C4.4 & C6.6
INDUSTRIAL ENGINE
electronics application & installation guide
LEBH7120-00
Table of Contents 1 Introduction and Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 1.1 Applicable Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 1.2 Electronic Applications Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 1.3 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 1.3.1 Warning — Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 1.3.2 Warning — Electrostatic Paint Spraying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 1.3.3 Warning — Jump-Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 2 Engine Component Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 2.1 Electronic Control Unit (ECU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 2.2 Sensor Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 2.2.1 Intake Manifold Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 2.2.2 Intake Manifold Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 2.2.3 Coolant Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 2.2.4 Fuel Rail Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 2.2.5 Fuel Pump Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 2.2.6 Electronic Unit Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 2.2.7 Crankshaft Speed/Timing Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 2.2.8 Pump/Camshaft Speed/Timing Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 2.2.9 Oil Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 2.2.10 Wastegate Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 2.3 Engine Component Diagrams and Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 2.3.1 C6.6 Factory-Installed Wiring and Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 2.3.2 C6.6 Engine Wire Harness Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 2.3.3 C4.4 Factory-Installed Wiring and Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 2.3.4 C4.4 Engine Wire Harness Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 2.3.5 C6.6 Principal Engine Electronic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 2.3.6 C4.4 Principal Engine Electronic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 2.4 Customer System Overview Key Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 2.4.1 Connection, Power, and Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 2.4.2 Indication Starting and Stopping the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 2.4.3 Controlling the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 2.5 Required Components to Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 2.6 Optional Customer-Installed Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 2.6.1 Typical Customer-Installed Component Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 2.6.2 Example OEM Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 2.6.3 Example 1 Basic Engine Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 2.6.4 Example 2 Construction Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 2.6.5 Example 3 Industrial Open Power Unit Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 2.6.6 Example 4 Agricultural Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 2.6.7 Example 1 — Basic Schematic OEM Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 2.6.8 Example 2 — Construction Schematic OEM Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 2.6.9 Example 3 — Industrial Open Power Unit Schematic OEM Harness . . . . . . . . . . . . . . . . . . . . . . . . 24 2.6.10 Example 4 — Agricultural Schematic OEM Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 3 Power and Grounding Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 3.1 Engine Block Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 3.1.1 Ground Stud on Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 3.1.2 Ground Connection to Tapping on Engine Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 3.2 Voltage and Current Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
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Table of Contents 3.3
ECU Power Supply Circuit Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 3.3.1 Battery (+) Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 3.3.2 Battery (-) Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 3.3.3 Correct Method of ECU Battery Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 3.3.4 Correct Method of ECU Battery Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 3.4 Engine ECU Power Supply Circuit Resistance Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 3.4.1 Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 3.4.2 Inductive Energy — Fly-back Suppression Diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 4 Connectors and Wiring Harness Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 4.1 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 4.1.1 ECU Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 4.1.2 Connector Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 4.1.3 Tightening the OEM Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 4.1.4 ECU Connector Wire Gauge Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 4.1.5 ECU Connector Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 4.1.6 Terminal Retention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 4.1.7 Hand Crimping For Prototype Machines and Low Volume Production . . . . . . . . . . . . . . . . . . . . . . . 37 4.1.8 ECU Connector Sealing Plug Installation Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 4.1.9 OEM Harness Retention at the ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 4.1.10 Machine Crimping For High Volume Production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 4.2 Harness Wiring Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 4.2.1 General Recommendations for Machine Wiring Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 4.2.1.1 Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 4.2.1.2 Cable Routing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 4.2.1.3 Mounting Location for Electronic Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 4.2.1.4 Electromagnetic Compliance (EMC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 4.2.1.5 Diagnostic Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 4.2.1.6 Termination Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 4.2.1.7 Pin Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 5 Starting and Stopping the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 5.1 Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 5.2 Stopping the Engine (and Preventing Restart) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 5.2.1 Ignition Keyswitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 5.2.2 Emergency Stop Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 5.2.3 Battery Isolation Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 5.2.4 Remote Stop Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 5.2.5 Datalink Stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 5.2.6 Common Problems With the Application of Stop Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 6 Engine Speed Demand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 6.1 Analogue Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 6.1.1 Device Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 6.1.2 Analogue Sensors — Connection Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 6.1.3 Evaluating Component Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 6.1.3.1 Analogue Input Test Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 6.1.3.2 Idle Validation Switch Test Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 6.1.4 Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 6.1.5 Required Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 6.1.6 Analogue Throttle Switch — ET Configurable Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
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Table of Contents 6.2
PWM Sensor — Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 6.2.1 Device Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 6.2.2 Component Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 6.2.3 Connection Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 6.2.4 PWM Throttle — ET Configurable Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 6.3 PTO Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 6.3.1 PTO Mode On/Off Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 6.3.2 PTO Mode Set/Lower Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 6.3.3 PTO Mode Raise/Resume Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 6.3.4 PTO Mode Disengage Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 6.3.5 PTO Mode Preset Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 6.3.6 PTO Mode Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 6.3.7 PTO Mode — ET Configurable Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 6.3.8 Example of PTO Mode Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 6.4 Multi-Position Throttle Switch (MPTS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 6.4.1 Multi-Position Throttle Switch — ET Configurable Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 6.5 Torque Speed Control TSC1 (Speed Control Over CAN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 6.6 Arbitration of Speed Demand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 6.6.1 Manual Throttle Selection Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 6.7 Ramp Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 6.8 Throttle Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 6.8.1 Throttle Parameter Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 6.8.1.1 Diagnostic Lower Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 6.8.1.2 Lower Position Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 6.8.1.3 Initial Lower Position Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 6.8.1.4 Lower Dead Zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 6.8.1.5 Initial Upper Position Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 6.8.1.6 Upper Position Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 6.8.1.7 Upper Dead Zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 6.8.1.8 Diagnostic Upper Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 6.8.2 Throttle Calibration Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 6.8.2.1 Idle Validation Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 7 Cold Starting Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 7.1 Control of Glow Plugs by the Engine ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 7.1.1 Relay, Fuse, and Cable Gauge Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 7.1.2 Wait-to-Start/Start Aid Active Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 7.1.3 OEM/Operator Control or Override of the Glow Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 7.1.4 Ether Cold Start Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 7.1.5 Water Jacket Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 7.1.6 Ambient Temperature Sensor — ET Configurable Parameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 8 Operator Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 8.1 Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 8.1.1 Gauge Drivers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 8.1.2 Lamp Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 8.1.3 Indicator Lamps Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 8.1.4 Datalink-Driven Intelligent Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 8.1.5 Minimum Functional Specification for J1939 Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 8.1.6 Customer Triggered Engine Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
