C-9 electronics engine controls-01[1].pdf

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ELECTRONIC ENGINE CONTROLS

Nigel W

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SYSTEMS AND CONTROLS

SLIDES AND SCRIPT

AUDIENCE

Level II--Service personnel who understand the

Level II--Service personnel who understand the principles of engine systems operation, diagnosticprinciples of engine systems operation, diagnostic equipment, and procedures for testing and adjusting.

equipment, and procedures for testing and adjusting.

CONTENT

This presentation is designed to prepare a service technician to identify the components, explain their This presentation is designed to prepare a service technician to identify the components, explain their function, and service the C-9 Engine in all machine and industrial applications.

function, and service the C-9 Engine in all machine and industrial applications.

OBJECTIVES

After learning the information in this presentation, the serviceman will be able to: After learning the information in this presentation, the serviceman will be able to:

1.

1. Locate and identify tLocate and identify the major components in he major components in the C-9 engine sthe C-9 engine systems.ystems. 2.

2. Explain the functions of the majExplain the functions of the major components in the C-9 engine sysor components in the C-9 engine systems.tems. 3.

3. Trace the flow Trace the flow of fuel and oil through tof fuel and oil through the fuel system.he fuel system. 4.

4. Trace the flow Trace the flow of current through the engine electriof current through the engine electrical system.cal system.

PREREQUISITES

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Prior training in systems operation and testing and adjusting procedures for electronic engines should bedjusting procedures for electronic engines should be completed before participating in this

completed before participating in this training session. training session. AdditionallyAdditionally, the participants should have PC, the participants should have PC skills including training in the current Windows™ operating system and the most current Electronic skills including training in the current Windows™ operating system and the most current Electronic T

Technician (ET) echnician (ET) software.software.

Three serviceman's handouts are provided with

Three serviceman's handouts are provided with this STMG. this STMG. However, as tHowever, as this publication is availablehis publication is available electronically

electronically, it can be printed in color and used selectively or totally, it can be printed in color and used selectively or totally, in the class as a handout. , in the class as a handout. ThisThis feature will enable the student to follow the presentation and make notes in the book.

feature will enable the student to follow the presentation and make notes in the book. This publication is not available in p

This publication is not available in paper form and is only available from the aper form and is only available from the intranet at this time.intranet at this time. Estimated

Estimated Time: Time: 8 Hours8 Hours Vi

Visuals: suals: 72 Electronic 72 Electronic SlidesSlides Date: 07/2002

Date: 07/2002

(3)

SLIDES AND SCRIPT

AUDIENCE

Level II--Service personnel who understand the

Level II--Service personnel who understand the principles of engine systems operation, diagnosticprinciples of engine systems operation, diagnostic equipment, and procedures for testing and adjusting.

equipment, and procedures for testing and adjusting.

CONTENT

This presentation is designed to prepare a service technician to identify the components, explain their This presentation is designed to prepare a service technician to identify the components, explain their function, and service the C-9 Engine in all machine and industrial applications.

function, and service the C-9 Engine in all machine and industrial applications.

OBJECTIVES

After learning the information in this presentation, the serviceman will be able to: After learning the information in this presentation, the serviceman will be able to:

1.

1. Locate and identify tLocate and identify the major components in he major components in the C-9 engine sthe C-9 engine systems.ystems. 2.

2. Explain the functions of the majExplain the functions of the major components in the C-9 engine sysor components in the C-9 engine systems.tems. 3.

3. Trace the flow Trace the flow of fuel and oil through tof fuel and oil through the fuel system.he fuel system. 4.

4. Trace the flow Trace the flow of current through the engine electriof current through the engine electrical system.cal system.

PREREQUISITES

I Inntteerraaccttiivve Ve Viiddeeo Co Coouurrsse e ""FFuunnddaammeennttaalls s oof f EElleeccttrriiccaal l SSyysstteemmss" " ((CCD D RROOMM)) TTEEMMVV99000022 Se Serrvivice ce TTecechnhniicician an WWororkbkbenench ch TTututororiial al (C(CD RD ROM OM ininclclududed ed wiwith th STSTW sW sofofttwawarre)e) NENEHHS0S0818122 C Caatteerrppiillllaar r MMaacchhiinne e EElleeccttrroonniiccs s CCoouurrsse e ((FFiivve e MMoodduulleess)) SSEEGGVV3300001 1 - - SSEEGGVV33000055 C Caatteerrppiillllaar r HHEEUUI I HHII330000B B FFuueel l SSyysstteem m ((CCD D RROOMM)) RREENNRR11339922 Prior training in systems operation and testing and a

Prior training in systems operation and testing and adjusting procedures for electronic engines should bedjusting procedures for electronic engines should be completed before participating in this

completed before participating in this training session. training session. AdditionallyAdditionally, the participants should have PC, the participants should have PC skills including training in the current Windows™ operating system and the most current Electronic skills including training in the current Windows™ operating system and the most current Electronic T

Technician (ET) echnician (ET) software.software.

