
Olympian 1300EDi Models
D230P4* 1306-E87TA 330 WS
* New model to be released.
MDLC Fuel Systems 7

ydraulically Actuated
lectronically Controlled
nit
njector
MDLC Fuel Systems 8

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:
MDLC Fuel Systems 9

FUEL SYSTEM
•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.
MDLC Fuel Systems 10

FUEL SYSTEM
•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.

Injector Unit
•The injector uses the hydraulic energy of
the pressurised oil to cause injection.
Electronic
•The pressure of the incoming oil controls Solenoid
the speed of the intensifier piston and
Poppet
therefore, the rate of injection.
Valve
•The amount of fuel injected is Intensifier
determined by the duration of the pulse
from the ECM and how long it keeps the
Piston
solenoid energised.
•As long as the solenoid is energised and

the poppet valve is off its seat, oil
Check
continues to push down the intensifier Valve
Nozzle
and plunger until the intensifier reaches
the bottom of its bore. Assembly
FUEL SYSTEM
Injector Unit Top Section
Solenoid
Armature
Poppet
Wire to ECM
FUEL SYSTEM
Injector Unit Mid Section

Oil Outlet Port
An intensifier piston in the injector

unit multiplies hydraulic force on
the plunger.
By varying the hydraulic input Oil Feed Port
pressure, injection pressure can
be controlled in a range from Plunger
Spill Port
3,000 to 21,000 psi.
Fuel Port
FUEL SYSTEM
Injector Unit Bottom Section
Spill Port closed

during injection
Nozzle Assembly
Needle
FUEL SYSTEM
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.
FUEL SYSTEM
Injector Pilot Injection
Pilot Injection Main Injection

Delay Period
FUEL SYSTEM
5 Stages of Injection
FUEL SYSTEM
FUEL SYSTEM
FUEL SYSTEM
FUEL SYSTEM
FUEL SYSTEM
FUEL SYSTEM
Pressure
Relief
Valve
X
HEUI Injectors
Fuel Filter
Fuel Tank
Lift Pump
FUEL SYSTEM
INJECTOR
FUEL REGULATOR
MANIFOLD
RETURN
BLEEDER VALVE/TEST POINT
PRIMER PUMP
CHECK BALL
FUEL INLET
PUMP
STRAINER
FUEL FLOW
FILTER
NEGATIVE PRESSURE
PRIMARY TRANSFER PRESSURE (UNFILTERED)
PRIMARY TRANSFER PRESSURE (FILTERED)
RETURN PRESSURE



Fuel specification
Cetane number. 50 minimum

Viscosity 2.0/4.5 centistokes at 400C
Density 0,835/0,855 kg/litre
Sulphur 0.2% of mass, maximum
Distillation 85% at 3500C








Oil Sump
Engine Oil High Pressure Oil

Pump Supply Pump (Rexroth)
To Engine High Pressure Oil Rail

Lubrication
Injection pressure regulator valve
System
HEUI Injectors
Oil Cooler and Filter
OIL SYSTEM
OIL SYSTEM
High Pressure
Oil Rail
Rexroth
Pump
OIL SYSTEM
OIL SYSTEM
High Pressure Oil Rail
Relief
Valve
Rexroth Pump OIL SYSTEM

Oil Filter
Oil Cooler & Engine Oil
Thermostat Pump

ENGINE OIL
TEMPERATURE
SENSOR
FEED TO HIGH
PRESSURE PUMP

Oil specification
When available
API CG-4 or API CH-4
When NOT available
API CF-4

•Drain Oil gallery

•Drain Fuel 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

ECM management system

Engine Sensors Oil Pressure

Injection
Control
Pressure
Coolant
Boost Temperature
Pressure
Oil
Temperature Camshaft Position

Electronic Control
Module
ECM Stop / Start
Switch
HEUI Injectors Sensors

ECM
ICP
sensor
High pressure oil feeding injectors
IPR Valve Solenoid
Rexroth IPR
oil pump valve

INJECTION
ECM
CONTROL
PRESSURE
SYSTEM
INJECTION CONTROL
PRESSURE SENSOR INJECTOR
REXROTH
HIGH
PRESSURE
PUMP
HIGH PRESSURE MANIFOLD

HOSE
RESERVOIR INJECTION PRESSURE REGULATOR VALVE

ICP OLYMPIAN GENERATOR SETS
IPR ECM

IPR Valve Parts

IPR Valve Operation

IPR Valve Operation

IPR Valve Operation


Cam position Narrow

sensor (CPS) Vain
• 24 vanes
• 1 narrow vain
• Sends engine speed to ECM
C.P.S
• Sends engine position to ECM


Cam position sensor

Hall effect
Narrow vain
6
5
4
Volts
3
2
1
0
Degrees
Temperature sensors
Thermistor sensors
• Oil temp
• Coolant temp

System Components - Temperature Sensors

Output Curve
Ohms Volts
(Resistance)
250,000 Volts 5.0
Ohms
50,000 1.0
Increasing Temperature
ENGINE COOLANT TEMPERATURE SENSOR INFORMATION
TEMPERATURE SENSOR
THERMISTOR
Ohms (resistance) Volts
250,000 5
ECT 200,000 4
ENGINE COOLANT
TEMPERATURE Volts
SENSOR 150,000 3
Ohms
100,000 2
50,000 1
0 0
-40 0 32 68 104 140 176 212 248 284
-22 14 50 86 122 158 194 230 266 302
Temperature F

Coolant
Temp

ENGINE OIL TEMPERATURE SENSOR INFORMATION
TEMPERATURE SENSOR
Ohms (resistance) THERMISTOR
Volts
250,000 5
Default
212°F
200,000 4
Volts
150,000 3
Ohms
100,000 2
50,000 1
EOT
ENGINE OIL
TEMPERATURE 0 0
SENSOR
-40 0 32 68 104 140 176 212 248 284
-22 14 50 86 122 158 194 230 266 302
Temperature F

Oil Temp


Pressure sensors
Gives ECM information on:
• Oil pressure
• Injection control pressure
• Boost pressure (MAP)
• Barometric pressure (MAP)

System Components - Pressure Sensors

Change of Voltage with Pressure.
V
4.5
0.5
PRESSURE
MAP SENSOR INFORMATION
PRESSURE SENSOR
VARIABLE CAPACITANCE
5
Out of range high
4
V
O
L 3
T
S 2
1
Out of range low
0
MAP 1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35
MANIFOLD ABSOLUTE
PRESSUE SENSOR P.S.I.

