3054E 3056E Electronico Con VP 30 Ingles

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

Service Tool Connector

VLPM ET

36-1 Tooth Crank Gear

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

A4 E1 Machine Interface Connector

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

ELECTRONICALLY CONTROLLED FUEL SYSTEM HIGH PRESSURE STAGE FUEL RETURN CHECK VALVE

ENGINE ECM (A4 CONTROLLER)

LIFT PUMP (PRIMING PUMP)

PUMP ECU ROLLER PLATE

SPEED TIMING SENSOR

 ORIFICE FUEL QUANTITY SOLENOID VALVE

RING

PRESSURE REGULATOR

DISTRIBUTOR PLUNGER

TRANSFER PUMP

CAM PLATE TIMING ADVANCE 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

Switches/Pushbuttons Power Supply 12 v or 24 v

INPUTS

OUTPUTS

5/8 volts sensor supplies and operation

Computer Hardware + Software

Indicator lights Actuators Cables/Connectors

ECM

Relays

OUTPUTS CAT DATA LINK

SERVICE TOOL

C.A.N. DATA LINK

PUMP TO ECM/FLASH

System Components ECM Hardware INPUTS

COMMUNICATIONS LINKS

Digital

Digital Analogue voltage

OUTPUTS

PROCESSOR

PWM MEMORY

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 Throttle Position Sensors/Controls

• Cat Machines

- Pulse Width Modulation (PWM) - Set Speed Switches

• Industrial Engine, pedal

position/operator demand

Voltage o/p

- 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.

• The duty cycle is the relation between the time on to the time off.

• 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

A

ENGINE OIL PRESSURE

C

SENSOR COMMON

B

P1 J1

J200 P200

INTAKE MANIFOLD PRESSURE SENSOR

ENGINE COOLANT TEMPERATURE SENSOR

SENSOR VREF +5V

A

INTAKE MANIFOLD PRESSURE

C

SENSOR COMMON

B

ECM

L730

26

SENSOR VREF +5 VOLTS

994 X731

24 14

ENGINE OIL PRESSURE

995

15

ENGINE COOLANT TEMPERATURE

C967 L731

32 34

SENSOR COMMON O VOLTS

INTAKE MANIFOLD PRESSURE

J100 P100 ENGINE COOLANT TEMPERATURE

1

SENSOR COMMON

2

J103 P103

INTAKE MANIFOLD TEMPERATURE SENSOR

INTAKE MANIFOLD AIR TEMPERATURE SENSOR COMMON

1 2

J401 P401

SPEED AND TIMING SENSOR NO.1

CRANKSHAFT POSITION +

2

CRANKSHAFT POSITION -

1

INTAKE MANIFOLD AIR TEMP

E966

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 300ºF 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 Volts

Ohms (Resistance)

25,000

Volts Ohms

5.0

5,000 0.5 Increasing Temperature

ECM

Temperature (Passive) Sensor Operation

+5 VOLTS REFERENCE SUPPLY

R1

MIC R

ANALOGUE TO DIGITAL CONVERTER

R2 0 VOLTS TEMPERATURE SENSOR

OP RO CE SS OR

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.

Volts

4.5

Out of range

0.5

Out of Range

Pressure

Pressure Sensor Circuits ECM +5 VOLTS REFERENCE SUPPLY

+12V

ANALOGUE TO DIGITAL CONVERTER

0 VOLTS

MICROPROCESSOR

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.

40 Degrees - 6 Cylinder

Top Dead Center

70 Degrees 4 CYL

Rotation

System Components - Speed Sensors Passive Speed Sensors Iron Core

Magnet Coil Flux Lines

Pole Piece Direction of motion Teeth

Crankshaft

Secondary Speed/Timing Sensor Installation

ECM (6 cylinder Engine)

Speed/Timing Sensor

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

Common for all future Caterpillar electronic engines

z

Hardware and software required

z

Annual subscription

z

Not compatible with Perkins 1100 Series engines

ET Service Tool Communication Adapter Group

CAT ET (Electronic Technician) Functionality includes: z

Fault Codes

z

Data recording and graphing

z

Engine Configuration

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

z

Flash Programming (ECM re-programming)

z

Supports troubleshooting process

z

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

Cat Data Link (CDL)

z

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

Example of CAN wiring HAND HELD SERVICE TOOL

NODE DATA BUS

Address 249

Ohm TERMINATING RESISTOR

120 Ohm TERMINATING RESISTOR

MACHINE INTERFACE CONNECTOR 52 61

INSTRUMENT PANEL Address 23

GEARBOX ECM

NODE

Address 3

The CAN shield not connected to ECM

ENGINE ECM Address 0

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

3054E: Cross flow cylinder head

z

Electric fuel priming pump

z

Glow plugs for starting

z

Sensor locations

Training Material Resources z

ITIM 3056E Engine – SERV 2705

z

Systems Operation Testing & Adjusting

z

z

3054E Industrial Engine – RENR 7568

z

3056E Machine Engine – RENR 2416

The Service Training website contains: z

Information & this presentation

z

Tech Tips Newsletter No. 21 contains FAQ’s