Control of an overhead crane is impossible without specific knowledge and skills about special equipment of this type. This allows you to speed up the process of work, make the use of the device more efficient at times. The machine is used to move loads of various sizes, dimensions in industrial enterprises, warehouses.
Why is the overhead crane so popular?
Experts identify three main reasons that positively affect the growth in demand for equipment among the population of Ukraine:
- reliability;
- practicality in operation;
- high technical characteristics.
In addition, the mechanisms have three modes of operation (based on the basic purpose):
- easy;
- average;
- heavy.
This approach facilitates the operation of bridge-type equipment.
Design device features
Before starting to control a device of this type, it is necessary to understand how an overhead crane works. The design consists of a cabin, crane way, cargo trolley and bridge. It is allowed to have an auxiliary device that is capable of lifting 3-5 times less load than the main part. The electric drive starts the mechanism. It also guarantees three working strokes: lifting / lowering the load, moving the trolley, the bridge.
It is worth mentioning the beam crane - view overhead crane, in which the electric hoist is a cargo trolley. Their carrying capacity is over 5 tons. Such equipment is controlled using a pendant control.
Where to start work
Before embarking on direct duties, the crane operator must perform the following steps:
- read the entries in the watch log;
- receive a crane;
- make sure the design is correct.
The driver receives a key-mark for driving a special vehicle. This action has a set order. If the transfer is carried out at the time of repair, the procedure is postponed until the end of the work.
When entering the cab, the crane operator must follow the safety rules. In addition, he is obliged to check all mechanisms for malfunctions. If a breakdown is detected, the driver must report it.
Control methods
The crane is controlled in several ways:
- Regulation is carried out from the floor using a special wired or radio remote control.
- Control of the operation of the crane from the operator's cab.
Operating a crane from the floor does not require special skills. Over a short period of time, you can learn the main principles of the mechanism. An overhead crane control panel simplifies complex tasks.
Main functions:
- climb;
- descent;
- stop (neutral position)
- speed detection;
- emergency stop.
Floor operated bridge cranes are most often used for cranes that have a small lifting capacity. The results of this method are as accurate as possible, the safety is at the highest level.
For lifting / lowering loads of significant weight, use equipment controlled from the cab of an overhead crane. Such designs are subject to mandatory registration with the relevant authorities. Only a trained driver is allowed to operate such a special vehicle, who must know how to operate the crane.
Separately about the requirements for the cab driver
To the person who is in the crane cabin, they put forward increased requirements. He must:
- have technical knowledge of the operation of technology;
- be able to navigate in emergency and emergency situations;
- know "perfectly" crane control systems;
- be stress-resistant, responsible employee.
Crane control involves correct use levers and other means, according to the work performed. It also provides for monitoring the maintenance of the system in working condition. Special attention It is recommended to pay attention to the adjustment of clutches and brakes.
It is difficult to work with such equipment, which affects professional qualities driver.
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The company's specialists also provide installation and maintenance services for this type of equipment. The work is carried out by highly qualified craftsmen with experience of 3 years.
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Before starting work, the crane operator authorized to operate the crane must:
- read the entries in the watch log;
- accept the crane;
- make sure that all mechanisms, metal structures, assemblies and other parts of the crane, as well as the crane track, are in good condition.
The crane operator is obliged to receive a brand key for controlling an overhead crane in the manner established by the enterprise from the crane operator handing over the shift (from the person responsible for issuing brand keys). If at the time of acceptance the crane is under repair, then the key-mark is accepted upon completion of the repair from the person responsible for the repair.
The crane operator is obliged to observe safety measures when entering the crane cabin. If the entrance to the crane cabin is arranged through a bridge, then for magnetic cranes, the trolleys supplying the electromagnet should not be turned off when the door is opened in the end railing and should be fenced or located in a place inaccessible to contact;
The crane operator should inspect the crane mechanisms, their fastenings and brakes, as well as undercarriage and anti-theft grips.
It is also necessary to check the presence and serviceability of the mechanism guards and the presence of dielectric mats in the cab.
It is necessary to check the lubrication of the transmission, bearings and ropes, as well as the condition of the lubricators and glands, inspect in accessible places crane metal structures, welded, riveted and bolted connections.
The condition of the ropes and their fastening on drums and in other places is checked. Particular attention is paid to the correct laying of ropes in the streams of blocks and drums.
The hook is inspected, its fastening in the holder, the closing device on it (the same applies to another replaceable load-gripping body - a non-hook).
The presence of interlocks, safety devices and devices on the crane, the serviceability of the crane lighting and working area;
A thorough inspection of the crane tracks is necessary gantry crane and dead ends, as well as inspection of electric motors in accessible places, trolleys (or flexible current-carrying cable), current collectors, control panel, protective earth.
Attention should be paid to the fact that between the gantry crane and the stacks of goods and other structures along the entire length of the crane path there must be passages with a width of at least 700 mm.