ENGINE OIL PRESSURE SENSOR INFORMATION

PRESSURE SENSOR
5
Out of range high
4
V
O 3
L
T 2
S
1
0 Out of range low
1 11 21 31 41 51 61 71 81 91
EOP
ENGINE OIL OIL PRESSURE
PRESSURE SENSOR

INJECTION CONTROL PRESSURE SENSOR INFORMATION

PRESSURE SENSOR
Volts
5
Out of range high
Default
3 range
Out of range low

0
400 800 1200 1600 2000 2400 2800 3200 3600
P.S.I.

MAP
ICP
Oil Pressure



Sensor
Rai s
Camsha
P
l ressur HEUI Positio
ft
Contr
e Injectors n
ol Injection
Valve Engin Pressur
Control
High C
e ontr e
Oil Supply
Pressure Modul
ol Manifold
Pump e Pressur
Absolute
e
To Oi
Lubricati
Engine lTemperatu
Syste
on re
Filte
Oil m Oi
r lPressur
e
Coola
Coole
Oil Temperatu
nt
r re
Engin
e
Oil Pump
Fue Fue Fue

Sum
Oil l Transfer
l l
On/
p Tank Pump Filter
Off
LEGEN
Switch
D
Fuel
System
Hydraulic
System
Electronic
System


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.

Service and maintenance
Ref. User’s Handbook

1300 series Edi

Diagnostics Tools
• On engine flash codes
• MPSI - hand held 4 line display tool “PRO-LINK”
– Connected to ECM via standard diagnostic connector
– Engine operational data
– Fault code data
– Diagnostic routines
• PC based software and interface unit

– Functions as “PRO-LINK” (except display)

Flashing Lights
Active Faults
= 111 (No Faults)
Each active fault will be proceeded
by a red flash.
Inactive Faults
= 111 (No Faults)
OCC test
Both red and amber lights are momentarily
on during the output circuit continuity test.
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
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.
Green Red Push Buttons
OCC test
Both red and amber lights are
Lamps momentarily on during the
red amber
output circuit continuity test.

Olympian Electrical DWG

Olympian Electrical DWG

D27533E_0.DWG
Heui Relay Box

Fault finding using the MPSI

Fault finding using PC software
Part number 994 - 487 and 994 - 485

DIAGNOSTIC FUNCTIONS
This option allows you Diagnostic test are used to

to view all fault codes test the continuity of the
and clear inactive codes. electrical circuits and certain
functions in the ECM.
A data list is a list of fixed You may change the value The data recording facility
of variable data items of some parameters on the allows you to capture data
that the ECM monitors. engine to customize its operation from the engine data list over
a specified time period and
save the recorded data to a file.

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OLYMPIAN GENERATOR SETS

1300 Series Electronic Engine

•ECM management system

•Fault finding using the MPSI

•Fault finding using PC software

•Service and maintenance

MDLC Fuel Systems 2

Shaping the Future

• Improved engine emissions

• New reliability and durability features

• Expanded options range

• New service solutions

MDLC Fuel Systems 3

• Fully optimised power, torque and fuel curves for

• No engine power loss due to high fuel temperatures

• Improved transient conditions

• Unaided cold start of -20ºC (-4ºF)

MDLC Fuel Systems 4

• Excellent platform for stage 2

• Up to 3.5 dBA quieter, which equates

MDLC Fuel Systems 5

CODE LETTERS CAPACITY ASPIRATION SYSTEM

WR 8,7 Litre Turbocharged

Olympian 1300EDi Models

D230P4* 1306-E87TA 330 WS

* New model to be released.

MDLC Fuel Systems 7

MDLC Fuel Systems 8

The 1300 series electronic engine uses

This offers vastly improved performance

MDLC Fuel Systems 9

The rate of injection can be controlled to meet any

MDLC Fuel Systems 10

Both start and end of injection is electronically

MDLC Fuel Systems 11

•As long as the solenoid is energised and

Injector Unit Top Section

Injector Unit Mid Section

An intensifier piston in the injector

Injector Unit Bottom Section

Spill Port closed

Injector Unit Bottom Section

Each injection is made up

Injection Pressure can be as high

Injector Pilot Injection

Pilot Injection Main Injection

BLEEDER VALVE/TEST POINT

MDLC Fuel Systems 25

MDLC Fuel Systems 26

MDLC Fuel Systems 27

Cetane number. 50 minimum

MDLC Fuel Systems 28

MDLC Fuel Systems 29

MDLC Fuel Systems 30

MDLC Fuel Systems 31

MDLC Fuel Systems 32

MDLC Fuel Systems 33

MDLC Fuel Systems 34

MDLC Fuel Systems 35

Engine Oil High Pressure Oil

To Engine High Pressure Oil Rail

High Pressure Oil Rail

Rexroth Pump OIL SYSTEM

MDLC Fuel Systems 42