Three serviceman's handouts are provided with

Three serviceman's handouts are provided with this STMG. this STMG. However, as tHowever, as this publication is availablehis publication is available electronically

electronically, it can be printed in color and used selectively or totally, it can be printed in color and used selectively or totally, in the class as a handout. , in the class as a handout. ThisThis feature will enable the student to follow the presentation and make notes in the book.

feature will enable the student to follow the presentation and make notes in the book. This publication is not available in p

This publication is not available in paper form and is only available from the aper form and is only available from the intranet at this time.intranet at this time. Estimated

Estimated Time: Time: 8 Hours8 Hours Vi

Visuals: suals: 72 Electronic 72 Electronic SlidesSlides Date: 07/2002

Date: 07/2002

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SUPPLEMENTARY TRAINING MATERIAL

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RECOMMENDED C-9 ENGINE

RECOMMENDED C-9 ENGINE TOOLING

TOOLING

Software and Manuals

Caterp

Caterpillar Servillar Service Tice Tool Softwarool Software/Gette/Getting Started Guiding Started Guide - e - ServiService Tecce Technician Whnician Workbencorkbenchh NEHS07NEHS079696 or Cat

or Caterperpillillar Serar Servicvice Te Tool Soool Softwftwareare/Ge/Gettitting Stang Starterted - Cated - Caterpirpillallar Eler Electrctronionic Tc Technechniciicianan JEBJEBD30D300303 C

Caatteerrppiillllaar r SSeerrvviicce e TTooool l SSooffttwwaarree//UUsseerrs s MMaannuuaall- - CCoommmmuunniiccaattiioon n AAddaapptteer r IIII NNEEHHSS00775588

Mechanical

Mechanical TToolsools

C C--9 9 TTooool l KKiit t ((ccoonnttaaiinns s aalll l CC--9 9 ssppeecciiaal l ttoooollss)) 119966--33116655 E Ennggiinnee TTuurrnniinngg TTooooll 99SS--99008822 E Ennggiinne e TTuurrnniinng g TTooool l ((ffoor r ttrraaccttoorrss)) 220088--00888888 Electronic

Electronic TToolsools

Laptop computer Laptop computer C

Coommmmuunniiccaattiioon n AAddaapptteer r III I ((GGrroouupp)) 117711--44440000 Cable,

Cable, PC PC to to Communication Communication Adapter Adapter 96-005596-0055 Cable,

Cable, Communication Communication Adapter Adapter to to Machine Machine 160-0133160-0133 C Caatteerrppiillllaar r DDiiggiittaal l MMuullttiimmeetteerr 114466--44008800 T Thhrreee e PPiin n DDT T BBrreeaakkoouut t HHaarrnneessss 77XX--66337700 C Caabbllee PPrroobbeess 77XX--11771100 A Auuxxiilliiaarry y EECCM M PPoowweer r SSuupppplly y HHaarrnneessss 116677--99222255 T Tiimmiinng g CCaalliibbrraattiioon n PPrroobbe e ((MMaaggnneettiic c PPiicckkuupp)) 66VV--22119977 T Tiimmiinng g CCaalliibbrraattiioon n PPrroobbe e AAddaapptteer r SSlleeeevvee 77XX--11117711 T Tiimmiinng g CCaalliibbrraattiioon n PPrroobbe e CCaabbllee 77XX--11669955

REFERENCES

S Syysstteemms s OOppeerraattiioon n TTeessttiinng g aannd d AAddjjuussttiinng g ""CC--9 9 IInndduussttrriiaal l EEnnggiinneess"" SSEENNRR99559988--0022 Sys

Systemtems Os Operperatiation Ton Testesting ing and and AdjAdjustusting ing "C-"C-9 En9 Engingine foe for Car Caterterpilpillar lar BuiBuilt lt MacMachinhines"es" SENSENR95R950101 T Troroububleleshshooootiting ng MaManunual al "C"C-9 -9 EnEngigine ne fofor Cr Catatererpipillllar ar BuBuililt Mt Macachihinenes" s" D6D6R TR Traractctoror SESENRNR95950303 D Diissaasssseemmbblly y aannd d AAsssseemmbblly y ""CC--9 9 EEnnggiinnees s ffoor r CCaatteerrppiillllaar r BBuuiillt t MMaacchhiinneess"" SSEENNRR99550022 S Sppeecciiffiiccaattiioonns s MMaannuuaal l ""CC--9 9 EEnnggiinnees s ffoor r CCaatteerrppiillllaar r BBuuiillt t MMaacchhiinneess"" SSEENNRR99550000 D Diiaaggnnoossttiic c CCaabbllees s aannd d HHaarrnneesssseess NNEEHHSS00882222

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INTRODUCTION TO SYSTEMS OPERATION INTRODUCTION TO SYSTEMS OPERATION

Introduction ...5

Lab Exercise ...23

SYSTEM POWER SUPPLIES SYSTEM POWER SUPPLIES Introduction ...27

Introduction ...27

ECM ECM Power Power Supply Supply ...2...288 Injector and Injector and Compression Brake Compression Brake Power Supply Power Supply ...32...32

Hydraulic Pump Hydraulic Pump Control VControl Valve Power Supplyalve Power Supply...33...33