Together with the slinger, the crane operator must check the serviceability of removable load-handling devices and containers, their compliance with the mass and nature of the cargo, the presence of stamps or tags on them indicating the carrying capacity, test date and number.
Inspection of the crane is carried out only when the mechanisms are not working and the switch in the crane operator's cab is turned off.
Inspection of the current-carrying cable is carried out with the switch turned off, which supplies voltage to the crane.
If it is needed additional lighting, a portable lamp with a voltage not higher than 12 V can be used.
After inspecting the crane for its testing, the crane operator must turn on the knife switch and the contact lock of the protective panel.
Before putting the crane into operation, the crane operator is obliged to test all the mechanisms of the crane in vain and at the same time check the serviceability of the operation:
- crane mechanisms and electrical equipment;
- brakes for lifting and moving mechanisms;
- interlocks, signal device, safety devices and devices available on the crane;
- zero lock magnetic controllers;
- emergency switch and contact lock with brand key.
In the event that the crane operator has detected malfunctions (malfunction) that prevent safe work, and if it is impossible to eliminate them on their own, the crane operator, he is obliged, without starting work, to make an entry in the logbook and notify the person responsible for the safe performance of work by cranes, and the engineering and technical worker responsible for the maintenance lifting machines in good condition.
It is forbidden to start work if:
- there are cracks or deformations in the metal structure of the crane, bolted or riveted connections are loosened;
- rope clamps are damaged or missing or their bolts are loose;
- the load rope has a number of wire breaks or wear that exceeds the norm established by the crane operation manual, as well as a broken strand or local damage;
- the mechanisms for lifting the load, moving the crane or trolley are defective;
- parts of the brakes or crane mechanisms are damaged;
- the wear of the hook in the throat exceeds 10% of the initial height of the section, the device that closes the mouth of the hook is faulty, the fastening of the hook in the holder is broken;
- faulty or missing interlocks, audible signaling device, Limit switches mechanisms for lifting cargo, moving a crane or trolley;
- rope blocks or pulley blocks are damaged;
- load hook or blocks do not rotate;
- there are no guards for mechanisms or non-insulated live parts of electrical equipment, and there is no or damaged grounding;
- crane ways are faulty;
- anti-theft devices are damaged or missing;
- deadlines for technical inspection, repair, Maintenance and preventive examination.
It is forbidden for the crane operator to correct malfunctions of electrical equipment, connect the crane to the power supply, replace fuses, connection of heating devices. In the event of such malfunctions, the crane operator is obliged to call an electrician.
In addition, the crane operator is obliged to check the availability of a certificate for the right to sling cargo and a distinctive sign from the slinger who first starts working with him.
The crane operator does not have the right to start work if workers who do not have a slinger's certificate are allocated for slinging loads.
The crane operator must ensure that there is sufficient illumination of the working area in the area of the crane.
An appropriate entry is made in the watch log about the acceptance of the crane. After receiving the task and permission to work from the person responsible for the safe operation of cranes, the crane operator can start work.
OOO KranShtal offers to significantly reduce the likelihood of emergency situations at work. We will provide the most a full range of maintenance services for lifting equipment of domestic and foreign production.
Produced by our certified specialists:
- checking the condition of crane tracks (leveling of crane tracks);
scheduled inspections of the technical condition of the hoists;
scheduled inspections of crane beams (overhead cranes), steel structures, etc.
will ensure your peace of mind and the safety of your employees at the facility.
Driving a truck crane is a hard but interesting job. Those who have ever seen competitions professional excellence machinists must have admired how professionals close a matchbox with a hook without crushing it. Each driver has his own developments, which he is unlikely to tell uninitiated people about. But it is useful and interesting to know the basics of working on a truck crane even for those who simply hire equipment for loading and unloading or building a house.
During construction, truck cranes are usually used for “zero cycle” work, that is, when laying the foundation. Loading and unloading operations can be carried out either manually or using machinery. The first way is called - manual, the second - mechanized. The latter is mandatory for loads weighing more than 50 kg, as well as when lifting loads to a height of more than 2 m.
Before starting work, the truck crane driver reads the project of construction and installation works, if the crane is used in construction, or inspects the site where loading and unloading will take place. If there is a power line closer than 30 meters from the work site, the driver must obtain a work permit to operate the crane.
A truck crane is allowed for use, the resource of which has not yet been exhausted. The operation of decommissioned cranes is technically prohibited.
Before starting work, the driver inspects the crane that has not yet been launched, checks technical condition mechanisms, readiness for work. Then the operator checks the serviceability of the mechanisms at idle.
The work area must be well lit. If there is heavy fog, snowfall within the working area, and the crane operator does not distinguish between the load and the signals of the slinger, work stops until improvement weather conditions. The crane operator does the same during a thunderstorm or in strong winds.