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Table of Contents 8.2
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Engine Software Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 8.2.1 Engine Monitoring System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 8.2.1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 8.2.1.2 Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 8.2.1.3 Derate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 8.2.1.4 Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 8.2.2 Monitoring Mode — ET Configurable Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 8.2.3 Monitoring Mode Thresholds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 8.2.3.1 Coolant Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 8.2.3.2 Engine Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 8.2.3.3 Intake Manifold Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 8.2.4 Other Derate Reasons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Monitored Inputs for Customer-Fitted Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 9.1 Configurable States . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 9.2 Air Filter Service Indicator — Air Intake Restriction Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 9.3 Coolant Low Level Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 9.4 Fuel in Water Trap Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Engine Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 10.1 Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 10.1.1 All Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 10.1.2 Torque Limit Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 10.1.3 Droop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 10.1.4 High Speed Governor (Governor Run-Out) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 10.2 Auxiliary Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 10.3 Rating Selection Via Service Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 10.4 Mode Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 10.4.1 Rating and Droop Changes Requested Via the J1939 Datalink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 10.4.2 Service Maintenance Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Using the ET Service Tool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Datalink Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 12.1 SAE J1939 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 12.1.1 Summary of Key J1939 Application Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 12.1.2 Physical Layer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 12.1.3 Network Layer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 12.1.4 Application Layer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 J1939 Supported Parameters Quick Reference Summary Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82-85 J1939 Parameters — Detailed Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 14.1 Sending Messages to the ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 14.2 J1939 Section 71 — Vehicle Application Layer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87-104 14.3 J1939 Section 73 — Diagnostic Layer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105-106 14.4 Supported Parameters — Section 21 — Simplified Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 14.5 Supported Parameters — Section 81 Network Management — Detailed Descriptions . . . . . . . . . . . . . 107 Appendices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 15.1 Appendix 1 — ECU J1 Connector Terminal Assignments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108-109 15.2 Appendix 2 — List of Diagnostic and Event Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110-111
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Introduction and Purpose 1 Introduction and Purpose This document will provide necessary information for correct electrical and electronic installation of C4.4 or C6.6 Industrial engines into an off-highway machine. Caterpillar expects that there will be some additions and modifications to this document as the engine program development continues, and as OEM requests for information not currently addressed are added. The information herein is the property of Caterpillar Inc. and/or its subsidiaries. Without written permission, any copying or transmission to others, and any use except that for which it is loaned is prohibited.
1.1 Applicable Engines The information contained is the best available at the time of authoring to describe the application and installation requirements of the production software as of January 2007. Some engines shipped before this date will not have all the features described in this document. Likewise, some additional features will be added after this date. Contact the electronic applications team for the latest information on software feature release dates.
1.2 Electronic Applications Contacts If the information in this document is incomplete, incorrect, or further details are required, please contact your applications engineer. Electronic Applications Team Mark Tegerdine — Electronic Application Team Leader Telephone: +44(0) 1733 583222 Email:
[email protected]
1.3 Safety Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools in order to perform these functions properly. The information in this publication was based upon current information at the time of publication. Check for the most current information before you start any job. Caterpillar dealers will have the most current information. Improper operation, maintenance or repair of this product may be dangerous. Improper operation, maintenance or repair of this product may result in injury or death.
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Introduction and Purpose Do not operate or perform any maintenance or repair on this product until you have read and understood the operation, maintenance, and repair information. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are not all-inclusive. If a tool, a procedure, a work method, or an operating technique that is not specifically recommended by Caterpillar is used, you must be sure that it is safe for you and for other people. You must also be sure that the product will not be damaged. You must also be sure that the product will not be made unsafe by the procedures that are used. 1.3.1 Warning — Welding Welding can cause damage to the on-engine electronics. The following precautions should be taken before and during welding: • Turn the engine off. Place the ignition keyswitch in the OFF position. • Disconnect the negative battery cable from the battery. If the machine is fitted with a battery disconnect switch, open the switch. • Clamp the ground cable of the welder to the component that will be welded. Place the clamp as close as possible to the weld. • Protect any wiring harnesses from welding debris and splatter. DO NOT use electrical components in order to ground the welder. Do not use the ECU or sensors or any other electronic components in order to ground the welder. 1.3.2 Warning — Electrostatic Paint Spraying The high voltages used in electrostatic paint spraying can cause damage to the engine electronics. The damage can manifest itself through immediate failure of components or by weakening electronic components, causing them to fail at a later date. The following precautions should be taken when using electrostatic paint spraying techniques on engines: • Connect all 64 pins of the ECU J1 connector directly to the spraying booth ground. • Connect the engine block to ground at 2 points. Ensure that good screwed connections onto bright metal are used. 1.3.3 Warning — Jump-Starting Jump-starting an engine can cause higher than normal voltages to appear across the battery terminals. Care must be taken that this does not exceed the recommended maximum voltage for the ECU.
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Engine Component Overview 2 Engine Component Overview 2.1 Electronic Control Unit (ECU) The A4E2 ECU is an electronic control device, fundamentally a computer that governs engine speed and torque output. The ECU processes sensor measurements from the connected sensors to determine fuel quantity, fuel timing, fuel pressure, and intake pressure. The device is assembled to a special mounting plate fitted to the engine. The location is common on both C4.4 and C6.6 engines, left hand side close to the fuel rail. The device has two connection sockets, one for the engine wire harness (J2) that is blue in color and the other for the machine OEM harness connection (J1) that is grey in color. There are two ECU options, a fueled-cooled version and an aircooled version. The choice of option depends on the maximum ambient temperature (see mechanical installation guide for details of fuel connection requirements and temperature restrictions).
