The engine monitoring system incorporates the follow- ing features:
Coolant system level Coolant temperature Engine speed Fuel pressure Fuel temperature
Inlet manifold air temperature Oil pressure
The engine is programmed for warning, derate and stop:
I Warning. Orange icon
Warning icon on driller’s control panel turn on in order to alert the operator that one or more of the engine pa- rameters is not within normal operating range.
II Warning - Derate. Orange Icon
Warning icon on driller’s control panel turn on in order to alert the operator that one or more of the engine pa- rameters is not within normal operating range.
After the warning the engine will derate speed and power output. Fully derated, the engine speed will be 1350 r/min and output max. 120 kW. The icon will flash during the derate phase.
III Warning - Derate-Stop. Red Icon
Warning icon on driller’s control panel turns on in order to alert the operator that one or more of the engine pa- rameters is not within normal operating range.
After the warning the engine will derate speed and power output until a shutdown of the engine occurs. A shutdown of the engine may occur within 20 sec- onds. The engine can be restarted after a shutdown for use in an emergency. However, if the cause of the initial shutdown still exists, the engine may shut down again within 20 seconds.
Coolant system level
Correct coolant level is of vital importance. The engine may be seriously damaged if the coolant level is too low and the engine is allowed to overheat.
Fault type FMI Warning Result
Coolant level low 17 Yellow warning Warning Coolant level low 18 Yellow warning Engine derate Coolant level low 1 Red warning Engine stop
Coolant system temperature
The engine coolant temperature sensor monitors the temperature of the engine coolant. The coolant temperature signal is sent to the ECM for engine monitoring and for improved engine control. The sig- nal is used by the ECM for all of the following engine functions: Engine timing control, operating mode and engine protection. The ECM is capable of adjusting the engine timing relative to the engine operating tem- perature. The concept of dynamic timing provides the engine with the ability to control exhaust emissions. Timing control also aids in white smoke cleanup during cold engine operation. The ECM also uses the signal from the engine coolant temperature sensor to deter- mine the mode of operation for the engine. Several aspects of engine operation are affected by the engine operating mode: acceleration ramp rates, engine tim- ing, and fuel injection timing.
Fault type FMI Warning Result
Sensor error - Yellow warning ECM error Coolant temp high 15 Yellow warning Engine high temp Coolant temp high 16 Yellow warning Engine derate Coolant temp high 0 Red warning Engine stop
50 © 2012 Atlas Copco Craelius AB | 2012-05-15
06 Operation Explorac 220 RC Ed.1
Engine speed
The engine speed governor monitors the throttle po- sition and the actual engine speed in order to help control the following items: engine speed, response, torque output, and smoke limiting. The engine speed governor also helps to maintain constant engine speed. The engine speed is controlled by the govern- ing of the fuel injection duration of the electronic unit injectors. Throttle input is used to calculate the desired engine speed.
Fault type FMI Warning Result
Engine speed high - Red warning Engine stop Fuel pressure
The fuel pressure sensor monitors filtered fuel pres- sure. Although fuel pressures that are outside the normal operating range may adversely affect engine performance, there should not be any noticeable re- duction in the engine horsepower. Abnormal fuel pres- sure will not cause an engine shutdown. A low filtered fuel pressure may indicate that the low pressure fuel system requires maintenance.
The fuel pressure sensor measures the fuel pressure after the fuel has been filtered. The sensor connector for the fuel pressure sending unit is located on the ma- chine side of the machine connector. For more infor- mation, refer to the Caterpillar Troubleshooting Guide for this engine.
,Please refer to the maintenance section in Caterpillar Operation and Maintenance Manual for further infor- mation on fuel system maintenance.
Fault type FMI Warning Result
Fuel pressure over max 16 Red warning Engine stop Fuel pressure high 15 Yellow warning Engine derate Fuel pressure below min 18 Yellow warning Low fuel level Fuel pressure over max 0 Yellow warning - Fuel pressure sensor Yellow warning ECM error Fuel temperature
The fuel temperature sensor monitors the inlet fuel temperature. The ECM utilizes the signal from the fuel temperature sensor to provide fuel temperature com- pensation for the engine fuel control system. Fuel tem- perature compensation provides stable rated power and accurate fuel consumption rates e.g. optimum fuel consumption. Changes in the temperature of the fuel effect the power output of the engine. The ECM adjusts the engine fuel rate according to the tempera- ture of the fuel. This feature allows full engine power to be realized by the operator at any fuel temperature. Fuel temperature will also affect the calculation of fuel consumption rate that is performed by the ECM. The ECM utilizes the fuel temperature signal to provide an adjusted value for these calculations.