In winter, the truck crane can only work with permissible sub-zero temperature indicated in his data sheet. For example, the truck crane KS-45717 can be used at temperatures from +40 to -40 degrees Celsius. Faucets also have humidity limits. environment. Usually, at temperatures above 25 Celsius, the humidity should be no more than 80%.
For work in more severe climatic conditions, for example, in the tropics or in the Far North, special models truck cranes.
The truck crane must be serviced by a team of at least 2 people - a driver and a slinger. In some firms, it is believed that one person can be both. But technically this is unacceptable, since the crane operator must always be in the cab, behind the control panel. From there, he controls the situation.
A slinger is a person who secures loads for lifting. For this there is special devices- slings. All slingers are trained by profession, no one will take a person “from the street” to fasten tons of bricks and metal. On the contrary, the more experience the slinger has, the better. After all, when securing different loads, sometimes you have to solve very intricate engineering problems!
A load weighing 5-10 tons can be secured by one slinger. It is already physically unrealistic to sling a load weighing 40-50 tons alone. In some cases (cargo weighing 80-100 tons, special climatic conditions etc.) three or more slingers may be needed. The load is fixed only in a stable position, not in weight and not at an angle. If the weight of the load is unknown, it will be slinged and moved only after determining the actual weight.
Lifting, lowering, transferring cargo, braking are performed smoothly, without jerks. When moving, the load must rise above the objects encountered on the way by at least half a meter.
Do not believe the stereotype "Construction is a place where accidents happen all the time." Any risky technical work- shipbuilding, car repair and even installation of wiring in a residential building. Therefore, they all require compliance with safety regulations. About what you can not do when the truck crane is working, we describe in detail in the corresponding article. And if you do not make gross mistakes, working with a truck crane will be easy technical process. Quite challenging - and just as exciting.
Proper control of the crane ensures smooth, without jerking and swinging, moving the load, as well as accurately stopping it over a given place. This reduces the cycle time, increases the productivity of the crane and ensures the safety of the riggers and assemblers serving the cargo.
Tower crane mechanisms are controlled from the crane cab. In addition, for a number of cranes, one or more mechanisms can be controlled from a remote control panel during the installation and dismantling of cranes.
Cabin control. The direction of movement of the handles, levers or flywheels of controllers and controllers installed in the crane cabin, as a rule, corresponds to the direction of the movements they cause (Fig. 125).
Rice. 125. The direction of movement of the handles of controllers in a unified cabin of cranes KB
Turning on the handles by the driver away from himself corresponds to lowering the load (boom) or turning to the right, and turning the handles towards you corresponds to lifting the load (boom) or turning the crane to the left. The crane cab rotates with the tower, so the forward and backward movement of the crane may not match the position of the cab relative to the construction site. In this regard, when working on cranes with a rotary cabin, it is recommended to conditionally take any of the ends of the crane path as the initial one, so that the movement of the crane from it corresponds to the direction "Forward", and to it - the direction "Back".
Depending on the design of the crane and the electric drive circuit, the control of the mechanisms of cranes of various types has its own characteristics. Detailed information about the control is given in the Operating Instructions supplied with the crane by the manufacturer.
When operating a crane, a number of provisions must be observed that are common to cranes of any type.
Crane mechanisms can be switched from forward to reverse only after a complete stop. Sudden switching of the mechanism without stopping causes large dynamic loads on the crane and can lead to a breakdown of the mechanism and even to an accident of the crane.
If you need to quickly stop several mechanisms to prevent an accident or accident, you should disable emergency switch. This will turn off the line contactor and the motors will be disconnected from the mains.
It is forbidden to use the limit switches to stop the crane mechanisms, except for the cases of checking the operation of the limit switches before starting the shift.
It is forbidden to use a remote control panel to control the crane when moving loads, since when controlled from the remote control, the operating modes of the electric drive do not correspond to the normal modes when controlled from the cab. In addition, when switching control to a remote control in the crane circuit, some of the protective devices are shorted out: maximum relays, limit switches, alarms.
It is not allowed to use self-made releasing devices with manual or foot control that are not registered in the crane passport for smooth landing of the load.
The mechanism should be turned on smoothly, with shutter speeds at each position of the controller. A sharp transfer of the control handle from zero to the last position is not allowed if the circuit does not provide for stepwise acceleration under the control of a time relay.
Low (landing) speeds of the mechanisms should be used for a short time and only for precise setting of the load. Work on low speed for a long time reduces the performance of the crane, and in some cases (for example, a drive with a brake machine) leads to overheating and rapid failure of electrical equipment.
