3500 Engine Controls - Electronic Unit Injection (slides).pdf

(1)

3500B ENGINE CONTROLS

ELECTRONIC UNIT INJECTION (EUI)

(2)

(3)

(4)

FUEL TANK

PRIMARY

FUEL

FILTER

SECONDARY

FUEL FILTERS

(2 MICRON)

ENGINE

BLOCK

OIL RENEWAL

INJECTOR

FUEL

PRESSURE

REGULATOR

FUEL

TRANSFER

PUMP

FUEL

HEATER

ECM

3516B FUEL SUPPLY CIRCUIT (793C)

PRIMING PUMP SUPPLY

FUEL

DIFFERENTIAL

PRESSURE

SWITCH

CYLINDER

HEAD

(5)

TO PRELUBRICATION PUMP + BATTERY GROUND BOLT 15 AMP BREAKER KEY START SWITCH

24 V

P20/J20 SPEED/TIMING SENSOR J3/P3 MACHINE INTERFACE CONNECTOR COOLANT TEMPERATURE SENSOR 8/12/16

INJECTORS GROUND BOLT P26 T/C CONNECTOR J4/P4 THROUGH J19/P19 J2 J1 ECM UNFILTERED OIL PRESSURE SENSOR AFTERCOOLER TEMPERATURE SENSOR CRANKCASE PRESSURE SENSOR J29/P29 RIGHT TURBOCHARGER INLET PRESSURE SENSOR J25/P25 LOW OIL LEVEL SWITCH ATMOSPHERIC PRESSURE SENSOR FUEL FILTER DIFFERENTIAL PRESSURE SWITCH TURBOCHARGER OUTLET PRESSURE SENSOR J23/P23 COOLANT FLOW SWITCH FILTERED OIL PRESSURE SENSOR J22/P22 LEFT TURBOCHARGER EXHAUST TEMPERATURE SENSOR RIGHT TURBOCHARGER EXHAUST TEMPERATURE SENSOR LEFT TURBOCHARGER INLET PRESSURE SENSOR J28/P28 J35/P35 THROTTLE POSITION SENSOR THROTTLE BACK-UP SWITCH WASTEGATE CONTROL SOLENOID

USER DEFINED SHUTDOWN GROUND LEVEL SHUTDOWN SWITCH BATTERY ENGINE FAN CONTROL SOLENOID A/C ON SWITCH FAN SPEED SENSOR

+ BATTERY RELAY

CYLINDER ENGINE ETHER START VALVE STARTING AID SWITCH J21/P21 J32/P32 J105/P105 J106/P106 J47/P47 P30/J30 J27/P27 J48/P48 P84/J84 P41/J41 308-YL 113-OR

BASIC ENGINE BLOCK DIAGRAM

APPLICATION BLOCK DIAGRAM

ELECTRONIC SERVICE TOOL CONNECTOR TO VIMS, EPTC II OR MONITORING SYSTEM DISCONNECT SWITCH OIL RENEWAL CONTROL SOLENOID 15 AMP BREAKER COOLANT TEMPERATURE SENSOR J4/P4 THROUGH J19/P19 RELAY J21/P21 J47/P47 J103/P103 J113/P113 P31/J31

(6)

(7)

(8)

(9)

(10)

(11)

(12)

(13)

(14)

(15)

(16)

(17)

(18)

(19)

(20)

(21)

(22)

(23)

(24)

(25)

(26)

(27)

(28)

(29)

(30)

OTHER SYSTEMS CONTROLLED BY THE ECM

• Oil Renewal

• Exhaust Wastegate Control

• Engine Oil Prelube

• Variable Speed Fan Control

(31)

24 V

BASIC ENGINE BLOCK DIAGRAM

APPLICATION BLOCK DIAGRAM

(32)

ELECTRONIC

(33)

(34)

(35)

(36)

• INJECTOR SOLENOID TEST

• CYLINDER CUT-OUT

• AUTOMATIC INJECTOR TEST

EUI INJECTOR TESTING

METHODS

(37)

EUI CONTROL LOGIC

ENGINE SPEED

FUEL QUANTITY

FUEL RPM

COLD MODE

SELECT

TIMING

CONVERT

DESIRED

TIMING

COOLANT

TEMPERATURE

TIMING CONTROL

DEGREES BTDC

DESIRED

TIMING

BTDC

TIMING

FUEL INJECTION

TIMING WAVE FORM

(38)

