Presentation Objective

At the end of this presentation you will be able to:

Describe the benefits of electronically controlled

engines.

Answer basic questions relating to system

components.

Understand the functions of Electronic Technician (ET) Describe the basic concept of Controller Area Network
(CAN) and SAE J1939.

Caterpillar 3000 Series 3054E/3056E

Engine Coolant Temperature Sensor Intake Air Temperature Sensor Manifold Pressure Sensor

Machine Interface Connector Bosch VP30 Pump Service Tool Connector (Industrial Engine)

Primary Speed/Timing Sensor Engine Oil Pressure Sensor Electronic Control Module (ECM)

3000 Series Basic Engine Schematic

VP30 Electronic Distributor Pump Pump ECU VLPM ET Service Tool Connector

36-1 Tooth Crank Gear

A4 E1
Machine Interface Connector

Primary Speed/Timing Sensor Intake Manifold Pressure Sensor Engine Oil Pressure Sensor

Intake Manifold Temperature Sensor Engine Coolant Temperature Sensor

System Components - Wiring Harness

Engine harness connects engine mounted sensors and
actuators to ECM

Traditionally wiring and connectors is highest cause of

reliability problems

Incorporates robust sealed connectors Connectors are designed for long service life Cable insulation is capable of withstanding temperature
and fluid exposure

Outer covering provides protection from damage due to

vibration, heat and general abuse

Harness routing and connector keying is used to prevent

incorrect connection of components

Electronically Controlled Fuel Systems

Caterpillar 3000 Series
z VP30 Pump

Bosch VP30 Fuel Injection Pump

Pump ECU Fuel Temperature Sensor PUMP CONNECTOR Pump Supply/CAN Link/ Engine Speed/Timing/ Fuel Shutoff Connector

Fuel Quantity Solenoid Valve

Secondary Speed/Timing Sensor Timing Control Solenoid

ELECTRONICALLYCONTROLLEDFUELSYSTEM
HIGHPRESSURESTAGE
ENGINEECM (A4CONTROLLER) PUMPECU
ROLLER PLATE RING SPEEDTIMING SENSOR ORIFICE FUELQUANTITY SOLENOID VALVE FUELRETURN CHECKVALVE LIFT PUMP (PRIMINGPUMP)

PRESSURE REGULATOR

DISTRIBUTOR PLUNGER

TRANSFER PUMP

CAM PLATE TIMINGADVANCE MECHANISM TIMING SOLENOID ROLLER

DELIVERY VALVE INJECTOR

A4 ECM (3054E/3056E)

One ECM fits all applications

Basic System - Interactions

CONTROL INPUTS
Sensors: Pressure,Temperature, Speed/Timing
Cables/Connectors

5/8 volts sensor supplies and operation

OUTPUTS
Indicator lights Actuators
Cables/Connectors

Switches/Pushbuttons Power Supply 12 v or 24 v

Computer Hardware + Software ECM

CAT DATA LINK

Relays

OUTPUTS
C.A.N. DATA LINK

INPUTS

SERVICE TOOL

PUMP TO ECM/FLASH

System Components ECM Hardware

INPUTS Digital Analogue voltage PWM MEMORY PROCESSOR COMMUNICATIONS LINKS OUTPUTS Digital PWM

Electronic Control Module: Essential Facts

High reliability External connectors most vulnerable No serviceable parts Never replace without full diagnostic test All warranty returns checked No fault warranty returns - no warranty credit ECM is the LAST component you should suspect
being faulty

Engine Speed Controls

Sensor Types

System Components Speed Controls

Cat Machines
Throttle Position Sensors/Controls

- Pulse Width Modulation (PWM) - Set Speed Switches

Industrial Engine, pedal

Voltage o/p

position/operator demand
- Pulse Width Modulation (PWM) - Contacting, resistive track potentiometer type devices.
Provide linear voltage output (0.5v to 4.5v)

Low Idle

High Idle

Should have idle validation switches on mobile applications for failure detection.

PWM Throttle Position Sensor

Three wires:

Ground +8 Volt supply PWM Output

System Components Throttle Position Sensors

Pulse Width Modulation (PWM) is an output that is
defined by its duty cycle. to the time off.