The nature of the control is determined by the crane electric drive scheme, however, the same scheme requires different control methods for the turning or moving mechanism, cargo or boom winch. So, with the usual regulation of the engine speed by stepping the ballast in the rotor circuit, the speed of lifting the load or boom increases when the controller handle is moved from zero to the last position, and when lowering the load or boom, the speed in the first positions of the controller will be greater than in the last position. This phenomenon does not apply to some drive schemes (double motor winch, drive with brake machine, system Mr. direct current), in which the first positions of the descent correspond to a low (landing) speed obtained by special regulation.
For the mechanisms of rotation, movement of the crane and the cargo trolley, an increase in speed is characteristic when the handle is moved from the first position to the last, regardless of the direction of movement of the mechanism.
Remote control. Control of mechanisms from a remote control is carried out only during installation and adjustment of the crane, when the driver cannot be in the control cabin.
Rice. 126. Remote control panel of the K.B-401A crane: 1 - buttons S25, S26 for controlling the movement mechanism, 2 - buttons S24, S23 for controlling the turning mechanism, 3 - buttons S28, S27 for controlling the boom winch, 4-6 - buttons SI9, S20 , S21, S22 cargo winch control, 7 - emergency switch S10
The remote control is a metal box (Fig. 126), in which control devices (buttons, emergency switch, etc.) are placed, connected to the electrical equipment of the crane with a multicore cable 18-20 m long.
Depending on the electrical circuit different types cranes from the remote control, you can control all the mechanisms or part of the crane mechanisms. Switching on the devices of the remote control when controlling the mechanisms should be carried out only in the sequence that is permitted by the Crane Operating Instructions.
IN electrical diagrams cranes are provided with a blocking, which excludes the possibility of simultaneous control from the cab and from the remote control. This interlock is usually performed using a universal switch that switches the control circuit to the cab or remote control.
ELECTRONIC ENGINE CONTROL SYSTEM
SAFETY REQUIREMENTS FOR OPERATION OF A VEHICLE WITH ELECTRONIC SYSTEMS
1. When repairing or replacing elements of electronic systems on a car, the battery must be disconnected;
4. Voltage measurements in the system must be made only with appropriate measuring instruments! Input impedance measuring instrument must be at least 10 MΩ;
5. Connectors of the electronic control unit should be disconnected and connected to the unit only when the starter and instrument switch key is in the “off” position;
6. It is not allowed to operate a car with a circuit resistance between the “minus” of the battery and the connector of the electronic unit of more than 3 ohms;
7. When conducting electro welding work by car is necessary;
Disconnect all connectors of the electronic unit;
Disconnect the battery by removing the tips of the positive and negative battery cables from the battery terminals;
The tips of the positive and negative battery cables are electrically connected to each other.
At the same time, the main power switch of the car, which turns off the "plus" battery, must be on (its contacts must be closed).The grounding of the welding machine must be connected as close as possible to the welding site.When carrying out welding work on the cab, connect grounding only to the cab, and when welding on the vehicle chassis - only to the chassis;
9. When carrying out painting work, the electronic components of the system can be heated in the drying chamber to a temperature of 95°C for a short time (up to 10 minutes), and at a temperature in the drying chamber of no more than 85°C up to 2 hours. In this case, the batteries must be disconnected.
10. Change fuses, control lamps and disconnect / connect cables and other switching devices only when the power (battery) of the car is turned off.When replacing a fuse, be sure to use a fuse of the same rating.
11. Not allowed short circuit conclusions of the electronic control unit to the mass or positive pole of the power source.
12. It is not allowed to open - close the contact connector of the electronic control unit when the power source is on.
ELECTRONIC ENGINE CONTROL SYSTEM KAMAZ
Auto maintain functions constant speed"Cruise control";
Execution of restriction functions top speed or speed limits at the request of the driver.
The system contains:
The electronic unit management,
High pressure fuel pump rail solenoid;
Retracting electromagnet;
Sensors (see fig.Installation of sensors on the engine):
The speed sensor of the camshaft high pressure fuel pump;
Coolant temperature sensor;
Fuel temperature sensor;
Charge pressure and temperature sensor air;
Cruise switch - control / speed limit;
Engine diagnostic mode switch;
Auxiliary button brake system;
Fuel supply pedal;
Brake pedal sensor;
Parking brake sensor;
Engine emergency stop valve;
Clutch pedal sensor. The distance between the clutch pedal sensor 1 and the clutch pedal 2 should be 1.5 ± 0.5 mm, if necessary, the distance should be adjusted with the nut 4 (see Fig. Sensor installation clutch pedal).
Clutch pedal sensor installation: 1 - clutch pedal sensor; 2 - clutch pedal; 3 - clutch pedal bracket; 4 - nut
In addition to the basic modes of operation(fuel management, auxiliary brake) the system performs a number of functions that provide additional consumer qualities car.