Analog Analog Sensor Sensor Power Power Supply Supply ...34...34

Digital Sensor Power Supply ...35

Air Intake Heater Power Supply...36

Service Tool Power Supply...37

Lab Exercise ...38

ELECTRONIC CONTROL SYSTEM ELECTRONIC CONTROL SYSTEM Introduction...41

Introduction...41

Fuel Injection ...44

Fuel Inj Fuel Injection Control ection Control System System ...46...46

SYSTEM CALIBRATIONS SYSTEM CALIBRATIONS Introduction...53

Introduction...53

Speed/Timing Sensor Calibration ...53

Injector Calibration ...58

Pressure Sensor Calibration ...60

Oil Oil Grade Grade DetectionDetection...6161 Engine Warnings and Derates...63

Engine Warnings and Derates...63

Lab Exercise ...64

ELECTRONIC SENSORS AND SYSTEMS ELECTRONIC SENSORS AND SYSTEMS Introduction ...67

Introduction ...67

Injector Injector and Compressand Compression Brake ion Brake SystemsSystems...68...68

Speed/Timing Sensors ...69

Analog Sensors and Circuits ...72

Digital Sensors and Circuits ...86

Engine Shutdown Systems ...89

Cold Cold Starting Starting Aids Aids ...9090 Data Link Circuits ...93

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CYLINDER AND VALVE LOCATION

FIRING ORDER 1 5 3 6 2 4

BORE 112 MM (4.4 IN) STROKE 149 MM (5.9 IN)

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• Major components

• ECM

This view of an industrial engine, shows some of the major components of the engine.

The major fuel system and electronic components are mounted on the left hand side of the engine.

Note the ECM on the lower right hand side.

The Systems Operation portion of the Systems Operation Testing and Adjusting manual for C-9 Industrial Engines (SENR9598-02) can be used to locate the various components. Otherwise the appropriate Service Manual for the application should be used.

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• HEUI system schematic

• Similar to other HEUI systems

• Some system differences

- New HEUI hydraulic pump

- No jumper tubes - Two hydraulic oil

temperature sensors - Water in fuel and

fuel pressure sensors available

This visual is taken from the Caterpillar HEUI HI300B Fuel System CD RENR1392. This CD will supply all the information on the HEUI fuel system, electronics and related diagnostics.

This HEUI system is very similar to the 3408E, 3412 E and 3126 HEUI systems. There are a number of features which differ from other engines.

The hydraulic pump is a completely new design.

There are no jumper tubes on the injectors. Oil under pressure is fed directly from the cylinder head to the injectors.

There are two Hydraulic Oil Temperature Sensors installed on the engine.

Optional water in fuel and fuel pressure sensors may be installed in the fuel supply system.

See also Student Handout No. 1 for a dedicated fuel supply system diagram.

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• HEUI system hydraulic pump

• Transfer pump mounted on rear of HEUI pump

This view shows a cutaway of the HEUI pump.

The hydraulic pump is a high pressure, variable delivery piston pump. This pump provides the hydraulic power to actuate the injectors.

The fuel system transfer pump is mounted on the rear of the hydraulic pump and will deliver 450 ± 100 kPa (65 ± 1.5 psi).

This pump is fully described in the CD RENR1392 (described on the previous page).

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• Cross flow cylinder head

- Improves emissions and fuel

consumption

The C-9 engine has a cross flow cylinder head. This feature allows for improved emissions and fuel consumption by improving the combustion airflow through the engine.

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• Air intake and exhaust system schematic

• Air intake heater

The air to air aftercooler is used in most applications, the exception is the marine engine. By cooling the precharge air, this component increases the mass flow of air through the engine, thus allowing more horsepower.

The air intake heater is used to aid starting and reduce white smoke in cold conditions.

In most applications, the air intake heater has replaced the ether aid. In extreme cold (Arctic) conditions, it is possible to use the ether aid in conjunction with the air intake heater. At this time however, C-9 engines are noT being built with an ether aid.

AIR INLET EXHAUST OUTLET EXHAUST MANIFOLD EXHAUST VALVE INLET VALVE COMPRESSOR SIDE TURBINE SIDE TURBOCHARGER INTAKE HEATER AIR TO AIR AFTERCOOLER

AIR INTAKE AND EXHAUST SYSTEM

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• Turbocharger components

The turbocharger is conventional and may be equipped with a Wastegate (next page). AIR INLET COMPRESSOR HOUSING COMPRESSOR WHEEL BEARING OIL OUTLET PORT TURBINE HOUSING BEARING TURBINE WHEEL EXHAUST OUTLET EXHAUST INLET OIL INLET PORT TURBOCHARGER 8

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• Turbocharger wastegate

• Wastegate bypasses exhaust around the turbocharger

Some C-9 applications are equipped with a turbocharger wastegate.

If the engine is required to respond rapidly at low rpm, it may be

necessary to optimize the turbocharger for this speed. In this case, the turbocharger may develop excessive boost at rated speed and load.

The wastegate redirects a portion of the exhaust gasses past the

turbocharger which effectively limits turbocharger speed and boost. This feature also limits cylinder pressure, thus protecting the engine from undue stress.

The wastegate is preset at the factory and no adjustments can be made.

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• Valve train

• Camshaft mounted high in the block

The C-9 Camshaft is mounted high up in the block to reduce the size of the pushrods and therefore reduces the reciprocating mass of the valve mechanism. This feature improves the ability of the engine to sustain an overspeed without damage.