2.2 Sensor Details 2.2.1 Intake Manifold Pressure Sensor The intake manifold pressure sensor measures the air pressure inside the intake manifold, after the turbo. There are two sensor options dependent on the choice of rating. The operating range of the sensor options differs. The range is either 0-339 kPa absolute or 0-440 kPa absolute. The sensor is used to determine atmospheric (barometric) pressure. During certain operating conditions the ECU will take a snapshot of the measured pressure to set the atmospheric pressure value. The atmospheric pressure is used to determine the atmospheric related fuel limits (if any); e.g., at high altitude fuel may be limited during cranking to prevent turbo over-speed. The ECU also uses the atmospheric value to calculate gauge pressure of other absolute engine pressure sensors. When the engine is running, the sensor measurement is used as an input parameter to calculate torque and air fuel ratio limits. This helps prevent black smoke during transient engine conditions, mainly during acceleration or upon sudden load application; i.e., if intake manifold pressure is too low for the requested fuel, the fuel is limited to prevent the over-fuel condition. The measurement will also be used to select certain timing maps. Intake manifold pressure is also used to control the turbo wastegate regulator, if fitted. The turbo wastegate regulator control system regulates intake manifold pressure to a desired value, calibrated in the software. In order to do this, the software needs to know the actual value of intake manifold pressure, hence the need for the sensor measurement. If the intake manifold pressure sensor/circuit fails, a low default value is used in the software. The wastegate regulator control (if fitted) will go to open loop, whereby the resultant intake manifold pressure will be low (as determined by the wastegate hardware chosen) and fuel will be limited under certain engine conditions, effectively providing a fuel/torque derate.
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Engine Component Overview 2.2.2 Intake Manifold Temperature Sensor This sensor measures the temperature inside the inlet air manifold. There are two sensor options on the C4.4 engine depending on the turbo arrangement. The operating range of the sensors differs. The range is either -40°C to +120°C or -40°C to +200°C (used on straight turbo options). The C6.6 engine uses the -40°C to +120°C option. Note: This is the sensor to which the engine is calibrated. Intake air temperature measurement is very sensitive to location. If the OEM adds additional inlet air temperature monitoring; for example, during prototype evaluation, it should be anticipated that there may be a difference of several degrees Celsius between the engine sensor and the OEM sensor. Intake manifold temperature measurement is used as an input to the cold start strategy. When the engine is running the sensor measurement is used as an input parameter to calculate torque and air fuel ratio limits. The OEM has no connection to this sensor, but if the intake air is required by some machine system; for example, for fan control strategy, the data can be accessed on the J1939 datalink. It is possible, if extreme temperatures are measured at the intake, that the engine will derate. In the event of a derate, an event code will be generated on the J1939 datalink or displayed on the service tool, and the warning lamp will illuminate. 2.2.3 Coolant Temperature Sensor The coolant temperature sensor measurement is used as an input to the cold start strategy. The measurement is also used to select certain maps at 0°C, 50°C, 65°C, and 70°C. The engine is considered warm at 65°C. The fuel delivery characteristics will change dependent on the engine temperature. The sensor is also used for activating the glow plugs for cold engine starting and for detecting high coolant temperatures for raising an event. The range is -40°C to +120°C If the sensor/circuit fails, a default value is used and a diagnostic code is raised. For glow plug control if this sensor/circuit is faulted, the intake manifold air temperature sensor is used. It is possible that with this sensor/circuit in a failure condition, white smoke may result during a cold engine start. The high coolant temperature event will not be raised under this fault condition. The sensor reading of coolant temperature is also used to determine the maximum fuel allowed during engine starting. If the sensor/circuit fails, it is possible the engine will not start under cold engine conditions. It is possible, if the coolant temperature exceeds the design limits, that the engine will derate. In the event of a derate, a fault code will be generated on the J1939 datalink or displayed on the service tool, and the warning lamp will illuminate. 2.2.4 Fuel Rail Pressure Sensor The fuel rail pressure sensor is used to measure the fuel pressure in the high-pressure fuel rail. (The fuel in the fuel rail feeds all injectors. Injection takes place when each injector is electrically operated.) The fuel rail pressure measurement is used in conjunction with the high-pressure fuel pump to maintain the desired fuel pressure in the fuel rail. This pressure is determined by engine calibrations to enable the engine to meet emissions and performance objectives. If the fuel rail pressure sensor/signal is faulted, a diagnostic code is set with a warning; a default value used and a 100 percent engine derate results. The default value for fuel rail pressure will allow the engine to run in a limp-home fashion whereby a known fuel rail pressure will be controlled within reasonable engine conditions. Emissions compliance cannot be guaranteed under this fault condition.