ELECTRONIC

GOVERNOR

TORQUE

MAPS

FRC

MAPS

TURBO OUTLET AND

ATMOSPHERIC

PRESSURE SENSORS

ENGINE

CONTROL

LOGIC

THROTTLE

SHUTDOWNS

ENGINE RPM

TDC

8

7

6

5

4

3

2

1 SIGNALS

TO FUEL

INJECTORS

FUEL

INJECTION

CONTROL

SPEED/TIMING

SIGNAL

ENGINE RPM

SPEED/TIMING

SENSOR

TIMING

WHEEL

ENGINE RPM

ECM

COOLANT

TEMPERATURE

SENSOR

3500B

ELECTRONIC GOVERNOR

(39)

P20/J20

SPEED/TIMING SENSOR

MACHINE INTERFACE

CONNECTOR

COOLANT

TEMPERATURE SENSOR

8/12/16

INJECTORS

GROUND BOLT

J4/P4 THROUGH

J19/P19

J2

J1

ECM

UNFILTERED OIL

PRESSURE SENSOR

CRANKCASE

PRESSURE SENSOR

ATMOSPHERIC

PRESSURE SENSOR

TURBOCHARGER OUTLET

PRESSURE SENSOR

FILTERED OIL

PRESSURE SENSOR

RIGHT TURBOCHARGER

INLET PRESSURE SENSOR

LEFT TURBOCHARGER

INLET PRESSURE SENSOR

AFTERCOOLER

TEMPERATURE SENSOR

LOW OIL

LEVEL SWITCH

FUEL FILTER

DIFFERENTIAL

PRESSURE SWITCH

COOLANT

FLOW SWITCH

LEFT TURBOCHARGER

EXHAUST

TEMPERATURE SENSOR

RIGHT TURBOCHARGER

EXHAUST

TEMPERATURE SENSOR

J21/P21

J32/P32

J105/P105

J106/P106

J47/P47

P30/J30

P31/J31

J25/P25

J28/P28

J22/P22

J23/P23

J27/P27

J29/P29

J48/P48

J3/P3

P26

T/C CONNECTOR

(40)

32

29

38

18

12 996-GN

998-BR

999-WH

F723-PK

F724-PU

+V TIMING

DIGITAL RETURN

PRIMARY ENGINE SPEED

TIMING CAL +

TIMING CAL

-ECM

P2 J2

A

B

C

OR

BK

WH

SPEED/TIMING

SENSOR

TIMING CALIBRATION

CONNECTOR

1

2 SPEED/TIMING SENSOR

P20 J20

P26

_{P1 J1}

(41)

(42)

50/50

TOOTH

SLOT

50/50

TOOTH

SLOT

50/50

TOOTH

SLOT

80/20

TOOTH

SLOT

SPEED/TIMING

SENSOR

TIMING

CALIBRATION

RANGE

±

7 °

CYL. NO. 3

REF

TDC

CYL. NO. 4

REF

TDC

CYL. NO. 8

TDC

REF

(43)

TIMING GEAR TOOTH TABLE

TABLE

ENTRY

CYLINDER

REFERENCE

A

B

C

D

E

F

G

H

80 %

50 %

80 %

50 %

80 %

NONE IDENTIFIED

PWM DUTY

CYCLE

A

B

C

_D

E

F

G

H

TIMING WHEEL ROTATION

CRANKING

(44)

TIMING GEAR TOOTH TABLE

TABLE

ENTRY

CYLINDER

REFERENCE

A

B

C

D

E

F

G

H

80 %

50 %

80 %

50 %

80 %

NONE IDENTIFIED

PWM DUTY

CYCLE

A

B

C

_D

E

F

G

H

TIMING WHEEL ROTATION

CRANKING

(45)

TIMING GEAR TOOTH TABLE

PWM DUTY

CYCLE

CYLINDER

REFERENCE

80 %

50 %

80 %

50 %

80 %

NORMAL OPERATION

NO

CYL. NO. 1

NO

CYL. NO. 2

NO

CYL. NO. 7

CYL. NO. 1

REFERENCE

DES TIMING

DELAY

60 °

BTDC (EEPROM)

NO. 1

INJECTION

ASSUMED

TDC

CYL. NO. 1

ACTUAL TDC

(CALIBRATED)

CYL. NO. 2

REFERENCE

CYL. NO. 2

ACTUAL TDC

(CALIBRATED)

60 °

BTDC (EEPROM)

TABLE

ENTRY

A

B

C

D

E

F

G

H

A

B

C

_D

E

F

G

H

TIMING WHEEL ROTATION

NO. 2

INJECTION

DES TIMING

ASSUMED

TDC

(46)

32

29

38

18

12 996-GN

998-BR

999-WH

F723-PK

F724-PU

+V TIMING

DIGITAL RETURN

PRIMARY ENGINE SPEED

TIMING CAL +

TIMING CAL

-ECM

P2 J2

A

B

C

OR

BK

WH

SPEED/TIMING

SENSOR

TIMING CALIBRATION

CONNECTOR

P26

TIMING CALIBRATION

SENSOR

TIMING CALIBRATION SENSOR

P20 J20

P1 J1

1

2

(47)