PUSH ROD LIFTER ROCKER ARM BRIDGE VALVE SPRING

VALVE SYSTEM COMPONENTS

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• Air intake heater and temperature sensor

• Heater controlled by ECM

• System warns of high air intake temperature

The air intake system has a heater and a temperature sensor. The Air Intake Temperature Sensor is used by the ECM in conjunction with the Coolant Temperature Sensor to calculate the need for air intake heating.

The ECM controls the heater through a relay mounted above the intake manifold.

The Intake Temperature Sensor is also used by the ECM to warn the operator of excessive air intake temperatures.

This view shows a Challenger C-9 installation. Other C-9 applications will vary slightly in the sensor installation.

The Service Manual, Systems Operation section, describes the various modes of operation of this system. A description of the operation is also included with the Electronic Sensors and Systems portion of this STMG.

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• Lubrication system schematic

The lubrication system is conventional with the exception of the oil cooler which is recessed (as shown on the next page) into the cylinder block.

OIL FILTER OIL COOLER HEUI PUMP TO TURBOCHARGER C-9 LUBRICATION SYSTEM 12

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• Lubrication system cross section

• Oil cooler recessed

The lubrication oil supply system is shown here in this cross sectional view of the cylinder block.

Note the oil cooler recessed into the block. This feature reduces the overall width of the engine and reduces the possibility of leaks.

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• Cooling system schematic

• Water pump is belt driven

The system is conventional with a full flow by-pass outlet thermostat.

The water pump is belt driven by a pulley from the crankshaft.

CYLINDER HEAD CYLINDER BLOCK OIL COOLER WATER PUMP RADIATOR BYPASS HOSE EXPANSION TANK WATER TEMPERATURE REGULATOR HOUSING

COOLING SYSTEM

14

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• Fractured rod

• Use care when handling mating surfaces

• Fractured rod manufacturing process

This visual shows the fractured rod. The rod is deliberately fractured during the manufacturing process in order to provide a mating surface that does not allow fretting or sideways movement between the two halves of the rod.

NOTE: Care should be taken to avoid damage to the mating faces during handling. The rod must be replaced if there is any damage to the mating surfaces. If the surfaces are damaged, bearing crush will be insufficient which can cause the bearing to spin in its bore.

The fracture process involves the following steps:

The bolt holes are fully drilled, and tapped prior to fracture.

The fracture process begins with rough boring the crank end prior to fracture (approximately. 1 mm undersize).

A laser (or "V" broach) is then used to etch a "V" notch for initiating the crack split line.

A wedge is used in a hydraulically activated expanding mandrill to force apart the rod and cap at the split line.

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After the rod is split, the bolts are inserted and the cap reassembled. The bolts are tightened to about 90% of final torque, backed off, and the cap removed.

The joint is then cleaned to remove any chips that may have broken off, before the cap and rod are reassembled and the bolts

re-tightened down again. This procedure is performed twice.

Once tightened, the cap is not separated from the rod again during the rest of the machining process. (Note: A fixture or torque gun would be required to loosen the bolts prior to dispatch, or during piston sub-assembly).

The advantages associated with fracturing the split are primarily reduced machining operations. Some examples are as follows:

No machining of joint faces necessary.

No deburring of joint face edges due to perfectly matched joint faces.

Elimination of dowels or fitted bolts (fracture surface results in a perfectly mated joint).

Near net shape forgings (may eliminate the need for additional balance machining).

Single clamping fixture required for machining bolt holes (no separate cap and rod machining - same for bearing tab slots).

The majority of the benefits with fractured split rods lie in the manufacturing process. There are other benefits such as virtual

elimination of fretting on the joint face, with the rod being able to accept higher loads, due to perfectly matched surfaces. In addition, one of the reported benefits of fractured split rods is that they tend to have a higher processing quality than conventional rods due to the reduced machining

steps and controlled machining process. From a cost standpoint, this feature can result in a part cost that is significantly reduced.

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• Crankshaft oil flow

• Oil flow to rod bearings

• Related failure

analysis publications

This visual shows the path of oil flow from the main bearings to the rod bearings.

It can be seen that three main bearings (1, 4 and 7) do not feed any rod bearings. Two more main bearings (2 and 6) supply oil to one rod bearing

each. Main bearing numbers 3 and 5 supply oil to two rod bearings each.

This information is important if a bearing failure analysis is performed.

For additional information in bearing failure analysis, please refer to the following AFA (Applied Failure Analysis) publications:

STMG Engine Bearings (SERV8001)

Engine Bearing Failure Analysis (SEBV0544)

OIL GALLERY MAIN BEARINGS (7) ROD BEARINGS (6) 1 2 3 4 5 6 7 1 2 3 4 5 6

CRANKSHAFT OIL FLOW

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• Viscous crankshaft vibration damper

The viscous crankshaft vibration damper is also used to reduce crankshaft torsional vibrations. This damper uses a heavy ring enclosed within a casing and suspended by a viscous oil to oppose torsional vibration forces.

CRANKSHAFT

WEIGHT

CASE

VISCOUS VIBRATION DAMPER

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• Lab exercise

material introduced in the preceding pages and will allow questions to be answered.

Lab Exercise:

The following exercise will reinforce the material introduced in the preceding slides and will allow questions to be answered.

At this time, it is recommended that each component be located on the machine and the function of each component reviewed with the students. A list of the components follows on the next page.