High fuel temperature is an undesirable condition. The “High Fuel Temperature” parameters are pro- grammed to warn, derate and shutdown the engine in order to protect the engine.
Fault type FMI Warning Result
Fuel temp over max
0 Red
warning
Engine stop
Fuel conservation practices
The efficiency of the engine can affect the fuel econ- omy. Follow the recommended procedures in order to attain performance for the life of the engine.
Cold engines consume excess fuel. Thermostats and coolers must be kept in good working condition. Observe the service indicator. Replace air and fuel
filters according to program.
Avoid spilling fuel. Fuel expands when the fuel is warmed up. The fuel may overflow from the fuel tank. Inspect fuel lines and connections for leaks. Repair as needed.
Be aware of the properties of the different fuels. Use only the recommended fuels. Refer to Caterpillar’s Operations and Maintenance manual: Fuel recom- mendations.
Avoid necessary idling. Shut off the engine rather than idle for long periods of time.
Maintain batteries and electrical system in good or- der.
Ensure that belts are properly adjusted and in good condition.
Do not engage driven components unless required (compressor loading, water pumps etc.).
51 © 2012 Atlas Copco Craelius AB | 2012-05-15
06 Operation Explorac 220 RC Ed.1
Engine air intake temp
The air inlet temperature sensor detects the tempera- ture of the air that is passing through the inlet mani- fold. A signal is sent to the ECM for interpretation. The ECM uses the information from the inlet air tem- perature sensor in order to accurately control the emissions level of the engine. As the inlet air tempera- ture changes, the fuel injection timing is advanced. This is done in order to maintain the exhaust emission standards.
Excessive inlet air temperature is an undesired operat- ing condition. The “High Engine Air Inlet Temperature” parameter is programmed for warning and derate for protection of the engine.
Fault type FMI Warning Result
Intake air over max - Yellow warning High temp Intake air over max 15 Yellow warning High temp Intake air over max 16 Yellow warning Engine derate Air filter stop - Yellow warning Air filter, engine
Engine oil pressure
Typical oil pressure for an engine at rated speed with SAE 10W30 or SAE 15W40 is 3-6 bar. A lower oil pressure is normal at low idle. If the load is stable and the gauge reading changes, check the oil level: remove the load, reduce speed to idle, shut down the engine and allow time for the lubrication oil to settle. Check the oil level. Maintain the oil level at the recom- mended level. Low engine oil pressure is an undesir- able operating condition. When a low oil pressure condition occurs in the engine there is a possibility of major engine failure. The Low Engine Oil Pressure parameter for the monitoring system is programmed to Derate or Shutdown in order to protect the engine against damage from low engine oil pressure.
Fault type FMI Warning Result
Oil pressure below min 17 Yellow warning Low oil pressure Oil pressure below min 18 Yellow warning Engine derate Oil pressure below min 1 Red warning Engine stop Engine oil sensor error - Yellow warning ECM- error
Atmospheric pressure sensor
The atmospheric pressure sensor measures the pres- sure in the engine crankcase. This sensor assumes that crankcase pressure is a representation of atmo- spheric pressure. A signal is sent to the ECM. The ECM utilizes the value that is read by the atmospheric pressure sensor for the following functions:
Reference source for pressure sensor calibrations Calculating the operation altitude
Calculating boost pressure Checking for air inlet restriction
When the ECM is powered, all of the pressure sen- sors that are used for engine monitoring receive an automatic calibration. The ECM uses the value that is received from the atmospheric pressure sensor to cal- culate the pressure offset value. The ECM also utilizes atmospheric pressure to determine the active engine derate during high altitude operation. The engine mon- itoring system compares the current atmospheric pres- sure value to the programmed derate set point. The engine is derated by limiting the fuel delivery at a rate approximately 3 % for each 300 m (1000 ft) of altitude. Actual boost pressure is calculated by subtracting the atmospheric pressure from the turbocharger outlet pressure. Boost pressure is used for calculating fuel system adjustments.
ECM = Electronic Control Module FMI = Failure Mode Identifier
52 © 2012 Atlas Copco Craelius AB | 2012-05-15
06 Operation Explorac 220 RC Ed.1