REFERENCE EDGE TO TDC DISTANCE

REFERENCE

EDGE

ASSUMED

CYL. NO. 1 TDC

ACTUAL

CYL. NO. 1 TDC

TIMING

REFERENCE

OFFSET

MAXIMUM TIMING REFERENCE OFFSET

±

7 DEGREES

TIMING CALIBRATION

SENSOR SIGNAL

TIMING

WHEEL

TIMING CALIBRATION

±

7 _°

-7

°

+7

_°

(48)

0

1

2

3

4 CURRENT FLOW

TIME (MILLISECONDS)

5 PULL-IN PEAK CURRENT

HOLD-IN PEAK CURRENT

INJECTION CURRENT WAVEFORM

(49)

• Speed Control

• Fuel Limiting

• Injection Timing

• Ether Injection

• Injector Cold Mode Cutout

(50)

FUEL SYSTEM LIMITS

• Cranking Fuel Limit

• Cold Mode Limit

• Fuel Ratio

• Maximum Torque

(51)

FUEL SYSTEM DERATES

• Automatic Altitude Compensation

• Automatic Filter Compensation

• High and Low Boost Derate

(52)

(53)

FUEL TANK

PRIMARY

FUEL

FILTER

SECONDARY

FUEL FILTERS

(2 MICRON)

ENGINE

BLOCK

OIL RENEWAL

INJECTOR

FUEL

PRESSURE

REGULATOR

FUEL

TRANSFER

PUMP

FUEL

HEATER

ECM

3516B FUEL SUPPLY CIRCUIT (793C)

PRIMING PUMP SUPPLY

FUEL

DIFFERENTIAL

PRESSURE

SWITCH

CYLINDER

HEAD

ENGINE

BLOCK

(54)

(55)

(56)

MUI

EUI

CYLINDER HEADS

(57)

PRIMARY

FILTER

TRANSFER

PUMP

SECONDARY

FILTER

FUEL TANK

ELECTRONIC

UNIT INJECTOR

ECM

FUEL

TANK

FUEL

PRESSURE

REGULATOR

(58)

3500B SYSTEM POWER SUPPLIES

• ECM: 24 VOLTS

• INJECTORS: 105 VOLTS

• ANALOG SENSORS: 5 VOLTS

• SPEED/TIMING SENSORS: 12.5 VOLTS

• DIGITAL SENSORS: 8 VOLTS

(59)

GROUND

BOLT

(FRAME)

15 AMP

BREAKER

24 V

J3/P3 MACHINE

INTERFACE

CONNECTOR

8/12/16

INJECTORS

GROUND BOLT (ENGINE)

P26 T/C CONNECTOR

J4/P4 THROUGH

J19/P19

J2

J1

ECM

BATTERY

113-OR

BASIC ENGINE BLOCK DIAGRAM

APPLICATION BLOCK DIAGRAM

DISCONNECT

SWITCH

KEY START

SWITCH

(60)

05

11

04

06

23 ECM

(-) BATTERY

(+) BATTERY

KEY SWITCH ON

229-BK-14

150-RD-14

113-OR

24 VOLTS DC

(+)

(-)

ENGINE BLOCK

GROUND BOLT

BREAKER

ENGINE BATTERY

AND CHARGING

SYSTEM

R

C

S

B

ST

OFF

308-YL

200-BK

105-RD

KEY START SWITCH

112-PU

117-RD

113-OR

15 A

10 AMP

P1 J1

ECM POWER SUPPLY CIRCUIT

MACHINE INTERFACE

CONNECTOR

1

2

26 P3 J3

(61)

7

13

19

23

29

12

18

22

28

34

1

2

3

4

5

6

35

36

37

38

39

40

7

13

19

23

29

12

18

22

28

34

1

2

3

4

5

6

35

36

37

38

39

40 ECM CONNECTORS

40 PINS, WIRE SIDE

(62)

32

29

38

18

12 996-GN

998-BR

999-WH

+V TIMING

DIGITAL RETURN

ENGINE SPEED

TIMING CAL +

TIMING CAL

-ECM

P2 J2

A

B

C

OR

BK

WH

SPEED/TIMING

SENSOR

SPEED/TIMING SENSOR POWER SUPPLY

12.5 ±

1 VOLTS

P20 J20

(63)