If an engine is available out of a machine, component identification will be easier because some components are difficult to see.

Some additional (used/defective) components available for examination on a table will be helpful.

The Systems Operation portion of the Systems Operation Testing and Adjusting manual for C-9 Industrial Engines (SENR9598-02) can be used to supplement the Slide/Text information.

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Electrical Component List

ECM and 70 Pin Connectors (2)

Timing Calibration Installation Location Timing Calibration Connector

Speed Timing Sensors

Coolant Temperature Sensor Inlet Air Temperature Sensor Atmospheric Pressure Sensor

Turbocharger Outlet Pressure Sensor Oil Pressure Sensor

Hydraulic Oil Temperature Sensors Fuel Temperature Sensor

Machine Interface Connector Engine and Machine Ground Bolts Service Tool Connector

Throttle Position Sensor Shutdown Switches

Battery Disconnect Switch

Mechanical (Fuel Delivery) Component List

Primary Filter and Water Separator Water in Fuel Sensor (if installed) Secondary Filter

Priming Pump Transfer Pump

Pressure Regulator Valve Injectors (6)

Cylinder Head Fuel Passage

ECM Fuel Cooling Passage and Connectors (if installed)

Mechanical Component List

Thermostat By-pass hose

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• Seven system power supplies

SYSTEM POWER SUPPLIES

Introduction

The C-9 HEUI system has seven power supplies with various voltages as shown.

EXTERNAL POWER SUPPLY

ECM power supply (machines) 24 Volts Challenger Tractors and some industrial engines 12 Volts Air intake heater (machines) 24 Volts Service Tool Power Supply 24 Volts

INTERNAL POWER SUPPLIES

Injector and compression brake power supplies 70 Volts

Pump control valve PWM

Analog sensor power supply 5 Volts Digital sensor power supply 8 Volts

These power supplies are described in detail in the following section.

C-9 HEUI

SYSTEM POWER SUPPLIES

ECM

Injectors and Compression Brake

Pump Control Valve

Analog Sensors

Digital Sensors

Air Intake Heater

Service Tool

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• 24 Volt power supply • Power supply components • Power supply diagnostic message J2 J1 6 DRIVERS 3 RETURNS ENGINE RETARDER SOLENOIDS ECM TIMING CALIBRATION CONNECTOR GROUND BOLT 20 AMP BREAKER MAIN POWER

RELAY KEY START SWITCH

24 V

20 AMP FUSE

CRANK WITHOUT INJECT PLUG DISCONNECT SWITCH

ECM Power Supply

The power supply to the ECM and the system is provided by the 24 Volt machine battery. The principle components in this circuit are:

- Battery

- Key Start Switch - Main Power Relay - 20 Amp Breaker - 20 Amp Fuse - Ground Bolt

- ECM Connector (P1/JI)

If the supply voltage exceeds 32.5 Volts or is less than 9.0 Volts, a diagnostic message is logged. (See the Troubleshooting Guide for complete details on voltage event logging.)

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• ECM power supply circuit • ECM switched connection - Energizes ECM 48 52 53 70 ECM (C-9) 24 VOLTS DC (+) (-) ENGINE BLOCK GROUND BOLT 15 AMP CIRCUIT BREAKER BATTERY R C S B ST OFF ON KEY SWITCH P1 J1 (-) BATTERY (-) BATTERY (-) BATTERY 61 63 65 (+) BATTERY (+) BATTERY (+) BATTERY (+) SWITCHED POWER (+) BATTERY SUPPLY WIRES

INPUT SIGNAL WIRES TO ECM OUTPUT SIGNAL WIRES FROM ECM

SENSOR SUPPLY VOLTAGE SIGNAL PLUS

SIGNAL MINUS

(-) BATTERY / SENSOR RETURN WIRE FUNCTION COLOR CODE

FUSE

20 A

DISCONNECT SWITCH

ECM POWER SUPPLY CIRCUIT

This schematic shows the principle components for a typical C-9 power supply circuit. Battery voltage is normally connected to the ECM.

However, an input from the key start switch turns the ECM ON.

Note the seven power connections on the ECM. There are three wires permanently connected to the ECM battery positive and three to the battery negative. This feature is used to reduce the amperage on the

individual pins. The actual current draw with the engine stopped with the key off is very small.

There is also a switched connection from the battery positive (ECM

pin 70). The purpose of the "switched power" connection is to energize or "wake up" the ECM. The key switch circuit energizes the whole ECM from "sleep mode," which in turn activates power supplies, sensors, actuators, injectors, data links etc.

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switch

• Wiring harness bypass

depending on the application. The relevant Troubleshooting Guide will show the location and the polarity of the switch.

The machine wiring harness can be bypassed for troubleshooting purposes. These steps are described in the Troubleshooting Guide

procedure. A breakout harness can be used and is referenced under "C-9 Recommended Tooling" at the front of this book.

The supply voltage may be conveniently checked using the ET Status Screen display.

NOTE 1: The Challenger Tractor engine and some industrial engines may have a 12 Volt power supply.

NOTE 2: The Wire Function Color Code is shown here for the first time and is used through the presentation.