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Engine Component Overview 2.2.5 Fuel Pump Solenoid The fuel rail pump solenoid is used to control the output from the high-pressure fuel pump. It is energized when fuel is required to be pumped into the high-pressure fuel rail. Varying the energize time of the solenoid controls the fuel delivery from the pump. The earlier the solenoid is energized (degrees before TDC), the more fuel is pumped into the fuel rail. The solenoid forms part of the fuel rail pressure closed loop control system in conjunction with the fuel rail pressure sensor, ECU, and software. The fuel rail pressure sensor measures the fuel rail pressure; the signal is processed by the ECU, and software and compared to the desired fuel rail pressure for the given engine operating conditions. The control algorithmcontrols the fuel rail pump solenoid energize time. There is no OEM connection to this component. If the fuel rail pump solenoid fails, it is likely that fuel will not be pumped into the fuel rail and engine shutdown or failed start is expected. 2.2.6 Electronic Unit Injectors Each fuel injector contains a solenoid to control the quantity of fuel injected. Both positive and negative wires to each solenoid are wired directly back to the ECU. There is no OEM connection to this component. Voltages of up to 70V are used to drive the injectors. The signals to the injectors are sharp pulses of relatively high current. The OEM should ensure that any systems that are sensitive to electromagnetic radiation are not in proximity to the harness components that lead to the injectors. 2.2.7 Crankshaft Speed/Timing Sensor The crankshaft speed-timing sensor is a Hall-effect sensor. The sensor works in conjunction with the timing ring fitted to the engine crankshaft. The sensor produces a signal as the timing ring/crank rotates past the sensor. The ECU uses this signal to calculate crankshaft speed and crankshaft position. The crank speed/timing signal is used during normal engine running since it is more accurate than the signal obtained from the cam speed/timing sensor. If the crank speed/timing sensor signal is lost or faulted, the engine is capable of starting provided the cam speed/ timing signal is healthy. A diagnostic and warning will be raised if the fault occurs during engine running. A full derate will result since the engine is not guaranteed to be emissions compliant due to the accuracy of the cam speed/timing signal. The diagnostic and derate will not be raised during engine cranking (if fault present), but the service tool will provide a means to read the condition of the cam and crank speed signals to aid fault finding. The OEM has no connection to this sensor. If the OEM requires accurate engine speed information, it may be obtained from the SAE J1939 datalink. The software includes logic to prevent reverse engine running.
10
C 4 . 4
A N D
C 6 . 6
I N D U S T R I A L
E L E C T R O N I C
Engine Component Overview 2.2.8 Pump/Camshaft Speed/Timing Sensor The camshaft speed/timing sensor works in conjunction with the timing ring fitted inside the high pressure fuel pump. The sensor produces a signal as the timing ring/pump rotates past the sensor. The ECU uses this signal to calculate camshaft speed, camshaft position and engine cycle. The cam speed/timing signal is required for determining the correct engine cycle and is also used for limp-home operation in the event of the crank speed sensor/circuit being faulted/lost. If the camshaft speed/timing sensor/signal is lost or faulted, the engine will not start (since engine cycle is not known from the crank signal only), but if the engine is already running, no engine performance effect will be noticed. A diagnostic and warning will be raised if the fault occurs during engine running. The diagnostic will not be raised during engine cranking, but the service tool will provide a means to read the condition of the cam and crank speed signals to aid fault finding. The software includes logic to compensate for minor timing errors. 2.2.9 Oil Pressure Sensor The oil pressure sensor measures the engine oil pressure in kPa. Oil pressure is used for engine protection, whereby if insufficient oil pressure is measured for a given speed, an event for low oil pressure would be raised. The low oil pressure threshold is defined as a map against engine speed. Currently, two levels of event are specified. Level 1 is the least severe and raises a warning. Level 3 is the most severe and raises a warning which requests that the engine be shutdown. Automatic engine shutdown can be configured for certain applications, such as gensets, to occur when a level 3 event is raised. If the oil pressure sensor fails, a diagnostic is raised and a default value is used by the software, which has been chosen to be a healthy (high) pressure value. It is not possible to raise an event while an oil pressure diagnostic is present. 2.2.10 Wastegate Regulator The regulator controls the pressure in the intake manifold to a value that is determined by the ECU. The wastegate regulator provides the interface between the ECU and the mechanical system that regulates intake manifold pressure to the desired value that is determined by the software.
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Engine Component Overview 2.3 Engine Component Diagrams and Schematics 2.3.1 C6.6 Factory-Installed Wiring and Components Electronic Unit Injectors
A4E2 ECM Diagnostic (If Equipped)
Fuel Pump
J1
J2 64 Pin Plug
Coolant Temperature
Wastegate Regulator
Oil Pressure
(If Equipped)
Intake Manifold Pressure Pump/Cam Speed/ Timing
Intake Manifold Temperature
Crank Speed/Timing
12
Fuel Rail Pressure
C 4 . 4
A N D
C 6 . 6
I N D U S T R I A L
E L E C T R O N I C
Engine Component Overview 2.3.2 C6.6 Engine Wire Harness Schematic A4E2 ECU J2 Connector
INJECTOR CYLINDER 6 INJECTOR CYLINDER 5
T962 BK
1
T956 BK
2
T961 BK
3
T955 BK
4
T960 BK
1
T954 BK
2
T959 BK
3
T953 BK
4
T958 BK
1
T952 BK
