The control system consists of the following components:
- Electronic Control Module (ECM)
- Software (flash file)
- Wiring
- Sensors
- Actuators
The following information provides a general description of the control system. Refer to Systems Operation, Testing, and Adjusting for detailed information about the control system.
Electronic Control Circuit Diagram
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| Illustration 1 | g06079934 |
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C7.1 Propulsion Engine Electronic System (1) A5E2V2 Engine Control Module (2) Cat ET Service Tool (3) SAE J1939 (CAN)/CDL Data Bus (4) Starter Relay (5) Starter Motor (6) CAN Bus Terminator or Trolling Mode Processor Connector (7) +ve Glow Plug Relay (8) Glow Plugs Case Ground (9) -ve Glow Plug Relay (10) Alternator Charging Relay Input (11) 430-9454 Coolant Level Sensor (Opt) (12) 416-2211 Exhaust Gas Temperature Sensor (Opt) (13) Customer Interface Connector (14) MPD/SAE J1939 CAN Data Bus Transmission/Vessel (15) Power Supply (12V/24V) (16) Primary Throttle (PWM) (17) Secondary Throttle (PWM) (18) Warning Lamp (19) Diagnostic Lamp (20) Maintenance Lamp (21) Low Coolant Level Lamp (22) Low Oil Pressure Lamp (23) High Coolant Temperature Lamp (24) Water in Fuel Lamp (25) Ignition Switch (26) Remote Shutdown Switch (27) Troll Mode Switch (28) Throttle Synchronize 1 Switch (29) Throttle Synchronize 2 Switch (30) Trip Clear Switch (31) Slow Vessel Mode (32) Maintenance Check Switch (33) Fuel Lift Pump Relay (34) 349-7378 Fuel Supply Pressure Sensor (Opt) (1200 kPA) (35) 423-6434 Water in Fuel Sensor (Opt) (36) 320-3064 Transmission Oil Pressure Sensor (Opt) (3500 kPA) (37) 398-5399 Raw Water Pressure Sensor (Opt) (38) 238-0112 Transmission Oil Temperature Sensor (Opt) (39) 337-3905 Fuel Temperature Sensor (Built into Fuel Rail Pump) (40) 274-6721 Return Fuel Pressure Sensor (882 kPA) (41) 327-8803 Fuel Rail Pressure Sensor (42) 320-3062 Intake Manifold Air Pressure Sensor (400 kPA) (43) 288-3783 Intake manifold Air Temperature Sensor (44) 256-6454 Coolant Temperature Sensor (45) 320-3060 Oil Pressure Sensor (46) 238-0120 Crankshaft Speed/Timing Sensor (47) 238-0120 Camshaft Speed/Timing Sensor (48) 446-5412 Fuel Lift Pump (12V), 446-5413 Fuel Lift Pump (24V) (49) Fuel Rail Pump Actuator (50) Fuel Injectors #1-6 | |
The ECM governs the engine. The ECM determines the timing, the injection pressure, and the amount of fuel that is delivered to each cylinder. These factors are based on the actual conditions and on the desired conditions at any given time during starting and operation.
The governor uses the throttle position sensor to determine the desired engine speed. The governor compares the desired engine speed to the actual engine speed. The actual engine speed is determined through interpretation of the signals that are received by the ECM from the engine speed/timing sensors. If the desired engine speed is greater than the actual engine speed, the governor injects more fuel in order to increase engine speed.
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| Illustration 2 | g01860934 |
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Typical example | |
The desired engine speed is typically determined by one of the following conditions:
- The position of the throttle
- The desired engine speed in Power Take-Off (PTO)
Once the governor has determined the amount of fuel that is required, the governor must determine the timing of the fuel injection. Fuel injection timing is determined by the ECM after considering input from the following components:
- Coolant temperature sensor
- Intake manifold air temperature sensor
- Intake manifold pressure sensor
- Barometric pressure sensor
The ECM adjusts timing for optimum engine performance and for fuel economy. Actual timing and desired timing cannot be viewed with the electronic service tool. The ECM determines the location of top center of the number one cylinder from the signals that are provided by the engine speed/timing sensors. The ECM determines when injection should occur relative to top center. The ECM then provides the signal to the injector at the desired time.