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• P1/P2 70 pin ECM connectors • P1/J1 machine interface connector 13 23 31 39 47 57 70 1 14 24 32 40 48 58 1 14 2 3 4 5 6 8 9 10 11 12 13 58 59 60 61 62 63 65 66 67 68 69 70 24 40 48 23 31 47 57 36 >PEI<

ECM SIDE HARNESS SIDE

ECM CONNECTOR (P1)

There are two 70 pin connectors which identify the ADEM III ECM. The previous ADEM II ECM used a pair of 40 pin connectors.

The 70 pin ECM connectors are vital parts of all the power supplies (and sensor circuits). This illustration shows one of the two ECM 70 pin connectors, P1. The pins highlighted in this connector are for the ECM power supply circuit.

The C-9 Engine does not have a separate machine interface connector. The P1/J1 connector performs this function and transmits the power supply from the machine wiring to the engine wiring harnesses.

The Troubleshooting Guide identifies the relevant pins for each circuit in this manner. This feature greatly simplifies troubleshooting by easily identifying the connections in the circuit.

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• 70 volt power supply

• Power supply wires are paired

• Injectors and brake solenoids are switched on return side 2 1 ECM 20 36 44 21 37 45 28 38 46 29 39 47 65 54 67 66 55 68

BRAKE RETURN CYL 1 INJECTOR/BRAKE CYL 1 INJECTOR RETURN CYL 1 BRAKE RETURN CYL 2 INJECTOR/BRAKE CYL 2 INJECTOR RETURN CYL 2 BRAKE RETURN CYL 3 INJECTOR/BRAKE CYL 3 INJECTOR RETURN CYL 3 BRAKE RETURN CYL 4 INJECTOR/BRAKE CYL 4 INJECTOR RETURN CYL 4 BRAKE RETURN CYL 5 INJECTOR/BRAKE CYL 5 INJECTOR RETURN CYL 5 BRAKE RETURN CYL 6 INJECTOR/BRAKE CYL 6 INJECTOR RETURN CYL 6 BRAKE SOLENOID CYL. 6 12 1 18 11 2 17 10 3 16 9 4 15 8 5 14 7 6 13 1 2 2 1 1 2 2 1 1 2 1 2 2 1 1 2 2 1 1 2 P300 J300 P2 J2 2 1 INJECTOR SOLENOID CYL. 6 J306 P306 BRAKE SOLENOID CYL. 5 INJECTOR SOLENOID CYL. 5 J305P305 BRAKE SOLENOID CYL. 4 INJECTOR SOLENOID CYL. 4 J304P304 BRAKE SOLENOID CYL. 3 INJECTOR SOLENOID CYL. 3 J303 P303 BRAKE SOLENOID CYL. 2 INJECTOR SOLENOID CYL. 2 J302 P302 BRAKE SOLENOID CYL. 1 INJECTOR SOLENOID CYL. 1 J301P301

SOLENOID CIRCUITS

Injector and Compression Brake Power Supply

The injector and compression brake solenoids are supplied with power from the ECM at 70 Volts. For this reason, precautions must be observed when performing maintenance around the valve covers.

If an open or a short circuit occurs in an injector or compression brake component, the ECM will disable that circuit. The ECM will periodically try to actuate that circuit to determine if the fault is still present and will disconnect or reconnect the injector/compression brake as appropriate.

The power supply wires are paired for each injector and brake solenoid. Individual return circuits are provided which contain the solenoid drivers. An 18 pin (P300/J300) connector is used to connect the main engine wiring harness to the injector harness within the valve cover.

NOTE: If an injector is replaced, it must be calibrated. Also if an ECM is replaced and injector calibration or copy configuration is not performed, a fault message will be generated. (The Copy

Configuration function will transfer all calibrations to the new ECM.) 22

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• Pump control valve signal

• System tested using ET + CONTROL VALVE - CONTROL VALVE 61 62 P2 J2 A B J500 P500 PUMP CONTROL VALVE SUPPLY RETURN ECM (C-9 HEUI)

PUMP CONTROL VALVE

POWER SUPPLY

Hydraulic Pump Control Valve Power Supply

The ECM supplies a PWM signal through the J2/P2 connector to the Pump Control Valve (also known as the injection actuation pressure control valve).

The Pump Control Valve and its power supply can be tested on the engine using ET and the Hydraulic Injection Actuation Pressure Test. Using the test, the pressure can be adjusted manually with the ET service tool from minimum to maximum. Therefore, this function can be used to verify the operation of the control valve, the power supply from the ECM, and the hydraulic system.

There is no voltage specification for the Pump Control Valve Power Supply. Current flow may vary between 250 and 1000 mA.