16

05

32 A701-GY

F726-YL

A703-BR

F726-YL

P2 J2

3512B INJECTOR WIRING SCHEMATIC

SOLENOID 1 POWER

SOLENOID 1/3 RETURN

SOLENOID 3 POWER

ECM

40

11

34 A702-PU

F727-BU

A704-GN

F727-BU

SOLENOID 2 POWER

SOLENOID 2/4 RETURN

SOLENOID 4 POWER

32

17

38 A705-BU

F728-BR

A707-PU

F728-BR

SOLENOID 5 POWER

SOLENOID 5/7 RETURN

SOLENOID 7 POWER

28

21

22 A706-GY

F729-GN

A708-BR

F729-GN

SOLENOID 6 POWER

SOLENOID 6/8 RETURN

SOLENOID 8 POWER

37

27

31 A709-OR

F730-GY

A711-PU

F730-GY

SOLENOID 9 POWER

SOLENOID 9/11 RETURN

SOLENOID 11 POWER

18

33

12 A710-GY

F731-OR

A712-BR

F731-OR

SOLENOID 10 POWER

SOLENOID 10/12 RETURN

SOLENOID 12 POWER

SOL 1

SOL 3

J52/P52

SOL 2

SOL 4

J56/P56

SOL 5

SOL 7

J53/P53

SOL 6

SOL 8

J57/P57

SOL 9

SOL 11

J54/P54

1

2

3

4 SOL 10

SOL 12

J58/P58

INJECTOR

SOLENOIDS

1

2

3

4

1

2

3

4

1

2

3

4

1

2

3

4

1

2

3

4

(64)

P22 J22

ENGINE COOLANT

TEMPERATURE SENSOR

FILTERED OIL

PRESSURE SENSOR

+V ANALOG

ANALOG RETURN

SIGNAL

+V ANALOG

ANALOG RETURN

SIGNAL

P23 J23

TURBO OUTLET

PRESSURE SENSOR

+V ANALOG

ANALOG RETURN

SIGNAL

P25 J25

RIGHT TURBO INLET

PRESSURE SENSOR

+V ANALOG

ANALOG RETURN

SIGNAL

P27 J27

ATMOSPHERIC

PRESSURE SENSOR

+V ANALOG

ANALOG RETURN

SIGNAL

P28 J28

LEFT TURBO INLET

PRESSURE SENSOR

+V ANALOG

ANALOG RETURN

SIGNAL

36

30 3500B ANALOG SENSOR

POWER SUPPLY

P1 J1

P43 J43

+V ANALOG

ANALOG RETURN

SIGNAL

CRANKCASE

PRESSURE SENSOR

P48 J48

+V ANALOG

ANALOG RETURN

SIGNAL

UNFILTERED OIL

PRESSURE SENSOR

A

B

C

A

B

C

A

B

C

A

B

C

A

B

C

A

B

C

A

B

C

J21 P21

5 ±

0.5 VOLTS

+V ANALOG SUPPLY

ANALOG RETURN

ECM

A

B

C

(65)

+ V DIGITAL SUPPLY

- V DIGITAL RETURN

29

35 DIGITAL SENSOR

POWER SUPPLY

P1 J1

A

B

C

J31 P31

+V DIGITAL

DIGITAL RETURN

SIGNAL

RIGHT EXHAUST

TEMPERATURE SENSOR

A

B

C

J35 P35

THROTTLE

POSITION SENSOR

+V DIGITAL

DIGITAL RETURN

SIGNAL

8 ±

0.5 VOLTS

A

B

C

J30 P30

+V DIGITAL

DIGITAL RETURN

SIGNAL

LEFT EXHAUST

TEMPERATURE SENSOR

A

B

C

J84 P84

+V DIGITAL

DIGITAL RETURN

SIGNAL

FAN

SPEED SENSOR

ECM

(66)

WASTEGATE CONTROL

PWM DRIVER & SOLENOID RETURN

29

35 P2 J2

A

B

J41 P41

WASTEGATE CONTROL

SOLENOID VALVE

SUPPLY

RETURN

WASTEGATE CONTROL SOLENOID

POWER SUPPLY

0 TO 1.04 Amps PWM

(67)

3500B ELECTRONIC

(68)

24 V

INJECTORS GROUND BOLT

P26 T/C CONNECTOR J4/P4 THROUGH J19/P19 J2 J1 ECM UNFILTERED OIL PRESSURE SENSOR AFTERCOOLER TEMPERATURE SENSOR CRANKCASE PRESSURE SENSOR J29/P29 RIGHT TURBOCHARGER INLET PRESSURE SENSOR J25/P25 LOW OIL LEVEL SWITCH ATMOSPHERIC PRESSURE SENSOR FUEL FILTER DIFFERENTIAL PRESSURE SWITCH TURBOCHARGER OUTLET PRESSURE SENSOR J23/P23 COOLANT FLOW SWITCH FILTERED OIL PRESSURE SENSOR J22/P22 LEFT TURBOCHARGER EXHAUST TEMPERATURE SENSOR RIGHT TURBOCHARGER EXHAUST TEMPERATURE SENSOR LEFT TURBOCHARGER INLET PRESSURE SENSOR J28/P28 J35/P35 THROTTLE POSITION SENSOR THROTTLE BACK-UP SWITCH WASTEGATE CONTROL SOLENOID