2
T957 BK
3
T951 BK
4
X931YL
6
X925PK
62
X930 GY
7
X924 BR
63
INJECTOR CYLINDER 6 RETURN INJECTOR CYLINDER 6 INJECTOR CYLINDER 5 RETURN INJECTOR CYLINDER 5
X929BU
8
X923 OR
64
INJECTOR CYLINDER 4
INJECTOR CYLINDER 4 RETURN
X928 GN
33
INJECTOR CYLINDER 3 RETURN
X922 WH
59
INJECTOR CYLINDER 3
X927 YL
34
INJECTOR CYLINDER 2 RETURN
X921 PK
58
INJECTOR CYLINDER 2
X926 GY
35
INJECTOR CYLINDER 1 RETURN
X920 BR
57
INJECTOR CYLINDER 1
T997 OR
INJECTOR CYLINDER 4 INTERNAL (ROCKER COVER)
INJECTOR CYLINDER 3
EXTERNAL
INJECTOR CYLINDER 2
INTAKE MANIFOLD PRESSURE SENSOR
1 2
INJECTOR CYLINDER 1
3
OIL PRESSURE SENSOR
46
IMP POWER SUPPLY (+5V)
T993 BR
38
IMP RETURN
X731 BU
55
IMP SIGNAL
1
L730 OR
47
OIL PRESSURE SENSOR PWR (+5V)
2
Y947 BR
39
OIL PRESSURE SENSOR RETURN
3
994 GY
56
OIL PRESSURE SENSOR SIGNAL
1
R997 OR
48
FMP SENSOR POWER SUPPLY (+5V)
FUEL MANIFOLD PRESSURE SENSOR
2
Y948 BR
40
FMP SENSOR GROUND
3
Y946 BU
51
FMP SENSOR SIGNAL
COOLANT TEMPERATURE SENSOR
1
995 BU
43
COOLANT TEMP SIGNAL
INTAKE MANIFOLD TEMPERATURE SENSOR
1
C967 BU
42
IMT SIGNAL
2
L731 BR
37
TEMPERATURE SENSOR RETURN
CRANKSHAFT SPEED/ TIMING SENSOR
1
996 GN
10
SPEED SENSOR POWER (+8V)
2
E965 BU
52
CRANK SPEED/TIME SENS SIG
P920 BR
53
PUMP /CAM SPEED SENS SIG
PUMP / CAM SPEED SENSOR
1
FUEL PUMP SOLENOID
2
2
Y950 YL
25
FUEL PUMP SOLENOID PWM SIG
Y951 PU
26
FUEL PUMP SOLENOID RETURN
C211 BK
19
WASTEGATE RETURN
M795 WH
17
WASTEGATE PWM SIGNAL
1 2
101 RD
18
BAT+ (FOR COMMS ADAPTER)
B
229 BK
45
BAT - (FOR COMMS ADAPTER)
D
944 OR
21
CDL+
E
945 BR
20
CDL-
F
Y793 YL
23
J1939 -
G
Y792 PK
24
J1939 +
A
DIAGNOSTIC CONNECTOR (9 PIN)
C H
ELECTRONIC WASTEGATE ACTUATOR
J
1 2
NOT ALWAYS FITTED ON FIXED SPEED ENGINES
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Engine Component Overview 2.3.3 C4.4 Factory-Installed Wiring and Components Electronic Unit Injectors
A4E2 ECM Diagnostic (If Equipped)
Fuel Pump
J1
J2 64 Pin Plug
Coolant Temperature
Wastegate Regulator
Oil Pressure
(If Equipped)
Intake Manifold Pressure Pump/Cam Speed/ Timing
Intake Manifold Temperature
Crank Speed/Timing
14
Fuel Rail Pressure
C 4 . 4
A N D
C 6 . 6
I N D U S T R I A L
E L E C T R O N I C
Engine Component Overview 2.3.4 C4.4 Engine Wire Harness Schematic A4E2 ECU J2 Connector
T960 BK
1
X929BU
34
INJECTOR CYLINDER 4 RETURN
T954 BK
2
X923 OR
58
INJECTOR CYLINDER 4
X928 GN
8
X922 WH
64
X927 YL
7
T959 BK
3
T953 BK
4
INJECTOR CYLINDER 3
INJECTOR CYLINDER 2 RETURN
T958 BK
1
X921 PK
63
INJECTOR CYLINDER 2
T952 BK
2
X926 GY
35
INJECTOR CYLINDER 1 RETURN
X920 BR
57
INJECTOR CYLINDER 1
T997 OR
T957 BK
3
T951 BK
4
INTERNAL (ROCKER COVER)
INJECTOR CYLINDER 4
INJECTOR CYLINDER 3 RETURN
EXTERNAL
INJECTOR CYLINDER 3 INJECTOR CYLINDER 2 INJECTOR CYLINDER 1
INTAKE MANIFOLD PRESSURE SENSOR
OIL PRESSURE SENSOR
1 2 3
46
IMP POWER SUPPLY (5V)
T993 BR
38
IMP RETURN
X731 BU
55
IMP SIGNAL
1
L730 OR
47
OIL PRESSURE SENSOR PWR (5V)
2
Y947 BR
39
OIL PRESSURE SENSOR RETURN
3
994 GY
56
OIL PRESSURE SENSOR SIGNAL
1
R997 OR
48
FMP SENSOR POWER SUPPLY (5V)
FUEL MANIFOLD PRESSURE SENSOR
2
Y948 BR
40
FMP SENSOR GROUND
3
Y946 BU
51
FMP SENSOR SIGNAL
COOLANT TEMPERATURE SENSOR
1
995 BU
43
COOLANT TEMP SIGNAL
INTAKE MANIFOLD TEMPERATURE SENSOR
1
C967 BU
42
IMT SIGNAL
2
L731 BR
37
TEMPERATURE SENSOR RETURN
CRANKSHAFT SPEED/ TIMING SENSOR
1
996 GN
10
SPEED SENSOR POWER (8V)
2
E965 BU
52
CRANK SPEED/TIME SENS SIG
P920 BR
53
PUMP /CAM SPEED SENS SIG
PUMP / CAM SPEED SENSOR
1
Y950 YL
25
FUEL PUMP SOLENOID PWM SIG
Y951 PU
26
FUEL PUMP SOLENOID RETURN
C211 BK
19
WASTEGATE RETURN
M795 WH
17
WASTEGATE PWM SIGNAL
FUEL PUMP SOLENOID
2
2
1 2
101 RD
18
BAT+ (FOR COMMS ADAPTER)
B
229 BK
45
BAT - (FOR COMMS ADAPTER)
D
944 OR
21
CDL+
E
945 BR
20
CDL-
F
Y793 YL
23
J1939 -
G
Y792 PK
24
J1939 +
A
DIAGNOSTIC CONNECTOR (9 PIN)
C
ELECTRONIC WASTEGATE ACTUATOR
H J
1 2
NOT ALWAYS FITTED ON FIXED SPEED ENGINES
A P P L I C AT I O N
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Engine Component Overview 2.3.5 C6.6 Principal Engine Electronic Components
Intake Pressure Sensor
Intake Temperature
Fuel Rail Pressure Sensor
Coolant Sensor
ECU
Fuel Pump Solenoid
Pump/Cam Speed Sensor
Oil Pressure Sensor Crank Speed Sensor
16
C 4 . 4
A N D
C 6 . 6
I N D U S T R I A L
Note: Variable Wastegate Fitted to Right Hand Side
E L E C T R O N I C
Engine Component Overview 2.3.6 C4.4 Principal Engine Electronic Components
Fuel Pump Solenoid
Fuel Rail Pressure Sensor
Intake Temperature Sensor
Coolant Temperature Sensor ECU J1 Connector
Intake Manifold Pressure Sensor
Pump/Cam Speed Sensor Crank Speed Sensor Oil Pressure Sensor
A P P L I C AT I O N
A N D
Note: Wastegate Regulator Fitted to Right Hand Side of Engine
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Engine Component Overview 2.4 Customer System Overview Key Elements The engine can be wired and configured many different ways dependent on the requirements of the OEM. The key elements to consider are: 2.4.1 Connection, Power, and Grounding The engine ECU requires electrical power. The requirements for powering the ECU need careful review. It is important to understand how to connect the ECU to the machine battery; more detail is given in the power and grounding section of this document. 2.4.2 Indication Starting and Stopping the Engine With the battery connected, a single connection to the ECU is required to initialize the ECU. Once initialized the ECU will be ready to control the engine. It is important to consider how the power to pin 40 is controlled; most machines use a simple keyswitch to start and stop the engine. There are specific recommendations for stopping the engine that are specified in the starting and stopping section of this guide. Mandatory requirements regarding operator indication are in place; see the operator display section of this document. 2.4.3 Controlling the Engine There are specific requirements in this document for controlling engine speed and auxiliary components. Further information is available in the speed demand section of this document.