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• Analog power supply

• Four power supply terminals • Power supply protection • Analog return C B A ENGINE OIL PRESSURE SIGNAL

ANALOG SENSOR RETURN 3 ANALOG SENSOR POWER (+5V) 3

J201/P201

24 42 41

ENGINE OIL PRESSURE SIGNAL ANALOG SENSOR RETURN 3 ANALOG SENSOR POWER (+5V) 3 C

B A FUEL PRESSURE SIGNAL

J209/P209

18 FUEL PRESSURE SIGNAL C

B A ATMOSPHERIC PRESSURE SIGNAL

J203/P203 14 3 2 C B A HYDRAULIC OIL PRESSURE SIGNAL

J204/P204

40

27 TURBO OUTLET PRESSURE SIGNALHYDRAULIC OIL PRESSURE SIGNAL C

B A TURBO OUTLET PRESSURE SIGNAL

J200/P200

ATMOSPHERIC PRESSURE SIGNAL ANALOG SENSOR RETURN 1 ANALOG SENSOR POWER (+5V) 1

ECM P2 J2

POWER SUPPLY CIRCUIT

5 ± 0.5 VOLTS

Analog Sensor Power Supply

The Analog Sensor Power Supply provides power to all the active analog sensors (pressure and temperature sensors). The ECM supplies 5.0 ± 0.5 Volts DC (Analog Supply) through the J2/P2 connector to each sensor. A power supply failure will cause all active analog sensors to fail. This

failure could be caused by a short in a sensor. An open circuit in the common lines close to the P2/J2 connector can also cause multiple

failures. Unlike previous EUI/HEUI engines, the C-9 uses four individual ECM analog power connections from the J1/P1 connector (two supply and two return).

The Analog Sensor Power Supply is protected against short circuits. A short in a sensor or a wiring harness will not cause damage to the ECM.

NOTE: When checking the analog power supply voltage, always use the analog return for the measurement and not the frame ground. A difference can occur between the measurements of analog power supply and system voltage. The analog power supply is held to close tolerances.

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• Digital power supply

• Power supply protection

• Digital power supply voltage check • Digital return ECM (C-9 HEUI) + V DIGITAL SUPPLY - V DIGITAL RETURN 4 5

DIGITAL SENSOR

POWER SUPPLY CIRCUIT

P1 J1 A B C J405 P405 A B C +V DIGITAL DIGITAL RETURN SIGNAL FAN SPEED SENSOR THROTTLE POSITION SENSOR +V DIGITAL DIGITAL RETURN SIGNAL 8 ± 0.5 VOLTS

Digital Sensor Power Supply

The ECM supplies power at 8 ± 0.5 Volts through the J1/P1 connector to the Throttle Position Sensor circuit.

Like the Analog power supply, this circuit is protected against short circuits, which means that a short in the sensor will not cause damage to the ECM.

Some other C-9 applications may use this power supply to power fan speed or exhaust temperature sensors for example.

NOTE: It is necessary when checking this system power supply voltage to use the digital return for the measurement and not the frame ground. A difference between these values can occur if an incorrect ground is used.

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• Uses coolant and intake temperature sensors as references • Modes of operation 24V 1 2 B A AIR INTAKE HEATER RELAY AIR INTAKE HEATER LAMP J501/P501 J648 P648

850-BU 12 _{HEATER RELAY}AIR INTAKE ECM

AIR INTAKE HEATER CIRCUIT

AIR INTAKE HEATER

J2/P2

Air Intake Heater

The Air Intake Heater is used to improve the cold start ability of the engine.

The heater is controlled by the ECM using inputs from the Air Intake Temperature and Coolant Temperature Sensors. The ECM sends a signal to the relay which controls the supply of current to the heater element.

There are a various modes of operation depending on temperatures and other conditions. These parameters and the defaults are fully described in the C-9 Troubleshooting Guide and later in this presentation in the section "Electronic Sensors and Systems."

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• Communication adapter uses power from ECM

• Circuit is energized with the keyswitch

A B C D E F G SERVICE TOOL CONNECTOR J63 70 65 8 9 34 50 BAT + (SWITCHED) BAT

-CAT DATA LINK + CAT DATA LINK CAN DATA LINK -CAN DATA LINK +

P1 J1 ENGINE ECM

8 7 CAT DATA LINK +

CAT DATA LINK

-8 7

CAT DATA LINK + CAT DATA LINK -TRANSMISSION ECM

CATERPILLAR MONITORING SYSTEM

TYPICAL SERVICE TOOL POWER SUPPLY CIRCUIT

DATA LINKS

Service Tool Power Supply

In the past, the ECAP (Electronic Analyzer Programmer) Service Tool drew it's power from the Service Tool Connector. In the same way, when using ET, the Communicator Adapter II also requires a power supply. This power is taken from pins A and B on the Service Tool Connector.

This illustration shows the path of the current from the ECM to the

Service Tool Connector. This power supply requires the engine keyswitch to be ON.

Pin 70 on the J1/P1 connector, is the same terminal which is used by the Keyswitch to turn on the ECM.

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• Lab exercise

material introduced in the preceding pages and will allow questions to be answered.

Lab Exercise:

Remove and install the following components on an engine in accordance with service manual procedures:

Pressure sensor

Temperature sensor

Throttle position sensor

Speed/timing sensors

ECM

Test the following power supply circuits on an engine in accordance with the appropriate service manual procedures:

ECM power supply

HEUI pump control valve power supply

Analog sensor power supply

Digital sensor power supply

Intake heater power supply

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• Control system components:

ELECTRONIC CONTROL SYSTEM

Introduction

This section of the presentation explains the C-9 Electronic Control System including the following components:

- ECM

- Personality Module - Timing Wheel

Also covered are the following subsystems and related procedures:

- Timing Control

- Fuel Quantity Control - Speed Control

- System Calibrations

NOTE: There is no separate Cold Mode on the C-9 engine.

