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Cummins ISL-G Fuel Systems Level One

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Cummins ISL-G Fuel Systems Level One Cummins ISL-G Fuel Systems Level One Technical Resource Guide Doing what matters for jobs and the economy with funding provided by the California Energy Commission (senate bill AB118) through a partnership with the California Community Colleges, Offi ce of Workforce Development, Advanced Transportation and Renewable Energy sector. Project Director/Editor Cal Macy Development team of Subject Matter Experts Cal Macy Bob Vannix Rich Mensel Pete Sparks Photography Cal Macy Bob Vannix Created by: Long Beach City College Advanced Transportation Technology Center 1305 E. Pacifi c Coast Highway Long Beach, CA 90806 562-938-3067 http://www.lbcc.edu/attc/ This material is based upon work supported by the [email protected] California Energy Commission under Grant No. 12-041-008 Revision 1 ISL-G Fuel Systems October 1, 2014 COURSE INTRODUCTION Course Title Reference Material installed on technician-provided USB drive upon completion of levels I and II. Cummins ISL-G Level I Prerequisites Course Length Familiarity with Multi-meters, Electrical I or 16 hours CNG courses. Course Description Objectives This course is designed to give technicians the hands- Upon completion of the course, students will be able to: on skills needed to diagnose and repair the 8.9L ▪ Analyze Mass Air Flow Fuel Management Systems Cummins ISL-G CNG Fuel System. The course in- ▪ Identify and evaluate the following parameters with a cludes discussion of: DVOM ▪ Computerized engine management system ▪ Temperature Sensors operation ▪ Pressure Sensors ▪ Sensors ▪ Position Sensors ▪ Actuators ▪ Voltage Producing Sensors ▪ Pin-out voltage values ▪ Mass Gas and Air Flow Sensors ▪ Cummins Electronic Service Tools ▪ Set up INSITE™ to compare readings on parameters It is intended to raise the reliability of the industry and the confidence of the general public in understanding the characteristics, safe handling and working around Competence LNG storage systems. Competence will be measured by both lab Course Benefits demonstration, pre and post tests. Students receive a wealth of experience working on the system and understanding where everything is located and how it works. This class is a must for technicians involved with diagnosis and repair of CNG engine management and fuel delivery systems. Students will learn the proper and safe methods of working with the high-pressure CNG fuel systems using DVOMs and the laptop diagnostic software specific to the Cummins controllers. ISL-G Fuel Systems 1 Course Introduction Important Agenda The Material presented here is intended for ▪ Component Identification and Location instructional purposes only. Please be sure to follow ▪ Taking Resistance and Voltage Measurements manufacturer’s latest bulletins and procedures as the ultimate source. ▪ Temperature Sensors ▪ Cummins Diagnostic Tools ▪ INSITE™ Introduction ▪ Pressure Sensors ▪ Position Sensors ▪ Voltage Producing Sensors ▪ Mass Gas and Air Flow Sensors ▪ Actuators, Solenoids, Switches and Miscellaneous Signals 2 ISL-G Fuel Systems Course Introduction Pretest ISL-G Fuel Systems 1. What is the function of temperature sensors? a. Equates a resistance to a temperature b. Equates a temperature to a resistance c. Equates a current to a resistance d. Equates a voltage to a temperature 2. What is the function of pressure sensors? a. Equates a pressure to a resistance b. Equates a current to a pressure c. Equates a pressure to a voltage d. Equates a voltage to a pressure 3. What sensing device does the ECM look at to control fuel delivery? a. Engine Coolant Temperature Sensor / Pressure Sensor b. O 2 Sensor c. Engine Manifold Pressure Sensor d. Engine Manifold Temperature Sensor 4. What is closed-loop? a. ECM gets the air fuel mixture data from the Exhaust Temperature Sensor b. ECM gets the air fuel mixture data from the Engine Coolant Sensor c. ECM gets the air fuel mixture data from the Engine Manifold Pressure Sensor d. ECM gets the air fuel mixture requirements from the O2 Sensor 5. What sensor acts as a choke for fuel enrichment? a. Turbine Temperature Sensor b. Intake Manifold Pressure Sensor c. Engine Coolant Temperature Sensor d. EGR Temperature Sensor 6. What is the purpose of the Knock Sensors? a. Sense for engine detonation and advances timing b. Sense for engine detonation and retards timing c. Sense for engine detonation and lean out the fuel mixture d. Sense for engine detonation and increase engine load ISL-G Fuel Systems 3 Table of Contents A. Introduction ▪ Pretest 1. Theory of Operation ▪ Mass Air Flow Systems ▪ Cummins Powertrain Management ▪ Inputs: Sensors ▪ Review Questions ▪ Activity 1.1 2. Inputs ▪ Temperature Sensors ▪ Testing Temperature Sensors ▪ Engine Coolant Temperature Sensor ▪ Intake Manifold Pressure/Temperature Sensor ▪ Turbocharger/Compressor Inlet Humidity/Temp Sensor ▪ Turbine Inlet Temperature Sensor ▪ EGR Temperature Sensor ▪ Fuel Outlet Pressure/Temperature Sensor ▪ Catalyst Temperature Sensor ▪ Mass Air Flow Temperature Sensor ▪ Review Questions ▪ Activity 1.2 ▪ Pressure Sensors ▪ Intake Manifold Pressure/Temperature Sensor ▪ Atmospheric Pressure Sensors ▪ Intake Manifold Pressure/Temperature Sensor ▪ EGR Differential Pressure Sensor ▪ Mixer Inlet Pressure Sensor ▪ Fuel Inlet Pressure Sensor ▪ Fuel Outlet Pressure/Temperature Sensor ▪ Engine Oil Pressure Sensor ▪ Review Questions ▪ Activity 1.3 ▪ Speed Sensors ▪ Speed Sensor Types ▪ Camshaft Speed/Position Sensor (EPS) ▪ Crankshaft Speed/Position Sensor (ESS) ▪ Vehicle Speed Sensors ▪ Position Sensors ▪ Throttle Plate Position Sensors 1 and 2 ▪ Accelerator Pedal Sensors 4 ISL-G Fuel Systems ▪ Remote Accelerator Pedal Assembly ▪ EGR Position Sensors ▪ Review Questions ▪ Activity 1.4 ▪ Signal Producing Sensors ▪ Catalyst Inlet Oxygen Sensor ▪ Catalyst Outlet Oxygen Sensor ▪ Testing Heated Oxygen Sensors ▪ Signal Producing Sensors ▪ Combustion Knock Sensors 1 and 2 ▪ Combustion Knock Control Systems ▪ Review Questions ▪ Activity 1.5 ▪ Mass Sensing ▪ Mass Gas Sensor ▪ Mass Air Flow Sensor ▪ Review Questions ▪ Activity 1.6 ▪ Turbocharger Compressor Inlet Humidity Sensor ▪ Coolant Level Sensor ▪ ICM Spark Voltage and Misfire Signals ▪ CAN, J1939 and J1587 Data Bus ▪ Switched ECM Inputs 3. Outputs ▪ Outputs, Actuators, Solenoids and Signals ▪ Fuel Control Valve ▪ Wastegate Control Valve ▪ Activity 1.7 ▪ Throttle Actuator ▪ Fuel Shut-Off Valve ▪ Activity 1.8 ▪ Electronic EGR Valve ▪ Warning and Indicator Lamps ▪ Control and Data Signals ▪ Ignition Control Module ▪ Coil Over Plus Ignition ▪ Review Questions Test CNG Safety Considerations References ISL-G Fuel Systems 5 Module One 1 6 ISL-G Fuel Systems Theory of Operation content. The second O sensor, referred to as the ISL-G Theory of Operation 2 Post-Cat HO2S, is located after the output of the The ISL-G system uses a mass airflow and mass gas catalytic converter. Its only function is to monitor the measurements to determine the correct fuel delivery condition of the catalytic converter. It is not used to based upon the engine operating conditions that determine the air-fuel mixture. are present. The airflow measurement is used to The first O sensor’s output is used by the ECM to precisely mix the correct amount of fuel delivery with 2 the metered air entering the engine. A fuel control verify that the fuel control valve position and throttle solenoid is used as an injector to meter fuel delivery plate actuator position are providing the desired exhaust gas condition. If the oxygen content of the with an O2 sensor. This allows the ECM to adjust fuel trim to maintain the most ideal ratio for the operating exhaust indicates a mixture that is rich or lean, the O sensor input to the ECM takes priority over the mode of the engine. An ideal ratio, switching evenly 2 control valve. The second O sensor’s output is between lean and rich, called “stoichiometery” is 2 needed for proper 3-way catalyst operation. used by the ECM to verify the catalyst is operating properly by measuring how effectively it’s storing The control system for this engine is a closed-loop and releasing oxygen. control system. The CM2180A ECM determines the The ECM will use the O sensor information to adjust amount of fuel being delivered by the fuel control 2 valve. It also controls the throttle plate position and the fuel control valve and throttle plate actuator fuel control valve open time to provide the correct positions and provide proper fuel delivery. This air/fuel ratio based upon driver and vehicle demands. compensation deviation commanded by the ECM can In addition, the ECM monitors use the gas mass flow be monitored using INSITE™. If the compensation sensor to compare actual fuel flow to commanded deviation exceeds set limits, the system reverts to fuel flow to compensate for errors. open-loop operation. The ECM uses preprogrammed look-up table parameters to meet various conditions to satisfy engine requirements when the engine is in open-loop (engine warming up or faults codes are set), and relies on the pre-cat O2 sensor to provide the air-fuel mixture update information when the engine is in closed-loop mode. Each time the engine is started it is in open-loop mode for approximately 1½ to 2 minutes before going into closed-loop mode. The engine uses a closed-loop control system for Pre-Catalyst Oxygen Sensor its operation. There are two O2 sensors on this engine. The pre-cat oxygen sensor is located just after the turbocharger and before the 3-way catalytic converter. This O2 sensor is used to notify the ECM of the current air-fuel mixture by its oxygen ISL-G Fuel Systems 7 Module One The industry utilizes two basic fuel systems, speed Cummins Powertrain Management density and mass airflow. Speed density reacts to changes in manifold absolute pressure. Mass airflow Computers only react where they have been reacts to volume of air entering the engine. Cummins programmed to do so. To operate properly, the mass airflow fuel management uses features from computer must receive a clean steady power supply both systems with the addition of two pressure and have a proper ground. The ECM receives input sensors and a gas mass flow sensor.
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