Installation of sensors on the engine: 1 - speed sensor crankshaft engine; 2 - speed sensor of the camshaft of the injection pump; 3 - coolant temperature sensor; 4 - fuel temperature sensor; 5 - charge air temperature and pressure sensor; 6 - harness of the engine control system, 7 - electromagnet of the injection pump rack; 8 - retracting electromagnet; I - to the electronic control unit
Fast engine warm-up;
Quick pumping of the brake system;
Better control of variable power on the output shaft in power take-off mode (possibility to set different values idling engine, depending on the operating mode or the type of power take-off used (for example, for one power take-off 1000 min -1, for another 1200 min -1, etc.)).
Speed control idle move engine is produced on a stationary vehicle.
Idle speed adjustment can be carried out both by the fuel supply pedal and by the cruise control lever located on the steering column (see fig. Cabin). The functions of the cruise control lever (in some vehicle configurations) can be performed by the idle speed / cruise control speed / speed limit switch 13 and the set / reset switch 14 (see Fig. SCH flow of instruments ").
Unlike pedal control, the cruise control lever and switches 13 and 14 fix the set idle speed (see tableIdle speed control/cruise control speed/speed limit mode).
Maintaining the set speed "Cruise control"
In the cruise control mode, the vehicle speed is maintained at a given level by controlling the engine speed. The mode can be activated when the vehicle speed is at least 25 km/h.
The cruise control mode can be controlled using the cruise control lever located on the steering column or, in certain vehicle configurations, the idle speed control / cruise control speed / speed limit mode switch 13 and the set / reset switch 14 (see table
The cruise control mode is activated when the cruise control / speed limit switch 12 is in the upper fixed position (see Fig. instrument panel and Table of switches on the instrument panel f. "IKAR-LTD"),
After turning the instrument and starter switch to the first fixed position, the cruise control speed set value is erased.
To avoid possible damage car and for personal safety, it is not recommended to use the cruise control mode V following cases:
- on winding roads, under difficult driving conditions, when driving at variable speeds, etc., when it is impossible to keep the car at a constant speed;
On slippery roads.
Speed limit mode
In the speed limit mode, you can set the desired limit value for the speed of movement. The mode is activated when the vehicle speed is at least 25 km/h.
The speed limit mode can be controlled using the cruise control lever located on the steering column or, in some vehicle configurations, the idle speed control / cruise control speed / speed limit mode switch 13 and the set / reset switch 14 (see tableIdle/speed control/cruise control/speed limit control).
The activation of the speed limit mode occurs in the middle or lower fixed positions of the cruise control / speed limit switch 12.
After turning the instrument switch and starter to the first fixed position, the set speed value is erased.
|
cruise control lever |
The switch of regulation of idling turns / speed cruise - kontrol; speed limit mode 13* set/reset switch 14* |
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|
idle control |
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To increase the crankshaft speed |
Pull the cruise control lever up in the direction of the "+" arrow until the desired idle speed is reached. |
Press switch 13 to the top position and hold it until the desired idle speed is reached. |
|
To reduce the crankshaft speed |
Pull the cruise control lever down in the direction of the "-" arrow until the desired idle speed is reached. |
Press switch 13 to the bottom position and hold it until the desired idle speed is reached. |
|
Return to preset speed |
It is performed by bringing the switch located on the lever to the "Reset" ("AUS") position, by operating the clutch or brake pedal, or by operating the auxiliary brake system button |
Produced by pressing a switch 14 to the lower position, by actuating the clutch or brake pedal, or by actuating the button of the auxiliary brake system. |
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Cruise control speed control |
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Upon reaching desired speed motion (cruise control speed) |
Move the switch on the cruise control lever to the "MEMORY" position. |
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The speed set in this way will be maintained by the car without affecting the fuel pedal |
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To increase cruise control speed |
Pull the lever up in the direction of the "+" arrow until the desired cruise control speed is reached. |
Press switch 13 to the top position and hold it until the desired cruise control speed is reached. |
|
If necessary, temporarily increase the speed of the vehicle, press the fuel pedal. After releasing the pedal, the car will automatically reduce the speed to the set cruise control speed. |
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To reduce cruise control speed |
Pull the lever down in the direction of the "-" arrow until the desired cruise control speed is reached |
Push switch 13 to the bottom position and hold it down until the desired cruise control speed is reached. |
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Switching off the cruise control mode |
Produced by bringing the switch located on the lever to the "Reset" ("AUS") position, when acting on the clutch pedal, brake or auxiliary brake system button |
Produced by pressing the switch 14 to the lower position, when acting on the clutch pedal, brake or button of the auxiliary brake system |
|
Regulation of the speed limit mode |
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Setting the speed limit threshold (when the desired speed is reached) |
Move the switch on the cruise control lever to the "MEMORY" position |
Push switch 14 to the top position |
|
To increase the previously reached speed limit threshold |
Pull the lever up in the direction of the "+" arrow until the desired speed limit threshold is reached. |
Press switch 13 to the top position and hold it until the desired speed limit threshold is reached |
|
To lower the previously reached speed limit threshold |
Pull the lever down in the direction of the "-" arrow until the desired speed limit threshold is reached. |
Press the switch 13 to the lower position and hold it until the desired speed limit threshold is reached |
|
Switching off the speed limit mode |
Occurs when the switch located on the lever is moved to the "Reset" ("AUS") position, when the clutch pedal, brake pedal or auxiliary brake system button is actuated |
Occurs when switch 14 is pressed to the lower position, when the clutch pedal, brake or auxiliary brake system button is actuated |
* - Switches that perform the functions of a cruise control lever in its absence (depending on the vehicle configuration).