+ BATTERY

RELAY

BASIC ENGINE BLOCK DIAGRAM

APPLICATION BLOCK DIAGRAM

TO VIMS, EPTC II OR MONITORING SYSTEM DISCONNECT SWITCH OIL RENEWAL CONTROL SOLENOID 15 AMP BREAKER COOLANT TEMPERATURE SENSOR J4/P4 THROUGH J19/P19 RELAY J21/P21 J47/P47 J103/P103 J113/P113 P31/J31 ELECTRONIC SERVICE TOOL CONNECTOR

(69)

P20/J20

SPEED/TIMING

SENSOR

8/12/16

INJECTORS

GROUND BOLT

P26 T/C CONNECTOR

J4/P4 THROUGH

J19/P19

J2

J1

ECM

SPEED/TIMING SENSOR

(70)

ANALOG SENSORS

• Aftercooler temperature sensor

• Oil pressure sensors

• Turbocharger outlet (boost) sensor

• Turbocharger inlet pressure sensors

• Atmospheric pressure sensor

• Coolant temperature sensor

(71)

P20/J20

SPEED/TIMING

SENSOR

COOLANT

TEMPERATURE

SENSOR

8/12/16

INJECTORS

GROUND BOLT

P26 T/C CONNECTOR

J4/P4 THROUGH

J19/P19

J2

J1

ECM

J21/P21

(72)

P20/J20

SPEED/TIMING

SENSOR

COOLANT

TEMPERATURE

SENSOR

8/12/16

INJECTORS

GROUND BOLT

P26 T/C CONNECTOR

J4/P4 THROUGH

J19/P19

J2

J1

ECM

AFTERCOOLER

TEMPERATURE

SENSOR

J21/P21

J32/P32

(73)

OIL PRESSURE SENSORS

P20/J20

SPEED/TIMING

SENSOR

J3/P3 MACHINE

INTERFACE

CONNECTOR

COOLANT

TEMPERATURE

SENSOR

8/12/16

INJECTORS

GROUND BOLT

J4/P4 THROUGH

J19/P19

J2

J1

ECM

UNFILTERED OIL

PRESSURE

SENSOR

AFTERCOOLER

TEMPERATURE

SENSOR

FILTERED OIL

PRESSURE

SENSOR

J22/P22

J21/P21

J32/P32

J48/P48

T/C

CONNECTOR

P26

(74)

OIL PRESSURE IN kPa

600

700

800

900 1000

1100

1200

1300

1400

1500

1600

1700

1800

60

80

100

120

140

160

180

200

220

240

260

280

300 ENGINE RPM

OIL PRESSURE MAP

1900

320

340

8.7

11.6

14.5

17.4

20.3

23.2

26.1

29

31.9

34.8

37.7

40.6

43.5

46.4

49.3 OIL PRESSURE IN PSI

kPa x 0.145 = PSI

(75)

P20/J20

SPEED/TIMING

SENSOR

COOLANT

TEMPERATURE

SENSOR

8/12/16

INJECTORS

GROUND BOLT

P26

J4/P4 THROUGH

J19/P19

J2

J1

ECM

UNFILTERED OIL

PRESSURE

SENSOR

AFTERCOOLER

TEMPERATURE

SENSOR

ATMOSPHERIC

PRESSURE

SENSOR

FILTERED OIL

PRESSURE

SENSOR

J22/P22

J21/P21

J32/P32

J27/P27

J48/P48

T/C

CONNECTOR

(76)

100%

98%

96%

94%

92%

90%

88%

86%

84%

82%

80%

78%

76%

74%

77 76

75 74

73 72 71 70

69 68 67

66 65 64

63 62 61 60 59 58 57

56 55 54

53 8,210

8,920

9,630

10,340

11,050

11,760

12,470

13,890

14,600

15,310

16,020

16,730

17,440

13,180

7,500

72%

ENGINE POWER DERATING MAP

ACCORDING TO ATMOSPHERIC PRESSURE

ATMOSPHERIC PRESSURE IN kPa

PERCENT OF FULL LOAD POWER

(77)

P20/J20

SPEED/TIMING

SENSOR

COOLANT

TEMPERATURE

SENSOR

8/12/16

INJECTORS

GROUND BOLT

P26

J4/P4 THROUGH

J19/P19

J2

J1

ECM

UNFILTERED OIL

PRESSURE

SENSOR

AFTERCOOLER

TEMPERATURE

SENSOR

RIGHT

TURBOCHARGER

INLET PRESSURE

SENSOR

J25/P25

ATMOSPHERIC

PRESSURE

SENSOR

FILTERED OIL

PRESSURE

SENSOR

J22/P22

LEFT

TURBOCHARGER

INLET PRESSURE

SENSOR

J28/P28

J21/P21

J32/P32

J27/P27

J48/P48

TURBOCHARGER

INLET

PRESSURE

SENSORS

T/C

CONNECTOR

(78)