ELECTRONIC CONTROL

SYSTEM

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• ECM: - Governor - Fuel system computer - Injection timing controller • Communicates with Cat Monitoring system • Recognized by 2

70 pin connectors • 70 pin connector

designations

• Same ECM used in all C-9 applications

• Personality module contains application software

The principle component in the HEUI system, the Electronic Control Module (ECM) is mounted on the left hand side of the engine.

The ECM is the brain of the engine, it functions as the governor and fuel system computer. The ECM receives all the signals from the sensors and energizes the injector solenoids to control timing and engine speed. The ECM also communicates with the instrument display system, usually the Caterpillar Monitoring System through the Cat Data link.

This ECM is known as the ADEM III and is the third generation of ECMs in a series. It can be easily recognized by the two 70 pin connectors (previous ecms had two 40 pin connectors). NOTE: The right hand connector is designated as J1/P1 and the left hand connector is designated as J2/P2.

This ECM is used in all C-9 engine applications. The ECM can be moved from one application to another. However, a password is required to

activate the ECM when a different application software is installed.

The Personality Module contains the software with all the fuel setting information such as: horsepower, torque rise and air/fuel ratio rates, pressure, and temperature warning trip points. These settings determine

how the engine will perform in a specific application.

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• Software updated by flash programming only

• Upgrading personality module software

• ECM is fuel cooled in most machine

applications

• ECM is sealed, no access necessary

This view shows a cutaway of an ADEM III ECM (note the two 70 pin connectors). The Personality Module is an integral part of the ECM and no access panel is provided, therefore Flash Programming is the only method used to update the software on the C-9. This method requires electronic reprogramming of the Personality Module software.

Upgrading the software is not a routine task, but might be performed for reasons of a product update, a performance improvement or a product problem repair. Also possible is an application change where an ECM is

moved to a different type of machine powered by a C-9 engine.

This ECM is currently fuel cooled in all machine applications except Track-Type Tractors. Future On-highway Truck applications will not be fuel cooled. Generally speaking, compared with On-highway Trucks, machines do not have large quantities of cool air flowing around the engine due to the low ground speed. Therefore fuel cooling on machines is necessary to protect the ECM where there are high engine compartment temperatures.

NOTE: The ECM is sealed and needs no routine adjustment or

maintenance. The Personality Module cannot be accessed other than by Flash Programming. The ECM has an excellent record of

reliability. Therefore, any problems in the system are most likely to be in the connectors and wiring harness. In other words, the ECM should typically be the last item in troubleshooting. Using a

substitute ECM is a convenient method of troubleshooting the unit. 30

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• Unit injectors

• Electrically signalled, hydraulically actuated • ECM controls opening and closing of injector

• System controls nozzle opening and closing

• Injector trim codes

Fuel Injection

The C-9 HEUI unit injector is electrically and physically similar to the 3126E HEUI electronic unit injector. It is controlled electrically by the ECM and is actuated hydraulically. There are other advanced features which are described later in this presentation. The signal from the ECM controls the opening and the closing of the solenoid valve. The solenoid valve controls the flow of high pressure oil to the injector. This system enables the ECM to control fuel volume, timing and injection actuation hydraulic pressure.

This system can control both the opening and closing of the injector nozzle.

The C-9 injector has a bar code and a numerical code marked on the tappet. The numerical code must be entered into the ECM using ET. The purpose of this code is to ensure that all injectors are matched as perfectly

as possible in performance, both in timing and fuel quantity.

The C-9 injector solenoids operate on 70 Volts direct current. Always remain clear of the injector area when the engine is running or electrical shock may occur.

31

C-9 electronics engine controls-01[1].pdf

ELECTRONIC ENGINE CONTROLS

ELECTRONIC ENGINE CONTROLS

Nigel W

SYSTEMS AND CONTROLS

SYSTEMS AND CONTROLS

SLIDES AND SCRIPT

SLIDES AND SCRIPT

AUDIENCE

AUDIENCE

CONTENT

CONTENT

OBJECTIVES

OBJECTIVES

PREREQUISITES

PREREQUISITES

SLIDES AND SCRIPT

SLIDES AND SCRIPT

AUDIENCE

AUDIENCE

CONTENT

CONTENT

OBJECTIVES

OBJECTIVES

PREREQUISITES

PREREQUISITES

SUPPLEMENTARY TRAINING MATERIAL

SUPPLEMENTARY TRAINING MATERIAL

RECOMMENDED C-9 ENGINE

RECOMMENDED C-9 ENGINE TOOLING

TOOLING

REFERENCES

REFERENCES

TABLE OF CONTENTS

CYLINDER AND VALVE LOCATION

COOLING SYSTEM

CRANKSHAFT OIL FLOW

C-9 HEUI

SYSTEM POWER SUPPLIES

ECM

Injectors and Compression Brake

Pump Control Valve

Analog Sensors

Digital Sensors

Air Intake Heater

Service Tool

ECM CONNECTOR (P1)

SOLENOID CIRCUITS

PUMP CONTROL VALVE

POWER SUPPLY

POWER SUPPLY CIRCUIT

DIGITAL SENSOR

POWER SUPPLY CIRCUIT

AIR INTAKE HEATER CIRCUIT

TYPICAL SERVICE TOOL POWER SUPPLY CIRCUIT

ELECTRONIC CONTROL

SYSTEM