Engine diagnostic mode
The engine diagnostics mode is used to monitor the operation of the engine and issue fault codes - blink codes (see.Table of fault codes (Blink codes)).
The engine diagnostics mode is activated by the engine diagnostics switch located on the instrument panel.
After turning on the ignition, the engine diagnostic lamp located on the instrument panel lights up for 3 seconds. If the diagnostic lamp stays on, or if it comes on while the engine is running, there is a problem with the engine management system. Information about this fault is stored in the electronic unit and can be read using a diagnostic tool or using a diagnostic lamp. After the fault has been eliminated, the diagnostic lamp goes out.
Engine diagnostics is carried out by pressing and holding the diagnostic mode switch in the upper or lower positions for more than 2s. After releasing the diagnostic mode switch, the diagnostic lamp will flash an engine fault blink code in the form of several long flashes (the first digit of the blink code) and several short flashes (the second digit of the blink code).
The next time you press the switchthe diagnostic press will flash the blink code next fault. Thus, all faults stored in the electronic unit are output. After the last stored fault is output, the unit starts to output the first fault again.
To erase the blink codes output by the diagnostic lamp from the memory of the control unit with the diagnostic mode switch pressed, turn on the devices by turning the instrument and starter switch key to the first fixed position, then hold the diagnostic mode switch for about 5 seconds.
Table of fault codes (Blink codes)
|
Error Description |
blink-code* |
Restrictions |
What to do |
|
Accelerator pedal malfunction |
n max =1900 rpm |
Check the connection of the gas pedal. Contact service center |
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Malfunction of the atmospheric pressure sensor (the sensor is built into the electronic control unit) |
Nmax ≈300 hp |
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Physical error of the barometric pressure sensor |
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Clutch Sensor Malfunction |
n max 1900 rpm |
Check clutch sensor. You can keep moving. Do not use the cruise control function. |
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Malfunction of the main engine speed sensor ( crankshaft) (see fig.Installation of sensors on the engine) |
n max =1600 rpm |
Check the condition and connection of the relevant engine speed sensors. You can keep moving. Contact the service center. |
|
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Incorrect polarity or reversal of speed sensors |
n max =1800 rpm n max =1900 rpm |
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Malfunction of the auxiliary engine speed sensor (camshaft) (see fig. |
n max =1800 rpm |
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Malfunction of the main relay of inclusion of the electronic block of management |
No |
Check the main relay and its connection. You can keep moving. Contact the service center. |
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Faulty injection pump |
21,22, 24-26 |
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Mismatch between the position of the gas pedal and the brake pedal |
N max ≈200 hp |
Check the gas pedal, it may be stuck.Urgently contact the service center! |
|
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Poor contact of rail position sensor (sensor built into actuating mechanism injection pump) |
The engine may not start. |
Check the contact of the injection pump plug.Urgently contact the service center! |
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Brake Pedal Sensor Malfunction |
N max ≈200 hp |
Check brake pedal sensor and brake relay. You can keep moving. Contact the service center. |
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Malfunction of the electronic control unit (hardware) |
29, 51-53, 81-86, |
The engine may not start. |
Urgently contact the service center! |
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Charge air temperature sensor malfunction |
Nmax ≈300 hp |
Check the charge air temperature sensor. You can keep moving. Contact the service center. |
|
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Charge air temperature sensor physical error |
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Charge air pressure sensor malfunction |
N max ≈250 hp |
Check the charge air pressure sensor. You can keep moving. Contact the service center. |
|
Cruise Control Module Malfunction |
No |
Check the connection of the cruise control lever. You can keep moving. Contact the service center. This error also appears due to the simultaneous pressing of several control elements of the cruise control lever. |
|
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Coolant Temperature Sensor Malfunction |
Nmax ≈300 hp n max =1900 rpm |
Check coolant temperature sensor. You can keep moving. Contact the service center. |
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Physical error of the coolant temperature sensor (see os.Installation of sensors on the engine) |
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Malfunction of the fuel temperature sensor (see os.Installation of sensors on the engine) |
n max =1900 rpm |
Check fuel temperature sensor. You can keep moving. Contact the service center. |
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Physical fuel temperature sensor error |
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Wrong signal from multi-stage input |
No |
You can keep moving. Contact the service center. |
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Exceeding the maximum allowable engine speed |
After a complete stop of the engine, a new start is possible |
If the excess was due to incorrect gear shifting from higher to lower: check the engine; If the engine is in order, you can start the engine and continue driving. If the engine spontaneously increases the speed, do not start the engine! Urgently contact the service center! |
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Vehicle speed signal error |
n max =1550 rpm |
Check the connection of the tachograph to the electronic control unit. You can keep moving. Contact the service center. |
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Excess on-board voltage |
No |
Check battery charge. |
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Incorrectly completed work cycle of the electronic control unit |
No |
This error appears due to the mass being turned off earlier than 5 s after the ignition is turned off or the power supply to the electronic control unit is interrupted.You can keep moving. Contact service center |
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CAN line fault |
61-76 |
No |
Check CAN line connection to other CAN devices (ABS, automatic transmission, etc.). You can keep moving. Contact service center |
* - The first digit of the blink code - the number of long flashes of the diagnostic lamp; the second digit of the blink code is the number of short flashes of the diagnostic lamp
SAFETY REQUIREMENTS FOR OPERATION OF CUMMINS ENGINE WITH ELECTRONIC CONTROL SYSTEM
1. Before carrying out arc welding all connections leading from the battery to the engine control unit must be disconnected, no matter where they are located in the vehicle.