CAT

AUTOMATIC AIR FILTER COMPENSATION

TURBOCHARGER

INLET PRESSURE

SENSOR

ATMOSPHERIC

PRESSURE

SENSOR

Filter differential pressure calculated with formula:

Atmospheric sensor pressure - Turbo sensor pressure =

∆

P

Fuel limited 2% per 4 inches H

₂

0 to max 20%

(79)

P20/J20

SPEED/TIMING

SENSOR

COOLANT

TEMPERATURE

SENSOR

8/12/16

INJECTORS

GROUND BOLT

P26 T/C CONNECTOR

J4/P4 THROUGH

J19/P19

J2

J1

ECM

UNFILTERED OIL

PRESSURE

SENSOR

AFTERCOOLER

TEMPERATURE

SENSOR

RIGHT

TURBOCHARGER

INLET PRESSURE

SENSOR

J25/P25

ATMOSPHERIC

PRESSURE

SENSOR

TURBOCHARGER

OUTLET

PRESSURE SENSOR

J23/P23

FILTERED OIL

PRESSURE

SENSOR

J22/P22

LEFT

TURBOCHARGER

INLET PRESSURE

SENSOR

J28/P28

J21/P21

J32/P32

J27/P27

J48/P48

TURBOCHARGER

OUTLET

PRESSURE

SENSOR

(80)

P20/J20

SPEED/TIMING

SENSOR

COOLANT

TEMPERATURE

SENSOR

8/12/16

INJECTORS

GROUND BOLT

P26 T/C CONNECTOR

J4/P4 THROUGH

J19/P19

J2

J1

ECM

UNFILTERED OIL

PRESSURE

SENSOR

AFTERCOOLER

TEMPERATURE

SENSOR

CRANKCASE

PRESSURE

SENSOR

J29/P29

RIGHT

TURBOCHARGER

INLET PRESSURE

SENSOR

J25/P25

ATMOSPHERIC

PRESSURE

SENSOR

TURBOCHARGER

OUTLET

PRESSURE SENSOR

J23/P23

FILTERED OIL

PRESSURE

SENSOR

J22/P22

LEFT

TURBOCHARGER

INLET PRESSURE

SENSOR

J28/P28

J21/P21

J32/P32

J27/P27

J48/P48

CRANKCASE

PRESSURE

SENSOR

(81)

P20/J20

SPEED/TIMING

SENSOR

COOLANT

TEMPERATURE

SENSOR

8/12/16

INJECTORS

GROUND BOLT

P26 T/C CONNECTOR

J4/P4 THROUGH

J19/P19

J2

J1

ECM

UNFILTERED OIL

PRESSURE

SENSOR

AFTERCOOLER

TEMPERATURE

SENSOR

CRANKCASE

PRESSURE

SENSOR

J29/P29

RIGHT

TURBOCHARGER

INLET PRESSURE

SENSOR

J25/P25

LOW OIL

LEVEL

SWITCH

ATMOSPHERIC

PRESSURE

SENSOR

FUEL FILTER

DIFFERENTIAL

PRESSURE SWITCH

TURBOCHARGER

OUTLET

PRESSURE SENSOR

J23/P23

COOLANT

FLOW

SWITCH

FILTERED OIL

PRESSURE

SENSOR

J22/P22

LEFT

TURBOCHARGER

INLET PRESSURE

SENSOR

J28/P28

J21/P21

J32/P32

J105/P105

J106/P106

J47/P47

J27/P27

J48/P48

ENGINE

SWITCHES

(82)

24 ECM

LOW OIL

LEVEL

SWITCH

P1 J1

LOW OIL LEVEL

26

29 COOLANT FLOW

DIGITAL RETURN

F719-BR

998-BR

J105 P105

1

2 SIGNAL

DIGITAL RETURN

COOLANT

FLOW

SWITCH

412-BU

998-BR

J47 P47

1

2 SIGNAL

DIGITAL RETURN

17 FUEL FILTER SW

FUEL FILTER

DIFFERENTIAL

PRESSURE

SWITCH

F725-WH

998-BR

J106 P106

1

2 SIGNAL

DIGITAL RETURN

(83)

• Wastegate control

• Exhaust temperature

• Throttle position

(84)