The ECM sends a high voltage signal to the injector solenoids in order to energize the solenoids. By controlling the timing and the duration of the high voltage signal, the ECM can control the following aspects of injection:
- Injection timing
- Fuel delivery
The flash file inside the ECM establishes certain limits on the amount of fuel that can be injected. The "FRC Fuel Limit" is a limit that is based on the intake manifold pressure. The "FRC Fuel Limit" is used to control the air/fuel ratio for control of emissions. When the ECM senses a higher intake manifold pressure, the ECM increases the "FRC Fuel Limit". A higher intake manifold pressure indicates that there is more air in the cylinder. When the ECM increases the "FRC Fuel Limit", the ECM allows more fuel into the cylinder.
The "Rated Fuel Limit" is a limit that is based on the power rating of the engine and on the engine rpm. The "Rated Fuel Limit" is like the rack stops and the torque spring on a mechanically governed engine. The "Rated Fuel Limit" provides the power curves and the torque curves for a specific engine family and a specific engine rating. All of these limits are determined at the factory. These limits cannot be changed.
Customer Parameters and Engine Speed Governing
A unique feature with electronic engines is customer specified parameters. These parameters allow the owner of the machine to fine-tune the ECM for engine operation. Fine-tuning the ECM allows the machine owner to accommodate the typical usage of the machine and the power train of the machine.
Many of the customer parameters provide additional restrictions on the actions that will be performed by the ECM in response to input from the operator. The "PTO Top Engine Limit" is an engine rpm limit that is used by the ECM to limit the fuel during operation of the PTO. The ECM will not fuel the injectors above this rpm.
Some parameters are intended to notify the operator of potential engine damage (engine monitoring parameters). Some parameters enhance fuel economy (machine speed, engine speed limit, and idle shutdown). Other parameters are used to enhance the engine installation into the machine. Other parameters are used to provide engine operating information to the owner of the machine.
Other ECM Functions for Performance
The ECM can also provide enhanced control of the engine for machine functions such as controlling the cooling fan. Refer to Troubleshooting, "Customer Specified Parameters" for additional information .
The ECM maintains total data of the engine for the following parameters:
- "Total Operating Hours"
- "Engine Lifetime Hours"
- "Total Idle Time"
- "Total Idle Fuel"
- "Total Fuel"
- "Total Max Fuel"
- "Engine Starts"
- "Lifetime Total Engine Revolutions"
- "Average Load Factor"
The "Total Operating Hours" is the operating hours of the engine. The operating hours do not include the time when the ECM is powered but the engine is not running.
The "Engine Lifetime Hours" is the number of hours when electrical power has been applied to the engine. These hours will include the time when the ECM is powered but the engine is not running.
"Total Idle Time" and "Total Idle Fuel" can include operating time when the engine is not operating under a load.
Fuel Information can be displayed in US gallons or in liters.
"Total Fuel" is the total amount of fuel that is consumed by the engine during operation.
"Total Max Fuel" is the maximum amount of fuel that could have been consumed by the engine during operation.
"Engine Starts" is the total number of times when the engine has been started.
"Lifetime Total Engine Revolutions" is the total number of revolutions that have been completed by the engine crankshaft.
"Average Load Factor" provides relative engine operating information. "Average Load Factor" compares actual operating information of the engine to the maximum engine operation that is available. "Average Load Factor" is determined by using "Total Max Fuel", "Total Idle Fuel"and "Total Fuel". All of these parameters are available with the electronic service tool. These parameters are available within the menu for "Current Totals".
Certain parameters that affect engine operation may be changed with the electronic service tool. The parameters are stored in the ECM, and the parameters are protected from unauthorized changes by passwords. These parameters are either system configuration parameters or customer parameters.
System configuration parameters are set at the factory. System configuration parameters affect emissions or power ratings within an engine family. Factory passwords must be obtained and factory passwords must be used to change the system configuration parameters.
Customer parameters are variable. Customer parameters can be used to adjust the following characteristics of the engine within preset limits:
- Rpm ratings
- Power ratings
Customer passwords may be required to change customer specified parameters.
Some of the parameters may affect engine operation in an unusual way. An operator might not expect this type of effect. Without adequate training, these parameters may lead to power complaints or performance complaints even though the performance of the engine is to the specification.
Refer to Troubleshooting, "Configuration Parameters" for additional information on this subject.
System configuration parameters are protected by factory passwords. Factory passwords are calculated on a computer system that is available only to Caterpillar dealers. Since factory passwords contain alphabetic characters, only the electronic service tool may change system configuration parameters. System configuration parameters affect the power rating family or emissions.
Customer parameters can be protected by customer passwords. The customer passwords are programmed by the customer. Factory passwords can be used to change customer passwords if customer passwords are lost.
Refer to Troubleshooting, "Factory Passwords" for additional information on this subject.