2. During the welding process, do not connect any sensors, wiring elements or the engine control unit located on the engine to ground wires.
3. To the part on which the welding operation is carried out, it is necessary to connect a cable for grounding the welding machine with a length of no more than 0.61 m.
4. Welding operations on the engine or components mounted on the engine are not recommended.
5. For the duration of painting operations in an electrostatic field, the battery connections to the engine control unit must be removed. Disconnect both the positive and negative battery wires from the battery before painting the vehicle.
6. When disconnecting the vehicle battery, the positive wire must always be disconnected first.
7. All electrically mating connectors must be connected prior to painting. Unconnected connectors must be masked during the painting process.
8. For the duration of the painting work, the rating plate on the engine control unit must be disguised. After finishing painting, all masking materials must be removed.
CUMMINS ELECTRONIC ENGINE CONTROL SYSTEM
The electronic engine management system provides:
Fulfillment of EURO-3 requirements;
Functions of automatic maintenance of a constant speed "Cruise - control";
The ability to control the operation of the engine;
The possibility of increasing the average safe speed movement;
Improving acceleration dynamics and reducing fuel consumption when starting off and driving on slippery areas roads;
Implementation of maximum speed limiting functions.
The system contains:
Electronic control unit (ECU) - control center electronic system engine;
crankshaft speed sensor;
Intake manifold air pressure/temperature sensor, connected to the intake air manifold and monitors manifold pressure and temperature;
Coolant temperature sensor, mounted on the cylinder head near the thermostat;
Oil pressure sensor, mounted on the engine in the oil filter housing;
Pressure meter fuel rail, provides fuel pressure data to the ECU to control the pressure regulator and to calculate fuel metering;
Fuel heater;
Cruise control switch;
Diagnostic mode switch;
Auxiliary brake button. The use of the auxiliary brake system is possible only when driving at a speed of at least 30 km/h;
Engine diagnostic control lamp;
Engine malfunction control lamp;
Control lamp waiting to start the engine, after which it is not recommended to start the engine;
Fuel supply pedal;
Clutch pedal sensor (see subsection "Electronic engine control system KAMAZ»);
Brake pedal sensor;
Parking brake sensor.
In addition to the main operating modes (fuel supply control, auxiliary brake), the system performs a number of functions that provide additional consumer qualities of the car.
idle control
In idle mode, idle speed control allows you to:
Fast engine warm-up;
Quick bleeding of the brake system.
The engine idle speed is adjusted with the vehicle stationary.
To control the idle speed, which is supposed to be carried out between 600 and 800 rpm, the set / reset switch 11 is used (see Fig. Dashboard ): each short press of the switch to the upper position increases the idle speed by 25 rpm, and a short press to the lower position decreases it by 25 rpm.
Maintaining the set speed "Cruise - control"
In the cruise control mode, the speed of the vehicle is maintained at a given level by controlling the engine speed. The mode can be activated when the vehicle speed is at least 48 km/h. To control the mode, the cruise control switch 12 and the switchset/reset 11 (see fig. Dashboard ).
If necessary, overtake can be exceeded by pressing the fuel pedal. After the pedal is released, the system does not exit the speed maintenance mode, and the speed value is restored, as before the pedal was pressed.
When you set the desired speed with a fixed middle or lower position of the switch 12 to activate the cruise control mode, you must bring the switch 11 to the depressed upper position. Switch 11 remembers the speed of movement. Further driving is carried out with the fuel pedal released. In the pressed down position, switch 11 resets the set speed value.