P20/J20

SPEED/TIMING

SENSOR

COOLANT

TEMPERATURE

SENSOR

8/12/16

INJECTORS

GROUND BOLT

P26 T/C CONNECTOR

J4/P4 THROUGH

J19/P19

J2

J1

ECM

UNFILTERED OIL

PRESSURE

SENSOR

AFTERCOOLER

TEMPERATURE

SENSOR

CRANKCASE

PRESSURE

SENSOR

J29/P29

RIGHT

TURBOCHARGER

INLET PRESSURE

SENSOR

J25/P25

LOW OIL

LEVEL

SWITCH

ATMOSPHERIC

PRESSURE

SENSOR

FUEL FILTER

DIFFERENTIAL

PRESSURE SWITCH

TURBOCHARGER

OUTLET

PRESSURE SENSOR

J23/P23

COOLANT

FLOW

SWITCH

FILTERED OIL

PRESSURE

SENSOR

J22/P22

LEFT

TURBOCHARGER

INLET PRESSURE

SENSOR

J28/P28

WASTEGATE

CONTROL SOLENOID

J21/P21

J32/P32

J105/P105

J106/P106

J47/P47

J27/P27

J48/P48

WASTEGATE

CONTROL

SOLENOID

(85)

P20/J20

SPEED/TIMING

SENSOR

COOLANT

TEMPERATURE

SENSOR

8/12/16

INJECTORS

GROUND BOLT

P26 T/C CONNECTOR

J4/P4 THROUGH

J19/P19

J2

J1

ECM

UNFILTERED OIL

PRESSURE

SENSOR

AFTERCOOLER

TEMPERATURE

SENSOR

CRANKCASE

PRESSURE

SENSOR

J29/P29

RIGHT

TURBOCHARGER

INLET PRESSURE

SENSOR

J25/P25

LOW OIL

LEVEL

SWITCH

ATMOSPHERIC

PRESSURE

SENSOR

FUEL FILTER

DIFFERENTIAL

PRESSURE SWITCH

TURBOCHARGER

OUTLET

PRESSURE SENSOR

J23/P23

COOLANT

FLOW

SWITCH

FILTERED OIL

PRESSURE

SENSOR

J22/P22

LEFT

TURBOCHARGER

EXHAUST

TEMPERATURE

SENSOR

RIGHT

TURBOCHARGER

EXHAUST

TEMPERATURE

SENSOR

LEFT

TURBOCHARGER

INLET PRESSURE

SENSOR

J28/P28

WASTEGATE

CONTROL SOLENOID

J21/P21

J32/P32

J105/P105

J106/P106

J47/P47

P30/J30

P31/J31

J27/P27

J48/P48

EXHAUST

TEMPERATURE

SENSORS

(86)

GROUND BOLT 15 AMP BREAKER KEY START SWITCH

24 V

INJECTORS GROUND BOLT

P26 T/C CONNECTOR J4/P4 THROUGH J19/P19 J2 J1 ECM UNFILTERED OIL PRESSURE SENSOR AFTERCOOLER TEMPERATURE SENSOR CRANKCASE PRESSURE SENSOR J29/P29 RIGHT TURBOCHARGER INLET PRESSURE SENSOR J25/P25 LOW OIL LEVEL SWITCH ATMOSPHERIC PRESSURE SENSOR FUEL FILTER DIFFERENTIAL PRESSURE SWITCH TURBOCHARGER OUTLET PRESSURE SENSOR J23/P23 COOLANT FLOW SWITCH FILTERED OIL PRESSURE SENSOR J22/P22 LEFT TURBOCHARGER EXHAUST TEMPERATURE SENSOR RIGHT TURBOCHARGER EXHAUST TEMPERATURE SENSOR LEFT TURBOCHARGER INLET PRESSURE SENSOR J28/P28 J35/P35 THROTTLE POSITION SENSOR WASTEGATE CONTROL SOLENOID BATTERY J21/P21 J32/P32 J105/P105 J106/P106 J47/P47 P30/J30 P31/J31 J27/P27 J48/P48 308-YL 113-OR

THROTTLE

POSITION

SENSOR

DISCONNECT SWITCH

(87)

90%

ON

OFF

ON

OFF

ON

OFF

10%

50%

DUTY

CYCLE

DUTY CYCLE = PERCENT OF TIME ON VS PERCENT OF TIME OFF

1 CYCLE

= 90%

DUTY

CYCLE

= 50%

DUTY

CYCLE

= 10%

(88)