The duty cycle is the relation between the time on More consistent than a linear sensor type. Above 90% and below 10% implies there is an
error present.

IDLE(0.9volts)

FULL THROTTLE (4.6volts)

System Components
Temperature Sensors: Passive type
- Commonly known as magnetic pick-ups - Produce a sinusoidal voltage signal. Signal conditioning is required in the ECM

Pressure Sensors: Active type:

- Hall effect - Produce a conditioned square wave signal - More costly than passive sensors

Engine Mounted Sensors

On Engine Sensor Wiring

J201 P201

ENGINE OIL PRESSURE SENSOR

SENSOR VREF +5V ENGINE OIL PRESSURE SENSOR COMMON

A C B

P1 J1

ECM
SENSOR VREF +5 VOLTS
ENGINE OIL PRESSURE

J200 P200

L730 994 X731

26
24 14

INTAKE MANIFOLD PRESSURE SENSOR

SENSOR VREF +5V INTAKE MANIFOLD PRESSURE SENSOR COMMON

A C B

INTAKE MANIFOLD PRESSURE

ENGINE COOLANT TEMPERATURE SENSOR INTAKE MANIFOLD TEMPERATURE SENSOR

J100 P100
ENGINE COOLANT TEMPERATURE SENSOR COMMON

1 2

995

15

ENGINE COOLANT TEMPERATURE

J103 P103
INTAKE MANIFOLD AIR TEMPERATURE SENSOR COMMON

1 2

C967 L731

32 34

INTAKE MANIFOLD AIR TEMP

SENSOR COMMON O VOLTS

J401 P401

E966

SPEED AND TIMING SENSOR NO.1

CRANKSHAFT POSITION + CRANKSHAFT POSITION -

2 1

E965

41 49 33

CRANKSHAFT POSITION +

CRANKSHAFT POSITION CRANKSHAFT POSITION SCREEN

System Components
Temperature Sensors
Thermistors:
- Semiconductor sensing devices - Resistance varies with temperature - Negative Temperature Coefficient (NTC) most common i.e. As temperature increases its resistance decreases - 40 to 300F range - Passive sensor lower cost

Temperature Sensors
Thermistor
Ground Pin No 2

Signal Pin No 1

Temperature Sensors
3054E/3056E Applications
- Intake Manifold Temperature Sensor - Engine Coolant Temperature Sensor

System Components Temperature Sensors

Ohms (Resistance)

Volts Volts Ohms 5.0

25,000

5,000 0.5
Increasing Temperature

ECM

Temperature (Passive) Sensor Operation

+5 VOLTS REFERENCE SUPPLY

R1

MIC R

ANALOGUE TO DIGITAL CONVERTER

OP RO CE SS OR

R2 0 VOLTS TEMPERATURE SENSOR

System Components Pressure Sensors

Pressure: Active Sensors (i.e. with built in conditioning electronics) provide
analogue voltage output with linear and temperature compensation.

Various working ranges to suit measured parameter e.g.

- 12 to +17 psi (abs) - Atmospheric pressure 0 to 70 psi (abs) - Intake manifold pressure 0 to 115 psi (abs) - Engine oil pressure abs = absolute (pressure)

Pressure Sensors
A (5 Volts)

C (Signal)

Intake Manifold Pressure Sensor

B (Sensor Return)

Oil Pressure Sensor

Pressure Sensors
Change of Voltage with Pressure. 4.5 Volts
Out of range

0.5

Out of Range

Pressure

Pressure Sensor Circuits

ECM +5 VOLTS REFERENCE SUPPLY

+12V

ANALOGUE TO DIGITAL CONVERTER

MICROPROCESSOR

0 VOLTS

System Components
Other Sensors (Industrial): Coolant Level Sensor

System Components
Speed/Timing Sensors
Applications:
- Determine rotational speed and rotational position Primary - Crankshaft speed and position Secondary - Camshaft/fuel pump speed and position

Primary Speed/Timing Sensor

Speed/Timing Sensor
The 3000 series engines
use a 36-1 tooth ring. i.e. the timing ring has space for 36 teeth, and one is missing. The missing tooth allows the ECM to determine the timing of the engine. The wheel is dowelled to index it to the crankshaft.
Top Dead Center