2.5 Required Components to Install
18
Mandatory or Required Components
Section
Battery
Power and Grounding Considerations
Circuit Protection
Power and Grounding Considerations
Keyswitch
Starting the Engine
Warning Lamp
Operator Displays
Shutdown
Operator Displays
Wait-to-Start Lamp
Operator Displays
Glow Plug Relay
Cold Starting Aid
Speed Demand Input
Engine Speed Demand
C 4 . 4
A N D
C 6 . 6
I N D U S T R I A L
E L E C T R O N I C
Engine Component Overview 2.6 Optional Customer-Installed Components* Optional Components
Section
Low Oil Pressure Lamp
Operator Displays
PTO Mode Lamp
Operator Displays
Maintenance Due Lamp
Operator Displays
Remote Shutdown Switch (Normally Open)
Stopping the Engine
Coolant Level Sensor
Monitored Inputs for Customer Fitted Sensors
Water Fuel Sensor
Monitored Inputs for Customer Fitted Sensors
Air Filter Restriction Switch
Monitored Inputs for Customer Fitted Sensors
PWM Throttle Position Sensor
Engine Speed Demand
Analogue Throttle Position Sensor with Idle Validation Switch (1)
Engine Speed Demand
Analogue Throttle Position Sensor with Idle Validation Switch (2)
Engine Speed Demand
Throttle Selection Switch
Engine Speed Demand
Multi-Position Switch
Engine Speed Demand
PTO On/Off Switch
Engine Speed Demand
PTO Set/Lower Switch
Engine Speed Demand
PTO Raise/Resume Switch
Engine Speed Demand
PTO Disengage Switch
Engine Speed Demand
Mode Switch (1)
Engine Governor
Mode Switch (2)
Engine Governor
Maintenance Due Reset Switch
Additional Options
Ambient Temperature Sensor
Additional Options
* Check compatibility in specific sections, some components cannot be used together.
A P P L I C AT I O N
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Engine Component Overview 2.6.1 Typical Customer-Installed Component Diagram
Battery Isolation Switch
Glow Plug Relay
-
+
PWM Throttle
Battery
Analogue Throttle with IVS IVS
Circuit Protection (Mandatory)
Air Filter Restriction Switch
Keyswitch
Coolant Level Switch
Magnetic Switch
PTO On/Off Switch
Warning Lamp
PTO Raise/Resume Button
Stop Lamp
PTO Set/Lower Button Wait to Start Lamp PTO Disengage Low Oil Pressure Lamp Modes Switch 1 Maintenance Due Lamp Modes Switch 2 Service Tool Connector
Shutdown Switch Maintenance Due Reset Switch
J1939 Termination Resistor
20
C 4 . 4
A N D
C 6 . 6
I N D U S T R I A L
E L E C T R O N I C
Engine Component Overview 2.6.2 Example OEM Schematic The engine can be configured and wired many different ways dependent on the requirements of the OEM. The following four example schematics and descriptions provide a guide for the OEM. 2.6.3 Example 1 Basic Engine Application This solution is suitable for applications where very little integration or additional engineering is a requirement when compared to the solution used for a mechanical engine. This solution can be used in most mechanically governed engine replacement situations. The OEM needs to consider only basic functions: power supply, operator indication, cold start aid, and a simple method of controlling the engine speed. 2.6.4 Example 2 Construction Application An application where the engine, in response to an arrangement of switched inputs will operate at one of a range of defined speeds. This is suitable for applications where the device has multiple operating speeds that are defined for the specific output reasons, for simplicity of operator use, or for operation dependent upon the environment — e.g., quiet modes. This could include auxiliary engine on-road sweeper, multiple speed water pumps, etc. There are sixteen possible set speeds based on four discrete ECU inputs. In addition to the keyswitch, a separate engine shutdown switch is used to stop the engine. 2.6.5 Example 3 Industrial Open Power Unit Application An application where the engine, in response to a control input such as a button press, accelerates from idle speed up to the pre-defined operating engine speed. Once at the pre-defined operating speed, the engine speed may be raised or lowered by increment/decrement button presses. This is suitable for enhancing some of the applications of the single speed (set speed) control or to provide a variable speed control without having a throttle pedal/lever. This functionality may benefit when the user wants to use “set speed operation,” but with the capability to adjust it themselves — users may have a favorite operating speed. This could include concrete pumps and hydraulic driven machines. 2.6.6 Example 4 Agricultural Application The application will allow single or twin throttles, engine twin set speed control, multi mode operation, integrated display drive, etc. This set-up is suitable for applications where the customer requires a high degree of operator control over the machine’s behavior. It is one of the most complex applications. Typically, this is used in mobile applications that may be driven to the place of work and require operator selectable speed operation while performing their chosen task. This could include tractors, combines, and backhoe loaders.