24 V

INJECTORS GROUND BOLT P26 T/C CONNECTOR J4/P4 THROUGH J19/P19 J2 J1 ECM UNFILTERED OIL PRESSURE SENSOR AFTERCOOLER TEMPERATURE SENSOR CRANKCASE PRESSURE SENSOR J29/P29 RIGHT TURBOCHARGER INLET PRESSURE SENSOR J25/P25 LOW OIL LEVEL SWITCH ATMOSPHERIC PRESSURE SENSOR FUEL FILTER DIFFERENTIAL PRESSURE SWITCH TURBOCHARGER OUTLET PRESSURE SENSOR J23/P23 COOLANT FLOW SWITCH FILTERED OIL PRESSURE SENSOR J22/P22 LEFT TURBOCHARGER EXHAUST TEMPERATURE SENSOR RIGHT TURBOCHARGER EXHAUST TEMPERATURE SENSOR LEFT TURBOCHARGER INLET PRESSURE SENSOR J28/P28 J35/P35 THROTTLE POSITION SENSOR THROTTLE BACK-UP SWITCH WASTEGATE CONTROL SOLENOID BATTERY J21/P21 J32/P32 J105/P105 J106/P106 J47/P47 P30/J30 P31/J31 J27/P27 J48/P48 308-YL 113-OR

THROTTLE

BACK-UP

SWITCH

(89)

24 V

INJECTORS GROUND BOLT P26 T/C CONNECTOR J4/P4 THROUGH J19/P19 J2 J1 ECM UNFILTERED OIL PRESSURE SENSOR AFTERCOOLER TEMPERATURE SENSOR CRANKCASE PRESSURE SENSOR J29/P29 RIGHT TURBOCHARGER INLET PRESSURE SENSOR J25/P25 LOW OIL LEVEL SWITCH ATMOSPHERIC PRESSURE SENSOR FUEL FILTER DIFFERENTIAL PRESSURE SWITCH TURBOCHARGER OUTLET PRESSURE SENSOR J23/P23 COOLANT FLOW SWITCH FILTERED OIL PRESSURE SENSOR J22/P22 LEFT TURBOCHARGER EXHAUST TEMPERATURE SENSOR RIGHT TURBOCHARGER EXHAUST TEMPERATURE SENSOR LEFT TURBOCHARGER INLET PRESSURE SENSOR J28/P28 J35/P35 THROTTLE POSITION SENSOR THROTTLE BACK-UP SWITCH WASTEGATE CONTROL SOLENOID GROUND LEVEL SHUTDOWN SWITCH BATTERY J21/P21 J32/P32 J105/P105 J106/P106 J47/P47 P30/J30 P31/J31 J27/P27 J48/P48 308-YL 113-OR

GROUND

LEVEL

SHUTDOWN

SWITCH

(90)

USER SHUTDOWN

1 P2 J2

USER DEFINED SHUTDOWN

12 J3

USER SHUTDOWN

DEVICE

(91)

25

29

40

22 ECM

ETHER SWITCH

315-GN

317-YL

ETHER REQUEST

DIGITAL RETURN

ETHER ON

ETHER HOLD

P1 J1

F720-GN

998-BR

710-BR

707-WH

ETHER ON RELAY

200-BK

P37 J37

ETHER

SOLENOID VALVE

ETHER HOLD RELAY

315-GN

F707-WH

317-YL

K984-GY

START AID

RESISTOR

998-BR

1

2 +24V

(92)

GROUND STUD 15 AMP BREAKER KEY START SWITCH

24 V

INJECTORS GROUND BOLT P26 T/C CONNECTOR J4/P4 THROUGH J19/P19 J2 J1 ECM UNFILTERED OIL PRESSURE SENSOR AFTERCOOLER TEMPERATURE SENSOR CRANKCASE PRESSURE SENSOR J29/P29 RIGHT TURBOCHARGER INLET PRESSURE SENSOR J25/P25 LOW OIL LEVEL SWITCH ATMOSPHERIC PRESSURE SENSOR FUEL FILTER DIFFERENTIAL PRESSURE SWITCH TURBOCHARGER OUTLET PRESSURE SENSOR J23/P23 COOLANT FLOW SWITCH FILTERED OIL PRESSURE SENSOR J22/P22 LEFT TURBOCHARGER EXHAUST TEMPERATURE SENSOR RIGHT TURBOCHARGER EXHAUST TEMPERATURE SENSOR LEFT TURBOCHARGER INLET PRESSURE SENSOR J28/P28 J35/P35 THROTTLE POSITION SENSOR THROTTLE BACK-UP SWITCH WASTEGATE CONTROL SOLENOID USER SHUTDOWN GROUND LEVEL SHUTDOWN SWITCH BATTERY ENGINE FAN CONTROL SOLENOID A/C ON SWITCH FAN SPEED SENSOR

+ BATTERY

RELAY

CYLINDER ENGINE ETHER START VALVE STARTING AID SWITCH J21/P21 J32/P32 J105/P105 J106/P106 J47/P47 P30/J30 P31/J31 J27/P27 J48/P48 P84/J84 P41/J41 308-YL 113-OR