Increase and decrease the fixed speed using the set/reset switch 11: to smoothly increase the speed in the cruise control mode, hold the switch 11 for top position, for a smooth decrease - in the lower position. By briefly pressing the switch 11 upwards, the speed of movement increases stepwise with a step of 1.6 km/h, downward - decreases with a step of 1.6 km/h.
The cruise control mode is deactivated and put into standby mode in the following cases:
When you press the brake pedal;
When the parking brake is applied;
When you press the clutch pedal;
When the engine speed drops below 1000 rpm;
When the vehicle speed drops below 48 km/h.
After turning the instrument and starter switch to the first fixed position, the cruise control speed set value is erased.
To avoid possible damage to the vehicle and for personal safety, it is not recommended to use the cruise control mode. V following cases:
On winding roads, under difficult driving conditions, when driving at variable speeds, etc., when it is impossible to keep the car at a constant speed;
- on slippery roads.
Engine diagnostic mode.
The engine diagnostics mode is used to control the operation of the engine and issue fault codes - blink codes.
When the ignition key is turned to position 1, the ECU performs diagnostics and monitoring of the engine condition - the warning lamps for an engine malfunction, an emergency engine start condition, located in the control lamp block on the instrument panel, light up.
The lamps light up for approximately two seconds, after which they go out in the order shown, one after the other.
In the event of a malfunction, one of the remaining lamps will remain on, indicating the type of malfunction detected:
The malfunction indicator lamp is on - the car needs to be serviced, but the car can remain in working mode;
The warning lamp of the emergency condition of the engine is on - there are problems in the operation of the engine, in this case the car should not be operated until the malfunction is eliminated.
In the same way, the malfunction indicator lamp and the engine alarm indicator lamp indicate malfunctions while the engine is running.
To determine the type of malfunction, it is necessary to carry outforced diagnosticsengine. Engine diagnostic switch 13 and set/reset switch 11 are used to control the forced engine diagnostic mode.
With the ignition key in the “I” position, turn on the engine diagnostics mode by pressing the engine diagnostics switch 13 to the middle or lower position.located in the block of control lamps on the instrument panel. If no malfunctions are found in the engine operation, the lamps are lit continuously.
If there is a malfunction, the engine warning light will begin to generate a malfunction code (blink code), which can be three or four digits. Fault codes are read visually by the flashes of the control lamp, and the type of fault is determined by the table of light flashing codes (in service center). After the code is displayed, the engine malfunction indicator lamp lights up, indicating that the sending of this malfunction code is completed (see Fig.Example of flashing concontrol lamps when issuing a fault code 143).
An example of flashing control lamps when issuing a fault code 143: I- flashes of a control lamp of malfunction of the engine (color - orange); II - flashes of a control lamp of an emergency condition of the engine (color - red)
The display of the malfunction continues until the set / reset switch 11 is used to display the next and previous error codes, which, in the pressed upper position, outputs the next error code in order, in the pressed lower position, the previous error code.
Diagnostic mode remains active until the diagnostic switch or engine is turned off. After reading the light codes, it is necessary to troubleshoot and clear the computer memory. For this you need:
Turn the ignition key to position I;
Press the fuel pedal three times;
Turn the ignition to position "0".
In this case, all inactive fault codes are erased from the electronic unit. In order to make sure that all malfunctions have been eliminated and there are no blink codes in the ECU memory, it is necessary to carry out diagnostics again. If any codes remain in the ECU memory after erasing, this means that the malfunction data is present in this moment and the code can be erased only after the malfunction itself has been eliminated.
More complete diagnostics system is carried out using special diagnostic equipment at the maintenance station.
ENGINE PROTECTION SYSTEM
The engine protection system monitors four engine parameters: coolant level, coolant temperature, oil pressure and air temperature in the intake manifold, and deforces the engine if one or more of these parameters is out of range.
The engine protection system can reduce torque, reduce engine speed and possibly cause the engine to stall.
Grate heaters
Electric grate heaters located in intake manifold, are used to facilitate starting and reduce smoke in cold weather conditions.
There are two operating modes for heating the intake air:
Preheating (after turning on the ignition switch before turning the crankshaft);
Post-heating (immediately after a successful engine start).
The duration of the activation time of the grate heaters depends on the ambient temperature. The preheating time increases as the temperature decreases.
Control lamp waiting for engine start, located in the block of control lamps of the car on the instrument panel, burns during the entire time the grill heaters are turned on to indicate to the driver that it is impossible to start cranking the crankshaft. During cranking, to ensure the possibility of using maximum current for the starter, the intake air heater is switched off.
The post-heating phase begins after a successful start of the engine. The duration of the post-heating cycle increases as the temperature decreases.
Starter lock
The electronic engine management system protects the starter motor and flywheel from damage caused by unwanted starting. The electronic control unit controls the engine speed and allows the starter to be turned on only if the engine is not running.