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Engine Component Overview 2.6.7 Example 1 — Basic Schematic OEM Harness A4E2 ECU J1 CONNECTOR
Basic OEM Wiring Schematic Chris Crawford
21st AUG 2006
UNCONTROLLED DOCUMENT FOR INDICATION ONLY Caterpillar Confidential Green
NOTE 7
OFF ON
7
BATTERY +
8
BATTERY +
15
BATTERY +
16
BATTERY +
1
BATTERY -
2
BATTERY -
3
BATTERY -
9
BATTERY -
10
BATTERY -
40
IGNITION KEYSWTICH
60
STOP LAMP
59
WARNING LAMP
63
COLD START LAMP
62
LOW OIL PRESSURE LAMP (OPTIONAL)
57
START AID CONTROL
43
SENSOR SUPPLY 8V
53
PWM THROTTLE SENSOR INPUT
33
SENSOR RETURN
5A
START
IGNITION KEY SWITCH
STOP LAMP TO STARTER MOTOR MAG SWITCH WARNING LAMP NOTE 2 COLD START - WAIT TO START LAMP
LOW OIL PRESSURE LAMP
NOTE 4
NOTE 5
GLOW PLUG RELAY
TO GLOW PLUGS
Battery
PWM THROTTLE SENSOR
NOTES J1 PLUG
1. N/A 2. Fuse value depends on Mag Switch circuit current 3. N/A 4. Fit suppression diodes across relay coils 5. Glow Plug fuse rating differs between 4cyl and 6cyl engines and system voltage 6. Starter motor control circuits will vary 7. Fuse value dependant on system voltage
Rear View of J1 Plug
22
C 4 . 4
A N D
C 6 . 6
Front View of J1 Plug
I N D U S T R I A L
E L E C T R O N I C
Engine Component Overview 2.6.8 Example 2 — Construction Schematic OEM Harness 120 OHM
Construction OEM Wiring Schematic Chris Crawford
A4E2 ECU J1 CONNECTOR
21st AUG 2006
UNCONTROLLED DOCUMENT FOR INDICATION ONLY Caterpillar Confidential Green
CAN J1939 BUS NOTE 1
NOTE 3
20
CAN J1939 +
21
CAN J1939 -
22
CAN J1939 SHIELD
23
CDL +
24
CDL -
120 OHM
NOTE 7
OFF ON
7
BATTERY +
8
BATTERY +
15
BATTERY +
16
BATTERY +
1
BATTERY -
2
BATTERY -
3
BATTERY -
9
BATTERY -
10
BATTERY -
40
IGNITION KEYSWTICH
60
STOP LAMP
59
WARNING LAMP
63
COLD START LAMP
62
LOW OIL PRESSURE LAMP (OPTIONAL)
57
START AID CONTROL
5A
START
IGNITION KEY SWITCH
STOP LAMP TO STARTER MOTOR MAG SWITCH WARNING LAMP NOTE 2 COLD START - WAIT TO START LAMP
LOW OIL PRESSURE LAMP
NOTE 4
NOTE 5
GLOW PLUG RELAY
TO GLOW PLUGS
Battery
S1
CMN
10 POSITION ROTARY SWITCH
49
THROTTLE POSITION SWITCH 1
S2
50
THROTTLE POSITION SWITCH 2
S3
51
THROTTLE POSITION SWITCH 3
52
THROTTLE POSITION SWITCH 4
48
SHUTDOWN SWITCH (CLOSE TO STOP)
35
SWITCH RETURN
S4
NOTES J1 PLUG
1. CAN shield connection at ECM is optional 2. Fuse value depends on Mag Switch circuit current 3. CDL connection may be used for secondary diagnostic connection 4. Fit suppression diodes across relay coils 5. Glow Plug fuse rating differs between 4cyl and 6cyl engines and system voltage 6. Starter motor control circuits will vary 7. Fuse value dependent on system voltage Rear View of J1 Plug
A P P L I C AT I O N
A N D
I N S TA L L AT I O N
Front View of J1 Plug
G U I D E
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Engine Component Overview 2.6.9 Example 3 — Industrial Open Power Unit Schematic OEM Harness A4E2 ECU J1 CONNECTOR
IOPU OEM Wiring Schematic Chris Crawford
21st AUG 2006
UNCONTROLLED DOCUMENT FOR INDICATION ONLY Caterpillar Confidential Green
NOTE 7
OFF
7
BATTERY +
8
BATTERY +
15
BATTERY +
16
BATTERY +
1
BATTERY -
2
BATTERY -
3
BATTERY -
9
BATTERY -
10
BATTERY -
40
IGNITION KEYSWTICH
61
PTO MODE LAMP (OPTIONAL)
60
STOP LAMP
59
WARNING LAMP
63
COLD START LAMP
62
LOW OIL PRESSURE LAMP (OPTIONAL)
57
START AID CONTROL
52
PTO MODE - ON / OFF
51
PTO MODE - SET/ LOWER
50
PTO MODE - RAISE /RESUME
49
PTO MODE - DISENGAGE (NC)
35
SWITCH RETURN
5A
ON START
PTO MODE LAMP IGNITION KEY SWITCH
STOP LAMP TO STARTER MOTOR MAG SWITCH WARNING LAMP NOTE 2 COLD START - WAIT TO START LAMP
LOW OIL PRESSURE LAMP
NOTE 4
NOTE 5
GLOW PLUG RELAY
TO GLOW PLUGS
Battery
ON / OFF SET / LOWER
RAISE / RESUME
DISENGAGE SWITCH
NOTES J1 PLUG
1. N/A 2. Fuse value depends on Mag Switch circuit current 3. N/A 4. Fit suppression diodes across relay coils 5. Glow Plug fuse rating differs between 4cyl and 6cyl engines and system voltage 6. Starter motor control circuits will vary 7. Fuse value dependent on system voltage
Rear View of J1 Plug
24
C 4 . 4
A N D
Front View of J1 Plug
C 6 . 6
I N D U S T R I A L
E L E C T R O N I C
Engine Component Overview 2.6.10 Example 4 — Agricultural Schematic OEM Harness 120 OHM
Agricultural OEM Wiring Schematic Chris Crawford
A4E2 ECU J1 CONNECTOR
21st AUG 2006
UNCONTROLLED DOCUMENT FOR INDICATION ONLY Caterpillar Confidential Green
CAN J1939 BUS NOTE 1
NOTE 3
20
CAN J1939 +