70 Degrees 4 CYL

Rotation

40 Degrees - 6 Cylinder

System Components - Speed Sensors

Passive Speed Sensors
Iron Core Magnet Coil Flux Lines Pole Piece Direction of motion Teeth

Secondary Speed/Timing Sensor Installation

Crankshaft Speed/Timing Sensor

ECM (6 cylinder Engine)

System Components Speed/Timing Sensors

Speed/Timing Sensors failure Modes
Primary sensor
Defaults to Secondary Engine runs in limp home mode (max 1200 rpm) Engine will start and run with a failed sensor

Secondary sensor
Engine stops and will not start

Teeth

System Components Output Devices

Typically include:
- Relays - Lamps - Gauges (PWM)

System Components - Actuators

Electronically Controlled Fuel Pump

Intelligent rotary pump e.g. Bosch VP30

- Local pump mounted ECU controls pump solenoids to achieve desired fuel delivery and timing. - Main ECM communicates desired timing and fuelling via CAN communication link

Electronic Service Tools

Communication Adapter (CA II)
(CA I can be used if necessary)

CAT ET (Electronic Technician)

Electronic Service Tools

CAT ET Service Tool:

PC based, multi function

- Status Screens - Diagnostics - Flash Programming

Electronic Technician
CAT ET
z

The first element of STW (Service Technician

Workbench)

z z z z

Common for all future Caterpillar electronic engines Hardware and software required Annual subscription Not compatible with Perkins 1100 Series engines

ET Service Tool Communication Adapter Group

CAT ET (Electronic Technician)

Functionality includes:
z z z

Fault Codes Data recording and graphing

Horsepower, customer operational parameters, P.T.O. cruise, Multi-position switch.

Engine Configuration

z z z

Flash Programming (ECM re-programming) Supports troubleshooting process Displays parameters, temperature, speed, pressure etc.

Electronically Controlled Engines

ARE ABLE TO

Indicate active faults, logged faults and

events

Identify sensor and actuator short and open

circuits CANNOT

Troubleshoot themselves Identify inaccurate sensor readings

Data Links
z z

Cat Data Link (CDL) Controller Area Network (CAN)

z (Two CAN data links on 3054E/56E)

Example of CAN wiring

HAND HELD SERVICE TOOL Address 249 NODE DATA BUS

Ohm TERMINATING RESISTOR

120 Ohm TERMINATING RESISTOR

MACHINE INTERFACE CONNECTOR 52 61

ENGINE ECM Address 0

INSTRUMENT PANEL Address 23

GEARBOX ECM Address 3

NODE

The CAN shield not connected to ECM

Controller Area Networks (CAN)

Introduction:

CAN is the communication network between

intelligent electronic devices used on an application.

Ground based equipment use a version of CAN that

conforms to an international standard known as J1939

Application control, monitoring and diagnostics is

possible using J1939.

Controller Area Networks (CAN)

Advantages:

Uses less wiring, lower weight, lower cost, etc. Uses fewer connections, more reliable. Easier to install. Improved quality of signal. Transmission of huge amounts of data.

3054E/3056E CAN Data Link Usage

CAN J1939

Flash Programming

CAN Proprietary Data Link

ECM to Pump ECU

communication

CAN - J1939
Examples of CAN Data link Uses: ECM to Engine Fuel Pump: Transmits engine power
requirements to pump ECU

Transmission to Engine: Tells the engine what gear is

currently selected

Engine to Machine: Broadcasting of engine parameters

(e.g. engine speed, oil pressure, coolant temp.)

Flash Programming: ECM Personality Module only

3054E Versus 3056E Differences

z z z z

3054E: Cross flow cylinder head Electric fuel priming pump Glow plugs for starting Sensor locations

Training Material Resources

z z

ITIM 3056E Engine SERV 2705 Systems Operation Testing & Adjusting
z z

3054E Industrial Engine RENR 7568 3056E Machine Engine RENR 2416

The Service Training website contains:

z z

Information & this presentation Tech Tips Newsletter No. 21 contains FAQs