21
CAN J1939 -
22
CAN J1939 SHIELD
23
CDL +
24
CDL -
120 OHM
NOTE 7
OFF ON
7
BATTERY +
8
BATTERY +
15
BATTERY +
16
BATTERY +
1
BATTERY -
2
BATTERY -
3
BATTERY -
9
BATTERY -
10
BATTERY -
40
IGNITION KEYSWTICH
61
PTO MODE LAMP (OPTIONAL)
60
STOP LAMP
59
WARNING LAMP
63
COLD START LAMP
62
LOW OIL PRESSURE LAMP (OPTIONAL)
58
MAINTENANCE DUE LAMP (OPTIONAL)
36
MAINTENANCE DUE RESET SWITCH
57
START AID CONTROL
41
SENSOR SUPPPLY 5V
54
ANALOGUE THROTTLE INPUT 1
33
SENSOR RETURN
45
IDLE VALIDATION (IVS 1) N/C
42
SENSOR SUPPPLY 5V
55
ANALOGUE THROTTLE INPUT 2
34
SENSOR RETURN
44
IDLE VALIDATION (IVS 2) N/C
52
PTO MODE - ON / OFF
51
PTO MODE - SET/ LOWER
50
PTO MODE - RAISE /RESUME
49
PTO MODE - DISENGAGE (NC)
39
MODE SWITCH 1
46
MODE SWITCH 2
47
THROTTLE SELECTION SWITCH
35
SWITCH RETURN
5A
START
PTO MODE LAMP IGNITION KEY SWITCH
STOP LAMP TO STARTER MOTOR MAG SWITCH WARNING LAMP NOTE 2 COLD START - WAIT TO START LAMP
LOW OIL PRESSURE LAMP MAINTENANCE DUE LAMP
MAINTENANCE DUE RESET SWITCH NOTE 4
NOTE 5
GLOW PLUG RELAY
TO GLOW PLUGS
ANALOGUE THROTTLE SENSOR 1
ANALOGUE THROTTLE SENSOR 2
Battery
ON / OFF SET / LOWER
RAISE / RESUME
DISENGAGE SWITCH
MODE SWITCH 1 MODE SWITCH 2
THROTTLE SELECTION SWITCH
NOTES J1 PLUG
1. CAN shield connection at ECM is optional 2. Fuse value depends on Mag Switch circuit current 3. CDL connection may be used for secondary diagnostic connection 4. Fit suppression diodes across relay coils 5. Glow Plug fuse rating differs between 4cyl and 6cyl engines and systme voltage 6. Starter motor control circuits will vary 7. Fuse value dependent on system voltage Rear View of J1 Plug
A P P L I C AT I O N
A N D
I N S TA L L AT I O N
Front View of J1 Plug
G U I D E
25
Power and Grounding Considerations 3 Power and Grounding Considerations 3.1 Engine Block Grounding Although the engine electronics are all directly grounded via the ECU connector, it is also necessary that the engine block be properly grounded to provide a good return path for components such as starter motor, alternator, and cold start aids. Improper grounding results in unreliable electrical circuit paths. Stray electrical currents can damage mechanical components and make electronic systems prone to interference. These problems are often very difficult to diagnose and repair. 3.1.1 Ground Stud on Starter Motor If the starter motor has a grounding stud it should be used. The ground connection should preferably be made directly back to the battery negative terminal. The starter motor ground path must not include any flanges or joints. Painted surfaces and flexible mounts in particular must be avoided. Star washers must not be relied upon to make contact though paint. The ground cable should be of cross section 67.4 mm2 (00 AWG) or greater. 3.1.2 Ground Connection to Tapping on Engine Block A separate engine block ground should be used in addition to the starter motor ground. A ground cable, direct from the battery negative or starter ground terminal, should be connected to a ring terminal which connects to one of the three tappings shown in diagrams 1 and 2. The tapped holes will be reserved for customer use and can be used for grounding purposes. If a tapping is used it should be checked to be free of lacquer, paint, and dirt before the connection is made. An M10 metric screw plated with zinc should be used. A washer should retain the ring terminal and the screw tightened to 44 Nm (32 Ib-ft). It is preferable to use a conductive grease to ensure the reliability of this connection.
26
C 4 . 4
A N D
C 6 . 6
I N D U S T R I A L
E L E C T R O N I C
Power and Grounding Considerations
Ground Point Option 1
Ground Point Option 2
Diagram 1 Ground Points 1 & 2
Ground Point Option 3
Diagram 2 Ground Point 3
A P P L I C AT I O N
A N D
I N S TA L L AT I O N
G U I D E
27
Power and Grounding Considerations 3.2 Voltage and Current Requirements The ECU power supply requirements must be carefully considered when designing the supply circuit; there are specific limitations that must be considered in the design to ensure a reliable consistent power supply to the engine electronic components. The table provides the electrical characteristics and limitations for the A4:E2 ECU. Voltage Supply System
12V
24V
Max Peak Current
60A
60A
Peak Current Cranking
36A
36A
Max RMS Current*
13A
7.5A
Suggested Fuse Rating**
25A
20A
